SERVICE MANUAL Lep 84402827B EN
CX350C - CX370C Tier 4 Crawler Excavator
Issue date May 2011
CRAWLER EXCAVATORS CX350C - CX370C TIER 4 SERVICE MANUAL TABLE OF CONTENTS DIVISION/SECTION
SECTION N°
1
GENERAL INFORMATION Safety, general information and standard torque data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002A Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002B Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002C Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002D Bolt Size and Torque Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002E Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002F List of Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003 Fluid and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1004 Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1005 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1900
2
ENGINE Removal and Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of the Fuel Cooler Engine Inter-Cooler Radiator and Oil Cooler . . . . . . . . . . . Removal and Installation of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of EGR Cooler and EGR Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly, Removal and Installation of DPD Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2000 2001 2004 2005 2006 2007 2401 2415 2425 2445 2455 2465 2470
3
FUEL SYSTEM Removal and Installation of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3001 Removal and Installation of Fuel Supply Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004A Removal and Installation of Common Rail Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004B Removal and Installation of Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3005
4
ELECTRICAL SYSTEM Electrical and Engine Basic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001A Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001B Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001C Symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001E Functional Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001F Maintenance Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001G Removal and Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4004 Removal and Installation of Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005 Preheating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4008 Electrical Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020A Connection Connector Pin Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020B Sequence Circuit Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4020C Engine-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4021 Main Unit-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4022 Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023B Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023D Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023G Main Unit-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023H Lep 84402827B EN May 2011
Copyright © 2011 CNH France S.A. Printed in France
TABLE OF CONTENTS DIVISION/SECTION
SECTION N°
Data Reference Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4023K Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4040 5
UNDERCARRIAGE Removal and Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001A Removal and Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5001B Removal and Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003A Assembly and Disassembly of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003B Removal and Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003C Assembly and Disassembly of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5003D Removal and Installation of the Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5004 Removal and Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005A Assembly and Disassembly of Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005B Removal and Installation of Grease Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005C Assembly and Disassembly of Grease Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5005D
6
DRIVE TRAIN Removal and Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly and Disassembly of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly and Disassembly of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6001 6002 6003 6004
7
UNDERCARRIAGE HYDRAULICS
8
UPPERSTRUCTURE HYDRAULICS Overall view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001A Port Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001B Pressure Measurement and Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001D Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001E Drain Volume Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001F Air Bleed Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8001G Removal and Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8002 Removal and Installation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8003 Removal and Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8004 Removal and Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005A Removal and Installation of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005B Removal and Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8005C Removal and Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8006 Removal and Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007A Removal and Installation of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007B Removal and Installation of 4 Stack Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007C Removal and Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8007D Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit . . . . . . . . . . . . . . . . . . . . . . . . 8008 Pump Main Unit Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8010 Procedures for Assembly and Disassembly of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8011 Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . 8012 Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . 8013 Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . 8014 Assembly and Disassembly of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8016 Removal and Installation of Arm HBCV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017A Removal and Installation of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8017B Assembly and Disassembly of Center Joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8018 Assembly and Disassembly of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8019 Explanation of Hydraulic Circuit and Operations (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8020A Explanation of Hydraulic Circuit and Operations (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8020B
Lep 84402827B EN
Issued 2011-05
TABLE OF CONTENTS DIVISION/SECTION
SECTION N°
Structure and Operation Explanation of Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030A Structure and Operation Explanation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030B Structure and Operation Explanation of Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030C Structure and Operation Explanation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030D 4 Stack Solenoid Valve Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030E Structure and Operation Explanation of Upper Pilot Valve (remote control valve) . . . . . . . . . . . . . . . . . 8030F Structure and Operation Explanation of Travel Pilot Valve (remote control valve). . . . . . . . . . . . . . . . . . 8030G Structure and Operation Explanation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8030H 9
UPPERSTRUCTURE Removal and Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9002 Removal and Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003A Removal and Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003B Removal and Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003C Removal and Installation of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9003D Removal and Installation of Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9004 Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005A Removal and Installation of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005B Removal and Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005C Removal and Installation of Wiper Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005D Removal and Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005E Removal and Installation of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005F Window Lock Adjustment Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005G Cab Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9005H Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9006 Assembly and Disassembly of Air Conditioner Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9007 Removal and Installation of Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9009 Removal and Installation of Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9010 Removal and Installation of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9011 Air Conditioning Gas Vacuum and Filling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9015
10
LARGE SIZE SCHEMATICS Large size hydraulic schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84402838EN Large size electrical schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84402837EN
NOTE: CNH France S.A. Company reserves the right to make changes in the specification and design of the machine without prior notice and without incurring any obligation to modify units previously sold. The description of the models shown in this manual has been made in accordance with the technical specifications known as of the date of design of this document. All data given in this manual is subject to production variations. Dimensions and weights are provided with approximate values and the machine fitting shown in the illustrations may not correspond with standard models. For precise information on specific machine models and versions, please contact your CASE dealer. Reproduction or tranlation, even partial, is prohibited without written authorization from CNH France SA Company.
Lep 84402827B EN May 2011
Copyright © 2011 CNH France S.A. Printed in France
Lep 84402827B EN
Issued 2011-05
Section 1001
Safety, general information and standard torque data
84402827B - May 2011
84402827B - May 2011
CONTENTS GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ROPS Judgment Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Standard Torque Data For Cap Screws And Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402827B - May 2011 1001-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1001-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Safety, general information and standard torque data GENERAL INFORMATION CLEANING Clean all metal parts except bearings, in a suitable cleaning solvent or by steam cleaning. Do not use caustic soda for steam cleaning. After cleaning, dry and put oil on all parts. Clean oil passages with compressed air. Clean bearings in a suitable cleaning solvent, dry the bearings completely and put oil on the bearings. INSPECTION Check all parts when the parts are disassembled. Replace all parts that have wear or damage. Small scoring or grooves can be removed with a hone or crocus cloth. Complete a visual inspection for indications of wear, pitting and the replacement of parts necessary to prevent early failures. BEARINGS Check bearings for easy action. If bearings have a loose fit or rough action replace the bearing. Wash bearings with a suitable cleaning solvent and permit to air dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE BEARINGS Before you press needle bearings in a bore always remove any metal protrusions in the bore or edge of the bore. Before you press bearings into position put petroleum jelly on the inside and outside diameter of the bearings. GEARS Check all gears for wear and damage. Replace gears that have wear or damage. Oil seals, O-rings and gaskets. Always install new oil seals, O-rings and gaskets. Put petroleum jelly on seals and O-rings. SHAFTS Check all shafts that have wear or damage. Check the bearing and oil seal surfaces of the shafts for damage. SERVICE PARTS Always install genuine Case service parts. When ordering refer to the Parts Catalogue for the correct part number of the genuine Case replacement items. Failures due to the use of other than genuine Case replacement parts are not covered by warranty. LUBRICATION Only use the oils and lubricants specified in the Operator’s or Service Manuals. Failures due to the use of non-specified oils and lubricants are not covered by warranty.
84402827B - May 2011 1001-3
Safety, general information and standard torque data Safety This symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. The message that follows the symbol contains important information about safety. Carefully read the message. Make sure you fully understand the causes of possible injury or death.
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual. Put the warning tag shown below on the key for the key switch when servicing or repairing the machine. One warning tag is supplied with each machine. Additional tags are available from your service parts supplier. WARNING Read the operator's manual to familiarize yourself with the correct control functions. WARNING Operate the machine and equipment controls from the seat position only. Any other method could result in serious injury. WARNING This is a one man machine, no riders allowed. WARNING Before starting engine, study Operator’s Manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturers instructions on machine operation, service and to observe pertinent laws and regulations. Operator's and Service Manuals may be obtained from your CASE dealer. WARNING If you wear clothing that is too loose or do not use the correct safety equipment for your job, you can be injured. Always wear clothing that will not catch on objects. Extra safety equipment that can be required includes hard hat, safety shoes, ear protection, eye or face protection, heavy gloves and reflector clothing. WARNING When working in the area of the fan belt with the engine running, avoid loose clothing if possible, and use extreme caution. WARNING When doing checks and tests on the equipment hydraulics, follow the procedures as they are written. DO NOT change the procedure. WARNING When putting the hydraulic cylinders on this machine through the necessary cycles to check operation or to remove air from a circuit, make sure all people are out of the way. WARNING Use insulated gloves or mittens when working with hot parts. 84402827B - May 2011 1001-4
Safety, general information and standard torque data WARNING Lower all attachments to the ground or use stands to safely support the attachments before you do any maintenance or service. WARNING Pin sized and smaller streams of hydraulic oil under pressure can penetrate the skin and result in serious infection. If hydraulic oil under pressure does penetrate the skin, seek medical treatment immediately. Maintain all hoses and tubes in good condition. Make sure all connections are tight. Make a replacement of any tube or hose that is damaged or thought to be damaged. DO NOT use your hand to check for leaks, use a piece of cardboard or wood. WARNING When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze) hammer or use a driver made from brass or bronze and a steel head hammer. WARNING When using a hammer to remove and install pivot pins or separate parts using compressed air or using a grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye protectors). WARNING Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine in place with suitable safety stands. WARNING When servicing or repairing the machine, keep the shop floor and operator's compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material and/or shop cloths as required. Use safe practices at all times. WARNING Some components of this machine are very heavy. Use suitable lifting equipment or additional help as instructed in this Service Manual. WARNING Engine exhaust fumes can cause death. If it is necessary to start the engine in a closed place, remove the exhaust fumes from the area with an exhaust pipe extension. Open the doors and get outside air into the area. WARNING When the battery electrolyte is frozen, the battery can explode if (1), you try to charge the battery, or (2), you try to jump start and run the engine. To prevent the battery electrolyte from freezing, try to keep the battery at full charge. If you do not follow these instructions, you or others in the area can be injured.
84402827B - May 2011 1001-5
Safety, general information and standard torque data ROPS Judgment Method 1.
2.
Purpose Check against the ROPS judgment criteria to judge whether the machine satisfies the ROPS criteria or not. The weight and boom of the machine greatly effects whether the ROPS judgment criteria is satisfied or not. The ROPS test assumes that the weight being used is the weight of the machine when the maximum number of selectable options are mounted (as of 2009). However, depending on the derivative machinery or the order details, the weight and boom position may differ from the assumed weight or position. Criteria for judging whether a machine satisfies the ROPS criteria 1)
Weight The weight must not be over the weight shown below for each class. If the weight is exceeded, there is a danger that the cab could be damaged and the operator could die or sustain a serious injury when the machine falls over. If the weight exceeds the stipulated weight, the machine will not satisfy the ROPS criteria. • Weight (C series model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine weight
body
total
Class CX250C CX250CLR CX300C CX370C CX470C
31000 kg or less 40000 kg or less 50000 kg or less
* The ROPS test assumes that the CX470C has a cage guard (alone). • Weight (B series model) To satisfy the ROPS criteria, the weight must not be over the indicated weight. (The below weights are the weights indicated on the nameplate within the ROPS cab) Machine weight
body
25000 kg or less
total
Class CX130B CX160B CX180B CX210B CX230B
84402827B - May 2011 1001-6
Safety, general information and standard torque data 2)
Boom position WARNING • If the machine has been modified so that the boom position has been lowered, the machine will not satisfy the ROPS criteria. • It is necessary to consult with our company if it is possible that the boom's position has been lowered by modification. • The extent to which a boom position has moved cannot be determined in the same way for all machines.
a
Ground point
With the tip of the bucket in contact with the ground surface at maximum work radius, if the position (* in the diagram) that overlaps with the cab when viewed from the side is markedly lower than that of a standard machine (standard arm), the machine will not satisfy the ROPS criteria. Also, with a machine body with a cab mounted that can withstand up to 31 tons, the effect of mounting a 24 ton machine, which is near the restriction weight, and a 21 ton machine to the same cab will not be the same.
84402827B - May 2011 1001-7
Safety, general information and standard torque data 3.
Prohibited items • Modifications that reduce the strength of a platform that has a cab with a ROPS mounted to it. (Actions or modifications that reduce the functionality of the anchoring part at the left-rear of the cab) • Modifications that effect the strength of the ROPS of a cab. A forbidden all modifications (red part) Allow under specified conditions (gray part)
All modifications (grinding, welding, drilling holes, removing, etc.) are prohibited. Removal of parts is prohibited. Bar welding and making holes (up to diameter 20 mm) by drilling are possible.
[C series Cab]
84402827B - May 2011 1001-8
Safety, general information and standard torque data [B series Cab]
• In general, high cabs do not satisfy the ROPS criteria. (It is necessary to consult with our company to check if the high cab model satisfies the ROPS criteria.)
84402827B - May 2011 1001-9
Safety, general information and standard torque data Standard Torque Data For Cap Screws And Nuts BOLT AND NUT TIGHTENING • Tighten alternating between left and right and top and bottom so that uniform tightening force is applied.
• If Loctite was used on a removed bolt (there is something white sticking to the bolt when it is removed), clean the old Loctite off with cleaning fluid, dry the bolt, then apply 2 - 3 drops of Loctite to the thread section of the bolt. Torque table Bolt nominal diameter (size) Wrench Hexagon bolt Tightening torque Wrench Hexagon socket Tightening head bolt torque
[mm]
M6 10
M8 13
M10 17
M12 19
M14 22
M16 24
M18 27
M20 30
[N･m]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[mm]
5
6
8
10
12
14
14
17
[N･m]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
84402827B - May 2011 1001-10
Section 1002A
Specifications
84402827B - May 2011
84402827B - May 2011
CONTENTS Overall (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overall (CX370C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Main Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Upper Side Work System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Operating Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Swing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Travel Lower Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Control Valve and Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Capacities, Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Coolant and Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402827B - May 2011 1002A-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Specifications Overall (CX350C) Main Data 34700 kg 198 kW/1900 min-1
Operating weight Engine output
Performance Standard weight Swing speed
18.0 kN 9.7 min-1 Low speed 3.2 km/h High speed 5.4 km/h 264 kN 70 ％ (35°) 65 kPa (600 mm grouser 57 kPa (700 mm grouser 50 kPa (800 mm grouser 47 kPa (850 mm grouser 45 kPa (900 mm grouser
Travel speed Maximum pulling force Grade ability
Ground pressure
Standard weight Swing speed
shoe) shoe) shoe) shoe) shoe)
18.0 kN 9.7 min-1 Low speed 3.2 km/h High speed 5.4 km/h 264 kN 70 ％ (35°) 58 kPa (700 mm grouser shoe) 51 kPa (800 mm grouser shoe) 48 kPa (850 mm grouser shoe)
Travel speed Maximum pulling force Grade ability Ground pressure
Main Unit Dimensions Main unit length Main unit width Upper swing body width Cab width Main unit height Swing radius (rear end) Swing body rear end distance Swing body rear section bottom height Distance between tumblers Overall track length Overall track width Distance between tracks Track shoe width Minimum ground clearance
6010 3200 3030 1000 3160 3550 3520
mm mm (600 G shoe) mm mm mm mm mm
1210 mm (not including lug height of 36 mm) 4040 mm 4980 mm 3200 mm (600 G shoe) 2600 mm 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm) 480 mm (to bottom of lower frame) (not including lug height of 36 mm)
Engine Name Model
Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft type Common rail system (electronic control), cooled EGR, with turbocharger (variable displacement type), DPD system
Number of cylinders - bore x 6 - D115 mm x 125 mm stroke 84402827B - May 2011 1002A-3
Specifications Total stroke volume Maximum torque Starter Charging generator Battery
7.790 L 1043 N¡m/1500 min-1 24 V 5.0 kW reduction type 24 V 50 A AC type 12 V 128 Ah/5 HR x 2
Cooling System Fan type Radiator Fin type Fin pitch Oil cooler Fin type Fin pitch Intercooler Fin type Fin pitch Fuel cooler Fin type Fin pitch
D850 mm, 6 blades, suction Wavy 1.75 mm Wavy 1.75 mm Wavy 2.5 mm Wavy 2.0 mm
Upper Side Work System Model Components, dimensions, working dimensions Bucket capacity (reference) Bucket width Bucket width with side cutter Bucket weight with side cutter Boom length Arm type Arm length Bucket radius Bucket wrist angle Maximum digging radius Maximum digging radius at ground line Maximum digging depth Maximum vertical straight wall digging depth Maximum digging height Maximum dump height Minimum swing radius at front Height for minimum swing radius at front
Backhoe Attachment Heaped 1.40 m3 (Leveled 1.04 1300 mm 1440 mm 1150 kg 6450 mm Standard Long (STD/HD) (4.04 m) (3.25 m) 3250 mm 4040 mm 1680 mm 173° 11170 mm 11900 mm
m3)
10980 mm
Short (2.63 m)
Ultra-short (2.21 m)
2630 mm
2210 mm
10670 mm
10200 mm
11720 mm
10470 mm
9990 mm
7340 mm
8140 mm
6730 mm
6300 mm
6350 mm
7150 mm
5970 mm
5080 mm
10370 mm 7230 mm 4500 mm
10670 mm 7540 mm 4560 mm
10320 mm 7140 mm 4630 mm
9850 mm 6770 mm 4660 mm
8480 mm
8490 mm
8540 mm
8650 mm
Operating Device Operator's seat Position Structure Cab Levers and pedals For travel use
Left side Adjustable forward and back and up and down, reclining mechanism, with seat suspension Sealed steel type, all reinforced glass, ROPS, with sunroof Lever and pedal type (hydraulic pilot type) x 2 84402827B - May 2011 1002A-4
Specifications For operating machine use Lever type (hydraulic pilot type) x 2 Instruments and switches Work mode switchover 3 modes (SP/H/A) Travel mode switchover Low-speed/high-speed switch type Knob switch type One-touch idle Engine emergency stop Switch type Monitor device Machine status display (TFT color liquid crystal) Message display Work mode select status SP/H/A Instruments Fuel gauge Engine coolant temperature gauge Hydraulic oil temperature gauge Hour meter Rear view camera monitor Warning display and warning alarm * has warning alarm Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant (*) Engine pre-heat Auto Warm-up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine emergency stop (*) Illumination equipment Right front tool Working light box front sur- 24 V 70 W x 1 face: 24 V 70 W x 2 Cab top: Boom side: 24 V 70 W x 1 Interior light 4 V 10 W x 1 Horn Electric horn x 2 Wiper with intermittent function, window washer, air conditioner, 4 rear view mirrors (2 on cab sides, 1 front right stay, 1 CTWT Other rear right), 1 rear view mirror (on CTWT)
Swing Units Swing circle Swing hydraulic motor Reduction gear Swing parking brake
Swing bearing type (with inner gear) Fixed displacement piston motor x 1 Planetary gear 2-stage reduction gear Mechanical lock (operational lever linkage type)
Travel Lower Body Travel hydraulic motor Reduction gear Travel brake Parking brake Track shoe Model Number of shoes (per side) Shoe width Grouser height Link pitch Roller No. of upper rollers (per side) No. of lower rollers (per side) Track belt tension adjuster
Variable displacement piston motor x 2 Planetary gear 2-stage reduction gear(Nabtesco Corporation) Hydraulic lock Mechanical lock (travel lever linkage type) Assembly-type triple grouser shoe 48 600 mm (options 700 mm, 800 mm, 850 mm, 900 mm) 36 mm 216 mm 2 8 Grease cylinder type (with cushion spring) 84402827B - May 2011 1002A-5
Specifications Hydraulic Equipment Hydraulic Device Hydraulic pump drive type Hydraulic pump
Direct engine link (no transmission)
Model Discharge volume Pump control method Set pressure of main relief valve Set pressure of overload relief valve
Double variable displacement piston pump x 1 Gear pump x 1 Piston pump 2 x 285 L/min Gear pump 28.5 L/min Simultaneous output full-horsepower control 34.3 MPa (37.3 MPa for pressure boost) 27.4 MPa (boom down) 39.2 MPa (boom up/arm/bucket)
Control Valve and Cylinder Control valve Model Operating method Cylinder Boom cylinder Arm cylinder Bucket cylinder
Quadruple spool + quintuple spool x 1 Hydraulic pilot type: travel, swing, and operating machine No. of cylinders x tube bore - rod diameter - stroke 2 x D145 mm - D100 mm - 1495 mm 1 x D170 mm - D120 mm - 1748 mm 1 x D150 mm - D105 mm - 1210 mm
Capacities, Filters Coolant and Oil Capacities Coolant Fuel Engine lubricating oil (including remote oil filter) Travel reduction gear lubricating oil (one side) Swing reduction gear lubricating oil Hydraulic oil Hydraulic oil tank regulation amount
35.4 L 580 L 49 L 11 L 5L 350 L 175 L
Hydraulic Oil Filters Suction filter (inside tank) Return filter (inside tank) Pilot line filter (inside pump chamber)
105 μm 6 μm 8 μm
Fuel Filter Main filter Pre-filter
2 μm 7 μm
84402827B - May 2011 1002A-6
Specifications Overall (CX370C) Main Data Operating weight Engine output
36800 kg 198 kW/1900 min-1
Performance Standard weight Swing speed
18.0 kN 9.7 min-1 Low speed 3.2 km/h High speed 5.4 km/h 263 kN 70 ％ （ 35°） 69 kPa (600 mm grouser shoe) 60 kPa (700 mm grouser shoe) 53 kPa (800 mm grouser shoe)
Travel speed Maximum pulling force Grade ability Ground pressure
Main Unit Dimensions Main unit length Main unit width Upper swing body width Cab width Main unit height Swing radius (rear end) Swing body rear end distance Swing body rear section bottom height Distance between tumblers Overall track length Overall track width Distance between tracks Track shoe width Minimum ground clearance
6010 3200 3030 1000 3160 3550 3520
mm mm (600 G shoe) mm mm mm mm mm
1210 mm (not including lug height of 36 mm) 4040 mm 4980 mm 3200 mm (600 G shoe) 2600 mm 600 mm (options 700 mm, 800 mm) 480 mm (to bottom of lower frame) (not including lug height of 36 mm)
Engine Name Model
Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft type Common rail system (electronic control), cooled EGR, with turbocharger (variable displacement type), DPD system
Number of cylinders - bore x 6 - D115 mm x 125 mm stroke Total stroke volume 7.790 L Maximum torque 1043 N·m/1500 min-1 24 V 5.0 kW reduction type Starter Charging generator 24 V 50 A AC type Battery 12 V 128 Ah/5 HR x 2
Cooling System Fan type Radiator Fin type Fin pitch Oil cooler Fin type
D850 mm, 6 blades, suction Wavy 1.75 mm Wavy 84402827B - May 2011 1002A-7
Specifications Fin pitch Intercooler Fin type Fin pitch Fuel cooler Fin type Fin pitch
1.75 mm Wavy 2.5 mm Wavy 2.0 mm
Upper Side Work System Model Dimensions, working dimensions Bucket capacity (reference) Bucket width Bucket width with side cutter Bucket weight with side cutter Boom length Arm type Arm length Bucket radius Bucket wrist angle Maximum digging radius Maximum digging radius at ground line Maximum digging depth Maximum vertical straight wall digging depth Maximum digging height Maximum dump height Minimum swing radius at front Height for minimum swing radius at front
Backhoe attachment Heaped 1.40 m3 (Leveled 1.04 m3) 1310 mm 1420 mm 1480 kg 6450 mm Standard (HD) Short (3.25 m) (2.63 m) 3250 mm 2630 mm 1680 mm 173° 11170 mm 10670 mm
10200 mm
10980 mm
10470 mm
9990 mm
7340 mm
6730 mm
6300 mm
6350 mm
5970 mm
5080 mm
10370 mm 7230 mm 4500 mm
10320 mm 7140 mm 4630 mm
9850 mm 6770 mm 4660 mm
8480 mm
8540 mm
8650 mm
Ultra-short (2.21 m) 2210 mm
Operating Device Operator's seat Position Structure Cab Levers and pedals For travel use For operating machine use Instruments and switches Work mode switchover Travel mode switchover One-touch idle Engine emergency stop Monitor device Machine status display (TFT color liquid crystal) Message display Work mode select status Instruments Fuel gauge Engine coolant temperature gauge Hydraulic oil temperature gauge Hour meter
Left side Adjustable forward and back and up and down, reclining mechanism, with seat suspension Sealed steel type, all reinforced glass, ROPS, with sunroof Lever and pedal type (hydraulic pilot type) x 2 Lever type (hydraulic pilot type) x 2 3 modes (SP/H/A) Low-speed/high-speed switch type Knob switch type Switch type
SP/H/A
84402827B - May 2011 1002A-8
Specifications Rear view camera monitor Warning display and warning alarm * has warning alarm Overheat (*) Battery charge (*) Electrical system abnormality (*) Refill fuel (*) Engine oil pressure (*) Refill coolant (*) Engine pre-heat Warm up Air cleaner (*) Anti-theft device triggered Engine system abnormality (*) Engine emergency stop (*) Illumination equipment Right front tool Working light 24 V 70 W x 1 box front surface: 24 V 70 W x 2 Cab top: Boom side: 24 V 70 W x 1 Interior light 24 V 10 W x 1 Horn Electric horn x 2 Wiper with intermittent function, window washer, air conditioner, 4 rear view mirrors (2 on cab sides, 1 front right stay, Other 1 CTWT rear right), 1 rear view mirror (on CTWT)
Swing Units Swing circle Swing hydraulic motor Reduction gear Swing parking brake
Swing bearing type (with inner gear) Fixed displacement piston motor x 1 Planetary gear 2-stage reduction gear Mechanical lock (operational lever linkage type)
Travel Lower Body Travel hydraulic motor Reduction gear Travel brake Parking brake Track shoe Model No. of shoes (per side) Shoe width Grouser height Link pitch Roller No. of upper rollers (per side) No. of lower rollers (per side) Track belt tension adjuster
Variable displacement piston motor x 2 Planetary gear 2-stage reduction gear Hydraulic lock Mechanical lock (travel lever linkage type) Assembly-type triple grouser shoe 48 600 mm (options 700 mm,850 mm, 800 mm,900 mm) 36 mm 216 mm 2 8 Grease cylinder type (with cushion spring)
84402827B - May 2011 1002A-9
Specifications Hydraulic Equipment Hydraulic Device Hydraulic pump drive type Hydraulic pump
Direct engine link (no transmission)
Model Discharge volume Pump control method Set pressure of main relief valve Set pressure of overload relief valve
Double variable displacement piston pump x 1 Gear pump x 1 Piston pump 2 x 285 L/min Gear pump 28.5 L/min Simultaneous output full-horsepower control 34.3 MPa (37.3 MPa for pressure boost) 27.4 MPa (boom down) 39.2 MPa (boom up/arm/bucket)
Control Valve and Cylinder Control valve Model Operating method Cylinder Boom cylinder Arm cylinder Bucket cylinder
Quadruple spool + quintuple spool x 1 Hydraulic pilot type: travel, swing, and operating machine No. of cylinders x tube bore - rod diameter - stroke 2 x D145 mm - D100 mm - 1495 mm 1 x D170 mm - D120 mm - 1748 mm 1 x D150 mm - D105 mm - 1210 mm
Capacities, Filters Coolant and Oil Capacities Coolant Fuel Engine lubricating oil (including remote oil filter) Travel reduction gear lubricating oil (one side) Swing reduction gear lubricating oil Hydraulic oil Hydraulic oil tank regulation amount
35.4 L 580 L 49 L 11 L 5L 350 L 175 L
Hydraulic Oil Filters Suction filter (inside tank) Return filter (inside tank) Pilot line filter (inside pump chamber)
105 μm 6 μm 8 μm
Fuel Filter Main filter Pre-filter
2 μm 7 μm
84402827B - May 2011 1002A-10
Section 1002B
Main Equipment Table
84402827B - May 2011
84402827B - May 2011
CONTENTS Main Equipment Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Recoil Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Shoe (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Shoe (CX370C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Swing Unit (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Swing Unit (CX370C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Air Cleaner (double element) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Control-related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Solenoid Valve (4 stack) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote Control Valve (left/right, travel operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve for Left/Right Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve for Travel Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remote Control Valve Characteristic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation Remote Control Valve Control Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Travel Remote Control Valve Control Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cushion Valve (heat circuit, with shuttle valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Backhoe Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84402827B - May 2011 1002B-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Main Equipment Table Main Equipment Table Lower Component Travel Unit Manufacturer Motor type Intake amount Operating pressure Operating flow Brake torque Relief valve set pressure Automatic 2-speed switchover pressure Reduction gear Reduction gear type Reduction ratio Dry weight
Nabtesco Corporation Variable displacement piston motor Automatic 2-speed switchover with parking brake 290.7/170.1 cm3/rev 34.3 MPa 285 L/min 47.39 kN¡m min. (including reduction gear) 35.8 - 37.8 MPa 26.5 MPa Planetary gear 2-stage reduction gear 40.467 399 kg
Take-up Roller Sumitomo part No. Weight
LH5146 164.6 kg
Upper Roller Weight
43 kg
Lower Roller Weight
61 kg
Recoil Spring Item Yoke Sems B M16 x 50 Threaded rod Groove height N M64 SP pin 10 x 100 Recoil spring Grease cylinder assembly Sems B M16 x 65 Assembly (Total) Mounting length of spring
Weight (kg) 39.8 0.5 49.1 1.9 0.1 119.4 41.1 0.3 252.2 779 mm
Q'ty 1 4 1 1 1 1 1 2
84402827B - May 2011 1002B-3
Main Equipment Table Shoe (CX350C) 600 grouser Link Shoe Bolt Nut 700 grouser Link Shoe Bolt Nut 800 grouser Link Shoe Bolt Nut 850 grouser Link Shoe Bolt Nut 900 grouser Link Shoe Bolt Nut
Weight or Q'ty 2217 kg 1 set 48 192 192 2473 kg 1 set 48 192 192 2618 kg 1 set 48 192 192 2735 kg 1 set 48 192 192 2817 kg 1 set 48 192 192
Shoe (CX370C) 600 grouser Link Shoe Bolt Nut 700 grouser Link Shoe Bolt Nut 800 grouser Link Shoe Bolt Nut
Weight or Q'ty 2217 kg 1 set 48 192 192 2473 kg 1 set 48 192 192 2618 kg 1 set 48 192 192
84402827B - May 2011 1002B-4
Main Equipment Table Upper Component Swing Unit (CX350C) Swing motor assembly Swing motor Manufacturer Motor type Intake amount Operating pressure Operating flow Mechanical brake torque Brake off pressure Relief valve set pressure Swing reduction gear Reduction gear type Reduction ratio Dry weight Turntable bearing No. of teeth Weight Counterweight Weight
Kawasaki Precision Machinery Ltd. Fixed displacement piston motor With parking brake 180.1 cm3/rev 30.4 MPa 285 L/min 1010.8 Năƒťm min. 3.1 MPa max. 30.4 MPa Planetary gear 2-stage reduction gear 27.143 437 kg 92 540 kg 6400 kg
Swing Unit (CX370C) Swing motor assembly Swing motor Manufacturer Motor type Intake amount Operating pressure Operating flow Mechanical brake torque Brake off pressure Relief valve set pressure Swing reduction gear Reduction gear type Reduction ratio Dry weight Turntable bearing No. of teeth Weight Counterweight Weight
Kawasaki Precision Machinery Ltd. Fixed displacement piston motor With parking brake 180.1 cm3/rev 30.4 MPa 285 L/min 1010.8 Năƒťm min. 3.1 MPa max. 30.4 MPa Planetary gear 2-stage reduction gear 27.143 437 kg 92 540 kg 7400 kg
84402827B - May 2011 1002B-5
Main Equipment Table Engine-related Engine Sumitomo part No. Engine model name
KSH11600 Isuzu 6HK1X diesel engine 4-cycle, water-cooled, overhead camshaft type, common rail system Engine type (electronic control), cooled EGR, with turbocharger (variable displacement type), DPD system No. of cylinders - bore - stroke 6 - D115 mm - 125 mm Total displacement 7.79 L 17.5 Compression ratio Rated output 198 kW/1900 min-1 Maximum torque 1043 N¡m/about 1500 min-1 Fuel consumption ratio 221 - 241 g/kW¡h at 1900 min-1 Engine dry weight About 640 kg Engine dimension L 1388 - W 1047 - H 1194 mm D850 mm - suction type - 6 vanes, plastic and steel Cooling fan With bell mouth-type fan guide Pulley ratio 0.9 (reduction) Charging generator 24 V 50 A AC type 24 V 5 kW reduction type Starter motor Coolant capacity 14.5 L Oil pan capacity Max: 46 L Min: 36 L (not including oil filter) Right (viewed from fan side) Direction of rotation Compliant with JISD 0006-2000.
DPD Isuzu Motors, Ltd. 38 kg
Manufacturer Weight
Air Cleaner (double element) Nippon Donaldson, Ltd.
Manufacturer Element (outer) Element (inner) Weight
13 kg
Radiator Manufacturer Oil cooler Radiator Air cooler Fuel cooler Total weight
Weight Oil volume Weight Coolant capacity Weight Capacity Weight Capacity
Tokyo Radiator MFG. Co.,Ltd. 39.0 kg 12.9 L 11.9 kg 9.4 L 12.6 kg 1.0 kg x 2 0.3 L x 2 159 kg
84402827B - May 2011 1002B-6
Main Equipment Table Hydraulic Device Hydraulic Pump Manufacturer Main pump Pump type Displacement capacity Operating pressure Input revolution speed Maximum discharge flow Pilot pump Pump type Displacement capacity Operating pressure Maximum discharge flow Control method
Dry weight
Kawasaki Precision Machinery Ltd.
Rated Maximum
Double variable displacement piston pump 150 x 2 cm3/rev 34.3 MPa 37.3 MPa 1900 min-1 289 x 2 L/min (at Pd = 3.0 MPa. 1900 min-1) 285 x 2 L/min (at Pd = 8.0 MPa. 1900 min-1) Gear pump 15 cm3/rev 3.9 MPa 28.5 L/min (at 1900 min-1) Hydraulic simultaneous constant output control Maximum flow adjustment control through external commands (negative control) Maximum flow adjustment control through external command milli-amp (negative control, front side) Setting horsepower adjustment control through external command milli-amp 188 kg
84402827B - May 2011 1002B-7
Main Equipment Table Control-related Control Valve STD (with 2nd option add-on valve) Manufacturer Maximum flow Overload set pressure
Main relief set pressure (at boosting) Foot relief set pressure Function
Weight
KYB Corporation 285 L/min (at 1900 min-1) 27.4 MPa boom down 39.2 MPa boom up, arm, bucket 22.6 MPa attachment 2 34.3 MPa 37.3 MPa 2.55 MPa Straight travel circuit Boom-up/arm 2 pumps internal flow Boom and arm load holding circuit Boom-down regenerative circuit Bucket-close regenerative circuit Arm-in forced regenerative circuit Swing priority variable orifice 2 pumps flow (external flow merging) 199 kg 215 kg
Solenoid Valve (4 stack) Manufacturer Valve specifications Maximum flow Rated pressure Port size Solenoid specifications Operating voltage Power consumption Weight
Yuken Kogyo Co., Ltd.
G3/8 G1/4
P → B 20 L/min Other 5 L/min 4.5 MPa P.T.B. port C1, C2, C3, C4, C5 ports DC 20 - 32 V 17 W max. 5 kg
84402827B - May 2011 1002B-8
Main Equipment Table Remote Control Valve (left/right, travel operations) Remote Control Valve for Left/Right Operations Manufacturer Operating pressure Secondary pressure Operating
Kawasaki Precision Machinery Ltd. 3.92 MPa 0.64 - 2.45 MPa primary short type 19° 25° 1.9 kg
1, 3 port 2, 4 port
Weight
Remote Control Valve for Travel Operations Kawasaki Precision Machinery Ltd. 3.92 MPa 0.64 - 2.45 MPa primary short type 12.4° 5.5 kg
Manufacturer Operating pressure Secondary pressure Operating angle Weight
Remote Control Valve Characteristic Diagram Operation Remote Control Valve Control Diagram Ports 1, 3
Secondary pressure [MPa]
Push rod stroke [mm]
Operating angle [deg.]
Secondary pressure 1
84402827B - May 2011 1002B-9
Main Equipment Table Ports 2, 4
Secondary pressure [MPa]
Push rod stroke [mm]
Operating angle [deg.]
Secondary pressure 1
Travel Remote Control Valve Control Diagram
Secondary pressure [MPa]
Push rod stroke [mm]
Pedal operating angle [deg.]
Secondary pressure 1 84402827B - May 2011 1002B-10
Main Equipment Table Cushion Valve (heat circuit, with shuttle valve) Yanagisawa Seiki MFG. Co., Ltd. G 3/8 (A - P ports) G 1/4 (Q - V ports) 12.5 kg
Manufacturer Port size Weight
Center Joint Operating pressure
Flow
Port A Port B Port C Port D Port T Port P Weight
High-pressure passage (ABCD) Drain port (T) Pilot port (P) High-pressure passage (ABCD) Drain port (T) Pilot port (P) Forward right Forward left Backward right Backward left Drain port Pilot port 55.5 kg
Backhoe Attachment Cylinder Boom Cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight
D145 mm D100 mm 2090 mm 1495 mm 279 kg
Arm Cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight
D170 mm D120 mm 2445 mm 1748 mm 462 kg
Bucket cylinder Cylinder bore Rod diameter Maximum retracted length Stroke Weight
D150 mm D105 mm 1870 mm 1210 mm 276 kg
84402827B - May 2011 1002B-11
34.3 MPa 1.0 MPa 3.9 MPa 360 L/min 40 L/min 31 L/min G1 G1 G1 G1 G1/2 G1/4
Main Equipment Table
84402827B - May 2011 1002B-12
Section 1002C
Main Unit Weight
84402827B - May 2011
84402827B - May 2011
CONTENTS Main Unit Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Divided Weight (standard specifications) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Divided Weight (standard specifications) CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand Alone Part Weight (CX350C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stand Alone Part Weight (CX370C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe Weight (per side) CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shoe Weight (per side) CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Weight (CX350C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Weight (CX370C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 1002C-1
3 3 4 5 5 5 5 6 6
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Main Unit Weight Main Unit Weight Divided Weight (standard specifications) CX350C
Weight (kg) 34700
Code
Component name
A
Operating weight Upper component (including counterweight and turntable 15370 bearing) Counterweight 6420 Lower component (with grouser shoe) 12290 Main unit weight 27700 Attachments 7000 Boom (including cylinders) 3920 Arm (including cylinders and linkage) 1800
B C D E F G H
84402827B - May 2011 1002C-3
Main Unit Weight * The weights displayed are approximate weights.
Divided Weight (standard specifications) CX370C
Weight (kg) 36800
Code
Component name
A
Operating weight Upper component (including counterweight and turntable 16370 bearing) Counterweight 7420 Lower component (with grouser shoe) 12470 Main unit weight 28900 Attachments 7920 Boom (including cylinders) 4220 Arm (including cylinders and linkage) 2130
B C D E F G H
* The weights displayed are approximate weights. 84402827B - May 2011 1002C-4
Main Unit Weight Stand Alone Part Weight (CX350C) Component name 1
Travel unit
2 3 4 5 6 7 8 9 10 11 12 13
Take-up roller Upper roller Lower roller Swing unit Turntable bearing Engine Radiator Hydraulic pump Fuel tank Hydraulic oil tank Control valve Center joint
14
Boom
Nabtesco KYB
Standard HD
Weight (kg) 505 500 165 43 61 467 541 785 187 222 244 203 211 58 2427 2720
Stand Alone Part Weight (CX370C) 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Weight (kg) 505 165 43 61 467 541 785 187 222 244 203 211 58 2720
Component name Travel unit Take-up roller Upper roller Lower roller Swing unit Turntable bearing Engine Radiator Hydraulic pump Fuel tank Hydraulic oil tank Control valve Center joint Boom
Shoe Weight (per side) CX350C 1 2 3 4 5
Weight (kg) 2220 2470 2620 2740 2820
Component name 600mm grouser shoe 700mm grouser shoe 800mm grouser shoe 850mm grouser shoe 900mm grouser shoe
Shoe Weight (per side) CX370C 1 2 3
Component name 600mm grouser shoe 700mm grouser shoe 800mm grouser shoe
Weight (kg) 2220 2470 2620 84402827B - May 2011 1002C-5
Main Unit Weight Arm Weight (CX350C) 1 2 3 4
Component name Standard arm Ultra-short Arm Short Arm Long Arm
Weight (kg) 1112 1102 1209 1447
Arm Weight (CX370C) 1 2 3
Component name Standard arm Ultra-short Arm Short Arm
Weight (kg) 1421.5 1174.7 1282.3
84402827B - May 2011 1002C-6
Section 1002D
Maintenance Standards
84402827B - May 2011
84402827B - May 2011
CONTENTS Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Track Shoe (grouser shoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Attachment (backhoe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1. Boom and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2. Boom Cylinder and Swing Frame Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3. Boom and Boom Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4. Boom and Arm Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 5. Boom and Arm Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 6. Arm and Arm Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 7. Arm and Bucket Cylinder Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 8. Arm and Arm Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 9. Bucket and Bucket Link Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 10. Bucket Link and Bucket Cylinder Installation Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 11. Bucket and Arm Installation Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspection Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 For Drive Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 For Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 For Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 For Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
84402827B - May 2011 1002D-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Maintenance Standards Drive Sprocket
* See the gauge list for measurement gauges.
Part name
Code
Measurement di- Standard mensions value (mm) (mm)
a
Usage limit (mm)
83
73
b
D
D660.7
D650.7
c
D
D748
D738
d
D
D732.5
-
e
40
45
p
215.9
-
Drive sprocket
84402827B - May 2011 1002D-3
Judgment
Solution
Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Cladding by welding or replacement Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable
Maintenance Standards Take-up Roller
* See the gauge list for measurement gauges.
Part name
Take-up roller
Shaft
Code
Measurement di- Standard mensions value (mm) (mm)
Usage limit (mm)
a
D
D560
-
b
22.5
25.5
c
102
100
d
D
D85
D84
d
D
D85
D86
e
82
81
f
24
23.6
Bushing
Hub
84402827B - May 2011 1002D-4
Judgment Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable
Solution
Cladding by welding or replacement
Replacement
Replacement
Replacement
Maintenance Standards Upper Roller
* See the gauge list for measurement gauges.
Part name
Carrier roller
Code
Measurement di- Standard mensions value (mm) (mm)
Usage limit (mm)
a
D
D150
D138
b
15
-
c
104
-
Shaft
d
D
D65
D64
Bushing
d
D
D65
D66
Bushing
e
69
68
Thrust plate
f
9
8.5
Cover
g
15
-
84402827B - May 2011 1002D-5
Judgment Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable
Solution
Cladding by welding or replacement
Replacement Replacement Replacement Replacement Replacement
Maintenance Standards Lower Roller
* See the gauge list for measurement gauges.
Part name
Track roller
Shaft
Code
Standard Measurement divalue mensions (mm) (mm)
Usage Judgment limit (mm)
a
D
D180
D168
b
25
20
d
216
224
e
D
D75
D74
e
D
D75
D76
f
D82
D81
g
17.5
17.0
Bushing
Collar
84402827B - May 2011 1002D-6
Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable
Solution
Cladding by welding or replacement
Replacement
Replacement
Replacement
Maintenance Standards Track Shoe (grouser shoe)
Measurement di- Standard mensions value (mm) (mm)
Usage limit (mm)
Part name
Code
Shoe plate
a
49
34
Link
b
129
123
c
D
D71.4
D67.4
d
D
D47.9
-
e
D
D47.3
-
f
216.2
220.7
f'
864.6
882.6
Master bushing
Master pin Link pitch 4 linked sections
c'
D
D71.4
D67.4
d'
D
D48.4
-
e'
D
D47.6
-
Track bushing
Track pin
84402827B - May 2011 1002D-7
Judgment Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable Acceptable/ Unacceptable
Solution Replacement Cladding by welding or replacement Replacement
Replacement
Replacement
Replacement
Replacement
Maintenance Standards Attachment (backhoe)
84402827B - May 2011 1002D-8
Maintenance Standards 1. Boom and Swing Frame Installation Section
Usage limits Judgment (mm) Acceptable/ 861.5 869.5 Unacceptable Acceptable/ 857 855 Unacceptable Shim ad- Acceptable/ 1 mm max. justment Unacceptable Acceptable/ D110 D109 Unacceptable Acceptable/ D110 D111.5 Unacceptable
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Swing frame
a
Boom
b
Clearance
c
Pin
d
D
Bushing (boom)
e
D
84402827B - May 2011 1002D-9
Solution Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 2. Boom Cylinder and Swing Frame Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Swing frame
a
131
Boom cylinder (foot section)
b
130
Clearance
c
1.0 - 2.5
Pin
d
D
D90
Bushing (boom cylinder)
e
D
D90
Usage limits Judgment (mm) Acceptable/ 137 Unacceptable Acceptable/ 128 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable
84402827B - May 2011 1002D-10
Solution Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 3. Boom and Boom Cylinder Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Boom cylinder (top section)
a
123
Boom
b
669
Clearance
c
1.2 max.
Pin
d
D
D110
Bushing (boom cylinder)
e
D
D110
Usage limits Judgment (mm) Acceptable/ 121 Unacceptable Acceptable/ 665 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D109 Unacceptable Acceptable/ D111.5 Unacceptable
84402827B - May 2011 1002D-11
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 4. Boom and Arm Cylinder Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Boom
a
146
Arm cylinder (foot section)
b
145
Clearance
c
1.2 max.
Pin
d
D
D100
Bushing (arm cylinder)
e
D
D100
Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D99 Unacceptable Acceptable/ D101.5 Unacceptable
84402827B - May 2011 1002D-12
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 5. Boom and Arm Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Boom
a
Arm
b
Clearance
c
Pin
d
D
Bushing (arm)
e
D
Boom
f
D
Boom
g
Usage limits Judgment (mm) Acceptable/ 392 395 Unacceptable Acceptable/ 387.7 385.7 Unacceptable Shim ad- Acceptable/ 1 mm max. justment Unacceptable Acceptable/ D115 D114 Unacceptable Acceptable/ D115 D116.5 Unacceptable Acceptable/ D115 D116.5 Unacceptable Acceptable/ 89 87.5 Unacceptable
84402827B - May 2011 1002D-13
Solution Replacement Replacement Adjustment shims Replacement Replacement Replacement Replacement
with
Maintenance Standards 6. Arm and Arm Cylinder Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Arm
a
146
Arm cylinder (top section)
b
145
Clearance
c
0.5 - 3.0
Pin
d
D
D100
Bushing (arm cylinder)
e
D
D100
Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D99 Unacceptable Acceptable/ D101.5 Unacceptable
84402827B - May 2011 1002D-14
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 7. Arm and Bucket Cylinder Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Arm
a
146
Bucket cylinder (foot b section)
145 1.2 max.
Clearance
c
Pin
d
D
D95
Bushing (bucket cylinder)
e
D
D95
Usage limits Judgment (mm) Acceptable/ 152 Unacceptable Acceptable/ 143 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D94 Unacceptable Acceptable/ D96.5 Unacceptable
84402827B - May 2011 1002D-15
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 8. Arm and Arm Link Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Arm link
a
50
Arm
b
375
Clearance
c
1.2 max.
Pin
d
D
D85
Bushing (arm)
e
D
D85
Usage limits Judgment (mm) Acceptable/ 48 Unacceptable Acceptable/ 373 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ D84 Unacceptable Acceptable/ D86.5 Unacceptable
84402827B - May 2011 1002D-16
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 9. Bucket and Bucket Link Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Bucket
a
401
Bucket link
b
400
Clearance
c
1.0 - 3.5
Pin
d
D
D90
Bushing (bucket link)
e
D
D90
Usage limits Judgment (mm) Acceptable/ 406 Unacceptable Acceptable/ 398 Unacceptable Shim ad- Acceptable/ justment Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable
84402827B - May 2011 1002D-17
Solution Replacement Replacement Adjustment shims Replacement Replacement
with
Maintenance Standards 10. Bucket Link and Bucket Cylinder Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Arm link
a
Bucket link
b
Clearance
c
Bucket link
d
Bucket cylinder (top section)
e
Clearance
f
Pin
g
D
h
D
i
D
Bushing (bucket link) Bushing (bucket cylinder)
Usage limits Judgment (mm) Acceptable/ 50 48 Unacceptable Acceptable/ 375 373 Unacceptable 1.2 mm Shim ad- Acceptable/ max. justment Unacceptable Acceptable/ 121 123 Unacceptable Acceptable/ 120 118 Unacceptable Shim ad- Acceptable/ 1.0 - 2.0 justment Unacceptable Acceptable/ D105 D104 Unacceptable Acceptable/ D105 D106.5 Unacceptable Acceptable/ D105 D106.5 Unacceptable
84402827B - May 2011 1002D-18
Solution Replacement Replacement Adjustment shims
with
Replacement Replacement Adjustment shims Replacement Replacement Replacement
with
Maintenance Standards 11. Bucket and Arm Installation Section
Measurement di- Standard mensions value (mm) (mm)
Part name
Code
Bucket
a
401
Arm
b
400
Clearance
c
1.2 max.
Bushing (bucket)
d
16
Pin
e
D
D90
Bushing (arm)
f
D
D90
Bushing (bucket)
g
D
D90
Usage limits Judgment (mm) Acceptable/ 406 Unacceptable Acceptable/ 398 Unacceptable mm Shim ad- Acceptable/ justment Unacceptable Acceptable/ 7 Unacceptable Acceptable/ D89 Unacceptable Acceptable/ D91.5 Unacceptable Acceptable/ D91.5 Unacceptable
84402827B - May 2011 1002D-19
Solution Replacement Replacement Adjustment shims Replacement Replacement Replacement Replacement
with
Maintenance Standards Inspection Gauge For Drive Sprocket
84402827B - May 2011 1002D-20
Maintenance Standards For Take-up Roller
84402827B - May 2011 1002D-21
Maintenance Standards For Upper Roller
84402827B - May 2011 1002D-22
Maintenance Standards For Lower Roller
84402827B - May 2011 1002D-23
Maintenance Standards
84402827B - May 2011 1002D-24
Section 1002E
Bolt Size and Torque Table
84402827B - May 2011
84402827B - May 2011
CONTENTS Special Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 1002E-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002E-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Bolt Size and Torque Table Special Torque Settings Code
Retightening location
1* 2* 3* 4* 5* 6* 7 8 9* 10* 11* 12* 13* 14* 15*
Travel motor Drive sprocket Take-up roller Upper roller Lower roller Track guard Shoe Counterweight Turntable bearing Swing unit
16*
Hydraulic pump
17* 18* 19* 20* 21* 22 23
Hydraulic oil tank Fuel tank Control valve
Engine
Flange
Bolt nominal diameter M24 M20 M16 M20 M24 M24 M24 M33 M24 M24 M20 M10 M12 M16 M10
Pump
M20
Mount Front bracket Rear bracket
Radiator
Center joint
M16 M16 M16 M16 M12 M16 M10
Lock bar Joint
Cab Battery
Wrench 36 mm 30 mm 24 mm 30 mm 36 mm 36 mm 32 mm 50 mm 36 mm 36 mm 30 mm 17 mm 19 mm 24 mm 17 mm 17 mm hexagon socket head 24 mm 24 mm 24 mm 24 mm 19 mm 24 mm 17 mm
Tightening torque [N•m] 900 - 1051 521 - 608 267 - 312 521 - 608 902 - 1049 902 - 1049 1236 - 1510 1862 - 2058 900 - 1050 900 - 1050 289 - 337 64 - 73 109 - 127 147 - 176 64 - 73 367 - 496 233 - 276 233 - 276 267 - 312 267 - 312 109 - 127 149 - 173 20 - 29
CAUTION For items marked with *, always apply Loctite #262 or the equivalent and tighten to the specified torque. The tightening torque in kgf•m is determined with N•m ÷ 9.8. The tightening for bolts and nuts not otherwise specified in the table above is as follows. Bolt nominal diameter (size) Wrench Hexagon bolt Tightening torque Wrench Hexagon socket head Tightening bolt torque
[mm]
M6 10
M8 13
M10 17
M12 19
M14 22
M16 24
M18 27
M20 30
[N・m]
6.9
19.6
39.2
58.8
98.1
156.9
196.1
294.2
[mm]
5
6
8
10
12
14
14
17
[N・m]
8.8
21.6
42.1
78.5
117.7
176.5
245.2
343.2
84402827B - May 2011 1002E-3
Bolt Size and Torque Table
84402827B - May 2011 1002E-4
Bolt Size and Torque Table
84402827B - May 2011 1002E-5
Bolt Size and Torque Table
84402827B - May 2011 1002E-6
Section 1002F
Overall View
84402827B - May 2011
84402827B - May 2011
CONTENTS CX350C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Arm (3.25 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Arm (2.63 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Long Arm (4.04 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ultra-short Arm (2.21 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Arm (3.25 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short Arm (2.63 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ultra-short Arm (2.21 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 1002F-1
3 3 4 5 6 7 7 8 9
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1002F-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Overall View CX350C Standard Arm (3.25 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-3
Overall View Short Arm (2.63 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-4
Overall View Long Arm (4.04 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-5
Overall View Ultra-short Arm (2.21 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-6
Overall View CX370C Standard Arm (3.25 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-7
Overall View Short Arm (2.63 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-8
Overall View Ultra-short Arm (2.21 m) Note: 1. Numbers are subject to change without notice due to design change or other reason. Note: 2. The diagrams give values that include the shoe lug height (a) (36 mm).
84402827B - May 2011 1002F-9
Overall View
84402827B - May 2011 1002F-10
Section 1003
List of special tools
84402827B - May 2011
84402827B - May 2011
CONTENTS Tools to purchase or to make locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Take-up Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Upper Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lower Roller Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Grease Cylinder Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Center Joint Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Swing Motor Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remote Control Valve Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Gas Filling Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CX250C/CX350C/CX370C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CASE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Isuzu Engine Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4HK1X-6HK1X Tier 4 Isuzu Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Attachment Special Tool (for Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Special Jigs Part Number List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
84402827B - May 2011 1003-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
List of special tools Tools to purchase or to make locally Note: Dimensions in the drawings are shown in mm
Travel Motor Special Tool CX350C/CX370C
Code 1 2 3
Order No.
4 5 6
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Jig name Remarks Holder fitting Rear cover guide pin Brake piston removal jig Shim thickness adjustNo diagram ment jig Oil seal insertion jig Rear bearing insertion jig
List of special tools
Code 7 8
Order No.
Jig name Remarks Brake piston insertion jig Piston and shoe mea- When the rear cover bolts are used as is: D1: 2-20 drill, D2: 10 - Plain surement jig flat washer with rounded finish 18 mm
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List of special tools
Code 9 10 11
Order No.
Jig name Motor assembly pedestal Snap ring removal and installation (removal) jig Ball bearing removal and installation jig
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Remarks *1: Welding (8 locations)
List of special tools
Code
Order No.
12 13
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Jig name Remarks Holder A subassembly lifting jig Holder B subassembly lifting jig
List of special tools
Code 14 15 16
Order No.
Jig name
Remarks *1: Socket head bolt (1) Holder C subassembly lift- *2: M10 nut (1) *3: JIS B1354 Type A equiving jig alent (2) Motor assembly disassembly and assembly rod Angular bearing press-fit jig
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List of special tools
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List of special tools Code
Order No.
Jig name
17
Floating seal press-fit jig 1
18
Floating seal press-fit jig 2
Code 19 20
Order No.
84402827B - May 2011 1003-9
Jig name Floating seal press-fit jig 3 Oil seal press-fit jig
Remarks *1: 4 - M6 x 1.0 equipartition *2: 4 - 7 mm equipartition *3: 4 - 11 mm equipartition *1: 4 - M6 x 1.0 equipartition *2: 4 - 11 mm equipartition *3: 4 - 7 mm equipartition
Remarks
List of special tools Code 21
Order No.
22
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Jig name Remarks Bearing press-fit jig M12 x 1.75 x L45 socket head bolt
List of special tools Take-up Roller Special Tool CX350C/CX370C
Code 1 2 3
Order No.
84402827B - May 2011 1003-11
Jig name Remarks Bushing removal jig Bushing press-fit jig Floating seal installation jig
List of special tools Upper Roller Special Tool CX350C/CX370C
Code 1 2 3 4
Order No.
84402827B - May 2011 1003-12
Jig name Remarks Bushing removal jig Bushing press-fit jig 1 Bushing press-fit jig 2 Floating seal installation jig
List of special tools Lower Roller Special Tool CX350C/CX370C
Code 1 2 3
Order No.
84402827B - May 2011 1003-13
Jig name Remarks Bushing removal jig Bushing press-fit jig Floating seal installation jig
List of special tools Grease Cylinder Special Tool Jig Dimension Diagram
A B
Dust seal press-fit jig Removal jig
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List of special tools Center Joint Special Tool CX350C/CX370C Axle removal jig
a *1 *2 *3
b
Axle removal jig
*4
M16 - M20 full threaded bolt L = 370 - 420 mm M16 - M20 female thread Cover (9) installation dimensions
Removal jig (for O-ring and V-ring)
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*5
Hexagon socket head bolt (7) M10 x 25 Backing plate Axle (1) outer diameter - about 5 mm t = about 5 mm
List of special tools Swing Motor Special Tool CX350C/CX370C
Code 1 2
Order No.
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Jig name Remarks Oil seal assembly jig Pinion shaft assembly jig
List of special tools
Code 3
Order No.
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Jig name Remarks Brake piston removal jig
List of special tools Remote Control Valve Special Tool CX350C/CX370C
a b c *1 *2
SCM415N carburized S45C
*4 *5
*3
Bolt width
*6
Hole *7 Shaft *8 *1 and *2 are inserted by tightening. Code 1 84402827B - May 2011 1003-18
Order No.
Detailed diagram of jig main unit Joint installation state Detailed diagram of bushing Bushing 2
Jig name Remarks Joint disassembly jig
List of special tools
*1 Code
Order No.
2
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Center hole possible (φ 2 or less)
Jig name Remarks Special jig 1 (for bushing removal)
List of special tools Gas Filling Special Tool CX250C/CX350C/CX370C
Code 1 2 3 4 5 6 7
Jig name Gauge manifold Charging hose Quick joint 27.5 Quick joint 23.5 T joint Service can valve Vacuum pump adapter
Remarks
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List of special tools Hydraulic Circuit
1 2 3 4
Vacuum pump and power supply (for vacuum pump) Pressure gauge (10 MPa-1) Pressure gauge (60 MPa-2) Hexagon wrench (8 mm, 6 mm)
5 6 7 8
Wrenches (17, 19, 24, 27 x 2, 32, 36 x 2) Rag Extension cable Hydraulic oil tank lid (for vacuum pump)
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9
Recording sheet
10 11
Pen Cleaning fluid
List of special tools CASE SPECIAL TOOLS Isuzu Engine Special Tools 4HK1X-6HK1X Tier 4 Isuzu Engine Illustration
Description
Isuzu Reference
CASE Tool Number
8-9439-6856-0
380001712
Oil seal setting tool kit
5-8840-2627-0
380001719
Oil seal Installer
5-8840-2623-0
380001720
Remover; Nozzle sleeve
5-8840-2624-0
380001721
Installer; Nozzle sleeve
5-8840-2626-0
380001722
Installer; Bridge guide
5-8840-2360-0
380002574
Slinger puller
5-8840-2826-0
380002601
Fuel Injector Remover
5-8840-0019-0
380002602
Sliding Hammer
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List of special tools Illustration
Description
Isuzu Reference
CASE Tool Number
5-8840-2222-0
380002604
Sealing cup Installer
5-8840-9061-0
380002611
Oil seal installer kit
5-8840-2675-0 (5-85317002-0)
380002626
Compression Gauge (adapter)
8980131700
380002630
Main filter wrench
5-8840-0266-0
380300009
Angle gauge
5-8840-2625-0
380300013
Installer; Valve guide oil seal
5-8840-2628-00
380300014
Remover/Installer; Valve guide
5-8840-2815-0
380300015
Compression Gauge Adaptor
8–9439–6818–0
Common tool
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Crankshaft gear puller
List of special tools Illustration
Not Illustrated
Description
Isuzu Reference
CASE Tool Number
8–9439–6819–0
380002613
Crankshaft gear installer
5-8840–9018–0
380300022
Piston setting tool
1-8522–1029–0
380300005
Piston ring setting tool
5-8840-2835-0
Common Probes
5-8840-2621-0
Common Tool
Remover; Valve spring
5-8840-2691-0
Common Tool
Digital multimeter with an input impedance of 10MΩ
5-8840-2674-1
Not needed
Scissors gear spring wrench
8-9439-6862-0
Not needed
Pivot ASM
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Connector test adapter kit
List of special tools Attachment Special Tool (for Cylinder Assembly) Special Jigs Part Number List • Select jigs for the cylinder head according to the rod diameter. • Select jigs for the piston according to the cylinder bore. CASE Tool Number KHV0511 KHV0512 KHV0513 KHV0514 KHV0515 KHV0516 KHV0517 KHV0518 KHV0519 KHV0520 KHV0521 KHV0522 CASE Tool Number KHV0526 KHV0527 KHV0528 KHV0529 KHV0530 KHV0531 KHV0532 KHV0533 KHV0534 KHV0535 KHV0536 KHV0537 KHV0539
Description (applicable rod diameter in mm)
Illustration
Cylinder head assembly and disassembly jig (65) Cylinder head assembly and disassembly jig (70) Cylinder head assembly and disassembly jig (75) Cylinder head assembly and disassembly jig (80) Cylinder head assembly and disassembly jig (85) Cylinder head assembly and disassembly jig (90) Cylinder head assembly and disassembly jig (95) Cylinder head assembly and disassembly jig (100) Cylinder head assembly and disassembly jig (105) Cylinder head assembly and disassembly jig (110) Cylinder head assembly and disassembly jig (115) Cylinder head assembly and disassembly jig (120) Description (applicable cylinder bore diameter in mm) Seal ring insertion and calibration jig (100) Seal ring insertion and calibration jig (105) Seal ring insertion and calibration jig (110) Seal ring insertion and calibration jig (115) Seal ring insertion and calibration jig (120) Seal ring insertion and calibration jig (125) Seal ring insertion and calibration jig (130) Seal ring insertion and calibration jig (135) Seal ring insertion and calibration jig (140) Seal ring insertion and calibration jig (145) Seal ring insertion and calibration jig (150) Seal ring insertion and calibration jig (160) Seal ring insertion and calibration jig (170)
84402827B - May 2011 1003-25
Illustration
List of special tools CNH-EST DIAGNOSTIC TOOL (SCAN TOOL) The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the operating parameters of electronic control components (control units, sensors etc.). It is also capable of reading fault codes. To use this tool, please refer to the book provided during the CXC series training sessions. Y-Cable 380060269 is required to connect the EST to the controllers.
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Section 1004
FLUIDS AND LUBRICANTS
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84402827B - May 2011
CONTENTS HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conditions applicable to diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 3 3 3 3
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
FLUIDS AND LUBRICANTS Lubricants must have the correct properties for each application. IMPORTANT: The conditions of use for individual fluids and lubricants must be respected.
HYDRAULIC FLUID CASE/AKCELA hydraulic fluid is specially designed for high pressure applications and for the CASE hydraulic system. The type of fluid to be used depends on the ambient temperature.
ENGINE OIL The "CASE Tutela LE ENGINE OIL" is recommended for your engine. This oil ensures correct lubrication of your engine in all working conditions. If the "CASE Tutela LE ENGINE OIL" cannot be obtained, use the oil corresponding to one of the following categories: API CJ-4. ACEA E6.
FUEL The fuel must conform to Interim Tier 4/Stage 3B Exhaust Gas Control Regulations. Use grade number 2-D (S15) fuel. Using other types of fuel may lead to stalled engine output or deterioration in fuel economy. During cold weather (lower than -7℃), it is temporarily acceptable to use a mixture of No. 1-D (S15) and No. 2-D (S15). Consult the fuel supplier or the CASE dealer. If the temperature drops below the fuel cloud point, output deficiency or engine start problems may occur due to wax crystals.
Conditions applicable to diesel fuel The diesel fuel used must: -
be free from dust particles, even minute ones, have the proper viscosity, have a high cetane number, present great fluidity at low temperatures, have low sulphur content, have very little residual carbon.
RECOMMENDED CONDITIONS THAT CAN BE APPLIED TO DIESEL FUEL - JIS (Japanese Industrial Standards): No. 2 - DIN (Deutsche Industrie Normen): DIN 51601 - SAE-J-313C: SAE (Society of Automotive Engineers) based on No. 2-D (S15) - BS (British Standards) based on BS/2869-1970: Class A-1 - EN 590 (less than 10 ppm sulfur) - Or fuel specified by the country using these standards and this machine
IMPORTANT: EPA regulation ultra low sulfur fuel only. IMPORTANT: If a serious problem occurs when other fuels are used, the warranty is invalidated. Using a non-recommended fuel may lead to damage of the fuel injection pump, injector, DPD, and other fuel supply systems or to the engine. CASE assumes no responsibility for these damages. Note that the warranty will not be applied for these damages. It is recommended that the following safety information be considered in order to prevent damage to the engine fuel supply system. - Some fuel suppliers mix old engine oil and diesel fuel. Makers of larger engine permit the use of this kind of fuel. However, do not use diesel fuel contaminated with engine oil in customer's engines. Not only will this fuel damage the engine, it may also have a negative impact on the exhaust gas purification function. Before using diesel fuel, confirm with the supplier whether the fuel complies with the above specifications. IMPORTANT: Consult the supplier or the CASE dealer regarding appropriate use of fuel additives. Do not use fuel oil or gasoline as these may damage the engine. IMPORTANT: In order to prevent condensation during cold weather, fill the fuel tank to full after the completing the day's work.
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FLUIDS AND LUBRICANTS
84402827B - May 2011 1004-4
Section 1005
Conversion Table
84402827B - May 2011
84402827B - May 2011
CONTENTS Metric to U.S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S to Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 1005-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1005-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Conversion Table Metric to U.S AREA: FORCE: LENGTH: MASS: MASS/AREA: MASS/ENERGY: MASS/VOLUME: POWER: PRESSURE: TEMPERATURE: TORQUE: VELOCITY:
VOLUME:
VOLUME/TIME:
MULTIPLY square meter hectare newton newton millimeter meter kilometer kilogram kilogram/hectare gr/kW/hr. kg/cubic meter kilowatt kilopascal bar megapascal (MPA) degree C newton meter newton meter kilometer/hr cubic centimeter cubic meter cubic meter milliliter litre litre litre litre litre/min. litre/min
BY 10.763 91 2.471 05 3.596 942 2.224 809 0.039 370 3.280 840 0.621 371 2.204 622 0.000 466 0.001 644 1.685 555 1.341 02 0.145 038 14.50385 145.0385 1.8 x C +32 8.850 748 0.737 562 0.621 371 0.061 024 35.314 66 1.307 950 0.033 814 1.056 814 0.879 877 0.264 172 0.219 969 0.264 172 0.219 969
84402827B - May 2011 1005-3
TO OBTAIN square foot acre ounce force pound force inch foot mile pound ton/acre lbs/hp/hr. lb/cubic yd. horsepower lb/sq. inch lb/sq. inch psi degree F lb/inch lb/foot miles/hr. cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US liquid) gallon (Imperial) gallon/min. (US liquid) gallon/min. (Imperial)
Conversion Table U.S to Metric AREA: FORCE: LENGTH: MASS: MASS/AREA: MASS/ENERGY: MASS/VOLUME: POWER: PRESSURE:
psi TEMPERATURE: TORQUE: VELOCITY:
VOLUME:
VOLUME/TIME:
MULTIPLY square foot acre ounce force pound force inch foot mile pound ounce ton/acre lbs/hp/hr. lb/cubic yd. horsepower lb/sq. inch lb/sq. inch lb/sq. inch psi degree F lb/inch lb/foot miles/hr. cubic inch cubic foot cubic yd. ounce (US fluid) quart (US liquid) quart (Imperial) gallon (US) gallon (Imperial) gallon/min.
BY 0.092 903 0.404 686 0.278 014 4.448 222 25.4 0.304 8 1.609 344 0.453 592 28.35 2241 702 608.277 4 0.593 276 0.745 700 6.894 757 0.069 0.070 303 0.006 895 1.8 F - 32 0.112 985 1.355 818 1.609 344 16.387 06 0.028 317 0.764.555 29.573 53 0.946 353 1.136 523 3.785 412 4.546 092 3.785 412
84402827B - May 2011 1005-4
TO OBTAIN square meter hectare newton newton millimeter meter kilometer kilogram gram kilogram/hectare gr/kW/hr. kg/cubic meter kilowatt kilopascal bar kg/sq. cm megapascal (Mpa) degree C newton meter newton meter kilometer/hr cubic centimeter cubic meter cubic meter milliliter litre litre litre litre litre/min.
Section 1900
Abbreviations
84402827B - May 2011
84402827B - May 2011
CONTENTS Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 1900-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Abbreviations Abbreviations Abbreviation AC A/D ABDC AC ACC ACG ACT API ASM ATDC ATF drilled head B eye B full threaded B hexagon socket head B high-strength B reamer B B+ BAT BBDC BKT BRG BTDC C/B C/U CAL CAN CFG CHK CKP CMP CO CPU DC DI DIAG DLC DMM DPD DTC ECM ECT ECU EEPROM EGR EMI EMPS ENG EPF EVRV EXH F/B F/C F/L FLW FRT
description air conditioner analog/digital after bottom dead center alternating current accessory alternating current generator actuator american petroleum industry assembly after top dead center automatic transmission fluid drilled head bolt eye bolt full threaded bolt hexagon socket head bolt high-strength bolt reamer bolt battery + terminal battery before bottom dead center bracket bearing before the top dead center circuit breaker control unit calibration a control unit communication method (control area network) config check crankshaft position camshaft position carbon monoxide central processing unit direct current direct injection type diagnosis data link connector digital multi–meter diesel particulate diffuser self-diagnosis code engine control module engine coolant temperature electronic control unit electrically erasable/programmable ROM exhaust gas recirculation electromagnetic interference engine module programing system engine engine protection feature electric vacuum regulating valve exhaust feedback fuel cut fusible link fusible link wire front 84402827B - May 2011 1900-3
Abbreviations Abbreviation FT FWD GEN GND HBCV HC HO2S HR HRD IAC IAT IC ID Plate IMT INL INJ ISO ISP ITP J/C JIS KW LED LH LLC LM M/V MAF MAP Max MIL milli-amp Min MPU high-strength N NC NO NOx N-TDC PM O2S OBD OEM OPT OT P/L PCV P-I PM PTO PWM QOS QWS R/L RAM REF RH ROM
description fuel temperature front generator ground hose burst check valves hydrocarbon superheat O2 sensor hour high reach idle air control intake air temperature integrated circuit ID plate (Name plate) intake manifold temperature intake injection international organization for standardization intake shutter position intake throttle position joint connector japan Industrial Standard a communication method (Keyword) light emitting diode left long life coolant lifting magnet electromagnetic valve mass air flow manifold air pressure maximum warning light (diagnostic) milli-amperage minimum micro processing unit high-strength nut normally closed normally open nitrogen oxide top dead center revolution speed particle material O2 sensor on-board diagnosis original equipment manufacturer option oil temperature pilot light pump control valve/positive crankcase ventilation proportion-integration particle material power take-off pulse width modulation wave quick on start system quick warming up system relay RAM (random access memory) reference right ROM (read only memory) 84402827B - May 2011 1900-4
Abbreviations Abbreviation RP Rr RWD flush head S phillips pan head S truss head S subassembly SAE SBF SCV SIG SLD SP pin ST STD SW TDC TEMP TP TEMP UART VB VGS Turbo high-strength W toothed W W/H W/L W/S WOT
description rail pressure rear rear flush head screw phillips pan head screw truss head screw sub assembly society of atomotive engineers slow blow fuse suction control valve signal shield special pin starter/start standards switch top dead center temperature throttle position temperature universal asynchronous receiver transmitter battery voltage variable geometry system turbo high-strength washer toothed washer wire/harness warning light weld splice wide open throttle
84402827B - May 2011 1900-5
Abbreviations
84402827B - May 2011 1900-6
Section 2000
Removal and Installation of Engine Assembly
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402827B - May 2011 2000-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2000-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Engine Assembly Removal of Engine Assembly
WARNING • Keep away from fire. • Be sure to release hydraulic pressure before beginning work. • The air conditioner circuit is filled with highpressure gas, so there is the danger of gas spraying out when loosening lines. • Do not use open flames and do not allow sparks near the battery.
1. 2. 3. 4. 5.
Drain the engine oil.(For details, see "Engine Oil Replacing".) Drain the coolant from the radiator.(For details, see "Removal and Installation of Radiator".) Remove the engine hood.(For details, see "Removal and Installation of Engine Hood".) Remove the hydraulic pump.(For details, see "Removal and Installation of Hydraulic Pump".) Use a wrench (13 mm) to remove the 3 bolts (1).
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • Wrenches (7 mm, 8 mm, 13 mm, 17 mm, 19 mm, 36 mm) • Box wrench (30 mm) • Shackle (with the required lifting capacity) x 2 • Wire ropes (with the required breaking load) • Liftcrane (with the required lifting capacity) • Marking pen • Cap • Plug • Waste oil can • Rag • Cleaning fluid • Wood planks, etc.
84402827B - May 2011 2000-3
Removal and Installation of Engine Assembly 6.
Use a wrench (13 mm) to remove the 3 bolts (1), and then remove the bracket (2).
8.
Use a wrench (8 mm) to loosen the hose band (1) on the radiator, and then remove the upper hose (2).
9.
Remove the cushion seal on the side of the radiator, use a wrench (8 mm) to loosen the hose band (1) of the radiator, and then remove the lower hose (2). • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt. • Before removing the radiator hoses, completely drain the coolant.
7.
Remove the fan guard (1).
10. Use a wrench (13 mm) to loosen the line bolts (1) in 2 locations, and then remove the 2 lines (2) and (3) from the compressor. • Always remove the low-pressure (suction side) line (2) first. • Attach caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt. Tightening torque for bolt installation: 19.6 - 24.5 N•m
84402827B - May 2011 2000-4
Removal and Installation of Engine Assembly 12. Use a wrench (17 mm) to remove the 5 bolts (1), and then remove the under cover (2). • Use caution when removing as the parts are heavy. Tightening torque for bolt installation: 63.7 - 73.5 N•m
13. Prepare the waste oil can (1). • Drain the engine oil before removing the engine oil hose.
11. Use a wrench (8 mm) to loosen the hose band (1) on the inter cooler, and then remove the hose (2). • Use caps to cover the lines and hoses to prevent the entry of water, dust or dirt.
14. Use a wrench (36 mm) to remove the 2 engine oil remote hoses (1). • Mark the engine and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
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Removal and Installation of Engine Assembly • Clean the engine and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
16. Use a wrench (17 mm) to remove the 5 bolts (1), and then remove the under cover (2). Tightening torque for bolt installation: 63.7 - 73.5 N•m
17. Use a wrench (8 mm) to remove the 2 nuts (1), and then remove the wiring (2) from the starter motor.
15. Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. • Also, cover with a rubber cap to protect against sparks.
18. Remove the hose band (1), and then remove the fuel hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
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Removal and Installation of Engine Assembly 19. Remove the hose band (1), and then remove the fuel hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
20. Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the box cover (2).
22. Use a wrench (8 mm) to loosen the hose band (1), and then remove the heater hose (2). Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
23. Use a wrench (8 mm) to loosen the hose band (1), and then remove the heater hose (2). • Attach caps or plugs to the engine and hoses to prevent any entry of water, dust or dirt.
21. Remove the connectors (1) in the box. • Wrap the removed connectors in plastic after tying them together to prevent any entry of water, dust or dirt.
24. Use a wrench (8 mm) to loosen the hose band (1), and then remove the radiator hose (2). • Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt.
84402827B - May 2011 2000-7
Removal and Installation of Engine Assembly 25. Use a wrench (8 mm) to loosen the hose band (1), and then remove the air hose (2).
27. Remove the connectors (1) from the alternator.
• Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt.
28. Remove the cap (1), use the wrench (10 mm) to remove the nut (2), and then remove the alternator wiring (3). 26. Use a wrench (8 mm) to loosen the hose band (1), and then remove the air hose (2). • Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt. Tightening torque for bolt installation: 8.8 - 9.8 N•m
29. Install the 2 shackles (1), and then use the wire rope (2) and liftcrane to secure the engine main unit.
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Removal and Installation of Engine Assembly 30. Use a box wrench (30 mm) to remove the 4 bolts (1) from the mount. Tightening torque for bolt installation: 289 - 337 N•m
31. Use the wire rope (1) and liftcrane to lift the engine main unit. Thoroughly check that the location is safe before lowering the engine on wood planks, etc.
84402827B - May 2011 2000-9
Removal and Installation of Engine Assembly Installation of Engine Assembly
2.
1.
3.
To install the engine, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts". After installing the engine, resupply coolant and engine oil, perform fuel line air bleeding, and perform filling for the air conditioner gas. For details, see the individual explanations for each procedure.
Run the engine at no-load idling and check for any water or oil leaks. Attach the hydraulic pump, covers, and counterweight. For details, see the individual explanations for each procedure.
84402827B - May 2011 2000-10
Section 2001
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal and Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Fuel Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal and Installation of Engine Inter Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation of Inter Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal and Installation of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal of Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation of radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal and Installation of Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation of oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
84402827B - May 2011 2001-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2001-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Fuel Cooler
Removal of Fuel Cooler 1.
Mark the fuel cooler and hoses (1) and (2) so that the connectors match at the time of assembly. Use pliers to loosen the hose bands (3) and (4), and then remove the hoses. Fuel will spill out, so place a drip pan directly below the area. Attach caps or plugs to the fuel cooler and hoses to prevent any entry of water, dust or dirt.
2.
Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the fuel cooler (2).
CAUTION • Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly prohibit open flames. Items to prepare • • • • • • • • •
Wrench (13 mm) Screwdriver Pliers Marking pen Cap Plug Rag Cleaning fluid Drip pan
Installation of Fuel Cooler To installation, perform the reverse of the removal procedure. After connecting the hoses, carefully check for any fuel leaks. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Engine Inter Cooler
Removal of Inter Cooler 1.
Remove the fuel cooler.(For details, see "Removal and Installation of Fuel Cooler".) Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the bracket (2) from the fuel cooler.
2.
Use a wrench (8 mm) or flathead screwdriver to loosen the hose bands (1) in the 2 locations, and then remove the 2 hoses (2) and (3). Use caps to cover the inter cooler and hoses to prevent the entry of water, dust or dirt.
3.
Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the inter cooler (2).
CAUTION • Be sure to stop the engine before beginning work. • As the fuel hose will be removed, strictly prohibit open flames. Items to prepare • • • • • •
Wrenches (8 mm, 13 mm) Flathead screwdriver Wire cutters Cap Rag Cleaning fluid
84402827B - May 2011 2001-4
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Installation of Inter Cooler To install, perform the reverse of the removal procedure. Check for any air leaks. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
Removal and Installation of Radiator WARNING • Do not remove the radiator cap when the radiator coolant temperature is high. Hot liquid could spray out. CAUTION • Be sure to release hydraulic pressure before beginning work. • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • • • • •
Wrenches (8 mm, 14 mm, 19 mm) Box wrenches (8 mm, 10 mm) Pliers Shackle (with the required lifting capacity) x 2 Wire ropes (with the required breaking load) Liftcrane (with the required lifting capacity) Caps Plugs Drain tank Drain hose Rag Cleaning fluid Wood planks, etc.
84402827B - May 2011 2001-5
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal of Radiator 1.
4.
Loosen the drain plug (1), and then drain the coolant.
5.
Use a wrench (8 mm) to loosen the hose band (1), and then remove the hose (2).
Use a wrench (19 mm) to remove the 5 bolts (1), and then remove the under cover (2).
2.
Install the drain hose (1), and then prepare the drain tank (2).
3.
To make it easier to drain the coolant, remove the radiator cap (1).
• Use caps to cover the lines and hoses to prevent any entry of water, dust or dirt.
6.
Use a box wrench (13 mm) to remove the 1 nut (1) and the 3 bolts (2) of the radiator cover.
84402827B - May 2011 2001-6
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 7.
Use a wrench (8 mm) to loosen the hose band (1) on the radiator, and then remove the upper hose (2).
10. Loosen the hose band (2), and then remove the hose (1) from the radiator cap. • Attach caps or plugs to the hoses to prevent any entry of water, dust or dirt.
8.
Remove the cushion seal on the side of the radiator, use a wrench (8 mm) to loosen the hose band (1) of the radiator, and then remove the lower hose (2). • Use caps to cover the radiator and hoses to prevent the entry of water, dust or dirt. • Before removing the radiator hoses, completely drain the coolant.
9.
11. Use a wrench (13 mm) to remove the 3 bolts (1).
Remove the drain plug (1), loosen the hose band (2), and then remove the hose (3).
84402827B - May 2011 2001-7
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 12. Use a wrench (13 mm) to remove the 3 bolts (1), and then remove the bracket (2)
14. Remove the 2 butterfly bolts (1), and then remove the front anti-insect net (2).
15. Install the 2 shackles (1) to the top of the radiator, and then use the wire rope (2) and liftcrane to lift the radiator.
13. Remove the fan guard (1).
84402827B - May 2011 2001-8
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 16. Lift the radiator together with the radiator cover (2) until the fixtures (1) at the bottom of the radiator become disconnected.
Installation of radiator To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts". For details on the method for coolant filling, see the (Service Text Procedures for Replacing Consumable Parts • Radiator Coolant Replacement). Coolant capacity is 30 L. Finally, check that the level of coolant is correct.
17. Thoroughly check that the location is safe before lowering the radiator on square wooden pieces. When laying down the radiator, be careful not to bend or crush the bottom fixtures (1).
84402827B - May 2011 2001-9
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler Removal and Installation of Oil Cooler
Removal of oil cooler 1.
WARNING 2.
• Keep away from fire.
Drain the hydraulic oil from the hydraulic oil tank. See "Draining Oil from Hydraulic Oil Tank" for details of the procedure. Use a wrench (19 mm) to remove the 5 bolts (1), and then remove the under cover (2).
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • • • • •
Wrenches (17 mm, 19 mm) Hexagon wrench (10 mm) Pliers Screwdriver Eyebolts (M12 x 2) Shackle (with the required lifting capacity) x 2 Wire rope (with the required breaking load) Liftcrane (with the required lifting capacity) Caps Waste oil can Rag Cleaning fluid Wood planks, etc.
3.
Prepare the waste oil can (1).
4.
Remove the 4 butterfly bolts (1), and then remove the anti-insect net (2).
84402827B - May 2011 2001-10
Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 5.
Use a wrench (19 mm) to remove the 7 bolts (1) and bracket (2), and then remove the seal cushion.
6.
Use a hexagon wrench (10 mm) to remove the 2 upper hexagon socket head bolts (6) and 2 lower bolts (6), and then remove the lines (7) and (8). • Use caps to cover the oil cooler and lines to prevent the entry of water, dust or dirt.
7.
Use a wrench (13 mm) to remove the 5 bolts (1).
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Removal and installation of the fuel cooler engine inter-cooler radiator and oil cooler 8.
Install the 2 eyebolts (M12) (10) on the top of the oil cooler.
10. Thoroughly check that the location is safe before lowering the oil cooler on wood planks, etc.
• Fully tighten the eyebolts, and then loosen them by a half turn.
9.
Install the 2 shackles (11) to the eyebolts, and then use the wire rope (12) and liftcrane to lift the oil cooler main unit.
Installation of oil cooler To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
84402827B - May 2011 2001-12
Section 2004
Removal and Installation of Turbo Charger
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Turbo Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 2004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2004-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Turbo Charger Removal of Turbo Charger
WARNING The engine is extremely hot just after stopping. Wait for them to sufficiently cool before beginning work.
1.
1) 2.
CAUTION
Battery ground cable Disconnect
Coolant Drain 1)
• Be sure to stop the engine before beginning work.
Wrenches (8 mm, 10 mm, 13 mm, 17 mm) Cap Plug Rag Cleaning fluid
Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
Items to prepare • • • • •
Disengage the battery ground cable from the battery.
3.
Turbocharger assembly Removal 1) 2) 3) 4)
Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger. Disengage the oil feed pipe from the turbocharger assembly. ANNOTATION: • Remove the clip.
5) 6) 7)
Disengage the oil return pipe from the turbocharger assembly. Disengage the water return pipe from the turbocharger assembly. Disengage the water feed pipe from the turbocharger assembly. ANNOTATION: • Remove the clip.
8) 9)
Disengage the harness connector from the turbocharger assembly. Remove the turbocharger assembly from the exhaust manifold.
1 2 3 4 5
84402827B - May 2011 2004-3
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Removal and Installation of Turbo Charger Installation of Turbo Charger 1.
7)
Turbocharger assembly Installation 1) 2) 3)
4)
Replenish the engine oil with the turbocharger assembly. Align the gasket to the turbocharger assembly. Install the turbocharger assembly to the exhaust manifold. Tightening torque： 52 N・m { 5.3 kgf・m / 38 lb・ft } Connect the water feed pipe to the turbocharger assembly. Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft }
Connect the oil feed pipe to the turbocharger assembly. Tightening torque： 34 N・m { 3.5 kgf・m / 25 lb・ft } Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft } Clip CAUTION • Use a new gasket.
CAUTION • Use a new gasket. 5)
Connect the water return pipe to the turbocharger assembly. Tightening torque： 41 N・m { 4.2 kgf・m / 30 lb・ft } CAUTION 1 2 3 4 5
• Use a new gasket. 6)
Connect the oil return pipe to the turbocharger assembly. Tightening torque： 24 N・m { 2.4 kgf・m / 17 lb・ft }
8)
CAUTION 9)
• Use a new gasket.
10) 2.
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Install the exhaust pipe to the turbocharger assembly. Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.
Coolant Filling 1) 2)
Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts.
3)
Coolant overflow should be wiped off. Tighten the valve using a wrench. CAUTION • Use new gaskets. Tightening torque： 22 N・m { 2.2 kgf・m / 16 lb・ft }
84402827B - May 2011 2004-4
Removal and Installation of Turbo Charger 4)
Replenish the coolant with the radiator.
5)
Battery ground cable Connect 1)
1 2
Valve Gasket
84402827B - May 2011 2004-5
Connect the battery ground cable to the battery.
Removal and Installation of Turbo Charger
84402827B - May 2011 2004-6
Section 2005
Removal and Installation of EGR Cooler and EGR Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS EGR valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 EGR valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 2005-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2005-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of EGR Cooler and EGR Valve EGR valve Removal
3)
1.
4)
Battery ground cable Disconnect 1)
2.
Disengage the battery ground cable from the battery.
Coolant Drain 1)
5) 6)
Drain the coolant from the radiator.
Remove the EGR cooler C from the EGR bracket C. Remove the EGR bracket C from the EGR cooler B. Remove the EGR cooler B from the EGR cooler bracket A. Remove the EGR cooler bracket A from the EGR cooler A.
CAUTION • After the coolant is discharged, make sure to tighten the drain plug. 3.
EGR cooler Removal 1)
Disengage the water rubber hose from the EGR cooler.
1 2 3 4
7) 1 2)
Water rubber hose
EGR EGR EGR EGR
cooler C bracket C cooler B cooler bracket A
Remove the EGR heat protector from the EGR pipe A.
Remove the EGR pipe B from the EGR valve and the EGR cooler C.
1 1 2 3
EGR valve EGR pipe B EGR cooler C
8)
84402827B - May 2011 2005-3
EGR heat protector
Remove the EGR cooler A from the EGR pipe A.
Removal and Installation of EGR Cooler and EGR Valve 9)
Remove the EGR pipe A from the exhaust manifold.
EGR valve Installation 1.
EGR valve Installation 1)
1 2 3 4.
EGR cooler A EGR pipe A Exhaust manifold
EGR valve Removal 1) 2)
1
Disengage the harness connector from the EGR valve. Remove the EGR valve from the inlet pipe.
2) 2.
EGR valve
Connect the harness connector to the EGR valve.
EGR cooler Installation 1) 2)
1
Install the EGR valve to the inlet pipe. Tightening torque： 46 N・m ｛4.7 kgf・m / 33.9 lb・ft｝
Temporarily tighten the EGR pipe A to the exhaust manifold. Temporarily tighten the EGR cooler A to the EGR pipe A.
EGR valve
1 2 3 3) 4) 5)
84402827B - May 2011 2005-4
EGR cooler A EGR pipe A Exhaust manifold
Temporarily tighten the EGR cooler bracket A to the EGR cooler A. Temporarily tighten the EGR cooler B to the EGR cooler A. Temporarily tighten the EGR bracket C to the EGR cooler B.
Removal and Installation of EGR Cooler and EGR Valve 6)
13)
Temporarily tighten the EGR cooler C to the EGR bracket C.
14)
15)
16)
17) 1 2 3 4 7)
EGR cooler C EGR cooler bracket C EGR cooler B EGR cooler bracket A
18)
Temporarily tighten the EGR pipe B to the EGR cooler C and the EGR valve.
Securely tighten the EGR pipe B to the EGR cooler C. Tightening torque： 25 N・m ｛2.5 kgf・m / 18 lb・ft｝ Securely tighten the EGR pipe B to the EGR valve. Tightening torque： 46 N・m ｛4.7 kgf・m / 34 lb・ft｝ Securely tighten the EGR cooler bracket A to the EGR cooler bracket C. Tightening torque： 24 N・m ｛2.4 kgf・m / 17 lb・ft｝ Securely tighten the EGR cooler bracket C to the EGR cooler bracket B. Tightening torque： 46 N・m ｛4.7 kgf・m / 34 lb・ft｝ Securely tighten the EGR pipe B to the rear engine hanger bracket. Tightening torque： 46 N・m ｛4.7 kgf・m / 34 lb・ft｝ Install the EGR heat protector to the EGR pipe. Tightening torque： 31 N・m ｛3.2 kgf・m / 23 lb・ft｝
1 1 2 3 8)
9)
10)
11)
12)
EGR valve EGR pipe B EGR cooler C
19)
Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque： 67 N・m {6.8 kgf・m / 49 lb・ft} Securely tighten the EGR cooler A to the EGR pipe A. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Securely tighten the EGR cooler B to the EGR cooler A. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler B. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler C to the EGR cooler bracket C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
Connect the water rubber hose to the EGR cooler.
1 3.
EGR heat protector
Water rubber hose
Coolant Filling 1)
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Loosen the valve using a wrench.
Removal and Installation of EGR Cooler and EGR Valve 2)
Replenish the coolant with the radiator.
4)
Replenish the coolant with the radiator.
CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off. 3)
Tighten the valve using a wrench. CAUTION • Use new gaskets. Tightening torque： 22 N・m ｛2.2 kgf・m / 16 lb・ft｝ 1 2 4.
Valve Gasket
Battery ground cable Connect 1)
84402827B - May 2011 2005-6
Connect the battery ground cable to the battery
Section 2006
Removal and Installation of Engine Hood
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Engine Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 2006-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2006-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Engine Hood Removal of Engine Hood
CAUTION • Be sure to stop the engine before beginning work. • Do not perform this operation in strong wind. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
1.
Open the engine hood until the lock is engaged. Wrap the nylon sling around the engine hood, and then gently lift with the liftcrane until there is no force on the open lock stay (1). Remove the pin (2) and washer (3) that are on the engine hood side of the open lock stay (1), and then remove the open rock stay (1) from the guide.
Items to prepare • Wrench (19 mm) • Nylon sling (with the required breaking load) • Liftcrane (with the required lifting capacity)
84402827B - May 2011 2006-3
Removal and Installation of Engine Hood 2.
After closing the engine hood (1), use a wrench (19 mm) to remove the 9 bolts (2) from the engine hood.
3.
Wrap the nylon sling (1) around the engine hood (2), and then use the liftcrane to lift the engine hood (2).
Installation of Engine Hood To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
84402827B - May 2011 2006-4
Section 2007
Removal and Installation of Muffler
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 2007-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2007-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Muffler 2.
WARNING
Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the muffler (2).
• The engine is extremely hot just after stopping. Wait for it to sufficiently cool before beginning work. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • •
Wrench (14 mm) Cap Rag Cleaning fluid
Removal of Muffler
Installation of Muffler
1.
To Installation perform the reverse of the removal procedure. After installation, check for any leaks or vibration. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
Use a wrench (13 mm) to loosen the 4 nuts (1), and then remove the 4 bolts (2). • Use caps to cover the lines to prevent any entry of water, dust or dirt.
84402827B - May 2011 2007-3
Removal and Installation of Muffler
84402827B - May 2011 2007-4
Section 2401
Primary specifications
84402827B - May 2011
84402827B - May 2011
CONTENTS Primary specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 2401-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2401-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Primary specifications Primary specifications 1.
Primary specifications Engine main specifications Item Type Shape of combustion chamber Cylinder liner type Cylinder bore x stroke Displacement Compression ratio Compression pressure Idling rotation speed Valve clearance
Intake Exhaust
Engine model 6HK1X Diesel/ 4-cycle /water cooling, inline 6 cylinder OHC Direct injection type Dry type 115 mm ｛4.53 in｝ x 125 mm ｛4.92 in｝ 7.790 L {475.35 cu・in} 17.5 ： 3.04 MPa {31.0 kgf/cm2 / 441 psi} 200 min-1 {200 rpm} 900 min-1 {900 rpm} ： 0.4 mm {0.016 in} While cool ： 0.4 mm {0.016 in} While cool Compression ignition 1,5,3,6,2,4
Ignition method Injection order Lubricant system Lubricating type Pressure type Oil pump type Gear type Lubrication oil amount ： 36.0 - 46.0 L {9.5 - 12.2 US gal} Oil filter type Full-flow filter (cartridge type) Built-in type, water cooled Oil cooling type Cooling system Water cooling Cooling type Radiator type Corrugated fin (pressure type) Water pump type Centrifugal, belt type Thermostat type 2 wax type unit Open valve temperature of the thermostat ： 82 °C {180 °F} Without jiggle valve valve ： 85 °C {185 °F} With jiggle valve ： 16.0 L {4.2 US gal} Coolant container Fuel system Injection pump type Electronic control common rail type Electronic type Governor type Timer type Electronic type Multi-hole type 7 holes Injection nozzle type Inner diameter D0.14 mm {0.0055 in} Charging system Generator type AC type Output 24 - 90 V/50 A Regulator type IC Starting system Reduction type Starter type Output 24 V/5.0 kW Preheat system type Glow plug Glow plug standard voltage/current 23 V/3.5 A Cleaning system main specifications Item Water pump Pulley ratio Thermostat Open valve temperature Full-open temperature
Specifications Centrifugal impeller method 0.950 Wax pellet type ： 82 °C{180 °F} Without jiggle valve ： 85 °C {185 °F} With jiggle valve ： 95 °C {203 °F} Without jiggle valve ： 100 °C {212 °F} With jiggle valve 84402827B - May 2011 2401-3
Primary specifications Electrical system main specifications Generator Item Manufacturer name Isuzu parts number Manufacturer type Nominal voltage Output current Rated rotation count Output current/voltage No-load voltage Rotational direction Polarity Pulley diameter (P.C.D) Starter Item Manufacturer Isuzu parts number Manufacturer code number Output Rating York outer diameter Rotational direction Protection type Low speed mechanism Weight Module Pressure angle Pinion Number of teeth Gear ratio {ring gear/pinion gear} Voltage No load Current Rotational speed Voltage Restraint Current Torque Pinion/engaged voltage Glow plug Item Preheat device model Glow plug rated voltage/current
Specifications Mitsubishi Electric Corporation 1-81200-633-0 A009TU3782 24V 90 A 500 min-1 {5000 rpm} 114 A/27 V/5000 min-1 {5000 rpm} 24 V/900 min-1 {900 rpm} Clockwise direction (－) ： 90.0 mm {3.54 in}
1-81200-603-2 A004TU6285 50 A 50 A/27 V/5000 min-1 {5000 rpm}
： 80.0 mm {3.15 in}
Specifications Mitsubishi Electric Corporation 181100-4140 M008T60971 24 V/5.0 kW 30 sec : 85.0 mm {3.35 in} Right Dust proof, drip proof Inner contact gear ： 7.2 kg {15.9 lb} 3 14.5 11 12.8 {129/11} 23 V 85 A or less 3,300 min-1 {3,300 rpm} or more 9V 1,400 or less 88 N・m {9kgf・m} or more 16.0 V or less
Type Glow plug 23 V/3.5 A
84402827B - May 2011 2401-4
Section 2415
Removal and Installation of Cylinder Head
84402827B - May 2011
84402827B - May 2011
CONTENTS Cylinder head cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cylinder head cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal and Installation of Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cylinder head assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cylinder head assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cylinder head assembly Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cylinder head assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Cylinder head assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
84402827B - May 2011 2415-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2415-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Cylinder Head Cylinder head cover Removal 1.
4)
Remove the head cover gasket from the cylinder head cover.
Cylinder head cover Removal 1) 2)
Disengage the water pipe bracket from the cylinder head cover. Disengage the ventilation hose from the air breather.
1 2 3
1 2 3 3)
Ventilation hose Water pipe bracket Clip
Remove the cylinder head cover from the lower cover.
84402827B - May 2011 2415-3
Cylinder head cover Head cover gasket Lower cover
Removal and Installation of Cylinder Head Cylinder head cover Installation 1.
1 2 3
Cylinder head cover Installation 1) 2)
Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover. Tightening torque： 13 N・m ｛1.3 kgf・m / 115.1 lb・in｝
3) 4)
ANNOTATION:
Cylinder head cover Head cover gasket Lower cover
Connect the ventilation hose to the air breather. Connect the water pipe bracket to the cylinder head cover. Tightening torque： 20 N・m ｛2.0 kgf・m / 14.75 lb・ft｝
• Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them.
1 2 3
84402827B - May 2011 2415-4
Ventilation hose Water pipe bracket Clip
Removal and Installation of Cylinder Head Removal and Installation of Cylinder Head
11)
ANNOTATION:
Cylinder head assembly Removal 1.
2.
• Remove the clip.
Battery ground cable Disconnect 1)
Remove the water feed pipe from the cylinder block.
12)
Disengage the battery ground cable from the battery.
13)
Disengage the harness connector from the turbocharger assembly. Remove the turbocharger assembly from the exhaust manifold.
Coolant Drain 1)
Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
3.
Engine harness Disconnect 1)
Disengage the engine harness from the engine assembly. ANNOTATION: • Disconnect each connector.
4.
Turbocharger assembly Removal 1) 2) 3) 4)
Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger. Disengage the oil feed pipe from the turbocharger assembly.
1 2 3 4 5 5.
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
EGR cooler Removal 1)
Disengage the water rubber hose from the EGR cooler.
ANNOTATION: • Remove the clip. 5)
Remove the oil feed pipe from the pipe bracket. ANNOTATION: • Remove the clip.
6) 7) 8) 9) 10)
Disengage the oil return pipe from the turbocharger assembly. Remove the oil return pipe from the cylinder block. Disengage the water return pipe from the turbocharger assembly. Remove the water return pipe from the cylinder head assembly. Disengage the water feed pipe from the turbocharger assembly. ANNOTATION: • Remove the clip.
84402827B - May 2011 2415-5
1
Water rubber hose
Removal and Installation of Cylinder Head 2)
Remove the EGR pipe B from the EGR valve and the EGR cooler C.
1 2 3 3) 4) 5) 6)
7)
EGR valve EGR pipe B EGR cooler C
Remove the EGR heat protector from the EGR pipe A.
1 8)
Remove the EGR cooler C from the EGR bracket C. Remove the EGR bracket C from the EGR cooler B. Remove the EGR cooler B from the EGR cooler bracket A. Remove the EGR cooler bracket A from the EGR cooler A.
9)
Remove the EGR cooler A from the EGR pipe A. Remove the EGR pipe A from the exhaust manifold.
1 2 3 1 2 3 4
EGR cooler C EGR bracket C EGR cooler B EGR cooler bracket A
6.
EGR heat protector
EGR cooler A EGR pipe A Exhaust manifold
EGR valve Removal 1)
84402827B - May 2011 2415-6
Disengage the harness connector from the EGR valve.
Removal and Installation of Cylinder Head 2)
Remove the EGR valve from the inlet pipe.
2) 3)
1 7.
EGR valve
Oil separator bracket Removal 1)
Remove the ventilation hose from the air breather. Remove the oil separator bracket from the cylinder head assembly.
Remove the clip from the cylinder block.
84402827B - May 2011 2415-7
1 2
Oil separator bracket Clip
Removal and Installation of Cylinder Head 8.
EGR cooler water pipe Removal
84402827B - May 2011 2415-8
Removal and Installation of Cylinder Head 1)
Remove the fan guide stay from the fan guide and the fan guide bracket.
2) 3)
1 2 3
Fan guide Fan guide stay Fan guide bracket
Disengage the oil level gauge guide tube from the front engine hanger bracket. Remove the oil level gauge guide tube from the cylinder block.
1
Oil level gauge guide tube
10. Intake throttle valve Removal 2) 3) 4)
Disengage the radiator upper hose from the water outlet pipe. Remove the EGR cooler water pipe from the engine assembly. Remove the water bypass hose from the water pump assembly and the water duct.
1) 2)
Remove the air duct from the intake throttle valve. Disengage the harness connector from the intake throttle valve. ANNOTATION: • Pull the lock operation portion to release the lock.
1 9.
Water bypass hose
Oil level gauge guide tube Removal 1)
Remove the oil level gauge from the oil level gauge guide tube.
84402827B - May 2011 2415-9
1 2 3
Lock operation section Lock release Lock
Removal and Installation of Cylinder Head 3)
Remove the intake throttle valve from the inlet pipe.
5)
Remove the inlet pipe from the inlet cover.
1 1 2 3
Intake throttle valve Gasket Inlet pipe
Inlet pipe
12. Glow plug Removal 1)
Remove the glow plug connector from the glow plug.
2)
Remove the glow plug from the cylinder head assembly.
11. Inlet pipe Removal 1) 2) 3) 4)
Disengage the harness connector from the boost sensor. Disconnect the harness connector from the boost temperature sensor. Disconnect the harness connector from the IMT sensor. Remove the harness clip from the inlet pipe.
1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
13. Injection pipe Removal 1) 2)
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Remove the clip from the inlet pipe. Remove the injection pipe from the injector and the common rail assembly.
Removal and Installation of Cylinder Head CAUTION
3)
• Do not reuse the removed injection pipe. • Seal the common rail and injector to prevent foreign material from entering.
4)
1 2 3 4 5 6 7
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
Disengage the fuel leak-off pipe from the common rail assembly. Remove the fuel leak-off pipe from the inlet pipe. ANNOTATION: • Remove the clip.
1
pipe pipe pipe pipe pipe pipe
Fuel leak-off pipe
16. Common rail assembly Removal 1) 2)
Disengage the harness connector from the fuel pressure sensor. Remove the common rail assembly from the inlet cover.
14. Fuel pipe Removal 1)
Remove the fuel pipe from the fuel supply pump and the common rail assembly. ANNOTATION: • Remove the clip. CAUTION • Do not reuse the removed fuel pipe.
15. Fuel leak off pipe assembly Removal 1) 2)
Disengage the fuel leak-off pipe from the cylinder head. Remove the fuel leak-off pipe from the fuel supply pump. ANNOTATION:
1
Common rail assembly
17. Cylinder head cover Removal
• Remove the eyebolt tightened together with the fuel feed pipe.
1)
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Disengage the ventilation hose from the air breather.
Removal and Installation of Cylinder Head 2) 3)
Remove the cylinder head cover from the lower cover. Remove the head cover gasket from the cylinder head cover.
2)
Disengage the injector harness from the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3
Cylinder head cover Head cover gasket Lower cover 1 2 3
18. Injector harness Removal 1)
Remove the connector from the lower cover. 3)
CAUTION • Do not pull the wire, or pry the connector with a screwdriver.
Injector Injector harness Terminal nut
Remove the injector harness from the cylinder head assembly. ANNOTATION: • Remove the bracket tightening bolts and then remove the injector harness together with the bracket.
1 2
Injector harness terminal Injector harness bracket
19. Lower cover Removal 1) 2)
Remove the lower cover from the cylinder head assembly. Remove the rubber plug from the cylinder head assembly.
20. Injector Removal 1) 2) 84402827B - May 2011 2415-12
Remove the injector leak-off pipe from the injector. Remove the injector from the cylinder head assembly.
Removal and Installation of Cylinder Head ANNOTATION:
CAUTION
• When it is difficult to remove the injector, use a special tool.
• Confirm that the sleeve is not pulled out together when pulling out the injector using a special tool. • Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. • Be extremely careful not to damage the injector nozzle.
Special tool: fuel injector remover (refer to section 1003)
21. Rocker arm shaft Removal 1)
Loosen the adjust screw using the wrench. ANNOTATION: • Loosen all valve clearance adjustment screws.
Special tool: sliding hammer (refer to section 1003)
2)
Remove the rocker arm shaft from the cylinder head assembly. ANNOTATION:
1 2 3
• Evenly loosen the rocker arm shaft bracket and the rocker arm assembly bracket tightening bolts from both ends and remove them.
Sliding hammer Fuel injector remover Injector
CAUTION • Be careful not to remove the bolt shown in the diagram.
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Removal and Installation of Cylinder Head 23. Bridge Removal 1)
Remove the bridge cap from the bridge. CAUTION • Be careful not to drop the bridge cap into the engine.
2)
Remove the bridge from the bridge guide. ANNOTATION: • After removing, organize to avoid a mix-up with other installation locations.
22. Camshaft Removal 1) 2) 3) 4)
Remove the camshaft bearing cap from the cylinder head assembly. Remove the camshaft bearing from the camshaft bearing cap. Remove the camshaft from the cylinder head. Remove the camshaft bearing from the cylinder head assembly. ANNOTATION: • Temporarily assemble the removed caps and bearings in the original position to avoid a mix-up after the bearings have been inspected.
1 2
Bridge cap Bridge
24. Cylinder head assembly Removal 1)
Remove the cylinder head assembly from the cylinder block. ANNOTATION: • Loosening order of the head bolts
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Removal and Installation of Cylinder Head 1
CAUTION • Since the idle gear C protrudes from the bottom surface of the cylinder head, be careful not to damage the gear.
2)
Idle gear C
Remove the cylinder head gasket from the cylinder block. CAUTION • Do not reuse the cylinder head gasket.
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Removal and Installation of Cylinder Head Cylinder head assembly Disassembly 1.
2.
1)
Engine hanger bracket Removal 1) 2)
Inlet cover Removal
Remove the front engine hanger bracket from the cylinder head assembly. Remove the rear engine hanger bracket from the cylinder head assembly.
Remove the inlet cover from the cylinder head assembly.
1 2 3.
Exhaust manifold Removal 1) 2)
1 2 3 4
Gasket Inlet cover
Remove the exhaust manifold cover from the exhaust manifold. Remove the heat protector from the exhaust manifold.
Front engine hanger Front engine hanger bracket Rear engine hanger Rear engine hanger bracket 1 2
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Heat protector Exhaust manifold cover
Removal and Installation of Cylinder Head 3)
Remove the exhaust manifold from the cylinder head assembly.
1 2 4)
5.
Thermostat Removal 1)
Exhaust manifold Distance nut
1 2
Disassemble the exhaust manifold.
2) 3) 6.
4.
Fan guide bracket Water outlet pipe
Remove the thermostat from the cylinder head assembly. Remove the gasket from the thermostat.
Overheat switch Removal 1)
1 2 3
Remove the water outlet pipe from the cylinder head assembly.
Remove the overheat switch from the cylinder head assembly.
Rear side exhaust manifold Seal ring Front side exhaust manifold
Bracket Removal 1)
Remove the EGR cooler bracket B from the cylinder head assembly.
1
EGR cooler bracket B 84402827B - May 2011 2415-17
1
Overheat switch
Removal and Installation of Cylinder Head 7.
Engine coolant temperature sensor Removal 1)
Remove the idle gear C cover from the cylinder head assembly using the pliers.
3)
Remove the idle gear C from the cylinder head assembly.
Remove the engine coolant temperature sensor from the cylinder head assembly.
1 2
8.
2)
Overheat switch Water temperature sensor
CMP sensor Removal 1) 2)
Disengage the harness connector from the CMP sensor. Remove the CMP sensor from the cylinder head assembly.
1 2
Idle gear C Idle gear shaft
10. Valve spring Removal 1)
Press the valve spring using the special tool.
CAUTION • Be careful not to subject the sensor to shock. 9.
Idle gear C Removal 1)
Press the idle gear C cover using the driver. ANNOTATION: • Lightly tap the outer perimeter of the cover using a screwdriver and tilt the cover.
Special tool: remover, valve spring (refer to section 1003)
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Removal and Installation of Cylinder Head 1)
Remove the exhaust valve from the cylinder head assembly. ANNOTATION: • Organize the removed valve according to the cylinders.
Special tool: pivot ASM (refer to section 1003)
13. Valve stem oil seal Removal 1)
Remove the valve stem oil seal from the valve guide using the pliers. CAUTION • Do not reuse the valve stem oil seal.
2) 2) 3) 4) 5)
Remove the split collar from the spring seat. Remove the special tool from the cylinder head assembly. Remove the valve spring seat from the valve spring. Remove the valve spring from the cylinder head assembly.
Remove the valve spring seat from the cylinder head assembly.
14. Valve guide Removal 1)
Remove the valve guide from the cylinder head assembly using the special tool.
ANNOTATION: • Store the removed valve springs according to the cylinders. 11. Inlet valve Removal 1)
Remove the inlet valve from the cylinder head assembly. ANNOTATION: • Organize the removed valve according to the cylinders.
12. Exhaust valve Removal
Special tool: remover/installer valve guide (refer to section 1003) ANNOTATION: • Tap the valve guides out from the bottom surface of the cylinder head.
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Removal and Installation of Cylinder Head • Tap the injector sleeve out from the bottom surface of the cylinder head.
15. Valve seat insert Removal 1)
2)
Heat the valve seat insert with the gas burner. Heating temperature ： 700.0 - 800.0 °C ｛1292 - 1472 °F｝: 2 sections inner surface of the insert
1
ANNOTATION:
CAUTION
• Cool the valve seat insert naturally after heating.
• Be careful not to damage the bottom surface of the cylinder head. • Do not reuse the removed injector sleeve.
Specified time： 5 min Natural cooling Remove the valve seat insert from the cylinder head assembly using the driver. CAUTION
17. Bridge guide Removal 1)
• Electrically weld the nut to the top of the bridge guide.
16. Injector sleeve Removal Remove the injector sleeve from the cylinder head assembly using the special tool.
2)
Special tool: remover, nozzle sleeve (refer to section 1003) ANNOTATION:
Install the nut to the bridge guide. ANNOTATION:
• Be careful not to damage the cylinder head.
1)
Injector sleeve
Remove the bridge guide from the cylinder head assembly using the sliding hammer.
1 18. Oil seal Removal
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Nut
Removal and Installation of Cylinder Head 1)
Remove the oil seal from the cylinder head assembly.
Cylinder head assembly Reassembly 1.
ANNOTATION:
Oil seal Installation 1)
• Attach a rod from the inner surface of the cylinder head, and tap it to remove it to the outer side.
Install the oil seal to the cylinder head assembly.
Special tool: oil seal installer (refer to section 1003) CAUTION • Be careful not to damage the lip section of the oil seal.
1 2
2.
Cylinder head Oil seal installer
Bridge guide Installation 1)
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Apply the engine oil to the bridge guide.
Removal and Installation of Cylinder Head 2)
Install the bridge guide to the cylinder head assembly using the special tool.
4)
Apply the engine oil to the cylinder head assembly. ANNOTATION: • Apply engine oil to the injector sleeve contact surface.
Special tool: bridge guide setting tool (refer to section 1003)
Specified length： 122.0 - 123.0 mm {4.8031 to 4.8425 in} 1 in the diagram Specified length： 37.5 mm {1.4764 in} 2 in the diagram 3.
Injector sleeve Installation 1) 2) 3)
1 2 3 4
Install the O-ring to the injector sleeve. Apply the engine oil to the O-ring. Apply the cement to the injector sleeve. ANNOTATION: • Apply Loctite 620 to the tapered section of the injector sleeve.
5)
O-ring with white paint O-ring Loctite 620 application Engine oil application
Install the injector sleeve to the cylinder head assembly using the special tool.
Special tool: nozzle sleeve setting tool (refer to section 1003) 84402827B - May 2011 2415-22
Removal and Installation of Cylinder Head 4)
Install the valve seat insert to the cylinder head assembly using the press.
1 2 3 5.
Valve guide Installation 1) 2)
1 2 3 4 5 6
Dolly block Valve seat insert Press
Apply the engine oil to the valve guide. Install the valve guide to the cylinder head assembly using the special tool.
Punch bar Ball Guide sleeve Injector sleeve Clamp Bolt
CAUTION • Allow the cylinder head to float so that the ball comes out from the bottom surface. 4.
Special tool: remover/installer valve guide (refer to section 1003) ANNOTATION:
Valve seat insert Installation 1)
• Tap the valve guides from the upper side of the cylinder head.
Prepare the dolly block. ANNOTATION: • Prepare the one which has smaller outer diameter than the valve seat insert.
2) 3)
Align the valve seat insert to the cylinder head. Align the dolly block to the valve seat insert.
Specified length ： 17.1 - 17.9 mm {0.6732 - 0.7047 in} From the upper surface of the 84402827B - May 2011 2415-23
Removal and Installation of Cylinder Head cylinder head to the edge surface of the valve guide
6.
Special tool: installer valve guide oil seal (refer to section 1003)
CAUTION
CAUTION
• When replacing the valve guide, replace it with the valve.
• Inspect the valve stem oil seal for deformation or cracks. • Confirm that the garter spring has not come loose.
Valve stem oil seal Installation 1) 2)
Install the valve spring seat to the cylinder head assembly. Apply the engine oil to the valve guide.
7.
Exhaust valve Installation 1) 2)
ANNOTATION: • Apply engine oil to the outer circumference of the valve guide.
Apply the engine oil to the exhaust valve. Install the exhaust valve to the cylinder head assembly. ANNOTATION: • Confirm that there is an E-mark on the valve.
CAUTION • Use a new valve stem oil seal. 3)
Install the valve stem oil seal to the valve guide using the special tool.
8.
Inlet valve Installation 1)
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Apply the engine oil to the inlet valve.
Removal and Installation of Cylinder Head 2)
Install the inlet valve to the cylinder head assembly. ANNOTATION: • Confirm that there is an I-mark on the valve.
Special tool: remover, valve spring (refer to section 1003)
9.
Valve spring Installation 1)
Check the identification paint of the valve spring.
Valve spring identification paint Inlet Blue Exhaust White
Special tool: pivot ASM (refer to section 1003)
1 2 2)
Spring pitch (small) Identification paint
Install the valve spring to the cylinder head assembly.
5)
ANNOTATION:
ANNOTATION:
• Lightly tap the valve stem head to stabilize the split collar.
• Turn the valve spring to face the identification paint application area towards the cylinder head assembly. 3) 4)
Install the split collar to the spring seat.
CAUTION • Confirm that the split collar is in the valve stem groove.
Install the spring seat to the valve spring. Press the valve spring using the special tool.
10. Idle gear C Installation 1)
Apply the engine oil to the idle gear C. ANNOTATION: • Apply to the sliding surface of the gear.
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Removal and Installation of Cylinder Head 2)
Apply the engine oil to the idle gear shaft.
Special tool: sealing cup installer (refer to section 1003)
ANNOTATION: • Apply engine oil to the outer circumference of the idle gear shaft. 3)
Temporarily tighten the idle gear C to the cylinder head assembly. CAUTION • Confirm that the spigot of the idle gear shaft is firmly installed to the cylinder head assembly.
1
Between the idle gear C cover end surface and cylinder head chamfered edge section
Specified length： 1.5 - 2.5 mm ｛0.0591 0.0984 in｝ 11. CMP sensor Installation 1) 2) 1 2 4)
5)
Idle gear C Idle gear shaft
CAUTION
Securely tighten the idle gear C to the cylinder head assembly. Tightening torque： 95 N・m ｛9.7 kgf・m / 70 lb・ft｝ Apply the cement to the idle gear C cover.
• Be careful not to subject the sensor to shock. ANNOTATION: • Tighten together with the clip.
ANNOTATION: • Apply Loctite 962T to the outer circumference of the idle gear C cover. 6)
Apply the engine oil to the O-ring. Install the CMP sensor to the cylinder head assembly.
3)
Install the idle gear C cover to the cylinder head assembly using the special tool.
Tightening torque： 8 N・m ｛0.8 kgf・m / 69 lb・in｝ Connect the harness connector to the CMP sensor.
12. Engine coolant temperature sensor Installation
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Removal and Installation of Cylinder Head 1)
Install the engine coolant temperature sensor to the cylinder head assembly.
14. Thermostat Installation 1)
Install the gasket to the thermostat.
ANNOTATION: CAUTION
• Apply Loctite 572 to the threaded portion. Tightening torque： 25 N・m ｛2.5 kgf・m / 18.4 lb・ft｝
1 2
• Use new gaskets. 2)
Overheat switch Water temperature sensor
1
• Be careful not to mistake the assembly position and direction.
Install the overheat switch to the cylinder head assembly. ANNOTATION:
3)
• Apply Loctite 572 to the threaded portion. Tightening torque： 29 N・m ｛3.0 kgf・m / 21.4 lb・ft｝
1
Jiggle valve position
CAUTION
13. Overheat switch Installation 1)
Install the thermostat to the cylinder head assembly.
Install the water outlet pipe to the cylinder head assembly. Tightening torque： 25 N・m ｛2.5 kgf・m / 18.4 lb・ft｝
1 2
Overheat switch
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Fan guide bracket Water outlet pipe
Removal and Installation of Cylinder Head • It will ride on the casted surface of the cylinder head as shown in the diagram when installed incorrectly.
15. Bracket Installation 1)
Install the EGR cooler bracket B to the cylinder head assembly. Tightening torque： 24 N・m ｛2.4 kgf・m / 17 lb・ft｝
1 2 1
EGR cooler bracket B 2)
16. Exhaust manifold Installation 1)
Casted surface Gasket
Assemble the exhaust manifold. ANNOTATION:
Install the gasket to the cylinder head assembly.
• Assemble the seal ring onto the rear side exhaust manifold and adjust each seal ring joint to be 120 degrees apart.
ANNOTATION: • Install the gasket by turning the protruding section downward.
1 2 3
CAUTION • Confirm that the gasket is firmly installed to the cylinder head.
3)
ANNOTATION:
Rear side exhaust manifold Seal ring Front side exhaust manifold
Install the exhaust manifold to the cylinder head assembly. ANNOTATION:
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Removal and Installation of Cylinder Head • Assemble the distance tube and washer referring to the diagram.
1 2
5)
Exhaust manifold Distance nut
Install the exhaust manifold cover to the exhaust manifold. Tightening torque： 31 N・m ｛3.2 kgf・m / 23 lb・ft｝
1 2
Heat protector Exhaust manifold cover
17. Inlet cover Installation 1) 2)
Install the gasket to the inlet cover. Install the inlet cover to the cylinder head assembly. Tightening torque： 25 N・m ｛2.5 kgf・m / 18 lb・ft｝ ANNOTATION: • Refer to the diagram for the tightening order. • 1 and 7 in the diagram indicate reamer bolts.
1 2 3 4
4)
Distance tube Nut Washer Distance nut
Tightening torque： 55 N・m ｛5.6 kgf・m / 41 lb・ft｝ Nut Tightening torque： 34 N・m ｛3.5 kgf・m / 25 lb・ft｝ Distance nut Install the heat protector to the exhaust manifold. Tightening torque： 20 N・m ｛2.0 kgf・m / 14 lb・ft｝ Bolt Tightening torque： 41 N・m ｛4.2 kgf・m / 30 lb・ft｝ Nut
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1 2
Gasket Inlet cover
Removal and Installation of Cylinder Head 2)
Temporarily tighten the rear engine hanger bracket to the cylinder head assembly. CAUTION • Completely tighten the rear engine hanger bracket after installing the EGR cooler. Tightening torque： 94 N・m ｛9.6 kgf・m / 69 lb・ft｝ Rear engine hanger bracket Tightening torque： 48 N・m ｛4.9 kgf・m / 35 lb・ft｝ Rear engine hanger
18. Engine hanger bracket Installation 1)
Install the front engine hanger bracket to the cylinder head assembly. Tightening torque： 48 N・m ｛4.9 kgf・m / 35 lb・ft｝ Front engine hanger bracket Tightening torque： 94 N・m ｛9.6 kgf・m / 69 lb・ft｝ Front engine hanger
1 2 3 4
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Front engine hanger Front engine hanger bracket Rear engine hanger Rear engine hanger bracket
Removal and Installation of Cylinder Head Cylinder head assembly Installation 1.
2)
Cylinder head assembly Installation
CAUTION
CAUTION • Clean the aligning surface of the cylinder head and cylinder block before installing the cylinder head assembly. • Be careful not to damage the cylinder head and cylinder block while cleaning. 1)
Install the cylinder head gasket to the cylinder block.
• Use a new cylinder head gasket. 3)
Install the cylinder head assembly to the cylinder block. CAUTION • Be careful not to damage the cylinder head gasket.
Apply the liquid gasket to the cylinder block. ANNOTATION: • Use ThreeBond 1207B. Bead width： 3.0 mm {0.1181 in} Bead height： 2.0 mm {0.0787 in}
ANNOTATION: • Tightening order of the head bolts CAUTION • After applying liquid gasket, install the cylinder head within 5 minutes.
ANNOTATION: • 1 to 26 in the diagram indicate the M14 bolts. • 27 and 28 in the diagram indicate the M10 bolts. 4)
Prepare the head bolt.
• Apply engine oil to the seat surface and threaded portion of the M10 head bolts. 5) 6)
ANNOTATION: • Apply molybdenum disulfide grease to the seat surface and threaded portion of the M14 head bolts. 84402827B - May 2011 2415-31
Tighten the head bolt using the torque wrench. Tightening torque： 98 N・m {10.0 kgf・m / 72 lb・ft} M14 bolt Tighten the head bolt using the torque wrench. Tightening torque： 147 N・m {15.0 kgf・m / 108 lb・ft} M14 bolt
Removal and Installation of Cylinder Head 7)
Tighten the head bolt using the special tool.
Special tool: angle gauge (refer to section 1003) Tightening angle： 30 - 60 ° M14 bolt 8) Tighten the head bolt using the torque wrench. Tightening torque： 38 N・m {3.9 kgf・m / 28 lb・ft} M10 bolt 9) Tighten the head bolt using the torque wrench. Tightening torque：142 N・m {14.5 kgf・m / 105 lb・ft} Check the tightening M14 bolt 2.
1)
Align 1st cylinder to the compression top dead center.
2)
Apply the engine oil to the camshaft bearing. ANNOTATION: • Apply engine oil to the sliding surface of the bearing. CAUTION • Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and cylinder head.
Bridge Installation 1) 2)
Apply the engine oil to the bridge. Install the bridge to the bridge guide. 3)
CAUTION
Install the camshaft bearing to the cylinder head assembly.
• Confirm that the bridge moves smoothly. 3) 4)
ANNOTATION: • To prevent the effect of spring force on the sub gear, use a scissors gear spring wrench to rotate the sub gear before installing the camshaft on the cylinder head.
Apply the engine oil to the bridge cap. Install the bridge cap to the bridge. 4)
Align the sub gear to the camshaft gear using the special tool. ANNOTATION: • Install the alignment pin from the sub gear side if the holes of the sub gear and the camshaft main gear are aligned.
CAUTION • Be careful not to drop the bridge cap into the engine. 3.
Camshaft Installation
Special tool: scissors gear spring wrench (refer to section 1003)
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Removal and Installation of Cylinder Head 7)
Apply the engine oil to the camshaft bearing. ANNOTATION: • Apply engine oil to the sliding surface of the bearing. CAUTION • Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and camshaft bearing cap.
8) 9) 1 5)
Alignment pin
Install the camshaft bearing to the camshaft bearing cap. Install the camshaft bearing cap to the cylinder head assembly. ANNOTATION:
Install the camshaft to the cylinder head assembly.
• Turn the camshaft bearing cap so that the arrow mark on the top surface faces the engine front side, and assemble in numerical order.
ANNOTATION: • Mesh together the idle gear C and the camshaft gear so that the alignment mark on the camshaft gear matches the top surface of the cylinder head, and gently install the camshaft.
Tightening torque：28 N・m {2.8 kgf・m / 20 lb・ft} Engine oil application
CAUTION • Align the alignment marks of the sub gear side.
4.
Rocker arm shaft Installation 1)
Apply the engine oil to the bracket. ANNOTATION: • Apply to each sliding surface.
6)
Check alignment mark of the camshaft gear. CAUTION • Confirm that the alignment mark is not misaligned before installing the camshaft bearing cap. • If the alignment mark is not at the correct position, reinstall the camshaft.
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Removal and Installation of Cylinder Head 2)
Apply the engine oil to the rocker arm.
5.
Rocker arm shaft Adjustment
ANNOTATION:
ANNOTATION:
• Confirm that the adjust screw is fully loosened.
• Valve clearance adjustment CAUTION • Adjust the valve clearance while cool. • Loosen all adjust screws before adjustment.
1 2 3 3)
Front side camshaft bracket Rocker arm Rear side camshaft bracket
Install the rocker arm shaft to the cylinder head assembly.
1)
Align 1st cylinder to the compression top dead center.
2)
Prepare the feeler gauge. Thickness： 0.4 mm {0.0157 in} 2 pieces
ANNOTATION: • On the camshaft bearing assembly section only, apply oil to the threaded portion of the stud bolts and the seat surface/threaded portion of the nuts, then tighten them. • Tightening order
ANNOTATION: • Insert rocker • Insert bridge Rocker arm shaft tightening torque Tightening torque Parts Front side camshaft bearing cap : 28 N・m {2.8 kgf・m / Rear side camshaft 20 lb・ft} bearing cap : 56 N・m {5.7 kgf・m / Rocker arm bracket 41 lb・ft}
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the thickness gauge between the arm and bridge cap. the thickness gauge between the and valve.
Removal and Installation of Cylinder Head 3)
Turn the adjust screw. • When the movement of the thickness gauge becomes stiff, secure the adjust screw nut of the rocker arm.
• Check if the valve shaft end on the opposite side is floating or touching at an angle. • If it is floating or touching at an angle, slightly loosen the bridge adjust screw and adjust the valve shaft ends on both sides to touch properly.
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
Valve bridge clearance ： less than 0.1 mm {less than 0.0039 in}
ANNOTATION:
ANNOTATION: • To prevent turning, fix the bridge adjust screw with a flathead screwdriver, and tighten the adjust screw nut. Tightening torque： 22 N・m {2.2 kgf・m / 16.lb・ft}
4)
Turn the adjust screw. ANNOTATION: • With the thickness gauge inserted, lightly tighten the adjust screw of the bridge. • Confirm that the leading end of the adjust screw and valve shaft end have made contact and the movement of the thickness gauge has become stiff.
Cylinder No. 1 Condision Arrangement of valves IN When the #1 cylinder is set at the compression ○ Valve to be top dead center adjusted When the #6 cylinder is set at the compression top dead center 6.
2 EXH IN ○
3 EXH IN
○
○ ○
ANNOTATION:
6 EXH IN
EXH
○ ○
1 2
Apply the liquid gasket to the rubber plug.
5 EXH IN
○
○
Lower cover Installation 1)
4 EXH IN
○
○
○
Rubber plug Liquid gasket
CAUTION
• Apply ThreeBond 1207B.
• After applying the liquid gasket, install the lower cover within 5 minutes. 2) 3)
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Install the rubber plug to the cylinder head assembly. Install the gasket to the lower cover.
Removal and Installation of Cylinder Head 4)
Install the lower cover to the cylinder head assembly. Tightening torque： 13 N・m {1.3 kgf・m / 112 lb・in}
8.
Fuel leak off pipe assembly Installation 1)
Temporarily tighten the fuel leak-off pipe to the cylinder head assembly.
ANNOTATION:
CAUTION
• Tightening order
• Use new gaskets. 2)
Temporarily tighten the fuel leak-off pipe to the common rail assembly. CAUTION • Use new gaskets.
3)
Temporarily tighten the fuel leak-off pipe to the fuel supply pump. ANNOTATION: • Tighten the fuel feed pipe together. CAUTION
7.
• Use new gaskets.
Common rail assembly Installation 1) 2) 3) 4)
5)
Align the common rail assembly to the inlet cover. Temporarily tighten the bolt to the common rail assembly. Temporarily tighten the nut to the common rail assembly. Securely tighten the bolt to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft} Securely tighten the nut to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft}
1
4)
5)
6)
7)
Securely tighten the fuel leak-off pipe to the cylinder head assembly. Tightening torque： 14 N・m {1.4 kgf・m / 123.9 lb・in} Securely tighten the fuel leak-off pipe to the common rail assembly. Tightening torque： 20 N・m {2.1 kgf・m / 14.8 lb・ft} Securely tighten the fuel leak-off pipe to the fuel supply pump. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} Install the clip to the fuel leak-off pipe. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
Common rail assembly 1
6)
Connect the harness connector to the fuel pressure sensor.
9.
Fuel leak-off pipe
Fuel pipe Installation
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Removal and Installation of Cylinder Head 1)
Install the fuel pipe to the fuel supply pump and the common rail assembly.
4) 5)
CAUTION • Use new fuel pipes.
2)
Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the bracket. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
6)
CAUTION • Use new gaskets. Tightening torque： 14 N・m {1.4 kgf・m / 126 lb・in}
10. Injector Installation CAUTION
11. Injection pipe Installation
• When reusing an injector, do not change the installation position. 1) 2)
Apply the engine oil to the bolt. Temporarily tighten the injector to the cylinder head assembly.
1)
2)
CAUTION • Be extremely careful not to damage the injector nozzle.
1 2 3)
Temporarily tighten the injection pipe to the common rail assembly. Securely tighten the injector to the cylinder head assembly. Tightening torque： 30 N・m {3.1 kgf・m / 22 lb・ft} Install the injector leak-off pipe to the injector.
3)
1 2 3 4 5 6 7
Injector Installation bolt
Temporarily tighten the injection pipe to the injector. CAUTION • Use new injection pipes.
Securely tighten the injection pipe to the injector. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Securely tighten the injection pipe to the common rail assembly. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the inlet cover. Tightening torque： 6 N・m {0.6 kgf・m / 53.1 lb・ft}
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
12. Glow plug Installation
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pipe pipe pipe pipe pipe pipe
Removal and Installation of Cylinder Head 1)
Install the glow plug to the cylinder head assembly. Tightening torque： 20 N・m {2.0 kgf・m / 14.8 lb・ft}
1)
ANNOTATION: • Tighten the bolts on the bracket and install the injector harness together with the bracket.
CAUTION • Be careful not to exceed the specified torque when tightening.
2)
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
Install the glow plug connector to the glow plug. Tightening torque： 1 N・m {0.1 kgf・m / 8.9 lb・in} CAUTION
Install the injector harness to the cylinder head assembly.
1 2 2)
• Confirm that the glow plug connector does not interfere with the surrounding parts.
Injector harness terminal Injector harness bracket
Connect the injector harness to the injector. CAUTION • Be careful not to damage the injector side stud bolts.
13. Injector harness Installation 1 2 3 3)
Injector Injector harness Terminal nut
Install the connector to the lower cover. Tightening torque： 2 N・m {0.2 kgf・m / 18 lb・in}
14. Cylinder head cover Installation 1) 2) 84402827B - May 2011 2415-38
Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover.
Removal and Installation of Cylinder Head Tightening torque： 13 N・m {1.3 kgf・m / 115 lb・in}
1)
ANNOTATION:
Install the inlet pipe to the inlet cover. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
• Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them.
1 2) 3) 4) 5)
1 2 3 3)
Inlet pipe
Connect the harness connector to the boost sensor. Connect the harness connector to the boost temperature sensor. Connect the harness connector to the IMT sensor. Install the harness clip to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
Cylinder head cover Head cover gasket Lower cover
Connect the ventilation hose to the air breather.
15. Inlet pipe Installation 1 2 3 4
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Boost sensor Harness clip Boost temperature sensor IMT sensor
Removal and Installation of Cylinder Head 16. Intake throttle valve Installation 1)
Install the intake throttle valve to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
1 2 3 2)
3)
Intake throttle valve Gasket Inlet pipe
Install the air duct to the intake throttle valve.
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Connect the harness connector to the intake throttle valve. ANNOTATION: • After connecting the harness connector, press in the lock operation portion to lock.
1 2 3
Lock operation section Lock release Lock
Removal and Installation of Cylinder Head 17. EGR cooler water pipe Installation
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Removal and Installation of Cylinder Head 1)
Install the water bypass hose to the water pump assembly and the water duct.
1 2)
5)
Install the fan guide stay to the fan guide. Tightening torque： 30 N・m {3.1 kgf・m / 22 lb・ft}
Water bypass hose 1 2 3
Install the EGR cooler water pipe to the engine assembly. Clamp tightening torque： 20 N・m {2.0 kgf・ m / 14 lb・ft} ANNOTATION:
Fan guide Fan guide stay Fan guide bracket
18. Oil separator bracket Installation
• Tightening torque of bolt 1 in the diagram is different from others.
1)
Tightening torque： 39 N・m {4.0 kgf・m / 29 lb・ft}
Temporarily tighten the oil separator bracket to the cylinder head assembly. ANNOTATION: • Tighten together with the clip.
2) 3)
Install the ventilation hose to the air breather. Securely tighten the oil separator bracket to the cylinder head assembly. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft} CAUTION • Pay attention to the installation angle of the hose.
4)
1 3) 4)
Install the clip to the cylinder block. Tightening torque： 48 N・m {4.9 kgf・m / 35 lb・ft}
Installation bolt
Connect the radiator upper hose to the water outlet pipe. Install the fan guide stay to the fan guide bracket. Tightening torque： 40 N・m {4.1 kgf・m / 30 lb・ft}
1 2 84402827B - May 2011 2415-42
Oil separator bracket Clip
Removal and Installation of Cylinder Head 6)
19. EGR valve Installation 1)
Install the EGR valve to the inlet pipe. Tightening torque： 46 N・m {4.7 kgf・m / 33.9 lb・ft}
1
1 2 3 4
EGR valve
20. EGR cooler Installation 1) 2)
Temporarily tighten the EGR cooler C to the EGR bracket C.
7)
Temporarily tighten the EGR pipe A to the exhaust manifold. Temporarily tighten the EGR cooler A to the EGR pipe A.
Temporarily tighten the EGR pipe B to the EGR cooler C and the EGR valve.
1 2 3 1 2 3 3) 4) 5)
EGR cooler A EGR pipe A Exhaust manifold
8)
Temporarily tighten the EGR cooler bracket A to the EGR cooler A. Temporarily tighten the EGR cooler B to the EGR cooler A. Temporarily tighten the EGR bracket C to the EGR cooler B.
9)
10)
11)
12)
84402827B - May 2011 2415-43
EGR cooler C EGR cooler bracket C EGR cooler B EGR cooler bracket A
EGR valve EGR pipe B EGR cooler C
Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque： 67 N・m {6.8 kgf・m / 49 lb・ft} Securely tighten the EGR cooler A to the EGR pipe A. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Securely tighten the EGR cooler B to the EGR cooler A. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler B. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler C to the EGR cooler bracket C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
Removal and Installation of Cylinder Head 13)
14)
15)
16)
17)
18)
Securely tighten the EGR pipe B to the EGR cooler C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR pipe B to the EGR valve. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR cooler bracket A to the EGR cooler bracket C. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler bracket B. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR pipe B to the rear engine hanger bracket. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Install the EGR heat protector to the EGR pipe. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
21. Oil level gauge guide tube Installation 1)
2)
3)
Install the oil level gauge guide tube to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Connect the oil level gauge guide tube to the cylinder head assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Install the oil level gauge to the oil level gauge guide tube.
1
Oil level gauge guide tube
22. Turbocharger assembly Installation 1) 2) 3)
1 19)
4)
EGR heat protector
Connect the water rubber hose to the EGR cooler.
Replenish the engine oil with the turbocharger assembly. Align the gasket to the turbocharger assembly. Install the turbocharger assembly to the exhaust manifold. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft} Install the water feed pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION • Use a new gasket.
5)
Connect the water feed pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
1
Water rubber hose
84402827B - May 2011 2415-44
Removal and Installation of Cylinder Head 6)
7)
Install the water return pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
11)
Connect the oil feed pipe to the turbocharger assembly. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
CAUTION
CAUTION
• Use a new gasket.
• Use a new gasket.
Connect the water return pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
8)
Install the oil return pipe to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION • Use a new gasket.
9)
1 2 3 4 5
Connect the oil return pipe to the turbocharger assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION
12)
• Use a new gasket.
13) 10)
Install the oil feed pipe to the pipe bracket. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION
14)
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Install the exhaust pipe to the turbocharger assembly. Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.
23. Engine harness Connect 1)
• Use a new gasket.
Connect the engine harness to the engine assembly. ANNOTATION: • Connect each connector.
24. Coolant Filling 1) 2)
Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
84402827B - May 2011 2415-45
Removal and Installation of Cylinder Head 3)
4)
Tighten the valve using a wrench.
2)
Turn ON the starter switch.
CAUTION
ANNOTATION:
• Use new gaskets.
• This is for the models with an electromagnetic pump.
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft} Replenish the coolant with the radiator.
3) 4)
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more ANNOTATION: • Confirm that fuel comes out from around the plug.
5) 6)
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
7)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION:
1 2
Valve Gasket
• Remove the air in the fuel filter. 8) 9)
25. Battery ground cable Connect 1)
ANNOTATION:
Connect the battery ground cable to the battery.
• Wait for the specified time after operating the priming pump.
26. Fuel Air bleed CAUTION
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more
10)
• To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
11) 12)
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
13)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
14)
1 2 3 4 5 1)
Priming pump Plug Drain plug Case Fuel filter element
Prepare the pan.
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} CAUTION • Remove the fuel around the plug thoroughly after tightening.
15) 16) 84402827B - May 2011 2415-46
Operate the priming pump. Number of times： 10 count(s) Start the engine.
Removal and Installation of Cylinder Head ANNOTATION:
Specified time： 3 min
• Do not accelerate the engine revolution right after staring.
ANNOTATION:
Specified time： 5 s ANNOTATION: • Accelerate the engine revolution gradually.
84402827B - May 2011 2415-47
• Accelerate the engine revolution to maximum. • Lower the rotation.
Removal and Installation of Cylinder Head Cylinder head assembly Inspection 1.
3.
1)
Bridge cap Inspection 1)
Idle gear C Inspection
Measure the bridge cap using the dial gauge.
Measure the clearance using the feeler gauge. ANNOTATION:
ANNOTATION:
• Measure the clearance in the axis direction between the cylinder head and idle gear C.
• Measure the contact surface of the bridge cap and rocker arm.
Specified value： 0.090 - 0.145 mm {0.0035 0.0057 in} Limit： 0.20 mm {0.0079 in}
Limit： 0.1 mm {0.0039 in} Amount of wear on the bridge cap CAUTION • Replace the bridge cap if the measured value exceeds the limit value. • Replace the bridge cap if it has an abnormal wear such as band-shaped wear.
1 2)
Idle gear C
Measure the idle gear shaft using the vernier caliper. ANNOTATION:
2.
• Outer diameter of the idle gear shaft
Bridge Inspection 1)
Specified value： 30.00 mm {1.1811 in} Limit： 29.85 mm {1.1752 in}
Inspect the bridge. ANNOTATION:
4.
• Confirm that the bridge moves smoothly. 2)
Inlet valve Inspection 1)
Check the clearance of the bridge cap. Standard value： 0.020 - 0.057 mm {0.0008 0.0022 in} Between the bridge and bridge cap Specified value ： 0.1 mm {0.0039 in} Between the bridge and bridge cap
Measure the inlet valve using the micrometer. ANNOTATION: • Outer diameter of the valve stem Measurement part： 3 section(s) Specified value： 8.0 mm {0.3150 in} Diameter Limit： 7.88 mm {0.3102 in} Diameter CAUTION • Replace the inlet valve and valve guide if the measured value is under the limit value.
1 2
Bridge Bridge guide
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Removal and Installation of Cylinder Head
2) 3)
Install the inlet valve to the valve guide. Measure the valve guide clearance using the dial gauge.
CAUTION • Replace the inlet valve and valve guide if the measured value exceeds the limit value.
ANNOTATION: • Valve guide clearance Specified value： 0.039 - 0.071 mm {0.0015 0.0028 in} Limit： 0.2 mm {0.0079 in}
5)
Inspect the inlet valve using the red lead primer. ANNOTATION: • Inspect the contact surface of the inlet valve and valve seat. Specified value： 2.7 mm {0.1063 in} Contact width Limit： 3.0 mm {0.1181 in} Contact width CAUTION
1 2 3
Valve The position 10 mm under the valve guide head Valve guide
CAUTION • Replace the inlet valve and valve guide if the measured value exceeds the limit value. 4)
Measure the inlet valve using the micrometer. ANNOTATION: • Valve thickness Specified value： 1.71 mm {0.0673 in} Limit： 1.30 mm {0.0512 in}
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• If the measured value exceeds the limit value, fix the contact surface of the valve seat using a sheet cutter. • If the contact position is not in the center of the valve seat, fix the contact surface of the valve seat using a sheet cutter. • If the contact surface is not smooth, fix the contact surface of the valve seat using a sheet cutter.
Removal and Installation of Cylinder Head 6)
Adjust the valve seat to standard value using the valve seat cutter.
10)
CAUTION
Check the sinking amount of the inlet valve. Specified value： 0.80 - 1.03 mm {0.0315 0.0406 in} Limit： 2.3 mm {0.0906 in}
• Use a seat cutter suitable for the valve seat angle and valve stem diameter. Valve seat angle： 30 ° External diameter of the valve stem： 8.0 mm {0.3150 in} Diameter
5.
Exhaust valve Inspection 1)
Measure the exhaust valve using the micrometer. ANNOTATION: • Outer diameter of the valve stem
7) 8) 9)
Apply the compound to the valve seat. Install the inlet valve to the valve guide. Adjust contact surface to standard value using the valve lapper.
Measurement part： 3 section(s) Specified value： 8.00 mm {0.3150 in} Diameter Limit： 7.88 mm {0.3102 in} Diameter
ANNOTATION:
CAUTION
• Lightly tap the inlet valve on the valve seat while turning it.
• Replace the exhaust valve and valve guide if the measured value is under the limit value.
CAUTION • After fixing the valve, remove all compounds.
2) 3)
Install the exhaust valve to the valve guide. Measure the valve guide clearance using the dial gauge. ANNOTATION: • Valve guide clearance Specified value： 0.064 - 0.096 mm {0.0025 0.0038 in} Limit： 0.25 mm {0.0098 in}
84402827B - May 2011 2415-50
Removal and Installation of Cylinder Head Limit： 3.0 mm {0.1181 in} Contact width CAUTION • If the measured value exceeds the limit value, fix the contact surface of the valve seat using a sheet cutter. • If the contact position is not in the center of the valve seat, fix the contact surface of the valve seat using a sheet cutter. • If the contact surface is not smooth, fix the contact surface of the valve seat using a sheet cutter. 1 2 3
Valve The position 10 mm under the valve guide head Valve guide
CAUTION • Replace the exhaust valve and valve guide if the measured value exceeds the limit value. 4)
Measure the exhaust valve using the micrometer. 6)
ANNOTATION: • Valve thickness
Adjust the valve seat to standard value using the valve seat cutter. CAUTION
Specified value： 1.75 mm {0.0689 in} Limit： 1.30 mm {0.0512 in}
• Use a seat cutter suitable for the valve seat angle and valve stem diameter. Valve seat angle： 45 ° External diameter of the valve stem： 8.0 mm {0.3150 in} Diameter
CAUTION • Replace the exhaust valve and valve guide if the measured value exceeds the limit value. 5)
Inspect the exhaust valve using the red lead primer.
7) 8) 9)
ANNOTATION: • Inspect the contact surface of the exhaust valve and valve seat. Specified value： 2.5 mm {0.0984 in} Contact width 84402827B - May 2011 2415-51
Apply the compound to the valve seat. Install the exhaust valve to the valve guide. Adjust contact surface to standard value using the valve lapper. ANNOTATION: • Tap the exhaust valve on the valve seat while turning it.
Removal and Installation of Cylinder Head ANNOTATION: • Fix it if it is possible.
CAUTION • After fixing the valve, remove all compounds. 10)
Check the sinking amount of the exhaust valve. Specified value： 1.24 - 1.47 mm {0.0488 0.0579 in} Limit： 2.8 mm {0.1102 in}
2)
Perform dye penetrant check. ANNOTATION: • Check if there is a problem which cannot be detected by visual inspection.
3) 4)
Align the simple straight ruler to the cylinder head assembly. Measure the clearance using the feeler gauge. ANNOTATION: • Flatness of the bottom of the cylinder head
6.
Cylinder head assembly Inspection CAUTION • Clean the each part of the cylinder head assembly before inspecting. • Be careful not to damage the cylinder head while cleaning the cylinder head assembly. 1)
5)
Inspect the cylinder head assembly. ANNOTATION: • Installation surface of the cylinder head gasket • Combustion chamber • Exhaust port • Valve seat • Glow plug hole CAUTION • Replace the cylinder head if damage such as a crack has been found in the inspection. 84402827B - May 2011 2415-52
Measurement part： 6 section(s) Limit： 0.2 mm {0.0079 in} Inspect the water leak using the water pressure tester. Specified pressure： 490.0 kPa {5.00 kgf/cm2 / 71 psi} Specified time： 3 min ANNOTATION: • Perform a hydraulic test with the injector holder installed.
Section 2425
Removal and Installation of Cylinder Block
84402827B - May 2011
84402827B - May 2011
CONTENTS Cylinder block Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cylinder block Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cylinder block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
84402827B - May 2011 2425-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2425-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Cylinder Block Cylinder block Removal 1.
Remove the fan guide from the fan guide bracket.
Battery ground cable Disconnect 1)
2.
1)
Disengage the battery ground cable from the battery.
Coolant Drain 1)
Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
3.
Engine oil Drain 1) 2) 3)
4.
Remove the drain plug from the oil pan. Drain the engine oil from the oil pan. Install the drain plug to the oil pan. Tightening torque： 70 N・m {7.1 kgf・m / 52 lb・ft}
1 2 3 4 5 6
Engine harness Disconnect 1)
Disengage the engine harness from the engine assembly. 2)
ANNOTATION: • Disconnect each connector. 5.
1)
Remove the fan guide bracket from the engine assembly.
Drive belt Removal 1)
Remove the cooling fan from the adapter.
1 2 6.
7.
Cooling fan Removal
Bolt Washer Rubber mount Rubber mount Guide tube Fan guide
Cooling fan Adapter
Remove the drive belt from the engine assembly.
1 2 3
Adjust bolt Fixing bolt Fixing bolt
Fan guide Removal 8.
Crankshaft pulley Removal 1) 2)
9.
Remove the crankshaft pulley from the crankshaft. Remove the crankshaft damper from the crankshaft pulley.
Crankshaft front oil seal Removal
84402827B - May 2011 2425-3
Removal and Installation of Cylinder Block 1)
Remove the crankshaft front oil seal from the timing gear case. CAUTION • Be careful not to damage the oil seal press-fitting surface of the timing gear case.
10. Water pump assembly Removal
1 2 3 2)
1)
Remove the fan pulley from the water pump assembly.
2)
Remove the water bypass hose from the water pump assembly and the water duct.
Felt Slinger Crankshaft front oil seal
Remove the slinger from the crankshaft using the special tool.
Special tool: rear oil seal remover (refer to section 1003) CAUTION • When replacing the oil seal, replace the slinger.
1 3) 4)
Water bypass hose
Remove the water hose from the EGR cooler water pipe and the water pump assembly. Remove the water pump assembly from the gear case cover cover.
11. Cover of gear case cover Removal 1) 2)
Remove the adjust plate from the gear case cover cover. Remove the gear case cover cover from the cylinder block.
12. Turbocharger assembly Removal 84402827B - May 2011 2425-4
Removal and Installation of Cylinder Block 1) 2) 3) 4)
Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger. Disengage the oil feed pipe from the turbocharger assembly.
1)
Disengage the water rubber hose from the EGR cooler.
ANNOTATION: • Remove the clip. 5)
Remove the oil feed pipe from the pipe bracket. ANNOTATION: • Remove the clip.
6) 7) 8) 9) 10)
Disengage the oil return pipe from the turbocharger assembly. Remove the oil return pipe from the cylinder block. Disengage the water return pipe from the turbocharger assembly. Remove the water return pipe from the cylinder head assembly. Disengage the water feed pipe from the turbocharger assembly.
1 2)
Water rubber hose
Remove the EGR pipe B from the EGR valve and the EGR cooler C.
ANNOTATION: • Remove the clip. 11)
Remove the water feed pipe from the cylinder block. ANNOTATION: • Remove the clip.
12) 13)
Disengage the harness connector from the turbocharger assembly. Remove the turbocharger assembly from the exhaust manifold.
1 2 3 3) 4) 5)
1 2 3 4 5
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
13. EGR cooler Removal 84402827B - May 2011 2425-5
EGR valve EGR pipe B EGR cooler C
Remove the EGR cooler C from the EGR bracket C. Remove the EGR bracket C from the EGR cooler B. Remove the EGR cooler B from the EGR cooler bracket A.
Removal and Installation of Cylinder Block 6)
Remove the EGR cooler bracket A from the EGR cooler A.
1 2 3 4 7)
8)
Remove the EGR pipe A from the exhaust manifold.
1 2 3
EGR cooler C EGR bracket C EGR cooler B EGR cooler bracket A
EGR cooler A EGR pipe A Exhaust manifold
14. EGR valve Removal
Remove the EGR heat protector from the EGR pipe A.
1
9)
1) 2)
EGR heat protector
Disengage the harness connector from the EGR valve. Remove the EGR valve from the inlet pipe.
1
Remove the EGR cooler A from the EGR pipe A.
EGR valve
15. Oil separator bracket Removal 1)
84402827B - May 2011 2425-6
Remove the clip from the cylinder block.
Removal and Installation of Cylinder Block 2)
Remove the ventilation hose from the air breather.
3)
Remove the oil separator bracket from the cylinder head assembly.
1 2
84402827B - May 2011 2425-7
Oil separator bracket Clip
Removal and Installation of Cylinder Block 16. EGR cooler water pipe Removal
1)
Disengage the radiator upper hose from the water outlet pipe.
2)
84402827B - May 2011 2425-8
Remove the EGR cooler water pipe from the engine assembly.
Removal and Installation of Cylinder Block 3)
Remove the water bypass hose from the water pump assembly and the water duct.
2)
Disengage the harness connector from the intake throttle valve. ANNOTATION: • Pull the lock operation portion to release the lock.
1
Water bypass hose
17. Oil level gauge guide tube Removal 1) 2) 3)
Remove the oil level gauge from the oil level gauge guide tube. Disengage the oil level gauge guide tube from the front engine hanger bracket. Remove the oil level gauge guide tube from the cylinder block.
1
3)
Lock operation section Lock release Lock
Remove the intake throttle valve from the inlet pipe.
1 2 3
Oil level gauge guide tube
18. Intake throttle valve Removal 1)
1 2 3
Intake throttle valve Gasket Inlet pipe
19. Inlet pipe Removal
Remove the air duct from the intake throttle valve.
1)
84402827B - May 2011 2425-9
Disengage the harness connector from the boost sensor.
Removal and Installation of Cylinder Block 2) 3) 4)
Disconnect the harness connector from the boost temperature sensor. Disconnect the harness connector from the IMT sensor. Remove the harness clip from the inlet pipe.
2)
Remove the glow plug from the cylinder head assembly.
21. Injection pipe Removal 1) 2) 1 2 3 4 5)
Boost sensor Harness clip Boost temperature sensor IMT sensor
CAUTION • Do not reuse the removed injection pipe. • Seal the common rail and injector to prevent foreign material from entering.
Remove the inlet pipe from the inlet cover.
1
Inlet pipe 1 2 3 4 5 6 7
20. Glow plug Removal 1)
Remove the clip from the inlet pipe. Remove the injection pipe from the injector and the common rail assembly.
Remove the glow plug connector from the glow plug.
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
pipe pipe pipe pipe pipe pipe
22. Fuel pipe Removal 1)
Remove the fuel pipe from the fuel supply pump and the common rail assembly. ANNOTATION: • Remove the clip. CAUTION • Do not reuse the removed fuel pipe.
84402827B - May 2011 2425-10
Removal and Installation of Cylinder Block 23. Fuel leak off pipe assembly Removal 1) 2)
25. Cylinder head cover Removal
Disengage the fuel leak-off pipe from the cylinder head. Remove the fuel leak-off pipe from the fuel supply pump.
1) 2) 3)
ANNOTATION:
Disengage the ventilation hose from the air breather. Remove the cylinder head cover from the lower cover. Remove the head cover gasket from the cylinder head cover.
• Remove the eyebolt tightened together with the fuel feed pipe. 3) 4)
Disengage the fuel leak-off pipe from the common rail assembly. Remove the fuel leak-off pipe from the inlet pipe. ANNOTATION: • Remove the clip.
1 2 3
Cylinder head cover Head cover gasket Lower cover
26. Injector harness Removal 1)
Remove the connector from the lower cover. CAUTION
1
• Do not pull the wire, or pry the connector with a screwdriver.
Fuel leak-off pipe
24. Common rail assembly Removal 1) 2)
Disengage the harness connector from the fuel pressure sensor. Remove the common rail assembly from the inlet cover.
1
Common rail assembly
84402827B - May 2011 2425-11
Removal and Installation of Cylinder Block 2)
Disengage the injector harness from the injector. CAUTION • Be careful not to damage the injector side stud bolts.
Special tool: injector remover (refer to section 1003)
1 2 3 3)
Injector Injector harness Terminal nut
Remove the injector harness from the cylinder head assembly. ANNOTATION: • Remove the bracket tightening bolts and then remove the injector harness together with the bracket.
1 2
Injector harness terminal Injector harness bracket
2)
1 2 3
Sliding hammer Fuel injector remover Injector
CAUTION
27. Injector Removal 1)
Special tool: sliding hammer (refer to section 1003)
Remove the injector leak-off pipe from the injector. Remove the injector from the cylinder head assembly. ANNOTATION: • When it is difficult to remove the injector, use a special tool. 84402827B - May 2011 2425-12
• Confirm that the sleeve is not pulled out together when pulling out the injector using a special tool. • Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. • Be extremely careful not to damage the injector nozzle.
Removal and Installation of Cylinder Block
28. Lower cover Removal 1) 2)
30. Camshaft Removal
Remove the lower cover from the cylinder head assembly. Remove the rubber plug from the cylinder head assembly. Loosen the adjust screw using the wrench.
Remove the camshaft bearing cap from the cylinder head assembly. Remove the camshaft bearing from the camshaft bearing cap. Remove the camshaft from the cylinder head. Remove the camshaft bearing from the cylinder head assembly.
ANNOTATION:
ANNOTATION:
• Loosen all valve clearance adjustment screws.
• Temporarily assemble the removed caps and bearings in the original position to avoid a mix-up after the bearings have been inspected.
2)
2) 3) 4)
29. Rocker arm shaft Removal 1)
1)
Remove the rocker arm shaft from the cylinder head assembly. ANNOTATION:
31. Bridge Removal
• Evenly loosen the rocker arm shaft bracket and the rocker arm assembly bracket tightening bolts from both ends and remove them.
1)
CAUTION • Be careful not to remove the bolt shown in the diagram.
84402827B - May 2011 2425-13
Remove the bridge cap from the bridge. CAUTION • Be careful not to drop the bridge cap into the engine.
Removal and Installation of Cylinder Block 2)
Remove the bridge from the bridge guide. ANNOTATION:
32. Cylinder head assembly Removal 1)
• After removing, organize to avoid a mix-up with other installation locations.
Remove the cylinder head assembly from the cylinder block. ANNOTATION: • Loosening order of the head bolts
1 2
Bridge cap Bridge
1
CAUTION • Since the idle gear C protrudes from the bottom surface of the cylinder head, be careful not to damage the gear.
2)
Idle gear C
Remove the cylinder head gasket from the cylinder block. CAUTION • Do not reuse the cylinder head gasket.
33. Fuel supply pump Removal 1)
84402827B - May 2011 2425-14
Disengage the harness connector from the fuel supply pump.
Removal and Installation of Cylinder Block 2)
Remove the fuel supply pump from the cylinder block.
2)
ANNOTATION:
CAUTION
• Remove together with the bracket.
• Be careful not to subject the sensor to shock.
1 2 3 4 5 6 7 8 9 10
Fuel supply pump Bracket Gear Nut Bolt O-ring O-ring Nut Bolt Nut
1 2 3 4
2)
Oil pressure switch Oil port cover Flywheel housing CKP sensor
36. Flywheel Removal 1)
Remove the flywheel from the crankshaft. ANNOTATION: • Gradually loosen the flywheel installation bolts in the order shown in the diagram.
34. Starter assembly Removal 1)
Remove the CKP sensor from the flywheel housing.
Disengage the earth cable from the starter assembly. Remove the starter assembly from the flywheel housing.
CAUTION • Fix the flywheel firmly so that it will not rotate. 35. CKP sensor Removal 1)
37. Crankshaft rear oil seal Removal
Disengage the harness connector from the CKP sensor.
1)
84402827B - May 2011 2425-15
Remove the crankshaft rear oil seal from the crankshaft using the special tool.
Removal and Installation of Cylinder Block 3)
Remove the gasket from the oil pan.
39. Oil strainer Removal 1) 2)
Remove the oil strainer from the crankcase. Remove the O-ring from the oil strainer.
Special tool: rear oil seal remover (refer to section 1003)
40. Flywheel housing Removal 1) 2)
1 2 3
Remove the PTO oil pipe from the flywheel housing and the cylinder block. Remove the oil pipe from the pipe bracket and the oil port cover.
Felt Slinger Crankshaft rear oil seal
1 2 3 3)
Oil pipe Pipe bracket PTO oil pipe
Remove the cover from the flywheel housing.
CAUTION • Be careful not to damage the oil seal press-fitting surface. ANNOTATION: • Remove the slinger and oil seal together. 38. Oil pan Removal 1) 2)
Disengage the harness connector from the oil level switch. Remove the oil pan from the crankcase. 84402827B - May 2011 2425-16
1 2
O-ring Cover
Removal and Installation of Cylinder Block 4) 5)
Remove the PTO idle gear from the cylinder block. Remove the flywheel housing from the cylinder block and the crankcase. CAUTION • Do not forget to remove the bolt shown in the diagram.
3)
Measure the clearance using the feeler gauge. ANNOTATION: • Measure the clearance between the idle gear and the thrust collar. CAUTION
1
• Measure the play of the idle gear in the axis direction before removing the idle gear B.
Bolt
Specified value： 0.080 - 0.155 mm {0.0031 0.0061 in} Limit： 0.20 mm {0.0079 in}
41. Idle gear Measurement 1)
Align the dial gauge to the idle gear.
CAUTION
ANNOTATION:
• Replace the idle gear if the measured value exceeds the limit value.
• Attach the dial gauge to the idle gear tooth to be measured. 2)
Inspect the backlash. ANNOTATION: • Gently move the gear right and left to read the inconsistency on the dial gauge. CAUTION • Measure the idle gear backlash before removing the idle gear A. Specified value： 0.10 - 0.17 mm {0.0039 0.0067 in} Limit： 0.30 mm {0.0118 in} CAUTION
42. Idle gear A Removal
• Replace the idle gear if the measured value exceeds the limit value.
1)
84402827B - May 2011 2425-17
Remove the idle gear A from the idle gear A shaft.
Removal and Installation of Cylinder Block 2)
Remove the idle gear A shaft from the cylinder block.
1)
Clean the cylinder liner using the scraper. ANNOTATION: • Remove carbon from the top of the cylinder liner using a scraper.
43. Oil pump assembly Removal 1)
Remove the oil pump assembly from the cylinder block.
2)
Remove the connecting rod bearing cap from the connecting rod. ANNOTATION: • Set the piston of the cylinder to be removed to the bottom dead center.
44. Idle gear B Removal 1) 2)
Remove the idle gear B from the idle gear B shaft. Remove the idle gear B shaft from the cylinder block.
3)
Remove the connecting rod bearing from the connecting rod bearing cap. ANNOTATION: • Organize the removed bearings by the cylinders using tags, etc.
4)
Remove the piston from the cylinder block. ANNOTATION: • Pull out the piston and connecting rod together to the cylinder head side. CAUTION • Be careful not to damage the oil jet.
45. Piston Removal 5)
Remove the connecting rod bearing from the connecting rod. ANNOTATION: • Organize the removed bearings by the cylinders using tags, etc.
46. Crankshaft Removal 84402827B - May 2011 2425-18
Removal and Installation of Cylinder Block 1)
Measure the clearance using the feeler gauge. ANNOTATION: • Measure the crankshaft clearance in the axis direction at the bearing section No.7. Specified value： 0.104 - 0.205 mm {0.0041 0.0081 in}
1
3) 4) CAUTION
Replacer hole
: 4 section(s) Remove the thrust bearing from the crankcase. Remove the crankshaft bearing from the crankcase.
• Replace the thrust bearing if the measured value is not within the range of the standard value. 2)
Remove the crankcase from the cylinder block.
5) 6) 7)
Remove the crankshaft from the cylinder block. Remove the thrust bearing from the cylinder block. Remove the crankshaft bearing from the cylinder block.
47. Piston oil jet Removal ANNOTATION:
1)
• Remove the crankcase using the replacer holes.
Remove the piston oil jet from the cylinder block.
48. Cylinder liner Removal 84402827B - May 2011 2425-19
Removal and Installation of Cylinder Block 1)
Remove the cylinder liner from the cylinder block.
Cylinder block Installation 1.
Cylinder liner Preparation CAUTION • When replacing the cylinder liner, select the cylinder liner following the procedure below. 1)
Check marking of the cylinder block. ANNOTATION: • A marking on a cylinder block indicates the cylinder block bore grade.
CAUTION • Do not tilt the cylinder liner when storing.
1
2)
Check the grade of the cylinder liner.
1
3)
Grade marking location
Grade confirmation location
Select the cylinder liner.
Matching grades for cylinder block and liner outer diameter Marking on the block 1 2 3 Liner outer diameter 1X 3X 84402827B - May 2011 2425-20
Removal and Installation of Cylinder Block Cylinder block inner diameter, liner outer diameter grade 1・1X 2・1X 3・3X Grade : 118.001 : 118.011 : 118.021 - 118.010 - 118.020 - 118.030 Block inner mm mm mm diameter {4.6457 - {4.6461 - {4.6465 4.6461 in} 4.6464 in} 4.6468 in} : 118.001 - 118.010 Liner outer : 117.991 - 118.000 mm mm {4.6453 - 4.6457 in} diameter {4.6457 4.6461 in} 2.
CAUTION • After replacing the cylinder liner, be sure to measure the protrusion amount of the cylinder liner. 4)
Measure the cylinder liner using the dial gauge. Specified value： 0.05 - 0.10 mm {0.0020 0.0039 in} Protrusion amount of cylinder liner Limit： under 0.03 mm {0.0012 in} ANNOTATION: • The limit value indicates the difference in the protrusion amounts with the adjacent cylinder liner.
Cylinder liner Installation CAUTION • Since the cylinder liner is thin, handle it carefully. • Do not tilt the cylinder liner when storing.
3.
Piston oil jet Installation 1)
Install the piston oil jet to the cylinder block. CAUTION
1) 2) 3)
Clean the cylinder block using the air. Clean the cylinder liner using the air. Install the cylinder liner to the cylinder block. ANNOTATION: • Install the cylinder liner on the cylinder block vertically. CAUTION • Do not tap or apply excessive force when inserting the liner.
84402827B - May 2011 2425-21
• Be careful not to deform or damage the nozzle part of the piston oil jet. Tightening torque： 21 N・m {2.1 kgf・m / 15 lb・ft}
Removal and Installation of Cylinder Block
4.
Crankshaft bearing Preparation
ANNOTATION: • Check the marking on the crankshaft. • The marking on the crankshaft indicates the outer diameter grade of the journal section. • Grade indications are lined up as No.1, 2, 3, 4, 5, 6, 7 from the left when looking at the marking section from the front side.
CAUTION • When replacing the crankshaft bearing, select the crankshaft bearing following the procedure below. 1)
Check marking of the crankcase. ANNOTATION: • The marking on the crankcase indicates the inner diameter grade of the cylinder block journal section. • Grade indications are lined up as No.1, 2, 3, 4, 5, 6, 7 from the left when looking at the marking section from the front side.
2)
Select the crankshaft bearing. ANNOTATION: • Refer to the bearing selection table.
Bearing selection table Grade combination Cylinder block Crank grade grade 1
1
1
2
2
1
2
2
Oil clearance journal Bearing identifiNo.1, 2, 3, 5, 6, 7 cation color : 0.065 - 0.092 mm Black {0.0026 - 0.0036 in} : 0.063 - 0.089 mm Brown {0.0025 - 0.0035 in} : 0.067 - 0.094 mm Blue {0.0026 - 0.0037 in} : 0.065 - 0.091 mm Black {0.0026 - 0.0036 in}
CAUTION • Be careful not to mistake the bearing shape when installing the crankshaft bearing.
84402827B - May 2011 2425-22
No.4 : 0.095 - 0.122 mm {0.0037 - 0.0048 in} : 0.093 - 0.119 mm {0.0037 - 0.0047 in} : 0.097 - 0.124 mm {0.0038 - 0.0049 in} : 0.095 - 0.121 mm {0.0037 - 0.0048 in}
Removal and Installation of Cylinder Block 5) 6) 7)
Apply the engine oil to the crankshaft. Put the crankshaft on the cylinder block. Install the thrust bearing to the cylinder block. ANNOTATION: • Install the thrust bearing on the No.7 journal so that the oil groove faces the engine rear.
1 2 3 4 5 6 5.
Upper bearing Oil hole Grade identification color Oil groove Lower bearing Grade identification color
8)
Install the crankcase.
crankshaft
bearing
to
the
Crankshaft Installation 1)
CAUTION
Install the crankshaft bearing to the cylinder block.
• Make sure there is no grime or oil on the crankcase contact surface for the crankshaft bearing.
ANNOTATION: • Install a bearing with an oil hole on the cylinder block.
2)
9)
Apply the grease to the thrust bearing.
CAUTION
ANNOTATION:
• Make sure there is no grime or oil on the cylinder block contact surface for the crankshaft bearing.
• Apply a small amount of grease to the thrust bearing to prevent falling. 10)
Install the thrust bearing to the crankcase. ANNOTATION:
Apply the grease to the thrust bearing.
• Install the thrust bearing on the No.7 journal so that the oil groove faces the engine rear.
ANNOTATION: • Apply a small amount of grease to the thrust bearing to prevent falling. 3)
Install the thrust bearing to the cylinder block. ANNOTATION: • Install the thrust bearing on the No.7 journal so that the oil groove faces the engine front.
11) 12)
Apply the engine oil to the crankshaft bearing. Apply the liquid gasket to the crankcase. ANNOTATION: • Apply ThreeBond 1207B to the crankcase thoroughly so that there is no break in application of the bead.
4)
Apply the engine oil to the crankshaft bearing. 84402827B - May 2011 2425-23
Bead width： 3 - 4 mm {0.118 - 0.157 in}
Removal and Installation of Cylinder Block Bead hight： 3 - 4 mm {0.118 - 0.157 in}
15) CAUTION
16)
• After applying the liquid gasket, install the crankcase within 5 minutes. 13)
17)
Tighten the bolt using the torque wrench. Tightening torque： 98 N・m {10.0 kgf・m / 72 lb・ft} M14 bolt Tighten the bolt using the torque wrench. Tightening torque： 132 N・m {13.5 kgf・m / 97 lb・ft} M14 bolt Tighten the bolt using the special tool.
Put the crankcase on the cylinder block. CAUTION • Be careful not to let the thrust bearing fall.
14)
Special tool: angle gauge (refer to section 1003) Tightening angle： 30 ° M14 Bolt 18) Tighten the bolt using the torque wrench. Tightening torque： 37 N・m {3.8 kgf・m / 27 lb・ft} M10 bolt 19) Tighten the bolt using the torque wrench. Tightening torque：142 N・m {14.5 kgf・m / 105 lb・ft} Check the tightening M14 bolt
Apply the disulfide molybdenum grease to the bolt. ANNOTATION:
CAUTION
• Apply to the threaded portion and seat surface on the M14 bolt for crankcase installation. 6.
CAUTION • Do not apply grease to the M10 bolt. ANNOTATION:
• Confirm that the crankshaft turns smoothly after tightening the bolts. Piston Installation 1) 2)
Install the connecting rod bearing to the connecting rod. Apply the engine oil to the connecting rod bearing.
• Tightening order CAUTION • Apply engine oil only to the internal diameter of the connecting rod bearing. 3) 84402827B - May 2011 2425-24
Apply the engine oil to the piston ring.
Removal and Installation of Cylinder Block 4)
5)
6)
Align the piston to the cylinder block.
ANNOTATION:
ANNOTATION:
• Thoroughly apply engine oil to the ring grooves and piston side surface.
• Turn the piston so that the front mark faces the engine front. 9)
Adjust the piston ring.
Press the piston.
ANNOTATION:
CAUTION
• Shift each piston ring joint by the specified angle.
• To avoid damaging the oil jet, place the crank pin on the cylinder on which the piston will be installed at top dead center. • To avoid damaging the piston ring, firmly attach the piston installer to the cylinder block and push it. • Be careful not to damage the crank pin and cylinder liner. • Attach a stopper so that the liner does not protrude.
Specified angle： 90 ° Apply the engine oil to the cylinder liner.
1
7)
8)
Apply the engine oil to the piston.
Engine oil application
Install the piston installer to the piston. 1 2 3 4 10) 11)
No.1 compression ring joint No.2 compression ring joint Oil ring joint Front mark
Install the connecting rod bearing to the connecting rod bearing cap. Apply the engine oil to the connecting rod bearing. CAUTION
Special tool: piston setting tool (refer to section 1003)
84402827B - May 2011 2425-25
• Apply engine oil only to the internal diameter of the connecting rod bearing.
Removal and Installation of Cylinder Block 12)
Align the connecting rod bearing cap to the connecting rod.
14)
ANNOTATION:
ANNOTATION:
• Confirm that the numbers on the connecting rod bearing cap and the connecting rod are the same.
• Apply to the threaded portion and seat surface of the bolts for the connecting rod installation. 15) 16)
1 2 3
13)
Apply the disulfide molybdenum grease to the bolt.
Front and back side discrimination boss Grade mark of the large end hole diameter Cylinder number
Tighten the bolt using the torque wrench. Tightening torque： 39 N・m {4.0 kgf・m / 29 lb・ft} Tighten the bolt using the special tool.
Special tool: angle gauge (refer to section 1003) Tightening angle： 60 ° 17) Tighten the bolt using the special tool. Tightening angle： 30 ° 18) Tighten the bolt using the torque wrench. Tightening torque： 98 N・m {10.0 kgf・m / 72 lb・ft} Check the tightening
Install the connecting rod bearing cap to the connecting rod. ANNOTATION: • Precautions when tightening the connecting rod bolt CAUTION • Set each cylinder to the bottom dead center while working.
7.
Idle gear B Installation 1)
2) 3) CAUTION • Do not allow tightening tools to touch the oil jet. • Confirm that the crankshaft turns smoothly after tightening the connecting rod bolt. 84402827B - May 2011 2425-26
Install the idle gear B shaft to the cylinder block. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Apply the engine oil to the idle gear B shaft. Apply the engine oil to the idle gear B.
Removal and Installation of Cylinder Block 4)
Install the idle gear B to the cylinder block. Tightening torque： 95 N・m {9.7 kgf・m / 70 lb・ft}
CAUTION • Do not allow the liquid gasket to adhere to the locations indicated by arrows in the diagram. • After applying the liquid gasket, install the oil pump within 5 minutes.
CAUTION • Confirm that the idle gear B turns smoothly after installing. 8.
4)
Oil pump assembly Installation 1)
Clean the cylinder block using the scraper.
Install the oil pump to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 18 lb・ft}
ANNOTATION: • Remove grime and oil from the oil pump installation area. 2)
Apply the engine oil to the cylinder block.
9.
Idle gear A Installation 1) 2) 3) 4) 5)
CAUTION • Do not allow engine oil to adhere on the oil pump installation surface. 3)
Apply the liquid gasket to the oil pump.
Align 1st cylinder to the compression top dead center. Apply the engine oil to the idle gear A shaft. Apply the engine oil to the idle gear A. Install the idle gear A shaft to the idle gear A. Align the idle gear A to alignment mark. ANNOTATION: • Align the L mark on the crank gear with the O mark on the idle gear A.
ANNOTATION: • Refer to the diagram and apply the ThreeBond 1207C to the oil pump.
1 2
84402827B - May 2011 2425-27
L mark O mark
Removal and Installation of Cylinder Block 6)
Install the idle gear A to the cylinder block. Tightening torque： 133 N・m {13.6 kgf・m / 98 lb・ft}
10. Flywheel housing Installation 1)
Clean the cylinder block using the scraper. ANNOTATION: • Remove dust and oil from the flywheel housing installation area.
2)
Apply the liquid gasket to the cylinder block. ANNOTATION: • Refer to the diagram and apply the ThreeBond 1201 to the cylinder block.
1
Liquid gasket application prohibited area
CAUTION 1 2 3 4 5 6 7 8 9 10 11
• Do not apply liquid gasket to the location indicated in 1 in the diagram. • After applying the liquid gasket, install the flywheel housing within 5 minutes.
Camshaft gear Aligning position Idle gear B Aligning position PTO gear PTO idle gear Crank gear Oil pump gear Supply pump gear Idle gear A Idle gear C
84402827B - May 2011 2425-28
Removal and Installation of Cylinder Block 3)
Install the flywheel housing to the cylinder block.
6)
Install the PTO idle gear to the cylinder block. Tightening torque： 119 N・m {12.1 kgf・m / 88 lb・ft}
7) 8)
Install the O-ring to the cover. Install the cover to the flywheel housing.
ANNOTATION: • Install the flywheel housing after aligning with the knock pin position of the cylinder block. Tightening No.1 bolt No.2 bolt No.3 bolt No.4 bolt
torque : 96 N・m {9.8 kgf・m / 71 lb・ft} : 119 N・m {12.1 kgf・m / 88 lb・ft} : 86 N・m {8.8 kgf・m / 64 lb・ft} : 53 N・m {5.4 kgf・m / 39 lb・ft}
1 2 9)
4) 5)
Apply engine oil to the PTO gear shaft. Install the PTO idle gear shaft to the PTO idle gear.
84402827B - May 2011 2425-29
O-ring Cover
Install the oil pipe to the pipe bracket and the oil port cover. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Pipe bracket side Tightening torque： 28 N・m {2.8 kgf・m / 20 lb・ft} Oil port cover side Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
Removal and Installation of Cylinder Block 10)
Install the PTO oil pipe to the flywheel housing and the cylinder block. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Flywheel housing side Tightening torque： 15 N・m {1.5 kgf・m / 11 lb・ft} PTO side Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Cylinder block side Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
• Apply ThreeBond 1207B to each joint of the crankcase, flywheel housing and gear case. Bead width： 3.0 mm {0.1181 in} Bead height： 2.0 mm {0.079 in}
1 2 3
1 2 3
CAUTION
Oil pipe Pipe bracket PTO oil pipe
• After applying the liquid gasket, install the oil pan within 5 minutes. 2) 3)
11. Oil strainer Installation 1) 2)
Crankcase Timing gear case Flywheel housing
Install the O-ring to the oil strainer. Install the oil strainer to the crankcase. Tightening torque：24 N・m {2.4 kgf・m / 17 lb・ft} M8 bolt Tightening torque： 48 N・m {4.9 kgf・m / 35 lb・ft} M10 bolt
Install the gasket to the oil pan. Install the oil pan to the crankcase. Tightening torque： 11 N・m {1.1 kgf・m / 96 lb・in} 4 stud bolts Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} CAUTION • Note that one of the bolts has a different length from others.
1 2
M10 bolt M8 bolt 1 2
Short bolt installation area Stud bolt installation area
12. Oil pan Installation 1)
Apply the liquid gasket to the crankcase.
4)
ANNOTATION: 84402827B - May 2011 2425-30
Connect the harness connector to the oil level switch.
Removal and Installation of Cylinder Block 13. Crankshaft rear oil seal Installation 1)
4)
Prepare the special tool.
1 2 3
Special tool: oil seal installer (refer to section 1003) ANNOTATION: • In order to install the crankshaft rear oil seal, use the one(s) in the following table from among the parts included in the kit.
Legend 1：Adapter 2：Adapter tightening bolts 3：Center bolt 4：Sleeve 5：Collar 6：Adapter ring 7：Crankshaft rear oil seal 2)
Parts number 5–8840–2709–0 5–8840–2714–0 5–8840–2713–0 5–8840–9063–0 5–8840–2710–0 5–8840–2711–0 -
5) 6)
7) 8)
Apply the engine oil to the crankshaft rear oil seal.
• Apply only to the lip section of the oil seal. Install the crankshaft rear oil seal to the adapter.
84402827B - May 2011 2425-31
Collar Adapter tightening bolts Adapter
Install the adapter ring to the sleeve. Install the sleeve to the adapter.
1 2
CAUTION
3)
Install the adapter to the crankshaft.
Sleeve Adapter ring
Install the center bolt to the sleeve. Tighten the center bolt using the wrench. ANNOTATION: • Tighten the center bolt until the sleeve touches the adapter.
Removal and Installation of Cylinder Block 9)
4)
Inspect the crankshaft rear oil seal.
Tighten the bolt using the special tool.
ANNOTATION: • Measure the distance between the crankshaft head and the crankshaft rear oil seal. Specified value： 7.2 - 7.8 mm {0.283 - 0.307 in}
1 2 3 4
Flywheel housing Crankshaft rear oil seal Oil seal press-fitting measurement Crankshaft
Special tool: angle gauge (refer to section 1003) Tightening angle： 60 ° 5) Tighten the bolt using the special tool. Tightening angle： 60 ° 6) Tighten the bolt using the torque wrench. Tightening torque： 274 N・m {27.9 kgf・m / 202 lb・ft} Check the tightening 15. CKP sensor Installation 1)
CAUTION • Be careful not to subject the sensor to shock.
14. Flywheel Installation 1)
2)
Install the CKP sensor to the flywheel housing.
Apply the disulfide molybdenum grease to the bolt.
ANNOTATION:
ANNOTATION:
• Tighten together with the clip.
• Apply to the seat surface and threaded portion on the flywheel installation bolts.
Tightening torque： 6 N・m {0.6 kgf・m / 52 lb・in} Connect the harness connector to the CKP sensor.
2)
Install the flywheel to the crankshaft. CAUTION • Pay attention to the knock pin position of the crankshaft. ANNOTATION: • Tightening order
1 2 3 4
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
16. Starter assembly Installation 3)
Tighten the bolt using the torque wrench. Tightening torque： 78 N・m {8.0 kgf・m / 58 lb・ft} 84402827B - May 2011 2425-32
Removal and Installation of Cylinder Block 1)
2)
Install the starter assembly to the flywheel housing. Tightening torque： 82 N・m {8.4 kgf・m / 60.5 lb・ft} Connect the earth cable to the starter assembly. Tightening torque： 19 N・m {1.9 kgf・m / 14.0 lb・ft}
3)
Align the fuel supply pump to the cylinder block.
1 2
17. Fuel supply pump Installation 1) 2)
4)
Align 1st cylinder to the compression top dead center. Align alignment mark to the bracket.
1 2
Confirmation hole Supply pump gear
Install the fuel supply pump to the cylinder block. Tightening torque： 75 N・m {7.6 kgf・m / 55 lb・ft} No.5 in the diagram Tightening torque： 75 N・m {7.6 kgf・m / 55 lb・ft} No.8 in the diagram Tightening torque： 51 N・m {5.2 kgf・m / 38 lb・ft} No.10 in the diagram
Supply pump bracket side slit Supply pump gear side alignment mark 1 2 3 4 5 6 7 8 9 10
5)
Fuel supply pump Bracket Gear Nut Bolt O-ring O-ring Nut Bolt Nut
Connect the harness connector to the fuel supply pump.
18. Cylinder head assembly Installation 84402827B - May 2011 2425-33
Removal and Installation of Cylinder Block 2)
CAUTION • Clean the aligning surface of the cylinder head and cylinder block before installing the cylinder head assembly. • Be careful not to damage the cylinder head and cylinder block while cleaning. 1)
Install the cylinder head gasket to the cylinder block. CAUTION • Use a new cylinder head gasket.
3)
Apply the liquid gasket to the cylinder block.
Install the cylinder head assembly to the cylinder block.
ANNOTATION:
CAUTION
• Use ThreeBond 1207B.
• Be careful not to damage the cylinder head gasket.
Bead width： 3.0 mm {0.1181 in} Bead height： 2.0 mm {0.0787 in}
ANNOTATION: CAUTION
• Tightening order of the head bolts
• After applying liquid gasket, install the cylinder head within 5 minutes.
ANNOTATION: • 1 to 26 in the diagram indicate the M14 bolts. • 27 and 28 in the diagram indicate the M10 bolts. 4)
Prepare the head bolt.
• Apply engine oil to the seat surface and threaded portion of the M10 head bolts. 5) 6)
ANNOTATION: • Apply molybdenum disulfide grease to the seat surface and threaded portion of the M14 head bolts.
84402827B - May 2011 2425-34
Tighten the head bolt using the torque wrench. Tightening torque： 98 N・m {10.0 kgf・m / 72 lb・ft} M14 bolt Tighten the head bolt using the torque wrench. Tightening torque： 147 N・m {15.0 kgf・m / 108 lb・ft} M14 bolt
Removal and Installation of Cylinder Block 7)
Tighten the head bolt using the special tool.
4)
Install the gear case cover cover to the cylinder block. CAUTION • Pay attention to the knock pin position of the cylinder block. Tightening torque： 19 N・m {1.9 kgf・m / 14 lb・ft} Tightening torque： 13 N・m {1.3 kgf・m / 112 lb・in} Stud bolt
Special tool: angle gauge (refer to section 1003) Tightening angle： 30 - 60 ° M14 Bolt 8) Tighten the head bolt using the torque wrench. Tightening torque： 38 N・m {3.9 kgf・m / 28 lb・ft} M10 bolt 9) Tighten the head bolt using the torque wrench. Tightening torque：142 N・m {14.5 kgf・m / 105 lb・ft} Check the tightening M14 boltg 19. Cover of gear case cover Installation 1) 2)
Clean the cylinder block using the scraper. Apply the liquid gasket to the gear case cover cover.
1 2
ANNOTATION: • Use ThreeBond 1207B.
3)
Location for tightening together with the adjust plate Stud bolt
20. Water pump assembly Installation
Bead width： 1.5 - 5.0 mm {0.0591 - 0.1969 in} Bead height： 0.3 - 1.5 mm {0.0118 - 0.0591 in} Install the O-ring to the gear case cover cover.
1)
Install the water pump assembly to the gear case cover cover. CAUTION • Use new gaskets. Tightening torque： 39 N・m {4.0 kgf・m / 28.8 lb・ft} Nut in the diagram Tightening torque： 20 N・m {2.0 kgf・m / 14.8 lb・ft}
1
O-ring
CAUTION • After applying the liquid gasket, install the gear case cover cover within 5 minutes.
84402827B - May 2011 2425-35
1
Nut
Removal and Installation of Cylinder Block 2) 3)
Install the water hose to the EGR cooler water pipe and the water pump assembly. Install the water bypass hose to the water pump assembly and the water duct.
1)
Prepare the special tool.
Special tool: oil seal setting tool kit (refer to section 1003) ANNOTATION: 1 4)
Water bypass hose
• In order to install the front slinger, use the one(s) in the following table from among the parts included in the kit.
Install the fan pulley to the water pump assembly. Tightening torque： 52 N・m {5.3 kgf・m / 38.4 lb・ft}
21. Crankshaft front oil seal Installation
Legend 1：Slinger 2：Adapter 3：Adapter tightening bolt 4：Sleeve 5：Center bolt 2)
Parts number 8–9439–6857–0 8–9702–0656–0 8–9702–0623–0 8–9702–0655–0
Install the slinger to the adapter. ANNOTATION: • There is a left handed quadruple-start screw cut at the front slinger. CAUTION • Be careful not to allow the assembly direction of the slinger to be incorrect.
84402827B - May 2011 2425-36
Removal and Installation of Cylinder Block 3)
Install the adapter to the crankshaft.
7)
Inspect the slinger. ANNOTATION: • Measure the distance between the crankshaft head and the slinger. Specified value： 17.7 - 18.3 mm {0.6968 0.7205 in}
1 4) 5) 6)
Adapter
Install the sleeve to the adapter. Install the center bolt to the sleeve. Tighten the center bolt using the wrench. ANNOTATION: 1
• Tighten the center bolt until the sleeve touches the adapter.
2 3 8)
Slinger press-fitting measurement Slinger Crankshaft
Prepare the special tool. ANNOTATION: • In order to install the crankshaft front oil seal, use the one(s) in the following table from among the parts included in the kit.
Legend 1：Adapter 2：Oil seal 3：Adapter tightening bolt 4：Sleeve 5：Center bolt 9)
Parts number 8–9439–6857–0 8–9702–0656–0 8–9702–0625–1 8–9702–0655–0
Apply the engine oil to the crankshaft front oil seal. CAUTION • Apply only to the lip section of the oil seal.
84402827B - May 2011 2425-37
Removal and Installation of Cylinder Block 10) 11) 12) 13)
Install the crankshaft front oil seal to the adapter. Install the sleeve to the adapter. Install the center bolt to the sleeve. Tighten the center bolt using the wrench.
1)
Install the crankshaft damper to the crankshaft pulley. Tightening torque： 48 N・m {4.9 kgf・m / 35 lb・ft} ANNOTATION:
ANNOTATION:
• Tighten the bolts in a diagonal line order.
• Tighten the center bolt until the sleeve touches the adapter.
2) 14)
Install the crankshaft pulley to the crankshaft.
Inspect the crankshaft front oil seal.
CAUTION
ANNOTATION:
• Pay attention to the knock pin position of the crankshaft.
• Measure the distance between the crankshaft head and the crankshaft front oil seal.
Tightening torque： 200 N・m {20.4 kgf・m / 148 lb・ft} Apply engine oil on the threaded area of bolt
Specified value： 8.35 - 8.65 mm {0.3287 0.3406 in}
ANNOTATION: • Tightening order
1 2 3 4
Oil seal press-fitting measurement Timing gear case Crankshaft front oil seal Crankshaft
23. Bridge Installation 1) 2)
22. Crankshaft pulley Installation
Apply the engine oil to the bridge. Install the bridge to the bridge guide. CAUTION • Confirm that the bridge moves smoothly.
3)
84402827B - May 2011 2425-38
Apply the engine oil to the bridge cap.
Removal and Installation of Cylinder Block 4)
Install the bridge cap to the bridge.
4)
Align the sub gear to the camshaft gear using the special tool. ANNOTATION: • Install the alignment pin from the sub gear side if the holes of the sub gear and the camshaft main gear are aligned.
CAUTION • Be careful not to drop the bridge cap into the engine. 24. Camshaft Installation 1)
Align 1st cylinder to the compression top dead center.
2)
Apply the engine oil to the camshaft bearing.
Special tool: scissors gear spring wrench (refer to section 1003)
1
ANNOTATION: • Apply engine oil to the sliding surface of the bearing.
3)
5)
Alignment pin
Install the camshaft to the cylinder head assembly.
CAUTION
ANNOTATION:
• Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and cylinder head.
• Mesh together the idle gear C and the camshaft gear so that the alignment mark on the camshaft gear matches the top surface of the cylinder head, and gently install the camshaft.
Install the camshaft bearing to the cylinder head assembly.
CAUTION
ANNOTATION:
• Align the alignment marks of the sub gear side.
• To prevent the effect of spring force on the sub gear, use a scissors gear spring wrench to rotate the sub gear before installing the camshaft on the cylinder head.
84402827B - May 2011 2425-39
Removal and Installation of Cylinder Block 25. Rocker arm shaft Installation 1)
Apply the engine oil to the bracket. ANNOTATION: • Apply to each sliding surface.
2)
Apply the engine oil to the rocker arm. ANNOTATION: • Confirm that the adjust screw is fully loosened.
6)
Check alignment mark of the camshaft gear. CAUTION • Confirm that the alignment mark is not misaligned before installing the camshaft bearing cap. • If the alignment mark is not at the correct position, reinstall the camshaft.
7)
Apply the engine oil to the camshaft bearing. ANNOTATION:
1 2 3
• Apply engine oil to the sliding surface of the bearing. CAUTION
3)
• Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and camshaft bearing cap. 8) 9)
Front side camshaft bracket Rocker arm Rear side camshaft bracket
Install the rocker arm shaft to the cylinder head assembly. ANNOTATION: • On the camshaft bearing assembly section only, apply oil to the threaded portion of the stud bolts and the seat surface/threaded portion of the nuts, then tighten them. • Tightening order
Install the camshaft bearing to the camshaft bearing cap. Install the camshaft bearing cap to the cylinder head assembly. ANNOTATION: • Turn the camshaft bearing cap so that the arrow mark on the top surface faces the engine front side, and assemble in numerical order. Tightening torque：28 N・m {2.8 kgf・m / 20 lb・ft} Engine oil application
Rocker arm shaft tightening torque Tightening torque Parts Front side camshaft bearing cap : 28 N・m {2.8 kgf・m / 20 Rear side camshaft lb・ft} bearing cap : 56 N・m {5.7 kgf・m / 41 Rocker arm bracket lb・ft} 84402827B - May 2011 2425-40
Removal and Installation of Cylinder Block 26. Rocker arm shaft Adjustment
3)
Turn the adjust screw.
ANNOTATION:
ANNOTATION:
• Valve clearance adjustment
• When the movement of the thickness gauge becomes stiff, secure the adjust screw nut of the rocker arm.
CAUTION • Adjust the valve clearance while cool. • Loosen all adjust screws before adjustment.
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
4) 1)
Align 1st cylinder to the compression top dead center.
Turn the adjust screw. ANNOTATION: • With the thickness gauge inserted, lightly tighten the adjust screw of the bridge. • Confirm that the leading end of the adjust screw and valve shaft end have made contact and the movement of the thickness gauge has become stiff. • Check if the valve shaft end on the opposite side is floating or touching at an angle. • If it is floating or touching at an angle, slightly loosen the bridge adjust screw and adjust the valve shaft ends on both sides to touch properly. Valve bridge clearance ： less than 0.1 mm {less than 0.0039 in}
2)
Prepare the feeler gauge. Thickness： 0.4 mm {0.0157 in} 2 pieces ANNOTATION: • Insert rocker • Insert bridge
the thickness gauge between the arm and bridge cap. the thickness gauge between the and valve.
84402827B - May 2011 2425-41
ANNOTATION: • To prevent turning, fix the bridge adjust screw with a flathead screwdriver, and tighten the adjust screw nut. Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
Removal and Installation of Cylinder Block Cylinder No. 1 Condision Arrangement of valves IN When the #1 cylinder is set at the compression ○ Valve to be top dead center adjusted When the #6 cylinder is set at the compression top dead center
2 EXH IN ○
○
5 EXH IN
○
○
6 EXH IN
EXH
○ ○
○
○
○
28. Common rail assembly Installation
Apply the liquid gasket to the rubber plug.
1)
ANNOTATION:
2)
• Apply ThreeBond 1207B.
3) 4)
5)
1 2
4 EXH IN ○
○
27. Lower cover Installation 1)
3 EXH IN
Align the common rail assembly to the inlet cover. Temporarily tighten the bolt to the common rail assembly. Temporarily tighten the nut to the common rail assembly. Securely tighten the bolt to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft} Securely tighten the nut to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft}
Rubber plug Liquid gasket
CAUTION • After applying the liquid gasket, install the lower cover within 5 minutes. 2) 3) 4)
Install the rubber plug to the cylinder head assembly. Install the gasket to the lower cover. Install the lower cover to the cylinder head assembly. Tightening torque： 13 N・m {1.3 kgf・m / 112 lb・in} ANNOTATION:
1 6)
Common rail assembly
Connect the harness connector to the fuel pressure sensor.
29. Fuel leak off pipe assembly Installation 1)
• Tightening order
Temporarily tighten the fuel leak-off pipe to the cylinder head assembly. CAUTION • Use new gaskets.
2)
Temporarily tighten the fuel leak-off pipe to the common rail assembly. CAUTION • Use new gaskets.
3)
Temporarily tighten the fuel leak-off pipe to the fuel supply pump. ANNOTATION: • Tighten the fuel feed pipe together.
84402827B - May 2011 2425-42
Removal and Installation of Cylinder Block 1) 2)
CAUTION • Use new gaskets. 4)
5)
6)
7)
Apply the engine oil to the bolt. Temporarily tighten the injector to the cylinder head assembly. CAUTION
Securely tighten the fuel leak-off pipe to the cylinder head assembly. Tightening torque： 14 N・m {1.4 kgf・m / 123.9 lb・in} Securely tighten the fuel leak-off pipe to the common rail assembly. Tightening torque： 20 N・m {2.0 kgf・m / 14.8 lb・ft} Securely tighten the fuel leak-off pipe to the fuel supply pump. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} Install the clip to the fuel leak-off pipe. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
• Be extremely careful not to damage the injector nozzle.
1 2 3)
Injector Installation bolt
Temporarily tighten the injection pipe to the injector. CAUTION • Use new injection pipes.
4) 1
Fuel leak-off pipe
5)
30. Fuel pipe Installation 1)
Install the fuel pipe to the fuel supply pump and the common rail assembly.
6)
CAUTION
CAUTION
• Use new gaskets.
• Use new fuel pipes.
2)
Temporarily tighten the injection pipe to the common rail assembly. Securely tighten the injector to the cylinder head assembly. Tightening torque： 30 N・m {3.1 kgf・m / 22 lb・ft} Install the injector leak-off pipe to the injector.
Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the bracket. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
Tightening torque： 14 N・m {1.4 kgf・m / 126 lb・in} 32. Injection pipe Installation 1)
31. Injector Installation CAUTION
2)
• When reusing an injector, do not change the installation position.
84402827B - May 2011 2425-43
Securely tighten the injection pipe to the injector. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Securely tighten the injection pipe to the common rail assembly. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft}
Removal and Installation of Cylinder Block 3)
Install the clip to the inlet cover. Tightening torque： 6 N・m {0.6 kgf・m / 53.1 lb・in}
2)
Install the glow plug connector to the glow plug. Tightening torque： 1 N・m {0.1 kgf・m / 8.9 lb・in} CAUTION • Confirm that the glow plug connector does not interfere with the surrounding parts.
1 2 3 4 5 6 7
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
pipe pipe pipe pipe pipe pipe
34. Injector harness Installation 1)
33. Glow plug Installation 1)
Install the injector harness to the cylinder head assembly. ANNOTATION:
Install the glow plug to the cylinder head assembly. Tightening torque： 20 N・m {2.0 kgf・m / 14.8 lb・ft} CAUTION
• Tighten the bolts on the bracket and install the injector harness together with the bracket. Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
• Be careful not to exceed the specified torque when tightening.
1 2
84402827B - May 2011 2425-44
Injector harness terminal Injector harness bracket
Removal and Installation of Cylinder Block 2)
Connect the injector harness to the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3 3) 1 2 3 3)
Injector Injector harness Terminal nut
4)
Cylinder head cover Head cover gasket Lower cover
Connect the ventilation hose to the air breather. Connect the water pipe bracket to the cylinder head cover. Tightening torque： 20 N・m {2.0 kgf・m / 14 lb・ft}
Install the connector to the lower cover. Tightening torque： 2 N・m {0.2 kgf・m / 18 lb・in}
35. Cylinder head cover Installation 1) 2)
Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover. Tightening torque： 13 N・m {1.3 kgf・m / 115 lb・in} ANNOTATION: • Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them.
1 2 3
Ventilation hose Water pipe bracket Clip
36. Inlet pipe Installation
84402827B - May 2011 2425-45
Removal and Installation of Cylinder Block 1)
Install the inlet pipe to the inlet cover. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
1 2) 3) 4) 5)
1)
Install the intake throttle valve to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
Inlet pipe
Connect the harness connector to the boost sensor. Connect the harness connector to the boost temperature sensor. Connect the harness connector to the IMT sensor. Install the harness clip to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
1 2 3 4
37. Intake throttle valve Installation
1 2 3 2) 3)
Boost sensor Harness clip Boost temperature sensor IMT sensor
84402827B - May 2011 2425-46
Intake throttle valve Gasket Inlet pipe
Install the air duct to the intake throttle valve. Connect the harness connector to the intake throttle valve. ANNOTATION: • After connecting the harness connector, press in the lock operation portion to lock.
1 2 3
Lock operation section Lock release Lock
Removal and Installation of Cylinder Block 38. EGR cooler water pipe Installation
84402827B - May 2011 2425-47
Removal and Installation of Cylinder Block 1)
Install the water bypass hose to the water pump assembly and the water duct.
1 2)
5)
Install the fan guide stay to the fan guide. Tightening torque： 30 N・m {3.1 kgf・m / 22 lb・ft}
Water bypass hose 1 2 3
Install the EGR cooler water pipe to the engine assembly. Clamp tightening torque： 20 N・m {2.0 kgf・ m / 14 lb・ft} ANNOTATION:
Fan guide Fan guide stay Fan guide bracket
39. Oil separator bracket Installation
• Tightening torque of bolt 1 in the diagram is different from others.
1)
Tightening torque： 39 N・m {4.0 kgf・m / 29 lb・ft}
Temporarily tighten the oil separator bracket to the cylinder head assembly. ANNOTATION: • Tighten together with the clip.
2) 3)
Install the ventilation hose to the air breather. Securely tighten the oil separator bracket to the cylinder head assembly. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft} CAUTION • Pay attention to the installation angle of the hose.
4)
1 3) 4)
Install the clip to the cylinder block. Tightening torque： 48 N・m {4.9 kgf・m / 35 lb・ft}
Installation bolt
Connect the radiator upper hose to the water outlet pipe. Install the fan guide stay to the fan guide bracket. Tightening torque： 40 N・m {4.1 kgf・m / 30 lb・ft}
1 2 84402827B - May 2011 2425-48
Oil separator bracket Clip
Removal and Installation of Cylinder Block 6)
40. EGR valve Installation 1)
Install the EGR valve to the inlet pipe. Tightening torque： 46 N・m {4.7 kgf・m / 33.9 lb・ft}
1
1 2 3 4
EGR valve
41. EGR cooler Installation 1) 2)
Temporarily tighten the EGR cooler C to the EGR bracket C.
7)
Temporarily tighten the EGR pipe A to the exhaust manifold. Temporarily tighten the EGR cooler A to the EGR pipe A.
Temporarily tighten the EGR pipe B to the EGR cooler C and the EGR valve.
1 2 3 1 2 3 3) 4) 5)
EGR cooler A EGR pipe A Exhaust manifold
8)
Temporarily tighten the EGR cooler bracket A to the EGR cooler A. Temporarily tighten the EGR cooler B to the EGR cooler A. Temporarily tighten the EGR bracket C to the EGR cooler B.
9)
10)
11)
12)
84402827B - May 2011 2425-49
EGR cooler C EGR cooler bracket C EGR cooler B EGR cooler bracket A
EGR valve EGR pipe B EGR cooler C
Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque： 67 N・m {6.8 kgf・m / 49 lb・ft} Securely tighten the EGR cooler A to the EGR pipe A. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Securely tighten the EGR cooler B to the EGR cooler A. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler B. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler C to the EGR cooler bracket C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
Removal and Installation of Cylinder Block 13)
14)
15)
16)
17)
18)
Securely tighten the EGR pipe B to the EGR cooler C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR pipe B to the EGR valve. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR cooler bracket A to the EGR cooler bracket C. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler bracket B. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR pipe B to the rear engine hanger bracket. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Install the EGR heat protector to the EGR pipe. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
42. Oil level gauge guide tube Installation 1)
2)
3)
Install the oil level gauge guide tube to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Connect the oil level gauge guide tube to the cylinder head assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Install the oil level gauge to the oil level gauge guide tube.
1
Oil level gauge guide tube
43. Turbocharger assembly Installation 1) 2) 3)
1 19)
4)
EGR heat protector
Connect the water rubber hose to the EGR cooler.
Replenish the engine oil with the turbocharger assembly. Align the gasket to the turbocharger assembly. Install the turbocharger assembly to the exhaust manifold. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft} Install the water feed pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION • Use a new gasket.
5)
Connect the water feed pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
1
Water rubber hose
84402827B - May 2011 2425-50
Removal and Installation of Cylinder Block 6)
7)
Install the water return pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
11)
Connect the oil feed pipe to the turbocharger assembly. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
CAUTION
CAUTION
• Use a new gasket.
• Use a new gasket.
Connect the water return pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
8)
Install the oil return pipe to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION • Use a new gasket.
9)
1 2 3 4 5
Connect the oil return pipe to the turbocharger assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION • Use a new gasket.
10)
12)
Install the oil feed pipe to the pipe bracket. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
13) 14)
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Install the exhaust pipe to the turbocharger assembly. Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.
44. Drive belt Installation CAUTION • Use a new gasket.
1)
Install the drive belt to the engine assembly.
45. Drive belt Adjustment
84402827B - May 2011 2425-51
Removal and Installation of Cylinder Block 1)
2)
Press the drive belt. ANNOTATION:
Install the fan guide to the fan guide bracket. Tightening torque： 30 N・m {3.1 kgf・m / 22.1 lb・ft}
• Measure the amount of drive belt flex by pressing on the point indicated by the arrow in the diagram with the specified pressure. Standard： 98.0 N {10.0 kg / 22 lb} Specified value ： 5.5 - 7.5 mm {0.2165 0.2953 in} Amount of flex
1 2 3 2)
1 2 3 4 5 6
Crankshaft pulley Generator Fan pulley
47. Cooling fan Installation
Adjust the drive belt to standard value using the adjust bolt. Tightening torque： 75 N・m {7.6 kgf・m / 55.3 lb・ft} Nut of the adjust plate Tightening torque： 126 N・m {12.8 kgf・m / 92.9 lb・ft} Bolt of the bracket side
1)
Install the cooling fan to the adapter.
1 2
1 2 3
Cooling fan Adapter
Tightening torque： 52 N・m {5.3 kgf・m / 38.4 lb・ft}
Adjust bolt Adjust plate side nut Bracket side bolt
48. Engine harness Connect 1)
46. Fan guide Installation 1)
Bolt Washer Rubber mount Rubber mount Guide tube Fan guide
Install the fan guide bracket to the engine assembly. Tightening torque： 40 N・m {4.1 kgf・m / 29.5 lb・ft}
Connect the engine harness to the engine assembly. ANNOTATION: • Connect each connector.
49. Engine oil Filling
84402827B - May 2011 2425-52
Removal and Installation of Cylinder Block 1)
Replenish the engine oil with the engine assembly. CAUTION • Check the tightening of the drain plug before adding engine oil.
50. Coolant Filling 1) 2)
Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
3)
1 2 3 4 5
Tighten the valve using a wrench. CAUTION • Use new gaskets.
4)
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft} Replenish the coolant with the radiator.
1) 2)
Priming pump Plug Drain plug Case Fuel filter element
Prepare the pan. Turn ON the starter switch. ANNOTATION: • This is for the models with an electromagnetic pump.
3) 4)
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more ANNOTATION: • Confirm that fuel comes out from around the plug.
5) 6)
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION:
1 2
• Wait for the specified time after operating the priming pump.
Valve Gasket 7)
51. Battery ground cable Connect 1)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION:
Connect the battery ground cable to the battery.
• Remove the air in the fuel filter. 8) 9)
52. Fuel Air bleed CAUTION
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION:
• To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
• Wait for the specified time after operating the priming pump. 10)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
11) 84402827B - May 2011 2425-53
Tighten the plug using the wrench.
Removal and Installation of Cylinder Block 12)
Operate the priming pump. Number of times： 10 count(s) or more
CAUTION • Replace the cylinder block if damage such as a crack has been found in the inspection.
ANNOTATION: • Wait for the specified time after operating the priming pump. 13)
4)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
14)
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in}
CAUTION
CAUTION
• Replace the cylinder block if the measured value exceeds the limit value.
• Remove the fuel around the plug thoroughly after tightening. 15)
5)
Operate the priming pump. Number of times： 10 count(s)
6)
Cylinder block Inspection 1.
Measure the cylinder liner using the cylinder gauge. Measurement position ： 15.0 - 20.0 mm ｛ 0.5906 - 0.7874 in ｝ From the cylinder block top surface Specified value ： 115.021 - 115.050 mm ｛4.5284 - 4.5295 in｝ Diameter Limit： 115.20 mm ｛4.5354 in｝ Diameter
7)
Cylinder block Inspection
Remove the cylinder liner from the cylinder block. Align the simple straight ruler to the cylinder block. Measure the clearance using the feeler gauge.
CAUTION
ANNOTATION:
• Clean the each part of the cylinder block before inspecting. • Be careful not to damage the cylinder block while cleaning.
• Flatness of the cylinder block top surface Measurement part： 6 section(s) Limit： 0.2 mm ｛0.0079 in｝ CAUTION
1)
Inspect the cylinder block.
• Replace the cylinder block if the measured value exceeds the limit value.
CAUTION • Replace the cylinder block if damage such as a crack has been found in the inspection. 2)
Perform dye penetrant check. ANNOTATION: • Check if there is a problem which cannot be detected by visual inspection. CAUTION • Replace the cylinder block if damage such as a crack has been found in the inspection.
3)
Inspect the water leak using the water pressure tester. ANNOTATION:
1 8)
Thickness gauge
Inspect the oil jet.
• Check if there is a problem which cannot be detected by visual inspection.
ANNOTATION:
Specified pressure： 490 kPa {5 kgf/cm2 / 71 psi} Specified time： 3 min
• Oil hole clogging • The fuel pipe deformation • Check valve operation 160.0 kPa {2 kgf/cm2 / 23 psi} Open valve pressure of check valve
84402827B - May 2011 2425-54
Removal and Installation of Cylinder Block
84402827B - May 2011 2425-55
Removal and Installation of Cylinder Block
84402827B - May 2011 2425-56
Section 2445
Lubrication System
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal and Installation of Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil pan Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Oil pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal and Installation of Oil Level Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil level switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil level switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Removal and Installation of Oil Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Oil pump assembly Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil pump assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Oil pump assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Oil pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Engine oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removal and Installation of Oil Port Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Oil port cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Oil port cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
84402827B - May 2011 2445-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2445-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Lubrication System Removal and Installation of Oil Pan
Apply the liquid gasket to the crankcase. ANNOTATION: • Apply ThreeBond 1207B to each joint of the crankcase, flywheel housing and gear case.
Disengage the battery ground cable from the battery.
Bead width： 3 mm {0.118 in} Bead height： 2 mm {0.079 in}
Engine oil Drain 1) 2) 3)
3.
Oil pan Installation
Battery ground cable Disconnect 1)
2.
1.
1)
Oil pan Removal 1.
Oil pan Installation
Remove the drain plug from the oil pan. Drain the engine oil from the oil pan. Install the drain plug to the oil pan. Tightening torque： 70 N・m ｛7.1 kgf・m / 51.6 lb・ft｝
Oil pan Removal 1) 2) 3)
Disengage the harness connector from the oil level switch. Remove the oil pan from the crankcase. Remove the gasket from the oil pan.
1 2 3
Crankcase Timing gear case Flywheel housing
CAUTION • After applying the liquid gasket, install the oil pan within 5 minutes. 2) 3)
Install the gasket to the oil pan. Install the oil pan to the crankcase. Tightening torque： 11 N・m {1.1 kgf・m / 96 lb・in} 4 stud bolts Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} CAUTION • Note that one of the bolts has a different length from others.
1 2 84402827B - May 2011 2445-3
Short bolt installation area Stud bolt installation area
Lubrication System 4) 2.
Connect the harness connector to the oil level switch.
Engine oil Filling 1)
Replenish the engine oil with the engine assembly.
Removal and Installation of Oil Level Switch Oil level switch Removal 1.
CAUTION
1) 2) 3)
• Check the tightening of the drain plug before adding engine oil. 3.
Engine oil Drain
Battery ground cable Connect 1)
Connect the battery ground cable to the battery.
2.
Remove the drain plug from the oil pan. Drain the engine oil from the oil pan. Install the drain plug to the oil pan. Tightening torque： 70 N・m ｛7.1 kgf・m / 51.6 lb・ft｝
Oil level switch Removal 1) 2)
Disengage the harness connector from the oil level switch. Remove the oil level switch from the oil pan.
1 2 3
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O-ring Oil level switch Spacer
Lubrication System Oil level switch Installation 1.
Removal and Installation of Oil Pump Assembly
Oil level switch Installation 1)
Install the O-ring to the oil pan.
Oil pump assembly Removal
CAUTION
1.
• Use new O-rings. 2)
Battery ground cable Disconnect 1)
Install the oil level switch to the oil pan.
2.
CAUTION
Coolant Drain 1)
• Confirm that the O-ring is not misaligned or bent.
3)
Tightening torque： 10 N・m ｛1.0 kgf・m / 88.5 lb・in｝ Connect the harness connector to the oil level switch.
Disengage the battery ground cable from the battery. Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
3.
Engine oil Drain 1) 2) 3)
4.
Remove the drain plug from the oil pan. Drain the engine oil from the oil pan. Install the drain plug to the oil pan. Tightening torque： 70 N・m {7.1 kgf・m / 52 lb・ft}
Engine harness Disconnect 1)
Disengage the engine harness from the engine assembly. ANNOTATION: • Disconnect each connector.
5.
Turbocharger assembly Removal 1)
1 2 3
O-ring Oil level switch Spacer
2) 3)
2.
Engine oil Filling 1)
Replenish the engine oil with the engine assembly.
4)
Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger. Disengage the oil feed pipe from the turbocharger assembly. ANNOTATION:
CAUTION
• Remove the clip.
• Check the tightening of the drain plug before adding engine oil.
5)
Remove the oil feed pipe from the pipe bracket. ANNOTATION: • Remove the clip.
6) 7) 8) 9) 10)
Disengage the oil return pipe from the turbocharger assembly. Remove the oil return pipe from the cylinder block. Disengage the water return pipe from the turbocharger assembly. Remove the water return pipe from the cylinder head assembly. Disengage the water feed pipe from the turbocharger assembly. ANNOTATION: • Remove the clip.
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Lubrication System 11)
Remove the water feed pipe from the cylinder block.
2)
Remove the EGR pipe B from the EGR valve and the EGR cooler C.
ANNOTATION: • Remove the clip. 12) 13)
Disengage the harness connector from the turbocharger assembly. Remove the turbocharger assembly from the exhaust manifold.
1 2 3 3) 1 2 3 4 5 6.
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
4) 5) 6)
EGR valve EGR pipe B EGR cooler C
Remove the EGR cooler C from the EGR bracket C. Remove the EGR bracket C from the EGR cooler B. Remove the EGR cooler B from the EGR cooler bracket A. Remove the EGR cooler bracket A from the EGR cooler A.
EGR cooler Removal 1)
Disengage the water rubber hose from the EGR cooler.
1
1 2 3 4
Water rubber hose
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EGR cooler C EGR bracket C EGR cooler B EGR cooler bracket A
Lubrication System 7)
Remove the EGR heat protector from the EGR pipe A.
1) 2)
1
Disengage the harness connector from the EGR valve. Remove the EGR valve from the inlet pipe.
EGR heat protector 1
8) 9)
Remove the EGR cooler A from the EGR pipe A. Remove the EGR pipe A from the exhaust manifold.
8.
Oil separator bracket Removal 1) 2) 3)
1 2 3 7.
EGR valve
Remove the clip from the cylinder block. Remove the ventilation hose from the air breather. Remove the oil separator bracket from the cylinder head assembly.
EGR cooler A EGR pipe A Exhaust manifold 1 2
EGR valve Removal
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Oil separator bracket Clip
Lubrication System 9.
EGR cooler water pipe Removal
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Lubrication System 1)
Remove the fan guide stay from the fan guide and the fan guide bracket.
2) 3)
1 2 3
Fan guide Fan guide stay Fan guide bracket
Disengage the oil level gauge guide tube from the front engine hanger bracket. Remove the oil level gauge guide tube from the cylinder block.
1
Oil level gauge guide tube
11. Intake throttle valve Removal 2) 3) 4)
Disengage the radiator upper hose from the water outlet pipe. Remove the EGR cooler water pipe from the engine assembly. Remove the water bypass hose from the water pump assembly and the water duct.
1) 2)
Remove the air duct from the intake throttle valve. Disengage the harness connector from the intake throttle valve. ANNOTATION: • Pull the lock operation portion to release the lock.
1
Water bypass hose
10. Oil level gauge guide tube Removal 1)
Remove the oil level gauge from the oil level gauge guide tube.
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1 2 3
Lock operation section Lock release Lock
Lubrication System 3)
Remove the intake throttle valve from the inlet pipe.
5)
Remove the inlet pipe from the inlet cover.
1 1 2 3
Intake throttle valve Gasket Inlet pipe
Inlet pipe
13. Glow plug Removal 1)
Remove the glow plug connector from the glow plug.
2)
Remove the glow plug from the cylinder head assembly.
12. Inlet pipe Removal 1) 2) 3) 4)
Disengage the harness connector from the boost sensor. Disconnect the harness connector from the boost temperature sensor. Disconnect the harness connector from the IMT sensor. Remove the harness clip from the inlet pipe.
1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
14. Injection pipe Removal 1) 2)
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Remove the clip from the inlet pipe. Remove the injection pipe from the injector and the common rail assembly.
Lubrication System CAUTION
3)
• Do not reuse the removed injection pipe. • Seal the common rail and injector to prevent foreign material from entering.
4)
1 2 3 4 5 6 7
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
Disengage the fuel leak-off pipe from the common rail assembly. Remove the fuel leak-off pipe from the inlet pipe. ANNOTATION: • Remove the clip.
1
pipe pipe pipe pipe pipe pipe
Fuel leak-off pipe
17. Common rail assembly Removal 1) 2)
Disengage the harness connector from the fuel pressure sensor. Remove the common rail assembly from the inlet cover.
15. Fuel pipe Removal 1)
Remove the fuel pipe from the fuel supply pump and the common rail assembly. ANNOTATION: • Remove the clip. CAUTION • Do not reuse the removed fuel pipe.
16. Fuel leak off pipe assembly Removal 1) 2)
Disengage the fuel leak-off pipe from the cylinder head. Remove the fuel leak-off pipe from the fuel supply pump. ANNOTATION:
1
Common rail assembly
18. Cylinder head cover Removal
• Remove the eyebolt tightened together with the fuel feed pipe.
1)
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Disengage the ventilation hose from the air breather.
Lubrication System 2) 3)
Remove the cylinder head cover from the lower cover. Remove the head cover gasket from the cylinder head cover.
2)
Disengage the injector harness from the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3
Cylinder head cover Head cover gasket Lower cover 1 2 3
19. Injector harness Removal 1)
Remove the connector from the lower cover. CAUTION
3)
• Do not pull the wire, or pry the connector with a screwdriver.
Injector Injector harness Terminal nut
Remove the injector harness from the cylinder head assembly. ANNOTATION: • Remove the bracket tightening bolts and then remove the injector harness together with the bracket.
1 2
Injector harness terminal Injector harness bracket
20. Injector Removal 1) 2)
Remove the injector leak-off pipe from the injector. Remove the injector from the cylinder head assembly. ANNOTATION: • When it is difficult to remove the injector, use a special tool.
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Lubrication System
Special tool: injector remover (refer to section 1003)
21. Lower cover Removal 1) 2)
Remove the lower cover from the cylinder head assembly. Remove the rubber plug from the cylinder head assembly.
22. Rocker arm shaft Removal 1)
Loosen the adjust screw using the wrench. ANNOTATION: • Loosen all valve clearance adjustment screws.
Special tool: sliding hammer (refer to section 1003)
2)
Remove the rocker arm shaft from the cylinder head assembly. ANNOTATION:
1 2 3
• Evenly loosen the rocker arm shaft bracket and the rocker arm assembly bracket tightening bolts from both ends and remove them.
Sliding hammer Fuel injector remover Injector
CAUTION • Be careful not to remove the bolt shown in the diagram.
CAUTION • Confirm that the sleeve is not pulled out together when pulling out the injector using a special tool. • Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. • Be extremely careful not to damage the injector nozzle.
23. Camshaft Removal 1) 2) 3)
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Remove the camshaft bearing cap from the cylinder head assembly. Remove the camshaft bearing from the camshaft bearing cap. Remove the camshaft from the cylinder head.
Lubrication System 4)
Remove the camshaft bearing from the cylinder head assembly.
2)
Remove the bridge from the bridge guide. ANNOTATION:
ANNOTATION:
• After removing, organize to avoid a mix-up with other installation locations.
• Temporarily assemble the removed caps and bearings in the original position to avoid a mix-up after the bearings have been inspected.
1 2
Bridge cap Bridge
24. Bridge Removal 1)
Remove the bridge cap from the bridge.
25. Cylinder head assembly Removal 1)
CAUTION • Be careful not to drop the bridge cap into the engine.
Remove the cylinder head assembly from the cylinder block. ANNOTATION: • Loosening order of the head bolts
CAUTION • Since the idle gear C protrudes from the bottom surface of the cylinder head, be careful not to damage the gear.
1
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Idle gear C
Lubrication System 2)
Remove the cylinder head gasket from the cylinder block. CAUTION
28. CKP sensor Removal 1) 2)
• Do not reuse the cylinder head gasket.
Disengage the harness connector from the CKP sensor. Remove the CKP sensor from the flywheel housing. CAUTION
26. Fuel supply pump Removal 1) 2)
• Be careful not to subject the sensor to shock.
Disengage the harness connector from the fuel supply pump. Remove the fuel supply pump from the cylinder block. ANNOTATION: • Remove together with the bracket.
1 2 3 4 1 2 3 4 5 6 7 8 9 10
Fuel supply pump Bracket Gear Nut Bolt O-ring O-ring Nut Bolt O-ring
Oil pressure switch Oil port cover Flywheel housing CKP sensor
29. Flywheel Removal 1)
Remove the flywheel from the crankshaft. ANNOTATION: • Gradually loosen the flywheel installation bolts in the order shown in the diagram.
27. Starter assembly Removal 1) 2)
Disengage the earth cable from the starter assembly. Remove the starter assembly from the flywheel housing.
CAUTION • Fix the flywheel firmly so that it will not rotate. 30. Crankshaft rear oil seal Removal 1)
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Remove the crankshaft rear oil seal from the crankshaft using the special tool.
Lubrication System ANNOTATION: • Remove the slinger and oil seal together. 31. Oil pan Removal 1) 2) 3)
Disengage the harness connector from the oil level switch. Remove the oil pan from the crankcase. Remove the gasket from the oil pan.
32. Flywheel housing Removal 1) 2)
Remove the PTO oil pipe from the flywheel housing and the cylinder block. Remove the oil pipe from the pipe bracket and the oil port cover.
Special tool: rear oil seal remover (refer to section 1003)
1 2 3
Felt Slinger Crankshaft rear oil seal
1 2 3 3)
Remove the cover from the flywheel housing.
1 2
CAUTION • Be careful not to damage the oil seal press-fitting surface.
4)
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Oil pipe Pipe bracket PTO oil pipe
O-ring Cover
Remove the PTO idle gear from the cylinder block.
Lubrication System 5)
Remove the flywheel housing from the cylinder block and the crankcase. CAUTION • Do not forget to remove the bolt shown in the diagram.
3)
Measure the clearance using the feeler gauge. ANNOTATION: • Measure the clearance between the idle gear and the thrust collar. CAUTION
1
• Measure the play of the idle gear in the axis direction before removing the idle gear B.
Bolt
33. Idle gear Measurement 1)
Align the dial gauge to the idle gear.
Specified value： 0.080 - 0.155 mm {0.0031 0.0061 in} Limit： 0.20 mm {0.0079 in}
ANNOTATION: • Attach the dial gauge to the idle gear tooth to be measured. 2)
CAUTION • Replace the idle gear if the measured value exceeds the limit value.
Inspect the backlash. ANNOTATION: • Gently move the gear right and left to read the inconsistency on the dial gauge. CAUTION • Measure the idle gear backlash before removing the idle gear A. Specified value： 0.10 - 0.17 mm {0.0039 0.0067 in} Limit： 0.30 mm {0.0118 in} CAUTION • Replace the idle gear if the measured value exceeds the limit value.
34. Idle gear A Removal 1)
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Remove the idle gear A from the idle gear A shaft.
Lubrication System 2)
Remove the idle gear A shaft from the cylinder block.
Oil pump assembly Disassembly 1.
Oil pump assembly Disassembly 1)
Remove the driven gear from the body.
2) 3) 4)
Remove the cotter pin from the body. Remove the spring from the body. Remove the ball from the body.
35. Oil pump assembly Removal 1)
Remove the oil pump assembly from the cylinder block.
1
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Split pin
Lubrication System Oil pump assembly Reassembly
Oil pump assembly Installation
1.
1.
Oil pump assembly Reassembly 1) 2) 3)
Install the ball to the body. Install the spring to the body. Install the cotter pin to the body.
Oil pump assembly Installation 1)
Clean the cylinder block using the scraper. ANNOTATION: • Remove grime and oil from the oil pump installation area.
2)
1 4) 5)
Apply the engine oil to the cylinder block.
Split pin
Apply the engine oil to the driven gear. Install the driven gear to the body.
CAUTION • Do not allow engine oil to adhere on the oil pump installation surface. 3)
Apply the liquid gasket to the oil pump. ANNOTATION: • Refer to the diagram and apply the ThreeBond 1207C to the oil pump.
CAUTION • Do not allow the liquid gasket to adhere to the locations indicated by arrows in the diagram. • After applying the liquid gasket, install the oil pump within 5 minutes.
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Lubrication System 4)
2.
Install the oil pump to the cylinder block. Tightening torque: 24 N・m {2.4 kgf・m / 18 lb・ft}
6)
Install the idle gear A to the cylinder block. Tightening torque: 133 N・m {13.6 kgf・m / 98 lb・ft}
Idle gear A Installation 1) 2) 3) 4) 5)
Align 1st cylinder to the compression top dead center. Apply the engine oil to the idle gear A shaft. Apply the engine oil to the idle gear A. Install the idle gear A shaft to the idle gear A. Align the idle gear A to alignment mark. ANNOTATION: • Align the L mark on the crank gear with the O mark on the idle gear A.
1 2
1 2 3 4 5 6 7 8 9 10 11
L mark O mark 3.
Camshaft gear Aligning position Idle gear B Aligning position PTO gear PTO idle gear Crank gear Oil pump gear Supply pump gear Idle gear A Idle gear C
Flywheel housing Installation 1)
Clean the cylinder block using the scraper. ANNOTATION: • Remove dust and oil from the flywheel housing installation area.
2)
Apply the liquid gasket to the cylinder block. ANNOTATION: • Refer to the diagram and apply the ThreeBond 1201 to the cylinder block.
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Lubrication System 3)
Install the flywheel housing to the cylinder block. ANNOTATION: • Install the flywheel housing after aligning with the knock pin position of the cylinder block.
Tightening No.1 bolt No.2 bolt No.3 bolt No.4 bolt
1
torque 96 N・m {9.8 kgf・m / 71 lb・ft} 119 N・m {12.1 kgf・m / 88 lb・ft} 86 N・m {8.8 kgf・m / 64 lb・ft} 53 N・m {5.4 kgf・m / 39 lb・ft}
Liquid gasket application prohibited area
CAUTION • Do not apply liquid gasket to the location indicated in 1 in the diagram. • After applying the liquid gasket, install the flywheel housing within 5 minutes.
4) 5)
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Apply engine oil to the PTO gear shaft. Install the PTO idle gear shaft to the PTO idle gear.
Lubrication System 6)
Install the PTO idle gear to the cylinder block. Tightening torque: 119 N・m {12.1 kgf・m / 88 lb・ft}
7) 8)
Install the O-ring to the cover. Install the cover to the flywheel housing.
10)
Install the PTO oil pipe to the flywheel housing and the cylinder block. Tightening torque: 34 N・m {3.5 kgf・m / 25 lb・ft} Flywheel housing side Tightening torque: 15 N・m {1.5 kgf・m / 11 lb・ft} PTO side Tightening torque: 41 N・m {4.2 kgf・m / 30 lb・ft} Cylinder block side Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
1 2 3 4.
Oil pipe Pipe bracket PTO oil pipe
Oil pan Installation 1)
Apply the liquid gasket to the crankcase. ANNOTATION:
1 2 9)
• Apply ThreeBond 1207B to each joint of the crankcase, flywheel housing and gear case.
O-ring Cover
Bead width: 3.0 mm {0.118 in} Bead height: 2.0 mm {0.079 in}
Install the oil pipe to the pipe bracket and the oil port cover. Tightening torque: 34 N・m {3.5 kgf・m / 25 lb・ft} Pipe bracket side Tightening torque: 28 N・m {2.8 kgf・m / 20 lb・ft} Oil port cover side Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
1 2 3
Crankcase Timing gear case Flywheel housing
CAUTION • After applying the liquid gasket, install the oil pan within 5 minutes. 2) 84402827B - May 2011 2445-22
Install the gasket to the oil pan.
Lubrication System 3)
Install the oil pan to the crankcase. Tightening torque: 11 N・m {1.1 kgf・m / 96 lb・in} 4 stud bolts Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft}
1)
Prepare the special tool.
CAUTION • Note that one of the bolts has a different length from others.
Special tool: oil seal installer (refer to section 1003) ANNOTATION: • In order to install the crankshaft rear oil seal, use the one(s) in the following table from among the parts included in the kit.
1 2 4) 5.
Short bolt installation area Stud bolt installation area
Connect the harness connector to the oil level switch.
Crankshaft rear oil seal Installation
Legend 1: Adapter 2: Adapter tightening bolts 3: Center bolt 4: Sleeve 5: Collar 6: Adapter ring 7: Crankshaft rear oil seal 2)
Parts number 5–8840–2709–0 5–8840–2714–0 5–8840–2713–0 5–8840–9063–0 5–8840–2710–0 5–8840–2711–0 -
Apply the engine oil to the crankshaft rear oil seal. CAUTION • Apply only to the lip section of the oil seal.
3) 4) 5)
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Install the crankshaft rear oil seal to the adapter. Install the adapter to the crankshaft. Install the adapter ring to the sleeve.
Lubrication System 6)
Install the sleeve to the adapter.
9)
Inspect the crankshaft rear oil seal. ANNOTATION: • Measure the distance between the crankshaft head and the crankshaft rear oil seal. Specified value: 7.2 - 7.8 mm {0.283 - 0.307 in}
1 2 7) 8)
Sleeve Adapter ring
Install the center bolt to the sleeve. Tighten the center bolt using the wrench. ANNOTATION:
1 2
• Tighten the center bolt until the sleeve touches the adapter.
3 4 6.
Flywheel housing Crankshaft rear oil seal Oil seal press-fitting measurement Crankshaft
Flywheel Installation 1)
Apply the disulfide molybdenum grease to the bolt. ANNOTATION: • Apply to the seat surface and threaded portion on the flywheel installation bolts.
2)
Install the flywheel to the crankshaft. CAUTION • Pay attention to the knock pin position of the crankshaft. ANNOTATION: • Tightening order
3)
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Tighten the bolt using the torque wrench. Tightening torque: 78 N・m {8.0 kgf・m / 58 lb・ft}
Lubrication System 4)
Tighten the bolt using the special tool.
8.
Starter assembly Installation 1)
2)
Install the starter assembly to the flywheel housing. Tightening torque: 82 N・m {8.4 kgf・m / 60.5 lb・ft} Connect the earth cable to the starter assembly. Tightening torque: 19 N・m {1.9 kgf・m / 14.0 lb・ft}
Special tool: angle gauge (refer to section 1003) Tightening angle: 60 ° 5) Tighten the bolt using the special tool. Tightening angle: 60 ° 6) Tighten the bolt using the torque wrench. Tightening torque: 274 N・m {27.9 kgf・m / 202 lb・ft} Check the tightening 7.
CKP sensor Installation 1)
9.
Install the CKP sensor to the flywheel housing. CAUTION
Fuel supply pump Installation 1) 2)
Align 1st cylinder to the compression top dead center. Align alignment mark to the bracket.
• Be careful not to subject the sensor to shock. ANNOTATION: • Tighten together with the clip.
2)
Tightening torque: 6 N・m {0.6 kgf・m / 52 lb・in} Connect the harness connector to the CKP sensor.
1 2
1 2 3 4
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
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Supply pump bracket side slit Supply pump gear side alignment mark
Lubrication System 3)
Align the fuel supply pump to the cylinder block.
10. Cylinder head assembly Installation CAUTION
ANNOTATION:
• Clean the aligning surface of the cylinder head and cylinder block before installing the cylinder head assembly. • Be careful not to damage the cylinder head and cylinder block while cleaning.
• Confirm that the white paint can be seen through the timing confirmation hole on the top surface of the flywheel housing.
1)
Apply the liquid gasket to the cylinder block. ANNOTATION: • Use ThreeBond 1207B. Bead width: 3.0 mm {0.1181 in} Bead height: 2.0 mm {0.0787 in}
1 2 4)
Confirmation hole Supply pump gear
Install the fuel supply pump to the cylinder block. Tightening torque: 75 N・m {7.6 kgf・m / 55 lb・ft} No.5 in the diagram Tightening torque: 75 N・m {7.6 kgf・m / 55 lb・ft} No.8 in the diagram Tightening torque: 51 N・m {5.2 kgf・m / 38 lb・ft} No.10 in the diagram
CAUTION • After applying liquid gasket, install the cylinder head within 5 minutes. 2)
Install the cylinder head gasket to the cylinder block. CAUTION • Use a new cylinder head gasket.
3)
Install the cylinder head assembly to the cylinder block. CAUTION • Be careful not to damage the cylinder head gasket.
1 2 3 4 5 6 7 8 9 10 5)
Fuel supply pump Bracket Gear Nut Bolt O-ring O-ring Nut Bolt Nut
Connect the harness connector to the fuel supply pump. 84402827B - May 2011 2445-26
Lubrication System ANNOTATION:
• Tightening order of the head bolts
2)
ANNOTATION: • 1 to 26 in the diagram indicate the M14 bolts. • 27 and 28 in the diagram indicate the M10 bolts. 4)
• Apply molybdenum disulfide grease to the seat surface and threaded portion of the M14 head bolts. • Apply engine oil to the seat surface and threaded portion of the M10 head bolts. 5) 6) 7)
CAUTION • Confirm that the bridge moves smoothly.
Prepare the head bolt. ANNOTATION:
Install the bridge to the bridge guide.
3) 4)
Apply the engine oil to the bridge cap. Install the bridge cap to the bridge.
Tighten the head bolt using the torque wrench. Tightening torque: 98 N・m {10.0 kgf・m / 72 lb・ft} M14 bolt Tighten the head bolt using the torque wrench. Tightening torque: 147 N・m {15.0 kgf・m / 108 lb・ft} M14 bolt Tighten the head bolt using the special tool.
CAUTION • Be careful not to drop the bridge cap into the engine. 12. Camshaft Installation 1)
Align 1st cylinder to the compression top dead center.
2)
Apply the engine oil to the camshaft bearing.
Special tool: angle gauge (refer to section 1003) Tightening angle: 30 - 60 ° M14 Bolt 8) Tighten the head bolt using the torque wrench. Tightening torque: 38 N・m {3.9 kgf・m / 28.0 lb・ft} M10 bolt 9) Tighten the head bolt using the torque wrench. Tightening torque: 142 N・m {14.5 kgf・m / 105 lb・ft} Check the tightening M14 bolt 11. Bridge Installation 1)
Apply the engine oil to the bridge.
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Lubrication System 1
ANNOTATION: • Apply engine oil to the sliding surface of the bearing.
3)
5)
Install the camshaft to the cylinder head assembly.
CAUTION
ANNOTATION:
• Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and cylinder head.
• Mesh together the idle gear C and the camshaft gear so that the alignment mark on the camshaft gear matches the top surface of the cylinder head, and gently install the camshaft.
Install the camshaft bearing to the cylinder head assembly.
CAUTION
ANNOTATION:
• Align the alignment marks of the sub gear side.
• To prevent the effect of spring force on the sub gear, use a scissors gear spring wrench to rotate the sub gear before installing the camshaft on the cylinder head. 4)
Alignment pin
Align the sub gear to the camshaft gear using the special tool. ANNOTATION: • Install the alignment pin from the sub gear side if the holes of the sub gear and the camshaft main gear are aligned.
6)
Check alignment mark of the camshaft gear. CAUTION • Confirm that the alignment mark is not misaligned before installing the camshaft bearing cap. • If the alignment mark is not at the correct position, reinstall the camshaft.
Special tool: scissors gear spring wrench (refer to section 1003)
7)
Apply the engine oil to the camshaft bearing. ANNOTATION: • Apply engine oil to the sliding surface of the bearing. CAUTION • Apply engine oil after cleaning the bearing installation sections of the camshaft bearing and camshaft bearing cap.
8)
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Install the camshaft bearing to the camshaft bearing cap.
Lubrication System 9)
Install the camshaft bearing cap to the cylinder head assembly.
ANNOTATION: • On the camshaft bearing assembly section only, apply oil to the threaded portion of the stud bolts and the seat surface/threaded portion of the nuts, then tighten them. • Tightening order
ANNOTATION: • Turn the camshaft bearing cap so that the arrow mark on the top surface faces the engine front side, and assemble in numerical order. Tightening torque: 28 N・m {2.8 kgf・m / 20 lb・ft} Engine oil application
Rocker arm shaft tightening torque Tightening torque Parts Front side camshaft bearing cap : 28 N・m {2.8 kgf・m / 20 Rear side camshaft lb・ft} bearing cap : 56 N・m {5.7 kgf・m / 41 Rocker arm bracket lb・ft}
13. Rocker arm shaft Installation 1)
Apply the engine oil to the bracket. ANNOTATION: • Apply to each sliding surface.
2)
Apply the engine oil to the rocker arm. ANNOTATION: • Confirm that the adjust screw is fully loosened.
14. Rocker arm shaft Adjustment ANNOTATION: • Valve clearance adjustment CAUTION • Adjust the valve clearance while cool. • Loosen all adjust screws before adjustment.
1 2 3 3)
Front side camshaft bracket Rocker arm Rear side camshaft bracket
Install the rocker arm shaft to the cylinder head assembly.
84402827B - May 2011 2445-29
Lubrication System 1)
Align 1st cylinder to the compression top dead center.
ANNOTATION: • With the thickness gauge inserted, lightly tighten the adjust screw of the bridge. • Confirm that the leading end of the adjust screw and valve shaft end have made contact and the movement of the thickness gauge has become stiff. • Check if the valve shaft end on the opposite side is floating or touching at an angle. • If it is floating or touching at an angle, slightly loosen the bridge adjust screw and adjust the valve shaft ends on both sides to touch properly. Valve bridge clearance: less than 0.1 mm {less than 0.0039 in}
2)
Prepare the feeler gauge. Thickness: 0.4 mm {0.0157 in} 2 pieces
ANNOTATION: • To prevent turning, fix the bridge adjust screw with a flathead screwdriver, and tighten the adjust screw nut.
ANNOTATION: • Insert rocker • Insert bridge 3)
the thickness gauge between the arm and bridge cap. the thickness gauge between the and valve.
Tightening torque: 22 N・m {2.2 kgf・m / 16 lb・ft}
Turn the adjust screw. ANNOTATION: • When the movement of the thickness gauge becomes stiff, secure the adjust screw nut of the rocker arm. Tightening torque: 22 N・m {2.2 kgf・m / 16 lb・ft}
4)
Turn the adjust screw.
Cylinder No. 1 Condision Arrangement of valves IN When the #1 cylinder is set at the compression ○ Valve to be top dead center adjusted When the #6 cylinder is set at the compression top dead center
2 EXH IN ○
3 EXH IN
○
○ ○
○
15. Lower cover Installation 1)
4 EXH IN
5 EXH IN
○
6 EXH IN ○
○
○
ANNOTATION:
Apply the liquid gasket to the rubber plug. 84402827B - May 2011 2445-30
EXH
• Apply ThreeBond 1207B.
○
○
Lubrication System 5)
1 2
Securely tighten the nut to the common rail assembly. Tightening torque: 25 N・m {2.5 kgf・m / 18.4 lb・ft}
Rubber plug Liquid gasket
CAUTION • After applying the liquid gasket, install the lower cover within 5 minutes. 2) 3) 4)
Install the rubber plug to the cylinder head assembly. Install the gasket to the lower cover. Install the lower cover to the cylinder head assembly. Tightening torque: 13 N・m {1.3 kgf・m / 112 lb・in}
1 6)
Common rail assembly
Connect the harness connector to the fuel pressure sensor.
17. Fuel leak off pipe assembly Installation 1)
Temporarily tighten the fuel leak-off pipe to the cylinder head assembly. CAUTION • Use new gaskets.
ANNOTATION: 2)
• Tightening order
Temporarily tighten the fuel leak-off pipe to the common rail assembly. CAUTION • Use new gaskets.
3)
Temporarily tighten the fuel leak-off pipe to the fuel supply pump. ANNOTATION: • Tighten the fuel feed pipe together. CAUTION • Use new gaskets.
4)
16. Common rail assembly Installation 1) 2) 3) 4)
Align the common rail assembly to the inlet cover. Temporarily tighten the bolt to the common rail assembly. Temporarily tighten the nut to the common rail assembly. Securely tighten the bolt to the common rail assembly. Tightening torque: 25 N・m {2.5 kgf・m / 18.4 lb・ft}
5)
6)
84402827B - May 2011 2445-31
Securely tighten the fuel leak-off pipe to the cylinder head assembly. Tightening torque: 14 N ・ m {1.4 kgf ・ m / 123.9 lb・in} Securely tighten the fuel leak-off pipe to the common rail assembly. Tightening torque: 20 N・m {2.0 kgf・m / 14.8 lb・ft} Securely tighten the fuel leak-off pipe to the fuel supply pump. Tightening torque: 10 N・m {1.0 kgf・m / 88.5 lb・in}
Lubrication System 7)
Install the clip to the fuel leak-off pipe. Tightening torque: 9 N・m {0.9 kgf・m / 79.7 lb・in}
2)
Temporarily tighten the injector to the cylinder head assembly. CAUTION • Be extremely careful not to damage the injector nozzle.
1
Fuel leak-off pipe
18. Fuel pipe Installation 1)
Install the fuel pipe to the fuel supply pump and the common rail assembly. CAUTION
1 2 3)
• Use new fuel pipes.
2)
Tightening torque: 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the bracket. Tightening torque: 9 N・m {0.9 kgf・m / 79.7 lb・in}
• Use new injection pipes. 4)
CAUTION • When reusing an injector, do not change the installation position.
Temporarily tighten the injection pipe to the injector. CAUTION
5)
19. Injector Installation
Injector Installation bolt
6)
Temporarily tighten the injection pipe to the common rail assembly. Securely tighten the injector to the cylinder head assembly. Tightening torque: 30 N・m {3.1 kgf・m / 22 lb・ft} Install the injector leak-off pipe to the injector. CAUTION
1)
Apply the engine oil to the bolt.
• Use new gaskets. Tightening torque: 14 N・m {1.4 kgf・m / 126 lb・in} 20. Injection pipe Installation 1)
2)
84402827B - May 2011 2445-32
Securely tighten the injection pipe to the injector. Tightening torque: 44 N・m {4.5 kgf・m / 32.5 lb・ft} Securely tighten the injection pipe to the common rail assembly. Tightening torque: 44 N・m {4.5 kgf・m / 32.5 lb・ft}
Lubrication System 3)
Install the clip to the inlet cover. Tightening torque: 6 N・m {0.6 kgf・m / 53.1 lb・in}
2)
Install the glow plug connector to the glow plug. Tightening torque: 1 N・m {0.1 kgf・m / 8.9 lb・in} CAUTION • Confirm that the glow plug connector does not interfere with the surrounding parts.
1 2 3 4 5 6 7
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
pipe pipe pipe pipe pipe pipe
22. Injector harness Installation 1)
21. Glow plug Installation 1)
Install the injector harness to the cylinder head assembly. ANNOTATION:
Install the glow plug to the cylinder head assembly. Tightening torque: 20 N・m {2.0 kgf・m / 14.8 lb・ft} CAUTION
• Tighten the bolts on the bracket and install the injector harness together with the bracket. Tightening torque: 22 N・m {2.2 kgf・m / 16 lb・ft}
• Be careful not to exceed the specified torque when tightening.
1 2
84402827B - May 2011 2445-33
Injector harness terminal Injector harness bracket
Lubrication System 2)
Connect the injector harness to the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3 3) 1 2 3 3)
4)
Injector Injector harness Terminal nut
Cylinder head cover Head cover gasket Lower cover
Connect the ventilation hose to the air breather. Connect the water pipe bracket to the cylinder head cover. Tightening torque: 20 N・m {2.0 kgf・m / 14 lb・ft}
Install the connector to the lower cover. Tightening torque: 2 N・m {0.2 kgf・m / 18 lb・in}
23. Cylinder head cover Installation 1) 2)
Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover. Tightening torque: 13 N・m {1.3 kgf・m / 115 lb・in} ANNOTATION: • Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them.
1 2 3
Ventilation hose Water pipe bracket Clip
24. Inlet pipe Installation 1)
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Install the inlet pipe to the inlet cover. Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft}
Lubrication System 2) 3) 4) 5)
Connect the harness connector to the boost sensor. Connect the harness connector to the boost temperature sensor. Connect the harness connector to the IMT sensor. Install the harness clip to the inlet pipe. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft}
1)
Install the intake throttle valve to the inlet pipe. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft}
1 2 3 2) 3) 1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
Intake throttle valve Gasket Inlet pipe
Install the air duct to the intake throttle valve. Connect the harness connector to the intake throttle valve. ANNOTATION: • After connecting the harness connector, press in the lock operation portion to lock.
25. Intake throttle valve Installation
1 2 3
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Lock operation section Lock release Lock
Lubrication System 26. EGR cooler water pipe Installation
84402827B - May 2011 2445-36
Lubrication System 1)
Install the water bypass hose to the water pump assembly and the water duct.
1 2)
5)
Install the fan guide stay to the fan guide. Tightening torque: 30 N・m {3.1 kgf・m / 22 lb・ft}
Water bypass hose 1 2 3
Install the EGR cooler water pipe to the engine assembly. Clamp tightening torque: 20 N・m {2.0 kgf・ m / 14 lb・ft} ANNOTATION:
Fan guide Fan guide stay Fan guide bracket
27. Oil separator bracket Installation
• Tightening torque of bolt 1 in the diagram is different from others.
1)
Tightening torque: 39 N・m {4.0 kgf・m / 29 lb・ft}
Temporarily tighten the oil separator bracket to the cylinder head assembly. ANNOTATION: • Tighten together with the clip.
2) 3)
Install the ventilation hose to the air breather. Securely tighten the oil separator bracket to the cylinder head assembly. Tightening torque: 52 N・m {5.3 kgf・m / 38 lb・ft} CAUTION • Pay attention to the installation angle of the hose.
4)
1 3) 4)
Install the clip to the cylinder block. Tightening torque: 48 N・m {4.9 kgf・m / 35 lb・ft}
Installation bolt
Connect the radiator upper hose to the water outlet pipe. Install the fan guide stay to the fan guide bracket. Tightening torque: 40 N・m {4.1 kgf・m / 30 lb・ft}
1 2 84402827B - May 2011 2445-37
Oil separator bracket Clip
Lubrication System 6)
28. EGR valve Installation 1)
Install the EGR valve to the inlet pipe. Tightening torque: 46 N・m {4.7 kgf・m / 33.9 lb・ft}
1
1 2 3 4
EGR valve
29. EGR cooler Installation 1) 2)
Temporarily tighten the EGR cooler C to the EGR bracket C.
7)
Temporarily tighten the EGR pipe A to the exhaust manifold. Temporarily tighten the EGR cooler A to the EGR pipe A.
Temporarily tighten the EGR pipe B to the EGR cooler C and the EGR valve.
1 2 3 1 2 3 3) 4) 5)
EGR cooler A EGR pipe A Exhaust manifold
8)
Temporarily tighten the EGR cooler bracket A to the EGR cooler A. Temporarily tighten the EGR cooler B to the EGR cooler A. Temporarily tighten the EGR bracket C to the EGR cooler B.
9)
10)
11)
12)
84402827B - May 2011 2445-38
EGR cooler C EGR cooler bracket C EGR cooler B EGR cooler bracket A
EGR valve EGR pipe B EGR cooler C
Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque: 67 N・m {6.8 kgf・m / 49 lb・ft} Securely tighten the EGR cooler A to the EGR pipe A. Tightening torque: 31 N・m {3.2 kgf・m / 23 lb・ft} Securely tighten the EGR cooler B to the EGR cooler A. Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler B. Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler C to the EGR cooler bracket C. Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft}
Lubrication System 13)
14)
15)
16)
17)
18)
Securely tighten the EGR pipe B to the EGR cooler C. Tightening torque: 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR pipe B to the EGR valve. Tightening torque: 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR cooler bracket A to the EGR cooler bracket C. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler bracket B. Tightening torque: 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR pipe B to the rear engine hanger bracket. Tightening torque: 46 N・m {4.7 kgf・m / 34 lb・ft} Install the EGR heat protector to the EGR pipe. Tightening torque: 31 N・m {3.2 kgf・m / 23 lb・ft}
30. Oil level gauge guide tube Installation 1)
2)
3)
Install the oil level gauge guide tube to the cylinder block. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Connect the oil level gauge guide tube to the cylinder head assembly. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Install the oil level gauge to the oil level gauge guide tube.
1
Oil level gauge guide tube
31. Turbocharger assembly Installation 1) 2) 3)
1 19)
4)
EGR heat protector
Connect the water rubber hose to the EGR cooler.
Replenish the engine oil with the turbocharger assembly. Align the gasket to the turbocharger assembly. Install the turbocharger assembly to the exhaust manifold. Tightening torque: 52 N・m {5.3 kgf・m / 38 lb・ft} Install the water feed pipe to the cylinder block. Tightening torque: 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION • Use a new gasket.
5)
Connect the water feed pipe to the turbocharger assembly. Tightening torque: 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
1
Water rubber hose
84402827B - May 2011 2445-39
Lubrication System 6)
7)
Install the water return pipe to the cylinder block. Tightening torque: 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
11)
Connect the oil feed pipe to the turbocharger assembly. Tightening torque: 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
CAUTION
CAUTION
• Use a new gasket.
• Use a new gasket.
Connect the water return pipe to the turbocharger assembly. Tightening torque: 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
8)
Install the oil return pipe to the cylinder block. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION • Use a new gasket.
9)
1 2 3 4 5
Connect the oil return pipe to the turbocharger assembly. Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION
12)
• Use a new gasket.
13) 10)
Install the oil feed pipe to the pipe bracket. Tightening torque: 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque: 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION
14)
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Install the exhaust pipe to the turbocharger assembly. Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.
32. Engine oil Filling 1)
• Use a new gasket.
Replenish the engine oil with the engine assembly. CAUTION • Check the tightening of the drain plug before adding engine oil.
33. Engine harness Connect 1)
Connect the engine harness to the engine assembly. ANNOTATION: • Connect each connector.
34. Coolant Filling 1)
84402827B - May 2011 2445-40
Loosen the valve using a wrench.
Lubrication System 2)
1 2 3 4 3
Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
3)
1) 2)
Prepare the pan. Turn ON the starter switch. ANNOTATION:
Tighten the valve using a wrench.
• This is for the models with an electromagnetic pump.
CAUTION • Use new gaskets.
4)
Priming pump Plug Drain plug Case Drain plug
Tightening torque: 22 N・m {2.2 kgf・m / 16 lb・ft} Replenish the coolant with the radiator.
3) 4)
Loosen the plug using the wrench. Operate the priming pump. Number of times: 20 count(s) or more ANNOTATION: • Confirm that fuel comes out from around the plug.
5) 6)
Tighten the plug using the wrench. Operate the priming pump. Number of times: 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
7)
Specified time: 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
1 2
8) 9)
Valve Gasket
Tighten the plug using the wrench. Operate the priming pump. Number of times: 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
35. Battery ground cable Connect 1)
Connect the battery ground cable to the battery. 10)
36. Fuel Air bleed
Specified time: 1 min Loosen the plug using the wrench. ANNOTATION:
CAUTION
• Remove the air in the fuel filter.
• To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
11) 12)
Tighten the plug using the wrench. Operate the priming pump. Number of times: 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
13)
Specified time: 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
84402827B - May 2011 2445-41
Lubrication System 14)
Tighten the plug using the wrench. Tightening torque: 10 N・m {1.0 kgf・m / 88.5 lb・in}
Oil pump assembly Inspection 1.
Oil pump assembly Inspection 1)
CAUTION • Remove the fuel around the plug thoroughly after tightening. 15) 16)
Measure the clearance using the feeler gauge. ANNOTATION: • The clearance between the inner wall of the body and each gear tooth tip.
Operate the priming pump. Number of times: 10 count(s) Start the engine.
Specified value： 0.125 - 0.220 mm ｛0.0049 - 0.0087 in｝ Limit： 0.30 mm ｛0.0118 in｝
ANNOTATION: • Do not accelerate the engine revolution right after staring. Specified time: 5 s ANNOTATION: • Accelerate the engine revolution gradually. Specified time: 3 min ANNOTATION: • Accelerate the engine revolution to maximum. • Lower the rotation.
CAUTION • Replace the gear if the measured value exceeds the limit value. 2)
Measure the shaft using the micrometer. ANNOTATION: • Driven gear shaft outer diameter
3)
Specified value ： 15.989 - 16.000 mm ｛0.6295 - 0.6299 in｝ Limit： 15.900 mm ｛0.6260 in｝ Measure the body using the gauge. ANNOTATION: • Measure the bush inner diameter of the body.
84402827B - May 2011 2445-42
Lubrication System 4)
Measure the cylinder block using the gauge.
Engine oil Inspection
ANNOTATION:
1.
Engine oil Inspection
• Measure the bush inner diameter of the cylinder block.
CAUTION • The engine should be in a horizontal position. • Wait at least 5 minutes before starting the engine and after stopping the engine. 1)
Remove the oil level gauge from the oil level gauge guide tube. ANNOTATION: • Wipe off the engine oil remaining on the oil level gauge.
2) 3) 5)
Calculate the clearance from the measured value.
4)
Install the oil level gauge to the oil level gauge guide tube. Remove the oil level gauge from the oil level gauge guide tube. Inspect the engine oil.
ANNOTATION:
ANNOTATION:
• The difference between the shaft outer diameter and the bush inner diameter is the clearance.
• Check the engine oil remaining on the oil level gauge to inspect the engine oil level.
Specified value： 0.04 - 0.07 mm ｛0.0016 0.0028 in｝ Limit： 0.20 mm ｛0.0079 in｝ CAUTION • Replace the gear if the clearance exceeds the limit value. 6) 7)
Inspect the ball. Inspect the spring.
1 2
Upper limit Lower limit
ANNOTATION: • If the oil level is under the lower limit, add engine oil. • Replace the engine oil if engine oil is dirty.
1 2
Ball Spring
84402827B - May 2011 2445-43
Lubrication System Removal and Installation of Oil Port Cover
Oil port cover Installation 1.
1)
Oil port cover Removal 1.
Oil port cover Installation Install the O-ring to the oil port cover.
Oil pressure sensor Removal 1) 2)
Disconnect the harness connector from the oil pressure sensor. Remove the oil pressure sensor from the oil port cover.
1 2 2) 1 2 3 4 2.
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
O-ring O-ring
Install the oil port cover to the cylinder block. Tightening torque： 39 N・m {4.0 kgf・m / 29 lb・ft}
Oil port cover Removal 1) 2) 3)
Disengage the oil feed pipe from the oil port cover. Remove the oil port cover from the cylinder block. Remove the O-ring from the oil port cover.
1 2 3)
Bolt - short Bolt - long
Connect the oil feed pipe to the oil port cover. Tightening torque： 28 N・m {2.8 kgf・m / 20 lb・ft} eyebolt CAUTION • Use new gaskets.
1 2
O-ring O-ring
2.
Oil pressure sensor Installation 1)
Install the oil pressure sensor to the oil port cover. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use new gaskets.
84402827B - May 2011 2445-44
Lubrication System 2)
Connect the harness connector to the oil pressure sensor.
1 2 3 4
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
84402827B - May 2011 2445-45
Lubrication System
84402827B - May 2011 2445-46
Section 2455
Cooling System
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal and Installation of Water Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water pump assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water pump assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Water pump assembly Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal and Installation of Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Thermostat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Thermostat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drive belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal and Installation of Overheat Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overheat switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overheat switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84402827B - May 2011 2455-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2455-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Cooling System Removal and Installation of Water Pump Assembly
2) 5.
Water pump assembly Removal 1.
2.
Drive belt Removal 1)
Battery ground cable Disconnect 1)
Remove the fan guide bracket from the engine assembly. Remove the drive belt from the engine assembly.
Disengage the battery ground cable from the battery.
Coolant Drain 1)
Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
3.
Cooling fan Removal 1)
Remove the cooling fan from the adapter.
1 2 3 6.
1 2 4.
Adjust bolt Fixing bolt Fixing bolt
Water pump assembly Removal 1)
Remove the fan pulley from the water pump assembly.
2)
Remove the water bypass hose from the water pump assembly and the water duct.
Cooling fan Adapter
Fan guide Removal 1)
Remove the fan guide from the fan guide bracket.
1 2 3 4 5 6
Bolt Washer Rubber mount Rubber mount Guide tube Fan guide
1 84402827B - May 2011 2455-3
Water bypass hose
Cooling System 3) 4)
Remove the water hose from the EGR cooler water pipe and the water pump assembly. Remove the water pump assembly from the gear case cover cover.
Water pump assembly Installation 1.
Water pump assembly Installation 1)
Install the water pump assembly to the gear case cover cover. CAUTION • Use new gaskets. Tightening torque： 39 N・m {4.0 kgf・m / 28.8 lb・ft} Nut in the diagram Tightening torque： 20 N・m {2.0 kgf・m / 14.8 lb・ft}
1 2) 3)
Install the water hose to the EGR cooler water pipe and the water pump assembly. Install the water bypass hose to the water pump assembly and the water duct.
1
84402827B - May 2011 2455-4
Nut
Water bypass hose
Cooling System 4)
2.
2)
Adjust the drive belt to standard value using the adjust bolt. Tightening torque： 75 N・m {7.6 kgf・m / 55.3 lb・ft} Nut of the adjust plate Tightening torque： 126 N・m {12.8 kgf・m / 92.9 lb・ft} Bolt of the bracket side
Drive belt Installation 1)
3.
Install the fan pulley to the water pump assembly. Tightening torque： 52 N・m {5.3 kgf・m / 38.4 lb・ft}
Install the drive belt to the engine assembly. 1 2 3
Drive belt Adjustment 1)
Press the drive belt. ANNOTATION:
4.
Fan guide Installation
• Measure the amount of drive belt flex by pressing on the point indicated by the arrow in the diagram with the specified pressure.
1)
Standard value： 98.0 N {10.0 kg / 22 lb} Specified value ： 5.5 - 7.5 mm {0.2165 0.2953 in} Amount of flex
2)
1 2 3
Adjust bolt Adjust plate side nut Bracket side bolt
Crankshaft pulley Generator Fan pulley
Install the fan guide bracket to the engine assembly. Tightening torque： 40 N・m {4.1 kgf・m / 29.5 lb・ft} Install the fan guide to the fan guide bracket. Tightening torque： 30 N・m {3.1 kgf・m / 22.1 lb・ft}
1 2 3 4 5 6
84402827B - May 2011 2455-5
Bolt Washer Rubber mount Rubber mount Guide tube Fan guide
Cooling System 5.
Cooling fan Installation 1)
3)
Install the cooling fan to the adapter.
Tighten the valve using a wrench. CAUTION • Use new gaskets.
4)
1 2
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft} Replenish the coolant with the radiator.
Cooling fan Adapter
Tightening torque： 52 N・m {5.3 kgf・m / 38.4 lb・ft} 6.
Coolant Filling 1) 2)
1 2
Loosen the valve using a wrench. Replenish the coolant with the radiator. 7.
CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
Valve Gasket
Battery ground cable Connect 1)
84402827B - May 2011 2455-6
Connect the battery ground cable to the battery.
Cooling System Water pump assembly Inspection 1.
Removal and Installation of Thermostat
Water pump assembly Inspection 1)
Inspect the water pump assembly.
Thermostat Removal
ANNOTATION: • Cracks and damage on the water pump body • Cracks and corrosion on the impeller • Water leak from the seal unit
1.
Battery ground cable Disconnect 1)
2.
CAUTION
Coolant Drain 1)
• If any abnormality is found in the inspection, replace the water pump assembly. 2)
Disengage the battery ground cable from the battery. Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
Inspect the bearing unit. 3.
ANNOTATION: • Rotate the fan while pushing the fan center to the radius direction and inspect for any significant looseness or abnormal sounds.
Thermostat Removal 1)
Remove the fan guide stay from the fan guide and the fan guide bracket.
CAUTION • If any abnormality is found in the inspection, replace the water pump assembly.
1 2 3 2) 3)
Disengage the radiator upper hose from the water outlet pipe. Remove the water outlet pipe from the cylinder head assembly.
1 2 84402827B - May 2011 2455-7
Fan guide Fan guide stay Fan guide bracket
Fan guide bracket Water outlet pipe
Cooling System 4) 5)
Remove the thermostat from the cylinder head assembly. Remove the gasket from the thermostat.
Thermostat Installation 1.
Thermostat Installation 1)
Install the gasket to the thermostat. CAUTION • Use new gaskets.
2)
Install the thermostat to the cylinder head assembly.
1
Jiggle valve position
CAUTION • Be careful not to mistake the assembly position and direction. 3)
Install the water outlet pipe to the cylinder head assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft}
1 2 4) 5)
84402827B - May 2011 2455-8
Fan guide bracket Water outlet pipe
Connect the radiator upper hose to the water outlet pipe. Install the fan guide stay to the fan guide bracket. Tightening torque： 40 N・m {4.1 kgf・m / 29.5 lb・ft}
Cooling System 6)
Install the fan guide stay to the fan guide. Tightening torque： 30 N・m {3.1 kgf・m / 22.1 lb・ft}
3)
Tighten the valve using a wrench. CAUTION • Use new gaskets.
4)
1 2 3 2.
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft} Replenish the coolant with the radiator.
Fan guide Fan guide stay Fan guide bracket
Coolant Filling 1) 2)
1 2
Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION
3.
• Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
Valve Gasket
Battery ground cable Connect 1)
84402827B - May 2011 2455-9
Connect the battery ground cable to the battery.
Cooling System Thermostat Inspection 1.
CAUTION
Thermostat Inspection 1)
• Do not heat the thermostat directly.
Inspect the thermostat. 4)
ANNOTATION: • Inspect the pellet, spring, shaft, jiggle valve, and crimped sections for damage.
Measure the water temperature using the thermometer. ANNOTATION: • Measure open valve temperature of the thermostat. Valve opening temperature： 80 - 84 ℃ ｛176 - 183 °F｝ Temperature when fully open： 90.0 ℃ ｛194 °F｝ Lift amount： 8.0 mm ｛0.3150 in｝
1 2)
Jiggle valve
Prepare the container. ANNOTATION: • Put water and the thermostat into a heatable container.
3)
1 2
Raise the water temperature. ANNOTATION: • In order to equalize the water temperature in the container, stir well.
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Piece of wood Stirring rod
Cooling System Coolant Inspection 1.
3)
Coolant Inspection WARNING
Measure the specific gravity using the hydrometer. Engine coolant temperature： 0 - 50 °C{32 122 °F} For inspection ANNOTATION:
• If the coolant temperature is high, do not perform the inspection. • When removing the cap, be careful as the coolant will burst out if the coolant temperature is high.
• Use a container that is deeper than the length of the hydrometer.
CAUTION • Be sure to use long life coolant which is specified or recommended by Isuzu. • Using at an unspecified concentration may result in freezing due to decreased anti-freezing performance. • Use a coolant concentration appropriate for the usage environment. ANNOTATION: • Before using, dilute the specified long life coolant to the specified concentration with soft tap water. Area where the equipment is used General area; Area where the lowest temperature is higher than (-12) degrees. Cold area; Area where the lowest temperature is (-30) degrees. Area where temperature drop to (-30) degrees. 1)
LLC concentration
1 2 4)
： 30 ％ 5) ： 50 ％
Radiator Hydrometer
Measure the temperature using the thermometer. Engine coolant temperature： 0 - 50 °C {32 122 °F} For inspection Calculate the concentration from the measured value.
： 55 ％
Inspect the radiator reverse tank. ANNOTATION: • If coolant level is MIN or less, add it until it reaches MAX. CAUTION • When adding coolant, use coolant appropriate for the usage environment.
2)
SPECIFIC GRAVITY
Volume of coolant： 16.0 L {4.2 US gal} Inspect the water leak using the radiator cap tester. Inspection pressure ： 200.0 kPa {2.04 kgf/ cm2 / 29 psi} ANNOTATION: • • • • •
TEMPERATURE (°C)
Inspection locations Radiator assembly Water pump assembly Radiator hose Heater hose
ANNOTATION: • Measuring the coolant concentration using a coolant scope is also possible.
84402827B - May 2011 2455-11
Cooling System Drive belt Inspection 1.
Removal and Installation of Overheat Switch
Drive belt Inspection 1)
Inspect the drive belt.
Overheat switch Removal
ANNOTATION:
1.
• Inspect for wear or damage. 2.
1)
Drive belt Adjustment 1)
Overheat switch Removal
2)
Press the drive belt. ANNOTATION:
Disconnect the harness connector from the overheat switch. Remove the overheat switch from the cylinder head assembly.
• Measure the amount of drive belt flex by pressing on the point indicated by the arrow in the diagram with the specified pressure. Standard value： 98.0 N ｛10.0 kg / 22 lb｝ Specified value ： 5.5 - 7.5 mm ｛ 0.2165 0.2953 in｝ Amount of flex
1
1 2 3 2)
Crankshaft pulley Generator Fan pulley
Adjust the drive belt to standard value using the adjust bolt. Tightening torque： 75 N・m ｛7.6 kgf・m / 55.3 lb・ft｝ Nut of the adjust plate Tightening torque： 126 N・m ｛12.8 kgf・ m / 92.9 lb・ft｝ Bolt of the bracket side
1 2 3
Adjust bolt Adjust plate side nut Bracket side bolt 84402827B - May 2011 2455-12
Overheat switch
Cooling System Overheat switch Installation 1.
Overheat switch Installation 1)
Install the overheat switch to the cylinder head assembly. ANNOTATION: • Apply Loctite 572 to the threaded portion. Tightening torque： 29 N・m ｛3.0 kgf・m / 21.4 lb・ft｝
1
Overheat switch
ANNOTATION: • Connect the harness connector to the overheat switch.
84402827B - May 2011 2455-13
Cooling System
84402827B - May 2011 2455-14
Section 2465
Removal and Installation of Exhaust Manifold
84402827B - May 2011
84402827B - May 2011
CONTENTS Exhaust manifold Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exhaust manifold Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exhaust manifold Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84402827B - May 2011 2465-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2465-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Exhaust Manifold Exhaust manifold Removal 1.
Remove the turbocharger assembly from the exhaust manifold.
Battery ground cable Disconnect 1)
2.
13)
Disengage the battery ground cable from the battery.
Turbocharger assembly Removal 1) 2) 3) 4)
Remove the air cleaner duct from the air cleaner assembly and the turbocharger assembly. Remove the air intake hose from the turbocharger assembly and the intercooler. Remove the exhaust pipe from the turbocharger. Disengage the oil feed pipe from the turbocharger assembly. ANNOTATION:
1 2 3 4 5
• Remove the clip. 5)
Remove the oil feed pipe from the pipe bracket. ANNOTATION: 3.
• Remove the clip. 6) 7) 8) 9) 10)
Oil level gauge guide tube Removal 1)
Disengage the oil return pipe from the turbocharger assembly. Remove the oil return pipe from the cylinder block. Disengage the water return pipe from the turbocharger assembly. Remove the water return pipe from the cylinder head assembly. Disengage the water feed pipe from the turbocharger assembly.
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
2) 3)
Remove the oil level gauge from the oil level gauge guide tube. Disengage the oil level gauge guide tube from the front engine hanger bracket. Remove the oil level gauge guide tube from the cylinder block.
ANNOTATION: • Remove the clip. 11)
Remove the water feed pipe from the cylinder block. ANNOTATION: • Remove the clip.
12)
Disengage the harness connector from the turbocharger assembly. 1 4.
Oil level gauge guide tube
Exhaust manifold Removal 1)
84402827B - May 2011 2465-3
Remove the EGR heat protector from the EGR pipe A.
Removal and Installation of Exhaust Manifold 4)
1
EGR heat protector
CAUTION • Remove the EGR pipe A from the EGR cooler A and exhaust manifold.
1 2 3 2) 3)
1 2 5)
Heat protector Exhaust manifold cover 84402827B - May 2011 2465-4
Exhaust manifold Distance nut
Disassemble the exhaust manifold.
1 2 3
EGR cooler A EGR pipe A Exhaust manifold
Remove the exhaust manifold cover from the exhaust manifold. Remove the heat protector from the exhaust manifold.
1 2
Remove the exhaust manifold from the cylinder head assembly.
Rear side exhaust manifold Seal ring Front side exhaust manifold
Removal and Installation of Exhaust Manifold Exhaust manifold Installation 1.
2)
Assemble the exhaust manifold.
Exhaust manifold Installation
ANNOTATION:
1)
• Assemble the seal ring onto the rear side exhaust manifold and adjust each seal ring joint to be 120 degrees apart.
Install the gasket to the cylinder head assembly. ANNOTATION: • Install the gasket by turning the protruding section downward.
1 2 3
CAUTION • Confirm that the gasket is firmly installed to the cylinder head.
3)
ANNOTATION:
Install the exhaust manifold to the cylinder head assembly. ANNOTATION:
• It will ride on the casted surface of the cylinder head as shown in the diagram when installed incorrectly.
1 2
Rear side exhaust manifold Seal ring Front side exhaust manifold
Casted surface Gasket
• Assemble the distance tube and washer referring to the diagram.
1 2
84402827B - May 2011 2465-5
Exhaust manifold Distance nut
Removal and Installation of Exhaust Manifold 6)
1 2 3 4
4)
5)
Install the EGR pipe A to the EGR cooler A and the exhaust manifold. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Bolt Tightening torque： 67 N・m {6.8 kgf・m / 49 lb・ft} Nut
Distance tube Nut Washer Distance nut
Tightening torque： 55 N・m {5.6 kgf・m / 41 lb・ft} Nut Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Distance nut Install the heat protector to the exhaust manifold. Tightening torque： 20 N・m {2.0 kgf・m / 14 lb・ft} Bolt Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Nut Install the exhaust manifold cover to the exhaust manifold. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
1 2 3 7)
Install the EGR heat protector to the EGR pipe A. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
1 2.
EGR heat protector
Oil level gauge guide tube Installation 1)
1 2
EGR cooler A EGR pipe A Exhaust manifold
Heat protector Exhaust manifold cover 2)
84402827B - May 2011 2465-6
Install the oil level gauge guide tube to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Connect the oil level gauge guide tube to the cylinder head assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
Removal and Installation of Exhaust Manifold 3)
Install the oil level gauge to the oil level gauge guide tube.
6)
Install the water return pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION • Use a new gasket.
7)
Connect the water return pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION
1 3.
8)
Turbocharger assembly Installation 1) 2) 3)
4)
• Use a new gasket.
Oil level gauge guide tube
Replenish the engine oil with the turbocharger assembly. Align the gasket to the turbocharger assembly. Install the turbocharger assembly to the exhaust manifold. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft} Install the water feed pipe to the cylinder block. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip
CAUTION • Use a new gasket. 9)
Connect the oil return pipe to the turbocharger assembly. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} CAUTION • Use a new gasket.
10) CAUTION • Use a new gasket. 5)
Install the oil return pipe to the cylinder block. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
Connect the water feed pipe to the turbocharger assembly. Tightening torque： 41 N・m {4.2 kgf・m / 30 lb・ft} CAUTION • Use a new gasket.
84402827B - May 2011 2465-7
Install the oil feed pipe to the pipe bracket. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Clip CAUTION • Use a new gasket.
Removal and Installation of Exhaust Manifold 11)
Connect the oil feed pipe to the turbocharger assembly. Tightening torque： 34 N・m {3.5 kgf・m / 25 lb・ft} Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} clip
Exhaust manifold Inspection 1.
Exhaust manifold Inspection 1)
Inspect the exhaust manifold. ANNOTATION: • Inspect the exhaust manifold for cracks.
CAUTION 2)
• Use a new gasket.
3)
Align the simple straight ruler to the cylinder head assembly. Measure the clearance using the feeler gauge. ANNOTATION: • Flatness of the exhaust manifold Limit： 0.5 mm ｛0.0197 in｝ Specified value： 0.3 mm ｛0.0118 in｝
1 2 3 4 5 12) 13) 14) 4.
Oil feed pipe Clip Oil return pipe Water feed pipe Water return pipe
Install the exhaust pipe to the turbocharger assembly. Install the air intake hose to the turbocharger assembly and the intercooler. Install the air cleaner duct to the air cleaner assembly and the turbocharger assembly.
Battery ground cable Connect 1)
Connect the battery ground cable to the battery.
84402827B - May 2011 2465-8
CAUTION • Replace the exhaust manifold if flatness is above the limit value.
Section 2470
Disassembly, Removal and Installation of DPD Assembly
84402827B - May 2011
84402827B - May 2011
CONTENTS DPD assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DPD assembly Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DPD assembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
84402827B - May 2011 2470-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 2470-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Disassembly, Removal and Installation of DPD Assembly DPD assembly Disassembly
2)
1.
3)
Exhaust differential pressure sensor Safety Information
Disengage the harness connector from the exhaust differential pressure sensor. Remove the exhaust differential pressure sensor from the DPD assembly.
CAUTION
CAUTION
• Do not use a tool which causes vibrations such as an impact wrench when installing and removing the DPD differential pressure sensor. • Do not reuse a DPD differential pressure sensor which has been subjected to shock such as being dropped. • Install or remove the DPD differential pressure sensor together with the bracket. • Be sure not to loosen the 4 screws installed on the DPD differential pressure sensor. • Replace the DPD differential pressure sensor if the 4 screws installed on the DPD differential pressure sensor have been loosened.
• Remove the DPD differential pressure sensor with the attached bracket.
1
3.
DPD differential pressure sensor
Exhaust gas temperature sensor Safety Information CAUTION
1 2.
• Before removing, be sure to check the DPD pressure difference, status, and inspection/maintenance contents using a scan tool. • Do not reuse an exhaust gas temperature sensor which has been subjected to shock such as being dropped.
Screw
Exhaust differential pressure sensor Removal 4. CAUTION
Exhaust gas temperature sensor Removal 1)
• Before performing work, be sure to check the DPD differential pressure sensor precautions. 1)
Disengage the differential pressure hose from the exhaust differential pressure sensor.
84402827B - May 2011 2470-3
Disengage the harness connector from the exhaust gas temperature sensor. ANNOTATION: • To prevent incorrect assembling, make an alignment mark on the connector before disconnecting.
Disassembly, Removal and Installation of DPD Assembly 2)
Remove the exhaust gas temperature sensor from the DPD assembly.
1 2 5.
Exhaust gas temperature sensor 1 Exhaust gas temperature sensor 2
3)
Remove the differential pressure pipe from the DPD assembly.
1 2 5) 6)
DPD assembly Disassembly 1) 2)
4)
Bracket Differential pressure pipe
Remove the oxidation catalyst assembly from the filter assembly. Remove the filter assembly from the exhaust silencer assembly.
Remove the bracket from the DPD assembly. Loosen the differential pressure pipe using the wrench. Remove the clip from the differential pressure pipe.
1 2 3
84402827B - May 2011 2470-4
Oxidation catalyst assembly Filter assembly Exhaust silencer assembly
Disassembly, Removal and Installation of DPD Assembly DPD assembly Reassembly
6)
1.
7)
DPD assembly Reassembly CAUTION • Do not reuse gaskets, bolts, and nuts. 1)
8)
Temporarily tighten the filter assembly to the exhaust silencer assembly. ANNOTATION:
9)
• Tighten together with the bracket. 2)
Temporarily tighten the clip to the differential pressure pipe. Securely tighten the clip to the differential pressure pipe. Tightening torque： 10 N・m ｛1.0 kgf・m / 88.5 lb・in｝ Securely tighten the differential pressure pipe to the DPD assembly. Tightening torque： 35 N・m ｛3.6 kgf・m / 25.8 lb・ft｝ pipe sleeve nut Install the bracket to the DPD assembly. Tightening torque： 25 N・m ｛2.5 kgf・m / 18.4 lb・ft｝
Temporarily tighten the oxidation catalyst assembly to the filter assembly. ANNOTATION: • Tighten together with the bracket. • Place the DPD assembly tightened temporarily on a flat surface to determine the position so that the bracket installation area is horizontal.
3)
4)
Securely tighten the filter assembly to the exhaust silencer assembly. Tightening torque： 29 N・m ｛3.0 kgf・m / 21.4 lb・ft｝ Securely tighten the oxidation catalyst assembly to the filter assembly. Tightening torque： 29 N・m ｛3.0 kgf・m / 21.4 lb・ft｝
1 2 2.
Bracket Differential pressure pipe
Exhaust gas temperature sensor Installation CAUTION
1 2 3 5)
• Do not subject the tip of the exhaust gas temperature sensor to shock when installing. • Remove the old anti-seize lubricant on the sleeve nut. • Apply the anti-seize lubricant on the threaded portion of the sleeve nut. • Apply Never-Seez High Temperature Stainless Grade ： 5-87411-039-0 anti-seize lubricant, manufactured by Bostik in the United states. • Replace the oxidation catalyst assembly if damage has been found in the sensor installation section of the oxidation catalyst assembly.
Oxidation catalyst assembly Filter assembly Exhaust silencer assembly
Temporarily tighten the differential pressure pipe to the DPD assembly.
1)
Temporarily tighten the exhaust gas temperature sensor to the DPD assembly.
CAUTION • Remove the old anti-seize lubricant on the sleeve nut. • Apply the anti-seize lubricant on the threaded portion of the sleeve nut. • Apply Never-Seez High Temperature Stainless Grade ： 5-87411-039-0 anti-seize lubricant, manufactured by Bostik in the United states. 84402827B - May 2011 2470-5
CAUTION • To avoid damaging the sensor installation sections due to sensor incorrect assembly, tighten it by hand. ANNOTATION: • Exhaust gas temperature sensor identification
Disassembly, Removal and Installation of DPD Assembly Sensor type
Screw size
Connector color
Exhaust gas temperaM12 x 1.75 Dark gray ture sensor 1 Exhaust gas temperaM12 x 1.25 Light gray ture sensor 2 2)
3)
Securely tighten the exhaust gas temperature sensor to the DPD assembly. Tightening torque： 30 N・m ｛3.1 kgf・m / 22.1 lb・ft｝ Connect the harness connector to the exhaust gas temperature sensor. CAUTION 1
• Be careful not to twist the harness. 4.
Screw
Exhaust differential pressure sensor Installation CAUTION • Before performing work, be sure to check the DPD differential pressure sensor precautions. 1) 2) 3)
Install the exhaust differential pressure sensor to the DPD assembly. Connect the harness connector to the exhaust differential pressure sensor. Connect the differential pressure hose to the exhaust differential pressure sensor. CAUTION
1 2
Exhaust gas temperature sensor 1 Exhaust gas temperature sensor 2
ANNOTATION: • Start the engine after assembling each part, and check for gas leaks from each joint and for vibration. 3.
• Be careful not to mistake the connecting position of the differential pressure hose. • Since the differential pressure sensor may malfunction if exhaust gas leaks from the joint sections, confirm that there is no exhaust gas leakage after the engine starts.
Exhaust differential pressure sensor Safety Information CAUTION • Do not use a tool which causes vibrations such as an impact wrench when installing and removing the DPD differential pressure sensor. • Do not reuse a DPD differential pressure sensor which has been subjected to shock such as being dropped. • Install or remove the DPD differential pressure sensor together with the bracket. • Be sure not to loosen the 4 screws installed on the DPD differential pressure sensor. • Replace the DPD differential pressure sensor if the 4 screws installed on the DPD differential pressure sensor have been loosened. 84402827B - May 2011 2470-6
1
DPD differential pressure sensor
Disassembly, Removal and Installation of DPD Assembly DPD assembly Inspection
ANNOTATION:
1.
• Attach the filter on the DPD ash removal device.
Filter assembly Inspection 1)
Inspect the filter assembly. ANNOTATION: • Inspect the filter for erosion, crack, damage, or clogging. • Replace the filter assembly if light passes through when shining light from the other side of the filter.
ANNOTATION: • Add air pressure of the specified pressure to the air tank until it increases to the specified pressure, and then stop adding. Specified pressure： 0.4 MPa ｛58.0 psi｝ CAUTION 1 2 2.
Oxidation catalyst assembly Inspection 1)
3.
• Confirm that there is no air leakage on the pipe connections by checking the pressure gauge attached to the pressure reducing valve to avoid supplying air pressure to the air tank over the limit value.
Filter Filter case
Inspect the oxidation catalyst assembly. ANNOTATION:
Limit： 0.5 MPa ｛72.5 psi｝
• Inspect the catalyst section for erosion, damage, or clogging.
ANNOTATION:
Filter assembly Cleaning CAUTION
• Operate the mechanical valve for 3 seconds to clean the filter by backwashing. • Repeat the 2 operations above 3 times or more.
• Clean the filter when clogged because gradual accumulation or firm, sticky calcination occurs on the filter since ashes are nonflammable unlike particle materials (PM). • When cleaning, use a DPD ash removal device which blows compressed air instantaneously. • For further details on the cleaning procedure, check the DPD ash removal device handling manual.
84402827B - May 2011 2470-7
CAUTION • While cleaning, ashes may gush from the air removal filter with backwashing noise, so be sure to wear protective equipments such as a protective mask, protective glasses, earplugs, etc. and keep your face and hands away.
Disassembly, Removal and Installation of DPD Assembly
84402827B - May 2011 2470-8
Section 3001
Removal and Installation of Fuel Tank
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of fuel tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 3001-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 3001-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Fuel Tank WARNING
3.
Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the stay (2).
4.
Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the top cover (2).
5.
Use a wrench (19 mm) to remove the 2 bolts (1) from the fuel tank front cover (tank) (2), and then remove the cover (tank).
• Keep away from fire. CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • • •
Wrenches (19 mm, 24 mm) Eyebolts (M12 x 4) Shackle (with the required lifting capacity) x 4 Wire ropes (with the required breaking load) Liftcrane (with the required lifting capacity) Caps Plugs Drum can (for draining fuel) Rag Cleaning fluid Wood planks, etc.
Removal of Fuel Tank 1.
2.
Remove the cap (1) and filter (2).
Drain out all the fuel from the fuel tank into a drum can.
84402827B - May 2011 3001-3
Removal and Installation of Fuel Tank 6.
Use a wrench (19 mm) to remove the 6 bolts (1) and clamps (2), and then remove the handle (3).
8.
Use a wrench (19 mm) to remove the 5 bolts (1), and then remove the under cover (2). Tightening torque for bolt installation: 63.7 - 73.66 N•m
9.
Loosen the hose band (1), and then remove the hose (2). • Mark the fuel tank and hose so that the connectors match at the time of assembly. • Attach caps or plugs to the fuel tank and hoses to prevent any entry of water, dust or dirt.
7.
Use a wrench (19 mm) to remove the 5 bolts (1) from the fuel tank side cover (2), and then remove the side cover.
10. Remove the connector (1).
11. Use a wrench (24 mm) to remove the 6 bolts (1) and 6 spacers (2) from the bottom of the fuel tank. • Depending on the machine, there may be height adjustment shims between the tank and the frame. Do not lose them. • Also, mark or write down the locations where they are and how many.
84402827B - May 2011 3001-4
Removal and Installation of Fuel Tank • Tightening torque for bolt installation: 233.0 276.0 N•m
14. Connect the 4 shackles (1) to the eyebolts, then use the wire ropes (2) and liftcrane to lift. Thoroughly check that the location is safe before lowering the fuel tank (3) on wood planks.
12. Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the side covers (tank) (2).
13. Install the 4 eyebolts (M12) (1) on top of the fuel tank. • Fully tighten the eyebolts, and then loosen them by a half turn.
84402827B - May 2011 3001-5
Removal and Installation of Fuel Tank Installation of fuel tank To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque.
For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts". Finally, carefully check for any fuel leaks.
84402827B - May 2011 3001-6
Section 3004A
Removal and Installation of Fuel Supply Pump
84402827B - May 2011
84402827B - May 2011
CONTENTS Fuel supply pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel supply pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 3004A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 3004A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Fuel Supply Pump Fuel supply pump Removal 1.
Battery ground cable Disconnect 1)
2.
2)
Remove the fuel supply pump from the cylinder block. ANNOTATION:
Disengage the battery ground cable from the battery.
• Remove together with the bracket.
Engine harness Disconnect 1)
Disengage the engine harness from the engine assembly. ANNOTATION: • Disconnect each connector.
3.
Fuel pipe Removal 1)
Remove the fuel pipe from the fuel supply pump and the common rail assembly. ANNOTATION: • Remove the clip. CAUTION • Do not reuse the removed fuel pipe.
4.
Fuel leak off pipe assembly Removal 1) 2)
Disengage the fuel leak-off pipe from the cylinder head. Remove the fuel leak-off pipe from the fuel supply pump. ANNOTATION: • Remove the eyebolt tightened together with the fuel feed pipe.
3) 4)
Disengage the fuel leak-off pipe from the common rail assembly. Remove the fuel leak-off pipe from the inlet pipe. ANNOTATION: • Remove the clip.
1
5.
Fuel leak-off pipe
Fuel supply pump Removal 1)
Disengage the harness connector from the fuel supply pump. 84402827B - May 2011 3004A-3
1 2 3 4 5 6 7 8 9 10
Fuel supply pump Bract Gear Nut Bolt O-ring O-ring Nut Bolt Nut
Removal and Installation of Fuel Supply Pump Fuel supply pump Installation 1.
4)
Fuel supply pump Installation 1) 2)
Align 1st cylinder to the compression top dead center. Align alignment mark to the bracket.
1 2 3)
Supply pump bracket side slit Supply pump gear side alignment mark
Install the fuel supply pump to the cylinder block. Tightening torque： 75 N・m {7.6 kgf・m / 55 lb・ft} No.5 in the diagram Tightening torque： 75 N・m {7.6 kgf・m / 55 lb・ft} No.8 in the diagram Tightening torque： 51 N・m {5.2 kgf・m / 38 lb・ft} No.10 in the diagram
1 2 3 4 5 6 7 8 9 10
Align the fuel supply pump to the cylinder block. ANNOTATION: • Confirm that the white paint can be seen through the timing confirmation hole on the top surface of the flywheel housing. 5) 2.
Fuel supply pump Bracket Gear Nut Bolt O-ring O-ring Nut Bolt Nut
Connect the harness connector to the fuel supply pump.
Fuel leak off pipe assembly Installation 1)
Temporarily tighten the fuel leak-off pipe to the cylinder head assembly. CAUTION • Use new gaskets.
2)
1 2
Temporarily tighten the fuel leak-off pipe to the common rail assembly. CAUTION
Confirmation hole Supply pump gear
• Use new gaskets. 3)
Temporarily tighten the fuel leak-off pipe to the fuel supply pump. ANNOTATION: • Tighten the fuel feed pipe together. CAUTION • Use new gaskets.
84402827B - May 2011 3004A-4
Removal and Installation of Fuel Supply Pump 4)
5)
6)
7)
Securely tighten the fuel leak-off pipe to the cylinder head assembly. Tightening torque： 14 N・m {1.4 kgf・m / 123.9 lb・in} Securely tighten the fuel leak-off pipe to the common rail assembly. Tightening torque： 20 N・m {2.1 kgf・m / 14.8 lb・ft} Securely tighten the fuel leak-off pipe to the fuel supply pump. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} Install the clip to the fuel leak-off pipe. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in} 1 2 3 4 5 1) 2)
Priming pump Plug Drain plug Case Fuel filter element
Prepare the pan. Turn ON the starter switch. ANNOTATION: • This is for the models with an electromagnetic pump.
1 3.
3) 4)
Fuel leak-off pipe
Fuel pipe Installation
ANNOTATION:
1)
• Confirm that fuel comes out from around the plug.
Install the fuel pipe to the fuel supply pump and the common rail assembly. CAUTION
5) 6)
• Use new fuel pipes.
2)
4.
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION:
Connect the engine harness to the engine assembly.
• Remove the air in the fuel filter. 8) 9)
• Connect each connector.
6.
• Wait for the specified time after operating the priming pump. 7)
ANNOTATION:
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION:
Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the bracket. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
Engine harness Connect 1)
5.
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more
Battery ground cable Connect
ANNOTATION:
1)
• Wait for the specified time after operating the priming pump.
Connect the battery ground cable to the battery.
Fuel Air bleed 10)
CAUTION • To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
11)
84402827B - May 2011 3004A-5
Tighten the plug using the wrench.
Removal and Installation of Fuel Supply Pump 12)
Operate the priming pump. Number of times： 10 count(s) or more
15) 16)
ANNOTATION: • Wait for the specified time after operating the priming pump. 13)
14)
Operate the priming pump. Number of times： 10 count(s) Start the engine. ANNOTATION: • Do not accelerate the engine revolution right after staring.
Specified time： 1 min Loosen the plug using the wrench.
Specified time： 5 s
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution gradually.
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in}
Specified time： 3 min
CAUTION • Remove the fuel around the plug thoroughly after tightening.
84402827B - May 2011 3004A-6
ANNOTATION: • Accelerate the engine revolution to maximum. • Lower the rotation.
Section 3004B
Removal and Installation of Common Rail Assembly
84402827B - May 2011
84402827B - May 2011
CONTENTS Common rail assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Common rail assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
84402827B - May 2011 3004B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 3004B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Common Rail Assembly Common rail assembly Removal 1.
Battery ground cable Disconnect 1)
2.
2)
Disengage the harness connector from the intake throttle valve. ANNOTATION:
Disengage the battery ground cable from the battery.
• Pull the lock operation portion to release the lock.
Coolant Drain 1)
Drain the coolant from the radiator. CAUTION • After the coolant is discharged, make sure to tighten the drain plug.
3.
Engine harness Disconnect 1)
Disengage the engine harness from the engine assembly. ANNOTATION: • Disconnect each connector.
4.
Oil separator bracket Removal 1) 2) 3)
1 2 5.
1 2 3
Remove the clip from the cylinder block. Remove the ventilation hose from the air breather. Remove the oil separator bracket from the cylinder head assembly.
3)
Oil separator bracket Clip
1)
Remove the intake throttle valve from the inlet pipe.
1 2 3
Intake throttle valve Removal Remove the air duct from the intake throttle valve.
6.
Lock operation section Lock release Lock
Intake throttle valve Gasket Inlet pipe
EGR cooler Removal
84402827B - May 2011 3004B-3
Removal and Installation of Common Rail Assembly 1)
Disengage the water rubber hose from the EGR cooler.
5) 6)
1 2)
Water rubber hose 1 2 3 4
Remove the EGR pipe B from the EGR valve and the EGR cooler C.
7)
1 2 3 3) 4)
Remove the EGR cooler B from the EGR cooler bracket A. Remove the EGR cooler bracket A from the EGR cooler A.
EGR cooler C EGR bracket C EGR cooler B EGR cooler bracket A
Remove the EGR heat protector from the EGR pipe A.
EGR valve EGR pipe B EGR cooler C
Remove the EGR cooler C from the EGR bracket C. Remove the EGR bracket C from the EGR cooler B.
1 8)
84402827B - May 2011 3004B-4
EGR heat protector
Remove the EGR cooler A from the EGR pipe A.
Removal and Installation of Common Rail Assembly 9)
1 2 3 7.
4)
Remove the EGR pipe A from the exhaust manifold.
1 2 3 4
EGR cooler A EGR pipe A Exhaust manifold 5)
EGR valve Removal 1) 2)
Remove the harness clip from the inlet pipe.
Remove the inlet pipe from the inlet cover.
Disengage the harness connector from the EGR valve. Remove the EGR valve from the inlet pipe.
1 9. 1 8.
1) 2)
EGR valve
2) 3)
Inlet pipe
Injection pipe Removal
Inlet pipe Removal 1)
Boost sensor Harness clip Boost temperature sensor IMT sensor
Remove the clip from the inlet pipe. Remove the injection pipe from the injector and the common rail assembly. CAUTION
Disengage the harness connector from the boost sensor. Disconnect the harness connector from the boost temperature sensor. Disconnect the harness connector from the IMT sensor.
84402827B - May 2011 3004B-5
• Do not reuse the removed injection pipe. • Seal the common rail and injector to prevent foreign material from entering.
Removal and Installation of Common Rail Assembly 4)
Remove the fuel leak-off pipe from the inlet pipe. ANNOTATION: • Remove the clip.
1 2 3 4 5 6 7
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
pipe pipe pipe pipe pipe pipe
1
10. Fuel pipe Removal 1)
Fuel leak-off pipe
12. Common rail assembly Removal
Remove the fuel pipe from the fuel supply pump and the common rail assembly.
1)
ANNOTATION:
2)
• Remove the clip.
Disengage the harness connector from the fuel pressure sensor. Remove the common rail assembly from the inlet cover.
CAUTION • Do not reuse the removed fuel pipe. 11. Fuel leak off pipe assembly Removal 1) 2)
Disengage the fuel leak-off pipe from the cylinder head. Remove the fuel leak-off pipe from the fuel supply pump. ANNOTATION: • Remove the eyebolt tightened together with the fuel feed pipe.
3)
Disengage the fuel leak-off pipe from the common rail assembly.
84402827B - May 2011 3004B-6
1
Common rail assembly
Removal and Installation of Common Rail Assembly Common rail assembly Installation 1.
4)
Common rail assembly Installation 1) 2) 3) 4)
5)
Align the common rail assembly to the inlet cover. Temporarily tighten the bolt to the common rail assembly. Temporarily tighten the nut to the common rail assembly. Securely tighten the bolt to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft} Securely tighten the nut to the common rail assembly. Tightening torque： 25 N・m {2.5 kgf・m / 18.4 lb・ft}
5)
6)
7)
Securely tighten the fuel leak-off pipe to the cylinder head assembly. Tightening torque： 14 N・m {1.4 kgf・m / 123.9 lb・in} Securely tighten the fuel leak-off pipe to the common rail assembly. Tightening torque： 20 N・m {2.1 kgf・m / 14.8 lb・ft} Securely tighten the fuel leak-off pipe to the fuel supply pump. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} Install the clip to the fuel leak-off pipe. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
1 1 6) 2.
Common rail assembly
3.
Fuel pipe Installation 1)
Connect the harness connector to the fuel pressure sensor.
Fuel leak-off pipe
Install the fuel pipe to the fuel supply pump and the common rail assembly.
Fuel leak off pipe assembly Installation
CAUTION
1)
• Use new fuel pipes.
Temporarily tighten the fuel leak-off pipe to the cylinder head assembly. CAUTION 2)
• Use new gaskets. 2)
Temporarily tighten the fuel leak-off pipe to the common rail assembly.
4.
Injection pipe Installation 1)
CAUTION • Use new gaskets. 3)
Temporarily tighten the injection pipe to the injector. CAUTION
Temporarily tighten the fuel leak-off pipe to the fuel supply pump.
• Use new injection pipes.
ANNOTATION:
2)
• Tighten the fuel feed pipe together.
3)
CAUTION • Use new gaskets.
Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the bracket. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in}
4)
84402827B - May 2011 3004B-7
Temporarily tighten the injection pipe to the common rail assembly. Securely tighten the injection pipe to the injector. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Securely tighten the injection pipe to the common rail assembly. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft}
Removal and Installation of Common Rail Assembly 5)
Install the clip to the inlet cover. Tightening torque： 6 N・m {0.6 kgf・m / 53.1 lb・in}
1 2 3 4 5 6 7 5.
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
4) 5)
pipe pipe pipe pipe pipe pipe
1 2 3 4 6.
Install the inlet pipe to the inlet cover. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft}
Install the EGR valve to the inlet pipe. Tightening torque： 46 N・m {4.7 kgf・m / 33.9 lb・ft}
1 1 2) 3)
Inlet pipe
2)
Connect the harness connector to the boost sensor. Connect the harness connector to the boost temperature sensor.
7.
Boost sensor Harness clip Boost temperature sensor IMT sensor
EGR valve Installation 1)
Inlet pipe Installation 1)
Connect the harness connector to the IMT sensor. Install the harness clip to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
EGR valve
Connect the harness connector to the EGR valve.
EGR cooler Installation 1)
84402827B - May 2011 3004B-8
Temporarily tighten the EGR pipe A to the exhaust manifold.
Removal and Installation of Common Rail Assembly 2)
Temporarily tighten the EGR cooler A to the EGR pipe A.
1 2 3 3) 4) 5) 6)
7)
1 2 3
EGR cooler A EGR pipe A Exhaust manifold
Temporarily tighten the EGR cooler bracket A to the EGR cooler A. Temporarily tighten the EGR cooler B to the EGR cooler A. Temporarily tighten the EGR bracket C to the EGR cooler B. Temporarily tighten the EGR cooler C to the EGR bracket C.
8)
9)
10)
11)
12)
13)
1 2 3 4
EGR cooler C EGR cooler bracket C EGR cooler B EGR cooler bracket A
Temporarily tighten the EGR pipe B to the EGR cooler C and the EGR valve.
14)
15)
16)
17)
84402827B - May 2011 3004B-9
EGR valve EGR pipe B EGR cooler C
Securely tighten the EGR pipe A to the exhaust manifold. Tightening torque： 67 N・m {6.8 kgf・m / 49 lb・ft} Securely tighten the EGR cooler A to the EGR pipe A. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft} Securely tighten the EGR cooler B to the EGR cooler A. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler B. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR cooler C to the EGR cooler bracket C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR pipe B to the EGR cooler C. Tightening torque： 25 N・m {2.5 kgf・m / 18 lb・ft} Securely tighten the EGR pipe B to the EGR valve. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR cooler bracket A to the EGR cooler bracket C. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft} Securely tighten the EGR cooler bracket C to the EGR cooler bracket B. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft} Securely tighten the EGR pipe B to the rear engine hanger bracket. Tightening torque： 46 N・m {4.7 kgf・m / 34 lb・ft}
Removal and Installation of Common Rail Assembly 18)
1 19)
1)
Install the EGR heat protector to the EGR pipe. Tightening torque： 31 N・m {3.2 kgf・m / 23 lb・ft}
Install the intake throttle valve to the inlet pipe. Tightening torque： 24 N・m {2.4 kgf・m / 17 lb・ft}
1 2 3
EGR heat protector
Connect the water rubber hose to the EGR cooler.
2) 3)
Intake throttle valve Gasket Inlet pipe
Install the air duct to the intake throttle valve. Connect the harness connector to the intake throttle valve. ANNOTATION: • After connecting the harness connector, press in the lock operation portion to lock.
1 8.
Water rubber hose
Intake throttle valve Installation
1 2 3 9.
Lock operation section Lock release Lock
Oil separator bracket Installation 1)
Temporarily tighten the oil separator bracket to the cylinder head assembly. ANNOTATION: • Tighten together with the clip.
2)
84402827B - May 2011 3004B-10
Install the ventilation hose to the air breather.
Removal and Installation of Common Rail Assembly 3)
Securely tighten the oil separator bracket to the cylinder head assembly. Tightening torque： 52 N・m {5.3 kgf・m / 38 lb・ft}
4)
Replenish the coolant with the radiator.
CAUTION • Pay attention to the installation angle of the hose. 4)
Install the clip to the cylinder block. Tightening torque： 48 N・m {4.9 kgf・m / 35 lb・ft}
1 2
Valve Gasket
12. Battery ground cable Connect 1)
Connect the battery ground cable to the battery.
13. Fuel Air bleed CAUTION 1 2
• To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
Oil separator bracket Clip
10. Engine harness Connect 1)
Connect the engine harness to the engine assembly. ANNOTATION: • Connect each connector.
11. Coolant Filling 1) 2)
Loosen the valve using a wrench. Replenish the coolant with the radiator. CAUTION • Be careful not to let coolant overflow splash on the exhaust system parts. • Coolant overflow should be wiped off.
3)
1 2 3 4 5
Tighten the valve using a wrench. 1) 2)
CAUTION • Use new gaskets.
Priming pump Plug Drain plug Case Fuel filter element
Prepare the pan. Turn ON the starter switch. ANNOTATION:
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
84402827B - May 2011 3004B-11
• This is for the models with an electromagnetic pump.
Removal and Installation of Common Rail Assembly 3) 4)
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more
12)
ANNOTATION:
ANNOTATION:
• Wait for the specified time after operating the priming pump.
• Confirm that fuel comes out from around the plug. 5) 6)
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more
13)
• Remove the air in the fuel filter.
• Wait for the specified time after operating the priming pump.
14)
10)
CAUTION
ANNOTATION:
• Remove the fuel around the plug thoroughly after tightening.
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more
15) 16)
Operate the priming pump. Number of times： 10 count(s) Start the engine.
ANNOTATION:
ANNOTATION:
• Wait for the specified time after operating the priming pump.
• Do not accelerate the engine revolution right after staring.
Specified time： 1 min Loosen the plug using the wrench.
Specified time： 5 s ANNOTATION:
ANNOTATION:
• Accelerate the engine revolution gradually.
• Remove the air in the fuel filter. 11)
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in}
Specified time： 1 min Loosen the plug using the wrench. • Remove the air in the fuel filter.
8) 9)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION:
ANNOTATION:
7)
Operate the priming pump. Number of times： 10 count(s) or more
Specified time： 3 min
Tighten the plug using the wrench.
ANNOTATION: • Accelerate the engine revolution to maximum. • Lower the rotation.
84402827B - May 2011 3004B-12
Section 3005
Removal and Installation of Injector
84402827B - May 2011
84402827B - May 2011
CONTENTS Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 3005-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 3005-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Injector Injector Removal 1.
Injector harness Removal 1)
Battery ground cable Disconnect 1)
2.
4.
CAUTION
Disengage the battery ground cable from the battery.
• Do not pull the wire, or pry the connector with a screwdriver.
Engine harness Disconnect 1)
Remove the connector from the lower cover.
Disengage the engine harness from the engine assembly. ANNOTATION: • Disconnect each connector.
3.
Cylinder head cover Removal 1) 2)
Disengage the water pipe bracket from the cylinder head cover. Disengage the ventilation hose from the air breather.
2)
Disengage the injector harness from the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3
3) 4)
Ventilation hose Water pipe bracket Clip
Remove the cylinder head cover from the lower cover. Remove the head cover gasket from the cylinder head cover. 1 2 3
1 2 3
Cylinder head cover Head cover gasket Lower cover 84402827B - May 2011 3005-3
Injector Injector harness Terminal nut
Removal and Installation of Injector 3)
4 5 6 7
Remove the injector harness from the cylinder head assembly. ANNOTATION: • Remove the bracket tightening bolts and then remove the injector harness together with the bracket.
7.
No.4 injection pipe No.5 injection pipe No.6 injection pipe Fuel pipe
Injector Removal 1) 2)
Remove the injector leak-off pipe from the injector. Remove the injector from the cylinder head assembly. ANNOTATION: • When it is difficult to remove the injector, use a special tool.
1 2 5.
Lower cover Removal 1) 2)
6.
Injector harness terminal Injector harness bracket
Remove the lower cover from the cylinder head assembly. Remove the rubber plug from the cylinder head assembly.
Injection pipe Removal 1) 2)
Special tool: injector remover (refer to section 1003)
Remove the clip from the inlet pipe. Remove the injection pipe from the injector and the common rail assembly. CAUTION • Do not reuse the removed injection pipe. • Seal the common rail and injector to prevent foreign material from entering.
Special tool: sliding hammer (refer to section 1003)
1 2 3
No.1 injection pipe No.2 injection pipe No.3 injection pipe 84402827B - May 2011 3005-4
Removal and Installation of Injector 1 2 3
Injector Installation
Sliding hammer Fuel injector remover Injector
1.
Injector Installation CAUTION
CAUTION
• When reusing an injector, do not change the installation position.
• Confirm that the sleeve is not pulled out together when pulling out the injector using a special tool. • Store each ID code plate on the injector head with the cylinder number tag attached to avoid a mix-up. • Be extremely careful not to damage the injector nozzle.
1) 2)
Apply the engine oil to the bolt. Temporarily tighten the injector to the cylinder head assembly. CAUTION • Be extremely careful not to damage the injector nozzle.
1 2 3)
Injector Installation bolt
Temporarily tighten the injection pipe to the injector. CAUTION • Use new injection pipes.
4) 5)
6)
Temporarily tighten the injection pipe to the common rail assembly. Securely tighten the injector to the cylinder head assembly. Tightening torque： 30 N・m {3.1 kgf・m / 22 lb・ft} Install the injector leak-off pipe to the injector. CAUTION • Use new gaskets. Tightening torque： 14 N・m {1.4 kgf・m / 126 lb・in}
2.
Injection pipe Installation 1)
84402827B - May 2011 3005-5
Securely tighten the injection pipe to the injector. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft}
Removal and Installation of Injector 2)
3)
Securely tighten the injection pipe to the common rail assembly. Tightening torque： 44 N・m {4.5 kgf・m / 32.5 lb・ft} Install the clip to the inlet cover. Tightening torque： 6 N・m {0.6 kgf・m / 53.1 lb・in}
2) 3) 4)
Install the rubber plug to the cylinder head assembly. Install the gasket to the lower cover. Install the lower cover to the cylinder head assembly. Tightening torque： 13 N・m {1.3 kgf・m / 112 lb・in} ANNOTATION: • Tightening order
1 2 3 4 5 6 7 3.
No.1 injection No.2 injection No.3 injection No.4 injection No.5 injection No.6 injection Fuel pipe
pipe pipe pipe pipe pipe pipe
4.
Injector harness Installation 1)
ANNOTATION: • Tighten the bolts on the bracket and install the injector harness together with the bracket.
Lower cover Installation 1)
Install the injector harness to the cylinder head assembly.
Apply the liquid gasket to the rubber plug. ANNOTATION:
Tightening torque： 22 N・m {2.2 kgf・m / 16 lb・ft}
• Apply ThreeBond 1207B.
1 2 1 2
Rubber plug Liquid gasket
CAUTION • After applying the liquid gasket, install the lower cover within 5 minutes. 84402827B - May 2011 3005-6
Injector harness terminal Injector harness bracket
Removal and Installation of Injector 2)
Connect the injector harness to the injector. CAUTION • Be careful not to damage the injector side stud bolts.
1 2 3 3) 1 2 3 3)
5.
Injector Injector harness Terminal nut
4)
Cylinder head cover Head cover gasket Lower cover
Connect the ventilation hose to the air breather. Connect the water pipe bracket to the cylinder head cover. Tightening torque： 20 N・m {2.0 kgf・m / 14 lb・ft}
Install the connector to the lower cover. Tightening torque： 2 N・m {0.2 kgf・m / 18 lb・in}
Cylinder head cover Installation 1) 2)
Align the head cover gasket to the cylinder head cover. Install the cylinder head cover to the lower cover. Tightening torque： 13 N・m {1.3 kgf・m / 115 lb・in} ANNOTATION: • Referring to the tightening order in the diagram, temporarily tighten all bolts and then completely tighten them.
1 2 3 6.
Ventilation hose Water pipe bracket Clip
Engine harness Connect 1)
Connect the engine harness to the engine assembly. ANNOTATION: • Connect each connector.
7.
Battery ground cable Connect 1)
8.
Connect the battery ground cable to the battery.
Fuel Air bleed CAUTION • To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
84402827B - May 2011 3005-7
Removal and Installation of Injector 9)
Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
10)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
11) 12) 1 2 3 4 5
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION:
Priming pump Plug Drain plug Case Fuel filter element
• Wait for the specified time after operating the priming pump. 13)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION:
1) 2)
Prepare the pan. Turn ON the starter switch.
• Remove the air in the fuel filter. 14)
ANNOTATION: • This is for the models with an electromagnetic pump. 3) 4)
5) 6)
7)
8)
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} CAUTION
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more
• Remove the fuel around the plug thoroughly after tightening.
ANNOTATION:
15)
• Confirm that fuel comes out from around the plug.
16)
Operate the priming pump. Number of times： 10 count(s) Start the engine. ANNOTATION:
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more
• Do not accelerate the engine revolution right after staring.
ANNOTATION:
Specified time： 5 s
• Wait for the specified time after operating the priming pump.
ANNOTATION: • Accelerate the engine revolution gradually.
Specified time： 1 min Loosen the plug using the wrench.
Specified time： 3 min
ANNOTATION:
ANNOTATION:
• Remove the air in the fuel filter.
• Accelerate the engine revolution to maximum. • Lower the rotation.
Tighten the plug using the wrench.
84402827B - May 2011 3005-8
Section 4001A
Electrical and Engine Basic Functions
84402827B - May 2011
84402827B - May 2011
CONTENTS Monitor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Monitor Display Dimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Eco Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DPD Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Diagnostic Trouble Code Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Economy Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Neutral Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine Start/Stop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Idling Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Auto Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 One-touch Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Auto Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Quick Warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Idling Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Idle up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Travel Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Swing Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Static Horsepower Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Working Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Radio Mute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Back/Side View Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Swing Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Overload Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Swing Speed Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pressure Boost Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Free Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Energy saving / Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Swing Relief Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Stroke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Boom Down Energy Save. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Auto Energy Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Overload Reduction Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 End Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Breaker Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Crusher Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Anti-theft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 84402827B - May 2011 4001A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Enabling the anti-theft function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Immobilizer Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Pump Automatic Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Level Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPD Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Manual Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Assist Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 4001A-2
46 46 47 48 49 50 52 53 54 56 58 60 62
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Electrical and Engine Basic Functions Monitor Control Fuel Gauge Summary The fuel level is displayed as one of 9 levels, 0-8. When the fuel level reaches Level 1, a warning is issued. If the sensor breaks down, the level becomes 0. (When the sensor is normal, the Levels 1-8 are displayed.) Configuration
• The table below shows the correspondence between the fuel sensor % and the bar graph level. Lever angle [%] 100 83 67 50 33 17 1 0
Bar graph level 8 7 6 5 4 3 2 1
* Currently, the above settings are common to all models.
*1 *2 *3 *4 *5 *6 *7
Monitor Computer B Computer A Overhead Fuel sensor Reserve (1 hour of work) Fuel tank
Operation explanation • Computer A reads out the resistance of the fuel level sensor installed in the fuel tank and communicates it to the monitor. Resistance [Ω] 10 38 80
Fuel sensor [%] 100 50 0
• Refueling warning: When the gauge falls to Level 1, the "LOW FUEL" message is displayed on the monitor and the buzzer sounds for 5 sec.. • Monitor display: The following processing is used to prevent the monitor gauge from fluctuating due to fluctuation of the fuel surface. Sensor angle measurement period = 1 sec. Gauge update period = 5 sec. Gauge update judgment = Average of sensor angle for past 20 sec. (20 times) • Gauge display: For the work screen, an arc is displayed at the center of the screen. On the camera screen, displayed vertically on the right edge of the screen. • Trouble mode: If trouble occurs in the fuel level sensor, the fuel gauge itself is not displayed. If an abnormality occurs in monitor communication, the display will not update.
84402827B - May 2011 4001A-3
Electrical and Engine Basic Functions Coolant Temperature Gauge Purpose Displays the coolant temperature using a meter and bar graph.(Coolant temperature check)
1 2
Coolant temperature gauge Monitor
3 4
Computer A ECM
5 6
Coolant temperature sensor Engine
a b
Bar graph display Meter display
Operation explanation 1. 2. 3.
When the key is turned ON, the coolant temperature meter indicates the current coolant temperature range. When the camera screen select switch is pressed to switch to the camera screen, the coolant temperature bar graph is displayed on the left side. The meter and bar graph are not displayed if coolant temperature sensor trouble is detected.
Remarks The coolant temperature ranges are shown in the table below.
Temperature [°C] Lower than 50 50 77 82 97 100 102 105
Meter indicator angle [deg.] 0 - 15 15 58 66 90 118 137 165
84402827B - May 2011 4001A-4
Electrical and Engine Basic Functions Oil Temperature Gauge Purpose Displays the oil temperature on a meter.(Oil temperature check)
1 2
Oil temperature gauge Monitor
3 4
Computer A Hydraulic oil tank
5 6
Oil temperature sensor Hydraulic pump
a
Meter display
Operation explanation 1. 2. 3.
When the key is turned ON, the oil temperature meter indicates the current oil temperature range. When the camera screen select switch is pressed to switch to the camera screen, the oil temperature meter is not displayed. The meter is not displayed if oil temperature sensor trouble is detected.
Remarks The oil temperature ranges are shown in the table below.
Temperature [°C] Lower than 25 25 45 60 80 88 92 95 97 98
Meter indicator angle [deg.] 0 - 15 15 42 63 90 123 140 153 161 165
84402827B - May 2011 4001A-5
Electrical and Engine Basic Functions Monitor Display Dimming Purpose Adjusts the brightness of the backlight through operation that is linked to the working light and solar radiation sensor.
1 2
Monitor Computer A
3 4
Solar radiation sensor Working light switch a b
5
Working light relay
Dimming level automatic adjustment using the solar radiation sensor Working light-linked dimming using the working light relay
Operation explanation 1. 2.
When the operator turns the key ON, the monitor screen brightness is set to "brightness (day)". When the operator turns the working light ON, the monitor screen brightness is set to "brightness (night)" (= working light-linked dimming). • When working light-linked dimming is set to OFF on the rear screen, instead of using "brightness (night)" to adjust the monitor screen brightness when the working light is ON, the brightness is judged using the solar radiation sensor (= dimming level automatic adjustment). • The brightness when the working light is OFF is set to "brightness (day)" regardless of whether working lightlinked dimming is set to ON or OFF.
3.
The operator can set "brightness (day)" or "brightness (night)" in the menu screen. • The screen brightness setting is stored inside the monitor, so the setting is saved even if a computer is replaced.
84402827B - May 2011 4001A-6
Electrical and Engine Basic Functions Eco Gauge Purpose Displays on the monitor whether energy-saving operation is being performed.(Eco function)
1 2 3
Eco gauge Monitor Computer A
Operation explanation 1. 2.
The eco gauge is displayed on the monitor. The eco-saving performance is judged in levels from 0 to 9.(The higher the number, the better the eco performance.) In SP mode, the maximum is 4. In H mode, the maximum is 6. In A mode, the maximum is 8. In low idle, the maximum is 9.
84402827B - May 2011 4001A-7
Electrical and Engine Basic Functions DPD Gauge Purpose Displays an icon and bar graph on the monitor during DPD regeneration.
1 2 3
DPD gauge Monitor Computer A
Operation explanation 1.
DPD bar graph display conditions 1) 2)
2.
DPD amber lamp display condition 1)
3.
The DPD clogging level is displayed on the DPD bar graph during normal operation.(5-level display) When 5 white lamps are displayed, it indicates that the tank is full. The regeneration progress is displayed on the DPD bar graph during DPD regeneration (5-level display). The white lamps go off one by one, and when all have gone off, regeneration is complete. The amber lamp turns on and flashes during manual DPD regeneration.
DPD green lamp display condition 1)
The green lamp turns on and flashes during automatic DPD regeneration.
84402827B - May 2011 4001A-8
Electrical and Engine Basic Functions Diagnostic Trouble Code Indicator Purpose Displays a diagnostic trouble code (DTC) on the monitor when trouble occurs. (Makes troubleshooting easier)
1 2 3
Diagnostic trouble code Monitor Computer A
Operation explanation 1.
If trouble occurs, the "!" symbol and the diagnostic trouble code (DTC) are displayed in the top right of the monitor. • When multiple cases of trouble occur, they are displayed in turn at 5-second intervals. • At the same time, "ELEC. PROBLEM" and "CHECK ENGINE" are displayed. • Up to 8 items can be displayed.
2.
When the trouble is repaired, the diagnostic trouble code (DTC) goes off.
84402827B - May 2011 4001A-9
Electrical and Engine Basic Functions Clock Purpose Displays the time on the monitor. Operation explanation • The time is always displayed on the monitor. • The clock continues to operate, without display, when the key is turned OFF. (Because it uses power from the battery)
Fuel Economy Gauge Purpose Displays the fuel economy on the monitor.
1 2 3
Fuel economy gauge Monitor Computer A
Operation explanation 1. 2. 3.
The fuel economy gauge is displayed on the monitor after the key is turned ON. When trouble occurs, the fuel economy gauge goes off and the diagnostic trouble code is displayed. When the trouble is recovered from, the diagnostic trouble code goes off and the fuel economy gauge is displayed again.
84402827B - May 2011 4001A-10
Electrical and Engine Basic Functions Basic Operation Neutral Start Purpose The engine will not start with the gate lever lifted.(It will not crank.) This prevents accidental operation if the operation lever is touched when the engine is started. Configuration
1 2 3
Key switch Gate lock limit switch Starter motor
4 5 6
Starter cut relay Lever lock solenoid Battery relay
7 8 9
Operation explanation 1. 2. 3. 4.
Lower the gate lever. The starter cut relay is excited and the excitation to the safety relay is cut off. Engine cranking is prohibited. If the gate lever is then raised, cranking is enabled.
84402827B - May 2011 4001A-11
Starter relay Neutral start relay ECM
Electrical and Engine Basic Functions Engine Start/Stop Control Purpose Engine starting and stopping
1 2
Computer A Cam sensor
3 4
Crank sensor ECM
5 6
Speed Engine
Operation explanation 1. 2. 3. 4.
Start the engine. When the engine speed rises to 500 min-1 or higher, engine start is judged. Stop the engine. When the engine speed drops to less than 200 min-1, engine stop is judged.
a b
Start 500 min-1
84402827B - May 2011 4001A-12
c d
200 min-1 Stop
Electrical and Engine Basic Functions Preheating Purpose Before cranking, the insides of the engine cylinders are automatically heated to improve starting.(Warm-up operation)
1 2
Key switch Computer A
3 4
ECM Engine
5
Coolant temperature sensor
Operation explanation 1. 2. 3. 4. 5.
Turn the key ON. When the key is turned ON, the pre-glow time is calculated based on the current coolant temperature. At the same time, the glow relay is excited and the glow lamp is turned on. After pre-glow is completed, the glow lamp goes off and the operator is prompted to begin cranking. Perform cranking to start the engine. When engine start and cranking stop are recognized, the after-glow time is calculated from the current coolant temperature.
84402827B - May 2011 4001A-13
Electrical and Engine Basic Functions Throttle Purpose Indicates the target engine speed.
1 2
Monitor Computer A
3 4
Throttle volume ECM
5
Engine
a
Icon
Operation explanation 1. 2. 3.
Turn the key ON. The target engine speed is calculated based on the throttle VOL voltage signal. An icon that indicates the work mode is displayed on the monitor.
84402827B - May 2011 4001A-14
Electrical and Engine Basic Functions Idling Start Purpose When the engine starts, the engine speed starts in low idle regardless of the throttle volume position.(Warm-up operation, engine protection)
1 2 3
Throttle volume Computer A One-touch idle switch
4 5 6
Pressure sensor (upper) Pressure sensor (swing) Pressure sensor (travel)
7 8
Pressure sensor (option 1) Pressure sensor (option 2)
Operation explanation 1. 2.
Idling start operation condition Because idling start is a warm-up operation, it operates when the engine is started. Idling start end conditions The operation ends under the following conditions. 1) 2) 3)
When an operation lever is operated.(When one of the following pressure sensors is turned ON: upper, swing, travel, option 1, or option 2) When the throttle volume is operated. When the one-touch idle switch is pressed.
84402827B - May 2011 4001A-15
Electrical and Engine Basic Functions Auto Idle Purpose Automatically put the engine into an idling state (1200 min-1) when the machine is not being operated. (Energy saving)
Monitor display Computer A Engine ECM
1 2 3 4
5 6 7 8
One-touch idle switch Throttle volume Pressure sensor (option 1) Pressure sensor (option 2)
9 10 11
Pressure sensor (upper) Pressure sensor (swing) Pressure sensor (travel)
Operation explanation 1.
Operation conditions for auto idle Operation starts when all the conditions below are satisfied. 1) 2)
2.
The auto idle mode switch is pressed, turning the auto idle mode ON. An operating lever is not operated for a continuous period of 5 sec. (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for a continuous period of 5 sec.)
End conditions for auto idle Operation ends under the following conditions. 1) 2) 3)
An operation lever is operated during auto idle. (The upper, swing, travel, option 1, or option 2 pressure sensor is ON.) The throttle volume is operated. The one-touch idle switch is pressed.
84402827B - May 2011 4001A-16
Electrical and Engine Basic Functions One-touch Idle Purpose Reduces the engine speed when the one-touch idle switch is pressed. (Energy saving)
1 2 3 4
Monitor display Computer A Engine ECM
5 6 7 8
One-touch idle switch Throttle volume Pressure sensor (option 1) Pressure sensor (option 2)
9 10 11
Pressure sensor (upper) Pressure sensor (swing) Pressure sensor (travel)
Operation explanation 1. 2.
Operation conditions for one-touch idle When the one-touch idle switch is pressed. End conditions for one-touch idle When the one-touch idle switch is pressed once more after the one-touch idle switch is pressed and the engine has gone into low idle.
84402827B - May 2011 4001A-17
Electrical and Engine Basic Functions Auto Warm Up Purpose Incrementally raises the engine speed if the coolant temperature is low when the engine starts. 1. 2.
Operation conditions for auto warm up Auto warm up operates if the coolant temperature is less than 50°C when the engine starts. Summary The engine speed increases incrementally as shown in the diagram. 1) 2) 3) 4)
a b c 3.
Low idle; 5 min. 1200 min-1; 3 min. 1500 min-1; 3 min. SP mode; 3 min.
5 min. 3 min. 3 min.
d e f
3 min. SP mode 1500 min-1
g h
1200 min-1 Low idle
End conditions for auto warm up Auto warm up is ended and operation shifts to idling start under the following conditions. 1) 2) 3) 4)
Coolant temperature is 50°C or more. The one-touch idle switch is pressed. The entire auto warm up process has ended (after 14 min.). An operation lever is operated (upper, swing, travel, option 1, option 2 pressure sensor is ON).
84402827B - May 2011 4001A-18
Electrical and Engine Basic Functions Quick Warm-up Summary When the engine starts up, if the outside air temperature is low, a hydraulic load is put on to warm up the engine. Configuration
*1 *2 *3 *4 *5
Key switch Pump flow proportional valve (on hydraulic pump) Boom 2 proportional valve Color monitor Computer B
*6
Computer A
*11 Option pressure switch
*7
ECM
*12 2nd option pressure switch
*8 Upper pressure sensor *9 Swing pressure sensor *10 Travel pressure sensor
*13 Coolant temperature sensor *14 Suction air temperature sensor
Operation explanation 1.
When the following conditions are all detected, quick warm-up starts. The engine must be starting up. The engine must not be warming up (Step 1: low idle 5 minutes). The machine must not be operating (upper, swing, travel, option 1, or option 2). The outside air temperature must be -15°C. The coolant temperature must be between 0 and 80°C. There must not be any sensor abnormality (P1, upper, swing, travel, option (1 or 2), coolant temperature, outside air temperature. • DPD regeneration must not be underway. • • • • • •
2. 3. 4. 5.
This control can be disabled with the Setup/Parameters screen. When the engine starts, the speed incrementally increases according to the diagram below if the coolant temperature is < 50°C. (If the coolant temperature is 50°C, a normal idling start occurs.) When the quick warm-up starts, the system sets the pump flow proportional valve to the minimum flow (Current 740 mA). After 1 sec., the system sets the boom 2 proportional valve current to 540 mA. An icon that indicates the start of quick warm-up is displayed on the monitor for 2 sec.. 84402827B - May 2011 4001A-19
Electrical and Engine Basic Functions 6.
7.
After 1 sec., if the system detects event (a) below for 20 sec. or longer, it raises the boom 2 proportional valve target current at a pace of 2 mA/20 sec.. When event (b) is detected, the system sets the boom 2 proportional valve target current to 540 mA. Also, if no event is detected, the system holds the boom 2 proportional valve target current in its current state. (a) P1 pressure < 10 MPa (b) P1 pressure > 15 MPa If the system does not detect either of the above two conditions, it ends or stops quick warm-up.
84402827B - May 2011 4001A-20
Electrical and Engine Basic Functions Idling Stop Purpose Automatically stops the engine after a certain time has passed. (Energy saving)
1 2
Monitor Computer A
3 4
Engine Idle stop relay
5 6
One-touch idle switch Throttle volume
Operation explanation 1.
Operation conditions for idle stop mode Idle stop operates after performance of 1 through 3. 1) 2) 3)
The auto idle stop switch is pressed, switching on the idle stop mode. If the gate lever is raised, the engine speed is less than 1200 min-1, and the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period of 15 sec., an alarm displays on the monitor screen and a buzzer sounds. After another 3 min., the idle stop relay turns ON and the engine stops. * To restart, the key is switched OFF, and cranking is performed to start the engine. * If a restart is not performed, the key is to be switched OFF.
2.
Operations conditions for idle stop and auto idle mode Idling stop operates after performance of 1 through 4. 1) 2) 3) 4)
The auto idle stop switch is pressed, switching on the idle stop mode. If the operation lever is not operated for a continuous period of 5 sec., the engine speed is reduced to 1200 min-1. (The upper, swing, travel, option 1, and option 2 pressure sensor are OFF for a continuous period of 5 sec.) If the throttle volume, auto idle switch and one-touch idle switch are not operated for a continuous period of 3 min., an alarm displays on the monitor screen and a buzzer sounds. After another 3 min., the idle stop relay turns ON and the engine stops.
* To restart, the key is switched OFF, and cranking is performed to start the engine. * If a restart is not performed, the key is to be switched OFF.
84402827B - May 2011 4001A-21
Electrical and Engine Basic Functions Idle up Purpose Raises the engine speed and maintains mechanical speed.
1 2
1.
Throttle volume Computer A
Pressure sensor (travel) ECM
Operation conditions for idle up Operation starts when all the conditions below are satisfied. 1)
2.
3 4
Travel operation is performed. (Travel pressure sensor ON)
End conditions for idle up Operation ends under the following conditions. 1) 2)
The work mode is a mode other than SP mode. A travel operation is not performed.
84402827B - May 2011 4001A-22
5
Engine
a
Engine speed
Electrical and Engine Basic Functions Travel Speed Selection Purpose The travel motor tilting angle is changed by switching the travel speed between low speed and high speed with the switch. (Travel speed switchover)
1
Computer A
3
2
Travel 2-speed switchover so4 lenoid
Travel motor
5
Travel 2-speed switchover solenoid
Monitor
Operation explanation 1. 2. 3.
When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the monitor goes to low speed. When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel mode icon on the monitor goes to high speed. When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the monitor goes to low speed.
* Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low speed due to a travel motor function if the travel motor drive pressure becomes high. However, the travel 2-speed switchover solenoid is ON.
84402827B - May 2011 4001A-23
Electrical and Engine Basic Functions Swing Brake Purpose The swing brake is turned OFF when either the upper or swing is operating. (Operational ability is increased)
1 2 1.
Computer A Pressure sensor (upper)
3 4
Pressure sensor (swing) Swing brake solenoid valve
5
Swing brake
Operation conditions for swing brake Operation starts under the following conditions. 1)
An upper operation is not being performed. (Upper pressure sensor OFF) * The swing brake is applied 1 sec. after the upper pressure sensor turns OFF.
2)
A swing operation is not being performed. (Swing pressure sensor OFF) * The swing brake is applied 5 sec. after the swing pressure sensor turns OFF.
2.
End conditions for swing brake Operation ends under the following conditions. 1) 2)
An upper operation is performed. (Upper pressure sensor ON) A swing operation is performed. (Swing pressure sensor ON)
84402827B - May 2011 4001A-24
Electrical and Engine Basic Functions Static Horsepower Control Purpose Monitor the engine actual speed and the engine target speed and set the appropriate amount of horsepower. (Engine stop prevention, energy saving)
1 2 3
Hydraulic pump Horsepower control tional valve Computer A
propor-
7
4
ECM
5
Engine
6
Engine speed sensor a b
Pressure sensor (travel)
Engine target speed Discharge volume fluctuation
Operation Explanation 1. 2. 3. 4. 5.
The minimum milli-amp and maximum milli-amp is selected from the milli-amp set for each engine speed. When the engine actual speed falls 30/min or more below the target engine speed, the milli-amp is gradually lowered to the minimum. When the engine actual speed is not 30/min or more below the target engine speed, the milli-amp is gradually raised to the maximum. When the engine speed is at a low speed, the milli-amp decreases. When the engine speed is increasing after being at a low speed, the milli-amp increases.
84402827B - May 2011 4001A-25
Electrical and Engine Basic Functions Accessories Working Light Purpose Press the working light switch to turn the working light on.(To improve visibility during night work.)
1 2
Monitor Computer A
3 4
Working light relay Working light switch
Operation explanation 1. 2. 3.
When the key is turned ON, the working light is OFF. When the working light switch is pressed, the working light relay turns ON, and the working light icon on the monitor turns ON. The boom light and cab light turn on. When the working light switch is pressed again, the working light relay turns OFF, and the working light icon on the monitor turns OFF. The boom light and cab light turn off.
84402827B - May 2011 4001A-26
Electrical and Engine Basic Functions Radio Mute Purpose Enables the radio volume to be turned ON or OFF with a one-touch operation.
Operation explanation 1. 2.
Each time the radio mute switch (1) is pressed, the radio volume is switched between ON Ă&#x203A; OFF. When the key is switched ON, the radio always starts with mute off (normal radio volume).
84402827B - May 2011 4001A-27
Electrical and Engine Basic Functions Safety Engine Emergency Stop Purpose Stops the engine in an emergency.
1 2
Computer A Engine
3 4
Engine emergency stop switch ECM
Operation explanation 1. 2.
If an emergency occurs while the engine is running, press the emergency stop switch. When the ECM and computer A detect that the emergency stop switch is ON, the engine is stopped.
* To restart, make sure that the emergency stop switch is OFF, and then start cranking the engine.
84402827B - May 2011 4001A-28
Electrical and Engine Basic Functions Travel Alarm Purpose The travel alarm sounds when a travel operation is performed.(Safety function)
1 2 3
84402827B - May 2011 4001A-29
Computer A Travel pressure sensor Travel alarm
Electrical and Engine Basic Functions 1.
Operation conditions for travel alarm The operation starts under the following conditions. 1)
2.
When a travel operation is being performed.(Travel pressure sensor ON)
End conditions for travel alarm The operation ends under the following conditions. 1) 2)
When the travel operation is stopped. When 10 sec. or longer elapses while a travel operation is being performed.
a b c
84402827B - May 2011 4001A-30
Travel alarm Pressure sensor (travel) 10 sec.
Electrical and Engine Basic Functions Back/Side View Monitor Purpose Displays an image on the monitor from the camera that is installed on the shovel.(Improves rear visibility. Improves safety)
1 2
Monitor Camera screen switch
3 4
Camera select switch Rear camera
5
Side camera
a
Options
Operation explanation 1.
When the key is turned ON, the camera screen can be viewed by pressing the camera screen switch. • Each time the camera screen switch is pressed, the screen alternates between the work screen and the camera screen. • In the camera screen, only the minimum required icons and gauges are displayed.
2.
When the camera select switch is pressed in the camera screen, the screen display can be selected in the order of rear → side → rear + side → rear. • To perform camera selection, camera ON must be set in the camera setting screen. • The camera select switch is enabled when multiple cameras are set. The switch does not respond if there is only 1 rear camera.
3.
If image interruption due to camera trouble (disconnection, etc.) is detected, the camera screen turns black and ERROR is displayed.
* When the camera select switch is pressed in the work screen, the trip meter select switch function is activated. * The camera screen switch is disabled if no cameras are mounted.
84402827B - May 2011 4001A-31
Electrical and Engine Basic Functions Swing Lock Purpose Turns the swing brake ON.
1 2 3
Monitor Working light switch Auto idle switch
4 5 6
Travel speed select switch Computer A Swing brake solenoid
7
Swing brake
Operation explanation 1.
Operation conditions for swing lock 1)
Hold down the travel speed select switch, working light switch and auto idle switch at the same time for 3 sec.
* When the swing lock is ON and the key is OFF.Then, when the key is turned ON again, the swing lock stays ON. * When the swing lock and free swing are both ON, the swing lock is prioritized. * When the swing lock is ON, the swing lock icon is displayed on the monitor. * Even when an attachment operation or swing operation is performed while swing is ON, swing lock ON is prioritized.(Be careful because if the swing operation is performed in this condition, the swing brake plate will be dragged.) 2.
End conditions for swing lock 1)
While the swing lock is ON, hold down the travel speed select switch, working light switch and auto idle switch at the same time for 3 sec.
84402827B - May 2011 4001A-32
Electrical and Engine Basic Functions Overload Warning Summary Overload warning device for lifting work with shovel If the bottom pressure of the boom cylinder exceeds the stipulated pressure, it is judged that there is a danger of the machine falling over and the monitor buzzer sounds (overload warning). Configuration
*1 *2
Overload switch Color monitor
*3 *4
Computer B Computer A
*5
Overload pressure sensor
Operation explanation 1.
When the overload switch is turned ON, the buzzer sound starts and stops according to the conditions below. When the overload switch is OFF, the buzzer does not sound. 1) 2)
2.
Overload warning start: The boom bottom pressure is greater than or equal to the set pressure continuously for 1 sec. Overload warning stop: The boom bottom pressure is less than or equal to the set pressure -2 MPa continuously for 1 sec.
The alarm pattern is a 1-second cycle - ON for 0.5 sec. and OFF for 0.5 sec.
*1 *2 3.
Overload switch Boom bottom pressure
Display: The warning is only given with the monitor buzzer. The lamps etc. do not illuminate. 84402827B - May 2011 4001A-33
*3 *4
Monitor buzzer Set pressure
Electrical and Engine Basic Functions Operability Swing Speed Limit Purpose When the pump flow rises during a swing operation, the swing speed increases. To prevent this, control of the pump flow is performed.(Swing speed control)
1
Computer A
5
Pressure sensor (N1)
9
2
Throttle volume
6
Pressure sensor (N2)
10
3 4
Pressure sensor (travel) Pressure switch (option 1)
7 8
Pressure sensor (P1) Pressure sensor (P2)
a b c
Arm (1) Boom (2) Swing
d e f
Option 1 Travel (left) Arm (2)
g h i
Regulator P1 flow control proportional valve
Boom (1) Bucket Travel (right)
Operation explanation 1.
Operation conditions for swing speed limit control Control is executed when all the conditions below are satisfied. 1) 2) 3)
2.
Independent swing operation (swing pressure sensor ON) When travel or option operations are not being performed (travel and option pressure sensors OFF) Work mode is SP or H mode(except CX350C/CX370C/350X3)
Swing speed limit end conditions The operation ends under the following conditions. 1) 2)
Ends immediately after a travel or option operation is performed (travel or option pressure sensor ON). Ends gradually after an attachment operation is performed (upper pressure sensor ON).
84402827B - May 2011 4001A-34
Electrical and Engine Basic Functions Pressure Boost Control Purpose Raises the relief pressure.(Increases the digging force)
1 2 3 4 5
Computer A Engine Pressure sensor (upper) Pressure sensor (travel) Pressure sensor (option 1)
6 7 8 9 10
Pressure sensor (option 2) Control valve Main relief valve Pressure boost solenoid P1 pressure sensor
84402827B - May 2011 4001A-35
11 12 13 14 15
P2 pressure sensor Pump Monitor Regulator ECM
a b
Pressure boost icon Engine load ratio
Electrical and Engine Basic Functions Operation explanation 1.
Operation conditions for pressure boost control (SP or H mode) The operation starts when all the following conditions are satisfied. 1) 2)
2.
When high-load work is being performed (P1 or P2 is high pressure, upper pressure sensor ON, swing pressure sensor OFF) When the work mode is SP or H mode.
End conditions for pressure boost control (SP or H mode) The operation ends under the following conditions. 1)
When 8 sec. or longer elapses after starting the pressure boost (pressure boost time expires) * When the pressure boost time expires, pressure boost is not performed again unless the operation lever is returned one time to neutral.
2) 3)
When an attachment operation is not performed (upper pressure sensor OFF) When a travel or option operation is performed (travel or option pressure sensor ON) * Pressure boost is not performed to protect the travel and option circuits.
3.
Operation conditions for pressure boost control (A mode) When the work mode is A mode, pressure boost is performed for the lifting work. * When a travel or option operation is performed in A mode, the pressure boost is continued.
4.
Time chart (when work mode = SP or H)
a
Pressure boost solenoid valve d
b
High-load work
e
c
Pressure sensor (upper)
f
g Icon Pressure sensor (travel) and/or pressure sensor (option) 8 sec.
84402827B - May 2011 4001A-36
Less than 8 sec.
Electrical and Engine Basic Functions Free Swing Purpose Prevents swinging of the suspended load while swinging is stopped during lifting work.
1 2
Free swingďź&#x2C6;Locker switchďź&#x2030; Computer A
3 4
Monitor Free swing solenoid valve
Operation explanation 1.
Operation conditions for free swing 1)
When the free swing switch is pressed. * The free swing is disabled during a swing lock. * The free swing icon is displayed on the monitor.
2.
End conditions for free swing 1)
When the free swing switch is pressed during free swing.
84402827B - May 2011 4001A-37
5 6
Swing motor Control valve
a
Free swing icon
Electrical and Engine Basic Functions Energy saving / Noise Swing Relief Cut Purpose When independent swing operation is running, the pump flow is reduced, and the excess oil ejected from the swing motor relief valve is eliminated.
1 2
Computer A Oil temperature sensor
4 5
Pressure sensor (option 1) Pressure sensor (N2)
7 8
3
Pressure sensor (travel)
6
Pressure sensor (P1)
9
a b c
Arm (1) Boom (2) Swing
d e f
Option 1 Travel (left) Arm (2)
g h i
Pressure sensor (P2) Regulator P1 flow control proportional valve Boom (1) Bucket Travel (right)
Operation explanation 1.
Operation conditions for swing relief cut The operation starts when all the conditions below are satisfied. Oil temperature is 30°C or higher 1) 2) 3)
2.
When a swing operation is performed. (Swing pressure sensor ON) Within 1 sec. after start of swing When travel or option operations are not being performed.(Travel and option pressure sensors OFF)
Swing relief cut end conditions 1) 2)
When a swing operation is not being performed.(Swing pressure sensor OFF) When a travel or option operation is performed.(Travel or option pressure sensor ON)
84402827B - May 2011 4001A-38
Electrical and Engine Basic Functions Stroke Control Summary In order to improve fuel efficiency, the pump pressure is lowered by reducing the orifice loss. A 3-stack proportional valve is used for control. Arm 2 control 1. 2.
In normal operations, flow volume loss is reduced by suppressing the spool opening for Arm 2. In the second half of leveling work, the spool opening is opened to reduce P2-arm bottom pressure loss and to give priority to the arm for flow volume, thus suppressing flow volume loss. Configuration • The larger the proportional valve output current, the more the secondary pressure output is suppressed.
*1
P2 pressure sensor
*4
*2
Travel pressure sensor
*5
*3
Computer A
*6
Computer B *7 Arm-in reverse proportional *8 valve Boom-up pressure sensor
Arm-in pressure sensor Bucket-close pressure sensor
Operation explanation 1. 2.
The operator operates the shovel. When the system detects the events below, it judges that this is the start of leveling. • When any of the following conditions is established the instant that arm-in operation becomes full • Boom-up lever operation is at half lever. • The boom-up and bucket-close levers are operated at the same time.
3. 4.
When the system judges leveling to be starting, it releases the restriction on Arm 2. If the events below occur when the system does not judge leveling to be starting, it releases the restriction on Arm 2. When that is not the case, it restricts Arm 2. • Boom-up lever operation is at half lever.
5. 6.
The operator stops arm-in full operation or travels. The system restricts Arm 2. * When Arm 2 is released from the restricted state, it is released gradually as a measure against shock from the restriction release.
Boom 2 control In leveling work, the boom spool is pressed back to reduce P1-arm bottom pressure loss and to allow more flow to the arm and bucket. Configuration • When the output current is raised, the force pushing back the spool is increased.
84402827B - May 2011 4001A-39
Electrical and Engine Basic Functions
*1 *2 *3
Boom-up proportional valve Travel pressure sensor Computer A
*4 *5 *6
Computer B Boom-up pressure sensor Arm-in pressure sensor
*7
Bucket-close pressure sensor
Operation 1. 2.
The operator operates the shovel. When the system detects the events below, it judges that this is the start of leveling. • When any of the following conditions is established the instant that arm-in operation becomes full • The boom-up lever operation is at half lever. • The boom-up and bucket-close levers are operated at the same time.
3.
If the system detects any of the events below when the system judges leveling to be starting, it issues the Boom-2-down proportional valve instruction. • The boom-up lever operation is at half lever. • During bucket-close operation
4. 5. 6.
When the system does not judge leveling to be starting, it does not issue the Boom-2-down proportional valve instruction. The operator stops arm-in full operation or travels. The system stops the Boom-2-down proportional valve instruction. * When the Boom-2-down proportional valve instruction changes, as a measure against vibration, the Boom2-down proportional valve command current value is lowered gradually (for both ON→OFF and OFF→ON).
Bucket control Mostly in the second half of leveling and when collecting dirt and sand during digging, the spool opening is opened so that a larger volume can flow. Configuration The larger the output current, the more the secondary pressure output is suppressed.
*1
Travel pressure sensor
*4
*2 *3
Computer A Computer B
*5 *6
Bucket-close reverse propor*7 tional valve Boom-up pressure sensor Arm-in pressure sensor 84402827B - May 2011 4001A-40
Bucket-close pressure sensor
Electrical and Engine Basic Functions Operation explanation 1. 2.
The operator operates the shovel. If any of the events below occurs, the system outputs current restricting the bucket secondary pressure. • Not arm-in full operation • The boom-up operation is not at half lever. • During travel
84402827B - May 2011 4001A-41
Electrical and Engine Basic Functions Boom Down Energy Save Purpose Reduces the engine speed during swinging (except during lift swinging).
1 2 3
Computer A ECM Engine
4 5 6
Pressure sensor (P1) Pressure sensor (P2) Pressure sensor (N2)
7 8 9
Pressure sensor (swing) Pressure sensor (upper) Throttle volume
a
Engine speed control
Operation explanation 1.
Operation conditions for boom down energy save The operation starts when all the conditions below are satisfied. 1) 2)
2.
When the work mode is H mode or lower. When the boom down and swing operation is performed.Or when the swing operation is performed.
End conditions for boom down energy save The operation ends when all the conditions below are satisfied. 1) 2)
When the work mode is SP mode. When an operation other than boom down and swing is performed.Or when an operation other than swing is performed.
* When control is established at the same time as auto energy save, the control that reduces the engine speed the most is prioritized.
84402827B - May 2011 4001A-42
Electrical and Engine Basic Functions Auto Energy Save Purpose Reduces the engine speed when machine operations are not being performed.(Energy saving)
1 2 3
Computer A ECM Engine
4 5 6
Pressure sensor (P1) Pressure sensor (P2) Pressure sensor (N2)
7 8
Pressure sensor (swing) Pressure sensor (upper)
a
Engine speed control
Operation explanation 1.
Operation conditions for auto energy save. 1)
2.
When a machine operation is not being performed.
End conditions for auto energy save. 1)
When a machine operation is performed.
* When control is established at the same time as boom down energy save, the control that reduces the engine speed the most is prioritized.
84402827B - May 2011 4001A-43
Electrical and Engine Basic Functions Overload Reduction Control Purpose Prevents reductions in the engine speed by detecting sharp attachment operations and sharp loads during operation. (Lowers the pump milli-amp and prevents reductions in the engine speed.) Operation explanation 1.
Operation conditions for transient load reduction control The milli-amp of the pump horsepower proportional valve is temporarily reduced under the following conditions. 1) 2)
2.
When a sharp attachment operation is performed. (Judged from the upper pressure sensor pressure boost state.) When there is a sharp load during operation. (Judged from the main pressure boost state of the P1 or P2 pressure sensor.)
End conditions for transient load reduction control The milli-amp of the pump horsepower proportional valve is restored under the following conditions. 1) 2)
When a sharp attachment operation is not being performed. (Judged from the upper pressure sensor pressure boost state.) When there is no sharp load during operation. (Judged from the main pressure boost state of the P1 or P2 pressure sensor.)
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Electrical and Engine Basic Functions End Attachment Breaker Mode Purpose Maximum flow and maximum pressure settings can be set for each breaker used for up to 5 breakers.(Available for models with an electromagnetic proportional relief valve only.) Operation explanation 1.
The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher mode → normal mode each time the attachment select switch is pressed. The maximum flow for the mode that has been switched to will display on the indicator for 2 sec. * In the default state, there is only 1 breaker mode, but more can be added in the flow setting screen.
2.
The breaker can be used when breaker mode is selected. * Set the maximum flow and maximum pressure in the flow setting screen first. * If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3.
The suitability of the flow volume to the breaker will be judged. If the acceptable flow volume has been exceeded, the message “CHECK FLOW RATE” will display. * This message only displays during breaker operation. The display ends if operation is stopped.
4.
The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode that was selected.
Crusher Mode Purpose Maximum flow and maximum pressure settings can be set for each crusher used for up to 5 crushers.(Available for models with an electromagnetic proportional relief valve only.) Operation explanation 1.
The mode is switched from one mode to the next in the sequence normal mode → breaker mode → crusher mode → normal mode each time the attachment select switch is pressed. The maximum flow for the mode that has been switched to will display on the indicator for 2 sec. * In the default state, there is only 1 crusher mode, but more can be added in the flow setting screen.
2.
The crusher can be used when crusher mode is selected. * Set the maximum flow and maximum pressure in the flow setting screen first. * If 2 pumps flow is necessary at the set flow volume, 2 pumps flow will be used.
3.
When an arm in + crusher operation is performed, milli-amp control will be performed so that the arm-in operation will not be performed with 2 pumps flow. * This is to prevent crusher operation from being stopped.
4.
The next time the key is switched OFF and then ON again, the machine will be set to the last attachment mode that was selected.
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Electrical and Engine Basic Functions Maintenance Anti-theft Enabling the anti-theft function With the key OFF, connect the anti-theft knob terminal. When the male and female knob terminals are connected on the cab main harness in the rear cover, the anti-theft function is enabled. The factory setting is for these knob terminals to be disconnected. Anti-theft setting knob Connect VG (purple / green) and BG (black / green)
Password Purpose Locks the machine if is operated without authorization. (Anti-theft) Operation explanation 1. 2.
When the anti-theft function is ON, turn the key ON. Enter the correct password at the password input screen. * If an incorrect password is input, "ERROR" is displayed and the buzzer buzzes. If the correct password is then input, the lock is released.
3.
The machine lock is released and the normal screen is displayed. * If the “ERROR” message is ignored and the engine is started, the machine will lock. Machine lock conditions • The engine speed is fixed at low idle. • The swing brake cannot be released. • The travel alarm buzzes continuously. * In addition, if the operator tries to operate the machine in the machine lock state, the engine will be stopped. Machine operation judgment conditions • The P1 or P2 pressure rises to 5 MPa or higher. • The engine load ratio is 50 % or higher for 2 sec. cumulative. • The upper, travel, P1, or P2 pressure sensor is removed. 84402827B - May 2011 4001A-46
Electrical and Engine Basic Functions Immobilizer Key Purpose Prevents starting of the engine with keys other than the designated key. (Anti-theft) Operation explanation • When the key is switched ON, the immobilizer computer performs verification of the key. • If the key is verified as the designated key, cranking is performed. • If the key is not verified as the designated key, cranking is not performed. * At this time, cranking will not be performed even if the key is turned up to ST.
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Electrical and Engine Basic Functions Feed Pump Automatic Stop Summary The feed pump power supply is controlled and when the fuel tank is full (Level 8), the fuel feed is automatically stopped. Configuration
*1 *2
Monitor FUEL PUMP RL
*3 *4
FUEL PUMP STOP RL FUEL PUMP
*5
BUZZER
Operation explanation The fuel pump rocker switch has three positions: Manual, OFF, and Auto. â&#x20AC;˘ Auto mode The switch is the toggle type. When it comes ON, the fuel feed starts. When the fuel tank angle sensor reaches the full level (Level 8), the monitor relay is driven and the feed pump power is switched OFF. In place of that, the relay buzzes the buzzer to announce that the automatic feed has ended. To silence the buzzer, the rocker switch must be switched to OFF or Manual. â&#x20AC;˘ Manual mode The switch is the momentary type. The feed pump only drives fuel feed while the switch is pressed.
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Electrical and Engine Basic Functions Coolant Level Drop Summary If the engine coolant level drops, the low coolant level warning is issued. Configuration
*1 *2
Reserve tank Coolant level switch
*3 *4
Computer A Computer B
*5 *6
Monitor Buzzer
Operation 1.
The radiator reserve tank level switch is detected and an warning is issued. • SW ON: 0.33 - 0.53 L
2.
When the monitor receives the level drop signal, it carries out the following operation. • Message: "LOW COOLANT" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. • Diagnostic Trouble Code: "7423" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. • Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automatically stops after 5 sec.
3.
When 3 sec. have passed after the coolant level switch was detected going OFF, the low coolant level alarm stops, the "LOW COOLANT" message goes off, and the buzzer stops.
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Electrical and Engine Basic Functions Hydraulic Oil Filter Clog Summary If the hydraulic oil filter clogs, a warning is issued. Configuration
*1
Monitor
*4
*2
Computer B
*5
*3
Computer A
*6
Breaker mode switch *7 Breaker/crusher (1st option) *8 pedal Hydraulic oil filter clog switch
Hydraulic oil tank 1st option pressure switch
Operation explanation If clogging occurs in the return filter inside the hydraulic tank, a message is displayed on the monitor giving the diagnostic trouble code and the warning buzzer sounds. (For breaker, multi-purpose machines only) 1. 2.
Configuration: When the clog detection pressure switch goes open, Computer A detects the clog and sends a command to the monitor. Clog detection: Starts 10 sec. after the engine starts. When the clog switch contact opens, Computer A detects this. If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged. However, detection does not occur in the following cases. • During breaker operation: Because pulsation is severe (In other words, no warning is issued while the breaker is operating.) • When the oil temperature is less than 30°C: Because the hydraulic oil viscosity is high and accurate detection is not possible. • When the clog detection switch is broken: For details, see the sections below.
3.
Warning: When the monitor receives the filter clog command, it carries out the following operation. • Message: "RETURN FILTER" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. • Diagnostic Trouble Code: "7423" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. 84402827B - May 2011 4001A-50
Electrical and Engine Basic Functions â&#x20AC;˘ Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automatically stops after 5 sec. 4.
5.
Clog switch trouble detection: Before engine starting, the contact point of the clog detection switch should be closed (B contact point). However, if the circuit is open (continuously for 1 sec.), it is judged that the clog detection switch is disconnected, the "Electrical system abnormality" message and diagnostic trouble code "7063" are displayed, and the buzzer sounds for 5 sec.. Time chart:
*1 *2
1st option pressure switch Hydraulic oil filter clog switch
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*3 *4
Message trouble card Monitor buzzer
Electrical and Engine Basic Functions Air Filter Clog Summary If clogging occurs in the air cleaner filter, a message is displayed on the monitor giving the diagnostic trouble code and the warning buzzer sounds. Configuration
*1 *2
Color monitor Computer B
*3 *4
Computer A Clog sensor
*5 *6
Barometric pressure Air cleaner
Operation explanation 1. 2. 3. 4.
When the clog detection pressure switch comes ON, Computer A detects the clog and sends a command to the monitor via Computer B Clog detection starts 10 sec. after the engine starts. When the clog switch comes ON, Computer A detects this. If the contact point is ON continuously for 1 sec., the return filter is judged to be clogged. When the monitor receives the filter clog command, it carries out the following operations. • Message: "AIR FILTER" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. • Diagnostic Trouble Code: "7424" is displayed. Even after the coolant level is restored to normal, the "LOW COOLANT" message remains displayed while the key is ON. • Monitor buzzer: The buzzer sounds at the same time that the message is displayed and the buzzer automatically stops after 5 sec.
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Electrical and Engine Basic Functions Fuel Filter Clog Summary If the fuel filter clogs, a warning is issued. There are 2 types of clogs: Stage 1 and Stage 2. Configuration
*1 *2
Color monitor Buzzer
*3 *4
Computer B Computer A
*5 *6
ECM Fuel filter clog sensor
Operation explanation 1.
Turn the key ON. • Control is performed by Computer A and is displayed on the monitor via Computer B.
2.
When the system detects the following, it issues the fuel filter clog warning. • The fuel filter clog signal from the ECM is ON continuously for 5 sec. or longer. • The clog is judged by the ECM and only the results are sent to the computer via the CAN. • The signal is sent with values of 0-2. Signal numeric value 0 1 2
3.
Meaning No clog Clog stage 1 Clog stage 2
Sensor pressure
Error code
-30 kPa max. -40 kPa max.
7426 7427
A message is displayed and the buzzer sounds. • The "FUEL FILTER CLOG" warning message is displayed on the monitor. • The buzzer sounds.
4.
Engine protection When a 2nd stage clog (40 kPa max.) occurs, the engine speed is fixed to 1700 min-1.
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Electrical and Engine Basic Functions DPD Regeneration Purpose The DPD (Diesel Particle Diffuser) is a device that purifies particulate matter (PM) from exhaust gases. Particulate matter is collected in the DPD filter, and when a certain amount has accumulated, that particulate matter is automatically combusted to regenerate the filter. During normal work, the amount of PM accumulated is displayed on the DPD gauge. Configuration
*1 *2 *3 *4
ECM CONT_A CONT_B MONITOR
*5 *6 *7 *8
DPD SW Water Temp. sensor DPD(CT) Temp. sensor DPD(FT) Temp. sensor
*9 *10 *11 *12
DPD Prerss sensor Pump Flow P-S/V Boom2 P-S/V Lever lock S/V
Operation explanation There are the following 4 regeneration methods. • Automatic regeneration: The filter is automatically regenerated during machine operation. The machine can work normally. • Manual regeneration: If automatic regeneration is incomplete or the amount of accumulated PM is large, the filter is regenerated with a switch. The machine cannot operate. • Forced manual regeneration: During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration. • Slow regeneration: When manual regeneration is interrupted for a prolonged period, it is necessary to combust the PM slower than normal. The diagnostic trouble code is displayed and service engineer operation is required. The machine cannot operate. 1.
Switch the key ON and operate. The system displays the current amount of PM accumulated on the DPD bar graph. The PM accumulated on the filter continually self-combusts due to high-temperature exhaust gases during engine operation.
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Electrical and Engine Basic Functions 2.
3.
4. 5.
6.
When the work was at low load, because the exhaust gas temperature is low, the PM does not self combust but accumulates. When the DPD differential pressure is high or every 8 hours, the ECM forces up the exhaust gas temperature to combust the accumulated PM. (See Automatic Regeneration.) Normally, the above continuous regeneration and automatic regeneration keep the accumulated amount of PM from going above a certain amount, but if the operating conditions are such that the accumulated amount of PM becomes excessive, in order to avoid the risk of damage to the DPD assembly due to excessive temperature rise during regeneration, the ECM prohibits automatic regeneration and requests the operator to perform manual regeneration. The operator receives this request and starts regeneration. (See Manual Regeneration.) While automatic regeneration is stopped, the operator can execute manual regeneration at any time with switch operation. (See Forced Manual Regeneration.) If the operator ignores the manual regeneration request and continues to work, this causes (excess PM collection) and the ECM issues the diagnostic trouble code. When this point is reached, regeneration by the operator is no longer possible and special regeneration using service tools has become necessary. (See Slow Regeneration.) If any of the following troubles occurs during regeneration, the hydraulic pressure load is stopped.
Excess PM collection When the accumulated amount of PM exceeds the limit and the excess PM collected state is reached, the system behaves as follows. • • • •
Ends the hydraulic pressure assist load. Lights the red lamp. Lights up the DPD gauge all red. Displays the "CHECK ENGINE" message.
Slow regeneration Regeneration through a process that raises the temperature slower than for normal regeneration.
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Electrical and Engine Basic Functions Automatic Regeneration Summary The filter is automatically regenerated during machine operation. The machine can work normally. The ECM determines the amount of PM accumulated from the difference in pressure before and after the DPD filter. When a certain amount has accumulated, the ECM regenerates the filter automatically. Also, if the operating time since the last regeneration reaches a certain level, the ECM automatically regenerates the filter. Configuration
*1 *2 *3 *4
ECM CONT_A CONT_B MONITOR
*5 *6 *7 *8
DPD SW Water Temp. sensor DPD(CT) Temp. sensor DPD(FT) Temp. sensor
*9 *10 *11 *12
DPD Prerss sensor Pump Flow P-S/V Boom2 P-S/V Lever lock S/V
Operation explanation 1.
Conditions for the start of automatic regeneration: When the automatic regeneration request comes from the ECM, if the following conditions are met, automatic regeneration is started. • • • • •
2.
Start of automatic regeneration: If the conditions above are met, the computer starts the following control. • • • • • •
3.
Engine is starting The engine coolant temperature is at least 70°C but less than 100°C. The difference in pressure before and after the DPD filter has been stable for a certain period of time. The gate bar limit switch is ON (hydraulic operation is enabled). There is no sensor or DPD related abnormality. Lights the DPD green lamp. Sets off the buzzer for 2 sec.. Switches the DPD gauge from accumulated amount display to regeneration progress display. Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating. Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM. Stops the auto idle/idle stop control.
Stopping automatic regeneration: When the operations below are performed, the ECM regeneration prohibition signal is sent and automatic regeneration is stopped. 84402827B - May 2011 4001A-56
Electrical and Engine Basic Functions While automatic regeneration is stopped, the DPD green lamp goes out. Displays the "PUSH DPD SWITCH TO ACTIVATE" message. Switches the DPD gauge from regeneration progress display to accumulated amount display. Starts the auto idle/idle stop control. To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch. • If the gate bar limit switch comes OFF (hydraulic operation is disabled), regeneration is stopped. • During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped. • If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped. 4.
Ending automatic regeneration: The computer receives the automatic regeneration end signal from the ECM and ends the control. • • • •
Puts out the DPD green lamp. Switches the DPD gauge from regeneration progress display to accumulated amount display. Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages. Starts the auto idle/idle stop control.
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Electrical and Engine Basic Functions Manual Regeneration Summary If automatic regeneration is incomplete or the amount of accumulated PM is large, the ECM requests manual regeneration. The machine cannot be operated during manual regeneration. The computer controls the regeneration assist load. Configuration
*1 *2 *3 *4
ECM CONT_A CONT_B MONITOR
*5 *6 *7 *8
DPD SW Water Temp. sensor DPD(CT) Temp. sensor DPD(FT) Temp. sensor
*9 *10 *11 *12
DPD Prerss sensor Pump Flow P-S/V Boom2 P-S/V Lever lock S/V
Operation explanation 1.
Requesting manual regeneration: When the manual regeneration request comes from the ECM to the computer, it displays the following items on the monitor. • Flashes the DPD amber lamp (2-second cycle at first, high-speed 0.6-second cycle afterward) • Displays the "PUSH DPD SWITCH TO ACTIVATE" message.
2.
Manual regeneration start conditions: When the following conditions are all met and the DPD switch is pressed, the computer sets the engine speed to 1000 min-1 and starts manual regeneration. • • • •
3.
The gate bar limit switch is OFF (hydraulic operation is disabled). The engine coolant temperature is at least 70°C but less than 100°C. There is no sensor or DPD related abnormality. When released, automatically goes to 1000 min-1.
Start of manual regeneration: If the conditions above are met, Computer A starts the following control. • • • • •
Lights the DPD amber lamp. Sets off the buzzer for 2 sec.. Switches the DPD gauge from accumulated amount display to regeneration progress display. Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating. Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM. 84402827B - May 2011 4001A-58
Electrical and Engine Basic Functions • Stops the auto idle/idle stop control. • Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature). 4.
Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition signal is sent and manual regeneration is stopped. While regeneration is stopped, the DPD amber lamp flashes. Displays the "PUSH DPD SWITCH TO ACTIVATE" message. Switches the DPD gauge from regeneration progress display to accumulated amount display. Starts the auto idle/idle stop control. To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch. • • • • •
5.
Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and ends the control. • • • •
6.
If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped. During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped. If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped. If the hydraulic pressure assist proportional valve breaks down during regeneration If the throttle is operated
Puts out the DPD amber lamp. Switches the DPD gauge from regeneration progress display to accumulated amount display. Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages. Starts the auto idle/idle stop control.
Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to raise the exhaust gas temperature. • • • •
Computer A set the pump flow proportional valve to the minimum flow at 740 mA. After 1 sec., Computer A sets the boom 2 proportional valve to 600 mA for the maximum load. After 1 sec., Computer A sets the pump flow proportional valve to 600 mA. After 30 sec., Computer A controls the pump flow proportional valve so that the DPD exhaust gas temperature (before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update width 5 mA)
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Electrical and Engine Basic Functions Forced Manual Regeneration Summary During automatic regeneration, it is possible to interrupt automatic regeneration and switch to manual regeneration. This can only be executed while automatic regeneration is stopped. Configuration
*1 *2 *3 *4
ECM CONT_A CONT_B MONITOR
*5 *6 *7 *8
DPD SW Water Temp. sensor DPD(CT) Temp. sensor DPD(FT) Temp. sensor
*9 *10 *11 *12
DPD Prerss sensor Pump Flow P-S/V Boom2 P-S/V Lever lock S/V
Operation explanation 1. 2.
With automatic regeneration stopped and with the gate bar open, if the DPD switch is held down for 3 sec., Computer A sends the forced manual regeneration start request signal to the ECM via the DPD relay. When the ECM receives the forced manual regeneration start request signal, the following is displayed on the monitor. • Lights up the amber lamp for 3 sec..
3.
If the system meets the following conditions, the ECM judges that manual regeneration is necessary, puts out the amber lamp, and returns to the automatic regeneration stopped state. • If the state of it being impossible to complete automatic regeneration has continued or longer than 8 hours • If the ECM judges that manual regeneration is not necessary
4.
If the ECM judges that manual regeneration is necessary, the system receives the manual regeneration request signal from the ECM, and waits for the manual regeneration switch to be pressed. • After 10 sec., it flashes the amber lamp (2-second cycle). Displays the "PUSH DPD SWITCH TO ACTIVATE" message on the monitor. • The operator presses the DPD switch during this time. • If the operator does not press the DPD switch at least 10 sec., the ECM puts out the amber lamp and returns to the automatic regeneration stopped state.
5.
(From here on is the same process as from 2 in manual regeneration.) Lowers the engine speed to 1000 min-1 and starts manual regeneration. 84402827B - May 2011 4001A-60
Electrical and Engine Basic Functions 6.
Start of manual regeneration: If the conditions above are met, the computer starts the following control. • • • • • • •
7.
Stopping manual regeneration: When the operations below are performed, the ECM regeneration prohibition signal is sent and manual regeneration is stopped. While regeneration is stopped, the DPD amber lamp flashes. Displays the "PUSH DPD SWITCH TO ACTIVATE" message. Switches the DPD gauge from regeneration progress display to accumulated amount display. Starts the auto idle/idle stop control. To restart regeneration, after the cause of the stoppage has been eliminated, press the DPD switch. • • • • •
8.
If the gate bar limit switch comes ON (hydraulic operation enabled), regeneration is stopped. During automatic regeneration, if the monitor's DPD switch is pressed, regeneration is stopped. If the exhaust gas temperature reaches 400°C or higher, regeneration is stopped. If the hydraulic pressure assist proportional valve breaks down during regeneration If the throttle is operated
Ending manual regeneration: The computer receives the manual regeneration end signal from the ECM and ends the control. • • • •
9.
Lights the DPD amber lamp. Sets off the buzzer for 2 sec.. Switches the DPD gauge from accumulated amount display to regeneration progress display. Displays the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages alternating. Computer A drives the DPD relay and sends the DPD regeneration signal to the ECM. Stops the auto idle/idle stop control. Starts the hydraulic pressure assist load control (in order to raise the exhaust gas temperature).
Puts out the DPD amber lamp. Switches the DPD gauge from regeneration progress display to accumulated amount display. Puts out the "AUTO DPD RE-GEN" and "CAUTION! HOT EXHAUST" messages. Starts the auto idle/idle stop control.
Regeneration hydraulic pressure load assist: During manual regeneration, puts a load on the pump in order to raise the exhaust gas temperature. • • • •
The computer set the pump flow proportional valve to the minimum flow at 740 mA. After 1 sec., the computer sets the boom 2 proportional valve to 600 mA for the maximum load. After 1 sec., the computer sets the pump flow proportional valve to 600 mA. After 30 sec., the computer controls the pump flow proportional valve so that the DPD exhaust gas temperature (before DOC) is constant at 270°C. (Lowers it gradually 50 mA/second. update period 15 sec., update width 5 mA)
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Electrical and Engine Basic Functions Hydraulic Assist Load Summary During DPD manual regeneration, hydraulic load is added to raise the exhaust gas temperature. Operation explanation 1. 2. 3. 4.
When regeneration starts, the system sets the pump flow proportional value to the minimum flow (Current 740 mA). After 1 sec., the system sets the boom 2 proportional valve to the maximum load (Current 600 mA). After 1 sec., the system sets the current for pump flow proportional valve to 600 mA. (*1) After 30 sec., the system controls the pump flow proportional valve so that the DPD exhaust gas temperature (before DOC) is constant at 270°C. (*2) (*3) • Lowers it gradually 50 mA/sec.. • Current update width: 5 mA, update period 15 sec. • If the DPD exhaust gas temperature (before DOC) exceeds 400°C, addition of the hydraulic load is stopped. When the temperature falls below 250°C, the addition of the hydraulic load resumes after 1 sec..
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Section 4001B
Service Support
84402827B - May 2011
84402827B - May 2011
CONTENTS Service Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Screen Display List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 CHECK Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MACHINE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FAULT HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 WORK HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 ENGINE HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 HYDRAULIC HISTORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 PART NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SETUP Screen List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 MACHINE SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Model Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Throttle Volume Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Password Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Adjusting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Parameter Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Option Flow Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Screen Brightness Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
84402827B - May 2011 4001B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4001B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Service Support Service Support Screen Operations Screen Display List
1 2
Travel speed select switch Attachment select switch
3 4
Menu screen display switch Working light switch
84402827B - May 2011 4001B-3
5 6
Wiper switch Auto idling switch
Service Support CHECK Screen List In CHECK mode, in addition to the machine status (milliamp, oil pressures, temperatures, etc.), it is possible to
1
check sensor and switch input/output states, as well as the angle, load ratio and work radius, etc. at the applied machine (liftcrane specifications machine, lifting magnet machine).
MACHINE STATUS
Section
For the CHECK mode section types and their contents, see the separate sheet.
1.
Engine and pump
By pressing and on the monitor, MACHINE STATUS, FAULT HISTORY, etc. can be selected. Detailed data for the selected item can be seen by press-
ing
.
ENGINE SPEED min-1 ENGINE LOAD % RATIO P1 PRESS.
MPa
P2 PRESS.
MPa
N1 PRESS.
MPa
N2 PRESS.
MPa
P.SOL;PUMPPOWER
mA
P.SOL;PUMPFLOW
mA
SOL;POWERSAVE
on/off
84402827B - May 2011 4001B-4
Engine speed Engine load ratio Pump 1; Discharge pressure Pump 2; Discharge pressure Pump 1; Negative control pressure Pump 2; Negative control pressure Horsepower control proportional valve; Actual milli-amp Flow milli-amp proportional valve; Actual milli-amp Power save solenoid
Service Support 2.
Temperature and pressure
BOOST PRESS. BAROMETRIC PRESS. BOOST TEMP.
kPa
Boost pressure
kPa
Barometric pressure
°C
°C
Boost temperature Suction air temperature Fuel temperature
°C
Manifold temperature
°C °C
Coolant temperature Oil temperature
AIR INLET TEMP. °C FUEL TEMP. MANIFOLD INNER TEMP. COOLANT TEMP. HYD.OIL TEMP. 3.
4.
Pressure and solenoid
UPPER PILOT PRESS. SWING PILOT PRESS. TRAVEL PILOT PRESS. OPT.LINE PRESS SW. 2ND OPT.LINE PRESS SW. TRAVEL ALARM OUT. POWER SAVE SOL. SWING BRAKE SOL. FREE SWING SOL.
MPa
Upper pilot pressure
MPa
Swing pilot pressure
MPa
Travel pilot pressure
on/off
1st option operation
on/off
2nd option operation
on/off
Travel alarm
on/off
Power save solenoid
on/off
Swing brake solenoid
on/off
Free swing solenoid
Pressure and solenoid
BOOM-UP PILOT PRESS. ARM-CLOSE PILOT PRESS. BUCKET-CLOSE PILOT PRESS. P.SOL;BOOMDOWN P.SOL;BOOM-UP P.SOL;ARMCLOSE P.SOL;BUCKETCLOSE P.SOL;OFFSETLEFT SOL;BUCKET OPEN
84402827B - May 2011 4001B-5
MPa
Boom-up pilot pressure
MPa
Arm-in pilot pressure
MPa
Bucket-close pressure
mA
Boom-down solenoid
mA
Boom-up solenoid
mA
Arm-in solenoid
mA
Bucket-close noid
mA
Offset left solenoid
on/off
Bucket-open noid
pilot
sole-
sole-
Service Support 5.
Pressure and solenoid
PILOT SW.
on/off
P1 PRESS.
MPa
P2 PRESS.
MPa
N1 PRESS.
MPa
N2 PRESS.
MPa
P.SOL;OPT.LINE RELIEF SOL;OPTION 2SPEED SOL;OPTION SELECT SOL;POWER BOOST
mA on/off on/off on/off
6.
Pilot switch Pump 1; Discharge pressure Pump 2; Discharge pressure Pump 1; Negative control pressure Pump 2; Negative control pressure Option line solenoid 2 pumps flow solenoid Option selection solenoid Power boost solenoid
Engine
ENGINE PRESS COOLANT LEVEL SW.
OIL
AIR FILTER SW.
kPa on/off on/off
BATTERY VOLTV AGE BATTERY on/off CHARGE IDLE SHUT on/off DOWN OUT 2SPEED TRAVEL SOL FAN REVERSING SOL
84402827B - May 2011 4001B-6
Engine oil pressure LLC reserve level switch Air cleaner switch
tank clog
Battery voltage Alternator power generation Idling stop relay output Travel 2nd speed solenoid output Option switchover solenoid output
Service Support 7.
Fuel
FUEL DENSITY (RAW) FUEL DENSITY (15℃) FUEL TEMP. (INNER TANK) FUEL SENSOR POSITION REFUEL AUTOSTOP OUT HYD.OIL FILTER SW. LOCK STATUS1 LOCK STATUS2
8.
g/cm3
Fuel density
g/cm3
Fuel density
℃
Fuel temperature
%
Fuel sensor
on/off on/off -
Fuel supply automatic stop Hydraulic oil filter switch -
Engine
ENGINE SPEED ENGINE LOAD RATIO DPD DIFF.PRESS. EXHAUST TEMP. (DOC) EXHAUST TEMP. (DPD) P.SOL;REGEN.ASSIST
min-1
Engine speed
%
Engine load ratio
kPa ℃ ℃ mA
P.SOL;PUMPFLOW
mA
P1 PRESS.
MPa
N1 PRESS.
MPa
84402827B - May 2011 4001B-7
DPD exhaust gas differential pressure Exhaust gas temperature (DOC) Exhaust gas temperature (DPD)
Flow milli-amp proportional valve; Actual milli-amp Pump 1; Discharge pressure Pump 1; Negative control pressure
Service Support 9.
Engine
ENGINE TARGET SPEED ENGINE SPEED ENGINE LOAD RATIO FUEL INJECTION LIMIT COMMON RAIL PRESS. C.RAIL DIFF.PRESS. SUPPLYPUMP(IN) PRESS TARGET FUEL INJECTION FUEL FLOW
11. Safety distances
min-1
Engine target speed
min-1
Engine speed
%
Engine load ratio
%
Fuel injection ratio
MPa MPa kPa
Common rail pressure Common rail differential pressure Supply pump pressure (IN)
Target fuel injection mm3/st quantity L/h
BOOM ANGLE OFFSET ANGLE ARM ANGLE P.SOL;BOOM-UP P.SOL;OFFSETLEFT P.SOL;ARMCLOSE SAFETY DISTANCE(TOP) SAFETY DISTANCE(SIDE)
deg deg deg %
Boom angle Offset angle Arm angle Boom-up solenoid
%
Offset solenoid
mA
Arm-in solenoid
m
Safety (side) Safety (front)
m
distance distance
12. Hanging load
10. Work radius and height
BOOM ANGLE OFFSET ANGLE ARM ANGLE WORKING RADIUS LIFTING HEIGHT HEIGHT LIMIT LIFTING LOAD RATED LOAD WARNING BUZZER OUT
BOOM BOTTOM PRESS. BOOM ROD PRESS. WORKING RADIUS LIFTING LOAD RATED LOAD TOTAL MOMENT
deg deg deg
Boom angle Offset angle Arm angle
m
Work radius
m m kg kg
Work height Hanging limit height Hanging load Rated load
on/off
Liftcrane buzzer
ATT.MOMENT
84402827B - May 2011 4001B-8
MPa
Boom bottom pressure
MPa
Boom rod pressure
m
Work radius
kg kg kg.m
Hanging load Rated load Total moment Attachment independent moment
kg.m
Service Support FAULT HISTORY
13. GPS information
1.
With FAULT HISTORY, the contents for the trouble currently occurring and a log of trouble that has occurred in the past can be checked.
To switch to a page from 1 to 15, press the monitor
switch while the MACHINE STATUS screen is displayed and select the desired page.
1 2 3 4
Displayed/Not displayed Occurrence count Initial occurrence time Final occurrence time
• Diagnostic trouble codes that occur display in "DTC-1" - "DTC-4". • The cursor is moved with the and switches. (The cursor moves between "DTC-1" and "DTC-4".) • The information for the diagnostic trouble code for the location under the cursor is displayed with the items from "STATUS" to "LAST HOUR". • Up to 30 diagnostic trouble codes can be displayed. To switch to a page from 1 to 6, press the monitor
switch while the FAULT HISTORY screen is displayed and select the desired page.
84402827B - May 2011 4001B-9
Service Support WORK HISTORY Operation times for mechanical parts, electrical parts, etc., and operation counts for switches can be displayed.
1.
Machine main unit
2.
hour Key ON time Engine operation ENGINE-RUN TIME hour time OPERATION TIME hour Operation time UPPER OPERAhour Upper operation time TION TIME SWING OPERATION hour Swing operation time TIME TRAVEL OPERAhour Travel operation time TION TIME Independent travel INDEPENDENT hour operation time TRAVEL TIME 1st speed travel operLo-SPEED TRAVEL hour ation time TIME 2nd speed travel opHi-SPEED TRAVEL hour eration time TIME KEY-ON TIME
Work mode
SP-MODE OPERATION TIME H-MODE OPERATION TIME A-MODE OPERATION TIME POWER-BOOST TIME AUTO IDLE TIME ONE-TOUCH-IDLE TIME
84402827B - May 2011 4001B-10
hour hour hour hour hour
SP mode operation time H mode operation time A mode operation time Boosted pressure time Auto idle time
hour One-touch idle time
Service Support 3.
End attachment
5.
BREAKER OPERATION TIME CRUSHER OPERATION TIME OPT.1 PUMP OPERATION TIME OPT.2 PUMP OPERATION TIME 2ND OPT. OPERATION TIME CRANE OPERATION TIME MAGNET OPERATION TIME 4.
hour hour hour hour hour hour hour
Breaker operation time Crusher operation time 1st option operation time 2nd option operation time 2 pumps flow operation time Liftcrane operation time Lifting magnet operation time
Electrical part
WIPER-INT. OPERATION TIME WIPER-CNT. OPERATION TIME WASHER OPERATION TIME WORKING LAMP ON TIME RADIO MUTE TIME DISPLAY-MODE1 TIME DISPLAY-MODE2 TIME DISPLAY-MODE3 TIME
Electrical part
KEY-ON COUNT ENGINE-START COUNT IDLE SHUT DOWN COUNT WINDOW OPEN TIME WINDOW OPEN COUNT DOOR OPEN TIME DOOR OPEN COUNT
hour
Key ON count
hour
Engine ON count
hour
Front window open count
hour
Door open count
10 times Idle stop time hour
Front window open time
10 times Door open time 84402827B - May 2011 4001B-11
hour Wiper (INT) time hour Wiper (CNT) time hour hour hour hour hour hour
Washer operation time Working light ON time Radio mute time No camera screen selection time Camera screen display 1 selection time Camera screen display 2 selection time
Service Support 6.
Air conditioner
A/C OPERATION TIME A/C BLOWER-Lo TIME A/C BLOWER-M1 TIME A/C BLOWER-M2 TIME A/C BLOWER-M3 TIME A/C BLOWER-M4 TIME A/C BLOWER-Hi TIME MAG.CLUTCH RELAY ON TIME CLUTCH RELAY ON COUNT
7.
AC power supply ON time AC blower Lo sethour ting time AC blower M1 sethour ting time AC blower M2 sethour ting time AC blower M3 sethour ting time AC blower M4 sethour ting time AC blower Hi sethour ting time Electromagnetic hour clutch ON time Electromagnetic 10 times clutch ON count hour
Air conditioner
COOL-MAX TIME
hour
T1 TARGET TEMP hour ＜ T2 TIME T2 TARGET TEMP hour ＜ T3 TIME T3 TARGET TEMP hour ＜ T4 TIME HOT-MAX TIME
hour
RECIRC.AIR MAX℃ TEMP. RECIRC.AIR MIN℃ TEMP. INTAKE AIR MAX℃ TEMP. INTAKE AIR MIN℃ TEMP.
Maximum cooling operation time T1 Target temperature T ＜ T2 time T2 Target temperature T ＜ T3 time T3 Target temperature T ＜ T4 time Maximum heating operation time Maximum inside air temperature Minimum inside air temperature Maximum outside air temperature Minimum outside air temperature
To switch to a page from 1 to 7, press the monitor switch
while the WORK HISTORY screen is displayed and select the desired page.
84402827B - May 2011 4001B-12
Service Support ENGINE HISTORY The engine speed, coolant temperature, fuel temperature, and suction air temperature distributions, etc. can be displayed.
1.
Actual speed distribution
ROTATION ＜ R1 R1 REV. SPEED R2 R2 REV. SPEED R3 R3 REV. SPEED R4 R4 REV. SPEED R5 R5 REV. SPEED R6 R6 REV. SPEED
2.
hour S ＜ ＜ ＜ ＜ ＜
1025
hour 1025
S ＜ 1225
hour 1225
S ＜ 1425
hour 1425
S ＜ 1625
hour 1625
S ＜ 1825
hour 1825
S ＜ 2025
hour 2025
S
Water temperature distribution
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
84402827B - May 2011 4001B-13
T ＜ 77 77 T ＜ 82 82 T ＜ 97 97 T ＜ 100 100 T ＜ 103 103 T ＜ 105 105 T Maximum temperature
Service Support 3.
Fuel temperature distribution
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
5.
T ＜ 40 40 T ＜ 50 50 T ＜ 60 60 T ＜ 70 70 T ＜ 80 80 T ＜ 90 90 T Maximum temperature 6.
4.
Boost temperature distribution
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
T＜0 0 T ＜ 20 20 T ＜ 40 40 T ＜ 60 60 T ＜ 80 80 T ＜ 100 100 T Maximum temperature
Suction air temperature distribution
Suction air temperature distribution
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
T ＜ -20 -20 T ＜ 0 0 T ＜ 15 15 T ＜ 30 30 T ＜ 45 45 T ＜ 60 60 T Maximum temperature
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
PRESS. MAX
kPa
PRESS. MIN
kPa
84402827B - May 2011 4001B-14
P ＜ 100 100 P ＜ 140 140 P ＜ 180 180 P ＜ 220 220 P ＜ 260 260 P ＜ 300 300 P Maximum pressure Minimum pressure
Service Support 7.
8.
Oil pressure distribution
9.
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
PRESS. MAX
kPa
PRESS. MIN
kPa
P＜0 0 P ＜ 150 150 P ＜ 300 300 P ＜ 450 450 P ＜ 600 600 P ＜ 750 750 P Maximum pressure Minimum pressure
Load ratio distribution
RATIO ＜ R1 R1 RATIO ＜ R2 R2 RATIO ＜ R3 R3 RATIO ＜ R4 R4 RATIO ＜ R5 R5 RATIO ＜ R6 R6 RATIO
hour hour hour hour hour hour hour
R＜ 30 40 50 60 70 80
30 R ＜ 40 R ＜ 50 R ＜ 60 R ＜ 70 R ＜ 80 R
10. SP mode load ratio distribution
Boost pressure distribution
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
PRESS. MAX
kPa
PRESS. MIN
kPa
P＜0 0 P ＜ 150 150 P ＜ 300 300 P＜450 450 P ＜ 600 600 P ＜ 750 750 P Maximum pressure Minimum pressure
RATIO ＜ R1 R1 RATIO ＜ R2 R2 RATIO ＜ R3 R3 RATIO ＜ R4 R4 RATIO ＜ R5 R5 RATIO ＜ R6 R6 RATIO
84402827B - May 2011 4001B-15
hour hour hour hour hour hour hour
R ＜ 30 30 R ＜ 40 40 R ＜ 50 50 R＜60 60 R ＜ 70 70 R ＜ 80 80 R
Service Support 11. H mode load ratio distribution
RATIO ＜ R1 R1 RATIO ＜ R2 R2 RATIO ＜ R3 R3 RATIO ＜ R4 R4 RATIO ＜ R5 R5 RATIO ＜ R6 R6 RATIO
hour hour hour hour hour hour hour
13. DOC temperature distribution
R ＜ 30 30 R ＜ 40 40 R ＜ 50 50 R ＜ 60 60 R ＜ 70 70 R ＜ 80 80 R
12. Fuel density distribution
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
T ＜ 200 200 T ＜ 300 300 T ＜ 400 400 T ＜ 500 500 T ＜ 600 600 T ＜ 700 700 T Maximum temperature
14. DPD temperature distribution
DENSITY ＜ D1 D1 DENSITY ＜ D2 D2 DENSITY ＜ D3 D3 DENSITY ＜ D4 D4 DENSITY ＜ D5 D5 DENSITY ＜ D6 D6 DENSITY
hour hour hour hour hour hour hour
D＜ D1 D2 D3 D4 D5 D6
D1 D ＜ D2 D ＜ D3 D ＜ D4 D ＜ D5 D ＜ D6 D
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
84402827B - May 2011 4001B-16
T ＜ 200 200 T ＜ 300 300 T ＜ 400 400 T ＜ 500 500 T ＜ 600 600 T ＜ 700 700 T Maximum temperature
Service Support 15. Supply pump inlet pressure distribution
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
PRESS. MAX
kPa
PRESS. MIN
kPa
17. DPD differential pressure distribution
P ＜ -40 -40 P ＜ -30 -30 P ＜ -20 -20 P ＜ -10 -10 P ＜ 0 0 P ＜ 10 10 P Maximum pressure Minimum pressure
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
PRESS. MAX
kPa
PRESS. MIN
kPa
P＜0 0 P＜5 5 P ＜ 10 10 P ＜ 15 15 P ＜ 20 20 P ＜ 25 25 P Maximum pressure Minimum pressure
16. Hot shutdown 18. DPD regeneration count
ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9
-
-
ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9
-
-
To switch to a page from 1 to 18, press the monitor switch
while the ENGINE HISTORY screen is displayed and select the desired page. 84402827B - May 2011 4001B-17
Service Support HYDRAULIC HISTORY The P1 and P2 pilot pressure can be displayed.
1.
P1 pressure
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
2.
hour hour hour hour hour hour hour
P＜ 10 15 20 25 30 35
10 P＜ P＜ P＜ P＜ P＜ P
15 20 25 30 35
P2 pressure
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
84402827B - May 2011 4001B-18
hour hour hour hour hour hour hour
P ＜ 10 10 P ＜ 15 15 P ＜ 20 20 P ＜ 25 25 P ＜ 30 30 P ＜ 35 35 P
Service Support 3.
N1 pressure
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS. 4.
5.
hour hour hour hour hour hour hour
P＜ 1.0 1.5 2.0 2.5 3.0 3.5
1.0 P＜ P＜ P＜ P＜ P＜ P
1.5 2.0 2.5 3.0 3.5
P1 + P2 pressure
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
P＜ 20 30 40 50 60 70
20 P＜ P＜ P＜ P＜ P＜ P
30 40 50 60 70
N2 pressure 6.
PRESS. ＜ P1 P1 PRESS. ＜ P2 P2 PRESS. ＜ P3 P3 PRESS. ＜ P4 P4 PRESS. ＜ P5 P5 PRESS. ＜ P6 P6 PRESS.
hour hour hour hour hour hour hour
P＜ 1.0 1.5 2.0 2.5 3.0 3.5
1.0 P＜ P＜ P＜ P＜ P＜ P
1.5 2.0 2.5 3.0 3.5
Operation count
UPPER PILOT PRESS SWING PILOT PRESS TRAVEL PILOT PRESS ARM-CLOSE PILOT PRESS. OPT.LINE PRESS SW. 2ND OPT.LINE PRESS SW. POWER BOOST SOL. SWING BRAKE SOL. POWER-SAVE TIME
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1000 times 1000 times 1000 times 1000 times 1000 times 1000 times 1000 times 1000 times 1000 times
Upper operation count Swing operation count Travel operation count Arm-in operation count 1st option operation count 2nd option operation count Pressure boost operation count Swing operation count Power save operation count
Service Support 7.
PART NUMBER
Oil temperature distribution
The software version for computers A, B, C can be displayed.
TEMP. ＜ T1 T1 TEMP. ＜ T2 T2 TEMP. ＜ T3 T3 TEMP. ＜ T4 T4 TEMP. ＜ T5 T5 TEMP. ＜ T6 T6 TEMP. -
hour hour hour hour hour hour hour -
TEMP. MAX
℃
T ＜ 45 45 T ＜ 60 T ＜ 80 T ＜ 88 T ＜ 95 T ＜ 98 T Maximum ture
60 80 88 95 98
tempera-
To switch to a page from 1 to 7, press the monitor switch
while the HYDRAULIC HISTORY screen is displayed and select the desired page.
SETUP Screen List The model selection, work mode speed, etc. can be changed.
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Service Support
By pressing "Wiper switch" (5) and "Auto idling switch" (6) on the monitor, MACHINE SELECT, PARAMETERS, etc. can be selected. Detailed data for the selected item can be seen by pressing "Working light switch" (4).
MACHINE SELECT Machine data information, etc. are registered.
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
MACHINE Fix the selection. TERRITORY 0 1 2 3 4 5 6
JAPAN NA EU IHI TURK CHINA
0 1 2 3
SUMITOMO LBX CASE IHI
BRAND
LANGUAGE
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Japanese English Thai Chinese German French Italian Spanish Portuguese Dutch Danish Norwegian Swedish Finnish Turkish Arabic Malay Indonesian Russian Canadian French Pictographs only
Service Support PARAMETERS
3.
Work mode engine speed
The work mode speed and pump milli-amps can be set. 1.
Engine
Auto idling speed ITEM-1 min-1 ITEM-2 ms*100 Auto idle time Transient load minimum milliITEM-3 mA amp (normally 50 mA) Semi-transient load minimum ITEM-4 mA milli-amp Eco gauge update period (norITEM-5 ms*100 mally 1000 ms) 2.
ITEM-1 ITEM-2 ITEM-3 ITEM-4 4.
min-1 min-1 min-1 min-1
SP mode speed H mode speed A mode speed Idling speed
Energy save
Work mode milli-amp
ITEM-1 min-1 ITEM-2 ITEM-3 min-1
ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7
mA mA mA mA mA mA mA
SP mode milli-amp (Hi) SP mode milli-amp (Low) H mode milli-amp (Hi) H mode milli-amp (Low) A mode milli-amp (Hi) A mode milli-amp (Low) Minimum milli-amp
ITEM-4 ITEM-5 ITEM-6 ITEM-7
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mA
Speed change amount during boom-down swing operation Semi-auto idling speed change amount Speed limit milli-amp
Service Support 5.
ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9
-
-
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Service Support Setting Model Select Summary The model information is input to set the control parameters specific to the model. Configuration • Screen
Operation explanation Move up and down to move the cursor, left and right to select a model, set the throttle to H mode, and decide with the menu switch. • · Reset by holding down the left and right. (The display changes to "?" for all items.) * From Ver. 1.8.6 Without a reset, only the LANGUAGE and UNIT can be changed. Other changes always require a complete reset. Setting items, values and details Select "SET UP" on the service screen and input the following items. The setting item values and setting details are given below. Explanation of item Page
1
2
Item name MACHINE TERRITORY BRAND LANGUAGE UNIT
Explanation Model Destination Brand Language Unit OVERLOAD WARNING Load warning Interference prevenANTI INTERFERENCE tion Attachment type ATT. TYPE OPTION LINE Option Line Lifting magnet GENERATOR -
Remarks
0: {MPa, °C}, 1: {psi, °F}, 2: {kgf/cm2, °C}
Not currently supported Used for interference prevention·crane·overload warning Not currently supported
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Service Support Page
Item name
Explanation -
REMOTE SUPPORT FMS 3
RESERVE 1 RESERVE 2 RESERVE 3
Remarks
Currently not supported; used for Computer ST trouble diagnosis Fuel abnormality Currently not supported; used for density sensor trouble warning diagnosis Free Swing Not currently supported Reserve 2 Not currently supported Reserve 3 Remote Support
Explanation of number 1. 2.
3.
Model (Machine) Omitted Destination (Territory) Value 0
Details JAPAN
1
NA
2 3 4 5 6
- (Skipped number) EU IHI TURK CHINA
Value
Details
0
SUMITOMO
1
LBX
2
CASE
3
IHI
Remarks Travel alarm continuous buzzing function ON (Cannot be set OFF)
Brand Remarks Background color = blue, Sumitomo logo displayed after model selection completed Background color = black, LBX logo displayed after model selection completed Background color = black, CASE logo displayed after model selection completed Not currently supported, background color = ?
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Service Support 4.
Language • Can be changed with "LANGUAGE" on the menu screen.
5.
6.
Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Details Japanese English Thai Chinese German French Italian Spanish Portuguese Dutch Danish Norwegian Swedish Finnish Turkish Arabic Malay Indonesian Russian Canadian French Pictographs only
Value 0 1 2
Details Domestic, Europe (SI units) (MPa, °C) North America (psi, °F) Weight unit system (kgf/cm2, °C)
Not currently supported Not currently supported
Remarks
Load warning (OVERLOAD WARNING) Details None Liftcrane Overload warning Overload warning (rod pressure correction)
Interference prevention (ANTI INTERFERENCE) Value 0 1
8.
Not currently supported
Unit
Value 0 1 2 3 7.
Remarks
Details None Yes
Remarks Not currently supported Not currently supported
Attachment type (ATT. TYPE) Value 0 1 2
Details STD HD Ultra-long
Remarks
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Remarks Not currently supported Not currently supported
Service Support 9.
Option line Value 0 1 2 3 4 5
Details Remarks None (Option adjustment screen cannot be displayed) Breaker Double-acting no 2nd speed Double-acting with 2nd speed W/O multi-purpose pressure adjustment W/ Multi-purpose pressure adjustment
10. Lifting magnet (Generator) Value 0 1
Details None Yes
Remarks Not currently supported Not currently supported
Details None Yes
Remarks Not currently supported Not currently supported
11. Remote Support Value 0 1
12. Fuel abnormality warning (FMS) Value 0 1
Details None Yes
Remarks Not currently supported Not currently supported
13. Free swing (Reserve 1) Value 0 1
Details None Yes
Remarks
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Service Support Throttle Volume Default Setting Summary Corrects the throttle volume installation error. Configuration
*1 *2
Throttle volume Color monitor
*3 *4
Computer B Computer A
*5 *6
ECM ENG
Operation explanation 1. 2. 3.
Switch the key ON and select (Select Model). (See Select Model.) Set all the model selection items and set the throttle volume to H mode, then finalize the selections. The system performs the initial adjustment of the throttle volume. (*1) â&#x20AC;˘ The adjustment results are retained in memory even after the key is switched OFF.
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Service Support Password Setting Summary Set the anti-theft password. Configuration • Monitor: Connected to Computer B • Anti-theft setting knob: On the cab main harness Operation explanation 1. 2. 3.
With the key OFF, connect the anti-theft setting knob. After connecting the knob, when you switch ON the key, the system displays the password setting screen. After setting the 4-digit password, if you switch the key ON→OFF→ON→OFF, the system switches ON the anti-theft function. • All the key switching operations should be done within 2 sec.
4.
When the anti-theft function comes ON, the monitor sets off the buzzer and the key icon is displayed.
* See Anti-theft (password type).
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Service Support Adjusting the Clock
*1
Color monitor
Summary This adjusts the clock displayed on the monitor.
Operation explanation
â&#x20AC;˘ For details on the clock, see the clock section.
1.
Configuration
2.
3.
When the key is turned ON, --:-- is displayed on the monitor. The operator can set the time with "CLOCK ADJUST" on the menu screen. Move left and right to move the cursor, up and down to change the time, and decide with the menu switch. The system displays the time on the monitor. â&#x20AC;˘ Since the clock data is stored in the monitor, the time is retained even if Computer B is replaced. When the monitor is replaced, it is necessary to set the clock again.
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Service Support Parameter Settings * The following covers software Version 1.8.7. Summary Control parameters can be changed using the monitor. For example, the time until auto idle is started or the current and speed for work mode can be set. The items up to the 3rd page of the setting screen can overwrite the parameters changed with the key OFF. Configuration The diagram below shows the items that can be checked with each page of the setting screen. Page
1
2
3
Item name Lo-IDLE ENGINE SPEED AUTO IDLE TIME AUTO IDLE ENGINE SPEED IDLE SHUT DOWN TIME AUTO POWER BOOST
Unit min-1 sec
Explanation Low idle engine speed Auto idle time
min-1
Auto idling speed
min Y/N
Remarks
PUMP POWER DOWN
mA
REV. LIMIT AT BREAKER
Y/N
ENABLE POWER SAVE
Y/N
ENABLE TRAVEL ALARM
Y/N
TRV. ALARM-ON TIME
sec
MEMORIZE TRV. SPEED
Y/N
ENABLE EPF OVERLOAD PRESS. MAINTENANCE MESSAGE FORCED DIM. BY W.LAMP AUTO CLOCK ADJUST TIME DIFFERENCE WITH UTC ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9
Y/N MPa
Idle shut-down time 10 minutes max. Auto pressure boost function Milli-amp for pump horsepower control proportional valve (mA); when ATT operations start Milli-amp for pump horsepower control proportional valve (mA); negative offset amount Flow control (breaker mode) with enNot currently supported gine speed Can only be changed for 20 Power save function tons - 29 tons. Cannot be switched OFF on Travel alarm function North American models Travel alarm sounding time Range = 1..30, Step = 1 Previous travel speed data hold function EPF Yes/No Overload set pressure
Y/N
Service due message
Y/N Y/N
working light linked dimming For automatic adjustment
Not currently supported
hour
-
Not currently supported
Y/N -
Eco gauge display -
PUMP POWER AT START mA
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Service Support Page
Item name
Unit
ITEM-1
mA
ITEM-2
mA
ITEM-3
mA
ITEM-4
mA
ITEM-5
mA
ITEM-6
mA
ITEM-7
mA
ITEM-8 ITEM-9 ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9 ITEM-1 ITEM-2 ITEM-3 ITEM-4 ITEM-5 ITEM-6 ITEM-7 ITEM-8 ITEM-9
Y/N min-1 min-1 min-1 -
4
5
6
Explanation Remarks Milli-amp for pump horsepower control proportional valve (SP_Hi) Milli-amp for pump horsepower control proportional valve (SP_Low) Milli-amp for pump horsepower control proportional valve (H_Hi) Milli-amp for pump horsepower control proportional valve (H_Low) Milli-amp for pump horsepower control proportional valve (A_Hi) Milli-amp for pump horsepower control proportional valve (A_Low) Milli-amp for pump horsepower control proportional valve (Min) Quick warm-up control ON/OFF Development parameter Development parameter Development parameter Development parameter Development parameter Development parameter Development parameter Development parameter Engine speed (SP) Engine speed (H) Engine speed (A) -
Operation explanation 1. 2.
Select an item with the cursor, then input the number with â&#x2020;?â&#x2020;&#x2019;. Decide the selection with the menu switch, then press the menu switch again to leave the screen.
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Service Support Option Flow Pressure Setting Summary Sets the option line flow / pressure. Sets the breaker/crusher maximum flow and maximum pressure. After making the setting, follow the procedure and correct so that the pressure becomes the set pressure. Configuration • The 1st option, 2nd option pressure switch: Connected to Computer A Used during pressure adjustment to judge whether or not operation is independent breaker (crusher) operation. • Bucket-close, arm-in, boom-up pressure sensor: Connected to Computer B and sent to Computer A via the CAN. Used during pressure adjustment to judge whether or not operation is independent breaker (crusher) operation. • Oil temperature sensor: Connected to Computer A Used to judge whether or not the temperature permits pressure adjustment. • Engine speed sensor: Connected to the ECM and recognized by Computer A via the CAN. Used to judge whether or not the speed permits pressure adjustment. • P1 pressure sensor: Connected to Computer A Used to judge whether pressure is being relieved according to the set pressure. • Option line switching solenoid: Connected to and controlled by Computer A. When this solenoid is ON, it switches to the breaker circuit and at the same time that the relief pressure reaches the breaker setting, the return hydraulic oil falls directly into the tank through the filter. • Pump flow proportional valve: Connected to and controlled by Computer A. So that the preset maximum flow is not exceeded in breaker/crusher mode. • Option relief pressure proportional valve: Connected to Computer B The target command current value is sent from Computer A via CAN communication. • 2 pumps flow solenoid: Connected to and controlled by Computer A. When this solenoid is ON, if a backup operation is carried out, 2 pumps flow. 2 pumps will not flow if a backup operation is not carried out even if this solenoid is ON. • With the X2, the 2 pumps flow switch was installed on the console as a rocker switch, but with X3, this was eliminated. Instead, this is decided beforehand with the option line setting screen. • Option line setting screen items: consists of following five items 1. 2. 3.
Attachment selection, Breaker No. (or Crusher No.) Maximum flow setting
4. 5.
Maximum pressure setting Pressure adjustment
For Item 1), when a multi-purpose circuit is set with model selection, the maximum pressure settings and pressure adjustment items in 4) and 5) are only displayed when pressure adjustment is set with the model selection. • Message displayed on the option line setting screen: There is one message display area at the top of the screen and one at the bottom of the screen. "PRESSURE ADJUSTING INCOMPLETE" or "ADJUST PRESSURE" is displayed in the top message display area. "BREAKER OPERATION REQUIRED/CRUSHER OPERATION REQUIRED", "SET IN SP-MODE", "INCREASE ENGINE RPM", "INCREASE OIL TEMP.", "ADJUSTING PRESSURE", "PRESSURE ADJUSTING. COMPLETE", PRESSURE ADJUSTING INCOMPLETE", or "CHECK FLOW RATE" is displayed in the bottom message display area.
Operation explanation 1.
The operator enters the option line setting screen from the menu. The system cuts away option line switching solenoid, pump flow proportional valve, option relief pressure proportional valve, 2 pumps flow from normal controls and sets to setting mode. • There are two ways to enter the option line setting screen. One is from the menu screen. The other is by holding down the ATT select switch for one second. When the former method is used, the ATT when one enters the option line setting screen is Breaker 1. (However, if a double-acting circuit is selected with the model selection, it is Crusher 1.) When the latter method is used, the display moves to the currently selected ATT and a switch guide is displayed on the monitor. (Normally, this is from Breaker 1. (However, if double-acting circuit is selected with the model selection, it is from Crusher 1).)
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Service Support 2.
3.
The operator selects the breaker or the crusher from the "Attachment selection". (When multi-purpose circuit is selected with model selection: For a breaker or crusher, "Attachment selection" is not displayed and the selection cannot be changed.) For a breaker, the system sets the item immediately below to "Breaker No." and for a crusher, "Crusher No.". At the same time, the system switches the option line switching solenoid to ON for a breaker or OFF for a crusher. The operator selects a number from 1 to 5 with the "Breaker No. (or Crusher No.)" item. The system displays the maximum flow and maximum pressure corresponding to that number in the two items immediately below "SET MAX FLOW" and "SET MAX PRESSURE". • The factory setting is that the maximum flow and maximum pressure setting are only for Breaker 1 and Crusher 1. (* The pressure is not adjusted, so for pressure adjustment model setting, the icon does not appear even if the ATT select switch is pressed. The icon appears for the model setting only with flow setting.) Other breakers, 2-5, and crushers, 2-5, are not set. When an breaker or crusher is selected that has not been set, four hyphens (---) are displayed for the "SET MAX FLOW" and "SET MAX PRESSURE". • If the maximum flow and maximum pressure have not yet been set, that breaker or crusher cannot be selected with a work screen. To put it the other way, everything set here can be selected with a work screen. Since the X3 has only one ATT selection switch, when the flow volume is set here for all the breakers or crushers, care is required because selecting the target ATT requires pressing the switch a number of times.
• •
• •
5.
6.
The operator sets the maximum flow from the "SET MAX FLOW" item and sets the maximum pressure from the "SET MAX PRESSURE" item. • As selection options for the maximum flow, the system has available 20 levels for the flow volume, 10 for without 2 pumps flow and 10 for with 2 pumps flow. • However, the maximum flow depends on the model. Even though 20 levels are displayed for all models, the flow volumes for the levels depend on the model. (See (Number table) flow adjustment levels below.) • When the flow volume is set, if a stand-alone option operation is executed, the flow proportional valve command current value is output to achieve that flow volume. (Breaker mode or crusher mode processing is executed.) • The range in which the maximum pressure can be set depends on the model, but for all models,
When the operator has changed the maximum flow or maximum pressure, the system redoes the option relief pressure proportional valve adjustment again. The system displays "ADJUST PRESSURE" on the monitor. The operator checks that the work mode is SP and that the oil temperature is 30°C minimum and operates the breaker (crusher). The system displays "ADJUSTING PRESSURE" on the monitor. At the same time, the "PRESSURE SETTING" and "CURRENT PRESSURE" items are displayed. • When the operator stops the operation, the display returns to "BREAKER OPERATION REQUIRED". • When the work mode is not SP, "SET IN SP-MODE" is displayed instead of "ADJUSTING PRESSURE". • During one-touch idle or while the engine is stopped, "INCREASE ENGINE RPM" is displayed instead of "ADJUSTING PRESSURE". • When the operator operates in SP mode, if the oil temperature is less than 30°C, "INCREASE OIL TEMP." is displayed instead of "ADJUSTING PRESSURE". At the same time, the "TARGET OIL TEMP." and "CURRENT OIL TEMP." items are displayed. • During adjustment, if any operation other than breaker (crusher) operation is done, the system stops the adjustment, displays "BREAKER OPERATING REQUIRED" on the monitor, and waits for operation of the breaker (crusher) independently.
* When items that had been set are reset, the reset items can no longer be selected. 4.
the settings are made in increments of 0.5 MPa. (See (Number table) pressure adjustment range below.) No maximum pressure can be set that exceeds the relief valve pressure setting range. When an item that had been set is reset, four hyphens (---) are displayed for either the "SET MAX FLOW" or the "SET MAX PRESSURE" and when you exit the options adjustment screen, the information that had been set is reset. If the pressure adjustment is not selected with the model selection, the option flow setting ends after just setting the maximum flow. When multi-purpose circuit is selected with model selection, when the flow volume for 2 pumps flow is set with breaker mode, "CHECK FLOW RATE" is displayed on the monitor. Once that flow volume is decided, the "CHECK FLOW RATE" display goes out.
7.
The operator continues operating the breaker (crusher). The system waits for the pressure to stabilize for 2 sec., then starts the adjustment. The system continues to compare the actual P1 pressure and the target set pressure and when the difference between them is no more than 0.5
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Service Support MPa (*) continuously for at least 5 sec., it judges the adjustment to be complete. The system displays "PRESSURE ADJUSTING. COMPLETE" on the monitor and puts out the "PRESSURE ADJUSTING INCOMPLETE" display. • During adjustment, the system updates the option relief pressure proportional valve current every 500 ms in increments of 5 mA. • If the pedal continues to be held down even after the setting value is finalized, the setting value is updated every 5 sec.. • If the pressure adjustment does not end within 30 sec., "PRESSURE ADJUSTING INCOMPLETE" is displayed on the monitor. 8.
Screen Brightness Setting <Summary> Decides the brightness of the backlight through operation that is linked to the working light and solar radiation sensor. <Operation explanation> The screen brightness can be selected on the menu screen. Dimming setting can be changed on the service screen. 1. 2.
When the operator presses the menu switch to exit the option line setting screen, the system stores the settings into memory.
3.
• If the setting screen was entered from the menu screen, the display returns to the menu screen. If the setting screen was entered from the main screen by holding down the ATT select switch for 1 sec., the display returns to the main screen.
4.
Working Light OFF: Normal (with key ON), "Brightness (day)" setting Working Light ON: The monitor brightness is reduced and the display changes automatically to the "Brightness (night)" setting. Brightness settings: "Brightness (day)" and "Brightness (night)" can be set on the menu screen. Dimming by solar radiation sensor: When the working light-linked dimming is set OFF on the menu screen, the dimming level is adjusted automatically to the ambient brightness by the solar radiation sensor.
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Service Support
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Section 4001C
Function, Structure, Operation
84402827B - May 2011
84402827B - May 2011
CONTENTS Function, Structure, Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 4001C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4001C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Function, Structure, Operation Function, Structure, Operation 1.
Engine number
1
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Engine number stamping
Function, Structure, Operation 2.
Function, Structure, Operation 1)
Engine structural diagram
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Function, Structure, Operation
2)
Description of functions and operations Engine electronic control The control provided by the control unit applies to the range from injection to air intake and exhaust including fuel injection amount, injection timing, air intake restriction, EGR and idling speed. Cylinder block The cylinder block is made of cast iron, and it has the equal center distance for each bore and a high rigidity, and the center of the crankshaft matches the center of the block. The bearing cap has the ladder frame structure, and is tightened using the plastic region rotational angle tightening method. Cylinder liner The cylinder liner is selected in accordance with the inner diameter of the cylinder block bore, and its identification number is stamped on the left side of the cylinder. Piston The piston is a strut cast autothermatic piston made of aluminum alloy, and the combustion chamber is the round re-entrant type. Cylinder head The cylinder head is made of cast iron, and has four valves per each cylinder. The angle tightening method has been adopted to the cylinder head bolt to further improve its reliability and durability. Crankshaft The tufftrided steel is being used, and the grade of each journal diameter is engraved on the No. 1 balance weight. EGR system The EGR system is controlled by the engine control module (ECM) according to various data including the water temperature, engine RPM, and engine load to recirculate the exhaust gas for purification. The primary components are the EGR valve, EGR cooler, and various sensors. Connecting rod cap bolt The angle tightening method has been adopted to the connecting rod cap bolt to further improve its reliability and durability. Common rail type electronic control injection system The common rail type electronic control injection system consists of the supply pump that sets the target pressure of high-pressure fuel to supply the fuel, the common rail that measures the high-pressure fuel and the fuel injector that injects the fuel in the form of a fine mist.
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Function, Structure, Operation Each of these are controlled by the ECM based on various signals to control the injection timing and injection amount in accordance with the working condition. Fuel injector The fuel injector has adopted the 7-hole nozzle, and adjusts the fuel injection amount and injection timing by opening or closing the electromagnetic valve on the injector head portion. The ECM corrects variation in the fuel injection amount from fuel injector to fuel injector in accordance with the ID code data in the memory. When adjusting the fuel injector, the ID code date must be recorded in the ECM. Fuel filter with sedimenter The fuel filter with sedimenter removes the water by using the difference in the relative density between diesel oil and water, and notifies the operator through the indicator when it becomes full of water. Preheat system The preheat system consists of the ECM, glow relay, glow plug and glow indicator light. The preheat system is activated when the engine coolant temperature is low to help engine start. Lubricating system It uses and oil filter with a full-flow bypass, and cools down the pistons using the water-cooled oil cooler and the oil jet. DPD An integrated DPD oxidation catalyst is installed for reducing exhaust gas.
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Function, Structure, Operation 3)
Fuel system Fuel system diagram
1 2 3
Unless specifically instructed in the diagnostic procedure, do not use a test light when diagnosing the 4 powertrain electronic system. When a probe connector is required in the diagnostic procedure, use the connector test adapter kit. 5 Fuel filter 6 Common rail
Fuel injector
7
Supply pump
Fuel return pipe Fuel tank
8
Pre-fuel filter
CAUTION â&#x20AC;˘ Since the high-precision fuel system has been adopted, take care to prevent any foreign matter from entering the fuel system.
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Function, Structure, Operation Common rail
1 2
Flow damper Pressure limiter
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3 4
Fuel inlet Pressure sensor
Function, Structure, Operation Fuel supply pump
1 2
Fuel temperature 3 sensor Suction control 4 valve
High pipe
pressure
Camshaft nut
5
Union
6
Joint bolt
CAUTION â&#x20AC;˘ There is a gauze filter assembled inside the union of the fuel supply pump, but the union should not be removed to prevent any foreign matter from entering.
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Function, Structure, Operation
1 2 3 4 5
Union Gauze filter Supply pump Strainer Joint bolt
1 2 3 4 5 6
ID plate Terminal stud Injector drive section Injector assembly Gasket O-ring Leak-off pipe installation section
Injector
7 84402827B - May 2011 4001C-10
Function, Structure, Operation Fuel filter
1 2 3 4
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Priming pump Air bleed Case Drain plug
Function, Structure, Operation 4)
1 2 3 4 5
Cooling system The coolant system is the forced-circulation system, and its main components are the water pump, thermostat and radiator.
Water jacket Drain plug Oil cooler Water pump Drain cock
6 7 8 9 10
Radiator Cooling fan Radiator cap Radiator reserve tank Water outlet pipe
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11 12 13 14
Thermostat, 2 units Water temperature sensor Bypass route EGR cooler
Function, Structure, Operation Water pump The water pump is a centrifugal impeller type pump and is driven by the engine fan belt.
1 2
Fan guide Bearing
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3 4
Impeller Seal unit
Function, Structure, Operation Thermostat The thermostat is the wax pellet type, and consists of 2 units. One unit is the bottom bypass type and its initial open valve temperature is 82 째C (180째F), and the other unit is the inline type and its initial open valve temperature is 85 째C (185 째F). The structure allows the water temperature to be fine adjusted, and it is assembled inside the thermostat housing unit.
1 2
Jiggle valve 3 Stamp mark (initial open valve 4 temperature)
Valve Gasket
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5
Piston
Function, Structure, Operation 5)
*1 *2 *3 *4 *5 *6 *7 *8
Lubrication system A full-flow bypass integrated filter element, wateră&#x20AC;&#x20AC;cooling oil cooler, and piston coolant oil jet are adopted ă&#x20AC;&#x20AC;for the lubrication system.
Delivery Valve Oil Port Full Flow Oil Filter Oil pressure switch Oil Pressure Indicator Lamp Fuse Starter Switch Battery
*9 *10 *11 *12 *13 *14 *15 *16
Oil Cooler Thermo Valve Oil gallery Valve Mechanism Crankshaft Bearing Crank Valve Relief Valve Gear Train
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*17 *18 *19 *20 *21 *22 *23
Conn-rod Bearing Oiling jet Oil pump Strainer Flywheel P.T.O Turbochager Engine Oil Pan
Function, Structure, Operation Oil pump structural diagram
1 2 3
Driven gear assembly Oil pump body Drive gear assembly
4 5 6
Oil pump drive gear Oil pump body Drive gear assembly
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7 8
Driven gear assembly Oil pump drive gear
Function, Structure, Operation 6)
1 2 3 4
Induction system Turbocharger structural diagram
Turbine housing Heat protector Floating metal Oil thrower
5 6 7 8
Compressor housing Seal plate Compressor impeller Seal ring
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9 10
Seal ring Turbine shaft
Function, Structure, Operation 7)
Exhaust system
1
DPD assembly
2
Exhaust temperature sensor 1 4
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3
Exhaust temperature sensor 2 DPD differential pressure sensor
Function, Structure, Operation 8)
Emission control device EGR The EGR system recirculates a part of the exhaust gas to the intake manifold, and the generation of NOx is suppressed. By controlling the EGR system, high operability and exhaust gas reduction are both achieved. The control current from the ECM activate the solenoid to control the EGR valve lift amount. The EGR position sensor detects the actual valve lift amount and the data is used for precise control of the EGR amount. The EGR operates when the engine RPM, engine coolant temperature, intake temperature, and atmospheric pressure satisfy certain criteria. Thereafter, the valve opening angle is calculated according to the engine RPM and the desired fuel injection amount. The calculated valve opening angle is used to determine the motor drive duty and the valve is driven accordingly. The intake throttle valve closes when the EGR operates to ensure an appropriate internal pressure of the intake manifold.
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Function, Structure, Operation *1 *2 *3 *4 *5 *6
Intake throttle position sensor EGR valve EGR position sensor ECM ITA/MAF sensor Intake air
*7 *8 *9 *10 *11 *12
Engine speed Engine load Outlet port coolant Inlet port coolant EGR cooler IMT sensor
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*13 *14 *15 *16
Exhaust Intake throttle valve Boost temperature sensor Boost sensor
Function, Structure, Operation 9)
Electrical system Charging system The main components of the charging system are the battery, generator, and battery discharge indicator light circuit. Generator is a self-rectifier type with a regulator built in. Generator The generator is the brushless type. The main components are the rotor, stator, rectifier assembly, front bracket, rear bracket, IC regulator, bearing, pulley, etc. The moving parts are the rotor and pulley. The field coil is fixed to the rear bracket. 6 main diodes and 2 additional diodes are used to change the three-phase alternating current generated in the stator coil to a direct current. 3 out of the 6 main diodes are referred to as positive diode, and the rest is referred to as negative diode. In addition, 3 small diodes that are referred to as triodiode are used to supply the field current. This generator has 3 terminals of B terminal (direct current output terminal), L terminal and R terminal. Since the L terminal is connected to the field coil, it works as an input terminal together with the R terminal until the generator starts generating power. Also, it functions as an output terminal. (current capacity is 1 A) When the L terminal voltage reaches the battery voltage, the charge light turns off. Since the both bearings are sealed, periodic lubrications are not required. The IC regulator cannot be disassembled, so it should be handled as an assembly.
Starter system The starter is 5 kW and uses a reduction type. Gear housing and armature end bearing housing are made of aluminum. Brush assembly is an replaceable type. Commutator bar is insulated with mica and undercut. Starter circuit is started using a battery. The battery cable is connected to a large terminal on the starter. The wiring is connected from the terminal to the engine control switch and the starter relay. Starter The starter is an outer gearing mesh method reduction starter adopting the magnetic shift type. When the starter switch is turned ON, the plunger is drawn in, the contact point of the magnetic switch closes and the armature rotates. 84402827B - May 2011 4001C-21
Function, Structure, Operation At the same time, the pinion is pushed to the front via the shift lever to mesh with the ring gear. When the ring gear rotates, the crankshaft is turned to start the engine. After the engine is started, the plunger returns, the pinion separates from the ring gear, and the armature stops rotating when the starter switch is turned OFF. When the engine rotation becomes faster than the pinion, the pinion is caused to turn in reverse, but the pinion just idles due to the one-way clutch function, so the armature is not driven.
1 2 3
Brush holder Magnetic switch assembly Lever assembly
4 5 6
Pinion Clutch Internal gear
7 8
Preheat system The preheat system has adopted the QOS system glow plug type. Also, the energization control is performed by the ECM.
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Armature Yoke
Function, Structure, Operation 10)
Engine control system Engine control system overview and implementation The engine control system is an electronic control system that controls the engine to be always in the optimal combustion state according to the driving condition, and consists of the electronic control fuel injection system, EGR, and idling control. Also, besides controlling the engine, the engine control system has the QOS system, engine RPM signal output, self-diagnosing function, and CAN communication SAE J1939/21 and SAE J1939/11 system control functions. System control schematic The specifications vary depending on the actual unit, so refer to the manual of the actual unit.
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Function, Structure, Operation Correction
a
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Engine coolant temperature correction Barometic Pressure Fuel temperture boost pressure correction Correction between sylinder Q-key correction QR correction
Function, Structure, Operation *1
Accelerator position sensor in*8 put
*2
Boost sensor input
*9
*3 *4 *5 *6 *7
CKP sensor input CMP sensor input Engine control module (ECM) Basic fule injection amount Correction
*10 *11 *12 *13 *14
SCV opening time determination Injector coil energizing time Timing determination CAN communication Machine control unit Water temperture sensor input Common rail pressure sensor Common rail
*15 SCV *16 Supply pump *17 Fuel tank *18 Injector coil *19 Injector
Fuel injection correction The ECM calculates the basic injection amount based on the signals from the accelerator position sensor, boost sensor, crankshaft position sensor, camshaft position sensor, etc. At this time, the open or close timing of the SCV and the energizing time of the injector are controlled based on the conditions such as the common rail pressure and engine coolant temperature to make optimal corrections to the injection timing and injection amount.
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Function, Structure, Operation About initial Q correction ECM implements the initial Q correction when the initial Q correction is under the specified engine rotation during engine start. Also, ECM cannot implement the initial about initial Q correction and cannot start the engine because it does not recognize the engine rotation when it is under the engine rpm the system can recognize.
Engine speed (r/min)
*1 *2 *3 *4
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Idle speed Starting Q specified engine Minimum firing engine speed Systme realization engine speed
Function, Structure, Operation About high altitude correction ECM calculates the current altitude using signals from the atmospheric pressure sensor. According to the conditions such as the current altitude, the fuel amount is corrected properly.
Fuel flow limit (mm3/st)
Barometric pressure kPa (psi) *1
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High/and
Function, Structure, Operation Control during overheat To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 °C (212 °F). When the engine coolant temperature increases further, the fuel flow is also restricted further. When the temperature reaches 110 °C (230 °F), a failure is recorded in the ECM. When the temperature is near 120 °C (248 °F), the fuel flow is restricted to a certain level. The setting varies depending on the actual unit manufacturer. The actual unit is designed to issue an alarm from 105 °C (221 °F). By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condition with fuel flow restriction.
Fuel flow
Water temperature *1
Warning indication DTC set
If the ECM is equipped with an emergency stop function by a high engine coolant temperature, it stops the engine when the temperature has reached 105 °C (221 °F).
Fuel flow
Water temperature *1
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Engine emergency stop
Function, Structure, Operation Engine emergency stop function The ECM is designed to make an emergency engine stop when an input from the engine stop switch, decrease in the engine oil pressure, increase in the engine coolant temperature or overrun occurs. As for emergency stop made due to decrease in the engine oil pressure, increase in the engine coolant temperature or overrun, the control is performed when the corresponding function is added to the calibration of the ECM. Input from engine stop switch The engine stops when the battery voltage is applied to the ECM terminal No. 121.
*1 *2
Engine stop switch Starter switch (ON)
Decrease in engine oil pressure When the engine oil pressure drops to 100 kPa (100 °C) or lower, an alarm for engine oil pressure decrease is issued and the engine is stopped. Increase in engine coolant temperature When the engine coolant temperature increases to 105 °C (221 °F) or higher, an alarm for engine coolant temperature increase is issued and the engine is stopped. Overrun When the engine RPM reaches to the specified value, an alarm for overrun is issued and the engine is stopped. It varies depending on the actual unit manufacturer.
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Function, Structure, Operation I/O Table Injection control output
Sensor input • • • • • • • • • • • • • • • • •
CKP sensor CMP sensor Water temperature sensor Fuel temperature sensor IAT sensor IMT sensor Fuel pressure sensor Boost temperature sensor Barometric pressure sensor Accelerator position senser EGR position sensor Intake throttle position sensor DPD differential pressure sensor (1: in front of filter, 2: in front of oxidation catalyst) Boost sensor Oil pressure sensor MAF sensor Fuel sensor
• Suction control valve • TWV (injector) Actuator control output • EGR DC motor • Intake throttle motor Relay, lamp control output
ECM
• • • • • •
Switch input • • • • • • • • • • • • •
• • • • • • • •
Starter switch (ON/start) Diagmostic swich Idling control selector switch Idling control switch (UP/Down) Mode map switch 0 Mode map switch 1 Mode map switch 2 Reguration mode switch Load advance switch SCV switch Memory clear switch Engine stop switch DPD switch
Glow relay Starter cut relay ECM main relay Hour meter relay Fiagnosis lamp Glow lamp Engine hydraulic lamp Boost temperature sensor pilot lamp Overhead lamp Engine overrun lamp DPD regenerate lamp Fuel temperature lamp Fuel filter pressure lamp DPD lamp
Commumication • Speed signal • Diagnostic scan tool • CAN (ECU on machine side)
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Function, Structure, Operation Electronic control fuel injection system This is the system in which the ECM obtains information such as the engine RPM and engine load and sends the electrical signals based on the information to the supply pump, injectors, etc. to properly control the fuel injection amount and injection timing for each cylinder. Injection amount control To make the injection amount optimal, the fuel injection amount is controlled by regulating the injector based on mainly the signals from the engine RPM and accelerator opening angle or the instructed rotation from the control unit in the actual unit.
a
*1
Accelerator Pedal Position
*4
*2 *3
Engine Speed Basic Fuel Injection Quantity
*5 *6
Maximum Fuel Injection Quan*7 tity Recuction Rate *8 Final Fuel Injection Quantity *9
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• Boost Press. • Coolant Temp, • Barometiric Press. Fuel Injection Quantity Correction Injector ON Time Determination Cylinder Dry Cylinder Crrection
Function, Structure, Operation Injection pressure control The injection pressure is controlled by regulating the fuel pressure inside the common rail. The proper pressure inside the common rail is controlled by calculating from the engine RPM, fuel injection amount, etc., and the appropriate amount of the fuel is discharged by regulating the supply pump to be force-fed to the common rail. Injection timing control This control is performed by calculating the proper fuel injection timing mainly from the engine RPM or injection amount in substitution for the timer function to regulate the injector. Injection rate control To improve combustion inside the cylinder, only a small amount of the fuel is injected first to be ignited, and then the second injection is performed when ignition is made. This control for injection timing and injection amount is performed through regulating the injector. Maximum fuel injection amount The maximum fuel injection amount is the amount of fuel injection calculated by adjustment of initial injection amount under certain water temperature, limitation of maximum injection amount for the boost pressure, and control of injection amount for the high altitude due to the atmospheric pressure. Inter-cylinder correction It is not used for this engine.
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Function, Structure, Operation System schematic
Each sensor a
*1 *2 *3 *4
Electromagnetic pump Fuel filter Pre filter Supply pump
*5 *6 *7 *8
Fuel pressure sensor Common rail Pressure limiter Flow damper
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*9 *10 *11 *12
Accelerator, Boost pressure, Water tempe rature, etc. Injctor CMP sensor CKP sensor ECM
Function, Structure, Operation Fuel system The fuel is supplied to the supply pump from the fuel tank, and then it is boosted by the pump before supplied to the common rail. At this time, the fuel amount to be supplied to the common rail is controlled by regulating the suction control valve based on the signal from the ECM.
1 2 3
Electromagnetic pump Fuel filter Common rail
4 5 6
Fuel injector Fuel return pipe Fuel tank
7 8
Supply pump Pre-fuel filter
Fuel filter clog warning function and engine RPM restriction function When the clogged fuel filter is kept used, the ECM detects DTC P0093, and the output restriction is implemented. The first stage In order to notify a filter clogging before DTC P0093 is detected, the first stage alarm is issued when the output value from the fuel filter pressure sensor falls below the specified threshold value. The alarm stops when the output value exceeds the threshold value. The second stage The second stage alarm is issued when the output value from the fuel filter pressure sensor falls below the threshold value even after the first stage alarm occurs. The second stage alarm remains as issued until the starter switch is turned OFF. At the same time as the second stage alarm is issued, the target engine RPM is reduced gradually at a constant rate. When the output value from the sensor exceeds the specified threshold value, reduction of the restricted engine RPM is stopped, and the regulation is continued maintaining the restricted engine RPM at that time. When the output value from the sensor falls below the threshold value again, the restricted engine RPM is reduced further. When the starter switch is turned OFF and then turned back ON, the restriction is once cancelled.
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Function, Structure, Operation
1 2 3
Supply pump Warning light Monitor
4 5 6
Monitor, CAN communication Fuel tank Pre-filter
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7 8 9
Electromagnetic pump Fuel filter pressure sensor Main filter
Function, Structure, Operation
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1 2
First stage Second stage
*1 *2 *3
Lamp Starter SW Engine Speed (r/min)
Function, Structure, Operation Removing air from fuel system Place an appropriate pan under the air removal plug. Turn the starter switch ON, and activate the electromagnetic pump. Loose the air removal plug of the fuel filter sufficiently, and operate the priming pump 20 times or more until the fuel comes out from near the plug. Tighten the plug, and operate the priming pump 10 times or more until the fuel permeates. Wait for approx. 1 minute, and then loosen the plug to remove the air in the fuel filter. This should be repeated at least 3 times until no air comes out from the plug. Securely tighten each plug, and wipe off the fuel spilled around. Operate the priming pump 10 - 15 times until the fuel permeates and then is fed to the engine.
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a
On the machine with electromagnetic pump
*1 *2 *3 *4
Pre fuel filter Electromagnetic pump Fuel filter Supply pump
Function, Structure, Operation EGR The EGR system recirculates a part of the exhaust gas to the intake manifold, and by mixing in inert gas to the intake air, the combustion temperature is lowered and the generation of NOx is suppressed. The EGR amount is controlled by opening and closing the EGR valve provided between the exhaust manifold and intake manifold. The EGR amount is determined from the engine RPM and engine load ratio and the EGR valve is operated to control the EGR amount. By installing the EGR cooler on the path of the EGR gas, high-temperature gas is cooled by the EGR cooler and then mixed with fresh air to further lower the burning temperature in order to reduce NOx amount. Further, the EGR system is also equipped with a check valve to prevent the EGR from flowing in the opposite direction to increase the EGR amount. EGR control The ECM controls the EGR valve lift amount by operating the motor according to the engine status such as the engine RPM and engine load. The valve lift amount is detected by the EGR position sensor. Darker portions in the diagram represent large valve lift amounts and the darkest portion represents the lift amount of nearly 100 %.
Accelerator position
Engine speed *1
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No idle EGR
Function, Structure, Operation EGR system schematic diagram
*1 *2 *3 *4 *5 *6
Intake thottle position sensor EGR valve EGR position sensor ECM IAT/MAF sensor Intake air
*7 *8 *9 *10 *11 *12
Engine speed Engine load Outlet port of coolant Inlet port of coolant EGR cooler IMT sensor
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*13 *14 *15 *16
Exhaust Intake throttle valve Boost temperature sensor Boost sensor
Function, Structure, Operation EGR and turbine noise Some engines may generate high frequency noise due to the turbine rotation. This high frequency noise can be muted using an appropriate silencer. For some OEMs which use in residential areas is not assumed, the silencer for muting the high frequency noise may be omitted from the specifications, leaving the noise. The high frequency noise tends to become lower while controlling the EGR and louder when EGR control is not provided.
*1 *2
Without EGR Wiht EGR
Turbocharger control The turbocharger is a system that provides efficient supercharge to archive the turbo effect by overcoming the turbo's weakness of low exhaust energy during low engine revolution. The turbocharger optimizes the turbine revolution by varying the nozzle opening angle within the turbine housing to adjust the turbo inlet area according to the revolution and load of the engine and control the supercharging pressure. The ECM sends the target nozzle opening angle based on the information from each sensor to the turbocharger through CAN communication to control the boost pressure properly in accordance with the engine load requirements. The turbocharger drives the actuator based on the information received from the ECM and controls the nozzle opening angle through the control rod.
*1 *2 *3
ECM CAN communication Control rod
*4 *5 *6
Actuator with built-in ECU Nozzle closing direction Exhaust gas inlet
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*7 *8 *9
Exhaust gas outlet Turbine wheel Nozzle
Function, Structure, Operation Engine operation control There are the following 4 types of operation control instructions, and the selection varies depending on each specification. Voltage input by APS, 1 - 4 V Accelerator opening angle instruction given through CAN communication control, 0 - 100 %, RPM instruction RPM instruction given through mode map switch control, RPM instruction and change instruction given by APS Increase and decrease instruction for each rotation given by the idle switc Mode map switch The mode map switch has 6 rotation control mode types of H, S, L, B, I and LM. The rotation settings are H > S > L > B, I > LM. For H, S, L and B, the rotation speed can be decreased by the APS However, any change cannot be made from the APS for I and LM.
When the regulation mode switch input is present in addition to the mode map switch, the following 2 types of control methods are available.
84402827B - May 2011 4001C-41
*1
Directed speed
*1
Directed speed
Function, Structure, Operation H, S, L and B of the mode map switch change as follows depending on the APS input.
Meaning of mode map switch and each mode In the APS, a change toward the engine RPM decrease direction can be made from each mode point. The specified engine RPM for H, S, L and B are determined depending on the calibration of the ECM.
CAN communication When CAN controller does not exist on the actual unit side
*1 *2 *3 *4 *5 *6
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Diagnostic scan tool MCX ECM LCD TCM Shift Control
Function, Structure, Operation When CAN controller exists on the actual unit side
*1 *2 *3 *4 *5
Diagnostic scan tool MCX ECM TCM Shift Control
Mode map switch control
*1 *2 *3 *4
Accelerator position sensor Engine stop switch Idling selector switch Idle up switch
*5 *6 *7 *8
Idle down switch Mode map switch 0 Mode map switch 1 Mode map switch 2
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*9 Reguration mode switch *10 Load advance switch
Function, Structure, Operation Operation mode H
S L I B LM
Outer switch MAP0 MAP1 OFF OFF OFF ON ON ON ON OFF OFF ON OFF OFF ON ON ON OFF
Control MAP2 OFF ON ON OFF OFF ON OFF ON
Basic operations
Maximum rotation count control #1 Maximum rotation count control #2 Constant rotation operation #1 Maximum rotation count control #3 Constant rotation operation #2
I, LM and H modes
*1 *2 *3
Regulation mode switch Idle speed Max. speed
*1 *2
Idle speed Max. speed
H, S, L, and B modes
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Function, Structure, Operation H, S, L, and B modes (irrigation pump)
*1 *2
Idle speed Max. speed
Accelerator position switch By operating the accelerator position switch, the output voltage changes between 1 V and 4 V. Voltages between 0.2 V and 1.05 V are recognized as 1 V. When the voltage is lowered below 0.2 V or raised above 1.05 V, an error is detected. In addition, if the ECM terminals 85 and 86 are not at the same potential, DTC P2138 is detected.
*1
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Accelerator pedal position sensor
Function, Structure, Operation Accelerator position switch, with APS learning control If the APS learning control is available, for example, when the ignition cycle ends with the accelerator position as 2 V (1), the accelerator position learning causes the 2 V status to be recognized as the opening angle 0 % and the control range is set to 2 V to 4 V (2).
Regulation mode switch When an input from the regulation mode switch is present, the engine RPM changes as follows.
*1
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Regulation mode switch
Function, Structure, Operation Idling control By operating the idling control change switch during the warm-up operation, the minimum idling RPM can be adjusted. In addition, by operating the idling control change switch, the minimum idling RPM can be automatically set to the optimum value in accordance with the engine coolant temperature. ANNOTATION: â&#x20AC;˘ The specifications vary depending on the actual unit, so availability of functions also differ. Idling control change switch By operating the idling control change switch, the idling control functions can be switched. The idling control switch By operating idling control switch, the idling RPM can be adjusted. ANNOTATION: â&#x20AC;˘ As for the installation positions of the idling control change switch and idling control switch, refer to the manual of the actual unit. The engine RPM upper limit varies depending on the engine model, actual unit specifications and engine warming-up condition. Up While the Up side of the switch is pressed, the engine RPM is increased and the idling RPM can be raised. Down While the Down side of the switches is pressed, the engine RPM is decreased and the idling RPM can be lowered. However, the engine RPM cannot be decreased below the minimum idling RPM. Control during starter switch OFF state There are 2 types of controls provided when the starter switch is turned OFF after the idling control switch is operated, and either one of them is performed depending on the specification. The engine RPM adjusted by the idling control switch is recorded in the ECM, and the next operation is performed with the engine RPM at the time when the starter switch is turned OFF. The engine RPM adjusted by the idling control switch is not recorded in the ECM, and the next operation is performed with the default engine RPM. As for confirmation and questions regarding the specifications, contact an Isuzu service related person. Idle manual control
*1 *2
Starter switch Idle up switch
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*3 *4
Idle down switch Engine speed
Function, Structure, Operation Engine RPM output to tachometer The ECM outputs the engine rpm pulse to the tachometer as a tachometer output. The tachometer displays the engine RPM based on the engine RPM pulse sent from the ECM.
a *1 *2 *3
CKP sensor Engine speed Engine control module (ECM)
*4 *5 *6
CAN communication Control unit on machine side Tachometor output
Output from machine control unit by machine Tachometer
*7
Preheat control QOS system The ECM determines the glow time according to the engine coolant temperature, and activates the glow relay and the QOC indicator light. The QOS system is a system to facilitate engine start in a low temperature as well as reducing the amount of white smoke and noise generated immediately after engine start. When the starter switch is turned ON, the ECM detects the temperature of the engine coolant based on the signal sent from the water temperature sensor to change the glow time, so the engine can be always started under the optimum conditions. Also, the after-glow function can stabilize the idling immediately after engine start.
a *1 *2 *3
Starter switch (ON) Battery Glow relay
*4 *5 *6
QOS indicator lamp (ECM) Water temperature sensor
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*7
LCD or Lamp Glow plug
Function, Structure, Operation DPD DPD uses the oxidation catalyst to clean NOx and HC, and uses a dedicated filter to collect PM emitted from the engine. When PM has accumulated on the filter, the filter regeneration is performed.The ECM detects the accumulation status of PM from the DPD differential pressure sensor or mileage. When the accumulated amount of PM or mileage has reached a certain value, automatic regeneration of the filter is performed. During regeneration, the filter is heated up to burn the accumulated PM. To adjust the burning temperature to the optimum value, the ECM detects the exhaust temperature using the the exhaust temperature sensor and control fuel injection to raise the temperature to burn the accumulated PM. When regeneration has started, it must complete within a certain period of time. After regeneration has completed, the purification status of the filter can be determined by checking the exhaust differential pressure. When excessive amount of accumulated PM has been detected, regeneration is not performed because burning cannot be controlled, but the check engine warning light is turned ON instead.
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Function, Structure, Operation 1 2 3 4
Engine MAF sensor Air cleaner Various sensors
5 6 7 8
ECM DPD switch Silencer Filter
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9 10 11
Oxidation catalyst Exhaust gas temperature sensor DPD differential pressure sensor
Function, Structure, Operation ECM About ECM function The ECM constantly monitors the information sent from various sensors, and controls the each system of the powertrain. The ECM performs the diagnostic functions of the system, detects operational problems of the system, warns the operator via the monitor, and records the DTC. The DTC identifies the area where the problem has occurred to assist the repair operation performed by the technician. The ECM outputs voltages (e.g., 5 V) to supply power to various sensors and switches. The ECM controls the output circuit by controlling the ground or power supply circuit via one of the devices. ANNOTATION: • As for the ECM installation position, refer to the manual of the actual unit.
ECM and components The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel efficiency. The ECM monitors various engine functions via the sensors such as the crankshaft position sensor. ECM voltage The ECM applies the standard voltage to various switches and sensors. The ECM is able to apply voltage in such a way because the ECM resistance value is very high. The voltage that is actually applied to the circuit is low. Therefore, the test light may not illuminate even if it is connected to the circuit. The voltmeter that is normally used at maintenance factories may not display a correct reading because its input impedance is too low. An accurate voltage reading can be obtained by using a digital multimeter with an input impedance of 10MΩ (for example, 5-8840-2691-0). Electrically Erasable Programmable Read Only Memory, EEPROM EEPROM contains various programs and calibration information necessary for the ECM to control the power train operations. If abnormalities are found with the EEPROM, replace the ECM. The program and calibration information for the ECM power train control includes the engine type, engine number, ECM part number, DTC, inter-cylinder correction learning value, QR, Q tune, and EGR correction learning value. Notes on ECM maintenance The ECM has been designed to withstand the regular current consumption associated with the actual unit operation. Make sure that the circuit does not overload. When performing tests for an open circuit or short circuit, do not ground or apply voltage to the circuit of the ECM, unless otherwise instructed. When performing these circuit tests, make sure to use the digital multimeter 5-8840-2691-0. ANNOTATION: • Use the ECM which has the part No. corresponding to the actual unit. When performing welding work on the actual unit, start the work after disconnecting the negative terminal of the battery. Turning OFF of the ECM power supply In approximately 10 seconds after turning the starter switch to OFF, the internal power supply of the ECM is not turned to OFF. 84402827B - May 2011 4001C-51
Function, Structure, Operation When it is necessary to turn OFF the ECM power supply, e.g., when clearing the memory, it is required to wait for 10 seconds or longer after turning the starter switch OFF.
*1 *2
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Starter switch ON Starter switch OFF
Function, Structure, Operation Engine components location diagram Locations, shapes and existence or nonexistence of components vary depending on the specifications of the actual unit.
1 2 3 4 5
Overheat switch Water temperature sensor Glow plug Injector Boost sensor
6 7 8 9 10
Boost temperature sensor IMT sensor Fuel temperature sensor Suction control valve CKP sensor
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11 12 13 14 15
Oil pressure sensor Oil level switch Fuel pressure sensor EGR valve CMP sensor
Function, Structure, Operation Supply pump The supply pump highly pressurizes the fuel using the engine torque, and force-feeds the fuel to the common rail. Also, the suction control valve, fuel temperature sensor, feed pump, etc, are installed on the supply pump.
1 2 3
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Fuel temperature sensor Suction control valve Feed pump
Function, Structure, Operation Suction control valve The suction control valve is installed on the supply pump portion, and controls the fuel force-feed to the common rail. The ECM controls the fuel discharge amount by regulating the energizing time to the suction control valve.
1
84402827B - May 2011 4001C-55
Suction control valve
Function, Structure, Operation Fuel temperature sensor The fuel temperature sensor is installed on the supply pump, and the thermistor changes the resistance value according to the temperature change. The resistance value becomes lower when the fuel temperature is high, and it becomes higher when the fuel temperature is low. The ECM applies 5 V to the fuel temperature sensor through the pull-up resistor, and it calculates the fuel temperature from changes in the voltage and uses it for controlling the supply pump, etc. The voltage becomes lower when the resistance is lower, and it becomes higher when the resistance is higher. ANNOTATION: â&#x20AC;˘ Do not replace the fuel temperature sensor. When an abnormality is found, replace the supply pump assembly.
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Function, Structure, Operation Common rail The common rail receives the fuel from the supply pump, retains the fuel pressure and distributes the fuel to each cylinder. The fuel pressure sensor, flow damper and pressure limiter are installed on the common rail.
1 2 3 4
Flow damper Pressure limiter Fuel pressure sensor Common rail
Flow damper The flow damper is installed to the discharge port on the common rail leading to each injector, and regulates the pressure pulsation in the common rail and prevents excess fuel injection from the injector. When the flow damper is activated, fuel supply to the injector is stopped.
1
Flow damper
Pressure limiter The pressure limiter is activated when the pressure in the common rail becomes abnormally high to release the pressure inside the common rail.
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Function, Structure, Operation 1
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Pressure limiter
Function, Structure, Operation Fuel pressure sensor The fuel pressure sensor is installed on the common rail, and detects the fuel pressure inside the common rail to convert into the voltage signal and sends it to the ECM. The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the actual fuel pressure from the voltage signal sent from the sensor, and uses it to control the fuel injection, etc.
1
Fuel pressure sensor
Injector The injector is installed on the cylinder head portion, and is controlled by the ECM to perform fuel injection. The ECM internally boosts the voltage for driving the injector to apply it to the injector, and uses it for fuel injection amount control and injection timing control by regulating the energizing time of the injector.
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Function, Structure, Operation Water temperature sensor Water temperature sensor is installed on the engine block, and the thermistor changes the resistance value according to the temperature change. The resistance value becomes smaller when the engine coolant temperature is high, and the value becomes larger when the engine coolant temperature is low. The ECM applies 5 V to the water temperature sensor through the pull-up resistor, and calculates the engine coolant temperature from changes in the voltage. This value is used in various control mechanisms, such as for fuel injection control. The voltage becomes higher when the resistance is higher, and it becomes lower when the resistance is lower.
Overheat switch The overheat switch is installed on the water outlet pipe, and is turned ON when the engine coolant temperature exceeds 105 °C (221 °F).
Crankshaft position sensor The crankshaft position sensor is installed on the flywheel housing and the CKP signal is generated every time when the protruding section of the flywheel passes the sensor. The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the camshaft position sensor, and uses the information for the fuel injection control and calculation of the engine RPM. While this control is usually performed using the CKP signal, the CMP signal is used instead when the crankshaft position sensor is faulty.
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Function, Structure, Operation Camshaft position sensor The camshaft position sensor is installed behind the cylinder head, and generates a CMP signal when the camshaft cam passes by it. The ECM determines the cylinder and specifies the crank angle using the CMP signal input from the camshaft position sensor, and uses the information for the fuel injection control and calculation of the engine RPM. While this control is usually performed using the CKP signal, the CMP signal is used instead when the crankshaft position sensor is faulty.
1 2 3
Camshaft gear Rotational direction CMP sensor
Oil pressure sensor The oil pressure sensor is installed near the starter motor of the cylinder block, and it detects the pressure of the engine oil to convert into the voltage signal and send it to the ECM. The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower.
Accelerator position sensor The accelerator position sensor is installed on the console panel of the actual unit to supply the voltage signal which varies in accordance with the accelerator volume angle to the ECM. The ECM calculates the trottle accelerator switch position from the voltage signal, and uses it for fuel injection control and many other controls. ANNOTATION: â&#x20AC;˘ As for the installation position of the accelerator position sensor, refer to the manual of the actual unit.
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Function, Structure, Operation Atmospheric pressure sensor The atmospheric pressure sensor is installed on the actual unit side, and it replaces the atmospheric pressure with the voltage signal. The ECM calculates the atmospheric pressure from the voltage signal, and uses the atmospheric pressure to correct the fuel injection amount. ANNOTATION: â&#x20AC;˘ As for the installation position of the atmospheric pressure sensor, refer to the manual of the actual unit.
EGR position sensor This sensor is installed inside the EGR valve to detect the EGR valve lift amount. ANNOTATION: â&#x20AC;˘ Do not disassemble the EGR position sensor. When an abnormality is found, replace the EGR valve assembly.
Boost sensor The boost sensor detects the boost using the pressure hose between the boost sensor and intake pipe to convert into the voltage signal and sends it to the ECM. The voltage becomes higher when the pressure is higher, and it becomes lower when the pressure is lower. The ECM calculates the boost from the voltage signal sent from the sensor, and uses it to control the fuel injection, etc.
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Function, Structure, Operation
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Function, Structure, Operation The boost temperature sensor The boost temperature sensor is installed to the EGR valve upstream side of the intake manifold. The sensor is the thermistor type, and the resistance value inside the sensor changes in accordance with the change in the temperature.
Fuel filter pressure sensor The fuel filter pressure sensor is installed on the fuel filter, and converts the negative pressure in the fuel filter into the voltage signal. The ECM calculates the negative pressure in the fuel filter based on the voltage signal to determine clogging in the fuel filter.
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Function, Structure, Operation Intake air temparture and mass air flow sensors Intake air temperature sensor The intake air temperature sensor is installed on the duct between the air cleaner and turbocharger. The intake air temperature sensor is variable resistance inside the mass air flow sensor to measure the temperature of air taken into the engine. When the intake air temparture sensor is cold, the resistance of the sensor is high. When the air temperature rises, the resistance of the sensor becomes low. For high sensor resistance, the ECM detects a high voltage of the signal circuit. For low sensor resistance, the ECM detects a low voltage of the signal circuit. Mass air flow sensor The mass air flow sensor measures the amount of air taken into the engine, and it is installed on the duct between the air cleaner and turbocharger. The mass air flow sensor consists of the mass air flow sensor and intake air temperature sensor to measure some of air flowing in the duct. A small amount of air taken into the engine indicates deceleration or idle RPM. A large amount of air indicates acceleration or high load. Intake throttle valve
The intake throttle valve is installed on the inlet of the inlet manifold. The ECM controls the opening angle of the intake throttle valve according to the condition of engine operation. The motor inside the intake throttle valve is controlled based on the duty ratio signals sent from the ECM. The opening angle of the intake throttle valve is adjusted when the duty ratio is changing from 0 % to the appropriate ratio. The valve closes when the duty signal increases, and the valve opens when the duty signal decreases. The opening angle of the intake throttle valve is detected by the position sensor. The position sensor outputs the signal representing the intake throttle valve opening angle. The ECM detects a low signal voltage when the opening angle is small or the valve is at the closed position. Also, the ECM detects a high signal voltage when the opening angle is large.
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Function, Structure, Operation DPD differential pressure sensor The DPD differential pressure sensor is installed near DPD. DPD differential pressure sensor varies the signal voltage according to changes of the exhaust gas differential pressure between in front and rear of DPD filter. he ECM detects a lower signal voltage when the differential pressure is small due to a small amount of accumulated PM. The ECM detects a higher signal voltage when the differential pressure is large due to a large amount of accumulated PM. The ECM uses this voltage signal for controlling DPD regeneration and determining purification after regeneration. It also uses the signal voltage to detect filter failures such as a too low differential pressure.
Exhaust gas temperature sensor The exhaust gas temperature sensors are the variable resistors that are installed at 2 locations on the DPD housing, and one is installed in front of the DPD oxidation catalyst, and the other is installed in front of the filter. The exhaust gas temperature sensor 1 that is located in front of the filter measures the temperature of the exhaust gas before entering the DPD filter, and the exhaust gas temperature sensor 2 that is located in front of the oxidation catalyst measures the temperature of the exhaust gas before entering the oxidation catalyst. When the exhaust gas temperature sensor is cold, the resistance of the sensor is high. When the exhaust temperature rises, the resistance of the sensor decreases. The ECM detects a high voltage in the signal circuit when the sensor resistance is high. Also, the ECM detects a low voltage in the signal circuit when the sensor resistance is low. The ECM uses this voltage signal for temperature control during the DPD regeneration.
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Function, Structure, Operation IMT sensor The IMT sensor is a variable resistance installed on the intake manifold to measure the intake temperature of the intake manifold. When the sensor is cold, the sensor resistance is high. When the intake temperature rises, the sensor resistance decreases. For low sensor resistance, the ECM detects a low voltage of the signal circuit.
Turbocharger The turbocharger has an actuator with built-in control unit installed. The opening angle of the turbocharger variable nozzle is driven by the actuator. The built-in control unit performs CAN communication, and the ECM performs control that changes the boost pressure by adjusting the nozzle opening angle in accordance with the load requirement for the engine.
*1
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Turbo actuator
Function, Structure, Operation Monitor By turning ON the diagnostic switch, the DTC is indicated by blinking. ANNOTATION: â&#x20AC;˘ As for the installation position of the monitor, refer to the manual of the actual unit. DLC DLC is the connector for communication and connection between the trouble diagnosis scanning tool and various controllers. ANNOTATION: â&#x20AC;˘ As for the DLC installation position, refer to the manual of the actual unit.
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Function, Structure, Operation Diagnostic switch The diagnostic switch shorts the DLC terminal No. 1 and No.4 or No.5 and flashes the monitor to indicate the DTC. ANNOTATION: • As for the installation position and shape of the diagnostic switch, refer to the manual of the actual unit. Memory clear switch This is used when clearing the recorded DTCs in the ECM by operating the diagnostic switch and the memory clear switch. ANNOTATION: • As for the installation position of the memory clear switch, refer to the manual of the actual unit. Mode change switch (0, 1, 2) The operation can be performed at the engine RPM specified for each mode by switching the mode change switch. ANNOTATION: • As for the installation position of the mode change switch, refer to the manual of the actual unit.
1 2 3 4 5 6 7 8
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Starter switch Engine stop switch Fuel meter Memory clear switch Mode switch Water temperature gauge Oil temperature gauge Hour meter
Function, Structure, Operation ECM power distribution diagram Some sensors may not be connected to the ECM depending on the specifications of the actual unit. Since some sensors may perform input/output with the ECM depending on the CAN communication, confirm the specifications of the actual unit.
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Function, Structure, Operation
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Function, Structure, Operation *1 *2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 *13 *14 *15 *16 *17
Accelerator pedal position sensor BARO sensor DPD differential pressure sensor fuel filter pressure sensor Exhaust temperature sensor 1 (in front of filter) Exhaust temperature sensor 2 Engine stop switch Idling selector switch Idle up switch Idle down switch Mode map switch 0 Mode map switch 1 Mode map switch 2 Reguration mode switch Load advance switch DPD regeneration switch SCV switch
*18 Memory clear switch
*35 Power ground
*19 diagnosis switch
*36 Power ground
*20 MAF sensor
*37 Power ground
*21 IAT sensor
*38 Power ground
*22 CKP sensor
*39 diagnosis lamp
*23 *24 *25 *26 *27 *28 *29 *30 *31 *32 *33 *34
Fuel pressure sensor Starter switch (ON) Starter switch (START) Main relay Starter switch Battery Dropping resistor Case ground Signal ground Signal ground Power ground Power ground
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*40 *41 *42 *43 *44 *45 *46 *47 *48 *49 *50 *51
Oil pressure lamp Glow plug lamp Boost temperature lamp Over heat lamp Engine over run lamp DPD regemerate lamp Fuel temperature lamp Fuel filter pressure lamp DPD lamp Glow relay Glow plug ECM
Function, Structure, Operation
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Function, Structure, Operation *1 *2 *3 *4 *5 *6 *7 *8 *9
Boost sensor EGR position sensor Intake throttle position sensor Fuel temperature sensor CMP sensor Boost temperature sensor Oil pressure sensor Water temperature sensor IMT sensor
*10 *11 *12 *13 *14 *15 *16 *17 *18
Starter cut relay Hour meter relay Starter Tacho meter TOOL OEM unit Terminator Turbo unit EGR DC motor
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*19 *20 *21 *22 *23 *24 *25 *26 *27
Intake thrttle motor Fuel injector 1 (Cylinder #1) Fuel injector 1 (Cylinder #3) Fuel injector 1 (Cylinder #2) Fuel injector 1 (Cylinder #5) Fuel injector 1 (Cylinder #6) Fuel injector 1 (Cylinder #4) Suction control valve ECM
Function, Structure, Operation ECM pin assignment
60 pin connector Pin No. 1 2 3 4 5 6 7 8 9 10 11 12
Pin name OP-COM1A OP-COM1B OP-COM1C OM-EBM3 EGR SP-5V4 SP-5V8 IA-MAT IA-THL IA-THBST IA-PFUEL IA-OILPRESS
Connection Injector power supply 1, First cylinder Injector power supply 1, Third cylinder Injector power supply 1, Second cylinder valve DC servomotor power input W Boost sensor power supply IMT sensor signal Fuel temperature sensor signal Boost temperature sensor signal Fuel pressure sensor signal Oil pressure sensor signal 84402827B - May 2011 4001C-75
Function, Structure, Operation Pin No. 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Pin name IA-MAP IA-IDMPOS OP-SCVHI OP-COM2A OP-COM2B OP-COM2C OM-EBM2 SP-5V5 SP-5V6 SP-5V7 IA-THW
Connection Boost sensor signal Intake throttle position sensor signal SCV-HI drive Injector power supply 2, Fifth cylinder Injector power supply 2, Sixth cylinder Injector power supply 2, Fourth cylinder EGR valve DC servomotor power input V Crankshaft position sensor, fuel pressure sensor power supply Camshaft position sensor power supply Oil pressure sensor power supply Water temperature sensor signal Boost sensor, EGR position sensor, intake throttle position sensor, fuel temperature sensor SG-5VRT4 GND SG-SLD5 Crankshaft position sensor shield IA-OPLO OP-SCVHI SCV-HI drive Injector 1, First cylinder OS-INJ1 Injector 5, Second cylinder OS-INJ5 Injector 4, Sixth cylinder OS-INJ4 OM-EBM1 EGR valve DC servomotor power input U SG-5VRT7 Oil pressure sensor, water temperature sensor GND SG-5VRT5 Intake air temperature sensor, crankshaft position sensor, fuel pressure sensor GND SG-5VRT6 Camshaft position sensor, boost temperature sensor GND SG-SLD6 Camshaft position sensor GND IA-SCVLO SCV-LO drive Injector 3, Third cylinder OS-INJ3 Injector 6, Fourth cylinder OS-INJ6 Injector 2, Fifth cylinder OS-INJ2 Intake throttle motor, + OM-IDM1 Intake throttle motor, OM-IDM2 IS-EBMPOS1 EGR position sensor signal U IS-EBMPOS2 EGR position sensor signal V IS-EBMPOS3 EGR position sensor signal W SG-5VRT8 IMT sensor GND Camshaft position sensor signal IF-CAM Crankshaft position sensor signal IF-CRANK Fuel pressure sensor shield SG-SLD8 IA-SCVLO SCV-LO drive 94 pin connector
Pin No. 61 62 63 64 65
Pin name PG-POWER PG-POWER PG-POWER PG-POWER PG-POWER
Connection GND GND GND GND GND 84402827B - May 2011 4001C-76
Function, Structure, Operation Pin No. 66 67 68 69 70 71 72
111
Pin name PG-POWER PS-+B SP-5V1 SP-5V2 SP-5V3 CC-KW2000 (CCBOOTRX) IA-THE1 IA-THE2 IA-IAT IA-MAF IA-FIPRESS IA-EXHP IA-ACCEL1 IA-ACCEL2 IA-BARO CC-ISOCAN-L PS-+B SG-5VRT1 (CCBOOTTX) (MOD1) PG-SIGN IS-SCVSW IS-START IS-LOAD IS-REG IS-SWLO1 IS-IDLMNL IS-MDMAP0 IS-IDLUP IS-MDMAP1 IS-MDMAP2 IS-IDLDWN CC-ISOCAN-H PS-+B
112
SG-5VRT3
113 114 115 116 117 118 119
SG-12VRT OS-MAINR SG-SLD1 SP-12V PG-SIGN
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110
Connection GND Power supply Accelerator position sensor power supply Atmospheric pressure sensor power supply DPD differential pressure sensor, fuel filter pressure sensor power supply Data link connector Exhaust gas temperature sensor 1 signal Exhaust gas temperature sensor 2 signal Intake air temperature sensor signal Mass air flow sensor signal Fuel filter pressure sensor signal DPD differential pressure sensor signal Accelerator pedal position sensor 1 signal Accelerator pedal position sensor 2 signal Atmospheric pressure sensor signal ISO CAN-Low Power supply Accelerator position sensor GND GND SCV switch signal Starter switch start signal Load advance switch signal Regulation mode switch signal Idling control change selector switch signal Mode map switch 0 signal Idling control switch Up signal Mode map switch 1 signal Mode map switch 2 signal Idling control switch Down signal ISO CAN-High Power supply DPD differential pressure sensor, fuel filter pressure sensor, exhaust gas temperature sensor 1, exhaust gas temperature sensor 2 GND Mass air flow sensor GND ECM main relay Accelerator position sensor shield Mass air flow sensor power supply GND 84402827B - May 2011 4001C-77
Function, Structure, Operation Pin No. 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154
Pin name IS-ENGSTP IS-DPDREG OS-OVRL OS-OILPL OS-BOOSTL OS-OVHL OS-OPL1 OF-TACHO OS-DPDREG OS-DIAGL OS-EGRTL CC-CAN-L PS-+B IS-IGKEY SG-5VRT2 OS-MAINR PG-CASE PS-MAFBAT IS-SWHI1 IS-DIAG IS-MEMCL IS-DGSEL IS-SWHI2 OS-GLOWL OS-OPL2 OS-FIPRESSL OS-THLL OS-DPDSL OS-HOUR OS-STARTR OS-GLOWR CC-CAN-H
Connection Engine stop switch signal DPD switch Engine overrun light Engine oil pressure light Boost temperature sensor pilot light Overheat light Tachometer DPD regeneration light Moniter CAN-Low Power supply Starter switch ON signal Atmospheric pressure sensor GND ECM main relay signal GND dropping resistor Diagnostic switch signal Memory clear switch signal Diagnostic switch signal Glow light Fuel filter clogging light Fuel temperature light DPD light Hour meter relay Starter cut relay glow relay CAN-High
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Section 4001E
Symptom
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84402827B - May 2011
CONTENTS Frequent DPD regeneration by manual regeneration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Long DPD regeneration time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine start failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine stalling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine hunting, rough idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Excessive white smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Excessive black smoke in the exhaust gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Abnormal noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Large fuel consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Large oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Insufficient engine output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4001E-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Symptom Frequent DPD regeneration by manual regeneration 1.
DPD system manual regeneration frequently Description of Symptom The manual regeneration is frequently requested by blinking the DPD manual regeneration lamp or indicating Press DPD switch. Or, it is requested more frequently than before. {Automatic regeneration cannot be performed frequently} ANNOTATION: • Depending on the manufacturer of the actual unit, the indication may not be shown.
2.
DPD system manual regeneration frequently Diagnostics • Preliminary inspection Inspect the fuel quality. Inspect the engine oil level and quality. Inspect whether the hourmeter operates correctly. If excessive amount of black smoke is observed, inspect the black smoke. Inspect the inside of the DPD filter for excessive ash deposits. Check the scan tool data list. Check the service technical report. Confirm the ECM carry part number. Check the operator's operating habits and conditions. Recommend the owner to voluntarily carry out regeneration as necessary. Check whether the idling time is too long under the normal operation conditions. Check whether operation is frequently performed at low speed under the normal operation conditions. Check whether long downhill working is performed under the normal operation conditions. Check whether the idling time is too long in DPD regeneration. Check whether operation is frequently performed at low speed in DPD regeneration. Check whether PTO is activated frequently and for long period of time in DPD regeneration. Check whether the engine operating time is short in DPD regeneration. Check whether accelerator is switched frequently between ON and OFF in DPD regeneration. • Inspection of the sensor Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off. {The hose of the DPD differential pressure sensor has a specified installation direction}
Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting. Inspect the DPD differential pressure sensor for incorrect installation. Inspect the DPD differential pressure sensor for damage. Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its inlet. Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display exhaust differential pressure. Check the exhaust temperature sensor at various temperatures, and inspect for the possibility of sensor abnormalities. Check the mass air flow sensor for abnormalities and operation delay with the scan tool data display MAF. Check the boost pressure and atmospheric pressure when the starter switch is ON and the engine is not started. It is normal if both data displays are within 7.0 kPa {0.07 kgf/cm2 / 1.0 psi}. • Inspection of the air intake system Inspect the air cleaner and air intake duct for clogging, holes, and leakage. Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted. Inspect the intake throttle valve for anchoring. Inspect the inside of the intake manifold for clogging or air leaks. Inspect the air intake system for modification. Inspect the mass air flow sensor for contamination and damage. Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage. • Inspection of the exhaust system Inspect for any condition that restricts the flow of the exhaust system. Inspect for absence or damage of the exhaust system gasket. Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust temperature sensor, and DPD differential pressure sensor's hose and pipe. Inspect the exhaust system for modification. Inspect the inside of the DPD filter for excessive ash deposits. Inspect the DPD filter for damages, cracks, melt and excessive deposits. Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits. If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deteriorated or damaged.
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Symptom Long DPD regeneration time 1.
2.
DPD system regeneration long time Description of Symptom The regeneration requires more time than expected. Or, it takes longer than before. DPD system regeneration long time Diagnostics • Preliminary inspection Inspect the fuel quality. Check the scan tool data list. Check the service technical report. Check whether DPD regeneration and engine warm up control are mixed up. Check the operator's operating habits and conditions. Check whether the manual regeneration is started when the engine is cold in DPD regeneration. Check whether the idling time is too long in DPD regeneration. Check whether operation is frequently performed at low speed in DPD regeneration. Check whether the engine operating time is short in DPD regeneration. Check whether accelerator is switched frequently between ON and OFF in DPD regeneration. Check whether the temperature in the work environment is excessively high in DPD regeneration. • Inspection of the sensor Inspect the hose and pipe of the DPD differential pressure sensor for incorrect piping or if they came off. {The hose of the DPD differential pressure sensor has a specified installation direction} Inspect the hose and pipe of the DPD differential pressure sensor for clogging, collapsing, or twisting. Inspect the DPD differential pressure sensor for incorrect installation. Inspect the DPD differential pressure sensor for damage. Inspect the DPD differential pressure sensor for contamination and foreign materials which interfere with its inlet. Check the DPD differential pressure sensor for abnormalities and operation delay with the scan tool data display exhaust differential pressure. Check the exhaust gas temperature sensor at various temperatures, and inspect for the possibility of sensor abnormalities.
• Inspection of the cooling system Inspect the engine coolant level. Inspect the engine coolant leakage. Inspect the cooling fan belt slip. Inspect the operation of the cooling fan clutch. Inspect the operation of the thermostat. Inspect the operation of the water pump. Inspect the radiator for clogging. Inspect whether the cooling amount of the cooling system is not low due to modification. • Inspection of the air intake system Inspect the air cleaner, air intake duct, and intercooler for clogging, holes, or leakage. Inspect whether a condition exists where the flow in the turbocharger inlet duct is restricted. Inspect the intake throttle valve for anchoring. Inspect the inside of the intake manifold for clogging or air leaks. Inspect the air intake system for modification. Inspect the mass air flow sensor for contamination and damage. Inspect the turbocharger turbine wheel, shaft, or compressor wheel for wear and damage. • Inspection of the exhaust system Inspect for any condition that restricts the flow of the exhaust system. Inspect for absence or damage of the exhaust system gasket. Inspect for exhaust gas leakage from the exhaust pipe, gasket, DPD, exhaust gas temperature sensor, and DPD differential pressure sensor's hose and pipe. Inspect the exhaust system for modification. Inspect the inside of the DPD filter for excessive ash deposits. Inspect the DPD filter for damages, cracks, melt and excessive deposits. Inspect the oxidation catalyst for damages, cracks, melt and excessive deposits. If any excessive white smoke is observed in the regeneration process, the oxidation catalyst may be deteriorated or damaged. • Other inspections Inspect for possible factors of overheat.
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Symptom Engine start failure 1.
2.
Engine start failure Description of Symptom The cranking revolution is low. The cranking revolution is normal, but the engine does not start. The engine starts but cannot maintain its revolution stably or does not reach normal revolution speeds. Engine start failure Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Check whether the actual unit has a significant load. The ECM and monitor are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is grime or clogging of the fuel filter. Whether there is an improper connection of connectors. Particularly for the crankshaft position sensor and camshaft position sensor. Whether the battery terminal voltage has dropped. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily. Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts
*1 *2 *3
Pre fuel filter Electromagnetic pump Fuel filter
• Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Use of low-viscosity fuel such as kerosene causes wear on the supply pump plunger and may result in the discharge abnormalities and cause start failure. In such cases, replacement of the supply pump is required. When a start failure has occurred, check with the customer about the fuel used. If low-viscosity fuel such as kerosene has been used, instruct the customer not to use low-viscosity fuel because the malfunction recurs even after replacing the supply pump. A mixed oil biofuel containing long-term storage fuel and organic substances is easily oxidizable. An oxidized fuel causes wear on the camshaft related parts in the supply pump and may result in start failure due to discharge abnormalities. In such cases, replacement of the supply pump is required. Since the replacement of the supply pump due to the use of mixed oil biofuel containing longterm storage fuel and organic substances is at the
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Symptom customer’s expense, instruct the customer not to use mixed oil biofuel containing long-term storage fuel and organic substances. When using fuel with a high water content, add the larger sedimenter to the pre-fuel filter to prevent water from entering into the fuel system. Abnormalities of the supply pump, non-pressure fuel supply The ECM determination of the supply pump nonpressure fuel supply DTC will not be detected unless a condition continues for 3 seconds or more in which the engine revolution speed is 900 min-1 {900 r/min} and the absolute pressure is below 15 MPa {153 kgf/cm2 / 2175 psi}. Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to the supply pump abnormalities.
Absolute pressure
Engine speed (min-1 {r/min})
ANNOTATION: *1 *2 *3
• Since the crankshaft position sensor abnormalities will not be diagnosed unless cranking is performed 14 revolutions or more, crank for more than 14 seconds at 60 min-1 {60 r/min} or more. For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may not be detected. For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft position sensor related DTC is detected.
Non-criteria range P0093 Criteria range Range in P0093 is established
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing degradation Abnormalities of the injector, no fuel injection System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.
Engine speed (min-1 {r/min})
Engine stalling *1 *2 *3
P0093 Judgment required engine speed Minimum fining engine speed System realization engine speed
1.
2.
Engine stalling Description of Symptom Engine cranks but takes a long time to start. The engine ultimately operates, or starts but stops soon. Engine stalling Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Check whether the actual unit has a significant load. The ECM and monitor are operating correctly. Since the crankshaft position sensor abnormalities will not be diagnosed with cranking less than
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Symptom 14 revolutions, crank for more than 14 seconds at 60 r/min or more. DTC check. For crankshaft position sensor errors at low engine revolution speed, the crankshaft position sensor DTC may not be detected. For intermittent failure, increase the engine revolution speed to No Load Max and check if the crankshaft position sensor related DTC is detected. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. Check whether fuel is contained. â&#x20AC;˘ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of connectors. Particularly for the crankshaft position sensor and camshaft position sensor. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily. Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts
*1 *2 *3
Pre fuel filter Electromagnetic pump Fuel filter
â&#x20AC;˘ Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging and air intake piping abnormalities, etc. Abnormalities of the supply pump, non-pressure fuel supply The ECM determination of the supply pump nonpressure fuel supply DTC will not be detected unless a condition continues for 3 seconds or more in which the engine revolution speed is 900 r/min and the absolute pressure is below 15 MPa (2176 psi). Therefore, the DTC will not be detected when the engine does not start with non-pressure fuel supply due to supply pump abnormalities.
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Symptom *1 *2 *3
Engine
Abnormalities of the common rail such as the flow damper, operation of the pressure limiter, or inside sealing degradation Abnormalities of the injector, no fuel injection System down due to failure Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc.
speed (r/min)
*1 *2 *3
Non-criteria range P0093 Criteria range Range in P0093 is established
P0093 Judgment required engine speed Minimum fining engine speed System realization engine speed
Absolute pressure
Engine speed (r/min)
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ACG failure Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect to see if the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.
Symptom Engine hunting, rough idling 1.
2.
Engine hunching, rough idling Description of Symptom The engine has variable engine idling, or has change in idling revolution speed. In a severe case, the engine or the actual unit may vibrate. In either case, the engine stall may occur if the symptom gets worse. Engine hunching, rough idling Diagnostics â&#x20AC;˘ Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and monitor are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. â&#x20AC;˘ Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of connectors. Whether the battery terminal voltage has dropped. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Whether the layout of the fuel filter, pre-filter, and electromagnetic pump has a structure in which air accumulates easily.
Check whether they are arranged to prevent air accumulation as Isuzu genuine pre-filters do not have any plugs for air removal. Also check whether the inlet and outlet of the electromagnetic pump have an appropriate layout. Fix layouts which have the electromagnetic pump inlet on the upper side or have an outlet toward the motion direction of the actual unit. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts
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*1 *2 *3
Pre fuel filter Electromagnetic pump Fuel filter
Symptom â&#x20AC;˘ Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Abnormalities of the supply pump, non-pressure fuel supply Switch input circuit system abnormalities Abnormalities of the sensor input circuit system such as the accelerator position sensor, harness, and water temperature sensor Accelerator position sensor system abnormalities Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc.
Failure related to the actual unit equipment such as the oil pressure pump, etc. Effect of the post-installed accessories such as wireless devices and lights, etc. Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.
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Symptom Excessive white smoke in the exhaust gas 1. 2.
Excessive white smoke in the exhaust gas Description of Symptom Excessive white smoke when driving. Excessive white smoke in the exhaust gas Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and monitor are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is an improper connection of injector connectors. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power.
Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts • Diagnostic aids Fuel quality when using a product with a low cetane number or a product other than those specified Use of low-viscosity fuel such as kerosene may result in abnormal wear on the seat area of the injector and cause abnormal spray and white smoke. In such cases, replacement of the injector is required. Since the replacement of the injector due to the use of low-viscosity fuel such as kerosene is at the customer's expense, instruct the customer not to use low-viscosity fuel such as kerosene. Idling for a long time Failure of the water temperature sensor, fuel temperature sensor, intake air temperature sensor, boost sensor failure, or air pressure sensor Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and raised oil or sucked down oil, etc. ECM failure
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Symptom Excessive black smoke in the exhaust gas 1. 2.
Excessive black smoke in the exhaust gas Description of Symptom Excessive black smoke when driving. Excessive black smoke in the exhaust gas Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. The ECM and monitor are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following.
Whether there is grime or clogging in the air cleaner element Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power Whether the ECM ground is free of dirt, etc. and securely installed in the correct location Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts • Diagnostic aids Fuel quality when using a product other than those specified, etc. Air intake system abnormalities such as filter clogging, air intake piping abnormalities, etc. Abnormalities of the EGR control system Abnormalities of the exhaust system such as exhaust pipe abnormalities, etc. Water temperature sensor malfunction Boost sensor failure Engine body failure such as insufficient compression pressure, piston related failure, turbocharger failure, and raised oil, etc.
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Symptom Abnormal noise 1. 2.
Abnormal noise Description of Symptom Engine combustion noise is abnormal. Abnormal noise Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Refer to the actual unit manual and inspect the abnormal noise. The ECM and monitor are operating correctly. DTC check. The scan tool data is within the normal operating range. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Proper wiring connections, tightening, and disconnection Whether the ECM ground is free of dirt, etc. and securely installed in the correct location.
Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts • Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as EGR valve abnormalities, etc. Abnormalities of the injector, no fuel injection Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. Failure related to the actual unit equipment such as the oil pressure pump, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.
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Symptom Large fuel consumption 1. 2.
Large fuel consumption Description of Symptom Fuel consumption is significantly larger than indicated in the actual unit manual. Large fuel consumption Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Since the fuel consumption varies widely depending on the handling of the actual unit, check the reference fuel consumption (A) of the actual unit manufacturer. Reference fuel consumption (L {qts}/hour) Check the actual fuel consumption (B). Actual fuel consumption (L {qts}/hour) If B is greater than A, refer to the actual unit manual and check the setting of the unit. Check whether the actual unit does not have a significant load. Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the operation time of the actual unit. Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours. The ECM and monitor are operating correctly. DTC check. Check the condition of the actual unit, and locate the appropriate symptom. Check with the customers whether they are using the specified engine oil and fuel. Check whether engine oil change or periodical maintenance for the air cleaner filter or fuel filter, etc. has been performed. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following.
Proper wiring connections, tightening, and disconnection Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Abnormalities of the air intake system parts Abnormalities of the exhaust system parts • Diagnostic aids Fuel system abnormalities such as fuel running out, fuel freezing, mixture of air into the fuel piping, filter abnormalities, piping abnormalities, fuel quality, fuel tank, etc. Air intake system abnormalities such as EGR valve abnormalities, etc. Abnormalities of the injector such as excessive fuel injection Engine body abnormalities such as seizure, insufficient compression pressure, and other mechanical failures, etc. Failure related to the actual unit equipment such as the oil pressure pump, etc. ECM failure Inspect the connector for connection failures and the harness for abnormalities such as abrasions, bending, etc. Inspect that the wires inside the harness are separate and have not caused a short circuit with other circuits. Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found. For the inspection locations of the engine air intake and exhaust system Inspect the air intake and exhaust system for abnormalities such as clogging, collapsing and damage. Other than the inspection locations of the engine body, inspect the air cleaner, intercooler, and muffler.
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Symptom
1 2 3
Primary EGR cooler EGR duct EGR valve
4 5 6
From the intercooler From the air cleaner To the intercooler
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7 8
Exhaust pipe Secondary EGR cooler
Symptom Large oil consumption 1. 2.
Large oil consumption Description of Symptom The oil consumption amount described in the manual of the actual unit is significantly exceeded. Large oil consumption Diagnostics • Preliminary inspection Before using this section, perform the functional inspection and OBD system check to check all of the following. Since the oil consumption varies widely by handling of the actual unit, check the reference oil consumption (A) of the actual unit manufacturer. Reference oil consumption/hour Reference oil consumption per engine: 4 L {4.2 qts}/100 hours Check the actual oil consumption (B). Actual oil consumption/hour Refer to the inspections and maintenance list in the operation manual and perform the inspection based on the operation time of the actual unit. Refer to the actual unit manual to inspect an actual unit whose operation time exceeds 3,000 hours. The ECM and monitor are operating correctly. DTC check. Check the condition of the actual unit, and locate the appropriate symptom.
Check with the customers whether they are using the specified engine oil and fuel. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether bluish white smoke continuously comes out. Whether blow-by gas comes out excessively. Whether oil is mixed into the coolant. Proper connections, cracks, and twists in the pipes and hoses related to oil. Extensively check for any leaks or blockage. Whether there is any fuel leak, pipe damage, or dents in the lubricant system. Abnormalities of the air intake system parts such as the turbocharger inspection • Diagnostic aids Air intake system abnormalities such as sucked down oil or raised oil and excessive blow-by gas Engine body abnormalities such as oil combustion and excessive blow-by gas Perform inspections for functional diagnosis, and confirm the operation, control of each part, etc. Repair if abnormalities are found.
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Symptom Insufficient engine output 1.
2.
Insufficient engine output Description of Symptom The engine output is lower than expected, the output does not change when the accelerator lever (throttle lever) is lifted up, the operation is not effective. Insufficient engine output Diagnostics • Preliminary inspection Before using this section, perform the functional inspection, OBD system check to confirm the following all items. The ECM and the monitor are operating properly. DTC check. The scan tool data is within the normal operating range. Check the actual unit condition, and locate the corresponding symptom. Check with the customer if the customer is using the specified engine oil and fuel. For insufficient output, various causes can be suspected, so thoroughly investigate the relationship between the engine and the actual unit side. Check what kind of operations cause insufficient output. If hesitation or lug-down is included in the symptoms of insufficient output, it is related to the control on the actual unit side, so contact the manufacturer of the actual unit. Itrouble diagnosis scan tool is available, the engine output at the rated point can be easily verified by checking the boost at the rated point. • Visual inspection Careful visual inspection is required for several symptom procedures. This can lead to fixing a problem without further inspections, and can save valuable time. The inspection includes the following. Whether there is grime or clogging in the air cleaner element. Proper wiring connections, tightening, and disconnection Whether the power of any commercial accessories is being taken divergingly from the ECM power. Whether the ECM ground is free of dirt, etc. and securely installed in the correct location. Proper connections, cracks, and twists in the pipes and hoses related to fuel, air, and oil. Extensively check for any leaks or blockage. Whether there are any fuel leaks, pipe damage, or dents in the fuel system. Increased resistance due to grime, clogging, or air intake piping collapsing particularly in the air cleaner element among the air intake system parts Abnormalities of the exhaust system parts • Diagnostic aids Fuel system abnormalities such as running out of fuel, fuel freezing, air intrusion in the fuel pipe, filter abnormality, pipe abnormality, fuel quality, and fuel tank Air intake system abnormalities such as filter clogging and air intake pipe abnormality
Exhaust system abnormalities such as exhaust pipe abnormality Abnormalities of the sensor input circuit system including the accelerator position sensor and the harness Abnormalities of the switch input circuit system Engine unit abnormalities including other mechanical failures such as compression pressure, valve clearance, turbocharger, supply pump, injector, and common rail Failures related to actual unit side equipment such as hydraulic pump Influence of the post-mounted electrical components such as wireless devices and lights Inspect for connector improper connections, harness abnormalities such as abrasions and bends, and short circuits with other circuits due to wire split inside harness. Also, perform inspections for functional diagnosis, and check the operation and control of each part. Make repairs if any abnormality is found. Output reduction due to fuel flow restriction imposed upon overheat Insufficient output due to fuel flow restriction during operation at high altitude • Control when overheating To protect the engine, restriction on fuel flow is started when the engine coolant temperature exceeds 100 °C (212 °F). When the engine coolant temperature increases further, the fuel flow is also restricted further. When the temperature is near 120 °C (248 °F), the fuel flow is restricted to a certain level. The setting varies depending on the actual unit manufacturer. The actual unit is designed to issue an alarm from 105 °C (221 °F). By reducing the load applied to the actual unit upon alarm issuance, it is possible to avoid the operation condition with fuel flow restriction.
Fuel flow
Engine coolant temperature *1 *2
Warning indication DTC set
• High altitude correction
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Symptom The ECM calculates the current altitude in accordance with the signal from the atmospheric pressure sensor. Depending on the conditions of altitude, etc. at this time, the SCV opening and closing timing and injector energizing time are controlled and the fuel flow is corrected to be optimum. Fuel flow limit ( mm3/ st)
Barometric pressure kPa (psi) *1
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Highland
Section 4001F
Functional Inspection
84402827B - May 2011
84402827B - May 2011
CONTENTS Inspection of the monitor warning light blinking circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspection of the scan tool power circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspection of the starter circuit system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Compression pressure inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspection of the starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspection of the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspection of the air intake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspection of the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspection of the EGR control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspection of the glow control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Functional inspection of the DPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 OBD system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspection of the monitor warning light illumination circuit system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84402827B - May 2011 4001F-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4001F-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Functional Inspection Inspection of the monitor warning light blinking circuit system
Inspection of the scan tool power circuit system
1.
1.
2.
Inspection of the monitor warning light blinking circuit system Description of Function The monitor is supplied with power supply voltage via the starter switch and shows an abnormality display due to a signal from the ECM. The ECM makes the monitor show an abnormality display during a lamp check when the starter switch is ON and when the DTC is set. It also blinks the monitor depending on the detected DTC when the body ground terminal and diagnostic switch terminal of the DLC are shorted. A monitor circuit is incorporated inside the ECM and monitors operation of the light. Inspection of the monitor warning light blinking circuit system Inspection Inspection if the monitor continues showing an abnormality display and does not flash when the diagnostic switch is switched ON 1) 2) 3) 4) 5) 6)
Perform the OBD system check. Turn OFF the starter switch. Connect the DMM between the DLC diagnostic switch terminal and GND. Turn ON the starter switch. Confirm that the voltage displayed on the DMM exceeds the standard value. Standard value: 18 V Inspect the diagnostic switch circuit between the ECM and DLC using the DMM if it is under the standard value. • No open circuit or high resistance should be found. Standard value: 100 Ω or less • No short circuit with GND should be found. Standard value: 10 MΩ or more
7) 8) 9) 10) 11)
Inspection of the scan tool power circuit system Description of Function The ECM and other ECU communicate with the trouble diagnosis scan tool via the DLC. The power voltage of the trouble diagnosis scan tool is supplied by the battery or AC power. CAUTION • Draw power for the trouble diagnosis scan tool from the battery or AC power. • The power supply voltage is the same as the battery voltage of the actual unit.
2.
Inspection of the scan tool power circuit system Inspection Inspection when the trouble diagnosis scan tool does not power on 1) 2) 3) 4) 5) 6)
Repair if a problem is discovered. Turn OFF the starter switch. Confirm that there is continuity between the DLC body ground and GND. Turn ON the starter switch. Short the DTC. ANNOTATION: • Short the No.4 terminal and No.12 terminal.
12)
Check if the monitor is blinking. ANNOTATION: • If it does not blink, inspect the monitor blinking circuit system.
13) 14) 15) 16) 17) 18)
Replace the ECM. Removal of ECM Installation of ECM After replacing the ECM, perform EGR learning. Turn ON the starter switch. Short the body ground terminal and diagnostic switch terminal of the DLC. Check if the monitor is blinking. Perform the OBD system check 84402827B - May 2011 4001F-3
Inspect the battery voltage of the actual unit using the DMM. Standard value：18V Charge or replace the battery if it is below the standard value. Check that the battery cable of the trouble diagnosis scan tool does not have a defective connection. Repair the connection if a problem is discovered. Check that the battery cable of the trouble diagnosis scan tool does not have an open or short circuit. Request repair of the battery cable if a problem is discovered.
Functional Inspection Inspection of the starter circuit system 1.
2.
Inspection of the starter circuit system Description of Function The starter relay on the ECM is turned to ON when the starter switch moves to the START position. When the starter relay is turned to ON, the starter operates to start the engine. Inspection of the starter circuit system Inspection Inspection when the starter does not operate 1)
8)
• Connect the battery between the coil side terminals and check the continuity between the switch side terminals. Standard value: 100 Ω or less 9) 10)
ANNOTATION:
2)
11) 12)
Check the DTC. • If the DTC P0117, P0340, P0341, P0615, P0651, or P1625 is detected, inspect the corresponding DTC. Turn OFF the starter switch. Remove the starter cut relay. Inspect the starter cut relay. • Check the continuity between the switch side terminals. Standard value: 100 Ω or less
6) 7)
Repair the circuit if a problem is discovered. Inspect the starter circuit. • No open circuit should be found between the starter switch and starter cut relay. • No open circuit should be found between the starter cut relay and starter relay. • No open circuit should be found between the starter relay and GND. • No open circuit should be found between the starter relay and starter.
ANNOTATION:
3) 4) 5)
Replace the relay if a problem is discovered. Inspect the starter switch start signal circuit. • No open circuits or high resistance should be found between the starter switch and ECM. Standard value: 100 Ω or less • No short circuits with the GND should be found between the starter switch and ECM. Standard value: 10 MΩ or more
Turn the emergency stop switch to OFF. • If the actual unit does not have an emergency stop switch setting, do not perform this operation.
Inspect the starter relay.
13) 14) 15) 16)
Replace the relay if a problem is discovered. Remove the starter relay. 17)
84402827B - May 2011 4001F-4
Repair the circuit if a problem is discovered. Inspect the starter. Inspection of the starter Replace the starter if a problem is discovered. Replace the ECM. Removal of ECM Installation of ECM After replacing the ECM, perform EGR learning.
Functional Inspection Compression pressure inspection 1.
Engine compression pressure inspection Inspection ANNOTATION: • Warm-up the engine. 1)
Remove the glow plug from the cylinder head assembly. ANNOTATION: • Remove all glow plugs.
2)
Remove the injector harness connector from the lower cover. Special tool: compression gauge (adapter) (refer to section 1003)
3)
Install the special tool to the cylinder head assembly. ANNOTATION: • Insert the compression gauge adapter into the installation hole of the glow plug to install the compression gauge.
Special tool: compression gauge adapter (refer to section 1003)
1 2 4)
Compression gauge Compression gauge adapter
Measure the compression pressure. ANNOTATION: • Rotate the starter, and read the indication of the compression pressure when the compression gauge needle stabilizes at approximately 200 rpm. • Measure the compression pressure of all cylinders. Specified value: 3240.0 kPa {33.04 kgf/cm2 / 470 psi} Limit: 2260.0 kPa {23.05 kgf/cm2 / 328 psi}
84402827B - May 2011 4001F-5
Functional Inspection Difference between each cylinder: 294.0 kPa {3.00 kgf/cm2 / 43 psi}
1)
ANNOTATION:
CAUTION
• If the actual unit does not have an emergency stop switch setting, do not perform this operation.
• Note that air will burst out through the glow plug hole during rotation. 2) ANNOTATION:
• If the actual unit does not have a overheat switch setting, do not perform this operation. 3) 4)
Starting system check Description of Function This diagnosis chart is an organized approach to identifying a condition that causes the status for when an engine does not start. The appropriate system diagnosis can be performed with this diagnostic chart. • The battery should be fully charged when performing this diagnosis. • The battery cable should be securely connected when performing this diagnosis. • The rotation speed during cranking should be normal when performing this diagnosis. • The appropriate fuel should be sufficiently supplied when performing this diagnosis. • No fuel leaks should be found when performing this diagnosis. • No air should be mixed into the fuel when performing this diagnosis. • The air cleaner element should be clean when performing this diagnosis. • The fuel filter should be clean when performing this diagnosis. Starting system check Inspection Inspection when the starter operates and cranks but the engine does not start
Repair the circuit if a problem is discovered. Check the DTC. ANNOTATION:
Inspection of the starting system
2.
Inspect the overheat switch circuit. ANNOTATION:
• When the starter switch is turned to ON with the injector harness connector removed, the ECM determines a malfunction and records a DTC, so make sure the DTC has been cleared after the inspection is completed.
1.
Turn the emergency stop switch to OFF.
• If the DTC is detected, inspect the corresponding DTC. 5) 6) 7) 8)
Check the SCV F/B display using a trouble diagnosis scan tool while cranking the engine. Standard value: 900 mA Repair the SCVLO drive circuit if it is below the standard value. Remove the harness connector from the SCV. Crank the engine. ANNOTATION: • If the engine starts, diagnose the DTC P0090.
9) 10) 11) 12) 13) 14) 15) 16) 17) 18)
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Inspect the fuel system if the engine does not start. Inspect the engine coolant temperature sensor. Inspect the fuel pressure sensor. Inspect the EGR position sensor. Inspect the injector. Inspect the engine mechanical timing. Inspect the installation status of the flywheel. Inspect the air intake system. Inspect the exhaust piping for collapsing, damage, and exhaust leakage. Repair or replace the part found to have a problem.
Functional Inspection Inspection of the fuel system
Inspection of the air intake system
1.
1.
2.
Fuel system check Description of Function The fuel system is composed of the fuel filter, supply pump, common rail, and injector, and each of them connects with the fuel pipe. Fuel system check Inspection Inspection when there is a possibility that there is an abnormality in the fuel system 1) 2) 3)
4)
Inspect the quality of fuel. Appropriate fuel should be used. Check the amount of fuel. Sufficient amount should be supplied. Perform the fuel discharge inspection for the supply pump. Fuel discharge inspection The fuel discharge should be normal and no air should be mixed. Confirm that the genuine fuel filter, pre filter, and filters other than for the electromagnetic pump are added to the fuel piping of the actual unit.
Air intake system check Description of Function CAUTION • If the air intake system part is installed by the actual unit manufacturer, refer to the manual of the actual unit.
2.
The air intake system is comprised of the air cleaner, air intake piping, turbocharger, etc. The intake air is supplied to the engine through the air cleaner and intake manifold. Air intake system check Inspection Inspection when there is a possibility that there is an abnormality in the air intake system 1)
• No excessive contamination or clogging should be found. 2) 3)
ANNOTATION:
Remove it if the filter is added. Inspect the main fuel filter, pre-fuel filter, and electromagnetic pump filter. • No excessive contamination or clogging should be found. • No air should be mixed in.
7) 8)
Clean or replace if a problem is discovered. Inspect the fuel pipe.
4) 5)
6)
Repair or replace if a problem is discovered. Inspect the fuel tank. • No dust should be mixed in. • The fuel supply pipe should have no misalignment or damage. • The tank should have no collapsing or damage. • The fuel pipe should not be arranged incorrectly. • The fuel filler should have no clogging. • No water should be mixed into the tank.
11) 12)
Repair or replace if a problem is discovered. Inspect the turbocharger. • The turbine axis should have no abnormal looseness. • There are no oil leaks.
• No damage, clogging, or improper connections should be found. 9) 10)
Clean or replace if a problem is discovered. Inspect the air intake piping. • No collapsing, damage, or air leakage should be found. • There are no distorted or improper piping arrangements which may lead to an increase in the air intake resistance. • The lead valve should have no damage.
• A problem such as the detection of the DTC P0093 may occur as the resistance of fuel increases due to the added filter. 5) 6)
Inspect the air cleaner.
Repair or replace the fuel tank if a problem is discovered. Remove air.
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Repair or replace if a problem is discovered.
Functional Inspection Inspection of the exhaust system 1. 2.
Exhaust system check Description of Function The exhaust system is comprised of the exhaust pipe, tail pipe, etc. Exhaust system check Inspection Inspection when there is a possibility that there is an abnormality in the exhaust system 1)
1.
Inspect the exhaust pipe and tail pipe. • No collapsing, damage, or exhaust leakage should be found.
2) 3)
Inspection of the EGR control system
Repair or replace if a problem is discovered. Repair the actual unit.
2.
EGR control system check Description of Function The ECM controls the EGR valve based on the engine revolution speed, engine coolant temperature, intake air temperature, fuel injection amount, and atmospheric pressure. The EGR valve is driven by the EGR motor, and the EGR valve opening is detected by the EGR position sensor. EGR control system check Inspection Inspection when there is a possibility that there is an abnormality in the locations relating to the EGR. 1)
Check the DTC. ANNOTATION: • If the DTC is detected, inspect the corresponding DTC.
2)
3) 4) 5)
6) 7) 8)
9) 10)
11)
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Start the engine and warm it up until the coolant temperature exceeds the standard value. Specified value: 70 °C ｛158 °F｝ Check the EGR position display using a trouble diagnosis scan tool. Standard value: (-3) - 3 ％ Perform the actuator test EGR control using a trouble diagnosis scan tool if the EGR position display is outside the standard value. Execute an Up and Down command to the EGR valve and check the EGR position display. Standard value: (-3) - 3 ％ Inspect the EGR piping if the EGR position display is outside the standard value. No damage or gas leaks should be found. Repair or replace if a problem is discovered. Start the engine and warm it up until the coolant temperature exceeds the standard value. Specified value: 70 °C ｛158 °F｝ Check the EGR position display using a trouble diagnosis scan tool. Standard value: (-3) - 3 ％ Replace the EGR valve if the EGR position display is outside the standard value. EGR valve Removal EGR valve Installation When replacing the EGR valve, perform EGR learning to the ECM.
Functional Inspection Inspection of the glow control system 1.
2.
8) 9) 10)
Glow control system check Description of Function CAUTION
ANNOTATION:
• The starter ECM control specification and safety relay specification are the same for the QOS circuit.
• If it is outside the standard value, inspect the corresponding glow plug.
The QOS system is comprised of the ECM, glow relay, glow plug, and QOS indicator light. When the starter switch is turned to ON under low engine coolant temperature, the ECM determines the glow time according to the engine coolant temperature, and starts the glow relay and QOS indicator light. The ECM will turn to OFF the glow relay and QOS indicator light after a certain period of time. Glow control system check Inspection Inspection when there is a possibility that there is an abnormality in the locations relating to the QOS system control 1) 2)
11) 12) 13) 14)
• Turn the command to OFF and check the voltage value of the DMM. 15)
Perform the OBD system check. Check the DTC.
Turn ON the starter switch. Check the operation of the QOS indicator light.
• No short circuit to battery or ignition power supply should be found between the glow relay and glow plug.
7)
16) 17)
Repair or replace the circuit if a problem is discovered. Perform the actuator test glow plug relay using a trouble diagnosis scan tool.
ANNOTATION:
ANNOTATION:
• If the QOS does not operate, the QOS indicator light will illuminate when the starter switch is turned to ON by the light check function. • The QOS indicator light turns off within 10 seconds.
• Turn the command to ON and check the voltage value of the DMM. 18)
Repair or replace the circuit if a problem is discovered. Inspect the glow relay.
Standard value: 18 V Inspect the circuit if it is below the standard value. • No fuse should be blown. • No open circuit should be found between the fuse and glow relay. • No open circuit should be found between the glow relay and glow plug. • No open circuit should be found between the glow relay and ECM.
Inspect the circuit if the QOS indicator light does not illuminate or turn off. • No fuse should be blown. • No open circuit should be found between the fuse and QOS indicator light. • No open circuit or short circuit should be found between the the QOS indicator light and ECM. • The QOS indicator light should not have a burned-out bulb.
6)
Standard value: 0 V Inspect the circuit if it is outside the standard value. ANNOTATION:
• If the DTC P0117, P0118, P0380, or P0381 is detected, inspect the corresponding DTC.
5)
Replace the glow plug if a problem is discovered. Connect the DMM to the glow plug connector and GND. Turn ON the starter switch. Perform the actuator test glow plug relay using a trouble diagnosis scan tool. ANNOTATION:
ANNOTATION:
3) 4)
Replace the relay if a problem is discovered. Remove all glow plugs. Measure the resistance between the glow plug terminal and GND using the DMM. Standard value: 6 Ω at room temperature
19) 20) 21)
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Repair or replace the circuit if a problem is discovered. Replace the ECM. Removal of ECM Installation of ECM After replacing the ECM, perform EGR learning.
Functional Inspection Functional inspection of the DPD 1.
2.
DPD control system check Description of Function The ECM detects the condition of PM accumulations from the DPD differential pressure sensor. The DPD differential pressure sensor changes the signal voltage in accordance with changes in the exhaust gas pressure difference between the front and the rear of the DPD filter. When the DPD differential pressure sensor reaches to a certain amount of PM accumulation, or a certain period of operating hours, DPD automatic regeneration starts. If the automatic regeneration cannot be completed due to working, the DPD manual regeneration indicator light in the monitor panel blinks to prompt the driver to perform manual regeneration. When regeneration has once started, it must be completed within a certain period of time. After completion of DPD regeneration, purification status of the filter is determined based on the exhaust differential pressure. When the ECM detects excessive amount of PM accumulation, it becomes so hot that it is eroded during regeneration process and cannot control combustion; therefore, DPD regeneration is not allowed to start. DPD control system check Inspection Inspection for determining the failure location in the DPD system 1) 2) 3)
• Damage on the DPD differential pressure sensor • Foreign matter or contamination which interferes with the DPD differential pressure sensor inlet • Wrong detection or slow response for the DPD differential pressure sensor 12) 13) 14) 15)
Inspect the exhaust system. Inspect the air intake system. Start the engine and maintain idling for 30 seconds. Confirm that the DPD manual regeneration indicator light blinks. ANNOTATION: • If it is not blinking, use the trouble diagnosis scan tool to confirm DPD accumulation status and DPD time status and applicable area based on the DPD status table. • Compare DPD accumulation status and DPD time status and use the DPD status table to determine DPD regeneration process status. • To use the DPD status table, confirm the data display values on the trouble diagnosis scan tool and readings in the DPD status table.
Perform the inspection of the engine control system. Turn the starter switch ON for 30 seconds. Check that the monitor panel functions normally. • DPD automatic regeneration indicator light illuminates in green • DPD manual regeneration indicator light illuminates orange
DPD Accumulation Status
ANNOTATION: • If it does not illuminate, inspect the circuit of the DPD indicator light. 4) 5) 6) 7) 8) 9)
Turn the starter switch OFF for 30 seconds. Inspect the amount of engine oil. Connect the trouble diagnosis scan tool to the DTC. Start the engine. Display the scan tool data DPD regeneration switch using a trouble diagnosis scan tool. Check if the data displayed on the DPD regeneration switch of the trouble diagnosis scan tool is turned to ON or OFF when changing each switch. ANNOTATION:
DPD Distance Status Range A B C
• If the ON or OFF operation does not link, inspect the DPD switch and harness. 10) 11)
Inspect the installation condition of the DPD differential pressure sensor. Inspect the exhaust differential pressure sensor. 84402827B - May 2011 4001F-10
D
Normal range DPD amber lamp binks but manual regeneration is possible. Exhaust differential pressure is excessive high range and manual regeneration is inhibited. Time status is abnormal range and manual regeneration is inhibited.
ANNOTATION:
Functional Inspection • The area where 2 status values meets will point to either A, B, C, or D. 16)
Operate the trouble diagnosis scan tool.
• If no error message has been displayed, inspect for a problem in the fuel system. 19)
ANNOTATION: • Use a trouble diagnosis scan tool to reset the DPD status. • If it is range A or B, perform the DPD forced regeneration test with the trouble diagnosis scan tool. • If it is range C or D, perform the DPD forced slow regeneration test with the trouble diagnosis scan tool. ANNOTATION:
ANNOTATION: • If it is the standard value or greater, idle the engine until it reaches the standard value or lower. 20) 21)
• After the DPD forced slow regeneration is completed, replace the engine oil. 17)
Check the DTC detection with the trouble diagnosis scan tool if the regeneration does not start.
22)
ANNOTATION:
• If it is the standard value or lower, perform ash removal. • If it is the standard value or greater, inspect for the abnormalities in the DPD differential pressure sensor system.
Inspect the corresponding DTC if the regeneration is not completed and the scan tool displays an error message. ANNOTATION: • If no error message has been displayed, inspect the DPD filter for damage, cracks, or melting. • If no error message has been displayed, inspect the oxidation catalyst for degradation, damage, cracks, melting, or excessive sediment. • If no error message has been displayed, inspect for the cause of overheating.
Accelerate the engine revolution to maximum revolution speed without load. Check the data display of the exhaust differential pressure when the data display of exhaust temperature 1 reaches the standard value. Specified value: 150 °C {302 °F} Check the exhaust differential pressure data display using a trouble diagnosis scan tool. Specified pressure: 0.5 - 1.8 kPa {0.01 - 0.02 kgf/cm2 / 0.1 - 0.3 psi} ANNOTATION:
• If no DTC is detected, confirm data display related to DPD regeneration control. 18)
Confirm that the data display of exhaust temperature 1 is below the standard value using a trouble diagnosis scan tool if the regeneration completed. Specified value: 130 °C {266 °F}
23)
24) 25)
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Replace the ECM if any problem can be seen through the inspections above. ECM Removal ECM Installation Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
Functional Inspection OBD system check 1.
4)
OBD system check Description of Function The OBD system check is a systematic method for checking problems caused by functional failures in the engine control system, and is also the starting point for all diagnoses for driveability complaints. By correctly using this diagnostic step, it is possible to reduce the time for diagnosis and prevent the replacement of parts that are not defective.
ANNOTATION: • If the actual unit does not have a monitor setting, do not perform this operation. • If the monitor is not blinking, inspect the monitor blinking circuit system. 5)
ANNOTATION: • Points to remember regarding the OBD system check • If there are no complaints on driveability, do not perform these diagnostic steps unless otherwise instructed in other sections. • Check the service technical report before starting the diagnosis. • Do not delete the DTCs unless it is instructed in a diagnostic step. • If a malfunction is found in the engine starting system, inspect the starting system. • The battery should be fully charged. • The battery cable should be normal and securely connected. • The GND of the ECM should be securely connected in the correct position. • The harness connector of the ECM should be clean and correctly connected. 2.
6)
• If the starter does not operate, inspect the starter circuit system. • If the engine does not start, check the DTC. • If the DTC is detected, inspect the corresponding DTC. • If no DTC has been detected, inspect the starting system. 7) 8) 9) 10) 11) 12)
1) 2)
13)
ANNOTATION: • If the actual unit does not have a monitor setting, do not perform this operation. • If the monitor is off, an abnormality display is performed for the monitor illumination circuit system. 3)
14) 15) 16) 17) 18)
Short the DTC. 19)
ANNOTATION:
Use the trouble diagnosis scan tool and confirm the DTCs of the ECU that has communication established. Loss of communication with the trouble diagnosis scan tool occurs due to the abnormalities in the communication circuit of each ECU and trouble diagnosis scan tool. Start the engine. ANNOTATION:
OBD system check Inspection Inspection for determining the failure location in the OBD system Turn ON the starter switch. Check the abnormality display of the monitor.
Check if the monitor is blinking.
• Short the No.4 terminal and No.12 terminal. • If the actual unit does not have a monitor setting, do not perform this operation.
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Check the engine stalling for problems. Check the engine hunching and rough idling for problems. Check if there are problems with insufficient engine output, blowup failure, or engine hesitation. Check for problems with sudden stopping. Check for problems with sudden change. Check for problems with insufficient output or blowup failure. Check for problems with engine hesitation or acceleration failure. Check for problems with dark smoke. Check for problems with white smoke. Check for problems with the idling revolution speed maladjustment. Check for problems with the idling revolution speed not decreasing. Check for problems with frequent DPD regeneration by the manual regeneration. Check for problems with long DPD regeneration time.
Functional Inspection Inspection of the monitor warning light illumination circuit system
Inspection if the monitor does not show an abnormality display when the starter switch is switched ON
1.
1) 2) 3) 4)
2.
Inspection of the monitor warning light illumination circuit system Description of Function The monitor is supplied with power supply voltage via the starter switch and shows an abnormality display due to a signal from the ECM. The ECM makes the monitor show an abnormality display during a lamp check when the starter switch is ON and when the DTC is set. It also blinks the monitor depending on the detected DTC when the body ground terminal and diagnostic switch terminal of the DLC are shorted. A monitor circuit is incorporated inside the ECM and monitors operation of the light. Inspection of the monitor warning light illumination circuit system Inspection
Perform the OBD system check. Inspect the monitor bulb. Replace the valve if a problem is discovered. Inspect the monitor circuit. â&#x20AC;˘ No open circuit or high resistance should be found between the fuse and monitor. â&#x20AC;˘ No open circuit or high resistance should be found between the monitor and ECM.
5) 6) 7)
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Repair the circuit if a problem is discovered. Replace the ECM. Removal of ECM Installation of ECM After replacing the ECM, perform EGR learning.
Functional Inspection
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Section 4001G
Maintenance precautions
84402827B - May 2011
84402827B - May 2011
CONTENTS
84402827B - May 2011 4001G-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4001G-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Maintenance precautions 1.
aged due to foreign matter accidentally intruded. For this reason, extreme care must be taken to prevent any foreign matter from entering. When performing maintenance on the fuel system, take extreme care to prevent any foreign matter from entering the system.
Maintenance precautions 1)
Precautions on maintenance To prevent the engine from being damaged and to ensure the reliability of engine performance, be careful of the following points when performing maintenance works. When placing the engine on the ground, make sure that the bearing surface of the oil pan does not directly contact the ground. Use an appropriate wood frame, etc. to support the engine at the engine foot portion and the flywheel housing portion. There is only a small gap between the oil pan and oil pump strainer, so be careful not to damage the oil pan and oil strainer. • While the air duct or air cleaner is removed, cover the open section of the intake to prevent foreign matters from entering the cylinder. If a foreign matter enters the cylinder, it may seriously damage the cylinder when the engine starts. • When maintaining the engine, be sure to disconnect the negative battery cable. Failure to do this may cause the harness or electrical components to be damaged. If energizing is required for inspection, be careful not to cause a short. • Before assembly, apply the engine oil to the slide contact surface of the engine. This work ensures appropriate lubrication when first starting the engine. • When the valve train component, piston, piston ring, connecting rod, connecting rod bearing, and/or crankshaft journal bearing are removed, line them up in the correct order so that their original positions are clear. • When installing, install it in the same position as when it was removed. • When assembling the engine, replace the gasket, oil seal, and O-ring with new ones. • For a component with the liquid gasket applied, carefully remove the old liquid gasket and clean the component so that no oil, water, and/or dust remain. Thereafter, apply the specified liquid gasket to each component before assembly. • Assemble components with the liquid gasket applied within 5 minutes of applying the liquid gasket. If 5 minutes have passed, remove the old liquid gasket and apply liquid gasket again. • When assembling or installing a component, make sure to tighten them at the specified torque to ensure secure installation.
• Before starting maintenance, clean the fuel line and its surroundings. • Be sure to wash your hands before starting maintenance. Do not put on cotton work gloves. • When the fuel hose or fuel pipe is removed, cover the opening with a plastic bag and fix it with a piece of tape. WARNING When the high-pressure piping of the fuel system is removed, be sure to replace it with a new one. If it is reused, the sealing surface may be damaged to cause fuel leakage. • When replacing the fuel hose and/or fuel pipe, do not unpack new components before starting installation. • When the fuel pipe, injection pipe, fuel injector, fuel supply pump, and/or common rail are removed, seal each opening immediately. • Store the eyebolt and gasket in a clean parts box with a cover so that foreign matter does not attach to them. • Fuel leakage may cause a fire. Therefore, be sure to wipe spilled fuel after completing the maintenance work and confirm that there is no fuel leakage before starting the engine. 2)
Important precautions for handling this engine The holes and gaps in the fuel system including inside the injector where the fuel passes through are manufactured with high precision. Therefore, these are extremely sensitive to any foreign matter, and may be severely dam-
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Cautions on electronic system Using circuit test tools Unless specifically instructed in the diagnostic procedure, do not use a test light when diagnosing the powertrain electronic system. When a probe connector is required in the diagnostic procedure, use the connector test adapter kit.
Maintenance precautions Special tool: connector test adapter kit (refer to section 1003) Commercial electronic equipment Commercial electronic equipment refers to commercially available electronic equipment attached to the unit after it has been shipped from the factory. Be careful, as such accessories are not taken into particular consideration at the machine design stage. Commercial electronic equipment may cause malfunctions in the electronic control system, even if the equipment is properly attached. This includes equipment not connected to the electronic system of the machine, such as mobile telephones and radios. Therefore, when diagnosing power train problems, confirm whether such commercial electronic equipment is attached first and then remove them from the machine if such equipment is attached. If the problem has not been resolved after removing the equipment, perform the diagnosis using the regular procedure. CAUTION • Make sure that commercial electronic equipment is connected to a circuit that is not involved with the circuits of the electronic control system for both power and ground. Welding operation for the actual unit When performing welding to the actual unit, make sure to disconnect the battery in prior to the operation. Current that occurred during welding may lead to failure and/or damage to the electronic control system. Damage caused by electrostatic discharge As the electronic components used in the electronic control system are designed to operate at extremely low voltages, they can be easily damaged by electrostatic discharge, and some types of electronic components can be damaged by static electricity of 100 V or less, which cannot be felt by a person. Note that a voltage of 4000 V is required for a person to be able to detect electrostatic discharge. There are various ways a person can build up an electrostatic charge. The most common way to build up an electrostatic charge is through methods based on friction or induction. An example of when a person builds an electrostatic charge by friction is when
84402827B - May 2011 4001G-4
he/she slides across the seat of the machine. A person wearing insulated shoes can build an electrostatic charge by induction if he/she momentarily touches the ground while standing near a highly charged object. A charge of the same polarity flows out, and with a highly opposing polarity, that person becomes charged. As static electricity causes damage, be cautious when handling or testing electronic components. CAUTION • To prevent damage due to electrostatic discharge, do not touch the connector pins of the ECM or the electronic components soldered onto the circuit board of the ECM. • To prevent damage due to electrostatic discharge, do not open the packaging of a replacement part until installation preparation for the replacement part is completed. • To prevent damage due to electrostatic discharge, connect the part packaging to a properly working ground connection of the actual unit before removing the part from its packaging. • To prevent damage due to electrostatic discharge, when handling a part while sliding across the seat, sitting down from a standing position, or walking a certain distance, touch a properly working ground connection before attaching the part. Fuel injection system Fuel piping WARNING The high pressure pipe and injector pipe in the fuel system should not be reused. When it is once removed, make sure to replace it with new one. The pressure limiter or fuel pressure sensor should not be replaced individually. When a failure is found, the common rail assembly and all fuel pipes should be replaced.
Maintenance precautions
1 2 3 4 5 3)
Injector pipe Flow damper Pressure limiter Fuel pressure sensor Common rail
Programming Programming guideline When the ECM or injector has been replaced, the EST cannot be used to write
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injector data into the ECM - it can either be done with the Isuzu EIDSS or the engine service monitor on the machine. Doug Reinhardt wrote up the procedure in his service training document, XC Engine Service Monitor. Need clarification from Isuzu on use of the EIDSS. As for the programming method, refer to the instruction manual of the trouble diagnosis scan tool. Prior confirmation item for programming When performing programming, check the ECM part No. as necessary. When performing programming, check the engine type as necessary. When performing programming, check the engine No. as necessary. When performing programming, check the injector ID code as necessary. Items require programming When the ECM has been replaced, perform programming. When the engine has been replaced, perform programming. When the injector has been replaced, perform programming.
Maintenance precautions
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Section 4004
Removal and Installation of Starter Motor
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84402827B - May 2011
CONTENTS Removal of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 4004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Starter Motor Job code
Removal of Starter Motor
55201AE50
1. WARNING • Do not use open flames and do not allow sparks near the battery.
Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. Also, cover with a rubber cap to protect against sparks.
CAUTION • Be sure to stop the engine before beginning work. Items to prepare • Wrenches (8 mm, 14 mm, 17 mm, 19 mm) • Rag • Cleaning fluid
2.
Use a wrench (19 mm) to remove the 10 bolts (3), and then remove the under cover (4). Tightening torque for bolt installation: 63.7 - 73.5 N·m
3.
Use a wrench (8 mm) to remove the nut (5), then remove the wiring (6).
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Removal and Installation of Starter Motor 4.
Use a wrench (8 mm) to remove the bolt (7), and then remove the wiring (8).
Installation of Starter Motor Tighten bolts and nuts to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
5.
Use a wrench (14 mm) to remove the bolt (10), and then remove the wiring on the ground side (9).
6.
Use a wrench (17 mm) to remove the 2 nuts (11), then remove the starter motor (12). Tightening torque for nut installation: 82.4 N¡m
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Section 4005
Removal and Installation of Alternator
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4005-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Alternator Removal of Alternator
WARNING • Do not use open flames and do not allow sparks near the battery.
1. 2.
CAUTION • Be sure to stop the engine before beginning work.
Remove the fan belt.(For details, see "Removal and Installation of Fan Belt".) Use a wrench (17 mm) to remove the bolt (1), and then remove the battery cable (2) on the negative side. • When removing the terminal and harness, secure them so that they do not interfere with the frame. • Also, cover with a rubber cap to protect against sparks.
Items to prepare • Wrenches (10 mm, 17 mm, 20 mm) • Rag • Cleaning fluid
3.
Remove the connector (1).
4.
Remove the cap (1), use the wrench (10 mm) to remove the nut (2), and then remove the wiring (3).
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Removal and Installation of Alternator 5.
Use a wrench (20 mm) to remove the bolt (1), and then remove the alternator (2). Tightening torque for bolt installationďź&#x161;40 Nâ&#x20AC;˘m
Installation of Alternator To install, perform the reverse of the removal procedure.
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Section 4008
Preheating System
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal and Installation of Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plug Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 4008-1
3 3 4 5
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4008-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Preheating System Removal and Installation of Glow Plug
3)
Remove the intake throttle valve from the inlet pipe.
Glow plug Removal 1.
Battery ground cable Disconnect 1)
2.
Disengage the battery ground cable from the battery.
Intake throttle valve Removal 1) 2)
Remove the air duct from the intake throttle valve. Disengage the harness connector from the intake throttle valve. ANNOTATION: â&#x20AC;˘ Pull the lock operation portion to release the lock.
1 2 3 3.
1 2 3
Intake throttle valve Gasket Inlet pipe
Glow plug Removal 1)
Remove the glow plug connector from the glow plug.
2)
Remove the glow plug from the cylinder head assembly.
Lock operation section Lock release Lock
84402827B - May 2011 4008-3
Preheating System Glow plug Installation 1.
1)
Glow plug Installation 1)
Install the intake throttle valve to the inlet pipe. Tightening torque： 24 N・m ｛2.4 kgf・m / 17.7 lb・ft｝
Install the glow plug to the cylinder head assembly. Tightening torque： 20 N・m ｛2.0 kgf・m / 14.8 lb・ft｝ CAUTION • Be careful not to exceed the specified torque when tightening.
1 2 3 2) 3) 2)
Intake throttle valve Gasket Inlet pipe
Install the air duct to the intake throttle valve. Connect the harness connector to the intake throttle valve. ANNOTATION:
Install the glow plug connector to the glow plug. Tightening torque： 1 N・m ｛0.1 kgf・m / 8.9 lb・in｝
• After connecting the harness connector, press in the lock operation portion to lock.
CAUTION • Confirm that the glow plug connector does not interfere with the surrounding parts.
1 2 3 3. 2.
Intake throttle valve Installation
Lock operation section Lock release Lock
Battery ground cable Connect 1)
84402827B - May 2011 4008-4
Connect the battery ground cable to the battery.
Preheating System Glow plug Inspection 1.
Glow plug Inspection 1)
Measure the resistance using the circuit tester. Standard resistance： 5.00 Ω less than CAUTION • Replace the glow plug if the measured value is not within the range of standard value. • Use a set of 6 glow plugs from the same manufacturer.
84402827B - May 2011 4008-5
Preheating System
84402827B - May 2011 4008-6
Section 4020A
Electrical Equipment Layout Diagram
84402827B - May 2011
84402827B - May 2011
CONTENTS Electrical Equipment Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Main Unit Left Side Layout Diagram (radiator chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine Section Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Main Unit Right Side Layout Diagram (pump chamber) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Main Unit Center Section Layout Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cab Layout Diagram 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cab Layout Diagram 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Layout Around Operator Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Stand Alone Parts Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
84402827B - May 2011 4020A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4020A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Electrical Equipment Layout Diagram Electrical Equipment Layout Diagram Overall View
84402827B - May 2011 4020A-3
Electrical Equipment Layout Diagram 1 2
Main unit left side (radiator 3 chamber) Engine 4
Main unit right side (pump 5 chamber) Main unit center section
84402827B - May 2011 4020A-4
In Cab
Electrical Equipment Layout Diagram Main Unit Left Side Layout Diagram (radiator chamber)
1 2 3 4
Air cleaner sensor Fusible link 65A (F1):fuse box Fusible link 60A：safety relay Fusible link 50A：Back up
5 6 7 8
Fuse 15A：controller Relay compressor Swing pilot pressure sensor Starter relay
84402827B - May 2011 4020A-5
9 10 11
Battery relay Receiver dryer sensor Battery
Electrical Equipment Layout Diagram Engine Section Layout Diagram
84402827B - May 2011 4020A-6
Electrical Equipment Layout Diagram
2 3
Engine coolant temperature 5 sensor Boost pressure sensor 6 7 Overheat switch
4
Common rail pressure sensor
1
8
EGR valve
9
Suction control valve
Boost temperature sensor Starter motor
10 11
Crank position sensor
12
Fuel temperature sensor Cam position sensor Engine hydraulic pressure sensor
84402827B - May 2011 4020A-7
Electrical Equipment Layout Diagram Main Unit Right Side Layout Diagram (pump chamber)
84402827B - May 2011 4020A-8
Electrical Equipment Layout Diagram 1
Charge fuel pump
6
Lever lock
2 3 4
P1 pressure sensor P2 pressure sensor 4 Stack Solenoid Valve
7 8 9
5
Swing lock
10
Travel high speed 12 Boosted pressure 13 N1 pressure sensor P1 flow control proportional valve
84402827B - May 2011 4020A-9
11
Horsepower control proportional valve N2 pressure sensor Oil temperature sensor
Electrical Equipment Layout Diagram Main Unit Center Section Layout Diagram
1 2
Upper pressure sensor Travel pressure sensor
84402827B - May 2011 4020A-10
Electrical Equipment Layout Diagram Cab Layout Diagram 1
84402827B - May 2011 4020A-11
Electrical Equipment Layout Diagram 1 2 3 4 5
Air conditioner sunlight sensor Monitor display Knob Cigar lighter Wiper controller
6 7 8 9 10
Rocker switch Wiper motor Radio Throttle volume Key cylinder
84402827B - May 2011 4020A-12
11 12 13 14
Air conditioner control panel Engine emergency stop switch Rocker switch Gate lock limit switch
Electrical Equipment Layout Diagram Cab Layout Diagram 2
84402827B - May 2011 4020A-13
Electrical Equipment Layout Diagram 1 2
Computer B Computer A No. CN. A9 CN. A10 CN.A11 CN. A12 CN. A13 No. F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
3 4
Name ECM relay DPF relay Battery relay Idle stop relay Starter cut relay
Name Key switch ECM (engine control module) GPS computer Backup (radio, room lamp) Gate lock lever Solenoid Horn Cab top light Boom, house light Option power supply
ECM (engine control module) Fuse box No. CN. A14 CN. A15 CN. A16 CN. A17 CN.A18
Name Neutral start relay Key ON relay Horn relay Boom, house light relay Cab top light relay
15 A 20 A 15 A 10 A 10 A 10 A 10 A 15 A 15 A 15 A
No. F11 F12 F13 F14 F15 F16 F17 F18 F19 F20
5
Relay
No. CN. A19 CN. A20 CN. A21 CN. A22
Name Beacon relay Room lamp relay Right speaker relay Left speaker relay
Name Wiper, washer Travel alarm, signal lamp Cigar lighter, seat suspension DC converter Air conditioner unit Air conditioner blower motor Air conditioner compressor Option power supply Feed pump Option line solenoid
84402827B - May 2011 4020A-14
15 A 10 A 10 A 10 A 5A 15 A 5A 10 A 15 A 10 A
Electrical Equipment Layout Diagram Layout Around Operator Seat
84402827B - May 2011 4020A-15
Electrical Equipment Layout Diagram 1
Cup holder
5
Throttle volume
9
2
Starter switch
6
Tilt lever right
10
7
Tilt lever left
11
8
Ashtray
3 4
Rocker space Radio
switch
84402827B - May 2011 4020A-16
Air conditioner control panel Engine emergency stop switch Gate lever
Electrical Equipment Layout Diagram Stand Alone Parts Diagram Name
Shape
Circuit
Remarks
Starter relay
Model ； DC24 V Specifications Sumitomo part No. ； KHH13250
Battery relay
Model ； For +24 V DC Sumitomo part No. ； KHR1241
Starter motor
Model ； 5.0 kW-24 V Isuzu part No. ； 8980019150
Alternator
Model ； 50 A-24 V Isuzu part No. ； 8973750171
84402827B - May 2011 4020A-17
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Battery
Model ； 180G51 Sumitomo part No. ； KHR4197
Washer motor
Sumitomo part No. ； KHR2261 (Tank + Motor)
Fusible link (fuse box)
Model；65 A Sumitomo part No. ； KHR1592
Fusible link (safety relay)
Model；60 A Sumitomo part No. ； KHR3850
84402827B - May 2011 4020A-18
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Fusible link （back up）
Model；50 A
Fuse (computer)
Model；15 A
Relay denser
Sumitomo part No. ； KHR3802
Throttle ume
con-
Model ； RA30Y2 30SKB1KΩK Sumitomo part No. ； KHR2751
vol-
84402827B - May 2011 4020A-19
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Starter switch
Model ； DC24 V Sumitomo part No. ； KHR20050
Fuel level sensor
Sumitomo part No. ； KHR1935
Charge pump
Model ； DC24 V Sumitomo part No. ； KHH11880
fuel
Sumitomo part No. ； KHH10850
Reserve tank limit switch
84402827B - May 2011 4020A-20
Electrical Equipment Layout Diagram Name
Vacuum sor
Shape
Circuit
Remarks
Sumitomo part No. ； KHH10330
sen-
Glow plug
Isuzu part No. ； 8943907775
EGR motor EGR position sensor
EGR valve accessory EGR valve Isuzu part No. ； 8980011910
Common rail pressure sensor
Common rail accessory Common rail Isuzu part No. ； 8973060632
84402827B - May 2011 4020A-21
Electrical Equipment Layout Diagram Name
Shape
Cam sensor
angle
Crank sensor
angle
Circuit
Remarks
Isuzu part No. ； 8980148310
Isuzu part No. ； 8973061131
Oil pressure sensor
Isuzu part No. ； 8976004340
Boost pressure sensor
Isuzu part No. ； 1802200140
Boost temperature sensor
Isuzu part No. ； 812468300
84402827B - May 2011 4020A-22
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Fuel temperature sensor
Supply pump accessory Supply pump Isuzu part No. ； 8973060448
Suction control valve
Supply pump accessory Supply pump Isuzu part No. ； 8973060448
Injector
Isuzu part No. ； 8973297032
Suction Air Temperature Sensor
Sumitomo part No. ； KHH13270
Engine coolant temperature sensor
Isuzu part No. ； 8971703270
84402827B - May 2011 4020A-23
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Barometric pressure sensor
Sumitomo part No. ； KHH0536
Computer A
Sumitomo part No. ； KHR29000
Computer B
Sumitomo part No.;KHR2905 0
Relay
Model ； DC24 V Sumitomo part No. ； KHR3802
DC-DC verter
Sumitomo part No. ； KHR2447
con-
84402827B - May 2011 4020A-24
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Alarm (feed pump)
Sumitomo part No. ； KHR4024
Feed pump
Sumitomo part No. ； KHR12840
Feed switch
Sumitomo part No. ； KHR12900
pump
Lamp (front right housing)
Model ； 24 V 70 W Sumitomo part No. ； KHR2475
Lamp (boom)
Model ； 24 V 70 W Sumitomo part No. ； KHR0957
84402827B - May 2011 4020A-25
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Lamp (cab top)
Model ； 24 V 70 W Sumitomo part No. ； KHR16240
Speaker (right) (left)
Sumitomo part No. ； CAP2284
Monitor display
Model ； SD107023 Sumitomo part No. ； KHR23591
Pressure sensor (P1) (P2)
Model ； 50.0 MPa Sumitomo part No. ； KHR10290
84402827B - May 2011 4020A-26
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Pressure sensor (N1) (N2) (swing) (upper) (travel) (arm in)
Model ； 5.0 MPa Sumitomo part No. ； KHR26940
Pressure switch (option) (2nd option)
Model ； 0.49 MPa Sumitomo part No. ； KHR21490
Pressure switch (filter)
Sumitomo part No. ； KHR14470
4 stack solenoid valve
Sumitomo part No. ； KHJ15450
84402827B - May 2011 4020A-27
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
2 stack solenoid valve (knob switch type)
Sumitomo part No. ； KHJ14780
2 stack solenoid valve (pedal type)
Sumitomo part No. ； KHJ14000
P1 flow control proportional valve
Sumitomo part No. ； LJ016060
Horsepower control proportional valve
Sumitomo part No.；LJ00684
84402827B - May 2011 4020A-28
Electrical Equipment Layout Diagram Name
Free switch
Shape
Circuit
Remarks
Sumitomo part No. ； KHR16140
swing
KAB seat
Model ； KAB 555 Sumitomo part No. ； KHN13560
Free swing solenoid
Sumitomo part No.；KHJ0659
Hydraulic oil temperature sensor
Sumitomo part No. ； KHR2433
84402827B - May 2011 4020A-29
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Knob; Right (with onetouch switch)
Model；With 4 switches Sumitomo part No. ； KHJ24640
Knob; Left (with horn switch and radio mute)
Model；With 4 switches Sumitomo part No. ； KHJ24630
Travel alarm
Sumitomo part No. ； KHR3852 Basic frequency ； 2560 Hz
Horn (low)
Sumitomo part No. ； KHR11440 Basic frequency ； 303 Hz
Horn (high)
Sumitomo part No. ； KHR11450 Basic frequency ； 333 Hz
84402827B - May 2011 4020A-30
Electrical Equipment Layout Diagram Name
Shape
Circuit
Diode
Remarks Sumitomo Wiring Systems par ； 6098-0017 6098-0061 Sumitomo part No. ； KHP1796
Lever lock limit switch
Sumitomo part No. ； KHR14930
Radio
Model ； AM/FM ST （12/24 V） Sumitomo part No. ； KHR27980
Lamp (room lamp)
Model ； 24 V,10 W Sumitomo part No. ； KHN2714
84402827B - May 2011 4020A-31
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Accessory socket
Model ； DC12 V Sumitomo part No. ； KHR2501
Cigar lighter 24 V
Model ； DC24 V Sumitomo part No. ； KHR11210
Air conditioner unit
Sumitomo part No. ； KHR27160
Limit switch (front window) (door)
Sumitomo part No. ； KHN26000
84402827B - May 2011 4020A-32
Electrical Equipment Layout Diagram Name
Wiper troller
Shape
Circuit
Remarks
Sumitomo part No. ； KHN3392
con-
Wiper motor
Sumitomo part No. ； KHN25780
Solar radiation sensor
Sumitomo part No. ； KHR10540
Receiver dryer (switch)
Sumitomo part No. ； KHR13590
84402827B - May 2011 4020A-33
Electrical Equipment Layout Diagram Name
Shape
Circuit
Air conditioner compressor (magnetic clutch)
Remarks
Sumitomo part No. ďź&#x203A; KHR3197
Motor actuator (air mix) (mode) (inside/ outside air)
EVA sensor
Interior temperature sensor
84402827B - May 2011 4020A-34
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Relay (compressor) (blower OFF)
Blower motor
Blower amp
Sumitomo part No. ï¼&#x203A; KHR27250
Air conditioner switch panel
84402827B - May 2011 4020A-35
Electrical Equipment Layout Diagram Name
Travel switch
Shape
Circuit
Remarks
Sumitomo part No. ； KHR15850
alarm
Horn volume switch
Sumitomo part No. ； KHR28540
Engine emergency stop switch
Sumitomo part No. ； KHR28530
3 stack proportional valve (boom up, arm in, bucket close)
Sumitomo part No.; KHJ23870
84402827B - May 2011 4020A-36
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
Fuel filter sensor (Isuzu)
Sumitomo part No.; KHH13230
DPF exhaust gas pressure differential pressure sensor (Isuzu)
Isuzu part No.; 897360-3682 Sumitomo part No.; KHH13330
DPF temperature sensor (Isuzu) (center)
Isuzu part No.; 898004-3300 Sumitomo part No.; KHH13360
DPF temperature sensor (Isuzu) (front)
Isuzu part No.; 898004-3290 Sumitomo part No.; KHH13350
Turbo puter (Isuzu)
Isuzu part No.; 898077-1181 Sumitomo part No.; KBH13650
com-
84402827B - May 2011 4020A-37
Electrical Equipment Layout Diagram Name
Shape
Circuit
Remarks
EGR manifold temperature sensor (Isuzu)
Isuzu part No.; Sumitomo part No.; -
VGS TURBO
Sumitomo part No.; -
84402827B - May 2011 4020A-38
Section 4020B
Connection Connector Pin Layout
84402827B - May 2011
84402827B - May 2011
CONTENTS Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 4020B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4020B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Connection Connector Pin Layout Computer A
84402827B - May 2011 4020B-3
Connection Connector Pin Layout Monitor
84402827B - May 2011 4020B-4
Section 4020C
Sequence Circuit Diagram
84402827B - May 2011
84402827B - May 2011
CONTENTS Code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Computer A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Computer B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lever Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Working lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical Symbol List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
84402827B - May 2011 4020C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4020C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Sequence Circuit Diagram Code table FUSE 10A ; DC/DC CONVERTOR FUSE 5A ; AIR CONDITIONER HEATER UNIT FUSE 15A ; AIR CONDITIONER BLOWER FUSE 5A; AIR CONDITIONER COMPRESSOR
A1
COMPUTER
F14
A2
ENGINE CONTROLLER
F15
A4
WIPER CONTROLLER
F16
A6
BLOWER CONTROLLER
F17
A13
CONTROLLER B
F18
FUSE 10A ; SPARE
S22
B1
COOLANT SENSOR
F19
FUSE 15A; PUMP
S51
B2 B3 B5 B21 B22 B26 B27 B28 B40 B42 B43 B44 B45
TEMPERATURE
HYDRAULIC OIL TEMPERAF20 TURE SENSOR FUEL TEMPERATURE SENF41 SOR EVAPORATOR SENSOR ENGINE OIL SWITCH SWING PILOT SWITCH UPPER PILOT SENSOR TRAVEL PILOT SENSOR
PRESSURE PRESSURE PRESSURE PRESSURE
F42 F43 F45
FUSE 10A ; OPTION LINE
RESISTOR (MAF)
S1
KEY SWITCH
S9
ENGINE EMERGENCY STOP SWITCH
S13
OVERLOAD SWITCH (EU)
S52
FUSIBLE 50A ; LINK BACK UP S53 FUSE 15A ; CONT
S54
FUSIBLE 65A ; LINK FUSE S55 BOX FUSIBLE 60A ; LINK SAFETY S61 RL
S70
HORN VOLUME SWITCH
TRAVEL ALARM
S71
PRESSURE SWITCH FILTER INDICATOR (BREAKER OPTION)
H4
SPEAKER RIGHT
S85
BEACON (EU)
H5
SPEAKER LEFT
U1
K2
RELAY-GLOW PLUG
X2
K3
RELAY-HORN
X3
K5
RELAY-ROTARY LIGHT
X4
RELAY BATTERY
B49
CRANKSHAFT SENSOR
B83 B84 B85
REFUEL PUMP SWITCH
ALTERNATOR
AMBIENT AIR (BAROMETK7 RIC) PRESSURE SENSOR
B61 B82
LOW
G2
B48
B52
LIMIT
AIR CLEANER SENSOR
RELAY-AIR CONDITIONER X5 CONDENSER FAN
BOOST TEMPERATURE SENSOR COMMON RAIL PRESSURE SENSOR SUNLOAD SENSOR REFUEL PUMP STOP ALARM PRESS. SENSOR (PILOT ARM CLOSE) PRESS. SENSOR (PILOT BUCKET CLOSE) PRESS. SENSOR (PILOT BOOM UP)
FRONT WINDOW SWITCH RESERVE TANK SWITCH
S62
BOOST PRESSURE SENSOR K6
B51
DOOR LIMIT SWITCH
BATTERY
B47
POSITION
FREE SWING (NA) ; OPTIONAL (EU) HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH AIR CONDITIONING COMPRESSOR CLUTCH SWITCH
G1
SECOND OPTION PILOT CIRH2 CUIT 1 PRESSURE SWITCH PUMP PRESSURE SENSOR (NEGA-CONT. P2) PUMP PRESSURE SENSOR (P1) PUMP PRESSURE SENSOR (NEGA-CONT. P1) PUMP PRESSURE SENSOR (P2) (BLUE BAND) OVERLOAD INDICATOR PRESSURE SWITCH
FUEL FILLER
R7
K10 K11
X6
RELAY-WORKING LIGHT (UPPERSTRUCTURE / AT- X9 TACHMENT) RELAY-WORKING LIGHT X15 (CAB)
ANTI-THEFT SYSTEM CONNECTOR ACCESSORY SOCKET
K17
BLOWER OFF RELAY
K30 K31
REFUEL PUMP RELAY X24 REFUEL PUMP STOP RELAY X25
K34
RELAY STARTER CUT
X26
EST CONECTOR B
K35
RELAY ROOM LAMP
X27
TO GPS UNIT
K36
RELAY SPEAKER LEFT
X32
TO DRM
84402827B - May 2011 4020C-3
X23
DC-DC (24V-12V) CONVERTER ROTARY LIGHT CONNECTOR OPTIONAL POWER CONNECTOR ENGINE TEST POINT CONNECTOR CONTROLLER TEST POINT CONNECTOR CAB SEAT COMPRESSOR MOTOR CONNECTOR
CLEAR MEMORY 1 CLEAR MEMORY 2 TO CONTROLLER C
Sequence Circuit Diagram B86 B87
EGR INTAKE TEMP. SENSOR K37 CAM ANG(MRE) SENSOR K51
B88
FUEL FILTER SENSOR
B89
EXSHAUST PRESS. SENSOR K64
B90 B91
EXSHAUST SOR(CNT) EXSHAUST SOR(FNT)
RELAY SPEAKER RIGHT RELAY CONDENSER
X33 X34
RELAY ECM
X36
RELAY KEY ON
Y2
K65
RELAY BATTERY RL
Y3
K66
RELAY IDLE STOP
Y4
K63
TEMP.
SEN-
TEMP.
SEN-
B92
HORN LOW (LEFT)
K67
RELAY DPF
Y5
B93
HORN HIGH (RIGHT)
K68
RELAY NEUTRAL START
Y7
K69
RELAY STARTER
Y8
M1
STARTER MOTOR
Y9
M3
WIPER MOTOR
Y11
M4
WASHER MOTOR
Y18
MOTOR (AIR CHANGING)
Y23
B94 B95 E1 E2
PRESS. SWITCH (1ST OPTION) AIR INTAKE SENSOR MASS & TEMP WORKING LIGHT (UPPERSTRUCTURE) WORKING LIGHT (ATTACHMENT)
E3
WORKING LIGHT (CAB)
M5
E4
CAB LIGHT
M6
E51
CIGAR LIGHTER
M7
E52
AIR CONDITIONER
M8
E68
CONDENSER
M14 FUEL FEED PUMP MOTOR
Y27
F1
FUSE 15A ; KEY SWITCH
M20 ELECTRIC FUEL PUMP
Y35
F2
FUSE 20A ; ENGINE CONM23 VGS TURBO TROLLER
F3
FUSE 10A TROLLER
F4
FUSE 10A ; BACK UP
F5
FUSE 10A ; LEVER LOCK P1 (GATE)
F6
FUSE 10A ; SOLENOID
P2
F7
FUSE 10A ; HORN
P3
F8
FUSE 15A ; LAMP (CAB)
P6
F9
FUSE 15A ; LAMP (BOOM, P15 HOUSE)
F10
FUSE 15A ; SPARE
F11 F12 F13
;
GPS
CON-
AIR VENT DIRECTION CONY24 TROL MOTOR MOTOR ACTUATOR (AIR Y25 MIX) BLOWER MOTOR
Y26
Y59
M24
INTAKE THROTTLE DC-MOY60 TOR
M25
EXHAUST GAS RECIRCULAY61 TION VALVE INSTRUMENT PANEL
Y62
SWITCH PANEL (LEFTY63 HAND) SWITCH PANEL (RIGHTY64 HAND) AIR CONDITIONER SWITCH Y65 PANEL
FOR CRANE FOR FAN REVERSE 12V OUTPUT(FOR RADIO EU) PILOT PRESSURE SOLENOID VALVE (BLUE BAND) SWING BRAKE SOLENOID VALVE (WHITE BAND) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) POWER-UP SOLENOID VALVE (YELLOW BAND) MAIN PUMP POWER PROPORTIONAL SOLENOID AIR CONDITIONER MAGNET CLUTCH OPTION 2 SPEED SOLENOID VALVE (BLUE TAPE) MAIN PUMP FLOW PROPORTIONAL SOLENOID FREE SWING SOLENOID VALVE (NA) OPT.1 KNOB (R) -R SOLENOID VALVE (BLUE TAPE) OPT.1 KNOB (R) -L SOLENOID VALVE (RED TAPE) OPT.2 KNOB (L) -R SOLENOID VALVE (BLUE TAPE) OPT.2 KNOB (L) -L SOLENOID VALVE (RED TAPE) OPTION SELECT SOLENOID VALVE (RED TAPE) SUCTION CONTROL VALVE (SCV) BOOM UP PROPORTIONAL SOLENOID VALVE (NO TAPE) ARM CLOSE PROPOTIONAL SOLENOID VALVE (RED TAPE) BUCKET CLOSE PROPOTIONAL SOLENOID VALVE (BLUE TAPE) OPTION PRESS. PROPORTIONAL SOLENOID VALVE INJ1 (#1) INJ2 (#3) INJ3 (#4)
RADIO SET (NA)
Y66
GLOW PLUG
Y67
FUSE 15A ; WIPER/WASHER R3
THROTTLE VOLUME
Y68
FUSE 10A ; TRAVEL ARALM ; R4 BEACON FUSE 10A ; CIGAR LIGHTER ; R5 SEAT SUS
THERMISTOR INNER TEMY69 PERATURE
INJ5 (#2)
Y70
INJ6 (#4)
R1
FUEL SENSOR
84402827B - May 2011 4020C-4
INJ4 (#2) OPTION SELECT SOLENOID VALVE (BLUE TAPE) OPTION 2SPEED SOLENOID VALVE (RED TAPE)
Sequence Circuit Diagram Overall
84402827B - May 2011 4020C-5
Sequence Circuit Diagram
84402827B - May 2011 4020C-6
Sequence Circuit Diagram Block diagram Computer A
84402827B - May 2011 4020C-7
Sequence Circuit Diagram Computer B
84402827B - May 2011 4020C-8
Sequence Circuit Diagram ECM
84402827B - May 2011 4020C-9
Sequence Circuit Diagram Monitor
84402827B - May 2011 4020C-10
Sequence Circuit Diagram Air Conditioner
84402827B - May 2011 4020C-11
Sequence Circuit Diagram Lever Lock
Horn
Working lights
84402827B - May 2011 4020C-12
Sequence Circuit Diagram Option
84402827B - May 2011 4020C-13
Sequence Circuit Diagram Other
84402827B - May 2011 4020C-14
Sequence Circuit Diagram Electrical Symbol List Symbol
Name
Symbol
Name
Fuse
Variable solenoid valve
Diode
Resistor
LED
Variable resistor
Toggle switch "a" contact
Variable resistor
Push switch "a" contact
Alarm
Limit switch "a" contact
Buzzer
Limit switch "b" contact
Horn
Relay coil
Motor
Relay contact "a" contact
Solar radiation sensor
84402827B - May 2011 4020C-15
Sequence Circuit Diagram Symbol
Name
Symbol
Name
Relay contact "b" contact
Speaker
Solenoid valve
Lamp
84402827B - May 2011 4020C-16
Section 4021
Engine-side DTC List
84402827B - May 2011
84402827B - May 2011
CONTENTS Engine-side DTC List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 4021-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4021-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Engine-side DTC List Engine-side DTC List DTC code P0016 P0045 P0087 P0088 P0089 P0091 P0092 P0093 P0102 P0103 P0112 P0113 P0117 P0118 P0122 P0123 P0182 P0183 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P0217 P0219 P0234 P0299 P0237 P0238 P0335 P0336 P0340 P0341 P0404 P0409 P041C P041D P0426 P0427 P0428 P042B P042C P042D P0522 P0523 P0560 P0563 P0601 P0602 P0604 P0606 P060B P0638
Description Abnormally correlation between crankshaft position and camshaft position Turbocharger boost pressure control system abnormality Fuel rail system pressure low pressure error Fuel rail system pressure high pressure error Fuel rail pressure regulator characteristics error Fuel rail pressure regulator control system low input Fuel rail pressure regulator control system high input Fuel system leak detection Mass air flow sensor system law input Mass air flow sensor system high input Intake temperature sensor system low input Intake temperature sensor system high input Engine coolant temperature sensor system low input Engine coolant temperature sensor system high input Throttle sensor system low input Throttle sensor system high input Fuel temperature sensor system low input Fuel temperature sensor system high input Fuel rail pressure sensor system low input Fuel rail pressure sensor system high input Injector first cylinder system error Injector second cylinder system error Injector third cylinder system error Injector fourth cylinder system error Injector fifth cylinder system error Injector sixth cylinder system error Engine coolant high temperature error Engine high rpm error Turbocharger high boost pressure state Turbocharger low boost pressure state Boost sensor circuit low input Boost sensor circuit high input Crankshaft position sensor system error Crankshaft position sensor system characteristics error Camshaft position sensor system error Camshaft position sensor characteristics error EGR1 control system error EGR1 position sensor system error IMT sensor system high input IMT sensor system low input Pre-filtered exhaust gas high temperature error Exhaust temperature sensor 1 system low input Exhaust temperature sensor 1 system high input Exhaust gas high temperature error before oxidation catalyst Exhaust temperature sensor 2 system low input Exhaust temperature sensor 2 system high input Oil pressure sensor system low input Oil pressure sensor system high input System voltage error System voltage high input Control module memory checksum error Control module program error Control module RAM error Control module processing device error Control module A/D converter processing system characteristics error Throttle actuator control system characteristics error 84402827B - May 2011 4021-3
Engine-side DTC List DTC code P0641 P0650 P0651 P0685 P0687 P0697 P1093 P1112 P1113 P1261 P1262 P1293 P1294 P1404 P1455 P1471 P1621 P1655 P1669 P2122 P2123 P2127 P2128 P2146 P2149 P2228 P2229 P242F P2452 P2453 P2454 P2455 P2456 P2458 U0001 U0073 U0101 U0110 U0411
Description Sensor voltage system error MIL control system error Sensor voltage system error ECM main relay control system low input ECM main relay control system high input Sensor voltage system error Fuel rail pressure low pressure error Boost temperature sensor system low input Boost temperature sensor system high input Injector group 1 voltage control system error Injector group 2 voltage control system error Fuel filter pressure sensor system low input Fuel filter pressure sensor system high input EGR close position characteristics error DPD restriction 2 DPD regeneration error Control module EEPROM error Sensor voltage system error DPD light control system error Pedal position sensor 1 system low input Pedal position sensor 1 system high input Pedal position sensor 2 system low input Pedal position sensor 2 system high input Injector group 1 supplied voltage system error Injector group 2 supplied voltage system error Atmospheric pressure sensor system low input Atmospheric pressure sensor system high input DPD restriction DPD differential pressure sensor system error DPD differential pressure sensor system characteristics error DPD differential pressure sensor system low input DPD differential pressure sensor system high input DPD differential pressure sensor learning position error DPD regeneration time error CAN bus communication error Control module communication error TCM communication error Turbocharger control module communication error Turbocharger control module signal error
84402827B - May 2011 4021-4
Section 4022
Main Unit-side DTC List
84402827B - May 2011
84402827B - May 2011
CONTENTS Main Unit-side DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 4022-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4022-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Main Unit-side DTC List Main Unit-side DTC List DTC 7000 7001 7002 7003 7004 7005 7006 7020 7021 7022 7023 7040 7041 7045 7060 7061 7063 7065 7066 7200 7201 7202 7203 7204 7205 7206 7207 7210 7211 7240 7241 7242 7246 7247 7248 7250 7251 7252 7253 7400 7401 7402 7404 7405 7406 7420 7421 7422 7423 7424 7425 7600 7601 7602 7603
Trouble mode P1 Pressure Sensor Signal Abnormality P2 Pressure Sensor Signal Abnormality N1 Pressure Sensor Signal Abnormality N2 Pressure Sensor Signal Abnormality Overload Pressure Sensor Signal Abnormality Bottom Pressure Sensor Signal Abnormality Rod Pressure Sensor Signal Abnormality Upper Pressure Sensor Signal Abnormality Swing Pressure Sensor Signal Abnormality Travel Pressure Sensor Signal Abnormality Arm-in Pressure Sensor Signal Abnormality Fuel Level Sensor Signal Abnormality Oil Temperature Sensor Signal Abnormality Monitor Thermistor Signal Abnormality Boom Angle Sensor Signal Abnormality Arm Angle Sensor Signal Abnormality Return Filter Clogging Pressure Switch Signal Abnormality Boom-up Pilot Pressure Sensor Signal Abnormality Bucket-close Pilot Pressure Sensor Signal Abnormality Swing Brake Solenoid Signal Abnormality Travel High-speed Solenoid Signal Abnormality Pressure Boost Solenoid Signal Abnormality Travel Alarm Buzzer Signal Abnormality Power Save Solenoid Signal Abnormality Feed Pump Relay Signal Abnormality Option Line Switchover Solenoid Signal Abnormality Free Swing Solenoid Signal Abnormality Liftcrane Buzzer Signal Abnormality Rotating Light Relay and Bucket Lock Signal Abnormality Pump Horsepower Proportional Valve Signal Abnormality P1 Flow Control Proportional Valve Signal Abnormality Fan Proportional Valve Signal Abnormality 2 Pumps Flow Solenoid Signal Abnormality Boom-down Proportional Valve Signal Abnormality Arm-in Proportional Valve Signal Abnormality Option Relief Pressure Proportional Valve Signal Abnormality Battery Control Relay Signal Abnormality Idle Stop Relay Signal Abnormality DPD Regeneration Request Output Signal Abnormality Abnormally High Coolant Temperature (105℃ or higher) Abnormally High Coolant Temperature (110℃ or higher) Abnormally High Coolant Temperature (120℃ or higher) Abnormally High Oil Temperature (95℃ or higher) Boost temperature is abnormally high ( 80 ℃ or more ) Boost temperature is abnormally high ( 90 ℃ or more) Abnormally Low Alternator Voltage Coolant Level Reduction Abnormally Low Engine Oil Pressure Air Cleaner Clogging Return Filter Clogging (breaker specifications) Fuel Density Error Signal Abnormality CAN Bus Abnormality Monitor Communication Abnormality ECM Communication Abnormality Computer B Communication Abnormality 84402827B - May 2011 4022-3
Main Unit-side DTC List DTC 7605 7606 7607
Trouble mode ECM Mismatch EEPROM Data Abnormality Computer C Communication Abnormality
84402827B - May 2011 4022-4
Section 4023B
Introduction to the trouble diagnosis
84402827B - May 2011
84402827B - May 2011
CONTENTS Introduction to the trouble diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 4023B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4023B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Introduction to the trouble diagnosis Introduction to the trouble diagnosis 1.
Introduction to the trouble diagnosis 1)
2)
About trouble diagnosis The following trouble diagnosis procedure is extremely important to resolve problems of all electric/electronic systems. Neglecting to implement these steps may result in requiring unnecessary repairs. Read and understand the procedure carefully and proceed with the trouble diagnosis. Also, use available functions and the trouble diagnosis scan tool to perform the trouble diagnosis and system check. Trouble diagnosis procedure Checking complaints from customer • Use the check sheet to organize the trouble situation. Performing preliminary inspection • • • • •
Perform overall visual inspection. Check the past maintenance history. Detect any abnormality such as abnormal noise, smell, etc. Collect the failure trouble DTC information to provide effective repair. Inspect for an abnormality by comparing to the standard value.
Inspect the service information • Check the market service bulletin. Perform inspection for the displayed code. • Inspect the item shown by DTC. Perform an inspection for problems according to symptoms • Check the item that is not displayed in the DTC.
3)
NOTE System trouble diagnosis type The system diagnosis method is a standardized method applied for repairing all electric/electronic systems. Failures in electric/electronic systems often occur in the following steps unlike common actual unit failures. Initial stage of failure The failure occurs sporadically and for a short time, often times the driver does not notice it. At this stage, the customer's complaint is unclear, and the malfunction cannot be reproduced. However, the ECM may have recorded the failure. Past malfunction, past failures Middle stage of failure The failure occurs sporadically and for a short time, but may occur repeatedly at intervals, and occurs under specific conditions. The customer complaint is clear, but the failure conditions are unclear. Therefore, the person performing the diagnosis can reproduce the failure by understanding its conditions. Intermittent failures, intermittent Stage where failure is realistic The occurrence of the failure is set, and the customer complaint is real and clear. Therefore, the person performing the diagnosis can reproduce the failure. However, there may sometimes be more than 2 causes for the failure. Current malfunction, Current failures Diagnosis Fully understand the description given by the customer using the Engine Control System Check Sheet. ANNOTATION: • When questioning, do not ask randomly but focus on the system that is inferred to be defective based on the malfunction phenomenon. Determine failure information accurately. Have concrete understanding based on 5W1H. Low air temperature, at start or on a steady basis, near the engine parts, metallic sound, etc. Check points • Failure symptoms • Month and Date, Time, Frequency of occurrence • Road conditions 84402827B - May 2011 4023B-3
Introduction to the trouble diagnosis • Working conditions, Operation conditions, Weather • Feeling of symptom Engine control system check sheet When receiving the actual unit from the customer at the service factory, the failure symptoms and the data on occurrence of failure must be confirmed with the customer based on the engine control check sheet. • Failure symptoms may not be able to be reproduced at the service factory. • The customer's complaint may not always be a malfunction. • Notification of incorrect malfunction conditions to the person in charge of repairs may result in unnecessary man-hours for repairs. • The check sheet assists in actual unit diagnosis, repair, and repair confirmation at the vehicle servicing factory.
1 2
84402827B - May 2011 4023B-4
Failure symptoms Failure frequency・failure conditions
Introduction to the trouble diagnosis
4)
Preparatory check Visual inspection of engine room When implementing the diagnostic procedures, carefully make a visual inspection of the engine room. 84402827B - May 2011 4023B-5
Introduction to the trouble diagnosis This inspection can often lead to solving a problem without taking extra steps. • Visually inspect all air hoses for punched holes, cuts, disconnections, and appropriate piping. • Visually inspect the hoses that are difficult to see behind other components. • For every harness in the engine room, visually inspect that all harnesses are properly connected. Inspect that there are no burned or worn areas, that the harnesses are properly fastened and that they are not in contact with sharp edges or the hot exhaust manifold or pipes.
5)
Checking the actual unit maintenance status If the maintenance of the actual machine is not performed correctly, the monitor may illuminate. Restricted oil filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual unit faults that were not previously monitored prior to OBD. Poor vehicle maintenance cannot be classified as a non-machine failure, but since the sensitivity of OBD system checks is high, actual unit maintenance schedules must be further closely followed. Non-OEM parts All the OBD system checks are adjusted to operate with the genuine parts. Therefore, when a commercially sold sensor or switch, etc. is installed, a wrong diagnosis is made, and the monitor comes on. Accordingly, if general commercially-available sensors or switches are installed, this will cause mistakes in diagnosis and the monitor to show an abnormality display. If a commercially-available electronic device such as a mobile phone, stereo or anti-theft device is inappropriately installed, an EMI may be emitted to the control system. As a result, incorrect sensor information will be generated and the monitor will show an abnormality display. When conducting a trouble diagnoses, either turn OFF the power for all commercially sold parts or remove them, and then check the failure again. NOTE Related system failure Many OBD system checks go into the backup operation mode based on the instruction from the ECM which is given when the ECM detects a failure in the related systems or components. When the backup operation mode is activated, the output is reduced to protect the actual unit. Trouble diagnosis Basic knowledge of tools required ANNOTATION: • When performing the diagnostic procedure, lack of basic knowledge regarding this powertrain could result in an incorrect diagnosis or damage to the powertrain components. Do not attempt to diagnose a problem related to the powertrain without having the basic knowledge. A basic understanding of hand tools, such as the trouble diagnosis scan tools, is required to utilize the service manual effectively. About the diagnostic test performed on the actual unit Past failures • The diagnostic tests of the previous ignition cycle have been completed. • The diagnostic tests of the current ignition cycle have passed. • Problems identified in the diagnostic tests currently do not exist. Current failures • The diagnostic tests of the previous ignition cycle have been completed. • Problems identified in the diagnostic tests currently exist. • Problems exist in the current ignition cycle. Glossary DTC Every time the starter switch is turned ON, the ECM performs the self-test on most of the wiring and components, records any detected system failure in the memory of the ECM, and performs the backup control, depending on the DTC. Also, abnormalities that affect travel will cause the monitor to show an abnormality display to inform the operator. Ignition cycle Because the actual unit activates with a method to satisfy a predetermined diagnosis standard, an ignition cycle is defined as turning the starter switch ON, running, then turning the starter switch OFF. Monitor In general, the monitor shows an abnormality display when a malfunction occurs in electronic control such as the ECM and a DTC is detected. DLC The equipment for communicating with the control unit is the Data Link Connector (DLC). 84402827B - May 2011 4023B-6
Introduction to the trouble diagnosis The DLC is also provided to establish a connection with the scan tool. Identification of recorded DTC Reading the serial data ANNOTATION: • The installation position of the DLC and existence or nonexistence of the DLC vary depending on the actual unit, so refer to the manual of the actual unit.
6)
ECM OFF Turn the ECM off starter switch off and the ECM power supply completely tops in approximately 10 seconds to disable the ECM. General diagnostic operations of the components monitor To run the engine normally, a general diagnosis of the components is required. Input components Inspect the input components to see whether an open in the circuit or outside range value exists. Crankshaft position sensor Camshaft position sensor Water temperature sensor Boost sensor Fuel pressure sensor Accelerator position sensor Output components The output components are inspected to diagnose whether responses to commands from the control unit are appropriate. Inspect whether the circuits have disconnections and whether their values are within the range. Suction control valve Light, Relay control Magnetic valve Monitor DTC reading procedure Reading DTC with monitor Current and past DTCs recorded in the ECM can be displayed by connecting the diagnostic switch and blinking the monitor. • Switch the starter switch ON and check that the monitor shows an abnormality display. • Turn the starter switch ON, but the engine off. • Connect the diagnostic switch. For an actual unit with no diagnostic switch, short the DLC No. 1 and No. 4 or No. 5. • Read the blinking count of the monitor. • The DTC determines the failure contents from the diagnostic trouble code list. If the trouble diagnostic scan tool is connected, the diagnostic codes can be read by operating the trouble diagnostic scan tool. ANNOTATION: • As for the installation position of the monitor, refer to the manual of the actual unit. Display code when no DTC is recorded Code 1 (indicating the start of code display) continues to be displayed. Display when a DTC is recorded The recorded trouble codes are displayed 3 times. If more than 2 or more trouble codes have been recorded, the DTCs will be output in ascending order with each DTC being displayed three times. After displaying all codes, the codes will be displayed again starting with the smallest code number. This display continues while the diagnosis connector is connected.
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Introduction to the trouble diagnosis
a b *1 *2
ON Goes off
*3 *4
Tens digit Units digit t1 t2
Approx. 0.3 sec Approx. 0.6 sec
*5
At code "23" At code "413" Hundreds digit
t3 t4
Approx. 1.2 sec Approx. 2.4 sec
DTC indicated by monitor blinking display The current and past DTCs are both displayed while the engine is being stopped. While the engine is in operation, the light is turned on only when a current DTC exists. Using the trouble display monitor to read the DTC When a DTC occurs, the DTC can be displayed on the trouble display monitor of the actual unit. Using the scan tool to read the DTC The DTC can be read using the trouble diagnosis scan tool. ANNOTATION: â&#x20AC;˘ For the work procedure, refer to the manual of the trouble diagnosis scan tool. When the DTC is recorded Perform repairs accurately according to the specified DTC chart. If no DTC is available Select the symptom from "Diagnosis By Symptom". Complete the repair according to the diagnostic procedure. It is also possible to perform the inspection by referring to the functional diagnosis. When the appropriate symptom is not found; Investigate the complaint in detail. Create a diagnosis plan. Utilize the schematics and operation principles. When repair history for similar cases are available, request technical assistance. Combine technical knowledge and effective utilization of available service information. Intermittent 84402827B - May 2011 4023B-8
Introduction to the trouble diagnosis
7)
8)
A failure condition that does not necessarily always appear is referred to as intermittent. Check the DTC information and the data display. Verify the symptoms and conditions reported by the customer. Use a check sheet or other method to check the circuit or electronic system components. When no trouble is detected This status indicates that the actual unit is determined as operating properly. The condition reported by the customer may be normal. Check the customer complaint by comparing to other actual unit that is operating properly. However, depending on the condition, it may be an intermittent. Before returning the actual unit, check the complaint under the conditions given by the customer. Investigate the complaint again. If the complaint cannot be adequately detected or confirmed , it is necessary to perform the diagnosis again to verify the complaint. As stated above in "Intermittent", the complaint may be an intermittent or normal condition. Repair and confirm. Perform the repair when the cause has been confirmed. Confirm that the operation is performed properly, and that the symptom has been corrected. This includes the confirmation test performed on the actual unit or other methods to confirm that the complaint has been resolved. Confirm by testing under the conditions given by the customer. When a DTC is diagnosed, confirm that the failure has been repaired by reproducing the condition that appeared when the DTC was set while checking the scan tool data. Check after repair Check repair on actual unit When an repair has been performed for the electronic control system, it is necessary to check that the repair is accurate after repairing the actual unit. If this confirmation is not done thoroughly, the monitor may show an abnormality display again or operability problems may occur when the actual machine is handed over to the customer. It is especially necessary to recreate customer complaint conditions and confirm repair for intermittent problems. Especially for an intermittent failure, it is necessary to perform the check by reproducing the conditions of the customer complaint. About confirmation of the actual unit repairs It is effective to use the OBD system check for confirming actual unit repairs. After the repair is completed, the person who have performed the actual unit diagnosis shall review either the DTC that was diagnosed or scan tool data, or both, and record it. Clear the DTC. Run the actual unit based on the scan tool data. Check the DTC status information of the specified DTC that was diagnosed until the diagnosis test related to that DTC is implemented by the control unit. The implementation of these steps is extremely important when checking the repair status with the OBD system check. Neglecting to implement these steps may result in unnecessary repairs. Final check item list
Item Item
Objective
1
DTC check
Confirm the DTC display after the repair.
2
Idling speed To check whether the idling control is opcheck after warmerating normally. ing up the engine
3
Check the engine control, communicaConfirm the scan tion status error and abnormality under tool data list the standard condition.
Method Clear the previous DTCs. Keep the engine idling to warm up, then perform a racing run to increase the engine rpm to No Load Max to secure the test conditions. Check whether the idling rotation speed is constant under the no load condition after engine is warmed up. If a problem is detected, refer to Idling Unstable in Diagnosis by Symptom. Monitor the scan tool data list, and check the values using a typical value sheet. Confirm the typical values of the scan tool data list.
84402827B - May 2011 4023B-9
Introduction to the trouble diagnosis Item Item
Objective
4
Re-startability check
To check whether the starting control is normal.
5
When electromagnetic transmitters such Check powerful as a transceiver have been added to the electromagnetic vehicle, confirm that no interfering waves transmitters are being emitted.
Method After warming up the engine, confirm that the cranking time is 5 seconds or less when restarting the vehicle, and that the engine revolution is stable after starting. Check whether turning the electromagnetic transmitter such as a transceiver ON and OFF causes the idling engine rpm to change. If a problem is found, let the customer know that the installation position and output of the electromagnetic transmitter need to be changed.
Supplementary information regarding the check for powerful electromagnetic transmitters If you discover a problem in this item, convey it to the customer as necessary. • Install the antenna to the a place distant from the electronic control system of the actual unit such as the control units and sensors. • Install the antenna cord at least 20 cm away from the electronic systems of the actual unit, such as the control units and sensors. • Do not wire other cables together with antenna. Also, locate the antenna cord as far away from other wiring as possible. • Make sure to attach retrofitted equipment in accordance with their respective installation manuals. • Do not install high-output mobile communication devices. CAUTION • Follow the steps when performing the OBD system checks to confirm the repair. Failure to follow these steps may result in performing unnecessary repair works. • Review the scan tool data relating to the DTC that was diagnosed and make a record. • Clear the DTC. • Operate the actual unit while checking the related scan tool data. 9)
DTC clearing method Clearing DTC If an error occurs in the system and the DTC is recorded in the ECU, that DTC is not deleted from the memory even when the malfunctioning part is repaired, so use the following measures to execute a forced deletion. Using the scan tool to delete the DTC If the trouble diagnosis scan tool is connected, you can delete codes by performing turning off of the trouble diagnosis scan tool. Erasure by ECM A DTC recorded in the ECM is erased if the same DTC has not been satisfied for 40 consecutive ignition cycles. About trouble diagnosis scan tool This tool is effective for diagnosing electrical failures in engine control units and performing system checks. If you connect the SAE 16/19 adapter to the DLC installed in the unit, it performs communication with the control units of the machine, and enables various diagnoses and tests to be performed. Functions of the trouble diagnosis scan tool. Data display Snapshot Programming Actuator test CAUTION • When conditions such as the running state of the actual unit or the engine, water temperature, switches and gear position are not met, or when a DTC has been detected, each test may possibly not operate. ECM reflash The ECM can be updated by overwriting its control program using the most recent control data issued every 3 months. Normal reflash The ECM is reflashed by automatically searching for the ECM part number compatible with the part number currently reflashed. Forced reflash 84402827B - May 2011 4023B-10
Introduction to the trouble diagnosis The ECM is reflashed by specifying an arbitrary ECM part number. In this case, a password dedicated for forced reflash is necessary. Campaign reflash The ECM is reflashed by selecting the part number during a campaign carried out by the manufacturer. Rewriting injector QR code The injector QR code that is required when replacing the injector can be rewritten. This allows fuel compensation to be performed on each injector to optimize the engine condition. Engine replacement mode This should be used when changing back to the old ECM part number which requires hardware changes such as addition of actual unit wiring is performed along with engine replacement, etc. ECM replacement When replacing the ECM within the same model, the data can be updated from the current ECM to a trouble diagnosis scan tool and then downloaded it from the trouble diagnosis scan tool to the new ECM after replacement. Factory shipment settings Based on the engine serial number, data such as ECM injector QR code can be downloaded to ECM. Actuator test The injector test, fuel injection test, rail pressure test, glow plug test, and EGR control test are performed to inspect the operation and function of each target component. CAUTION â&#x20AC;˘ When conditions such as the running state of the actual unit or the engine, water temperature, switches and gear position are not met, or when a DTC has been detected, each test may possibly not operate. Links with the HTML manual display DTC to display the manual along with the failure diagnosis procedure. Reading saved data Read in the saved snapshot data to display reproduction. CAUTION â&#x20AC;˘ When using the trouble diagnosis scan tool, refer to the separate instruction manual for the trouble diagnosis scan tool. 10)
Reference data value
84402827B - May 2011 4023B-11
Introduction to the trouble diagnosis
84402827B - May 2011 4023B-12
Section 4023D
Engine Control System
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal and Installation of Suction Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Suction control valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Suction control valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal and Installation of Fuel filter pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel filter pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel filter pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal and Installation of Engine coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine coolant temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine coolant temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal and Installation of CKP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CKP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CKP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CKP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal and Installation of CMP sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CMP sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CMP sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CMP sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal and Installation of Oil pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil pressure sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oil pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal and Installation of Boost sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Boost sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Boost sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal and Installation of Boost temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Boost temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Boost temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal and Installation of IMT sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 IMT sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 IMT sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal and Installation of Exhaust differential pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exhaust differential pressure sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exhaust differential pressure sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Exhaust differential pressure sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal and Installation of Exhaust gas temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exhaust gas temperature sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exhaust gas temperature sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exhaust gas temperature sensor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
84402827B - May 2011 4023D-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4023D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Engine Control System Removal and Installation of Suction Control Valve
2)
Remove the suction control valve from the fuel supply pump.
Suction control valve Removal 1.
Battery ground cable Disconnect 1)
2.
Disengage the battery ground cable from the battery.
Suction control valve Removal CAUTION â&#x20AC;˘ Before removing the suction control valve, clean the surrounding area.
1 2 3 4 3)
1)
Relief valve Union Fuel temperature sensor Suction control valve
Remove the O-ring from the fuel supply pump.
Disengage the harness connector from the suction control valve.
1
84402827B - May 2011 4023D-3
O-ring
Engine Control System Suction control valve Installation 1.
2.
1)
Suction control valve Installation 1)
Battery ground cable Connect
Install the O-ring to the fuel supply pump. 3.
Connect the battery ground cable to the battery.
Fuel Air bleed CAUTION • To prevent engine failure, be sure to perform air removal after the installation or removal of fuel system parts.
1 2) 3)
O-ring
Apply the engine oil to the O-ring. Temporarily tighten the suction control valve to the fuel supply pump. ANNOTATION:
1 2 3 4 5
• Temporarily tighten by hand until it adheres the supply pump. CAUTION • Be careful not to allow the O-ring to caught in. 4)
5)
Securely tighten the suction control valve to the fuel supply pump. Tightening torque： 9 N・m {0.9 kgf・m / 79.7 lb・in} Connect the harness connector to the suction control valve.
1) 2)
Priming pump Plug Drain plug Case Fuel filter element
Prepare the pan. Turn ON the starter switch. ANNOTATION: • This is for the models with an electromagnetic pump.
3) 4)
Loosen the plug using the wrench. Operate the priming pump. Number of times： 20 count(s) or more ANNOTATION: • Confirm that fuel comes out from around the plug.
5) 6)
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
7) 1 2 3 4
Relief valve Union Fuel temperature sensor Suction control valve
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
8)
84402827B - May 2011 4023D-4
Tighten the plug using the wrench.
Engine Control System 9)
Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
10)
Removal and Installation of Fuel filter pressure Fuel filter pressure sensor Removal 1.
Fuel filter pressure sensor Removal
Specified time： 1 min Loosen the plug using the wrench.
1)
ANNOTATION:
2)
• Remove the air in the fuel filter. 11) 12)
Disengage the harness connector from the fuel filter pressure sensor. Remove the fuel filter pressure sensor from the fuel filter.
Tighten the plug using the wrench. Operate the priming pump. Number of times： 10 count(s) or more ANNOTATION: • Wait for the specified time after operating the priming pump.
13)
Specified time： 1 min Loosen the plug using the wrench. ANNOTATION: • Remove the air in the fuel filter.
14)
Tighten the plug using the wrench. Tightening torque： 10 N・m {1.0 kgf・m / 88.5 lb・in} CAUTION • Remove the fuel around the plug thoroughly after tightening.
15) 16)
Operate the priming pump. Number of times： 10 count(s) Start the engine. ANNOTATION: • Do not accelerate the engine revolution right after staring. Specified time： 5 s ANNOTATION: • Accelerate the engine revolution gradually. Specified time： 3 min ANNOTATION: • Accelerate the engine revolution to maximum. • Lower the rotation.
84402827B - May 2011 4023D-5
1
Fuel filter pressure sensor
Engine Control System Fuel filter pressure sensor Installation 1.
Fuel filter pressure sensor Installation 1)
Install the fuel filter pressure sensor to the fuel filter. CAUTION • After cleaning the threaded portion of the fuel filter body, install it.
2)
Tightening torque： 12 N・m {1.2 kgf・m / 106.2 lb・in} Connect the harness connector to the fuel filter pressure sensor.
Removal and Installation of Engine coolant temperature sensor Engine coolant temperature sensor Removal 1.
Engine coolant temperature sensor Removal 1) 2)
Disengage the harness connector from the engine coolant temperature sensor. Remove the engine coolant temperature sensor from the cylinder head assembly.
1 2 1 3)
Fuel filter pressure sensor
Start the engine. ANNOTATION: • Check that there is no fuel leaks. • Confirm that DTC has not yet been detected.
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Overheat switch Water temperature sensor
Engine Control System Engine coolant temperature sensor Installation
Engine coolant temperature sensor Inspection
1.
1.
Engine coolant temperature sensor Installation 1)
Install the engine coolant temperature sensor to the cylinder head assembly.
Engine coolant temperature sensor Inspection 1)
Inspect the engine coolant temperature sensor using the circuit tester.
ANNOTATION:
ANNOTATION:
• Apply Loctite 572 to the threaded portion.
• Confirm that the resistance value according to water temperature matches the thermistor characteristics.
Tightening torque： 25 N・m ｛2.5 kgf・m / 18.4 lb・ft｝
1 2
Overheat switch Water temperature sensor
1 2
2)
Connect the harness connector to the engine coolant temperature sensor.
3
GND terminal for engine control Signal terminal for engine control Signal terminal for meters
Resistance (kΩ)
Temperature°C (°F)
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Engine Control System Removal and Installation of CKP sensor
CKP sensor Installation 1.
1)
CKP sensor Removal 1.
2.
CKP sensor Installation Install the CKP sensor to the flywheel housing.
Battery ground cable Disconnect
CAUTION
1)
• Be careful not to subject the sensor to shock.
Disengage the battery ground cable from the battery.
CKP sensor Removal
ANNOTATION:
1)
• Tighten together with the clip.
2)
Disengage the harness connector from the CKP sensor. Remove the CKP sensor from the flywheel housing.
2)
CAUTION
Tightening torque： 6 N・m {0.6 kgf・m / 52 lb・in} Connect the harness connector to the CKP sensor.
• Be careful not to subject the sensor to shock.
1 2 3 4
Oil pressure switch Oil port cover Flywheel housing CKP sensor
1 2 3 4 2.
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
Battery ground cable Connect 1)
Connect the battery ground cable to the battery.
CKP sensor Inspection 1.
CKP sensor Inspection 1)
Inspect the CKP sensor. ANNOTATION: • Condition of the sensor installation • Grime on the sensor and connector
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Engine Control System Removal and Installation of CMP sensor
CMP sensor Installation 1.
1) 2)
CMP sensor Removal 1.
Battery ground cable Disconnect 1)
2.
CMP sensor Installation
Disengage the battery ground cable from the battery.
CAUTION • Be careful not to subject the sensor to shock.
CMP sensor Removal 1) 2)
Apply the engine oil to the O-ring. Install the CMP sensor to the cylinder head assembly.
Disengage the harness connector from the CMP sensor. Remove the CMP sensor from the cylinder head assembly.
ANNOTATION: • Tighten together with the clip.
3)
Tightening torque： 8 N・m {0.8 kgf・m / 69 lb・in} Connect the harness connector to the CMP sensor.
CAUTION • Be careful not to subject the sensor to shock.
2.
Battery ground cable Connect 1)
Connect the battery ground cable to the battery.
CMP sensor Inspection 1.
CMP sensor Inspection 1)
Inspect the CMP sensor. ANNOTATION: • Condition of the sensor installation • Grime on the sensor and connector
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Engine Control System Removal and Installation of Oil pressure sensor
1.
Oil pressure sensor Installation 1)
Oil pressure sensor Removal 1.
Oil pressure sensor Installation
Oil pressure sensor Removal 1) 2)
Disconnect the harness connector from the oil pressure sensor. Remove the oil pressure sensor from the oil port cover.
CAUTION • Use new gaskets. 2)
1 2 3 4
Install the oil pressure sensor to the oil port cover. Tightening torque： 41 N・m ｛4.2 kgf・m / 30.2 lb・ft｝
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
Connect the harness connector to the oil pressure sensor.
1 2 3 4
84402827B - May 2011 4023D-10
Oil pressure sensor Oil port cover Flywheel housing CKP sensor
Engine Control System Oil pressure sensor Inspection 1.
Oil pressure sensor Inspection
Removal and Installation of Boost sensor
1) 2)
Boost sensor Removal
3)
Turn OFF the starter switch. Disconnect the harness connector from the oil pressure sensor. Inspect the continuity using the circuit tester.
1. 2.
Battery ground cable Disconnect Disengage the battery ground cable from the battery. Boost sensor Removal 1) 2)
Disengage the harness connector from the boost sensor. Remove the boost sensor from the inlet pipe.
CAUTION â&#x20AC;˘ Replace the oil pressure sensor if there is no continuity. 4) 5)
Turn ON the starter switch. Inspect the circuit using the jumper wire.
6)
Check lighting of the warning light. ANNOTATION: â&#x20AC;˘ If the warning light does not illuminate, inspect the circuit between the meter and the oil pressure.
84402827B - May 2011 4023D-11
1 2
Boost sensor Inlet pipe
Engine Control System Boost sensor Installation 1.
Removal and Installation of Boost temperature sensor
Boost sensor Installation 1)
Install the boost sensor to the inlet pipe. Tightening torque： 2 N・m {0.2 kgf・m / 17.7 lb・in}
Boost temperature sensor Removal 1.
Boost temperature sensor Removal 1) 2)
1 2 2) 2.
Boost sensor Inlet pipe
Connect the harness connector to the boost sensor.
Battery ground cable Connect 1)
Disconnect the harness connector from the boost temperature sensor. Remove the boost temperature sensor from the inlet pipe.
Connect the battery ground cable to the battery.
84402827B - May 2011 4023D-12
1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
Engine Control System Boost temperature sensor Installation 1.
Boost temperature sensor Installation 1)
2)
Install the boost temperature sensor to the inlet pipe. Tightening torque： 13 N・m {1.3 kgf・m / 115.1 lb・in} Connect the harness connector to the boost temperature sensor.
Removal and Installation of IMT sensor IMT sensor Removal 1.
IMT sensor Removal 1) 2)
1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
84402827B - May 2011 4023D-13
Disconnect the harness connector from the IMT sensor. Remove the IMT sensor from the inlet pipe.
1 2 3 4
Boost sensor Harness clip Boost temperature sensor IMT sensor
Engine Control System IMT sensor Installation 1.
IMT sensor Installation 1) 2)
Install the IMT sensor to the inlet pipe. Tightening torque： 20 N・m ｛2.0 kgf・m / 14.8 lb・ft｝ Connect the harness connector to the IMT sensor.
Removal and Installation of Exhaust differential pressure sensor Exhaust differential pressure sensor Removal 1.
Exhaust differential pressure sensor Safety Information CAUTION
1 2 3 4
• Do not use a tool which causes vibrations such as an impact wrench when installing and removing the DPD differential pressure sensor. • Do not reuse a DPD differential pressure sensor which has been subjected to shock such as being dropped. • Install or remove the DPD differential pressure sensor together with the bracket. • Be sure not to loosen the 4 screws installed on the DPD differential pressure sensor. • Replace the DPD differential pressure sensor if the 4 screws installed on the DPD differential pressure sensor have been loosened.
Boost sensor Harness clip Boost temperature sensor IMT sensor
1 2.
Screw
Exhaust differential pressure sensor Removal CAUTION • Before performing work, be sure to check the DPD differential pressure sensor precautions. 1) 2)
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Disengage the differential pressure hose from the exhaust differential pressure sensor. Disengage the harness connector from the exhaust differential pressure sensor.
Engine Control System 3)
Remove the exhaust differential pressure sensor from the DPD assembly. CAUTION
Exhaust differential pressure sensor Installation 1.
• Remove the DPD differential pressure sensor with the attached bracket.
1
Exhaust differential pressure sensor Safety Information CAUTION • Do not use a tool which causes vibrations such as an impact wrench when installing and removing the DPD differential pressure sensor. • Do not reuse a DPD differential pressure sensor which has been subjected to shock such as being dropped. • Install or remove the DPD differential pressure sensor together with the bracket. • Be sure not to loosen the 4 screws installed on the DPD differential pressure sensor. • Replace the DPD differential pressure sensor if the 4 screws installed on the DPD differential pressure sensor have been loosened.
DPD differential pressure sensor
1 2.
Screw
Exhaust differential pressure sensor Installation CAUTION • Before performing work, be sure to check the DPD differential pressure sensor precautions. 1) 2) 3)
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Install the exhaust differential pressure sensor to the DPD assembly. Connect the harness connector to the exhaust differential pressure sensor. Connect the differential pressure hose to the exhaust differential pressure sensor.
Engine Control System CAUTION • Be careful not to mistake the connecting position of the differential pressure hose. • Since the differential pressure sensor may malfunction if exhaust gas leaks from the joint sections, confirm that there is no exhaust gas leakage after the engine starts.
Exhaust differential pressure sensor Inspection 1.
Exhaust differential pressure sensor Inspection CAUTION • Perform 0-point correction when replacing the DPD differential pressure sensor. • Perform 0-point correction when the DPD differential pressure sensor is at room temperature. • Do not perform 0-point correction within two hours after regenerating DPD. ANNOTATION: • 0-point correction 1) 2)
Turn OFF the starter switch. Turn ON the starter switch. CAUTION • Do not start the engine.
3) 1
DPD differential pressure sensor
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Starter switch ON time： 40 s or more Turn OFF the starter switch. Starter switch OFF time： 15 s or more
Engine Control System Removal and Installation of Exhaust gas temperature sensor
1.
Exhaust gas temperature sensor Removal 1.
Exhaust gas temperature sensor Installation Exhaust gas temperature sensor Installation CAUTION • Do not subject the tip of the exhaust gas temperature sensor to shock when installing. • Remove the old anti-seize lubricant on the sleeve nut. • Apply the anti-seize lubricant on the threaded portion of the sleeve nut. • Apply Never-Seez High Temperature Stainless Grade ： 5-87411-039-0 anti-seize lubricant, manufactured by Bostik in the United states. • Replace the oxidation catalyst assembly if damage has been found in the sensor installation section of the oxidation catalyst assembly.
Exhaust gas temperature sensor Safety Information CAUTION • Before removing, be sure to check the DPD pressure difference, status, and inspection/maintenance contents using a scan tool. • Do not reuse an exhaust gas temperature sensor which has been subjected to shock such as being dropped.
2.
Exhaust gas temperature sensor Removal 1)
Disengage the harness connector from the exhaust gas temperature sensor. ANNOTATION:
1)
• To prevent incorrect assembling, make an alignment mark on the connector before disconnecting. 2)
Temporarily tighten the exhaust gas temperature sensor to the DPD assembly. CAUTION • To avoid damaging the sensor installation sections due to sensor incorrect assembly, tighten it by hand.
Remove the exhaust gas temperature sensor from the DPD assembly.
ANNOTATION: • Exhaust gas temperature sensor identification Sensor type
Screw size
Connector color
Exhaust gas temperaM12 x 1.75 Dark gray ture sensor 1 Exhaust gas temperaM12 x 1.25 Light gray ture sensor 2 2) 1 2
Exhaust gas temperature sensor 1 Exhaust gas temperature sensor 2
3)
Securely tighten the exhaust gas temperature sensor to the DPD assembly. Tightening torque： 30 N・m ｛3.1 kgf・m / 22.1 lb・ft｝ Connect the harness connector to the exhaust gas temperature sensor. CAUTION • Be careful not to twist the harness.
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Engine Control System Exhaust gas temperature sensor Inspection 1.
Exhaust gas temperature sensor Inspection 1)
Measure the resistance using the circuit tester. ANNOTATION: • The reference values for the sensor characteristics are indicated in the diagram.
1 2
Exhaust gas temperature sensor 1 Exhaust gas temperature sensor 2
ANNOTATION: • Start the engine after assembling each part, and check for gas leaks from each joint and for vibration.
84402827B - May 2011 4023D-18
Temperature 1000.0°C ｛1832°F｝ 950.0°C ｛1742°F｝ 900.0°C ｛1652°F｝ 850.0°C ｛1562°F｝ 800.0°C ｛1472°F｝ 750.0°C ｛1382°F｝ 700.0°C ｛1292°F｝ 650.0°C ｛1202°F｝ 600.0°C ｛1112°F｝ 550.0°C ｛1022°F｝ 500.0°C ｛932°F｝ 450.0°C ｛842°F｝ 400.0°C ｛752°F｝ 350.0°C ｛662°F｝ 300.0°C ｛572°F｝ 200.0°C ｛392°F｝ 150.0°C ｛302°F｝ 100.0°C ｛212°F｝ 50.0°C ｛122°F｝
Resistance value 115 - 127 Ω 130 - 143 Ω 147 - 163 Ω 167 - 187 Ω 192 - 219 Ω 226 - 258 Ω 267 - 309 Ω 333 - 360 Ω 406 - 442 Ω 504 - 552 Ω 640 - 709 Ω 835 - 937 Ω 1130 - 1280 Ω 1590 - 1850 Ω 2360 - 2830 Ω 6230 - 7830 Ω 11900 - 16300 Ω 27600 - 41200 Ω 82000 - 137000 Ω
Section 4023G
Engine-side Trouble
84402827B - May 2011
84402827B - May 2011
CONTENTS Engine-side Trouble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DTC U0001 (Flash Code 84) CAN-Bus Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DTC U0073 (Flash Code 84) Control Module Communication Bus Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 DTC P0093 (Flash Code 227) Fuel System Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 DTC U0101 (Flash Code 85) Lost Communication with TCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 DTC U0110 (Flash Code 87) Lost Communication with VNT System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance. . . . . . . . . . . . . . . . . . . . . . . 34 DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance . . . . . . . . . . . . . . . . 36 DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1 . . . . . . . . . . . 38 DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 38 DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 39 DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DTC P0560 (Flash Code 155) System Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 DTC P0563 (Flash Code 35) System Voltage High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DTC P0602 (Flash Code 154) Control Module Programming Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 84402827B - May 2011 4023G-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error . . . . . . . . . . . . . . . DTC P0606 (Flash Code 51) ECM/PCM Processor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance . . . . . . . . . . . . . . . DTC P1455 (Flash Code 132) PM Over Accumulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1471 (Flash Code 149) DPD Insufficient Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1669 (Flash Code 75) DPD Lamp Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2229 (Flash Code 71) Barometric Pressure Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance . . . . . . . . . . . . . . . . DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P2458 (Flash Code 139) DPD Regeneration Duration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2 . . . . . . . . . . . DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance . . . . . . . . . . . . . . . . . . . . . . . . DTC P242F (Flash Code 131) DPD Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 4023G-2
44 45 45 46 47 48 49 49 50 53 53 54 55 55 56 57 58 60 61 61 62 63 64 65 66 67 68 69 70 71 72 72 73 74 74
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Engine-side Trouble Engine-side Trouble DTC U0001 (Flash Code 84) CAN-Bus Malfunction 1.
5)
DTC U0001 Diagnostics 1) 2) 3)
Turn OFF the starter switch. Disconnect the harness connector from the ECM. Measure the resistance between the CANHigh side terminal and CAN-Low side terminal. ANNOTATION:
DTC P0016 (Flash Code 16) Crankshaft Position - Camshaft Position Correlation 1.
2.
• Measure the resistance between the terminals of the ECM harness connector. 4)
Resistance： about 120.0 Ω If it is outside the standard range, inspect the CAN-Low circuit and CAN-High circuit between the ECM and the control unit of the actual unit.
6) 7) 8) 9)
DTC DTC DTC DTC DTC
P0016 Priority DTC P0335 P0336 P0340 P0016 Diagnostics
1)
Inspect the CKP sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Inspection". If a problem is discovered, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Installation". Inspect the CMP sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Inspection". If a problem is discovered, replace the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Installation". Inspect the flywheel.
2)
• There should be no short to the battery or ignition power supply. • There should be no open circuit or high resistance. • There should be no short to GND. 5)
3) 4)
If a problem is discovered, repair the CAN circuit. If the CAN circuit is normal, replace the control unit of the actual unit. Connect the harness connector to the ECM. Disconnect the harness connector from the control unit of the actual unit. Measure the resistance between the CANHigh side terminal and CAN-Low side terminal.
5)
• The sensor rotor should not be damaged. • The ring gear should be installed correctly. 6) 7)
ANNOTATION:
11) 12) 2.
Resistance： about 120.0 Ω If it is outside the standard range, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
If a problem is discovered, repair the flywheel. Inspect the camshaft gear. • The camshaft gear should not be damaged • The camshaft gear should be installed correctly.
• Measure the resistance between the terminals of the ECM harness connector. 10)
Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
8) 3.
If a problem is discovered, repair the camshaft gear.
DTC P0016 Confirm Resolution 1) 2) 3)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine.
DTC U0001 Confirm Resolution
ANNOTATION:
1)
• When the engine does not start, crank the engine for 10 seconds.
2) 3) 4)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run.
4) 5)
84402827B - May 2011 4023G-3
Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC U0073 (Flash Code 84) Control Module Communication Bus Off
1.
1.
2.
DTC P0045 Priority DTC DTC U0073 DTC P0045 Diagnostics 1) 2) 3) 4) 5) 6) 7) 8)
9) 10) 11) 12) 13) 14)
3.
1) 2)
Inspect the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Inspection". If a problem is discovered, repair the turbocharger assembly. Turn OFF the starter switch. Disconnect the turbocharger harness connector. Remove the fuse. Inspect the fuse for meltdown. If a problem is discovered, replace the fuse. Inspect to see if there is an open circuit or high resistance between the fuse and the power supply circuit of the turbocharger internal ECU. If a problem is discovered, repair the power supply circuit. Inspect to see if there is an open circuit or high resistance between the turbocharger GND circuit and GND. If a problem is discovered, repair the GND circuit. Inspect the turbocharger harness connector for an contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Installation".
2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn OFF the starter switch. Measure the resistance between the terminals of the termination resistor harness connector. ANNOTATION: • Make a measurement from the back with the harness connector connected. • Confirm that the parallel resistance of the 120 Ω resistor in the termination resistor and that of the 120 Ω resistor in the ECM are both 60Ω.
3) 4) 5) 6) 7) 8)
Resistance： 50.0 - 70.0 Ω Disconnect the harness connector from termination resistor if the resistance value is outside the standard range. Measure the resistance of the termination resistor. Resistance： 110.0 - 130.0 Ω If the resistance value is outside the standard range, replace the termination resistor. Connect the harness connector to the termination resistor . Disconnect the harness connector from the control unit of the actual unit. Measure the resistance between the terminals of the termination resistor harness connector. ANNOTATION: • Make a measurement from the back with the harness connector connected.
9)
DTC P0045 Confirm Resolution 1)
DTC U0073 Diagnostics
10) 11)
Resistance： 50.0 - 70.0 Ω If the resistance value is within the standard range, replace the control unit of the actual unit. Disconnect the harness connector from the ECM. Measure the resistance between the terminals of the termination resistor harness connector. ANNOTATION: • Make a measurement from the back with the harness connector connected.
12)
13) 14) 15) 84402827B - May 2011 4023G-4
Resistance： 110.0 - 130.0 Ω Replace the ECM if the resistance value is within the range of standard value. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. Turn OFF the starter switch.
Engine-side Trouble 16) 17) 18) 19)
20)
21) 22) 23) 24) 25) 26) 27)
28) 29) 2.
Connect the harness connector to the ECM. Turn ON the starter switch. Measure the voltage between the CAN-High terminal and GND of the termination resistor harness connector. Measure the voltage between the CAN-Low terminal and GND of the termination resistor harness connector. Voltage： 1.5 - 3.5 V If the voltage is outside the standard range, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. Turn OFF the starter switch. Connect the harness connector to the control unit of the actual unit. Turn ON the starter switch. Measure the voltage between the CAN-High terminal and GND of the termination resistor harness connector. Measure the voltage between the CAN-Low terminal and GND of the termination resistor harness connector. Voltage： 1.5 - 3.5 V If the voltage is outside the standard range, replace the control unit of the actual unit. If the voltage is within the standard range, replace the termination resistor.
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure - Too Low 1.
2.
DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
P0087 Priority DTC P0088 P0089 P0091 P0092 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P2146 P2149 P0087 Diagnostics
1) 2)
Start the engine. Rev the engine a few times in neutral while checking for a DTC with the trouble diagnosis scan tool. Check to see if the DTC P0087 is detected. If the DTC P0087 is not detected, replace the fuel filter element.
3) 4)
ANNOTATION: • An intermittent problem due to foreign matter in the fuel is suspected.
DTC U0073 Confirm Resolution 1) 2) 3) 4) 5)
Use the trouble diagnosis scan tool to clear the DTC. Turn the starter switch OFF for 30 seconds. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to check if a DTC has been detected.
5) 6)
7) 8) 9)
10) 11) 12) 13) 14)
84402827B - May 2011 4023G-5
Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". Turn OFF the starter switch. Wait for the specified period of time until the fuel pressure is released from the common rail. Specified time: 2 min Turn ON the starter switch. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage: 0.9 - 1.0 V If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered.
Engine-side Trouble 15)
ANNOTATION:
If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
• The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. • The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. • Inspect for fuel leaks into the engine oil.
ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 16) 17) 18) 19)
20) 21) 22) 23) 24)
If the fuel rail pressure sensor display is within the standard range, start the engine. Perform the injector stop test with the trouble diagnosis scan tool. Command each injector OFF, and confirm that the engine RPM changes on each injector. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. If a problem is discovered, repair the clogging of the fuel system. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack. If a problem is discovered, replace the fuel hose. • The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running. • When the fuel hose is not connected securely, the air can enter. • When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0087 may be detected.
26) 27)
33)
Start the engine. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail.
Connect the pressure gauge between the fuel filter and the removed fuel hose. ANNOTATION: • Confirm that the fuel system is connected securely.
34)
Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. Specified time: 5 s ANNOTATION: • Repeat this until the engine starts.
36)
37)
Leave the engine idling for the specified period of time or longer. Specified time: 1 min While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. Specified time: 1 min Rotational speed: 2500 min-1 {2500 r/min} Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. Specified value: 17.0 kPa {128 mmHg / 5 inHg} ANNOTATION: • Fuel clogging is checked with the negative pressure amount in the fuel system.
38)
• When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy. 28) 29)
• Use a pan to catch the fuel from the removed fuel hose. • Clean the pressure gauge and connection hose before connecting to the fuel pipe. • The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose.
Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. If a problem is discovered, replace the clamp. Operate the priming pump until the handle becomes heavy. ANNOTATION:
If fuel leak if found, fix the problem. Turn OFF the starter switch. Remove the fuel hose on the fuel supply pump side from the fuel filter. ANNOTATION:
35)
ANNOTATION:
25)
30) 31) 32)
39) 40) 41)
84402827B - May 2011 4023G-6
If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. If a problem is discovered, repair the fuel system. Inspect the fuel tank bent hose. If a problem is discovered, repair the bent hose.
Engine-side Trouble 42) 43) 44)
45)
53)
Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. If a problem is discovered, repair it. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.
54) 55) 56) 57) 58) 59)
ANNOTATION: • The fuel pipe can be disconnected and clogged with a plug. 46) 47)
Start the engine and use the idling control switch to increase the RPM to the highest level. Check the pressure gauge. Specified value: 27.0 kPa {203 mmHg / 8 inHg}
ANNOTATION:
ANNOTATION: • When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. • Air mixture is checked with the negative pressure amount while the fuel flow is being blocked. 48) 49) 50) 51) 52)
Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation".
If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. If a problem is discovered, replace the fuel hose. Inspect to see if appropriate clamp is used. If a problem is discovered, replace the clamp with an appropriate one. Turn OFF the starter switch.
• When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 60) 3.
Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0087 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-7
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0088 (Flash Code 118) Fuel Rail/System Pressure - Too High 1.
2.
DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
P0088 Priority DTC P0089 P0091 P0092 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P2146 P2149 P0088 Diagnostics
1) 2)
Start the engine. Rev the engine a few times in neutral while checking the actual fuel rail pressure display with the trouble diagnosis scan tool. Check the actual fuel rail pressure display with the trouble diagnosis scan tool. Standard value: (-5) - 5 MPa If it is at or below the standard value, replace the fuel filter element.
3) 4)
15)
ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 16) 17) 18) 19)
20) 21)
ANNOTATION: • An intermittent problem due to foreign matter in the fuel is suspected.
5) 6)
7) 8) 9)
10) 11) 12) 13) 14)
If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". Turn OFF the starter switch. Wait for the specified period of time until the fuel pressure is released from the common rail. Specified time: 2 min Turn ON the starter switch. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage: 0.9 - 1.0 V If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. If a problem is discovered, repair the circuit.
22) 23) 24)
Start the engine. Perform the injector stop test with the trouble diagnosis scan tool. Command each injector OFF, and confirm that the engine RPM changes on each injector. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. If a problem is discovered, repair the clogging of the fuel system. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack. If a problem is discovered, replace the fuel hose. ANNOTATION: • The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running. • When the fuel hose is not connected securely, the air can enter. • When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0088 may be detected.
25) 26) 27)
Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. If a problem is discovered, replace the clamp. Operate the priming pump until the handle becomes heavy. ANNOTATION: • When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy.
28) 29)
84402827B - May 2011 4023G-8
Start the engine. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail.
Engine-side Trouble
30) 31) 32)
ANNOTATION:
39)
• The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. • The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. • Inspect for fuel leaks into the engine oil.
40) 41)
If fuel leak if found, fix the problem. Turn OFF the starter switch. Remove the fuel hose on the fuel supply pump side from the fuel filter. ANNOTATION:
42) 43) 44)
45)
• Use a pan to catch the fuel from the removed fuel hose. • Clean the pressure gauge and connection hose before connecting to the fuel pipe. • The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose. 33)
ANNOTATION: • The fuel pipe can be disconnected and clogged with a plug.
Connect the pressure gauge between the fuel filter and the removed fuel hose.
46)
ANNOTATION:
47)
• Confirm that the fuel system is connected securely. 34)
• When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. • Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.
• Repeat this until the engine starts.
36)
37)
Leave the engine idling for the specified period of time or longer. Specified time: 1 min While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. Specified time: 1 min Rotational speed: 2500 min-1 {2500 r/min} Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. Specified value: 17.0 kPa {128 mmHg / 5 inHg} ANNOTATION: • Fuel clogging is checked with the negative pressure amount in the fuel system.
38)
If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank.
Start the engine and use the idling control switch to increase the RPM to the highest level. Check the pressure gauge. Specified value: 27.0 kPa {203 mmHg / 8 inHg} ANNOTATION:
Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. Specified time: 5 s ANNOTATION:
35)
If a problem is discovered, repair the fuel system. Inspect the fuel tank bent hose. If a problem is discovered, repair the bent hose. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. If a problem is discovered, repair it. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.
48) 49) 50) 51) 52) 53) 54) 55) 56) 57) 58)
84402827B - May 2011 4023G-9
If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. If a problem is discovered, replace the fuel hose. Inspect to see if appropriate clamp is used. If a problem is discovered, replace the clamp with an appropriate one. Turn OFF the starter switch. Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered.
Engine-side Trouble 59)
If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation".
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance 1.
ANNOTATION: • When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 60) 3.
Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0088 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
2.
DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
P0089 Priority DTC P0091 P0092 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P2146 P2149 P0089 Diagnostics
1)
Wait for the specified period of time until the fuel pressure is released from the common rail. Specified time： 2 min Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage： 0.9 - 1.0 V If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
2) 3)
4) 5) 6) 7) 8) 9)
ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 10) 11) 12) 13) 14) 15) 16) 17) 18)
84402827B - May 2011 4023G-10
Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Rev the engine a few times in neutral while checking the actual fuel rail pressure display with the trouble diagnosis scan tool.
Engine-side Trouble 19)
Use the trouble diagnosis scan tool to check if the actual fuel rail pressure display shows a value within the standard range at a sufficient rate. Standard values: (-5) - 5 MPa
1.
ANNOTATION: • If possible, compare with other actual unit equipped with the same model engine. 20)
21)
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
If it is within the standard range, replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". If it is outside the standard range, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation".
DTC P0091 Diagnostics 1)
2)
ANNOTATION: • When the High side circuit is shorted to the voltage, the engine stalls and does not start. 3) 4)
ANNOTATION:
3.
Perform the unit difference learning of the fuel supply pump to the ECM.
• When the Low side circuit is shorted to GND, DTC P0091 may not be detected. • When the Low side circuit is shorted to GND, the engine stalls and does not start. 5)
DTC P0089 Confirm Resolution 1) 2) 3) 4) 5)
If a problem is discovered, repair the High side circuit. If it is within the standard range, inspect to see if there is a short circuit to the GND with the Low side circuit between the ECM and the suction control valve. ANNOTATION:
• When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 22)
Check the rail pressure regulator feedback current display with the trouble diagnosis scan tool. Current： 300 - 900 mA If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the High side circuit between the ECM and the suction control valve.
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
6) 7) 8) 9) 10) 11)
If a problem is discovered, repair the Low side circuit. Turn the starter switch OFF for 30 seconds or longer. Disconnect the harness connector from the suction control valve. Connect the test light between the suction control valve High side circuit and a normal GND. Turn ON the starter switch. Check if the test light comes on and then goes off. If it does not turn off, inspect the High side circuit between the ECM and the suction control valve. • There should be no open circuit or high resistance. • There should be no short to GND. • There should be no short to the LOW side circuit.
12) 13) 14) 15) 16)
84402827B - May 2011 4023G-11
If a problem is discovered, repair the High side circuit. Turn the starter switch OFF for 30 seconds or longer. Connect the test light between the suction control valve Low side circuit and battery power supply. Turn ON the starter switch. Check if the test light comes on and then goes off.
Engine-side Trouble 17)
If it does not turn off, inspect the Low side circuit between the ECM and suction control valve. • There should be no open circuit or high resistance. • There should be no short to the battery or ignition power supply.
18) 19) 20) 21)
22) 23) 24)
25) 26) 2.
If a problem is discovered, repair the Low side circuit. Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the suction control valve. Refer to "1.Engine 1C.Fuel System(6HK1X) Suction control valve Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Suction control valve Installation". Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0091 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High 1.
DTC P0092 Diagnostics 1)
2)
Check the rail pressure regulator feedback current display with the trouble diagnosis scan tool. Current： 300 - 900 mA If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the High side circuit between the ECM and the suction control valve. ANNOTATION: • When the High side circuit is shorted to the voltage, the engine stalls and does not start.
3) 4)
If a problem is discovered, repair the High side circuit. If it is within the standard range, inspect to see if there is a short circuit to the GND with the Low side circuit between the ECM and the suction control valve. ANNOTATION: • When the Low side circuit is shorted to GND, DTC P0092 may not be detected. • When the Low side circuit is shorted to GND, the engine stalls and does not start.
5) 6) 7) 8) 9) 10) 11)
If a problem is discovered, repair the Low side circuit. Turn the starter switch OFF for 30 seconds or longer. Disconnect the harness connector from the suction control valve. Connect the test light between the suction control valve High side circuit and a normal GND. Turn ON the starter switch. Check if the test light comes on and then goes off. If it does not turn off, inspect the High side circuit between the ECM and the suction control valve. • There should be no open circuit or high resistance. • There should be no short to GND. • There should be no short to the LOW side circuit.
12) 13) 14) 15) 16)
84402827B - May 2011 4023G-12
If a problem is discovered, repair the High side circuit. Turn the starter switch OFF for 30 seconds or longer. Connect the test light between the suction control valve Low side circuit and battery power supply. Turn ON the starter switch. Check if the test light comes on and then goes off.
Engine-side Trouble 17)
18) 19) 20) 21)
22) 23) 24)
25) 26) 2.
If it does not turn off, inspect the Low side circuit between the ECM and suction control valve.
DTC P0093 (Flash Code 227) Fuel System Leak Detected
• There should be no open circuit or high resistance. • There should be no short to the battery or ignition power supply.
1.
If a problem is discovered, repair the Low side circuit. Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the suction control valve. Refer to "1.Engine 1C.Fuel System(6HK1X) Suction control valve Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Suction control valve Installation". Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
2.
DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
P0093 Priority DTC P0087 P0091 P0092 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P2146 P2149 P0093 Diagnostics
1)
Inspect for fuel leaks on the high-pressure side between the fuel supply pump and injector. • There should be no fuel leakage from the fuel supply pump. • There should be no fuel leakage from the common rail. • There should be no fuel leakage from the pressure limiter valve. • There should be no fuel leakage from the fuel pressure sensor. • There should be no fuel leakage from the fuel pipe between the fuel supply pump and common rail. • There should be no fuel leakage from the fuel pipe between the common rail and injector. • There should be no fuel leakage from the sleeve nut of the fuel pipe.
DTC P0092 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
2)
If fuel leak if found, fix the problem. ANNOTATION: • The fuel may leak to the bottom section of the cylinder head cover from the high pressure pipe inlet. • The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. • Inspect for fuel leaks into the engine oil. • Remove and inspect the high pressure pipe joint connected to the injector for a fuel leakage from the sleeve nut. • When foreign matter has been attached, replace the injector and the high pressure pipe.
3)
4) 5)
84402827B - May 2011 4023G-13
Remove each glow plug from the cylinder head assembly. Refer to "1.Engine 1B.Mechanical(6HK1X) Cylinder head assembly Removal". Inspect for fuel leaks into the combustion chamber Inspect to see if there is a cylinder from which fuel leaks into the combustion chamber.
Engine-side Trouble 6)
7) 8) 9)
10) 11) 12)
13) 14) 15) 16) 17) 18)
If fuel leak is found, replace the corresponding injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Turn OFF the starter switch. Wait for the specified period of time until the fuel pressure is released from the common rail. Specified time: 2 min Turn ON the starter switch. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage: 0.9 - 1.0 V If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
27)
ANNOTATION: • The fuel hose between the fuel tank and the supply pump becomes negative pressure state when the engine is running. • When the fuel hose is not connected securely, the air can enter. • When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P0093 may be detected. 28) 29) 30)
19) 20) 21) 22)
23) 24) 25) 26)
If the fuel rail pressure sensor display is within the standard range, start the engine. Perform the injector stop test with the trouble diagnosis scan tool. Command each injector OFF, and confirm that the engine RPM changes on each injector. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. If a problem is discovered, repair clogging. Inspect to see if there is cut or crack with the fuel hose in the fuel system between the fuel tank and the fuel supply pump.
Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. If a problem is discovered, replace the clamp with an appropriate one. Operate the priming pump until the handle becomes heavy. ANNOTATION: • When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy.
31) 32)
Start the engine. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail. ANNOTATION: • The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. • The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. • Inspect for fuel leaks into the engine oil.
ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.
If a problem is discovered, replace the fuel hose.
33) 34) 35)
If fuel leak if found, fix the problem. Turn OFF the starter switch. Remove the fuel hose on the fuel supply pump side from the fuel filter. ANNOTATION: • Use a pan to catch the fuel from the removed fuel hose. • Clean the pressure gauge and connection hose before connecting to the fuel pipe. • The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose.
36)
84402827B - May 2011 4023G-14
Connect the pressure gauge between the fuel filter and the removed fuel hose. ANNOTATION: • Confirm that the fuel system is connected securely.
Engine-side Trouble 37)
• When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. • Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.
Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. Specified time: 5 s ANNOTATION: • Repeat this until the engine starts.
38) 39)
40)
51)
Leave the engine idling for the specified period of time or longer. Specified time: 1 min While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. Specified time: 1 min Rotational speed: 2500 min-1 {2500 r/min} Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. Specified value: 17.0 kPa {128 mmHg / 5 inHg}
52) 53) 54) 55) 56) 57) 58)
ANNOTATION:
59)
• Fuel clogging is checked with the negative pressure amount in the fuel system. 41)
42) 43) 44) 45) 46) 47)
48)
• The fuel pipe can be disconnected and clogged with a plug.
50)
ANNOTATION: • When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 63) 3.
ANNOTATION:
49)
60) 61) 62)
If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. If a problem is discovered, repair the fuel system. Inspect the fuel tank bent hose. If a problem is discovered, repair the bent hose. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. If a problem is discovered, repair it. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.
Start the engine and use the idling control switch to increase the RPM to the highest level. Check the pressure gauge. Specified value: 27.0 kPa {203 mmHg / 8 inHg}
If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. If a problem is discovered, replace the fuel hose. Inspect to see if appropriate clamp is used. If a problem is discovered, replace the clamp with an appropriate one. Turn OFF the starter switch. Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation".
Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0093 Confirm Resolution 1) 2) 3) 4) 5)
ANNOTATION:
84402827B - May 2011 4023G-15
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC U0101 (Flash Code 85) Lost Communication with TCM
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
1.
DTC U0101 Diagnostics
1.
1)
2.
Inspect the CAN-Low circuit and CAN-High circuit between the ECM and the control unit of the actual unit.
1) 2)
• There should be no short to the battery or ignition power supply. • There should be no open circuit or high resistance. • There should be no short to GND. 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14)
15) 16) 2.
DTC P0102 Priority DTC DTC P0560 DTC P0102 Diagnostics
3) 4)
If a problem is discovered, repair the CAN circuit. If the CAN circuit is normal, connect all harnesses. Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform a test-run. Check the DTC. If a DTC has been detected, replace the control unit of the actual unit. Connect all harnesses. Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform a test-run. Check the DTC. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
5) 6) 7) 8) 9) 10)
• There should be no open circuit or high resistance. • There should be no short to GND. 11) 12) 13) 14)
DTC U0101 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn OFF the starter switch. Disconnect the harness connector from the mass air flow sensor. Inspect to see if there is an open circuit or high resistance in the 12 V power supply circuit between the ECM and the mass air flow sensor. If a problem is discovered, repair the 12 V power supply circuit. Connect the test cable with fuse between the 12 V power supply circuit and the signal circuit of the mass air flow sensor harness connector. Check the mass air flow sensor display with the trouble diagnosis scan tool. Voltage： 4.9 V If it is at or above the standard value, inspect to see if there is a contact failure with the mass air flow sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the mass air flow sensor. Inspect the signal circuit between the ECM and the mass air flow sensor.
15) 16) 3.
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0102 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-16
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0237 (Flash Code 32) Turbo Charger Boost Sensor Circuit Low
1.
1.
2.
DTC P0103 Priority DTC DTC P0560 DTC P0103 Diagnostics 1) 2) 3) 4)
2.
Turn OFF the starter switch. Disconnect the harness connector from the mass air flow sensor. Check the mass air flow sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the mass air flow sensor.
DTC P0237 Priority DTC DTC P1655 DTC P0237 Diagnostics 1) 2) 3) 4)
5)
• There should be no short to the battery or ignition power supply. • There should be no short to the 12 V or 5 V power supply. 5) 6) 7) 8) 9) 10) 11) 12) 13)
14) 15) 3.
If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the mass air flow sensor. If a problem is discovered, repair the GND circuit. Inspect the mass air flow sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the mass air flow sensor. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
ANNOTATION: • The boost sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected. 6) 7) 8) 9) 10) 11)
12)
2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the 5 V power supply circuit and the signal circuit of the boost sensor harness connector. Check the boost pressure sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the boost sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the boost sensor. Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Removal". Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Installation". Inspect the signal circuit between the ECM and the boost sensor. • There should be no open circuit or high resistance. • There should be no short to GND.
DTC P0103 Confirm Resolution 1)
Turn OFF the starter switch. Disconnect the harness connector from the boost sensor. Turn ON the starter switch. Measure the voltage between the 5 V power supply circuit of the boost sensor harness connector and a normal GND. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the boost sensor.
13) 14) 15) 16)
17) 84402827B - May 2011 4023G-17
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM.
Engine-side Trouble 18) 3.
Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0237 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0238 (Flash Code 32) Turbo Charger Boost Sensor Circuit High 1. 2.
DTC P0238 Priority DTC DTC P1655 DTC P0238 Diagnostics 1) 2) 3) 4)
Turn OFF the starter switch. Disconnect the harness connector from the boost Check the boost pressure sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the boost sensor. • There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply.
5) 6)
If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the boost sensor. ANNOTATION: • The boost sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
7) 8) 9) 10)
11) 12) 13)
14) 15) 3.
If a problem is discovered, repair the GND circuit. Inspect the boost sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the boost sensor. Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Removal". Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Installation". Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0238 Confirm Resolution sensor. 1) 2) 3)
84402827B - May 2011 4023G-18
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine.
Engine-side Trouble 4) 5)
Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC U0110 (Flash Code 87) Lost Communication with VNT System 1. 2.
DTC DTC DTC DTC
U0110 Priority DTC P0045 U0001 U0110 Diagnostics
1) 2)
Turn OFF the starter switch. Remove the harness connector from the turbo control unit. Measure the voltage between the ISO CANLow circuit and GND of the turbo control unit harness connector. Measure the voltage between the ISO CANHigh circuit and GND of the turbo control unit harness connector. Voltageďź&#x161; 1.5 - 3.5 V If it is outside the standard range, inspect to see if there is an open circuit or high resistance with the ISO CAN-High circuit between the turbo control unit and the ECM. If a problem is discovered, repair the ISO CAN-High circuit. Inspect to see if there is an open circuit or high resistance with the ISO CAN-Low circuit between the turbo control unit and the ECM. If a problem is discovered, repair the ISO CAN-Low circuit. Inspect the turbo control unit harness connector for a contact failure. If a problem is discovered, repair the harness connector. Replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Installation".
3) 4)
5)
6) 7) 8) 9) 10) 11)
3.
DTC U0110 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-19
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
1.
1.
2.
DTC P0112 Priority DTC DTC P0641 DTC P0112 Diagnostics 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)
12) 13) 3.
2.
Turn OFF the starter switch. Disconnect the harness connector from the intake air temperature sensor. Check the intake air temperature sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, replace the intake air temperature sensor. Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the intake air temperature sensor. If a problem is discovered, repair the signal circuit. Turn OFF the starter switch. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0113 Priority DTC DTC P0641 DTC P0113 Diagnostics 1) 2) 3) 4)
5)
• There should be no short to the battery or ignition power supply • There should be no short to the 12 V power supply. 6) 7) 8) 9)
DTC P0112 Confirm Resolution
10)
1)
11)
2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn OFF the starter switch. Disconnect the harness connector from the intake air temperature sensor. Turn ON the starter switch. Measure the voltage between the intake air temperature sensor signal circuit and a normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect the signal circuit between the ECM and the intake air temperature sensor.
12) 13) 14) 15) 16)
If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the intake air temperature sensor signal circuit and the GND circuit. Check the intake air temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the intake air temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the intake air temperature sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the intake air temperature sensor. Connect the test cable with fuse between the intake air temperature sensor signal circuit and a normal GND. Check the intake air temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the intake air temperature sensor. ANNOTATION: • The intake air temperature sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
17)
84402827B - May 2011 4023G-20
If a problem is discovered, repair the GND circuit.
Engine-side Trouble 18)
19) 20) 21) 22)
23) 24) 3.
Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the intake air temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low 1. 2.
DTC P0117 Priority DTC DTC P0697 DTC P0117 Diagnostics 1) 2) 3) 4)
DTC P0113 Confirm Resolution 1) 2) 3) 4) 5)
5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
6) 7) 8) 9)
10) 11) 3.
Turn OFF the starter switch. Disconnect the harness connector from the water temperature sensor. Check the coolant temperature sensor display with the trouble diagnosis scan tool. Voltageďź&#x161; 4.5 V If it is at or above the standard value, replace the water temperature sensor. Refer to "1.Engine 1D.Cooling(6HK1X) Engine coolant temperature sensor Removal". Refer to "1.Engine 1D.Cooling(6HK1X) Engine coolant temperature sensor Installation". Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and water temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0117 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-21
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High 1. 2.
14) 15)
DTC P0118 Priority DTC DTC P0697 DTC P0118 Diagnostics 1) 2) 3) 4)
5)
6) 7) 8) 9)
10) 11) 12) 13)
16)
Turn OFF the starter switch. Disconnect the harness connector from the water temperature sensor. Turn ON the starter switch. Measure the voltage between the water temperature sensor signal circuit and normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the water temperature sensor. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the water temperature sensor signal circuit and GND circuit. Check the coolant temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the water temperature sensor. If a problem is discovered, repair the signal circuit. Inspect to see if there is a contact failure with the water temperature sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the water temperature sensor. Refer to "1.Engine 1D.Cooling(6HK1X) Engine coolant temperature sensor Removal". Refer to "1.Engine 1D.Cooling(6HK1X) Engine coolant temperature sensor Installation".
Connect the test cable with fuse between the water temperature sensor signal circuit and normal GND. Check the coolant temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the water temperature sensor GND circuit. ANNOTATION: • The water temperature sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
17) 18) 19) 20) 21) 22)
23) 24) 3.
If a problem is discovered, repair the GND circuit. Inspect to see if there is a breakage or high resistance in the signal circuit of the water temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0118 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-22
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low 1. 2.
10) 11)
DTC P0122 Priority DTC DTC P1655 DTC P0122 Diagnostics 1) 2) 3) 4)
5)
12)
Turn OFF the starter switch. Disconnect the harness connector from the intake throttle valve. Turn ON the starter switch. Measure the voltage between the intake throttle position sensor 5 V power supply circuit and a normal GND. Voltage： 4.9 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the intake throttle position sensor.
• There should be no open circuit or high resistance. • There should be no short to GND. 13) 14) 15) 16)
ANNOTATION: • The intake throttle position sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected. 6) 7) 8) 9)
If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the intake throttle position sensor 5 V power supply circuit and the signal circuit. Check the intake throttle position sensor display with the trouble diagnosis scan tool. Voltage： 4.9 V If it is at or above the standard value, inspect to see if there is a contact failure with the intake throttle valve harness connector.
If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". Inspect the signal circuit between the ECM and intake throttle position sensor.
17) 18) 3.
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0122 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-23
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High 1. 2.
9)
ANNOTATION:
DTC P0123 Priority DTC DTC P1655 DTC P0123 Diagnostics 1) 2) 3) 4)
• The intake throttle position sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
Turn OFF the starter switch. Disconnect the harness connector from the intake throttle valve. Check the intake throttle position sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the intake throttle position sensor.
10) 11) 12) 13)
• There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply. 5) 6) 7) 8)
If a problem is discovered, repair the signal circuit. Inspect the intake throttle valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation".
Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the intake throttle position sensor.
14) 15) 3.
If a problem is discovered, repair the GND circuit. Check the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0123 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-24
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
1.
1.
2.
DTC P0182 Priority DTC DTC P1655 DTC P0182 Diagnostics 1) 2)
2.
DTC P0182 Confirm Resolution
Turn OFF the starter switch. Disconnect the harness connector from the fuel temperature sensor. Turn ON the starter switch. Measure the voltage between the fuel temperature sensor signal circuit and normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the fuel temperature sensor. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the fuel temperature sensor signal circuit and GND circuit. Check the fuel temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the fuel temperature sensor. If a problem is discovered, repair the signal circuit. Inspect to see if there is a contact failure with the fuel temperature sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the fuel temperature sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation".
1)
ANNOTATION:
3) 4)
Turn OFF the starter switch. Disconnect the harness connector from the fuel temperature sensor. Check the fuel temperature sensor display with the trouble diagnosis scan tool. voltage： 4.5 V If it is at or above the standard value, replace the fuel temperature sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". • Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump.
5) 6) 7) 8) 9)
10) 11)
2) 3) 4) 5)
1) 2) 3) 4) 5)
6)
ANNOTATION:
3.
DTC P0183 Priority DTC DTC P1655 DTC P0183 Diagnostics
Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and fuel temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
7) 8) 9)
10) 11) 12) 13)
• Do not replace the fuel temperature sensor separately. If a problem is found, replace the fuel supply pump. 14) 15) 16)
Connect the test cable with fuse between the fuel temperature sensor signal circuit and normal GND. Check the fuel temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and fuel temperature sensor. ANNOTATION: • The fuel temperature sensor shares the GND circuit with other sensors.
84402827B - May 2011 4023G-25
Engine-side Trouble • The DTC set on a sensor which shares this circuit may be detected. 17) 18) 19) 20) 21) 22)
23) 24) 3.
If a problem is discovered, repair the GND circuit. Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
2) 3) 4)
1. 2.
DTC P0192 Priority DTC DTC P0641 DTC P0192 Diagnostics 1) 2) 3) 4)
5) 6)
7)
DTC P0183 Confirm Resolution 1)
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run.
8) 9)
ANNOTATION: • Run the engine for 3 minutes or longer. 5)
Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn OFF the starter switch. Disconnect the harness connector from the fuel pressure sensor. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the signal circuit. Measure the voltage between the fuel pressure sensor 5 V power supply circuit and normal GND. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the fuel pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation". ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.
10)
Inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and fuel pressure sensor. ANNOTATION: • The fuel pressure sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
11) 12) 13) 14)
15) 16)
84402827B - May 2011 4023G-26
If a problem is discovered, repair the 5 V power supply circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
Engine-side Trouble 3.
DTC P0192 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High 1. 2.
DTC P0193 Priority DTC DTC P0641 DTC P0193 Diagnostics 1) 2) 3) 4) 5)
6) 7) 8)
9) 10) 11) 12) 13) 14)
Turn OFF the starter switch. Disconnect the harness connector from the fuel pressure sensor. Turn ON the starter switch. Measure the voltage between the fuel pressure sensor signal circuit and normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the signal circuit. Measure the voltage between the fuel pressure sensor signal circuit and normal GND. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the fuel pressure sensor signal circuit and GND circuit. Check the fuel rail pressure sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a contact failure with the fuel pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation". ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.
15)
Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the fuel pressure sensor. ANNOTATION: • The fuel pressure sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
16)
84402827B - May 2011 4023G-27
If a problem is discovered, repair the GND circuit.
Engine-side Trouble 17) 18) 19) 20) 21)
22) 23) 3.
Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0201 (Flash Code 271) Injector Circuit - Cylinder 1 1.
1) 2) 3)
4)
5) 6) 7)
DTC P0193 Confirm Resolution 1) 2) 3) 4) 5)
DTC P0201 Diagnostics
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the first cylinder injector power supply terminal and the first cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the first cylinder injector harness tightening nut is loose. If the first cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the first cylinder injector terminal. If a foreign matter is attached to the first cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the first cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the first cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0201 Confirm Resolution 1)
84402827B - May 2011 4023G-28
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0202 (Flash Code 272) Injector Circuit - Cylinder 2 1.
DTC P0202 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the second cylinder injector power supply terminal and the second cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the second cylinder injector harness tightening nut is loose. If the second cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the second cylinder injector terminal. If a foreign matter is attached to the second cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the second cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the second cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0202 Confirm Resolution 1)
84402827B - May 2011 4023G-29
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0203 (Flash Code 273) Injector Circuit - Cylinder 3 1.
DTC P0203 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the third cylinder injector power supply terminal and the third cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the third cylinder injector harness tightening nut is loose. If the third cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the third cylinder injector terminal. If a foreign matter is attached to the third cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the third cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the third cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0203 Confirm Resolution 1)
84402827B - May 2011 4023G-30
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0204 (Flash Code 274) Injector Circuit - Cylinder 4 1.
DTC P0204 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the fourth cylinder injector power supply terminal and the fourth cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the fourth cylinder injector harness tightening nut is loose. If the fourth cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the fourth cylinder injector terminal. If a foreign matter is attached to the fourth cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the fourth cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the fourth cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0204 Confirm Resolution 1)
84402827B - May 2011 4023G-31
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0205 (Flash Code 275) Injector Circuit - Cylinder 5 1.
DTC P0205 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the fifth cylinder injector power supply terminal and the fifth cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the fifth cylinder injector harness tightening nut is loose. If the fifth cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the fifth cylinder injector terminal. If a foreign matter is attached to the fifth cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the fifth cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the fifth cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0205 Confirm Resolution 1)
84402827B - May 2011 4023G-32
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0206 (Flash Code 276) Injector Circuit - Cylinder 6 1.
DTC P0206 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9) 10) 11) 12) 13)
Turn OFF the starter switch. Disconnect the injector harness intermediate connector from the cylinder head cover case. Measure the resistance between the sixth cylinder injector power supply terminal and the sixth cylinder injector drive signal terminal of the injector harness intermediate connector. Resistance： 2.0 Ω If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the circuit between the ECM and injector harness intermediate connector. Repair the circuit if a problem is discovered. Remove the cylinder head cover. Inspect to see if the sixth cylinder injector harness tightening nut is loose. If the sixth cylinder injector harness tightening nut is loose, tighten it. Inspect to see if a foreign matter is attached to the sixth cylinder injector terminal. If a foreign matter is attached to the sixth cylinder injector terminal, remove it. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the connector. Inspect the circuit between the sixth cylinder injector and intermediate connector. • There should be no open circuit or high resistance. • There should be no short between the injector circuits.
14) 15)
16) 17) 18) 19)
20) 21) 2.
Repair the circuit if a problem is discovered. If the circuit is normal, replace the sixth cylinder injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0206 Confirm Resolution 1)
84402827B - May 2011 4023G-33
Clear the DTC using the trouble diagnosis scan tool.
Engine-side Trouble 2) 3) 4) 5)
Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance 1.
2.
DTC DTC DTC DTC DTC
P0336 Priority DTC P0335 P0340 P0641 P0336 Diagnostics
1)
Inspect the crankshaft position sensor circuit. ANNOTATION: • It should not be too close to the wiring or components of the fuel injection device. • It should not be too close to any electronic device additionally installed. • It should not be too close to the solenoid and relay
2) 3) 4) 5) 6) 7) 8) 9) 10) 11)
3.
If a problem is discovered, repair the crankshaft position sensor circuit. Turn OFF the starter switch. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the crankshaft position sensor. Inspect the crankshaft position sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the CKP sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Inspection". If a problem is discovered, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Installation".
DTC P0336 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-34
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit 1. 2.
19)
DTC DTC DTC DTC
P0340 Priority DTC P0601 P0651 P0340 Diagnostics
1) 2)
Turn OFF the starter switch. Disconnect the harness connector from the camshaft position sensor. Turn ON the starter switch. Measure the voltage between the 5 V power supply circuit and normal GND of the camshaft position sensor harness connector. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the 5 V power supply circuit. Measure the voltage between the signal circuit and normal GND of the camshaft position sensor harness connector. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the signal circuit. Measure the voltage between the signal circuit of the camshaft position sensor harness connector and a normal GND again. Voltage： 4.5 V If it is at or below the standard value, inspect the signal circuit between the ECM and the camshaft position sensor.
3) 4)
5)
6) 7)
8)
9) 10)
11)
18)
20)
21)
22)
• The camshaft gear should not be damaged • The camshaft gear should be installed correctly. 23) 24)
13) 14) 15)
16) 17)
If a problem is discovered, repair the signal circuit. Connect the test light between the signal circuit and normal GND of the camshaft position sensor harness connector. Measure the voltage between the probe of the test light and a normal GND. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the signal circuit. Measure the voltage between the 5 V power supply circuit and GND circuit of the camshaft position sensor harness connector. Voltage： 4.5 V
If a problem is discovered, repair the camshaft gear. Inspect the GND circuit between the ECM and the camshaft position sensor for an open circuit and high resistance. ANNOTATION: • The camshaft position sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
25) 26) 27) 28)
• There should be no open circuit or high resistance. • There should be no short to GND. 12)
If it is at or above the standard value, inspect to see if there is a contact failure with the camshaft position sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, inspect the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Inspection". If a problem is discovered, replace the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Installation". Inspect the camshaft gear.
29) 30) 3.
If a problem is discovered, repair the GND circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0340 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-35
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0404 (Flash Code 45) Exhaust Gas Recirculation Control Circuit Range/Performance 1. 2.
• There should be no short to EGR position sensor circuit. 13) 14)
DTC P0404 Priority DTC DTC P0409 DTC P0404 Diagnostics 1) 2)
Remove the EGR valve assembly from the engine. Inspect the EGR valve.
15) 16) 17)
• There should be nothing to limit flow inside the EGR valve. • There should be no excessive accumulates inside the EGR valve. • There should be no bending with the valve shaft or valve itself inside the EGR valve. 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)
Turn OFF the starter switch. Disconnect the harness connector from the EGR valve. Inspect the EGR valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect to see if there is an open circuit or high resistance in the EGR control circuit. If a problem is discovered, repair the EGR control circuit. Inspect the EGR solenoid circuit between the ECM and EGR valve. • There should be no short to GND. • There should be no short to the battery or ignition power supply circuit. • There should be no short between the circuits.
18) 19) 20) 21) 22)
23) 24) 3.
If a problem is discovered, repair the EGR solenoid circuit. If the EGR solenoid circuit is normal, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Installation". Restore the actual unit. Turn ON the starter switch. Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. valve. Check the DTC using the trouble diagnosis scan tool. If the DTC P0404 has been detected, replace the ECM. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0404 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-36
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0409 (Flash Code 44) Exhaust Gas Recirculation Sensor Circuit
14)
1.
15)
2.
DTC P0409 Priority DTC DTC P1655 DTC P0409 Diagnostics 1) 2) 3) 4) 5)
Turn OFF the starter switch. Disconnect the harness connector from the EGR valve. Turn ON the starter switch. Use the trouble diagnosis scan tool to check if any of the EGR position 1, EGR position 2, and EGR position 3 shows ON. If there is a data display showing ON, inspect the signal circuit between the ECM and EGR valve of the EGR showing ON.
16)
17)
• There should be no open circuit or high resistance between ECM and EGR position sensor. • There should be no short to GND between ECM and EGR position sensor.
• There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply. 6) 7)
8)
18)
If a problem is discovered, repair the signal circuit. Measure the voltage between the EGR position sensor 5 V power supply circuit and a normal GND. voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the EGR position sensor.
19) 20) 21) 22) 23)
ANNOTATION: • The EGR position sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected. 9) 10)
11)
24)
If a problem is discovered, repair the 5 V power supply circuit. Measure the voltage between the EGR position sensor 5 V power supply circuit and the GND circuit. voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and EGR position sensor.
25) 26)
27) 28)
ANNOTATION: • The EGR position sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected. 12) 13)
If a problem is discovered, repair the GND circuit. While momentarily disconnecting the test cable with fuse from the EGR position sensor 1 signal circuit and 5 V power supply circuit, check the EGR position 1 display with the trouble diagnosis scan tool.
While momentarily disconnecting the test cable with fuse from the EGR position sensor 2 signal circuit and 5 V power supply circuit, check the EGR position 2 display with the trouble diagnosis scan tool. While momentarily disconnecting the test cable with fuse from the EGR position sensor 3 signal circuit and 5 V power supply circuit, check the EGR position 3 display with the trouble diagnosis scan tool. Check to see if there is a data display which does not display ON when the EGR position sensor signal circuit and 5 V power supply circuit are shorted. If there is a data display which does not display ON, inspect the EGR position sensor circuit which does not display ON.
3.
If a problem is discovered, repair the EGR position sensor circuit. Inspect the EGR valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. In the EGR solenoid circuit between the ECM and EGR valve, inspect to see if there is a short circuit with the EGR position sensor. If a problem is discovered, repair the EGR solenoid circuit. If the EGR solenoid circuit is normal, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Installation". Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0409 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-37
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
1.
2.
2.
DTC DTC DTC DTC DTC
P0426 Priority DTC P0093 P0427 P1093 P0426 Diagnostics
1)
Inspect the exhaust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Inspection". If a problem is discovered, replace the exhaust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Inspect the DPD filter for a damage. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection". If a problem is discovered, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Reassembly". Perform the DPD regeneration data reset with the trouble diagnosis scan tool.
2)
3) 4)
5) 3.
1.
DTC P0427 Priority DTC DTC P0697 DTC P0427 Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9)
DTC P0426 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
10) 11) 3.
Turn OFF the starter switch. Disconnect the harness connector from the exhaust gas temperature sensor 1. Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool. Voltageďź&#x161; 4.5 V If it is at or above the standard value, replace the exhaust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas temperature sensor 1. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0427 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-38
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1 1. 2.
16)
17)
DTC P0428 Priority DTC DTC P0697 DTC P0428 Diagnostics 1) 2) 3) 4)
5)
6) 7) 8)
9)
10) 11) 12) 13)
14) 15)
18)
Turn OFF the starter switch. Disconnect the harness connector from the exhaust gas temperature sensor 1. Turn ON the starter switch. Measure the voltage between the exhaust gas temperature sensor 1 signal circuit and normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 1. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and GND circuit. Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 1. If a problem is discovered, repair the signal circuit. Inspect to see if there is a contact failure with the exhaust gas temperature sensor 1 harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the exhaust gas temperature sensor 1. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Connect the test cable with fuse between the exhaust gas temperature sensor 1 signal circuit and normal GND. Check the exhaust temperature sensor (before the filter) display with the trouble diagnosis scan tool. Voltage： 0.1 V
If it is at or above the standard value, inspect to see if there is an open circuit or high resistance with the signal circuit between the ECM and the exhaust gas temperature sensor 1. If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust gas temperature sensor 1. ANNOTATION: • The exhaust gas temperature sensor 1 shares the GND circuit with other sensors. • The DTC may be detected on a sensor which shares this circuit.
19) 20) 21) 22)
23) 24) 3.
If a problem is discovered, repair the GND circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0428 Confirm Resolution 1) 2) 3)
4)
5)
6)
84402827B - May 2011 4023G-39
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine and warm it up until the coolant temperature exceeds the standard value. Specified value： 70 °C {158 °F} Repeatedly rev the engine in neutral to increase the engine rpm while checking the exhaust temperature sensor (in front of the filter) display with the trouble diagnosis scan tool. Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the filter) display does not exceed the standard value. Voltage： 4.8 V Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0522 (Flash Code 294) Oil Pressure Sensor Circuit Low 1. 2.
12)
• There should be no open circuit or high resistance. • There should be no short to GND.
DTC P0522 Priority DTC DTC P0697 DTC P0522 Diagnostics 1) 2) 3) 4)
5)
6) 7) 8) 9) 10) 11)
13)
Turn OFF the starter switch. Disconnect the harness connector from the oil pressure sensor. Turn ON the starter switch. Measure the voltage between the 5 V power supply circuit and normal GND of the oil pressure sensor harness connector. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the oil pressure sensor. If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the oil pressure sensor harness connector. Check the oil pressure sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the oil pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Installation".
Inspect the signal circuit between the ECM and the oil pressure sensor.
14) 15) 16)
17) 18) 3.
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0522 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-40
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0523 (Flash Code 294) Oil Pressure Sensor Circuit High 1. 2.
8) 9)
DTC P0523 Priority DTC DTC P0697 DTC P0523 Diagnostics 1) 2) 3) 4)
10)
Turn OFF the starter switch. Disconnect the harness connector from the oil pressure sensor. Check the oil pressure sensor display with the trouble diagnosis scan tool. voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the oil pressure sensor.
11) 12) 13)
• There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply. 5) 6)
7)
If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the oil pressure sensor.
14) 15) 3.
Inspect the oil pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Installation". Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0523 Confirm Resolution 1)
ANNOTATION:
2)
• The oil pressure sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
3) 4) 5)
If a problem is discovered, repair the GND circuit.
84402827B - May 2011 4023G-41
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0560 (Flash Code 155) System Voltage 1.
18)
DTC P0560 Diagnostics 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)
19)
Turn OFF the starter switch. Disconnect the harness connector from the mass air flow sensor. Use the trouble diagnosis scan tool to check if a DTC is detected. If a DTC has not been detected, inspect the mass air flow sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the mass air flow sensor. Turn OFF the starter switch. Leave the mass air flow sensor harness connector disconnected. Disconnect the harness connector from the dropping register. Use the trouble diagnosis scan tool to check if a DTC is detected. If a DTC has been detected, inspect the voltage supply circuit between the ECM and dropping register.
20) 21)
22)
23) 24) 25) 26) 27) 28)
• There should be no short to GND. • There should be no short to the battery or ignition power supply. 12) 13)
If a problem is discovered, repair the voltage supply circuit. If the voltage supply circuit is normal, inspect the 12 V power supply circuit between the ECM and the mass air flow sensor. • There should be no short to GND. • There should be no short to the battery or ignition power supply.
14) 15) 16) 17)
29)
If a problem is discovered, repair the 12 V power supply circuit. Check the resistance value of the dropping register. Resistance： 45.0 - 55.0 Ω If the resistance value is outside the standard range, replace the dropping register. Turn ON the starter switch.
30) 31) 2.
Measure the voltage between the ignition power supply circuit of the dropping register and a normal GND. Voltage： 18.0 V If it is at or below the standard value, inspect the fuse. If the fuse is faulty, replace the fuse. If it is at or below the standard value, repair an open circuit or high resistance in the ignition power supply circuit between the fuse and dropping register. Measure the voltage between the voltage supply circuit of the dropping register and a normal GND. Voltage： 13.0 V If it is at or above the standard value, inspect to see if there is a contact failure with the dropping register harness connector. If a problem is discovered, repair the harness connector. Inspect to see if there is an open circuit or high resistance in the voltage supply circuit between the ECM and the dropping register. If a problem is discovered, repair the voltage supply circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0560 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-42
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0563 (Flash Code 35) System Voltage High 1.
DTC P0563 Diagnostics
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
1)
1.
2) 3) 4)
5) 6)
7) 8) 2.
Check if the battery charger has been recently connected to the battery. Start the engine, and idle it. Check the ignition voltage display with the trouble diagnosis scan tool. Voltageďź&#x161; 32.0 V If it is at or above the standard value, inspect the charging system. Refer to "1.Engine 1J.Electrical(6HK1X) Generator Reassembly". If a problem is discovered, repair the charging system. If the charging system is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0601 Diagnostics 1)
2) 3) 2.
DTC P0601 Confirm Resolution 1) 2) 3) 4) 5)
DTC P0563 Confirm Resolution 1) 2) 3) 4)
5)
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine, and idle it. Check the ignition voltage display with the trouble diagnosis scan tool, and confirm that the value does not exceed the standard value. Voltageďź&#x161; 32.0 V Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
84402827B - May 2011 4023G-43
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM) Error
1.
1.
DTC P0602 Diagnostics 1) 2) 3)
Confirm that the connecting sections of all tools are securely connected. Confirm that the programming device is operating normally. Use the trouble diagnosis scan tool to confirm that the correct injector ID code has been entered to the ECM.
DTC P0604 Diagnostics 1)
2) 3)
ANNOTATION: â&#x20AC;˘ When the injector ID code has been correctly input, clear the DTC using the trouble diagnosis scan tool. 4) 5) 6) 7)
8) 9) 2.
Turn the starter switch OFF for 30 seconds or longer. Turn ON the starter switch. Use the trouble diagnosis scan tool to check if a DTC has been detected. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
2.
DTC P0604 Confirm Resolution 1) 2) 3) 4) 5)
DTC P0602 Confirm Resolution 1) 2) 3) 4) 5)
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
84402827B - May 2011 4023G-44
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0606 (Flash Code 51) ECM/PCM Processor 1.
DTC P0606 Diagnostics
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
1)
1.
2) 3) 2.
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0606 Confirm Resolution 1) 2) 3) 4) 5)
2.
DTC DTC DTC DTC
P0638 Priority DTC P0122 P0123 P0638 Diagnostics
1)
Remove the air intake hose from the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Inspect the intake throttle valve.
2)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
• The intake throttle valve flow should not be limited. • There should be no excessive deposit inside the throttle bore of the intake throttle valve. • There should be no bending with the butterfly valve of the intake throttle valve. • The intake throttle valve should not be locked 3)
4) 5) 6) 7) 8) 9) 10) 11) 12) 13)
If a problem is discovered, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". Turn OFF the starter switch. Disconnect the harness connector from the intake throttle valve. Inspect the intake throttle valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the intake throttle valve circuit for high resistance. Repair the circuit if a problem is discovered. Inspect the solenoid circuit between the ECM and the intake throttle valve. • There should be no short to GND. • There should be no short to the battery or ignition power supply. • There should be no short between the solenoid circuits. • There should be no short to the intake throttle position sensor circuit.
14) 15)
16) 84402827B - May 2011 4023G-45
If a problem is discovered, repair the solenoid circuit. If the solenoid circuit is normal, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". Restore the actual unit.
Engine-side Trouble 17) 18)
Turn ON the starter switch. Turn the starter switch OFF for 30 seconds. ANNOTATION: • The starter switch must be once turned ON and then turned OFF before clearing the DTC.
19) 20) 21) 22) 23)
24) 25) 3.
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Use the trouble diagnosis scan tool to check if a DTC has been detected. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit 1.
DTC P0641 Diagnostics 1) 2) 3) 4)
5)
6) 7)
DTC P0638 Confirm Resolution 1) 2)
Turn ON the starter switch. Turn the starter switch OFF for 30 seconds or longer.
8)
ANNOTATION: • The starter switch must be once turned ON and then turned OFF before clearing the DTC. 3) 4) 5) 6) 7)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run with the intake throttle solenoid drive duty of 20% or above. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
9)
10) 11)
12) 13) 14) 15) 16)
17)
18) 19) 20) 84402827B - May 2011 4023G-46
Turn OFF the starter switch. Disconnect the harness connector from the accelerator position sensor. Turn ON the starter switch. Measure the voltage between the 5 V power supply terminal and GND of the accelerator position sensor harness connector. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the accelerator position sensor 5 V power supply circuit between the ECM and the accelerator position sensor. If a problem is discovered, repair the accelerator position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor. If a problem is discovered, repair the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor. Inspect to see if there is a short circuit to the battery or ignition power supply with the fuel pressure sensor 5 V power supply circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the fuel pressure sensor 5 V power supply circuit. If it is at or below the standard value, measure the voltage between the 5 V power supply circuit and GND of the accelerator position sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the accelerator position sensor. If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the crankshaft position sensor. Turn ON the starter switch. Measure the voltage between the accelerator position sensor 5 V power supply circuit and GND of the accelerator position sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the crankshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CKP sensor Installation". If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the fuel pressure sensor. Turn ON the starter switch.
Engine-side Trouble 21)
22)
Measure the voltage between the accelerator position sensor 5 V power supply circuit and GND of the accelerator position sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit 1.
DTC P0651 Diagnostics 1) 2) 3) 4)
ANNOTATION: • Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly. 23)
24) 25)
26) 27)
28) 29)
30) 31) 2.
If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the accelerator position sensor 5 V power supply circuit between the ECM and the accelerator position sensor. If a problem is discovered, repair the accelerator position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the crankshaft position sensor 5 V power supply circuit between the ECM and the crankshaft position sensor. If a problem is discovered, repair the crankshaft position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the fuel pressure sensor 5 V power supply circuit between the ECM and the fuel pressure sensor. If a problem is discovered, repair the fuel pressure sensor 5 V power supply circuit. Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0641 Confirm Resolution 1) 2) 3) 4) 5)
5)
6) 7)
8) 9)
10)
11) 12)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
13) 14)
15) 16)
17)
84402827B - May 2011 4023G-47
Turn OFF the starter switch. Disconnect the harness connector from the camshaft position sensor. Turn ON the starter switch. Measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the camshaft position sensor 5 V power supply circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the camshaft position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the atmospheric pressure sensor 5 V power supply circuit between the ECM and atmospheric pressure sensor. If a problem is discovered, repair the atmospheric pressure sensor 5 V power supply circuit. If it is at or below the standard value, measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the camshaft position sensor. Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) CMP sensor Installation". If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the atmospheric pressure sensor. Turn ON the starter switch. Measure the voltage between the camshaft position sensor 5 V power supply circuit and GND of the camshaft position sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the atmospheric pressure sensor. If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the camshaft position sensor 5 V power supply circuit between the ECM and the camshaft position sensor. If a problem is discovered, repair the camshaft position sensor 5 V power supply circuit.
Engine-side Trouble 18)
19) 20)
21) 22) 2.
Inspect to see if there is a short circuit to the GND with the atmospheric pressure sensor 5 V power supply circuit between the ECM and the atmospheric pressure sensor. If a problem is discovered, repair the atmospheric pressure sensor 5 V power supply circuit. Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open 1.
1) 2) 3) 4) 5)
DTC P0651 Confirm Resolution 1) 2) 3) 4) 5)
DTC P0685 Diagnostics
6)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
7) 8) 9)
Turn the starter switch OFF for 30 seconds or longer. Replace the main relay with a glow relay or normal relay. Turn ON the starter switch. Use the trouble diagnosis scan tool to check if a DTC is detected. If a DTC has not been detected, replace the main relay. Inspect the body grounding terminal for a contact failure. If a problem is discovered, repair the terminal. Inspect the slow blow fuse. If a problem is discovered, replace the slow blow fuse. ANNOTATION: â&#x20AC;˘ When the fuse is blown again, repair the cause of slow-blow fuse meltdown.
10) 11) 12) 13) 14)
15) 16) 2.
Turn OFF the starter switch. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P0685 Confirm Resolution 1) 2) 3) 4)
84402827B - May 2011 4023G-48
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
1.
1.
DTC P0687 Diagnostics 1) 2) 3) 4) 5)
6) 7) 8) 9) 10) 2.
Turn OFF the starter switch. Remove the main relay. Turn ON the starter switch. Use the trouble diagnosis scan tool to see if DTC P0685 is detected. If the DTC P0685 is not detected, repair the short circuit to the battery power supply of the power supply circuit between the ECM and main relay. Turn the starter switch OFF for 30 seconds or longer. Replace the main relay with a glow relay or normal relay. Turn ON the starter switch. Use the trouble diagnosis scan tool to check if DTC P0687 has been detected. If the DTC P0687 is not detected, replace the main relay.
2) 3) 4)
1) 2) 3) 4)
5)
6) 7)
DTC P0687 Confirm Resolution 1)
DTC P0697 Diagnostics
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
8) 9)
10) 11)
12)
13) 14) 15) 16)
84402827B - May 2011 4023G-49
Turn OFF the starter switch. Disconnect the harness connector from the DPD differential pressure sensor. Turn ON the starter switch. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the DPD differential pressure sensor 5 V power supply circuit between the ECM and the DPD differential pressure sensor. If a problem is discovered, repair the DPD differential pressure sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor. If a problem is discovered, repair the oil pressure sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the fuel filter pressure sensor 5 V power supply circuit between the ECM and the fuel filter pressure sensor. If a problem is discovered, repair the fuel filter pressure sensor 5 V power supply circuit. If it is at or below the standard value, measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the oil pressure sensor. Turn ON the starter switch. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. Voltage： 4.5 V
Engine-side Trouble 17)
18) 19) 20) 21)
22)
23)
24) 25)
26) 27)
28) 29)
30) 31) 2.
If it is at or above the standard value, replace the oil pressure sensor. Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Removal". Refer to "1.Engine 1E.Lubrication(6HK1X) Oil pressure sensor Installation". If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the fuel filter pressure sensor. Turn ON the starter switch. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND of the DPD differential pressure sensor harness connector. Voltageďź&#x161; 4.5 V If it is at or above the standard value, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Installation". If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the DPD differential pressure sensor 5 V power supply circuit between the ECM and the DPD differential pressure sensor. If a problem is discovered, repair the DPD differential pressure sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the oil pressure sensor 5 V power supply circuit between the ECM and oil pressure sensor. If a problem is discovered, repair the oil pressure sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the fuel filter pressure sensor 5 V power supply circuit between the ECM and fuel filter pressure sensor. If a problem is discovered, repair the fuel filter pressure sensor 5 V power supply circuit. Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP) Too Low 1.
2.
DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC DTC
P1093 Priority DTC P0087 P0091 P0092 P0192 P0193 P0201 P0202 P0203 P0204 P0205 P0206 P2146 P2149 P1093 Diagnostics
1) 2)
Turn OFF the starter switch. Wait for the specified period of time until the fuel pressure is released from the common rail. Specified time: 2 min Turn ON the starter switch. Use the trouble diagnosis scan tool to check if the fuel rail pressure sensor display is within the standard range. Voltage: 0.9 - 1.0 V If the fuel rail pressure sensor display is outside the standard range, inspect the fuel pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the harness connector and each circuit are normal, replace the fuel pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
3) 4)
5)
6) 7) 8) 9) 10) 11)
ANNOTATION: â&#x20AC;˘ Do not replace the fuel pressure sensor separately. When a problem is found, replace the common rail assembly.
DTC P0697 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
12) 13) 14) 15)
Inspect to see if there is clogging with the fuel system between the fuel tank and the fuel supply pump. If a problem is discovered, repair the clogging of the fuel system. Inspect the fuel hose between the fuel tank and the fuel supply pump for a cut and crack. If a problem is discovered, replace the fuel hose. ANNOTATION:
84402827B - May 2011 4023G-50
Engine-side Trouble • The fuel hose between the fuel tank and the fuel supply pump becomes negative pressure state when the engine is running. • When the fuel hose is not connected securely, the air can enter. • When the engine RPM or the engine load increases while the air has intruded in the fuel system, fluctuation in the common rail pressure is caused, and DTC P1093 may be detected. 16) 17) 18)
26) 27)
28)
Check that an appropriate clamp is used between the fuel tank and the fuel supply pump. If a problem is discovered, replace the clamp. Operate the priming pump until the handle becomes heavy.
ANNOTATION: • Fuel clogging is checked with the negative pressure amount in the fuel system.
ANNOTATION: • When a leak exists in the fuel system between the priming pump and the fuel supply pump, the pressing weight of the priming pump does not become heavy. 19) 20)
Start the engine. Inspect the high-pressure side of the fuel system and check for fuel leak between the fuel supply pump and common rail. • The fuel may leak to the bottom section of the cylinder head cover from the high pressure hose inlet. • The engine oil level increases when the fuel leaks to the bottom portion of the cylinder head cover. • Inspect for fuel leaks into the engine oil.
21) 22) 23)
24)
29)
30) 31) 32) 33)
ANNOTATION:
If fuel leak if found, fix the problem. Turn OFF the starter switch. Remove the fuel hose on the fuel supply pump side from the fuel filter.
34) 35)
36)
If the negative pressure is at or above the standard value, inspect to see if there is damage or twisting with the fuel system between the fuel supply pump and the fuel tank. If a problem is discovered, repair the fuel system. Inspect the fuel tank bent hose. If a problem is discovered, repair the bent hose. Check to see if there is any foreign matter in the fuel tank or any foreign matter which can cause fuel clogging. If a problem is discovered, repair it. Replace the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation". If the negative pressure is at or below the standard value, pinch the fuel hose at a position as close as possible to the fuel tank, so that the fuel does not flow.
ANNOTATION:
ANNOTATION:
• Use a pan to catch the fuel from the removed fuel hose. • Clean the pressure gauge and connection hose before connecting to the fuel pipe. • The fuel supply pump may be damaged due to foreign matter that has entered in the connection hose.
• The fuel pipe can be disconnected and clogged with a plug. 37) 38)
Connect the pressure gauge between the fuel filter and the removed fuel hose.
• When the pressure gauge is likely to indicate a value exceeding the standard value during inspection, release the fuel being blocked. • Air mixture is checked with the negative pressure amount while the fuel flow is being blocked.
• Confirm that the fuel system is connected securely. Remove the air using the priming pump, and crank the engine for the specified period of time or shorter. Specified time: 5 s ANNOTATION: • Repeat this until the engine starts.
Start the engine and use the idling control switch to increase the RPM to the highest level. Check the pressure gauge. Specified value: 27.0 kPa {203 mmHg / 8 inHg} ANNOTATION:
ANNOTATION:
25)
Leave the engine idling for the specified period of time or longer. specified time: 1 min While keeping the engine rotating at the specified engine RPM for the specified period of time, check the pressure gauge. Specified time: 1 min Rotational speed: 2500 min-1 {2500 r/min} Check if the pressure gauge shows a negative pressure value at or above the standard value during inspection. Specified value: 17.0 kPa {128 mmHg / 5 inHg}
39) 40)
84402827B - May 2011 4023G-51
If the standard negative pressure cannot be generated, inspect to see if there is a cut or crack with the fuel hose. If a problem is discovered, replace the fuel hose.
Engine-side Trouble 41) 42) 43) 44) 45) 46) 47) 48) 49) 50)
55)
Inspect to see if appropriate clamp is used. If a problem is discovered, replace the clamp with an appropriate one. Turn OFF the starter switch. Inspect the suction control valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect each circuit for high resistance. Repair the circuit if a problem is discovered. If the suction control valve harness connector and the ECM harness connector are normal and there is no high resistance in each circuit, replace the fuel supply pump and the fuel filter element. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel supply pump Installation". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter element Installation".
56) 57)
58) 59)
ANNOTATION: • The pressure limiter valve may be fixed open, or the operation pressure may decrease. • Do not replace the pressure limiter valve separately. When a problem is found, replace the common rail assembly.
ANNOTATION: • When replacing the fuel supply pump, it is required to also replace the fuel filter element at the same time. 51) 52) 53) 54)
Perform the unit difference learning of the fuel supply pump to the ECM. If the negative pressure is normal, turn OFF the starter switch. Restore the fuel system. Start the engine.
Perform the injector stop test with the trouble diagnosis scan tool. Check to see if any injector does not change the engine RPM when OFF is instructed. If any injector does not change the engine RPM when OFF is instructed, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. If the engine RPM changes when OFF is instructed to all injectors, replace the pressure limiter valve. Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Common rail assembly Installation".
3.
DTC P1093 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-52
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
1.
1.
2.
DTC P1112 Priority DTC DTC P0651 DTC P1112 Diagnostics 1) 2) 3) 4)
5) 6) 7) 8) 9)
10) 11) 3.
2.
Turn OFF the starter switch. Remove the harness connector from the boost temperature sensor. Check the boost temperature sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, replace the boost temperature sensor. Refer to "1.Engine 1F.Induction(6HK1X) Boost temperature sensor Removal". Refer to "1.Engine 1F.Induction(6HK1X) Boost temperature sensor Installation". Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and boost temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1112 Confirm Resolution 1) 2) 3) 4) 5)
DTC P1113 Priority DTC DTC P0651 DTC P1113 Diagnostics 1) 2) 3) 4)
5)
6) 7) 8) 9)
10) 11) 12) 13)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
14) 15) 16)
Turn OFF the starter switch. Remove the harness connector from the boost temperature sensor. Turn ON the starter switch. Measure the voltage between the boost temperature sensor signal circuit and a normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the boost temperature sensor. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the boost temperature sensor signal circuit and GND circuit. Check the boost temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the boost temperature sensor. If a problem is discovered, repair the signal circuit. Inspect boost temperature sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the boost temperature sensor. Refer to "1.Engine 1F.Induction(6HK1X) Boost temperature sensor Removal". Refer to "1.Engine 1F.Induction(6HK1X) Boost temperature sensor Installation". Connect the test cable with fuse between the boost temperature sensor signal circuit and a normal GND. Check the boost temperature sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the boost temperature sensor. ANNOTATION: • The boost temperature sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
17) 84402827B - May 2011 4023G-53
If a problem is discovered, repair the GND circuit.
Engine-side Trouble 18) 19) 20) 21) 22)
23) 24) 3.
Inspect to see if there is an open circuit or high resistance in the signal circuit between the ECM and the boost temperature sensor. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1113 Confirm Resolution 1) 2) 3) 4)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run.
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1 1.
DTC P1261 Diagnostics 1)
2) 3) 2.
DTC P1261 Confirm Resolution 1) 2) 3) 4) 5)
ANNOTATION: â&#x20AC;˘ Run the engine for 3 minutes or longer. 5)
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
84402827B - May 2011 4023G-54
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 211) Fuel Pressure Sensor Circuit Low
1.
2.
DTC P1262 Diagnostics 1)
2) 3) 2.
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
1.
DTC P1293 Priority DTC DTC P0697 DTC P1293 Diagnostics 1) 2) 3) 4)
DTC P1262 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
5)
Turn OFF the starter switch. Disconnect the harness connector from the fuel filter pressure sensor. Turn ON the starter switch. Measure the voltage between the 5 V power supply circuit of the fuel filter pressure sensor harness connector and normal GND. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the fuel filter pressure sensor. ANNOTATION: • The fuel filter pressure sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
6) 7)
8) 9) 10) 11)
12)
If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the fuel filter pressure sensor harness connector. Check the fuel filter pressure sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the fuel filter pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Installation". Inspect the signal circuit between the ECM and the fuel filter pressure sensor. • There should be no open circuit or high resistance. • There should be no short to GND.
13) 14) 15) 16)
84402827B - May 2011 4023G-55
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation".
Engine-side Trouble 17) 18) 3.
Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1294 (Flash Code 211) Fuel Pressure Sensor Circuit High
DTC P1293 Confirm Resolution
1.
1)
2.
2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P1294 Priority DTC DTC P0697 DTC P1294 Diagnostics 1) 2) 3) 4)
Turn OFF the starter switch. Disconnect the harness connector from the fuel filter pressure sensor. Check the fuel filter pressure sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the fuel filter pressure sensor. • There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply.
5) 6)
If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the fuel filter pressure sensor. ANNOTATION: • The fuel filter pressure sensor shares the GND circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected.
7) 8) 9) 10)
11) 12)
13) 14) 3.
If a problem is discovered, repair the GND circuit. Inspect to see if there is a contact failure with the fuel filter pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the fuel filter pressure sensor. Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Fuel filter pressure sensor Installation". 11.Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1294 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-56
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer.
Engine-side Trouble 3) 4) 5)
Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation (EGR) Closed Position Performance 1. 2.
DTC DTC DTC DTC
P1404 Priority DTC P0404 P0409 P1404 Diagnostics
1)
Remove the EGR valve assembly from the engine. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Inspect the EGR valve.
2)
• There should be nothing to limit flow inside the EGR valve. • There should be no excessive accumulates inside the EGR valve. • There should be no bending with the valve shaft or valve itself inside the EGR valve. 3)
4) 5) 6) 7) 8) 9) 10) 11) 12) 13)
If a problem is discovered, repair or replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Installation". Turn OFF the starter switch. Disconnect the harness connector from the EGR valve. Inspect the EGR valve harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the EGR valve circuit between the ECM and the EGR valve for an open circuit and high resistance. If a problem is discovered, repair the EGR valve circuit. Inspect the solenoid circuit between the ECM and EGR valve. • There should be no short to GND. • There should be no short to the battery or ignition power supply circuit. • There should be no short between the circuits. • There should be no short to EGR position sensor circuit.
14) 15)
3.
If a problem is discovered, repair the solenoid circuit. If the circuit is normal, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Installation".
DTC P1404 Confirm Resolution
84402827B - May 2011 4023G-57
Engine-side Trouble 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P1455 (Flash Code 132) PM Over Accumulation 1.
DTC P1455 Diagnostics 1) 2)
Check with the operator if the DPD light has blinked before. If necessary, explain DPD regeneration. • Check with the operator if the engine operating time was short. • Ckeck with the operator if the idling time was too long.
3)
Inspect the DPD differential pressure sensor hose. • There should be no incorrect piping or disconnection.
4) 5)
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor. • DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor.
6)
7)
8)
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system. • There should be no absence or damage of the exhaust pipe gasket. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified. • There should be no damage or excessive deposits on the oxidation catalyst.
9) 10) 11) 12) 13) 14)
84402827B - May 2011 4023G-58
If a problem is discovered, repair or replace the exhaust system. Inspect the DPD assembly. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection". If a problem is discovered, replace the DPD assembly. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. Inspect the mass air flow sensor with the trouble diagnosis scan tool. If a problem is discovered, replace the mass air flow sensor.
Engine-side Trouble 15) 16) 17) 18) 19) 20) 21)
22) 23)
24)
34)
Use the trouble diagnosis scan tool to check if the boost pressure and atmospheric pressure are operating properly. Inspect the air cleaner element. Refer to "1.Engine 1F.Induction(6HK1X) Air cleaner element Inspection". If a problem is discovered, replace the air cleaner element. Check the intake duct for a clogging, hole, and leakage. If a problem is discovered, replace the intake duct. Inspect the intake throttle valve for fixing. If a problem is discovered, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". Inspect the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Inspection". If a problem is discovered, replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Installation". Inspect the quality of fuel.
35)
36) 37) 38) 39)
ANNOTATION: • After the DPD forced slow regeneration is completed, replace the engine oil. 40) 41)
ANNOTATION: 42)
• An appropriate fuel is used. 25)
Turn the starter switch ON for 30 seconds. 43)
ANNOTATION: • Do not start the engine. • This is for the DPD differential pressure sensor to relearn. 26) 27) 28) 29) 30) 31) 32) 33)
Clear the DTC using the trouble diagnosis scan tool. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. Confirm that the exhaust temperature is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F}
Use the trouble diagnosis scan tool to check if the exhaust differential pressure data display is at or below the standard value. Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1 psi} If it is at or above the standard value, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Reassembly". If the DPD filter has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. When a DTC has been detected, clear it using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform the DPD forced slow regeneration with the trouble diagnosis scan tool.
44)
45)
2.
Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. Confirm that the exhaust temperature is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 psi} If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection".
DTC P1455 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-59
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P1471 (Flash Code 149) DPD Insufficient Regeneration 1.
13) 14)
DTC P1471 Diagnostics 1)
15)
Inspect the DPD differential pressure sensor hose.
16)
ANNOTATION:
• There should be no incorrect piping or disconnection. 2) 3)
• Do not start the engine. • This is for the DPD differential pressure sensor to relearn.
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor. 17) 18)
• DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor. 4)
5)
6)
19)
8) 9)
10) 11) 12)
• When a DTC has been detected, clear it using the trouble diagnosis scan tool. 20)
If the situation falls in the area C or D, use the trouble diagnosis scan tool to perform the DPD forced slow regeneration. ANNOTATION: • When a DTC has been detected, clear it using the trouble diagnosis scan tool. • After the DPD forced slow regeneration is completed, replace the engine oil.
21) 22)
If a problem is discovered, repair or replace the exhaust system. Inspect the exhaust gas temperature sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Inspection". If a problem is discovered, replace the exhaust gas temperature sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Inspect the air cleaner element. Refer to "1.Engine 1F.Induction(6HK1X) Air cleaner element Inspection". If a problem is discovered, replace the air cleaner element. Inspect the air intake system. • There should be no crush, limited flow, or damage of the duct between the air cleaner and intake manifold. • The intake system should not be modified. • There should be no air leak with the intake system.
Start the engine. Use the trouble diagnosis scan tool to check the DPD accumulation status and the DPD time status, and confirm the corresponding area from the DPD status table. If the situation falls in the area A or B, use the trouble diagnosis scan tool to perform the DPD forced regeneration. ANNOTATION:
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system. • There should be no absence or damage of the exhaust pipe gasket. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified.
7)
If a problem is discovered, repair the intake system. Use the trouble diagnosis scan tool to inspect the mass air flow sensor. If a problem is discovered, replace the mass air flow sensor. Turn the starter switch ON for 30 seconds.
23) 24)
25)
26)
2.
Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. Confirm that the exhaust temperature is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 psi} If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection".
DTC P1471 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-60
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance 1.
1.
DTC P1621 Diagnostics 1) 2) 3) 4) 5) 6)
7) 8) 2.
DTC P1655 (Flash Code 57) Sensor Reference Voltage Circuit
Confirm that the connecting sections of all tools are securely connected. Confirm that the programming device is operating normally. Turn the starter switch OFF, and wait for 30 seconds. Turn ON the starter switch. Use the trouble diagnosis scan tool to check if a DTC has been detected. If a DTC has been detected, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1655 Diagnostics 1) 2) 3) 4)
5)
6) 7)
DTC P1621 Confirm Resolution 1) 2) 3) 4)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
8) 9)
10) 11)
12)
13) 14) 15) 16)
17)
18) 19) 20) 84402827B - May 2011 4023G-61
Turn OFF the starter switch. Disconnect the harness connector from the boost sensor. Turn ON the starter switch. Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the boost sensor 5 V power supply circuit between the ECM and the boost sensor. If a problem is discovered, repair the boost sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the intake throttle position sensor 5 V power supply circuit between the ECM and the intake throttle valve. If a problem is discovered, repair the intake throttle position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the battery or ignition power supply with the EGR valve position sensor 5 V power supply circuit between the ECM and EGR valve. If a problem is discovered, repair the EGR valve position sensor 5 V power supply circuit. If it is at or below the standard value, measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the boost sensor. Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Removal". Refer to "1.Engine 1F.Induction(6HK1X) Boost sensor Installation". If it is at or below the standard value, turn the starter switch OFF. Remove the harness connector from the intake throttle valve. Turn ON the starter switch. Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". If it is at or below the standard value, turn the starter switch OFF. Disconnect the harness connector from the EGR valve. Turn ON the starter switch.
Engine-side Trouble 21)
22)
23)
24) 25)
26) 27)
28) 29)
30) 31) 2.
Measure the voltage between the boost sensor 5 V power supply terminal and GND of the boost sensor harness connector. Voltage： 4.5 V If it is at or above the standard value, replace the EGR valve. Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Removal". Refer to "1.Engine 1H.Aux. Emission Control Devices(6HK1X) EGR valve Installation". If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the boost sensor 5 V power supply circuit between the ECM and the boost sensor. If a problem is discovered, repair the boost sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the intake throttle position sensor 5 V power supply circuit between the ECM and the intake throttle valve. If a problem is discovered, repair the intake throttle position sensor 5 V power supply circuit. Inspect to see if there is a short circuit to the GND with the EGR valve position sensor 5 V power supply circuit between the ECM and EGR valve. If a problem is discovered, repair the EGR valve position sensor 5 V power supply circuit. Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit 1.
DTC P1669 Diagnostics 1) 2) 3) 4)
ANNOTATION: • When the fuse is blown again, repair the cause of fuse meltdown. 5) 6) 7) 8) 9)
10) 11) 12) 13)
14)
15) 16) 17)
DTC P1655 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Confirm that the monitor panel operates properly. Turn OFF the starter switch. Inspect the fuse. If a problem is discovered, replace the fuse.
18) 19) 20) 21)
22) 23) 24) 25) 26) 27) 28)
84402827B - May 2011 4023G-62
Turn OFF the starter switch. Disconnect the harness connector from the ECM. Turn ON the starter switch. Check to see if the DPD light is off. If the DPD light is not turned off, repair the short circuit to GND in the DPD light control circuit between the ECM and the monitor panel. Turn OFF the starter switch. Remove the fuse. Turn ON the starter switch. Measure the voltage between the DPD light control circuit and GND of the ECM harness connector. Voltage： 1.0 V If it is at or above the standard value, repair the short circuit to the battery or ignition power supply circuit in the DPD light control circuit between the ECM and the monitor panel. Turn OFF the starter switch. Install the fuse. Connect the test cable with fuse between the DPD light control circuit and GND of the ECM harness connector. Turn ON the starter switch. If the DPD light turns on, inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. If the DPD light does not turn on, remove the DPD light bulb from the monitor panel. Inspect the DPD light bulb. Replace the valve if a problem is discovered. Inspect to see if there is an open circuit or high resistance in the ignition power supply circuit between the fuse and the monitor panel. If a problem is discovered, repair the ignition power supply circuit.
Engine-side Trouble 29) 30) 31) 32) 33) 2.
Inspect to see if there is an open circuit or high resistance in the DPD light control circuit between the ECM and the monitor panel. If a problem is discovered, repair the control circuit. Inspect the monitor panel harness connector for a contact failure. If a problem is discovered, repair the harness connector. When the harness connector is normal, replace the monitor panel.
DTC P1669 Confirm Resolution 1) 2) 3) 4) 5)
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit 1.
DTC P2146 Diagnostics 1) 2) 3) 4)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Turn the starter switch ON, and wait for 40 seconds. Start the engine. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn the starter switch OFF. Disconnect the harness connector from the cylinder head injector harness intermediate connector. Turn the starter switch ON. Measure the resistance between the solenoid control circuit and a normal GND. ANNOTATION: • Solenoid control circuit - normal GND of the first cylinder injector • Solenoid control circuit - normal GND of the second cylinder injector • Solenoid control circuit - normal GND of the third cylinder injector
5)
6) 7)
Resistance： 10.0 MΩ If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the control circuit between the ECM and injector harness intermediate connector. If a problem is discovered, repair the control circuit. Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector. • There should be no short to the battery or ignition power supply. • There should be no short to GND.
8) 9)
10) 11) 12) 13) 14) 15) 16) 17)
18)
84402827B - May 2011 4023G-63
If a problem is discovered, repair the charge voltage circuit. If the charge voltage circuit is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the injector harness intermediate connector. Disconnect the ECM harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. ECM and components The ECM is designed to maintain regulation levels of exhaust gases while obtaining excellent fuel efficiency. The ECM monitors various engine functions via the sensors such as the crankshaft position sensor. If a problem is discovered, repair the charge voltage circuit.
Engine-side Trouble 19) 20) 21) 22) 23) 24) 25) 26)
27)
28) 29)
2.
Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(6HK1X) Cylinder head cover Removal". Inspect the injector harness tightening nut for looseness. If the injector harness tightening nut is loose, tighten it. Inspect to see if any foreign matter is attached to the injector terminal. If any foreign matter is attached to the injector terminal, remove it. Inspect the injector harness intermediate harness connector for a contact failure. If a problem is discovered, repair the injector harness intermediate connector. Check if insulation resistance of the first cylinder, second cylinder, and third cylinder injector is at or above the standard value. Resistance： 1.0 MΩ If any injector is at or below the standard value, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. If all the resistance values are at or above the standard value, repair or replace the injector harness.
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit 1.
DTC P2149 Diagnostics 1) 2) 3) 4)
ANNOTATION: • Solenoid control circuit - normal GND of the fourth cylinder injector • Solenoid control circuit - normal GND of the fifth cylinder injector • Solenoid control circuit - normal GND of the sixth cylinder injector 5)
6) 7)
DTC P2146 Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Turn OFF the starter switch. Disconnect the harness connector from the cylinder head injector harness intermediate connector. Turn the starter switch ON. Measure the resistance between the solenoid control circuit and a normal GND.
Resistance： 10.0 Ω If it is at or below the standard value, inspect to see if there is a short circuit to the GND with the control circuit between the ECM and injector harness intermediate connector. If a problem is discovered, repair the control circuit. Inspect the charge voltage circuit between the ECM and the injector harness intermediate connector. • There should be no short to the battery or ignition power supply. • There should be no short to GND.
8) 9)
10) 11) 12) 13) 14) 15) 16) 17)
18) 19)
84402827B - May 2011 4023G-64
If a problem is discovered, repair the charge voltage circuit. If the charge voltage circuit is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM. Inspect the injector harness intermediate connector for a contact failure. If a problem is discovered, repair the injector harness intermediate connector. Disconnect the ECM harness connector. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect to see if there is an open circuit or high resistance with the charge voltage circuit between the ECM and the injector harness intermediate connector. If a problem is discovered, repair the charge voltage circuit. Remove the cylinder head cover. Refer to "1.Engine 1B.Mechanical(6HK1X) Cylinder head cover Removal".
Engine-side Trouble 20) 21) 22) 23) 24) 25) 26)
27)
28) 29)
2.
Inspect the injector harness tightening nut for looseness. If the injector harness tightening nut is loose, tighten it. Inspect to see if any foreign matter is attached to the injector terminal. If any foreign matter is attached to the injector terminal, remove it. Inspect the injector harness intermediate harness connector for a contact failure. If a problem is discovered, repair the injector harness intermediate connector. Check to see if insulation resistance of the fourth cylinder, fifth cylinder, and sixth cylinder injector is at or above the standard value. Resistance： 1.0 MΩ If any injector is at or below the standard value, replace the relevant injector. Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Removal". Refer to "1.Engine 1C.Fuel System(6HK1X) Injector Installation". When the injector has been replaced, set the injector ID code on the ECM. If all the resistance values are at or above the standard value, repair or replace the injector harness.
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low 1. 2.
1) 2) 3) 4)
5)
6) 7) 8)
DTC P2149 Confirm Resolution 1) 2) 3) 4) 5)
DTC P2228 Priority DTC DTC P0651 DTC P2228 Diagnostics
9)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Engine Control (6HK1X) 1A-103 Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
10) 11) 12)
Turn OFF the starter switch. Disconnect the harness connector from the atmospheric pressure sensor. Turn ON the starter switch. Measure the voltage between the atmospheric pressure sensor 5 V power supply circuit and GND. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the atmospheric pressure sensor. If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the atmospheric pressure sensor 5 V power supply circuit and the signal circuit. Check the atmospheric pressure sensor display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the atmospheric pressure sensor harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the atmospheric pressure sensor. If it is at or below the standard value, inspect the signal circuit between the ECM and the atmospheric pressure sensor. • There should be no open circuit or high resistance. • There should be no short to GND.
13) 14) 15) 16)
17) 18) 3.
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P2228 Confirm Resolution 1) 2) 3)
84402827B - May 2011 4023G-65
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine.
Engine-side Trouble 4) 5)
Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High 1. 2.
DTC P2229 Priority DTC P0651 DTC P2229 Diagnostics 1) 2) 3) 4)
Turn OFF the starter switch. Disconnect the harness connector from the atmospheric pressure sensor. Check the atmospheric pressure sensor display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the atmospheric pressure sensor. • There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply.
5) 6) 7) 8) 9) 10)
11) 12) 13) 14)
15) 16) 3.
If a problem is discovered, repair the signal circuit. Connect the test light between the atmospheric pressure sensor GND circuit and battery power supply. If the test light comes on, inspect the atmospheric pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the atmospheric pressure sensor. If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the atmospheric pressure sensor. If a problem is discovered, repair the GND circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P2229 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-66
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
18)
1.
19)
2.
17)
DTC P2452 Priority DTC DTC P2456 DTC P2452 Diagnostics 1)
20)
Inspect the DPD differential pressure sensor hose. • There should be no incorrect piping or disconnection.
2) 3)
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor.
21)
• DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor. 4)
5)
6)
22) 23)
ANNOTATION: • Do not start the engine. • This is for the DPD differential pressure sensor to relearn.
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system.
24) 25) 26) 27)
8) 9) 10) 11) 12) 13) 14) 15) 16)
If a problem is discovered, repair or replace the exhaust system. Inspect the DPD assembly. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection". If a problem is discovered, replace the DPD assembly. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. Turn OFF the starter switch. Disconnect the harness connector from the DPD differential pressure sensor. Inspect the DPD differential pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the ECM. Inspect the ECM harness connector for a contact failure.
Clear the DTC using the trouble diagnosis scan tool. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform the DPD forced regeneration with the trouble diagnosis scan tool. ANNOTATION: • When the DPD filter is replaced by a new one, do not perform the DPD forced regeneration.
• There should be no absence or damage of the exhaust pipe gasket. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified. 7)
If a problem is discovered, repair the harness connector. Inspect the signal circuit between the ECM and the DPD differential pressure sensor for a high resistance. If a problem is discovered, repair the signal circuit. If the harness connector and circuit are normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Restore the actual unit. Turn the starter switch ON for 30 seconds.
28)
29) 30)
31)
3.
Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or above the standard value. Specified value: 0.5 kPa {0.01 kgf/cm2 / 0.1 psi}
DTC P2452 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-67
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance 1. 2.
13) 14) 15)
DTC P2453 Priority DTC DTC P2456 DTC P2453 Diagnostics
16)
1)
Inspect the DPD differential pressure sensor hose.
17)
• There should be no incorrect piping or disconnection.
18)
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor.
19) 20)
2) 3)
• DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor. 4)
5)
6)
ANNOTATION: • Do not start the engine. • This is for the DPD differential pressure sensor to relearn. 21) 22)
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system.
23) 24) 25)
26) 27)
• There should be no missing or damage with the gasket of the exhaust pipe. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified. • There should be no flow limitation or crush of the exhaust system. 7) 8) 9) 10) 11) 12)
If a problem is discovered, repair or replace the exhaust system. Turn OFF the starter switch. Disconnect the harness connector from the DPD differential pressure sensor. Inspect the DPD differential pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. Disconnect the harness connector from the ECM.
Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. Inspect the signal circuit between the ECM and the DPD differential pressure sensor for a high resistance. If a problem is discovered, repair the signal circuit. If the harness connector and signal circuit are normal, replace the DPD assembly. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. Restore the actual unit. Turn the starter switch ON for 30 seconds.
28)
29)
3.
Clear the DTC using the trouble diagnosis scan tool. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform the DPD forced regeneration with the trouble diagnosis scan tool. Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 psi} If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection".
DTC P2453 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-68
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low 1. 2.
11)
DTC P2454 Priority DTC DTC P0697 DTC P2454 Diagnostics 1) 2) 3) 4)
5)
12)
Turn OFF the starter switch. Disconnect the harness connector from the DPD differential pressure sensor. Turn ON the starter switch. Measure the voltage between the DPD differential pressure sensor 5 V power supply circuit and GND. Voltage： 4.5 V If it is at or below the standard value, inspect to see if there is an open circuit or high resistance with the 5 V power supply circuit between the ECM and the DPD differential pressure sensor.
13)
• There should be no open circuit or high resistance. • There should be no short to GND. 14) 15)
ANNOTATION: 16)
• The DPD differential pressure sensor shares the 5 V power supply circuit with other sensors. • The DTC set on a sensor which shares this circuit may be detected. 6) 7) 8) 9)
10)
If a problem is discovered, repair the 5 V power supply circuit. Connect the test cable with fuse between the 5 V power supply circuit and signal circuit of the DPD differential pressure sensor. Check the exhaust differential pressure display with the trouble diagnosis scan tool. Voltage： 4.5 V If it is at or above the standard value, inspect to see if there is a contact failure with the DPD differential pressure sensor harness connector. If a problem is discovered, repair the harness connector.
If the harness connector is normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". If it is at or below the standard value, inspect the signal circuit between the ECM and the DPD differential pressure sensor.
17)
18) 19) 3.
If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P2454 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-69
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
10)
1.
11)
2.
DTC P2455 Priority DTC DTC P0697 DTC P2455 Diagnostics 1) 2) 3) 4)
Turn OFF the starter switch. Disconnect the harness connector from the DPD differential pressure sensor. Check the exhaust differential pressure display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or above the standard value, inspect the signal circuit between the ECM and the DPD differential pressure sensor.
ANNOTATION: • The DPD differential pressure sensor shares the GND circuit with other sensors. • The DTC may be detected on a sensor which shares this circuit. 12) 13)
• There should be no short to the battery or ignition power supply. • There should be no short to the 5 V power supply. 5) 6) 7) 8) 9)
If a problem is discovered, repair the signal circuit. Connect the test light between the GND circuit and battery power supply of the DPD differential pressure sensor. If the test light comes on, inspect DPD differential pressure sensor harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation".
When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". If the test light does not come on, inspect to see if there is an open circuit or high resistance with the GND circuit between the ECM and the DPD differential pressure sensor.
14) 15)
16) 17) 3.
If a problem is discovered, repair the GND circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P2455 Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-70
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P2458 (Flash Code 139) DPD Regeneration Duration 1.
2.
DTC DTC DTC DTC DTC DTC DTC DTC
P2458 Priority DTC P0426 P0427 P0428 P042B P042C P042D P2458 Diagnostics
1)
Inspect the DPD differential pressure sensor hose.
9) 10)
ANNOTATION: • Do not start the engine. • This is for the DPD differential pressure sensor to relearn. 11) 12) 13)
• There should be no incorrect piping or disconnection. 2) 3)
14)
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor.
5)
6)
• When a DTC has been detected, clear it using the trouble diagnosis scan tool. 15)
• When a DTC has been detected, clear it using the trouble diagnosis scan tool. • After the DPD forced slow regeneration is completed, replace the engine oil.
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system.
8)
If a problem is discovered, repair or replace the exhaust system. Inspect the engine cooling system for a factor causing overheat. Refer to "1.Engine 1D.Cooling(6HK1X) Coolant Inspection". Refer to "1.Engine 1D.Cooling(6HK1X) Drive belt Inspection". Refer to "1.Engine 1D.Cooling(6HK1X) Thermostat Inspection". Refer to "1.Engine 1D.Cooling(6HK1X) Water pump assembly Inspection". Refer to "1.Engine 1D.Cooling(6HK1X) Radiator Inspection".
If the situation falls in the area C or D, use the trouble diagnosis scan tool to perform the DPD forced slow regeneration. ANNOTATION:
16)
17) 18)
• There should be no absence or damage of the exhaust pipe gasket. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified. • There should be no incorrect detection or slow response from the exhaust temperature sensor. 7)
Turn the starter switch OFF for 30 seconds. Start the engine. Use the trouble diagnosis scan tool to check the DPD accumulation status and the DPD time status, and confirm the corresponding area from the DPD status table. If the situation falls in the area A or B, use the trouble diagnosis scan tool to perform the DPD forced regeneration. ANNOTATION:
• DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor. 4)
If a problem is discovered, repair the cooling system. Turn the starter switch ON for 30 seconds.
19)
20)
3.
Use the trouble diagnosis scan tool to confirm that the exhaust temperature (before the filter) display is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure data display when the exhaust temperature (in front of the filter) data display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Confirm if the exhaust differential pressure data display is at or below the standard value. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 psi} If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection".
DTC P2458 Confirm Resolution 1) 2)
84402827B - May 2011 4023G-71
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
1.
2.
2.
DTC DTC DTC DTC DTC
P042B Priority DTC P0093 P042C P1093 P042B Diagnostics
1)
Inspect the exhaust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Inspection". If a problem is discovered, replace the exhaust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Inspect the DPD filter for a damage. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection". If a problem is discovered, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Reassembly". Perform the DPD regeneration data reset with the trouble diagnosis scan tool.
2)
3) 4)
5) 3.
1.
DTC P042C Priority DTC DTC P0697 DTC P042C Diagnostics 1) 2) 3)
4)
5) 6) 7) 8) 9)
DTC P042B Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
10) 11) 3.
Turn OFF the starter switch. Disconnect the harness connector from the exhaust gas temperature sensor 2. Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool. Voltageďź&#x161; 4.5 V If it is at or above the standard value, replace the exhaust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Inspect to see if there is a short circuit to the GND with the signal circuit between the ECM and the exhaust gas temperature sensor 2. If a problem is discovered, repair the signal circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P042C Confirm Resolution 1) 2) 3) 4) 5)
84402827B - May 2011 4023G-72
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2 1. 2.
16)
17)
DTC P042D Priority DTC DTC P0697 DTC P042D Diagnostics 1) 2) 3) 4)
5)
6) 7) 8)
9)
10) 11) 12) 13)
14) 15)
18)
Turn OFF the starter switch. Disconnect the harness connector from the exhaust gas temperature sensor 2. Turn ON the starter switch. Measure the voltage between the exhaust gas temperature sensor 2 signal circuit and normal GND. Voltage： 5.5 V If it is at or above the standard value, inspect to see if there is a short circuit to the battery or ignition power supply with the signal circuit between the ECM and the exhaust gas temperature sensor 2. If a problem is discovered, repair the signal circuit. Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and GND circuit. Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool. Voltage： 0.1 V If it is at or below the standard value, inspect to see if there is a short circuit to the 5 V power supply circuit with the signal circuit between the ECM and the exhaust gas temperature sensor 2. If a problem is discovered, repair the signal circuit. Inspect to see if there is a contact failure with the exhaust gas temperature sensor 2 harness connector. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the exhaust gas temperature sensor 2. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust gas temperature sensor Installation". Connect the test cable with fuse between the exhaust gas temperature sensor 2 signal circuit and normal GND. Check the exhaust temperature sensor (before the oxidation catalyst) display with the trouble diagnosis scan tool. Voltage： 0.1 V
If it is at or above the standard value, inspect to see if there is an open circuit or high resistance with the signal circuit between the ECM and the exhaust gas temperature sensor 2. If a problem is discovered, repair the signal circuit. Inspect to see if there is an open circuit or high resistance in the GND circuit between the ECM and the exhaust gas temperature sensor 2. ANNOTATION: • The exhaust gas temperature sensor 2 shares the GND circuit with other sensors. • The DTC may be detected on a sensor which shares this circuit.
19) 20) 21) 22)
23) 24) 3.
If a problem is discovered, repair the GND circuit. Inspect the ECM harness connector for a contact failure. If a problem is discovered, repair the harness connector. If the harness connector is normal, replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
DTC P042D Confirm Resolution 1) 2) 3)
4)
5)
6)
84402827B - May 2011 4023G-73
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine, and warm it up until the coolant temperature reaches the standard value. Specified value： 70 °C {158 °F} Repeatedly rev the engine in neutral to increase the engine rpm while checking the exhaust temperature sensor (in front of the oxidation catalyst) display with the trouble diagnosis scan tool. Use the trouble diagnosis scan tool to confirm that the exhaust temperature sensor (before the oxidation catalyst) display does not exceed the standard value. Voltage ： 4.8 V Engine Control (6HK1X) 1A-57 Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance 1.
1.
DTC P242F Diagnostics
DTC P060B Diagnostics
1)
1)
2)
2) 3) 2.
DTC P242F (Flash Code 131) DPD Restriction
Replace the ECM. Refer to "1.Engine 1J.Electrical(6HK1X) ECM Removal". Refer to "1.Engine 1J.Electrical(6HK1X) ECM Installation". Set the injector ID code on the ECM. Perform the unit difference learning of the fuel supply pump to the ECM.
• Check with the operator if the engine operating time was short. • Ckeck with the operator if the idling time was too long. 3)
DTC P060B Confirm Resolution 1) 2) 3) 4) 5)
Clear the DTC using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Perform a test-run. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Check with the operator if the DPD light has blinked before. If necessary, explain DPD regeneration.
Inspect the DPD differential pressure sensor hose. • There should be no incorrect piping or disconnection.
4) 5)
If a problem is discovered, repair the hose. Inspect the DPD differential pressure sensor. • DPD differential pressure sensor unit should not be damaged. • There should be no dirt or foreign matter blocking the DPD differential pressure sensor entrance. • There should be no detection error or slow response from the DPD differential pressure sensor.
6)
7)
8)
If a problem is discovered, replace the DPD differential pressure sensor. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Removal". Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Installation". When the DPD differential pressure sensor has been replaced, perform the 0-point correction. Refer to "1.Engine 1G.Exhaust(6HK1X) Exhaust differential pressure sensor Inspection". Inspect the exhaust system. • There should be no absence or damage of the exhaust pipe gasket. • There should be no exhaust gas leak from the exhaust system. • The exhaust system should not be modified. • There should be no damage or excessive deposits on the oxidation catalyst.
9) 10) 11) 12) 13) 14)
84402827B - May 2011 4023G-74
If a problem is discovered, repair or replace the exhaust system. Inspect the DPD assembly. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection". If a problem is discovered, replace the DPD assembly. If the DPD assembly has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. Inspect the mass air flow sensor with the trouble diagnosis scan tool. If a problem is discovered, replace the mass air flow sensor.
Engine-side Trouble 15) 16) 17) 18) 19) 20) 21) 22) 23)
24) 25)
26)
35)
Use the trouble diagnosis scan tool to check if the boost pressure and atmospheric pressure are operating properly. Inspect the air cleaner element. Refer to "1.Engine 1F.Induction(6HK1X) Air cleaner element Inspection". If a problem is discovered, replace the air cleaner element. Inspect the intercooler. Refer to "1.Engine 1F.Induction(6HK1X) Intercooler Inspection". If a problem is discovered, replace the intercooler. Check the intake duct for a clogging, hole, and leakage. If a problem is discovered, replace the intake duct. Inspect the intake throttle valve for fixing. If a problem is discovered, replace the intake throttle valve. Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Removal". Refer to "1.Engine 1B.Mechanical(6HK1X) Intake throttle valve Installation". Inspect the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Inspection". If a problem is discovered, replace the turbocharger assembly. Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Removal". Refer to "1.Engine 1F.Induction(6HK1X) Turbocharger assembly Installation". Inspect the quality of fuel.
36)
37)
38) 39) 40) 41)
ANNOTATION: • After the DPD forced slow regeneration is completed, replace the engine oil. 42) 43)
ANNOTATION: • An appropriate fuel is used. 27)
44)
Turn the starter switch ON for 30 seconds. ANNOTATION:
45)
• Do not start the engine. • This is for the DPD differential pressure sensor to relearn. 28) 29) 30) 31) 32) 33) 34)
Clear the DTC using the trouble diagnosis scan tool. Perform the DPD regeneration data reset with the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Start the engine. Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. Confirm that the exhaust temperature is at or below the standard value. Specified value: 130°C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value.
Check the exhaust differential pressure display when the exhaust temperature (before the filter) display has reached the standard value with the throttle accelerator switch fully depressed. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. Specified value: 7.5 kPa {0.08 kgf/cm2 / 1.1 psi} If it is at or above the standard value, replace the DPD filter. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Disassembly". Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Reassembly". If the DPD filter has been replaced, use the trouble diagnosis scan tool to perform DPD regeneration data reset. When a DTC has been detected, clear it using the trouble diagnosis scan tool. Turn the starter switch OFF for 30 seconds or longer. Perform the DPD forced slow regeneration with the trouble diagnosis scan tool.
46)
47)
2.
Check the exhaust temperature (before the filter) display with the trouble diagnosis scan tool. Confirm that the exhaust temperature is at or below the standard value. Specified value: 130 °C {266 °F} If it is at or above the standard value, idle the engine until it falls to or below the standard value. Check the exhaust differential pressure display when the exhaust temperature 1 (in front of the filter) display has reached the standard value with the engine revolution increased to the maximum revolution speed without load. Specified value: 150 °C {302 °F} Use the trouble diagnosis scan tool to check if the exhaust differential pressure display is at or below the standard value. Specified value: 1.8 kPa {0.02 kgf/cm2 / 0.3 psi} If it is at or above the standard value, perform ash removal. Refer to "1.Engine 1G.Exhaust(6HK1X) DPD assembly Inspection".
DTC P242F Confirm Resolution 1) 2)
84402827B - May 2011 4023G-75
Turn ON the starter switch. Use the trouble diagnosis scan tool to confirm that a DTC has not been detected.
Engine-side Trouble
84402827B - May 2011 4023G-76
Section 4023H
Main Unit-side Trouble
84402827B - May 2011
84402827B - May 2011
CONTENTS Main Unit-side Trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Diagnostic Trouble Code: 7063 Return Filter Clogging Pressure Switch Signal Abnormality. . . . . . . . . . . . . . . . . . 34 (Breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 (Other than breaker specifications) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . 36 Diagnostic Trouble Code: 7066 Bucket-close Pilot Pressure Sensor Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 38 Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . 54 Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock Signal Abnormality . . . . . . . . . . . . . . . . . . . 58 Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . 59 Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . 61 Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality. . . . . . . . . . . . . . . . . . . . . . . . . 66 Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Signal Abnormality . . . . . . . . . . . . . . . 70 Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality. . . . . . . . . . . . . . . . . . . . . 75 Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature (105°C or higher) . . . . . . . . . . . . . . . . . . . 77 Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature (110°C or higher). . . . . . . . . . . . . . . . . . . . 77 Diagnostic Trouble Code: 7402 Abnormally High Coolant Temperature (120°C or higher) . . . . . . . . . . . . . . . . . . . 77 Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . 78 84402827B - May 2011 4023H-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature (80°C or higher), 7406 Abnormally High Boost Temperature (90°C or higher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Diagnostic Trouble Code: 7421 Coolant Level Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Diagnostic Trouble Code: 7423 Air Cleaner Clogging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Diagnostic Trouble Code: 7600 CAN Bus Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Diagnostic Trouble Code: 7601 Monitor Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Diagnostic Trouble Code: 7602 ECM Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Diagnostic Trouble Code: 7604 Computer B Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Diagnostic Trouble Code: 7605 ECM Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Diagnostic Trouble Code: 7606 EEPROM Data Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Diagnostic Trouble Code: 7607 Computer C Communication Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
84402827B - May 2011 4023H-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Main Unit-side Trouble Main Unit-side Trouble Diagnostic Trouble Code: 7000 P1 Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
8
Turn the key switch ON. Check whether diagnostic trouble code: 7000 is displayed.
Is diagnostic trouble code: 7000 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7000 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D45. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D45 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7000 displayed? 1. Check the P1 pressure sensor voltage 4.75 V or on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D45 4.75 V or Go to Step 6 harness side. lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D45 0.25 V or Go to Step 7 harness side. lower Is it 0.25 V or lower? Judge as a computer A defect. …Replace computer A 1. Inspect the P1 pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D45. 4. Measure the resistance between termi- About 10 Go to Step 9 nals 1 and 3 of the CN. D45 P1 pressure kΩ sensor side.
When 0.25 V or lower, go to Step 8
W400 harness defect (short). Replace
Y410 harness defect (short). Replace
BW420 harness defect (short). Replace
P1 pressure sensor defect. Replace
Is it about 10 kΩ? Inspect for shorts to ground and disconnections. 1. 9 2.
10
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D45 the D45
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D45 harness side. Is there continuity? 84402827B - May 2011 4023H-3
W400 or Y410 harness defect (short). Go to Step 10 Replace
Go to Step 11
BW420 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
11
12
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D45 About 5 V harness side.
Yes
No
Go to Step 12
W400 or W401 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D45 0.25 V or Computer A defect. Y410 harness defect (disconnection). Reharness side. higher Replace place Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-4
COMPUTER A PRESS. SENSOR (P1)
Main Unit-side Trouble Diagnostic Trouble Code: 7001 P2 Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7001 is displayed.
Is diagnostic trouble code: 7001 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7001 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D46. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D46 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7001 displayed? 1. Check the P2 pressure sensor voltage 4.75 V or on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W401 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D46 4.75 V or L411 harness defect Go to Step 6 harness side. (short). Replace lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D46 0.25 V or Computer A defect. BW420 or BW421 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the P1 pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D46. P2 pressure sensor 4. Measure the resistance between termi- About 10 Go to Step 8 defect. Replace nals 1 and 3 of the CN. D46 P2 pressure kΊ sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D46 the D46
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D46 harness side. Is there continuity?
84402827B - May 2011 4023H-5
W400, W401, or L411 harness defect Go to Step 9 (short). Replace
Go to Step 10
BW420 or BW421 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D46 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W401 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D46 0.25 V or Computer A defect. L411 harness defect (disconnection). Reharness side. higher Replace place Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-6
COMPUTER A PRESS. SENSOR (P1)
Main Unit-side Trouble Diagnostic Trouble Code: 7002 N1 Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7002 is displayed.
Is diagnostic trouble code: 7002 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7002 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D47. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D47 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7002 displayed? 1. Check the N1 pressure sensor voltage 4.75 V or on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W402 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D47 4.75 V or Lg412 harness deGo to Step 6 harness side. fect (short). Replace lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D47 0.25 V or Computer A defect. BW420 or BW422 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the P1 pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D47. N1 pressure sensor 4. Measure the resistance between termi- About 10 Go to Step 8 defect. Replace nals 1 and 3 of the CN. D47 N1 pressure kΊ sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D47 the D47
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D47 harness side. Is there continuity?
84402827B - May 2011 4023H-7
W400, W402, or Lg412 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BW420 or BW422 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D47 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W402 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D47 0.25 V or Computer A defect. Lg412 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-8
COMPUTER A PRESS. SENSOR (N1)
Main Unit-side Trouble Diagnostic Trouble Code: 7003 N2 Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7003 is displayed.
Is diagnostic trouble code: 7003 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7003 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D48. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D48 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7003 displayed? 1. Check the N2 pressure sensor voltage 4.75 V or on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W403 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D48 4.75 V or G413 harness defect Go to Step 6 harness side. (short). Replace lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D48 0.25 V or Computer A defect. BW420 or BW423 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the N2 pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D48. N2 pressure sensor 4. Measure the resistance between termi- About 10 Go to Step 8 defect. Replace nals 1 and 3 of the CN. D48 N2 pressure kΊ sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D48 the D48
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D48 harness side. Is there continuity?
84402827B - May 2011 4023H-9
W400, W403, or G413 harness defect Go to Step 9 (short). Replace
Go to Step 10
BW420 or BW423 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D48 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W403 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D48 0.25 V or Computer A defect. G413 harness defect (disconnection). Reharness side. higher Replace pair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-10
COMPUTER A PRESS. SENSOR (N2)
Main Unit-side Trouble Diagnostic Trouble Code: 7004 Overload Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7004 is displayed.
Is diagnostic trouble code: 7004 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7004 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D52-1. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D52-1 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7004 displayed? 1. Check the overload pressure sensor voltage on the service support screen. 4.75 V or Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W409 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D52-1 4.75 V or Gr419 harness deGo to Step 6 harness side. lower fect (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D52-1 0.25 V or Computer A defect. BW420 or BW429 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the overload pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D52-1. Overload pressure 4. Measure the resistance between termi- About 10 Go to Step 8 sensor defect. Renals 1 and 3 of the CN. D52-1 overload kΊ place pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between the ground and terminal 1 of the CN. D52-1 harness side. Inspect for continuity between the ground and terminal 2 of the CN. D52-1 harness side.
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D52-1 harness side. Is there continuity?
84402827B - May 2011 4023H-11
W400, W409, or Gr419 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BW420 or BW429 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D52-1 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W409 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D52-1 0.25 V or Computer A defect. Gr419 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-12
COMPUTER A PRESS. SENSOR (HBCV)
Main Unit-side Trouble Diagnostic Trouble Code: 7005 Bottom Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7005 is displayed.
Yes
Go to Step 3
Is diagnostic trouble code: 7005 displayed? 1. Check the bottom pressure sensor volt4.75 V or age on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply
2. 3.
No
Go to Step 2
Is diagnostic trouble code: 7005 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7005 is displayed.
1. 4
Standard value
Action
Turn the key switch OFF and disconnect CN. CR9. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. CR9 harness side.
Go to Step 5
When 0.25 V or lower, go to Step 7
W414 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR9 4.75 V or Y434 harness defect Go to Step 6 harness side. lower (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. CR9 0.25 V or Computer B defect. BW454 harness deharness side. fect (short). Replace lower Replace Is it 0.25 V or lower? Inspect the bottom pressure sensor. 1. 2. 3.
Turn the key switch OFF. Disconnect CN. CR9. About Measure the resistance between termikΊ nals 1 and 3 of the CN. CR9 bottom sensor.
10
Go to Step 8
Bottom pressure sensor defect. Replace
Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1. 8 2.
9
Inspect for continuity between the ground and terminal 1 of the CN. CR9 harness side. Inspect for continuity between the ground and terminal 2 of the CN. CR9 harness side.
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. CR9 harness side. Is there continuity?
84402827B - May 2011 4023H-13
W414 or Y434 harness defect (short). Go to Step 9 Replace
Go to Step 10
BW454 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. CR9 About 5 V harness side.
Yes
No
Go to Step 11
W414 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR9 0.25 V or Computer B defect. Y434 harness defect (disconnection). Reharness side. higher Replace pair or replace Is it 0.25 V or higher?
84402827B - May 2011 4023H-14
Main Unit-side Trouble Diagnostic Trouble Code: 7006 Rod Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7006 is displayed.
Yes
Go to Step 3
Is diagnostic trouble code: 7006 displayed? 1. Check the rod pressure sensor voltage 4.75 V or on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply
2. 3.
No
Go to Step 2
Is diagnostic trouble code: 7006 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7006 is displayed.
1. 4
Standard value
Action
Turn the key switch OFF and disconnect CN. CR10. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. CR10 harness side.
Go to Step 5
When 0.25 V or lower, go to Step 7
W414 or W415 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR10 4.75 V or L435 harness defect Go to Step 6 harness side. (short). Replace lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. CR10 0.25 V or Computer B defect. BW454 or BW455 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? Inspect the rod pressure sensor. 1. 2. 3.
Turn the key switch OFF. Disconnect CN. CR10. About Measure the resistance between termikΊ nals 1 and 3 of the CN. CR10 rod pressure sensor side.
10
Go to Step 8
Rod pressure sensor defect. Replace
Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1. 8 2.
9
Inspect for continuity between the ground and terminal 1 of the CN. CR10 harness side. Inspect for continuity between the ground and terminal 2 of the CN. CR10 harness side.
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. CR10 harness side. Is there continuity?
84402827B - May 2011 4023H-15
W414, W415, or L435 harness defect Go to Step 9 (short). Replace
Go to Step 10
BW454 or BW455 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. CR10 About 5 V harness side.
Yes
No
Go to Step 11
W414 or W415 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR10 0.25 V or Computer B defect. L435 harness defect (disconnection). Reharness side. higher Replace pair or replace Is it 0.25 V or higher?
84402827B - May 2011 4023H-16
Main Unit-side Trouble Diagnostic Trouble Code: 7020 Upper Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7020 is displayed.
Is diagnostic trouble code: 7020 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7020 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D50. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D50 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7020 displayed? 1. Check the upper pressure sensor volt4.75 V or age on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W405 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D50 4.75 V or V415 harness defect Go to Step 6 harness side. lower (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D50 0.25 V or Computer A defect. BW420 or BW425 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the upper pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D50. Upper pressure sen4. Measure the resistance between termi- About 10 Go to Step 8 kΊ sor defect. Replace nals 1 and 3 of the CN. D50 upper pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D50 the D50
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D50 harness side. Is there continuity?
84402827B - May 2011 4023H-17
W400, W405, or V415 harness defect Go to Step 9 (short). Replace
Go to Step 10
BW420 or BW425 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D50 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W405 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D50 0.25 V or Computer A defect. V415 harness defect (disconnection). Reharness side. higher Replace pair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-18
COMPUTER A PRESS. SENSOR (PILOT UPPER)
Main Unit-side Trouble Diagnostic Trouble Code: 7021 Swing Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7021 is displayed.
Is diagnostic trouble code: 7021 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7021 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D49. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D49 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7021 displayed? 1. Check the swing pressure sensor volt4.75 V or age on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W404 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D49 4.75 V or GR414 harness deGo to Step 6 harness side. lower fect (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D49 0.25 V or Computer A defect. BW420 or BW424 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the swing pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D49. Swing pressure sen4. Measure the resistance between termi- About 10 Go to Step 8 kΊ sor defect. Replace nals 1 and 3 of the CN. D49 swing pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D49 the D49
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D49 harness side. Is there continuity?
84402827B - May 2011 4023H-19
W400, W404, or GR414 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BW420 or BW424 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D49 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W404 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D49 0.25 V or Computer A defect. GR414 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-20
COMPUTER A PRESS. SENSOR SWING)
(PILOT
Main Unit-side Trouble Diagnostic Trouble Code: 7022 Travel Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7022 is displayed.
Is diagnostic trouble code: 7022 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7022 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D51. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D51 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7022 displayed? 1. Check the travel pressure sensor volt4.75 V or age on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
W400 or W406 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D51 4.75 V or YG416 harness deGo to Step 6 harness side. lower fect (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D51 0.25 V or Computer A defect. BW420 or BW426 harness defect harness side. lower Replace (short). Replace Is it 0.25 V or lower? 1. Inspect the travel pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D51. Travel pressure sen4. Measure the resistance between termi- About 10 Go to Step 8 kΊ sor defect. Replace nals 1 and 3 of the CN. D51 travel pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D51 the D51
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D51 harness side. Is there continuity?
84402827B - May 2011 4023H-21
W400, W406, or YG416 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BW420 or BW426 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D51 About 5 V harness side.
Yes
No
Go to Step 11
W400 or W406 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D51 0.25 V or Computer A defect. YG416 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
1 2
84402827B - May 2011 4023H-22
COMPUTER A PRESS. SENSOR TRAVEL)
(PILOT
Main Unit-side Trouble Diagnostic Trouble Code: 7023 Arm-in Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7023 is displayed.
Is diagnostic trouble code: 7023 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7023 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D54. Turn the key switch ON. Measure the voltage between the About 5 V ground and terminal 1 of the CN. D54 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7023 displayed? 1. Check the arm-in pressure sensor volt4.75 V or age on the service support screen. Go to Step 4 higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
WL430 harness defect (short). Replace
Is it about 5 V? 1. 1. Measure the voltage between the ground and terminal 2 of the CN. D54 YG445 harness de4.75 V or harness side. Go to Step 6 fect (short). Replace lower Is it 4.75 V or lower? 1. 1. Measure the voltage between the ground and terminal 3 of the CN. D54 0.25 V or Computer B defect. BL450 harness deharness side. fect (short). Replace lower Replace Is it 0.25 V or lower? 1. Inspect the arm-in pressure sensor. 2. Turn the key switch OFF. 3. Disconnect CN. D54. Arm-in pressure sen4. Measure the resistance between termi- About 10 Go to Step 8 kΊ sor defect. Replace nals 1 and 3 of the CN. D54 arm-in pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D54 the D54
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D54 harness side. Is there continuity? 84402827B - May 2011 4023H-23
WL430 or YG445 harness defect Go to Step 9 (short). Replace
Go to Step 10
BL450 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D54 About 5 V harness side.
Yes
No
Go to Step 11
WL430 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D54 0.25 V or Computer B defect. YG445 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
84402827B - May 2011 4023H-24
Main Unit-side Trouble Diagnostic Trouble Code: 7040 Fuel Level Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
Turn the key switch ON. Check whether diagnostic trouble code: 7040 is displayed.
Is diagnostic trouble code: 7040 displayed? 1. Inspect the connection status of each connector and ground. 2. Check whether diagnostic trouble code: 7040 is displayed.
Yes
Turn the key switch OFF and disconnect CN. D57. Measure the resistance between terminals 1 and 2 of the CN. D57 fuel level sensor side.(See the Float position and resistance table.)
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7040 displayed? 1. Check the fuel level sensor resistance 100 Ω or on the service support screen. Go to Step 4 higher Is it 100 Ω or higher? Inspect for disconnection. 1.
4
Standard value
Action
When 2 Ω or lower, go to Step 7
Go to Step 5
Fuel level sensor defect. Replace
Is it the standard value? 1. Inspect for continuity between the ground and terminal 1 of the CN. D57 harness side.
Go to Step 6
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 2 of the CN. D57 About 5 V harness side.
BG660 or BG601 harness defect (disconnection). Repair or replace
GL492 harness deComputer A defect. fect (disconnection). Replace Repair or replace
2.
Is it about 5 V? Inspect for shorts.
7
8
1. 2. 3.
Turn the key switch OFF. Connect CN. D57. Inspect for continuity between the ground and terminal 2 of the CN. D57 harness side.
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D57 0 V harness side. Is it 0 V?
84402827B - May 2011 4023H-25
GL492 harness deGo to Step 8 fect (short). Replace
BG660 or BG601 Computer A defect. harness defect Replace (short). Replace
Main Unit-side Trouble
1 2
84402827B - May 2011 4023H-26
COMPUTER A FUEL LEVEL SENSOR
Main Unit-side Trouble Diagnostic Trouble Code: 7041 Oil Temperature Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
Turn the key switch ON. Check whether diagnostic trouble code: 7041 is displayed.
Is diagnostic trouble code: 7041 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7040 is displayed.
Yes
Turn the key switch OFF and disconnect CN. D56. Measure the resistance between terminals 1 and 2 of the CN. D56 oil temperature sensor side.(See the Oil temperature and resistance table.)
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7040 displayed? 1. Check the oil temperature sensor resistance (or voltage) on the service support 67200 Ω (or 4.93 V) or Go to Step 4 screen. higher Is it 67200 Ω (or 4.93 V) or higher? Inspect for disconnection. 1.
4
Standard value
Action
When 111 Ω (or 0.5 V) or lower, go to Step 7
Go to Step 5
Oil temperature sensor defect. Replace
Is it the standard value? 1. Inspect for continuity between the ground and terminal 1 of the CN. D56 harness side.
Go to Step 6
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 2 of the CN. D56 About 5 V harness side.
BW491 or BW420 harness defect (disconnection). Repair or replace
YB490 harness deComputer A defect. fect (disconnection). Replace Repair or replace
2.
Is it about 5 V? Inspect for shorts.
7
8
1. 2. 3.
Turn the key switch OFF. Connect CN. D56. Inspect for continuity between the ground and terminal 2 of the CN. D56 harness side.
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D56 0 V harness side. Is it 0 V?
84402827B - May 2011 4023H-27
Go to Step 8
YB490 harness defect (short). Replace
BW491 or BW420 Computer A defect. harness defect Replace (short). Replace
Main Unit-side Trouble
1 2
84402827B - May 2011 4023H-28
COMPUTER A HYD. OIL TEMP SENSOR
Main Unit-side Trouble Diagnostic Trouble Code: 7045 Monitor Thermistor Signal Abnormality Step
Standard Yes value Monitor defect. Replace
Action
CAUTION
1. 2. 1
Turn the key switch ON. On the service support DIAG screen, check whether diagnostic trouble code: 7045 (â&#x2014;?) is displayed.
Is diagnostic trouble code: 7045 (â&#x2014;?) displayed?
Contrast correction is performed when the monitor thermistor is at an extremely high or low temperature. Even if the monitor thermistor has a defect, there is a correction function inside the monitor, so the monitor thermistor does not need to be replaced if the monitor contrast is not significantly affected.
84402827B - May 2011 4023H-29
No
Main Unit-side Trouble Diagnostic Trouble Code: 7060 Boom Angle Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7060 is displayed.
Is diagnostic trouble code: 7060 displayed? 1. Check the boom angle sensor voltage 4.8 V on the service support screen. higher Is it 4.8 V or higher? Inspect for shorts to the power supply
2. 3.
1. 2. 3.
Turn the key switch OFF. Disconnect CN. CR11. About Measure the resistance between termikΊ nals 1 and 3 of the CN. CR11 boom angle sensor side.
No
Go to Step 3
or
Turn the key switch OFF and disconnect CN. CR11. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 3 of the CN. CR11 harness side.
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR11 4.8 V harness side. lower Is it 4.8 V or lower? 1. Measure the voltage between the ground and terminal 1 of the CN. CR11 0.2 V harness side. lower Is it 0.2 V or lower? Inspect the boom angle sensor.
Yes
Go to Step 2
Is diagnostic trouble code: 7060 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7060 is displayed.
1. 4
Standard value
Action
or
Go to Step 4
When 0.2 V or lower, go to Step 7
Go to Step 5
W414 or W416 harness defect (short). Replace
Go to Step 6
Lg436 harness defect (short). Replace
BW454 or BW456 or Computer B defect. harness defect Replace (short). Replace
10
Go to Step 8
Boom angle sensor defect. Replace
Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1. 8 2.
9
Inspect for continuity between the ground and terminal 3 of the CN. CR11 harness side. Inspect for continuity between the ground and terminal 2 of the CN. CR11 harness side.
Is there continuity? 1. Inspect for continuity between the ground and terminal 1 of the CN. CR11 harness side. Is there continuity?
84402827B - May 2011 4023H-30
W414, W416, or Lg436 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BW454 or BW456 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 3 of the CN. CR11 About 5 V harness side.
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR11 0.2 V harness side. higher Is it 0.2 V or higher?
Yes
No
Go to Step 11
W414 or W416 harness defect (disconnection). Repair or replace
Lg436 harness deor Computer B defect. fect (disconnection). Replace Repair or replace
84402827B - May 2011 4023H-31
Main Unit-side Trouble Diagnostic Trouble Code: 7061 Arm Angle Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7061 is displayed.
Is diagnostic trouble code: 7061 displayed? 1. Check the arm angle sensor voltage on 4.8 V the service support screen. higher Is it 4.8 V or higher? Inspect for shorts to the power supply
2. 3.
1. 2. 3.
Turn the key switch OFF. Disconnect CN. CR12. About Measure the resistance between termikΊ nals 1 and 3 of the CN. CR12 arm angle sensor side.
No
Go to Step 3
or
Turn the key switch OFF and disconnect CN. CR12. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. CR12 harness side.
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR12 4.8 V harness side. lower Is it 4.8 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. CR12 0.2 V harness side. lower Is it 0.2 V or lower? Inspect the arm angle sensor.
Yes
Go to Step 2
Is diagnostic trouble code: 7061 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7061 is displayed.
1. 4
Standard value
Action
or
Go to Step 4
When 0.2 V or lower, go to Step 7
Go to Step 5
BW457 or W414 harness defect (short). Replace
Go to Step 6
Br437 harness defect (short). Replace
BW454 or W417 haror Computer B defect. ness defect (short). Replace Replace
10
Go to Step 8
Arm angle sensor defect. Replace
Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1. 8 2.
9
Inspect for continuity between the ground and terminal 1 of the CN. CR12 harness side. Inspect for continuity between the ground and terminal 2 of the CN. CR12 harness side.
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. CR12 harness side. Is there continuity?
84402827B - May 2011 4023H-32
BW457, W414, or Br437 harness defect Go to Step 9 (short). Replace
Go to Step 10
BW454 or W417 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. CR12 About 5 V harness side.
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. CR12 0.2 V harness side. higher Is it 0.2 V or higher?
Yes
No
Go to Step 11
BW457 or W414 harness defect (disconnection). Repair or replace
Br437 harness defect or Computer B defect. (disconnection). ReReplace pair or replace
84402827B - May 2011 4023H-33
Main Unit-side Trouble Diagnostic Trouble Code: 7063 Return Filter Clogging Pressure Switch Signal Abnormality (Breaker specifications) Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7063 is displayed.
Is diagnostic trouble code: 7063 displayed? 1. Inspect the connection status of each connector and ground. 2. Check whether diagnostic trouble code: 7063 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7063 displayed? Inspect the return filter clog pressure switch. 1. 3
2.
Turn the key switch OFF and disconnect CN. D81. Inspect for continuity between terminals 1 and 2 of the CN. D81 return filter clog pressure switch side.
Go to Step 4
Return filter clog pressure switch defect. Replace
Go to Step 5
BG652 harness defect (disconnection). Repair or replace
Is there continuity? Inspect for disconnection. 1. 4
5
Inspect for continuity between the ground and terminal 1 of the CN. D81 harness side.
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 2 of the CN. D81 About 5 V harness side.
YL538 harness deComputer A defect. fect (disconnection). Replace Repair or replace
Is it about 5 V?
1 2
84402827B - May 2011 4023H-34
COMPUTER A PRESS. SWITCH (FILTER INDICATOR)
Main Unit-side Trouble (Other than breaker specifications) Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7063 is displayed.
Is diagnostic trouble code: 7063 displayed? 1. Inspect the connection status of each connector and ground. 2. Check whether diagnostic trouble code: 7063 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7063 displayed? Inspect for disconnection. 1.
Go to Step 4
Jump harness defect (disconnection). Repair or replace
Is there continuity? 1. Inspect for continuity between the ground and terminal 1 of the CN. D81 harness side.
Go to Step 5
Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 2 of the CN. D81 About 5 V harness side.
BG652 harness defect (disconnection). Repair or replace
YL538 harness deComputer A defect. fect (disconnection). Replace Repair or replace
3
2.
4
5
Turn the key switch OFF and disconnect CN. D81. Inspect for continuity between terminals 1 and 2 of the CN. D81 jump harness side.
Is it about 5 V?
1
84402827B - May 2011 4023H-35
COMPUTER A
Main Unit-side Trouble Diagnostic Trouble Code: 7065 Boom-up Pilot Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7065 is displayed.
Is diagnostic trouble code: 7065 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7065 is displayed.
Yes
2. 3.
Turn the key switch OFF and disconnect CN. D53. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D53 harness side.
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7065 displayed? 1. Check the boom-up pilot pressure sensor voltage on the service support 4.75 V or Go to Step 4 screen. higher Is it 4.75 V or higher? Inspect for shorts to the power supply 1.
4
Standard value
Action
Go to Step 5
When 0.25 V or lower, go to Step 7
WL432 or WL430 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D53 4.75 V or GW444 harness deGo to Step 6 harness side. lower fect (short). Replace Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D53 0.25 V or Computer B defect. BL452 or BL450 harness defect (short). harness side. lower Replace Replace Is it 0.25 V or lower? 1. Inspect the boom-up pilot pressure sensor. 2. Turn the key switch OFF. Boom-up pilot pres3. Disconnect CN. D53. About 10 sure sensor defect. Go to Step 8 4. Measure the resistance between termi- kΊ Replace nals 1 and 3 of the CN. D53 boom-up pilot pressure sensor side. Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1.
8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D53 the D53
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D53 harness side. Is there continuity?
84402827B - May 2011 4023H-36
WL432, WL430, or GW444 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BL452 or BL450 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D53 About 5 V harness side.
Yes
No
Go to Step 11
WL432 or WL430 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. 120 0.25 V or Computer B defect. GW444 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
84402827B - May 2011 4023H-37
Main Unit-side Trouble Diagnostic Trouble Code: 7066 Bucket-close Pilot Pressure Sensor Signal Abnormality Step
1
2
3
1. 2.
5
6
7
Turn the key switch ON. Check whether diagnostic trouble code: 7067 is displayed.
Yes
Go to Step 3
Is diagnostic trouble code: 7067 displayed? 1. Check the bucket-close pilot pressure sensor voltage on the service support 4.75 V or Go to Step 4 screen. higher Is it 4.75 V or higher? Inspect for shorts to the power supply
2. 3.
No
Go to Step 2
Is diagnostic trouble code: 7067 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7067 is displayed.
1. 4
Standard value
Action
Turn the key switch OFF and disconnect CN. D55. Turn the key switch ON. About 5 V Measure the voltage between the ground and terminal 1 of the CN. D55 harness side.
Go to Step 5
When 0.25 V or lower, go to Step 7
WL431 or WL430 harness defect (short). Replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D55 4.75 V or LR446 harness deGo to Step 6 harness side. fect (short). Replace lower Is it 4.75 V or lower? 1. Measure the voltage between the ground and terminal 3 of the CN. D55 0.25 V or Computer B defect. BL451 or BL450 harness defect (short). harness side. lower Replace Replace Is it 0.25 V or lower? Inspect the bucket-close pilot pressure sensor. 1. 2. 3.
Turn the key switch OFF. Disconnect CN. D55. About Measure the resistance between termi- kΊ nals 1 and 3 of the CN. D55 bucketclose pilot pressure sensor side.
10
Go to Step 8
Bucket-close pilot pressure sensor defect. Replace
Is it about 10 kΊ? Inspect for shorts to ground and disconnections. 1. 8 2.
9
Inspect for continuity between ground and terminal 1 of the CN. harness side. Inspect for continuity between ground and terminal 2 of the CN. harness side.
the D55 the D55
Is there continuity? 1. Inspect for continuity between the ground and terminal 3 of the CN. D55 harness side. Is there continuity?
84402827B - May 2011 4023H-38
WL431, WL430, or LR446 harness de- Go to Step 9 fect (short). Replace
Go to Step 10
BL451 or BL450 harness defect (disconnection). Repair or replace
Main Unit-side Trouble Step
Action 1. 2.
10
11
Standard value
Turn the key switch ON. Measure the voltage between the ground and terminal 1 of the CN. D55 About 5 V harness side.
Yes
No
Go to Step 11
WL431 or WL430 harness defect (disconnection). Repair or replace
Is it about 5 V? 1. Measure the voltage between the ground and terminal 2 of the CN. D55 0.25 V or Computer B defect. LR446 harness defect (disconnection). harness side. higher Replace Repair or replace Is it 0.25 V or higher?
84402827B - May 2011 4023H-39
Main Unit-side Trouble Diagnostic Trouble Code: 7200 Swing Brake Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7200 is displayed.
Is diagnostic trouble code: 7200 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F13 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7200 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7200 displayed? Inspect the swing brake solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. D60. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. D60 swing brake solenoid side.
Swing brake solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. D60 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. D60 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. D60 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D60 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-40
Go to Step 5
W800 harness defect (short). Replace
R181, GR180, R105, or R104 harness de- Go to Step 6 fect (short). Replace
Go to Step 7
W800 harness defect (disconnection). Repair or replace
R181, GR180, R105, Computer A defect. or R104 harness deReplace fect (disconnection). Repair or replace
Main Unit-side Trouble
1 2 3 4 5
COMPUTER A ENGINE COMPUTER PRESS. SENSOR (PILOT SWING) PRESS. SENSOR (PILOT UPPER) CRANK ANGLE SENSOR
6 7
FUSE CONT SWING BRAKE
11 12
RELAY KEY ON FUSIBLE LINK FUSE BOX
8
RELAY BATTERY
13
KEY SWITCH
9
BATTERY (24 V)
10
FUSIBLE LINK BACK UP a
84402827B - May 2011 4023H-41
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7201 Travel High-speed Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7201 is displayed.
Is diagnostic trouble code: 7201 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F13 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7201 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7201 displayed? Inspect the travel high-speed solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. D61. Measure the resistance between ter- 34 立 - 47 立 Go to Step 4 minals 1 and 2 of the CN. D61 travel high-speed solenoid side.
Travel high-speed solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. D61 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. D61 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. D61 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D61 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-42
Go to Step 5
L801 harness defect (short). Replace
R183, GR180, R105a, R104, or Go to Step 6 R105 harness defect (short). Replace
Go to Step 7
L801 harness defect (disconnection). Repair or replace
R183, GR180, R105a, R104, or Computer A defect. R105 harness defect Replace (disconnection). Repair or replace
Main Unit-side Trouble
1 2 3 4
COMPUTER A ENGINE COMPUTER PRESS. SENSOR (PILOT TRAVEL) CRANK ANGLE SENSOR
5 6
FUSE CONT 2 STAGE TRAVEL
9 10
FUSE KEY RELAY KEY ON
7
RELAY BATTERY
11
FUSIBLE LINK FUSE BOX
8
BATTERY (24 V)
12
KEY SWITCH
a
84402827B - May 2011 4023H-43
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7202 Pressure Boost Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7202 is displayed.
Is diagnostic trouble code: 7202 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F13 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7202 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7202 displayed? Inspect the pressure boost solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. D62. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. D62 pressure boost solenoid side.
Pressure boost solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. D62 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. D62 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. D62 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D62 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-44
Go to Step 5
Y802 harness defect (short). Replace
R183, GR180, R105, or R104 harness de- Go to Step 6 fect (short). Replace
Go to Step 7
Y802 harness defect (disconnection). Repair or replace
R183, GR180, R105, Computer A defect. or R104 harness deReplace fect (disconnection). Repair or replace
Main Unit-side Trouble
84402827B - May 2011 4023H-45
Main Unit-side Trouble 1
COMPUTER A
7
2
ENGINE COMPUTER
8
3
THROTTLE VOL.
9
4 5
PRESS. SENSOR (P1) 10 PRESS. SENSOR (P2) 11 PRESS. SENSOR (PILOT UP12 PER)
6
PRESS. SENSOR (PILOT TRAVEL) PRESS. SWITCH (1ST OPTION) PRESS. SWITCH (2ND OPTION) FUSE CONT 2 STAGE RELIEF RELAY BATTERY
13
BATTERY (24 V)
14
BACK UP FUSIBLE LINK
15
RELAY KEY ON
16 17
MONITOR DISPLAY FUSIBLE LINK FUSE BOX
18
KEY SWITCH
a
84402827B - May 2011 4023H-46
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7203 Travel Alarm Buzzer Signal Abnormality Step
1. 2. 1
2
Standard value
Action Turn the key switch ON. On the service support DIAG screen, check whether diagnostic trouble code: 7203 (â&#x2014;?) is displayed.
Is diagnostic trouble code: 7203 (â&#x2014;?) displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F21 (10 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the travel alarm. 1. 2. 3
Turn the key switch OFF and disconnect CN. D69. Connect terminal 1 of the CN. D69 travel alarm side to the negative terminal of the battery and terminal 2 to the positive terminal, and inspect the operation of the travel alarm.
Go to Step 4
Travel alarm defect. Replace
Go to Step 5
WL807 harness defect (short). Replace
Does the travel alarm sound? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 1 of the CN. D69 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 2 of the CN. D69 harness side. Is there continuity? Inspect for disconnection. Inspect whether there is continuity between the ground and terminal 1 of the CN. D69 harness side for 0.4 sec. after the key switch is turned ON. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 2 of the CN. D69 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-47
GW215, R105, or R104 harness defect Go to Step 6 (short). Replace
Go to Step 7
WL807 harness defect (disconnection). Repair or replace
GW215, R105, or Computer A defect. R104 harness defect (disconnection). ReReplace pair or replace
Main Unit-side Trouble
1 2 3 4
COMPUTER A PRESS. SENSOR (PILOT TRAVEL) FUSE CONT TRAVEL ALARM 24 V, 107 dB
5
BACK UP FUSIBLE LINK
9
FUSIBLE LINK FUSE BOX
6
RELAY BATTERY
10
KEY SWITCH
7 8
RELAY KEY ON BATTERY (24 V)
84402827B - May 2011 4023H-48
Main Unit-side Trouble Diagnostic Trouble Code: 7204 Power Save Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7204 is displayed.
Is diagnostic trouble code: 7204 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F13 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7204 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7204 displayed? Inspect the power save solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. D60. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. D60 power save solenoid side.
Power save solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. D60 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. D60 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. D60 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D60 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-49
Go to Step 5
G812 harness defect (short). Replace
R184, GR180, R105, or R104 harness de- Go to Step 6 fect (short). Replace
Go to Step 7
G812 harness defect (disconnection). Repair or replace
R184, GR180, R105, Computer A defect. or R104 harness deReplace fect (disconnection). Repair or replace
Main Unit-side Trouble
84402827B - May 2011 4023H-50
Main Unit-side Trouble 1 2 3 4 5
COMPUTER A ENGINE COMPUTER PRESS. SENSOR (PILOT SWING) PRESS. SENSOR (PILOT UPPER) PRESS. SENSOR (PILOT TRAVEL)
6 7
CRANK ANG (MRE) SENSOR FUSE CONT
11 12
RELAY BATTERY FUSIBLE LINK BACK UP
8
POWER SAVE
13
FUSIBLE LINK FUSE BOX
9
RELAY BATTERY
14
KEY SWITCH
10
BATTERY (24 V)
15
COMPUTER B
a
84402827B - May 2011 4023H-51
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7205 Feed Pump Relay Signal Abnormalityă&#x20AC;&#x20AC; Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7205 is displayed.
Is diagnostic trouble code: 7205 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F (65 A) fuse and fuse box F19 (30 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the feed pump relay. 1. 3
2.
Turn the key switch OFF and disconnect CN. D83-1. Inspect for continuity between terminals 1 and 2 of the CN. D83-1 feed pump relay side.
Go to Step 4
Feed pump relay defect. Replace
Is there continuity? Inspect for shorts. 4
1. 2.
Install CN. D83-1. Inspect for continuity between the ground and terminal 1 of the CN. D83-1 harness side.
VR845, W250, VR894, L846, or R105 harness defect Go to Step 5 (short). Replace
Is there continuity? Inspect for disconnection. 5
1. 2.
Turn the key switch ON. Inspect for continuity between the ground and terminal 1 of the CN. D83-1 harness side.
Is there continuity?
84402827B - May 2011 4023H-52
VR845, W250, VR894, L846, or Computer B defect. R105 harness defect Replace (disconnection). Repair or replace
Main Unit-side Trouble
1 2 3
RELAY BATTERY FUSIBLE LINK FUSE BOX RELAY PUMP
4 5 6
RELAY STOP MANUAL/AUTO ALARM 24V,107dB
84402827B - May 2011 4023H-53
7 8
REFUEL PUMP MONITOR DISPLAY
Main Unit-side Trouble Diagnostic Trouble Code: 7206 Option Line Switchover Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7206 is displayed.
Is diagnostic trouble code: 7206 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F (65 A) fuse and fuse box F20 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7206 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7206 displayed? Inspect the option line switchover solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. 162. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. 162 option line switchover solenoid side.
Option line switchover solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. 162 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. 162 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. 162 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. 162 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-54
Go to Step 5
LY806 harness defect (short). Replace
WL260 or SR105 harness defect Go to Step 6 (short). Replace
Go to Step 7
LY806 harness defect (disconnection). Repair or replace
WL260 or SR105 Computer A defect. harness defect (disReplace connection). Repair or replace
Main Unit-side Trouble 1 2
RELAY BATTERY FUSIBLE LINK FUSE BOX
84402827B - May 2011 4023H-55
3 4
OPTION SELECT CONTROLLER A
Main Unit-side Trouble Diagnostic Trouble Code: 7207 Free Swing Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7207 is displayed.
Is diagnostic trouble code: 7207 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F (65 A) fuse and fuse box F6 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7207 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7207 displayed? Inspect the free swing solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. D64. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. D64 free swing solenoid side.
Free swing solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 2 of the CN. D64 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. D64 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 2 of the CN. D64 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. D64 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-56
Go to Step 5
Br803 harness defect (short). Replace
R187, GR180, or SR105 harness de- Go to Step 6 fect (short). Replace
Go to Step 7
Br803 harness defect (disconnection). Repair or replace
R187, GR180, or Computer A defect. SR105 harness deReplace fect (disconnection). Repair or replace
Main Unit-side Trouble Diagnostic Trouble Code: 7210 Liftcrane Buzzer Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7210 is displayed.
Is diagnostic trouble code: 7210 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F22 (15 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the liftcrane buzzer. 1. 2. 3
Turn the key switch OFF and disconnect CN. CR5 and CN. CR6. Connect the terminal of the CN. CR6 liftcrane buzzer side to the negative terminal of the battery and the terminal of the CN. CR5 liftcrane buzzer side to the positive terminal, and inspect the operation of the liftcrane buzzer.
Go to Step 4
Liftcrane buzzer defect. Replace
Go to Step 5
VG815 harness defect (short). Replace
Does the liftcrane buzzer sound? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and the terminal of the CN. CR6 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and the terminal of the CN. CR5 harness side.
BrW237, BrW236, R111, R106, or Go to Step 6 R105 harness defect (short). Replace
Is there continuity? BrW237, BrW236, Inspect for disconnection. R111, R106, or R105 Turn the key switch ON and measure the harness defect (disvoltage between the ground and the terminal About 24 V Go to Step 7 connection). Repair of the CN. CR5 harness side. or replace Is it about 24 V? 1. Turn the key switch OFF and disconnect CN. CR4. 2. Inspect whether there is continuity beVG815 harness deComputer B defect. tween the terminal of the CN. CR6 harfect (disconnection). Replace ness side and terminal 6 of the CN. CR4 Repair or replace harness side. Is there continuity?
84402827B - May 2011 4023H-57
Main Unit-side Trouble Diagnostic Trouble Code: 7211 Rotating Light Relay and Bucket Lock Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7211 is displayed.
Is diagnostic trouble code: 7211 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and fuse box F21 (10 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the rotating light relay. 1. 3
2.
Turn the key switch OFF and disconnect CN. 19. Inspect for continuity between terminals 1 and 2 of the CN. 19 rotating light relay side.
Go to Step 4
Rotating light relay defect. Replace
Is there continuity? Inspect for shorts. 4
1. 2.
Install CN. 19. Inspect for continuity between the ground and terminal 1 of the CN. 19 harness side.
Is there continuity? Inspect for disconnection. 5
1. 2.
Turn the key switch ON. Inspect for continuity between the ground and terminal 1 of the CN. 19 harness side.
Is there continuity?
84402827B - May 2011 4023H-58
VW858, GW226, GW227, R106, or Go to Step 5 R105 harness defect (short). Replace
VW816, VW817, GW227, GW226, Computer B defect. GW225, R106, or R105 harness defect Replace (disconnection). Repair or replace
Main Unit-side Trouble Diagnostic Trouble Code: 7240 Pump Horsepower Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7240 is displayed.
Is diagnostic trouble code: 7240 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7240 is displayed. Is diagnostic trouble code: 7240 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7240 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Is diagnostic trouble code: 7240 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. D39. Inspect for continuity between the ground and terminal 1 of the CN. D39 harness side.
Y900 harness defect Computer A defect. (short). Replace Replace
Is there continuity? Inspect the pump horsepower proportional valve. 5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. D39. Inspect for continuity between terminals 1 and 2 of the CN. D39 pump horsepower proportional valve side.
Go to Step 6
Pump horsepower proportional valve defect. Replace
Go to Step 7
YR940 harness defect (disconnection) between CN. D39 and CN. A56. Repair or replace
Go to Step 8
BY901 harness defect (disconnection) between CN. D39 and CN. A56. Repair or replace
Go to Step 9
Y900 harness defect (disconnection) between CN. A56 and CN. A4. Repair or replace
Is there continuity? Inspect for disconnection. 6
1. 2.
Disconnect CN. A56. Inspect for continuity between terminal 1 of the CN. D39 female side and terminal 1 of the CN. A56 male side.
Is there continuity? 7
Inspect for continuity between terminal 2 of the CN. D39 female side and terminal 9 of the CN. A56 male side. Is there continuity? 1. 2.
8
9
Disconnect CN. A4. Inspect for continuity between terminal 1 of the CN. A56 male side and terminal 3 of the CN. A4 female side.
Is there continuity? 1. Inspect for continuity between terminal 9 of the CN. A56 male side and terminal 6 of the CN. A4 female side. Is there continuity?
84402827B - May 2011 4023H-59
BY901 harness defect (disconnection) Computer A defect. between CN. A56 Replace and CN. A4. Repair or replace
Main Unit-side Trouble
1
COMPUTER A
4
2 3
PRESS. SENSOR (P1) PRESS. SENSOR (P2)
5 6
PRESS. SENSOR (PILOT UP7 PER) CRANK ANGLE SENSOR PUMP POWER a
84402827B - May 2011 4023H-60
ENGINE COMPUTER
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7241 P1 Flow Control Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7241 is displayed.
Is diagnostic trouble code: 7241 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7241 is displayed. Is diagnostic trouble code: 7241 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7241 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Is diagnostic trouble code: 7241 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. D40. Inspect for continuity between the ground and terminal 1 of the CN. D40 harness side.
L904 harness defect Computer A defect. (short). Replace Replace
Is there continuity? Inspect the P1 flow control proportional valve. 5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. D40. Inspect for continuity between terminals 1 and 2 of the CN. D40 flow control proportional valve side.
Go to Step 6
P1 flow control proportional valve defect. Replace
Go to Step 7
Y904 harness defect (disconnection) between CN. D40 and CN. A56. Repair or replace
Go to Step 8
BL905 harness defect (disconnection) between CN. D40 and CN. A56. Repair or replace
Go to Step 9
Y904 harness defect (disconnection) between CN. A56 and CN. A3. Repair or replace
Is there continuity? Inspect for disconnection. 6
1. 2.
Disconnect CN. A56. Inspect for continuity between terminal 1 of the CN. D40 male side and terminal 3 of the CN. A56 female side.
Is there continuity? 7
Inspect for continuity between terminal 2 of the CN. D40 male side and terminal 11 of the CN. A56 female side. Is there continuity? 1. 2.
8
Disconnect CN. A3. Inspect for continuity between terminal 3 of the CN. A56 male side and terminal 2 of the CN. A3 female side.
Is there continuity? 9
Inspect for continuity between terminal 11 of the CN. A56 male side and terminal 5 of the CN. A3 female side. Is there continuity?
84402827B - May 2011 4023H-61
BL905 harness defect (disconnection) Computer A defect. between CN. A56 Replace and CN. A3. Repair or replace
Main Unit-side Trouble
1 2 3
COMPUTER A
4
PRESS. SENSOR (PILOT 5 SWING) PRESS. SENSOR (PILOT UP6 PER)
1 2
PRESS. SENSOR TRAVEL)
(PILOT
7
ENGINE COMPUTER
a
CAN COMMUNICATION
3
WATER TEMP. SENSOR
CRANK ANGLE SENSOR P1 FLOW
COMPUTER A ENGINE COMPUTER
84402827B - May 2011 4023H-62
Main Unit-side Trouble Diagnostic Trouble Code: 7242 Fan Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7242 is displayed.
Is diagnostic trouble code: 7242 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7242 is displayed. Is diagnostic trouble code: 7242 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7242 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Is diagnostic trouble code: 7242 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. H1. Inspect for continuity between the ground and terminal 1 of the CN. H1 harness side.
YG944 harness de- Computer B defect. fect (short). Replace Replace
Is there continuity? Inspect the fan proportional valve.
5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. H1. Inspect for continuity between terminals 1 and 2 of the CN. H1 fan proportional valve side.
Go to Step 6
Fan proportional valve defect. Replace
Go to Step 7
YG494 harness defect (disconnection) between CN. H1 and CN. A54. Repair or replace
Is there continuity? Inspect for disconnection. 6
1. 2.
Disconnect CN. A54. Inspect for continuity between terminal 1 of the CN. H1 female side and terminal 5 of the CN. A54 female side.
Is there continuity? 1. 7
Inspect for continuity between terminal 2 of the CN. H1 female side and terminal 15 of the CN. A54 female side.
Go to Step 8
Is there continuity? 1. 2. 8
9
Disconnect CN. A7. Inspect for continuity between terminal 5 of the CN. A54 male side and terminal 1 of the CN. A7 female side.
Is there continuity? 1. Inspect for continuity between terminal 15 of the CN. A54 male side and terminal 4 of the CN. A7 female side. Is there continuity?
84402827B - May 2011 4023H-63
Go to Step 9
BY495 harness defect (disconnection) between CN. H1 and CN. A54. Repair or replace W908 harness defect (disconnection) between CN. A54 and CN. A7. Repair or replace
WB909 harness defect (disconnection) Computer B defect. between CN. A54 Replace and CN. A7. Repair or replace
Main Unit-side Trouble Diagnostic Trouble Code: 7246 2 Pumps Flow Solenoid Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7246 is displayed.
Is diagnostic trouble code: 7246 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F (65 A) fuse and fuse box F20 (10 A) fuse to see if either is blown. 3. Check whether diagnostic trouble code: 7246 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7246 displayed? Inspect the 2 pumps flow solenoid. 1. 3
2.
Turn the key switch OFF and disconnect CN. 163. Measure the resistance between termi- 34 立 - 47 立 Go to Step 4 nals 1 and 2 of the CN. 163 2 pumps flow solenoid side.
2 pumps flow solenoid defect. Replace
Is it 34 立 - 47 立? Inspect for shorts. 4
5
6
7
1. 2.
Turn the key switch ON. Measure the voltage between the 0V ground and terminal 3 of the CN. 163 harness side.
Is it 0 V? 1. Turn the key switch OFF. 2. Inspect for continuity between the ground and terminal 1 of the CN. 163 harness side. Is there continuity? Inspect for disconnection. Inspect for continuity between the ground and terminal 3 of the CN. 163 harness side. Is there continuity? 1. Turn the key switch ON. 2. Measure the voltage between the ground and terminal 1 of the CN. 163 24 V harness side. Is it 24 V?
84402827B - May 2011 4023H-64
Go to Step 5
YR805 harness defect (short). Replace
WL260, WL261, or SR105 harness de- Go to Step 6 fect (short). Replace
Go to Step 7
YR805 harness defect (disconnection). Repair or replace
WL260, WL261, or Computer A defect. SR105 harness defect (disconnection). Replace Repair or replace
Main Unit-side Trouble 1 2
RELAY BATTERY FUSIBLE LINK FUSE BOX
84402827B - May 2011 4023H-65
3 4
OPTION 2SPEED CONTROLLER A
Main Unit-side Trouble Diagnostic Trouble Code: 7247 Boom-down Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7247 is displayed.
Is diagnostic trouble code: 7247 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7247 is displayed. Is diagnostic trouble code: 7247 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7247 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Is diagnostic trouble code: 7247 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. D41. Inspect for continuity between the ground and terminal 1 of the CN. D41 harness side.
O902 harness defect Computer A defect. (short). Replace Replace
Is there continuity? Inspect the boom-down proportional valve.
5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. D41. Inspect for continuity between terminals 1 and 2 of the CN. D41 boom-down proportional valve side.
Go to Step 6
Boom-down proportional valve defect. Replace
Go to Step 7
O902 harness defect (disconnection) between CN. A56 and CN. D41. Repair or replace
Go to Step 8
O903 harness defect (disconnection) between CN. A56 and CN. D41. Repair or replace
Go to Step 9
O902 harness defect (disconnection) between CN. A56 and CN. A3. Repair or replace
Is there continuity? Inspect for disconnection. 6
1. 2.
Disconnect CN. A56. Inspect for continuity between terminal 1 of the CN. D41 female side and terminal 2 of the CN. A56 female side.
Is there continuity? 7
Inspect for continuity between terminal 2 of the CN. D41 female side and terminal 10 of the CN. A56 female side. Is there continuity? 1. 2.
8
Disconnect CN. A3. Inspect for continuity between terminal 2 of the CN. A56 male side and terminal 1 of the CN. A3 female side.
Is there continuity? 9
Inspect for continuity between terminal 10 of the CN. A56 male side and terminal 4 of the CN. A3 female side. Is there continuity?
84402827B - May 2011 4023H-66
O903 harness defect (disconnection) beComputer A defect. tween CN. A56 and Replace CN. A3. Repair or replace
Main Unit-side Trouble
1 2
84402827B - May 2011 4023H-67
CONTROLLER A BOOM DOWN
Main Unit-side Trouble Diagnostic Trouble Code: 7248 Arm-in Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7248 is displayed.
Is diagnostic trouble code: 7248 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7248 is displayed. Is diagnostic trouble code: 7248 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7248 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5.
Is diagnostic trouble code: 7248 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. D42. Inspect for continuity between the ground and terminal 1 of the CN. D42 harness side.
G906 harness defect Computer B defect. (short). Replace Replace
Is there continuity? Inspect the arm-in proportional valve.
5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. D42. Inspect for continuity between terminals 1 and 2 of the CN. D42 arm-in proportional valve side.
Go to Step 6
Arm-in proportional valve defect. Replace
Go to Step 7
G906 harness defect (disconnection) between CN. A56 and CN. D42. Repair or replace
Go to Step 8
GB907 harness defect (disconnection) between CN. A56 and CN. D42. Repair or replace
Go to Step 9
G906 harness defect (disconnection) between CN. A56 and CN. A7. Repair or replace
Is there continuity? Inspect for disconnection. 6
1. 2.
Disconnect CN. A56. Inspect for continuity between terminal 1 of the CN. D42 female side and terminal 4 of the CN. A56 female side.
Is there continuity? 7
Inspect for continuity between terminal 2 of the CN. D42 female side and terminal 12 of the CN. A56 female side. Is there continuity? 1. 2.
8
Disconnect CN. A7. Inspect for continuity between terminal 4 of the CN. A56 male side and terminal 3 of the CN. A7 female side.
Is there continuity? 9
Inspect for continuity between terminal 12 of the CN. A56 male side and terminal 6 of the CN. A7 female side. Is there continuity?
84402827B - May 2011 4023H-68
GB907 harness defect (disconnection) Computer B defect. between CN. A56 Replace and CN. A7. Repair or replace
Main Unit-side Trouble
1 2
84402827B - May 2011 4023H-69
CONTROLLER B ARM CLOSE
Main Unit-side Trouble Diagnostic Trouble Code: 7250 Option Relief Pressure Proportional Valve Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7250 is displayed.
Is diagnostic trouble code: 7250 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7250 is displayed. Is diagnostic trouble code: 7250 displayed? 1. Reset the diagnostic trouble code on the service support DIAG screen. 2. Check whether diagnostic trouble code: 7250 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Is diagnostic trouble code: 7250 displayed? Inspect for shorts. 1. 4
2.
Turn the key switch OFF and disconnect CN. D44-1. Inspect for continuity between the ground and terminal 1 of the CN. D44-1 harness side.
V910 harness defect Computer B defect. (short). Replace Replace
Is there continuity? Inspect the option relief pressure proportional valve. 5
1. 2. 3.
Turn the key switch OFF. Disconnect CN. D44-1. Inspect for continuity between terminals 1 and 2 of the CN. D44-1 option relief pressure proportional valve side.
Go to Step 6
Option relief pressure proportional valve defect. Replace
Go to Step 7
V910 harness defect (disconnection) between CN. D44-1 and CN. D44. Repair or replace
Is there continuity? Inspect for disconnection. 6
7
1. 2.
Disconnect CN. D44. Inspect for continuity between terminal 1 of the CN. D44-1 female side and terminal 1 of the CN. D44 male side.
Is there continuity? 1. Inspect for continuity between terminal 2 of the CN. D44-1 female side and terminal 2 of the CN. D44 male side.
Go to Step 8
Is there continuity? 1. 2. 8
Disconnect CN. A7. Inspect for continuity between terminal 1 of the CN. D44 female side and terminal 2 of the CN. A7 female side.
Is there continuity? 1. 9
Inspect for continuity between terminal 2 of the CN. D44 female side and terminal 5 of the CN. A7 female side.
Is there continuity?
84402827B - May 2011 4023H-70
Go to Step 9
VG911 harness defect (disconnection) between CN. D44-1 and CN. D44. Repair or replace V910 harness defect (disconnection) between CN. D44 and CN. A7. Repair or replace
VG911 harness defect (disconnection) Computer B defect. between CN. D44 Replace and CN. A7. Repair or replace
Main Unit-side Trouble
1 2 3
84402827B - May 2011 4023H-71
CONTROLLER B PROPORTIONAL S/V OPT PRESS
Main Unit-side Trouble Diagnostic Trouble Code: 7251 Battery Control Relay Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7251 is displayed.
Is diagnostic trouble code: 7251 displayed? 1. Inspect the connection status of each connector. Inspect the computer fuse (15 A) to see if it is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the battery control relay. 1. 3
2.
Turn the key switch OFF and disconnect CN. A11. Inspect for continuity between terminals 1 and 2 of the CN. A11 battery control relay side.
Go to Step 4
Battery control relay defect. Replace
Is there continuity? Inspect for shorts. 4
1. 2.
Install CN. A11. Inspect for continuity between the ground and terminal 1 of the CN. A11 harness side.
W113, W112, W107, or W106 harness de- Go to Step 5 fect (short). Replace
Is there continuity? Inspect for disconnection. 5
1. 2.
Turn the key switch ON. Inspect for continuity between the ground and terminal 1 of the CN. A11 harness side.
W113, W112, W107, W106, or OG804 harComputer A defect. ness defect (disconReplace nection). Repair or replace
Is there continuity?
1 2
RELAY BATTERY FUSE CONT
84402827B - May 2011 4023H-72
3 4
RELAY BATTERY RL CONTROLLER A
Main Unit-side Trouble Diagnostic Trouble Code: 7252 Idle Stop Relay Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7252 is displayed.
Is diagnostic trouble code: 7252 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F1 (65 A) fuse and computer (15 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the idle stop relay. 1. 3
2.
Turn the key switch OFF and disconnect CN. A12. Inspect for continuity between terminals 1 and 2 of the CN. A12 idle stop relay side.
Go to Step 4
Idle stop relay defect. Replace
Is there continuity? Inspect for shorts. 4
1. 2.
Install CN. A12. Inspect for continuity between the ground and terminal 1 of the CN. A12 harness side.
W115, W114, W112, W113, or W107 harGo to Step 5 ness defect (short). Replace
Is there continuity? Inspect for disconnection. 5
1. 2.
Turn the key switch ON. Inspect for continuity between the ground and terminal 1 of the CN. A12 harness side.
Is there continuity?
84402827B - May 2011 4023H-73
W106, W107, W112, W113, W114, W115, Computer B defect. or LY824 harness deReplace fect (disconnection). Repair or replace
Main Unit-side Trouble
1 2
RELAY BATTERY FUSE CONT
3 4
RELAY IDLE STOP RELAY KEY ON
84402827B - May 2011 4023H-74
5 6
KEY SWITCH MONITOR DISPLAY
Main Unit-side Trouble Diagnostic Trouble Code: 7253 DPD Regeneration Request Output Signal Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7253 is displayed.
Is diagnostic trouble code: 7253 displayed? 1. Inspect the connection status of each connector. 2. Inspect the fusible link F (50 A) fuse and fuse box F4 (10 A) fuse to see if either is blown.
Yes
No
Go to Step 2
Go to Step 3
Are 1 and 2 above both OK? Inspect the DPF relay. 1. 3
2.
Turn the key switch OFF and disconnect CN. A10. Inspect for continuity between terminals 1 and 2 of the CN. A10 DPF relay side.
Go to Step 4
DPF relay Replace
defect.
Is there continuity? Inspect for shorts. 4
1. 2.
Install CN. A10. Inspect for continuity between the ground and terminal 1 of the CN. A10 harness side.
WR147, WR141, or WR140 harness de- Go to Step 5 fect (short). Replace
Is there continuity? Inspect for disconnection. 5
1. 2.
Turn the key switch ON. Inspect for continuity between the ground and terminal 1 of the CN. A10 harness side.
Is there continuity?
84402827B - May 2011 4023H-75
WR147, WR141, WR140, or YL806 Computer A defect. harness defect (disReplace connection). Repair or replace
Main Unit-side Trouble
1 2
FUSIBLE LINK BACK UP RELAY ECM
3 4
RELAY DPF CONTROLLER A
84402827B - May 2011 4023H-76
5 6
ENGINE CONTROLLER RELAY BATTERY
Main Unit-side Trouble Diagnostic Trouble Code: 7400 Abnormally High Coolant Temperature (105°C or higher) Step
1.
1
2
Standard value
Action
2.
Start the engine and perform a warm-up operation until the engine is fully warmed up. On the service support DIAG screen, check whether diagnostic trouble code: 7400 (●) is displayed.
Yes
No
Go to Step 2
Is diagnostic trouble code: 7400 (●) displayed? Inspect the engine unit.
Diagnostic Trouble Code: 7401 Abnormally High Coolant Temperature (110°C or higher) Step
1.
1
2
Standard value
Action
2.
Start the engine and perform a warm-up operation until the engine is fully warmed up. On the service support DIAG screen, check whether diagnostic trouble code: 7401 (●) is displayed.
Yes
No
Go to Step 2
Is diagnostic trouble code: 7401 (●) displayed? Inspect the engine unit.
Diagnostic Trouble Code: 7402 Abnormally High Coolant Temperature (120°C or higher) Step
1.
1
2
Standard value
Action
2.
Start the engine and perform a warm-up operation until the engine is fully warmed up. On the service support DIAG screen, check whether diagnostic trouble code: 7402 (●) is displayed.
Is diagnostic trouble code: 7402 (●) displayed? Inspect the engine unit.
84402827B - May 2011 4023H-77
Yes
Go to Step 2
No
Main Unit-side Trouble Diagnostic Trouble Code: 7404 Abnormally High Oil Temperature (95°C or higher) Step
1.
1
2
Standard value
Action
2.
Start the engine and perform a warm-up operation until the engine is fully warmed up. On the service support DIAG screen, check whether diagnostic trouble code: 7404 (●) is displayed.
Yes
No
Go to Step 2
Is diagnostic trouble code: 7404 (●) displayed? Inspect the hydraulic oil temperature.
1 2
84402827B - May 2011 4023H-78
COMPUTER A HYD. OIL TEMP SENSOR
Main Unit-side Trouble Diagnostic Trouble Code: 7405 Abnormally High Boost Temperature (80°C or higher), 7406 Abnormally High Boost Temperature (90°C or higher) Step
1.
1
2
Standard value
Action
2.
Start the engine and perform a warm-up operation until the engine is fully warmed up. On the service support DIAG screen, check whether diagnostic trouble code 7405 (●) or 7406 (●) is displayed.
Is diagnostic trouble code 7405 (●) or 7406 (●) displayed? Inspect the engine unit.
84402827B - May 2011 4023H-79
Yes
Go to Step 2.
No
Main Unit-side Trouble Diagnostic Trouble Code: 7420 Abnormally Low Alternator Voltage Step
Standard value
Action 1. 2.
Yes
1
Turn the key switch ON. On the service support DIAG screen, check whether diagnostic trouble code: 7420 (â&#x2014;?) is displayed.
Go to Step 2
2
Is diagnostic trouble code: 7420 (â&#x2014;?) displayed? 1. Inspect the connection status of each connector.
Go to Step 3
No
Is 1 above OK? Inspect for shorts. 1. 3
2.
Turn the key switch OFF and disconnect CN. D14. Inspect for continuity between the ground and terminal 2 of the CN. D14 harness side.
Br515 harness defect Go to Step 4 (short). Replace
Is there continuity? Inspect the alternator. 4
1. 2.
Start the engine. Measure the voltage between the 10 V ground and terminal 2 of the CN. D14 lower alternator side.
or Alternator Replace
defect.
Go to Step 5
Is it 10 V or lower? Inspect for disconnection.
5
1. 2. 3. 4. 5.
Turn the key switch OFF. Connect CN. D14. Disconnect CN. A1. 10 V Start the engine. lower Measure the voltage between the ground and terminal 8 of the CN. A1 harness side.
or
Is it 10 V or lower?
84402827B - May 2011 4023H-80
Br515 harness defect Computer A defect. (disconnection). ReReplace pair or replace
Main Unit-side Trouble
84402827B - May 2011 4023H-81
Main Unit-side Trouble 1 2 3 4 5
COMPUTER A RELAY STARTER CUT BATTERY (24 V) RELAY BATTERY FUSE CONT
6 7 8 9 10
FUSIBLE LINK FUSE BOX FUSIBLE LINK BACK UP FUSIBLE LINK SAFETY RL RELAY KEY ON KEY SWITCH
84402827B - May 2011 4023H-82
11 12 13
STARTER MOTOR ALTERNATOR RELAY STARTER
Main Unit-side Trouble Diagnostic Trouble Code: 7421 Coolant Level Reduction Step
1.
1
2
Standard value
Action
2. 3. 4.
Check that the "LOW COOLANT" display appears. Fill with coolant. Turn the key switch ON. On the service support DIAG screen, check whether diagnostic trouble code: 7421 (●) is displayed.
Is diagnostic trouble code: 7421 (●) displayed? 1. Inspect the connection status of each connector. 2. On the service support DIAG screen, check whether diagnostic trouble code: 7421 (●) is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7421 (●) displayed? Inspect the coolant level switch. 1. 3
2.
Turn the key switch OFF and disconnect CN. D79. Inspect for continuity between terminals 1 and 2 of the CN. D79 coolant level switch side.
Coolant level switch Computer A defect. defect. Replace Replace
Is there continuity?
1 2
84402827B - May 2011 4023H-83
COMPUTER A LEVEL SWITCH (RESERVE TANK)
Main Unit-side Trouble Diagnostic Trouble Code: 7422 Abnormally Low Engine Oil Pressure Step
Standard value
Action 1. 2.
1
Start the engine and wait for 30 sec. On the service support DIAG screen, check whether diagnostic trouble code: 7422 (●) is displayed.
2
Is diagnostic trouble code: 7422 (●) displayed? Inspect the engine unit.
Yes
No
Go to Step 2
1 2 3
84402827B - May 2011 4023H-84
COMPUTER A ENGINE COMPUTER OIL PRESS SENSOR
Main Unit-side Trouble Diagnostic Trouble Code: 7423 Air Cleaner Clogging Step
Standard value
Action 1. 2.
Check that the "AIR FILTER" display appears. Clean or replace the air cleaner element. Start the engine and wait for 10 sec. On the service support DIAG screen, check whether diagnostic trouble code: 7423 (●) is displayed.
1
3. 4.
2
Is diagnostic trouble code: 7423 (●) displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7423 (●) is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7423 (●) displayed? Inspect the air cleaner clog pressure switch. 1. 3
Turn the key switch OFF and disconnect CN. D80. Inspect for continuity between terminals 1 and 2 of the CN. D80 air cleaner clog pressure switch side.
Air cleaner clog pressure switch defect. Go to Step 4 Replace
Is there continuity? Inspect for shorts. 1. 4
Inspect for continuity between the ground and terminal 2 of the CN. D80 harness side.
LW533 harness de- Computer A defect. fect (short). Replace Replace
Is there continuity?
1 2
84402827B - May 2011 4023H-85
COMPUTER A PRESS. SWITCH CLEANER)
(AIR
Main Unit-side Trouble Diagnostic Trouble Code: 7424 Return Filter Clogging (breaker specifications) Step
1.
1
2
Standard value
Action
2. 3. 4.
Check that the "HYD. OIL FILTER" display appears. Replace the return filter. Turn the key switch ON. Check whether diagnostic trouble code: 7424 is displayed.
Is diagnostic trouble code: 7424 displayed? 1. Inspect the connection status of each connector and ground. 2. Check whether diagnostic trouble code: 7424 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7424 displayed? Inspect the return filter clog switch. 1. 3
2.
Turn the key switch OFF and disconnect CN. D81. Inspect for continuity between terminals 1 and 2 of the CN. D81 return filter clog switch side.
Return filter clog Computer A defect. pressure switch deReplace fect. Replace
Is there continuity?
1 2
84402827B - May 2011 4023H-86
COMPUTER A PRESS. SWITCH (FILTER INDICATOR)
Main Unit-side Trouble Diagnostic Trouble Code: 7425 Fuel Density Error Signal Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7425 is displayed.
Is diagnostic trouble code: 7425 displayed? 1. View the fuel density data on the service support CHK-MAIN-11 screen. 2. Turn the key switch OFF, but just before doing so, record the fuel density data. 3. Turn the key switch OFF. 4. Turn the key switch ON, and record the fuel density data at this time. 5. Compare the data from 2 and 4 above to check whether the difference between the values has dropped by 0.01 g/cm3 or more. Has the value dropped by 0.01 g/cm3 or more? 1. While the diagnostic trouble code is displayed, turn the key switch OFF. 2. After checking that the display has turned off, turn the key switch ON again. 3. When the diagnostic trouble code is displayed, wait for at least 5 min. 4. Turn the key switch OFF, turn the ignition key ON again, and check whether the error code is displayed.
4
Has the error code disappeared? 1. Check whether the customer has changed gas station or fuel manufacturer.
5
Has the customer changed gas station or fuel manufacturer? 1. Drain the fuel. 2. Check whether the fuel density sensor is dirty. Is the fuel density sensor dirty?
84402827B - May 2011 4023H-87
Yes
No
Go to Step 2
The fuel is not appropriate. Go to Step 4 If the fuel density is a Go to Step 3 borderline value, perform fuel analysis.
End
Check again from the beginning of the step.
Have the customer return to the previous gas station or fuel manufacturer.
If the fuel density is clearly outside the standard, go to Step 5
Clean
Check for fuel density sensor trouble.
Main Unit-side Trouble Diagnostic Trouble Code: 7600 CAN Bus Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7600 is displayed.
Is diagnostic trouble code: 7600 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7600 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7600 displayed? Inspect for shorts. 1.
Turn the key switch OFF and disconnect CN. 50. Inspect for continuity between the ground and terminal A of the CN. 50 harness side.
3
2.
4
Is there continuity? 1. Inspect for continuity between the ground and terminal B of the CN. 50 harness side. Is there continuity? 1.
5
Inspect for continuity between terminals A and B of the CN. 50 harness side.
Is there continuity?
P040, P042, P044, P046, P048, or Go to Step 4 P050 harness defect (short). Replace
PG041, PG043, PG045, PG047, PG049, or P051 har- Go to Step 5 ness defect (short). Replace P040, P042, P044, P046, P048, P050, PG041, PG043, PG045, PG047, Go to Step 6 PG049, or P051 harness defect (short). Replace
Inspect the ECM, computer A, computer B, and computer S units. 6
1. 2. 3.
7
Connect CN. 50. Disconnect CN. A0 and turn the key switch ON. Check whether diagnostic trouble code: 7600 is displayed.
Is diagnostic trouble code: 7600 displayed? 1. Turn the key switch OFF and connect CN. A0. 2. Disconnect CN. C2 and turn the key switch ON. 3. Check whether diagnostic trouble code: 7600 is displayed. Is diagnostic trouble code: 7600 displayed?
84402827B - May 2011 4023H-88
Go to Step 7
ECM defect. place
Re-
Computer S defect. Computer A defect. Replace Replace
Main Unit-side Trouble Diagnostic Trouble Code: 7601 Monitor Communication Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7601 is displayed.
Is diagnostic trouble code: 7601 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7601 is displayed.
Yes
No
Go to Step 2
Go to Step 3
Is diagnostic trouble code: 7601 displayed? Inspect for disconnection. 1.
Turn the key switch OFF and disconnect CN. A2 and CN. C1. Inspect for continuity between terminal 10 of the CN. A2 harness side and terminal 8 of the CN. C1 harness side.
Go to Step 4
WL061 harness defect (disconnection). Repair or replace
4
Is there continuity? 1. Inspect for continuity between terminal 3 of the CN. A2 harness side and terminal 9 of the CN. C1 harness side.
Go to Step 5
5
Is there continuity? 1. Turn the key switch ON. 2. Check whether diagnostic trouble code: 7601 is displayed.
W060 harness defect (disconnection). Repair or replace
Computer A defect. Monitor defect. ReReplace place
3
2.
Is diagnostic trouble code: 7601 displayed?
84402827B - May 2011 4023H-89
1 2
COMPUTER A MONITOR
a
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7602 ECM Communication Abnormality Step
1
2
3
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7602 is displayed.
Is diagnostic trouble code: 7602 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble code: 7602 is displayed. Is diagnostic trouble code: 7602 displayed? 1. Check whether diagnostic trouble codes 7603 and 7604 are displayed at the same time. Are diagnostic trouble codes 7603 and 7604 displayed at the same time? Inspect for disconnection. 1.
Turn the key switch OFF and disconnect CN. C2 and CN. A0. Inspect for continuity between terminal 6 of the CN. C2 harness side and terminal 18 of the CN. A0 harness side.
4
2.
5
Is there continuity? 1. Inspect for continuity between terminal 14 of the CN. C2 harness side and terminal 37 of the CN. A0 harness side. Is there continuity?
84402827B - May 2011 4023H-90
Yes
No
Go to Step 2
Go to Step 3
Inspect the connecGo to Step 4 tion status of CN. C2.
Go to Step 5
P040 or P042 harness defect (disconnection). Repair or replace
ECM defect. place
PG041 or PG043 Re- harness defect (disconnection). Repair or replace
Main Unit-side Trouble Diagnostic Trouble Code: 7604 Computer B Communication Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7604 is displayed.
Is diagnostic trouble code: 7604 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble codes 7602 and 7603 are displayed at the same time.
Yes
No
Go to Step 2
Inspect the connecGo to Step 3 tion status of CN. C2.
Are diagnostic trouble codes 7602 and 7603 displayed at the same time? Inspect for disconnection. 1.
Turn the key switch OFF and disconnect CN. C2 and CN. C7. Inspect for continuity between terminal 6 of the CN. C2 harness side and terminal 8 of the CN. C7 harness side.
3
2.
4
Is there continuity? 1. Inspect for continuity between terminal 14 of the CN. C2 harness side and terminal 16 of the CN. C7 harness side. Is there continuity?
84402827B - May 2011 4023H-91
Go to Step 4
P040 or P048 harness defect (disconnection). Repair or replace
PG041 or PG049 Computer S defect. harness defect (disReplace connection). Repair or replace
Main Unit-side Trouble Diagnostic Trouble Code: 7605 ECM Mismatch Step
Standard value
Action
No
Turn the key switch ON. Check whether diagnostic trouble code: 7605 is displayed.
Go to Step 2
2
Is diagnostic trouble code: 7605 displayed? 1. Check for an error on the service support model selection screen.
Go to Step 3
3
Is the model selection screen correct? 1. Check that the ECM which matches the model is installed.
1
1. 2.
Yes
Does the ECM match the model?
84402827B - May 2011 4023H-92
ECM defect. place
Correctly set the model selection. Re-
Replace with an ECM that matches the model.
1 2
COMPUTER A ENGINE COMPUTER
a
CAN COMMUNICATION
Main Unit-side Trouble Diagnostic Trouble Code: 7606 EEPROM Data Abnormality Step
Standard value
Action 1. 2.
1
Turn the key switch ON. On the service support DIAG screen, check whether diagnostic trouble code: 7606 (â&#x2014;?) is displayed.
Yes
No
Go to Step 2
Is diagnostic trouble code: 7606 (â&#x2014;?) displayed? 1. 2
Rewriting of the computer changed the used space of the EEPROM. Computer A defect. Turn the key switch Replace OFF, and then turn the key switch ON again.
Check whether rewriting was performed on computer A before the diagnostic trouble code was displayed.
Was rewriting performed on computer A before the diagnostic trouble code was displayed?
Diagnostic Trouble Code: 7607 Computer C Communication Abnormality Step
1
2
Standard value
Action 1. 2.
Turn the key switch ON. Check whether diagnostic trouble code: 7607 is displayed.
Is diagnostic trouble code: 7607 displayed? 1. Inspect the connection status of each connector. 2. Check whether diagnostic trouble codes 7602, 7603, 7604 are displayed at the same time.
Yes
No
Go to Step 2
Inspect the connecGo to Step 3 tion status of CN. A2.
Are diagnostic trouble codes 7602, 7603, 7604 displayed at the same time? Inspect for disconnection. 1.
Turn the key switch OFF and disconnect CN. A2 and CN. A23. Inspect for continuity between terminal 6 of the CN. A2 harness side and terminal 7 of the CN. A23 harness side.
3
2.
4
Is there continuity? 1. Inspect for continuity between terminal 14 of the CN. A2 harness side and terminal 8 of the CN. A23 harness side. Is there continuity?
84402827B - May 2011 4023H-93
Go to Step 4
P040 or V050 harness defect (disconnection). Repair or replace
PG041 or VG051 Computer C defect. harness defect (disconnection). Repair Replace or replace
Main Unit-side Trouble
84402827B - May 2011 4023H-94
Section 4023K
Data Reference Values
84402827B - May 2011
84402827B - May 2011
CONTENTS Non-operational P rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Two pump relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 4023K-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 4023K-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Data Reference Values The purpose of data list is for checking the status of the machine and each equipment. This data is used in trouble diagnosis by comparing the each machine data with standard values, and checking whether the vehicle data is temporarily or always different from the reference values. Data display items
Unit
Battery voltage V Target engine rpm RPM Engine rpm RPM Throttle accelerator switch position sensor 1 V (APP1) Throttle accelerator switch position sensor 2 V (APP2) Throttle accelerator switch position (APP) ％ Fuel rail pressure sensor V Fuel rail pressurefeedback V Coolant temperature sensor Coolant temperature °C Intake air temperature sensor V Intake air temperature °C Fuel temperature sensor V Fuel temperature °C Barometric pressure sensor V Barometric pressure kPa voltage Boost temperature sensor Boost pressure sensor kPa 1st cylinder fuel correction amount mm3/st 2nd cylinder fuel correction amount mm3/st 3rd cylinder fuel correction amount mm3/st 4th cylinder fuel correction amount mm3/st 5th cylinder fuel correction amount mm3/st 6th cylinder fuel correction amount mm3/st Engine mode EGR valve 1 drive duty ％ ON/OFEGR position 1 F ON/OFEGR position 2 F ON/OFEGR position 3 F ON/OFIgnition switch F ON/OFStarter switch F ON/OFGlow relay F Fuel delivery rate data 1 Fuel delivery rate data 2 Fuel delivery rate data 3
This display menu is subject to change without notice.
Non-operational P rotation
Idling speed reference value This varies depending on the conditions of the machine. 22 - 30 800 895 - 905 0.0 0.0 0 1.8 Feedback mode 0.5 - 0.8 65 - 78 0.9 - 4.1 -10 - 40 2.3 20 Approx. 2 Approx. 100 V 4.4 Approx. 100 (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less Fuel mode 0 Any one among 1, 2 and 3 is polarity-inverted (Example: 1 = ON, 2 = ON, 3 = OFF) Any one among 1, 2 and 3 is polarity-inverted (Example: 1 = ON, 2 = ON, 3 = OFF) Any one among 1, 2 and 3 is polarity-inverted (Example: 1 = ON, 2 = ON, 3 = OFF) ON OFF OFF ON immediately after the starter switch is turned ON - Depending on the machine - Depending on the machine - Depending on the machine
84402827B - May 2011 4023K-3
Data Reference Values Two pump relief Data display items
Units
Battery voltage Target engine rpm Engine rpm Throttle accelerator switch position sensor 1 (APP1) Throttle accelerator switch position sensor 2 (APP2) Throttle accelerator switch position (APP) Fuel rail pressure sensor Fuel rail pressure feedback Coolant temperature sensor Coolant temperature Intake temperature sensor Intake air temperature Fuel temperature sensor Fuel temperature barometric pressure sensor Atmospheric pressure Boost temperature sensor voltage Boost pressure sensor First cylinder fuel correction amount Second cylinder fuel correction amount Third cylinder fuel correction amount Fourth cylinder fuel correction amount Fifth cylinder fuel correction amount Sixth cylinder fuel correction amount Engine mode EGR valve 1 drive duty
V min-1 min-1 V V ％ V
EGR position 1 EGR position 2 EGR position 3 Ignition switch starter switch glow relay Q adjustment compensation data 1 Q adjustment compensation data 2 Q adjustment compensation data 3
V °C V °C V °C V kPa V kPa mm3/st mm3/st mm3/st mm3/st mm3/st mm3/st ％ ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF
Two Pump Relief reference value It varies depending on the actual unit 22 - 30 500 1,945 - 1,950 0.0 0.0 0 1.5 Feedback mode 0.4 - 0.5 80 - 85 2.2 29 1.0 53 Approx. 2 Approx. 100 4.3 Approx. 180 - 200 (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less (-3) - 3 or less Fuel mode 0 - 97 Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) Reverse the polarity of either 1, 2, or 3 (Example: 1=ON, 2=ON, 3=OFF, etc) ON OFF OFF ON immediately after the starter switch ON - This differs depending on the actual unit. - This differs depending on the actual unit. - This differs depending on the actual unit.
84402827B - May 2011 4023K-4
Section 4040
Electrical Wiring Diagram
84402827B EN - May 2011
84402827B EN - May 2011
CONTENTS Main Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cab Main Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B EN - May 2011 4040-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine and Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Wiring Diagram Main Frame
84402827B EN - May 2011 4040-2
Electrical Wiring Diagram *1 *2
Yellow adhesive tape Blue adhesive tape
a
The connector (CN. D52F) be fastened with red tape. The connector (CN. D82F) be fastened with red tape. The connector (CN. D76F) be fastened with red tape. The connector (CN. D44F) be fastened with red tape.
b c d
CN. A50F CN. A51F CN. A52F CN. A53F CN. A54F CN. A55F CN. A56F CN. D1F CN. D2F CN. D5F CN. D6F CN. D7F CN. D8M CN. D9M CN. D10M CN. D11M
must must must must
Cab main harness: A Cab main harness: B Cab main harness: C Cab main harness: D Cab main harness: E Cab main harness: F Cab main harness: G ECM: 1 ECM: 2 Barometric pressure sensor DPD register Engine harness: A Engine harness: B Engine harness: C Engine harness: D Engine harness: H
*3 *4
Red adhesive tape White adhesive tape
e
The connector (CN. D83F) be fastened with red tape. The connector (CN. D38F) be fastened with red tape. The connector (CN. D58F) be fastened with red tape. The connector (CN. D74F) be fastened with red tape.
f g h
CN. D41F CN. D42F CN. D43F CN. D44F CN. D45F CN. D46F CN. D47F CN. D48F CN. D49F CN. D50F CN. D51F *CN. D52F CN. D53F CN. D54F CN. D55F CN. D56F
*5 *6 must must must must
i j k l
Pink adhesive tape Nameplate The connector (CN. D90F) must be fastened with red tape. The connector (CN. D68F) must be fastened with red tape. The connector (CN. D69F) must be fastened with red tape. Detail of engine controller connector
Reducing valve: Boom Reducing valve: Arm Reducing valve: Bucket Electromagnetic proportional valve P1 pressure sensor P2 pressure sensor N1 pressure sensor N2 pressure sensor Swing pressure sensor Upper pressure sensor Travel pressure sensor HBCV pressure sensor Boom-up pressure sensor Arm-in pressure sensor Bucket-close pressure sensor Oil temperature sensor
CN. D12 CN. D13 CN. D14F CN. D15 CN. D16 CN. D17 CN. D18 CN. D19 CN. D20 CN. D21 CN. D22M CN. D23M CN. D24M CN. D25 CN. D26F CN. D27F CN. D28F CN. D29F CN. D30F CN. D31F CN. D32M CN. D33M CN. D34M CN. D35F CN. D36F CN. D37F CN. D38F CN. D39F CN. D40F
84402827B EN - May 2011 4040-3
Starter motor: S Alternator: B Alternator: L/R Alternator: E Alternator: GND Battery relay: B Battery relay: IGN Battery relay: IGN Battery relay: Coil Battery relay: Coil Battery relay: GND Fusible link: 50 A Fusible link: 60 A Fusible link: 65 A Fusible link: 15 A Starter relay: B/C Starter relay: S/E Glow relay: Coil Glow relay: 1 Glow relay: 2 DPD pressure sensor DPD temperature sensor: CSF DPD temperature sensor: DOC MAF sensor Fuel filter sensor Charge fuel pump Diode: Pump Hydraulic pump Hydraulic pump: PTO
CN. D57F CN. D58F CN. D59F CN. D60F CN. D61F CN. D62F CN. D64F CN. D65F CN. D66F CN. D67F CN. D68F CN. D69F CN. D70F CN. D71F CN. D72F CN. D73F CN. D74F *CN. D76F CN. D77F CN. D78F CN. D79F CN. D80M CN. D81 *CN. D82F CN. D83F CN. D84 CN. D86F CN. D89F CN. D90F
Fuel level sensor Solenoid valve joint connector Lock lever SOL. V Swing brake SOL. V 2-stage travel SOL. V 2-stage relief SOL. V Free swing solenoid valve Housing lamp Boom lamp harness Washer motor Diode: Washer Travel alarm Horn: L+ Horn: LHorn: H+ Horn: HBeacon harness Feed pump harness Receiver dryer Air conditioner compressor Reserve tank switch Air cleaner sensor Ground G2 Oil feeding device Pressure switch filter Ground G1 Condenser relay Condenser fan Condenser fan diode
Electrical Wiring Diagram Cab Main Harness
84402827B EN - May 2011 4040-4
Electrical Wiring Diagram *1 *2
White adhesive tape Red ID tape
a
CN. A33M and A33F must be fastened with red tape. CN. A31M and A31F must be connected, then fastened with red tape. CN. A30 and A38 must be fastened with red tape. CN. A23 must be fastened with red tape.
b c d
CN. A1F CN. A2F CN. A3F CN. A4F CN. A5F CN. A6F CN. A7F CN. A8F CN. A9F
Computer A: Computer A: Computer A: Computer A: Computer B: Computer B: Computer B: Computer B: ECM relay
1 2 3 4 1 2 3 4
*3 *4
Blue ID tape Fuse box
e
CN. A24 must be fastened with red tape.
i
CN. A32F, 32M and 29F must be fastened with red tape.
f
CN. A26F must be fastened with red tape.
j
CN. A58 must be fastened with red tape.
k
CN. A40F, 41F and 42F must be tied together with red tape.
l
Nameplate position
g h
CN. A34F and 35F must be fastened with red tape. CN. A25M and CN. A25F must be connected. CN. A31M CN. A32F CN. A32M CN. A33F CN. A33M CN. A34F CN. A35F CN. A36F CN. A36M
Hour meter: Option power supply Option power supply: GND Immobilizer Immobilizer: GND CAN CAN Diagnostic switch Diagnostic switch: GND
CN. A10F CN. A11F CN. A12F CN. A13F CN. A14F CN. A15F CN. A16F CN. A17F CN. A18F CN. A19F CN. A20F CN. A21F CN. A22F CN. A23F CN. A24F CN. A25F CN. A25M CN. A26F CN. A27F CN. A28F CN. A29F CN. A30F CN. A31F
84402827B EN - May 2011 4040-5
DPD relay Battery relay Idle stop relay Starter cut relay Neutral start relay Key ON Horn relay Lamp relay Lamp relay: CAB Beacon relay Room lamp relay Speaker relay: R Speaker relay: L Computer C harness Computer T harness EST-B connector EST-B connector EST-A harness Diagnostic connector DC/DC converter FMS harness Diode Hour meter: +
CN. A37F CN. A37M CN. A38F CN. A39F CN. A40F CN. A41F CN. A42F CN. A43 CN. A44F CN. A45F CN. A46F CN. A47F CN. A48F CN. A49F CN. A50M CN. A51M CN. A52M CN. A53M CN. A54M CN. A55M CN. A56M CN. A57M CN. A58F
Memory clear Memory clear: GND ECM joint connector Joint connector: CONT Joint connector: GND Joint connector: A Joint connector: B Ground: Cab Cab harness: A Cab harness: B Console harness: A Console harness: B Console harness: C Console harness: D Frame main harness: A Frame main harness: B Frame main harness: C Frame main harness: D Frame main harness: E Frame main harness: F Frame main harness: G Option line harness Horn jumper
Electrical Wiring Diagram Frame
84402827B EN - May 2011 4040-6
Electrical Wiring Diagram
c
Marking position; Align white tape of harness. Tighten together with the starter cable ID: L
*1
Round terminal M8
*3
Wire harness; Light (frame main) (KHR14280)
*5
Register (engine accessory)
CN. D2
*2
Starter cable
*4
Floor
*6
Barometric pressure sensor (engine accessory)
CN. D6 CN. D35
a b
Code 1 2 3 4
Part name Wire; Ground (floor) Harness; Wire (frame main) Sensor; Pressure (5 MPa) G1/4 Horn; Electric (Assembly)
d
ID: H
e
Tighten together with the washer motor tube Applying the adhesive
f
Q'ty 1 1 7 1
Code 5 6 7
g
detail of cab
Part name Light; Working 24 V Ă&#x2014; 70 W Bracket lamp Alarm; Travel
CN. A52 CN. A53 CN. A54 CN. A55 CN. A56 CN. D1
Q'ty 1 1 1
CN. D41 CN. D42 CN. D43 CN. D44 CN. D47
CN. A50
Cab main harness: A (2-pin)
CN. D52
CN. A51
Cab main harness: B (8-pin)
CN. D53
HBCV harness (3-pin) (secured to harness with red tape) Pressure sensor: Boom (3-pin)
CN. D50 CN. D51
84402827B EN - May 2011 4040-7
Cab main harness: Cab main harness: Cab main harness: Cab main harness: Cab main harness: ECM: 1 (60-pin)
C (8-pin) D (14-pin) E (22-pin) F (20-pin) G (18-pin)
Pressure sensor: Arm (3-pin) ID tape: Red Pressure sensor: Bucket (3-pin) ID tape: Blue Free swing harness (2-pin) Lamp: Housing (2-pin) Boom lamp harness (2-pin) Washer motor (2-pin) Travel alarm (2-pin) (secured to harness with ECM: 2 (94-pin) CN. D69 red tape) Register (2-pin) CN. D70, 71 Horn (left) Suction air sensor (5-pin) CN. D72, 73 Horn (right) Grease-up pump harness (3-pin) (secured to Proportional valve: Boom (2-pin) ID tape: None CN. D76 harness with red tape) Proportional valve: Arm (2-pin) ID tape: Red Receiver dryer (2-pin) CN. D77 Proportional valve: Bucket (2-pin) ID tape: Blue CN. D80 Pressure switch; Air cleaner (2-pin) Option proportional valve harness (2-pin) (seCN. D81 Ground G2 cured to harness with red tape) Grease-up pump (2-pin) (secured to harness Pressure sensor: Swing (3-pin) CN. D82 with red tape) Pressure sensor: Upper (3-pin) Floor ground; Ground G1 CN. D84 Pressure sensor: Travel (3-pin) ID tape: Red CN. D89 Condenser fan: 2-pin CN. D54 CN. D55 CN. D64 CN. D65 CN. D66 CN. D67
Electrical Wiring Diagram Engine and Pump
84402827B EN - May 2011 4040-8
Electrical Wiring Diagram ANNOTATION: When assembling the ground terminals marked with a â&#x20AC;ť, it should be confirmed that the frame seating surface is not coated. If the surface is coated, assembly should be performed after removing the coating. Clean the terminal of the connectors marked with a * using cleaning agent (37) before mating, and then coat with an anti-rust agent (38). The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does not form sharp rounded shapes. (R = 10 mm or more)
1. 2. 3.
a
Engine harness (attached to engine main unit)
*4
*2
Round terminal M8
*5
*3
Round terminal M5
*6
Code 1 2 3 *CN. *CN. *CN. *CN.
10 11 D7 D8
Part name Sensor; Pressure (50 MPa) M18 Ă&#x2014; 1.5 Sensor; Thermo Sensor; Pressure (50 MPa) G1/4 Engine Engine Engine Engine
harness; harness; harness; harness;
D (20-pin) H (1-pin) A (32-pin) B (16-pin)
Engine harness; C (14-pin) Starter motor: S
CN. D48 CN. D56
CN. D15
Alternator: E Electrical wiring color: Black
CN. D58
CN. D16 CN. D32
Alternator ground CN. D59 Pressure sensor; Exhaust gas (3-pin) CN. D60 Temperature sensor DPD (FRONT) (2-pin) CN. D61 Connector color: Dark gray Temperature sensor DPD (CENTER) (2-pin) CN. D62 Connector color: Light gray Fuel filter (3-pin) CN. D78 Charge fuel pump (2-pin)
CN. D33 CN. D34
Be careful to assemble the battery cable in the correct direction.
*1
*CN. D9 CN. D12
Frame; Housing (center front)
*7
KHR28790 (battery starter cable)
CN. D36 CN. D37
Starter motor (attached to engine main unit) Engine ground (attached to engine main unit) Q'ty 2 1 1 CN. D39 CN. D40 CN. D45 CN. D46
Proportional valve; Horsepower control (2-pin) Proportional valve: Flow control (2-pin) Pressure sensor P1 (3-pin) ID tape: Red Pressure sensor P2 (3-pin) ID tape: Blue
84402827B EN - May 2011 4040-9
Pressure sensor N2 (3-pin) Sensor; Oil temperature (2-pin) Joint connector (8-pin) (secured to red tape harness) SV; Lever lock (2-pin) SV; Swing brake (2-pin) ID tape: Blue SV; 2-stage travel (2-pin) ID tape: Red SV; 2-stage relief (2-pin) Compressor (1-pin)
Electrical Wiring Diagram Attachments
84402827B EN - May 2011 4040-10
Electrical Wiring Diagram a b
Tighten together with the attachment line Tighten together with the arm line
Code 1 2 CN. D73
Part name Wire harness; Light (frame main) Light; Working
Q'ty 1 1
Connect to the frame main harness
84402827B EN - May 2011 4040-11
Electrical Wiring Diagram Battery
84402827B EN - May 2011 4040-12
Electrical Wiring Diagram ANNOTATION: 1.
CN. D19
When assembling the ground terminals marked with a *, it should be confirmed that the frame seating surface is not coated. If the surface is coated, assembly should be performed after removing the coating. The clamp positions of the electrical wiring that comes out from connectors should be adjusted so that the wiring does not form sharp rounded shapes. (R = 10 mm or more)
2.
a b
*1 *2
Marking position: Align white tape of harness Install the battery indicator in such a way that it is completely visible KSR13401 (harness; wire (frame main)) M10 (battery accessory)
Code 1 2 3 4 5 CN. D17 CN. D18
Part name Holder; Battery Cable; Battery relay (starter) Bracket; Battery relay Relay; Changeover (24 V) Relay; Battery
c
Detail of battery
d
Detail of battery box
*3
M8 (battery accessory)
*4
Glow relay (engine accessory) Q'ty 1 1 1 1 1
Code 6 7 8 9 10
Round terminal M8 (battery relay B) red ID tape CN. D26 Round terminal M8 (battery relay IGN) Wire CN. D27 color: red
*5
CN. D20 CN. D21 CN. D22 CN. D23 CN. D24 CN. D25
Starter relay (engine accessory)
Part name Battery 180G51 (with terminal) Cable; Battery bridge Cable; Battery B+ relay Cable; Battery ground Harness; Wire (diode)
Q'ty 2 1 1 1 1
Fuse 15 A CONT (2-pin) Starter relay B/C (2-pin)
84402827B EN - May 2011 4040-13
Round terminal M8 (battery relay IGN) Wire CN. D28 color: white Round terminal M4 (battery relay coil 1) Wire CN. D29 color: green Round terminal M4 (battery relay coil 2) Wire CN. D30 color: red stripe on white background Battery relay GND (1-pin) CN. D31 Fuse 50 A +B (2-pin) CN. D68 Fuse 60 A ST (2-pin) CN. D80 Fuse 65 A IGN (2-pin) CN. D86
Starter relay S/E (2-pin) Glow relay coil (2-pin) Glow relay 1 (1-pin) Glow relay 2 (1-pin) Switch; LLC tank (2-pin) Harness; Beacon (2-pin) Relay; Condenser (5-pin)
Electrical Wiring Diagram Cab
84402827B EN - May 2011 4040-14
Electrical Wiring Diagram a
Marking position (align white tape of harness)
d
b
Connect with the supplied cab antenna line.
e
c
Connect the (45) CN. A32 M and the cab main harness CN. A32F.
f
*1 *2 *3 *4
Monitor; System Trim; Side (upper) Engine controller (engine accessory) Barometric pressure sensor (engine accessory)
Code 1 2 3 4 5 6 7
Remove only CN. A31 F from the red tape and fasten it again with the red tape after connecting it with the joint harness (45). Tighten the harness and the antenna together. Fasten the harness with the clip. The clip (KHN17050) is a console accessory.
*5 *6
Cover; Top (console right) Cover; Top (console left)
*7
Register (engine accessory)
*8
Box; Fuse (cab main harness accessory)
Part name Switch; Rocker (horn switchover) Plastic plug (25) Harness; Wire (console) Harness; Wire (cab; main) Changeover relay; 24V Harness; Wire (EST-A) Code; Antenna
Q'ty 1 2 3 4 5 1 1
Code 8 9 10 11 12 13
CN. 52 CN. 54
EST: A: 9-pin Frame main harness: E: 22-pin
CN. A41 CN. A42
CN. A1
Computer A: 1: 26-pin
CN. A44
CN. A2
Computer A: 2: 16-pin
CN. A45
CN. A3
Computer A: 3: 12-pin
CN. A46
g
For HBCV specifications machines
*9 Air conditioner panel *10 Radio external input terminal Switch rocker; Overload warning *11 (KHR15490)
Part name Switch; Starter assembly (CASE) Switch; Rocker (E. STOP) Radio; Car (12/24 V) (with AUX; NA) Switch; Rocker (warning switchover) Switch; Rocker (beacon) Harness; Wire (joint)
Q'ty 1 1 1 1 1 1
Joint: A: 20-pin Joint: B: 20-pin Cab; Harness: A: 14-pin Connect with supplied cab harness Cab; Harness: B: 18-pin Connect with supplied cab harness Console harness: A: 10-pin
CN. A4 CN. A5 CN. A6 CN. A7 CN. A8 CN. A9 CN. A10
Computer A: 4: 22-pin Computer B: 1: 26-pin Computer B: 2: 16-pin Computer B: 3: 12-pin Computer B: 4: 22-pin ECM DPF; White marking
CN. A47 CN. A48 CN. A49 CN. A50 CN. A51 CN. A52 CN. A53
CN. A11
Battery relay
CN. A55
CN. A12 CN. A13 CN. A14 CN. A15 CN. A16 CN. A17 CN. A18 CN. A19 CN. A20 CN. A21 CN. A22 CN. A23 CN. A24 CN. A25 CN. A27 CN. A28
Idling start; White marking Starter cut Neutral start; White marking Key ON Horn; White marking Relay lamp: Upper CAB lamp; White marking Relay beacon Room lamp; White marking Speaker: R Speaker: L; White marking Computer C: 14-pin (fastened with red tape) Computer T: 8-pin (fastened with red tape) EST-B: 12-pin Diagnostic: 16-pin DC converter: 7-pin
CN. A55 CN. A56 CN. A57 CN. B1 CN. B2 CN. B3 CN. B4 CN. B5 CN. B7 CN. B8 CN. B9 CN. B10 CN. B11 CN. B12 CN. B12 CN. B17
CN. A34
CAN H
CN. B19
CN. A35
CAN L
CN. B20
CN. A36 CN. A37
Diagnostic SW Memory clear SW
CN. A39
Joint: Controller: 6-pin
CN. B21 CN. B22 CN. B23. Controller DRM (fastened with red tape) B24. B25
CN. A40
Joint: GND: 6-pin
84402827B EN - May 2011 4040-15
Console harness: B: 8-pin Console harness: C: 14-pin Console harness: D: 18-pin Frame main harness: A: 2-pin Frame main harness: B: 8-pin Frame main harness: C: 8-pin Frame main harness: D: 14-pin Frame main harness: F: 20-pin Connect with joint harness (45) Cab main harness: F Frame main harness: G: 18-pin Option line harness: 10-pin Starter switch: 6-pin Throttle volume: 3-pin Limit switch: 2-pin Knob right switch: 8-pin Knob left switch: 8-pin Engine stop SW: 10-pin ID: None Fan reverse SW: 10-pin ID: Red tape Free swing SW: 10-pin ID: Blue tape SW beacon: 10-pin ID: Red tape SW alarm switchover: 10-pin ID: Blue tape SW liftcrane: 10-pin ID: None Radio: 9-pin Seat suspension: 2-pin (fastened with red tape) Air conditioner unit A: 8-pin Connect with supplied air conditioner harness Air conditioner unit B: 22-pin Connect with supplied air conditioner harness Air conditioner panel: A: 20-pin Air conditioner panel: B: 16-pin
Electrical Wiring Diagram
84402827B EN - May 2011 4040-16
Section 5001A
Removal and Installation of Shoe Assembly
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Shoe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 5001A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5001A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Shoe Assembly Job code
48100AD07
2.
Use a box wrench (19 mm) to loosen the check valve (1) to release grease, and then loosen the track shoe tension. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening. Use a rag to catch grease that trickles out of the check valve. If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.
3.
Use a wrench (19 mm) to remove the bolt (1), and then remove the check valve (2) and stopper (3).
WARNING • When loosening the grease cylinder check valve, loosen it a little at a time. • The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off. The check valve adjustment procedure should not be done in front of the check valve. • Do not get under the main unit when it is jacked up. Make sure to place the main unit on crossties to prevent falling. CAUTION • Make sure to stop the engine for loosening shoes and when removing master pins. Items to prepare • • • • • • • • •
Wrench (19 mm) Box wrench (19 mm) Hammer Wood planks, etc. Striking jig Crowbar Rag Lifting equipment (with the required breaking load) Liftcrane (with the required lifting capacity)
Removal of Shoe Assembly 1.
Rotate the shoe and align it so that the master pin (1) is next to the idler.
• If the check valve (2) is removed, it is easier to loosen the track shoe tension.
4.
Straighten out the S-pin (2) attached to the master pin (1) by striking one side of it with a hammer, and use a crowbar, etc. to remove it.
84402827B - May 2011 5001A-3
Removal and Installation of Shoe Assembly
5.
6.
Remove the track shoe (1). At this time, place a wood plank (2) under the bottom track shoe (1) so that it does not fall.
7.
Start the engine, raise the lower side frame of the track shoe removal side about 20 cm, slowly set the travel lever to backwards, and move the track shoe (1) to remove it from the lower frame.
Use a hammer (2) and striking rod (3) to push the master pin (1) out.
84402827B - May 2011 5001A-4
Removal and Installation of Shoe Assembly Installation of Shoe Assembly 1.
2.
3.
Wrap the edge of the track shoe (1) onto the take-up roller (2). Place a wood plank (3) on the ground and lift the bottom-side link to align the position where the master pin is inserted.
4.
Insert the master pin (1). Insert the S-pin (2) and bend it so that it cannot slip out.
5.
Tighten the check valve (1). While monitoring the track shoe tension, inject grease into the grease cylinder.
Raise the lower side frame about 20 cm. Lift the track shoe (1) and align it with the sprocket (2). Pay attention to the backwards and forward direction of the track shoe.
Slowly set the travel lever to forward and feed the track shoe to the take-up roller side as shown in the diagram. In the middle of this procedure when the track shoe passes the upper roller, use a crowbar, etc. to lift the track shoe while it is being fed. Lower the lower side frame after the shoe has reached position A shown in the diagram.
84402827B - May 2011 5001A-5
Removal and Installation of Shoe Assembly 6.
To adjust the track shoe tension, raise the lower side frame with a wood plank (1) or other device as shown in the diagram.
7.
Adjust the tension so that the distance indicated with A between the frame bottom (1) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (2) is 340 - 360 mm.
84402827B - May 2011 5001A-6
Section 5001B
Removal and Installation of Shoe Plate
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Shoe Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 5001B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5001B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Shoe Plate Job code
Installation of Shoe Plate
48100AB14
1.
Install the shoe plate (1).
2.
Use a box wrench (32 mm) to install the 4 shoe bolts (1). Bolt (1) tightening torque: 1236 - 1510 N・m
CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • •
Box wrench (32 mm) Grease Rag Cleaning fluid
Removal of Shoe Plate 1.
2.
Use a box wrench (32 mm) to remove the 4 shoe bolts (1).
Remove the shoe plate (1).
84402827B - May 2011 5001B-3
Removal and Installation of Shoe Plate
84402827B - May 2011 5001B-4
Section 5003A
Removal and Installation of Upper Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Upper Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Upper Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 5003A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5003A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Upper Roller Job code
48138AB21
2.
Use a jack (3) to lift the top of the shoe, and then insert wood planks (4) to separate the shoe (2) and upper roller (1) by about 10 mm.
3.
Use a box wrench (30 mm) to remove the 4 bolts (2), and then remove the upper roller (1).
WARNING • When loosening the check valve, loosen it a little at a time and stop when any grease appears. The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much. The check valve adjustment procedure should not be done in front of the check valve. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • •
Box wrenches (19 mm, 30 mm) Jack (That meets the lifting weight.) Rag Cleaning fluid Wood planks, etc.
Removal of Upper Roller 1.
Use a box wrench (19 mm) to loosen the grease cylinder check valve (1), then loosen the shoe tension. • Grease drains out, so provide rag (2) close to the drain port. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening.
84402827B - May 2011 5003A-3
Removal and Installation of Upper Roller Installation of Upper Roller 1.
Use a jack (2) to lift the top of the shoe (1), and then insert wood planks (3).
2.
Use a box wrench (30 mm) to install the 2 bolts (4), and then install the upper roller (1). • Apply Loctite. • Bolt (2) tightening torque: 521 - 608 N・m
3.
4.
To adjust the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (1) under the lower frame to prevent falling.
5.
Adjust the tension so that the distance indicated with A between the frame bottom (1) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (2) is 340 - 360 mm.
Tighten the check valve (1). While monitoring the track shoe tension, inject grease into the grease cylinder.
84402827B - May 2011 5003A-4
Section 5003B
Assembly and Disassembly of Upper Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 5003B-1
4 5 6 7 9
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5003B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Upper Roller Job code
48138AC30
CAUTION • To ensure safe operations, wear protective devices before beginning work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Follow the precautions below when suspending the load. • The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. • Fix the roller to a level surface so it does not roll. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling touching parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. <General cautions> • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare • • • • • • • • • • • • •
Hexagon wrench (6 mm) Hammer Wrenches (17 mm) Box wrench (17 mm) Screwdriver Engine oil (Shell Rimula Oil #30) Specialty jigs Pressing machine Loctite 262 Special fiber cloth (Kimwipe) Marking pen Micrometer caliper Caliper 84402827B - May 2011 5003B-3
Assembly and Disassembly of Upper Roller Configuration Diagram
Code 1 2 3 4 5 6
Part name Cover O-ring Plug Hexagon bolt Loctite Thrust plate
Code 7 8 9 10 11 12
84402827B - May 2011 5003B-4
Part name Bushing Shaft Bushing Roller Floating seal Bracket
Assembly and Disassembly of Upper Roller Dimension Diagram
*1
Press fit length
84402827B - May 2011 5003B-5
Assembly and Disassembly of Upper Roller Jig Dimension Diagram
A B1
Bushing removal jig For bushing press-fit jig (7)
84402827B - May 2011 5003B-6
B2 C
For bushing press-fit jig (9) Floating seal installation jig
Assembly and Disassembly of Upper Roller Disassembly Procedures 1.
4.
Use a box wrench (17 mm) to remove the 3 bolts (1) inside the roller, and then remove the thrust plate (2).
5.
Lift the roller (1) and remove the shaft (2).
6.
Remove the floating seal (2) on the roller (1). Check whether the sliding surface has rusted or is damaged.
Stand the roller vertically and use a hexagon wrench (6 mm) (1) to remove the plug (2). â&#x20AC;˘ The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, using seal tape is necessary.
2.
Face down the part of the roller from which the plug was removed and empty the oil from within the roller. â&#x20AC;˘ It may take a few hours to completely empty the oil. â&#x20AC;˘ Place an oil pan (1) under the roller to catch the oil.
3.
Use a wrench (17 mm) to remove the 3 bolts (2) from the cover (1), and then remove the cover.
84402827B - May 2011 5003B-7
Assembly and Disassembly of Upper Roller 7.
Remove the floating seal (2) on the shaft (1).
8.
Remove the O-ring (2) on the cover (1) side.
9.
Use a caliper (4), micrometer caliper (5), and cylinder gauge (6) to measure the roller (with bushing) (1), bracket (2), and shaft (3) for wear and deformation. Replace with new parts as necessary.
â&#x20AC;˘ Check whether the O-ring is twisted. If it is twisted, replace it with a new one.
10. When replacing bushings (1) (2), use jig A (4) to restrain it from the side where the shaft (3) was removed and press it out with a pressing machine (5).
84402827B - May 2011 5003B-8
Assembly and Disassembly of Upper Roller Assembly Procedures 1.
4.
Invert the roller (1) and insert the bushing (2). Restraining from above using jig B1 (3), push in with the pressing machine (4). Push in all the way to the position where jig B1 stops.
5.
Insert the floating seal (3) into the roller (1) and bracket (2). Use jig C (4) to press it into position.
6.
Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.
Clean all parts. â&#x20AC;˘ Find a clean location. â&#x20AC;˘ Place a rubber plate or cloth on the work platform so as not to damage the parts.
1 2.
3.
Cleaning fluid After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.
If the bushing (1) was removed during disassembly, put it into the roller (2). Face up the thrust plate installation side, restrain from above using jig B2 (3), and push in with the pressing machine (4).
84402827B - May 2011 5003B-9
Assembly and Disassembly of Upper Roller 7.
Apply hydraulic oil to the roller (1).
8.
Install the shaft (1) to the roller (2).
10. Install the thrust plate (1) with 3 bolts (2). Degrease the bolts well, apply Loctite (3) to the bolt openings, and tighten the bolts. After tightening the bolts, mark them (4). Bolt (2) tightening torque: 62.8 - 72.6 Nă&#x192;ťm
11. Install the cover (1) with 3 bolts (2). Degrease the bolts, apply Loctite (3) to the bolt openings, and tighten the bolts. After tightening the bolts, mark them (4). Bolt (2) tightening torque: 62.8 - 72.6 Nă&#x192;ťm
9.
Use a special fiber cloth to thoroughly wipe the surface of the thrust plate (1) to prevent any dust or scratches.
12. Rotate the roller in the direction of the arrow and check that it rotates smoothly.
84402827B - May 2011 5003B-10
Assembly and Disassembly of Upper Roller 13. Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.
14. Fill engine oil (about 160 cc) into the roller. After filling the engine oil, use a hexagon wrench (1) to tighten the plug (2) (coated with seal nylon). After tightening the bolts, mark them (3). â&#x20AC;˘ To reuse a plug, wrap it with seal tape. Plug (2) tightening torque: 24.5 Nă&#x192;ťm
This completes the assembly.
84402827B - May 2011 5003B-11
Assembly and Disassembly of Upper Roller
84402827B - May 2011 5003B-12
Section 5003C
Removal and Installation of Lower Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Lower Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Lower Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 5003C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5003C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Lower Roller Job code
48138AD50
2.
Jack up the side frame on the side where the roller is being replaced, as shown in the diagram. Jack up so that the shoe is floating about 5 cm, and insert wood plank (1) under the lower frame to prevent falling.
3.
If it is impossible to insert wood planks (3) under the lower frame, insert wood planks (3) between the side frame and the link shoe (2) to separate the link shoe and lower roller (1) by about 15 mm.
4.
Use a box wrench (36 mm) to remove the 4 bolts (2), then remove the lower roller (1).
WARNING • Do not get under the main unit when it is jacked up. Make sure to place the main unit on wood planks to prevent falling. • When loosening the grease cylinder check valve, loosen it a little at a time and stop when any grease appears. The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • •
Box wrenches (19 mm, 36 mm) Rag Cleaning fluid Wood planks, etc.
Removal of Lower Roller 1.
Use a box wrench (19 mm) to loosen the check valve (1), and then loosen the shoe tension. Do not loosen the check valve all at once. Loosen it slowly while monitoring the grease output and shoe loosening. • Grease drains out, so provide rag (2) close to the drain port.
84402827B - May 2011 5003C-3
Removal and Installation of Lower Roller Installation of Lower Roller 1.
3.
When adjusting the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (1) under the lower frame to prevent falling.
4.
Adjust the tension so that the distance indicated with A between the lower frame (1) of the center area of the lower side frame and the lowest hanging part of the shoe plate (2) is 340 - 360 mm.
Insert wood planks (4) between the side frame and the link shoe (3), use a box wrench (36 mm) to install 4 bolts (2) and then install the lower roller (1). â&#x20AC;˘ Bolt (2) tightening torque: 902 - 1049 Nă&#x192;ťm
2.
Tighten the check valve (1). While monitoring the track shoe tension, inject grease into the grease cylinder.
84402827B - May 2011 5003C-4
Section 5003D
Assembly and Disassembly of Lower Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 5003D-1
4 5 5 6 9
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5003D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Lower Roller CAUTION • To ensure safe operations, wear protective devices before beginning work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Follow the precautions below when suspending the load. • The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. • Fix the roller to a level surface so it does not roll. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling sliding parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. <General cautions> • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare • • • • • • • • • • • • • •
Hexagon wrench (6 mm) Hammer Wire clip Pliers Gear puller Screwdriver Gear oil (Mobile Gear Oil SHC320) Specialty jigs Pressing machine Loctite Special fiber cloth (Kimwipe) Micrometer caliper Caliper Cylinder gauge 84402827B - May 2011 5003D-3
Assembly and Disassembly of Lower Roller Configuration Diagram
1 2 3 4 5
Part name Roller Shaft Bushing Floating seal O-ring
6 7 8 9
84402827B - May 2011 5003D-4
Part name Collar (with plug) Wire clip Plug Collar (without plug)
Assembly and Disassembly of Lower Roller Dimension Diagram
Jig Dimension Diagram
84402827B - May 2011 5003D-5
Assembly and Disassembly of Lower Roller A B C
Bushing removal jig Bushing press-fit jig Floating seal installation jig
Disassembly Procedures 1.
Stand the roller vertically and use a hexagon wrench (6 mm) (1) to remove the plug (2). • The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, using seal tape is necessary.
2.
Face down the part of the roller from which the plug was removed and empty the oil from within the roller. • It may take a few hours to completely empty the oil. • Place an oil pan (1) underneath to catch the oil. • Securely fasten so that the roller does not fall over.
3.
Remove the wire clip (1). Tap another wire (2) with the hammer (3) from the outside to push out the wire clip that is already in the roller. • Place the roller horizontally and secure it so it does not roll before doing this work. • The wire in the roller is very securely fixed, so prepare several wire clips. Also be sure to coat with lubricant.
84402827B - May 2011 5003D-6
Assembly and Disassembly of Lower Roller 6.
Check whether the surface of the floating seal (2) sliding against the removed collar (1) has rusted or is damaged. Also make sure the O-ring (3) on the seal ring (4) is not twisted. • The O-ring cannot be reused. Replace it with new part.
4.
5.
Use pliers (2) to remove the pushed out wire clip (1).
7.
Remove the floating seal (1) on the roller. As described in step 6, check whether the sliding surface has rusted or is damaged. Also make sure the O-ring is not twisted.
8.
Remove the O-ring (2) on the shaft (1).
Use a gear puller (2) to remove the collar (1). If the collar is difficult to remove, hook the collar on the bolt and catch the puller on that part. • If the collar has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. • When hitting it with a hammer, be careful not to dent it.
• The O-ring cannot be reused. Replace it with new part.
84402827B - May 2011 5003D-7
Assembly and Disassembly of Lower Roller 9.
Remove the shaft (1).
12. Use a caliper (6), micrometer caliper (5), and cylinder gauge (7) to measure the roller (with bushing) (1), collars (2) (3), and shaft (4) for wear and deformation. Replace with new parts as necessary.
10. Check whether the surface of the floating seal (2) sliding against the removed collar (1) on the opposite side has rusted or is damaged. Also make sure the O-ring (3) on the seal ring (4) is not twisted. â&#x20AC;˘ The O-ring cannot be reused. Replace it with new part.
11. As described in step 6,7, remove the floating seal (1) on the opposite side.
13. When replacing a bushing, insert jig A (3) into the bushing (1), and use a cylindrical object (such as a shaft) (2) to push from the top. The bushing comes off.
84402827B - May 2011 5003D-8
Assembly and Disassembly of Lower Roller Assembly Procedures 1.
4.
Use jig C (5) to push the floating seal (4) into the collars (2) (3) and roller (1) by hand.
5.
Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.
6.
Apply gear oil to the floating seals (3) on the collars (1) (2).
Clean all parts by immersing them in cleaning fluid (1). â&#x20AC;˘ Select a clean location. â&#x20AC;˘ Place a rubber plate or cloth on the work platform so as not to damage the parts.
2.
3.
After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.
If the bushing (2) was removed during disassembly, put it into the roller (1). Restraining from above using jig B (3), push in with the pressing machine (4). Invert the roller and insert the bushing on the opposite side in the same manner.
84402827B - May 2011 5003D-9
Assembly and Disassembly of Lower Roller 7.
Attach O-rings (3) to the shaft (2) and mount into the roller (1).
10. Turn the main unit and check that the roller rotates properly.
8.
Install the collars (1) (2) on both sides.
11. Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.
9.
Attach the wire clip (1). • When attaching the wire clip, secure the roller main unit so that it does not roll.
12. Fill gear oil (about 280 cc) into the roller. Use a hexagon wrench (6 mm) (2) to tighten the plug (1) with the nylon seal applied. • Mobile Gear Oil SHC320 is recommended for use. • To reuse a plug, wrap it with seal tape. Plug (1) tightening torque: 24.5 N・m
This completes the assembly.
84402827B - May 2011 5003D-10
Section 5004
Removal and Installation of Sprocket
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 5004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5004-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Sprocket 2.
WARNING • When loosening the check valve, loosen it a little at a time and stop when any grease appears. The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.
Slowly rotate the shoe so that the shoe joint section (1) is aligned as in the diagram on the right. Place wood plank (2) under the shoe and return the bucket to its original position. Perform air bleeding for the hydraulic line. For details, see Air Bleed Procedures.
CAUTION • Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • •
Box wrenches (19 mm) Wrenches (27 mm, 30 mm) Hammer (to remove the master pin) Striking jig (to remove the master pin) Liftcrane (with the required lifting capacity) Wire rope (with the required breaking load) Loctite #262 Wood planks, etc. Rag Cleaning fluid
Removal of Sprocket 1.
Allow the bucket (1) to touch the ground so as to elevate the shoe (2) of the side to be removed as in the diagram on the right.
84402827B - May 2011 5004-3
Removal and Installation of Sprocket 3.
Use a box wrench (19 mm) to rotate the grease cylinder check valve (1) and loosen the shoe tension.
5.
Place a striking jig (2) against the master pin (1) and hit it with a hammer (3) to push the master pin out.
6.
Open the shoe (1) to the rear.
7.
Use a wrench (30 mm) to remove the 26 bolts (1).
8.
Use a wire rope (1) to lift the drive sprocket (2) and remove it from the travel motor (3).
â&#x20AC;˘ Grease will flow out, so have rag ready. If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.
4.
Pull out the S-pin (1) from the rear of the joint section.
84402827B - May 2011 5004-4
Removal and Installation of Sprocket Installation of Sprocket
â&#x20AC;˘ Tightening torque M16: 267 - 312 Nă&#x192;ťm
To install, perform the reverse of the removal procedure.
84402827B - May 2011 5004-5
Removal and Installation of Sprocket
84402827B - May 2011 5004-6
Section 5005A
Removal and Installation of Take-up Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Take-up Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 5005A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5005A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Take-up Roller WARNING
3.
Install the lifting equipment (4) on the take-up roller (1) and recoil spring assembly (3) and hang them from the side frame (2) with the liftcrane.
4.
Place the take-up roller (1) and recoil spring assembly (2) onto wood planks (4) as in the diagram. Use a wrench (24 mm) to remove the take-up roller bolt (3) and separate the roller and the recoil spring assembly.
• When loosening the grease cylinder check valve, loosen it a little at a time. • The pressure inside the cylinder is very high, so there is a danger of grease being expelled and the plug flying off. The check valve adjustment procedure should not be done in front of the check valve. • Do not get under the machine when the main unit is jacked up. • Make sure to place the main unit on wood planks or the like to prevent falling. • Align the shoe assembly feed location and stop the engine except when working. Items to prepare • • • • • • • • •
Wrench (24 mm) Hammer Lifting equipment Loctite #262 Striking jig Liftcrane Crowbar Wood planks, etc. Rag
Removal of Take-up Roller 1. 2.
Remove the shoe assembly. See the "Removal and Installation of Shoe Assembly". Use a crowbar (3) to pull off the take-up roller (1) and recoil spring assembly from the side frame (2).
84402827B - May 2011 5005A-3
Removal and Installation of Take-up Roller Installation of Take-up Roller 1.
2.
Install the lifting equipment (4) on the take-up roller (1) and recoil spring assembly (3) as in the diagram, lift them up with the liftcrane, and insert them into the side frame (2). Push in with the crowbar until the recoil spring assembly contacts the grease cylinder.
3.
Install the shoe assembly. For details on installation, see the "Removal and Installation of Shoe Assembly" procedure.
Place the take-up roller (1) and recoil spring assembly (2) onto wood planks (4) as in the diagram. Use a wrench (24 mm) to fasten the take-up roller (1) and recoil spring assembly (2) with the bolt (3). At this time, be sure to coat the bolt with Loctite #262. Installation bolt tightening torque: 267 - 312 N¡m
84402827B - May 2011 5005A-4
Section 5005B
Assembly and Disassembly of Take-up Roller
84402827B - May 2011
84402827B - May 2011
CONTENTS Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 5005B-1
4 5 5 6 8
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5005B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Take-up Roller CAUTION • To ensure safe operations, wear protective devices before beginning work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Follow the precautions below when suspending the load.
• Seal tape • Oil pan (drip pan) • Water container for inspection
• The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. • Fix the roller to a level surface so it does not roll. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling sliding (5) parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. • The take-up roller is a heavy object and requires at least 2 workers to handle. <General cautions> • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare • • • • • • • • • • • • •
Hexagon wrench (6 mm) Hammer Pliers Gear puller Screwdriver Engine oil (Shell Rimula Oil #30) Specialty jigs Pressing machine Loctite Special fiber cloth (Kimwipe) Micrometer caliper Caliper Cylinder gauge 84402827B - May 2011 5005B-3
Assembly and Disassembly of Take-up Roller Configuration Diagram
Code 1 2 3 4 5
Part name Take-up roller Wrapping bearing Floating seal O-ring Roller shaft
Code 6 7 8 9
84402827B - May 2011 5005B-4
Part name Pin hub Hub (with plug) Plug Hub (without plug)
Assembly and Disassembly of Take-up Roller Dimension Diagram
Jig Dimension Diagram
84402827B - May 2011 5005B-5
Assembly and Disassembly of Take-up Roller A B C
Bushing removal jig Bushing press-fit jig Floating seal installation jig
Disassembly Procedures 1.
After cleaning the roller with kerosene, use the hexagon wrench (1) to remove the plug (2) from the hub (3). • The plug is coated with seal nylon, which comes off when the plug is removed. Seal tape is necessary for reusing.
2.
Face down the part of the roller from which the plug was removed and empty the oil from within the roller. • It may take a few hours to completely empty the oil. • Place an oil pan (1) underneath to catch the oil.
3.
Remove the pin hub (2) from the hub (1), and remove the hub (1) from the shaft (3). • Only remove on one side.
84402827B - May 2011 5005B-6
Assembly and Disassembly of Take-up Roller 4.
After removing the O-ring (2) on the shaft (1), pull the shaft (1) out from the roller (3).
7.
Remove the floating seals (2) from the roller (1).
8.
Use a micrometer caliper (4), cylinder gauge (5), and caliper (6) to measure the roller (with bushing) (1), hub (2), and shaft (3) for wear and deformation. Replace with new parts as necessary.
9.
When replacing the bushing (1), remove it by placing a striking rod (2) against the end surface and striking that with a hammer (3) uniformly left and right as in the diagram.
• The O-ring cannot be reused. Replace it with new part.
5.
Remove the pin hub (2) from the hub (1). Next, after removing the hub (1) from the shaft (3), remove the O-ring (4) from the shaft (3).
6.
Remove the floating seals (2) from the hub (1).
• Do not disassemble the bushing (1) unless it has become unusable due to wear, etc. • Be careful not to scratch the inside of the roller when striking the end of the bushing.
84402827B - May 2011 5005B-7
Assembly and Disassembly of Take-up Roller Assembly Procedures 1.
Clean all parts. • Find a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts. • In order to clean off adhered matter that forms sharp points and causes scratches, immerse parts in cleaning fluid (1) until dirt and grease float to the top.
10. Invert the roller (1), use jig A (2) to push up against the bushing (3), and press with a rod-shaped object (4) (such as a shaft). The bushing comes off.
2.
After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris. • If the parts are to be left as is for a long time after drying them, apply engine oil.
3.
If the bushing (1) was removed during disassembly, put it into the roller (2). Use a pressing machine (3) to press in both the left and right sides.
84402827B - May 2011 5005B-8
Assembly and Disassembly of Take-up Roller 4.
5.
6.
Use the jigs (1) (2) attached to the pressing machine to install the bushing (3). Use the pressing machine to press from the opposite side. Next, use a special fiber cloth to remove all dust and debris.
7.
Use a special fiber cloth to thoroughly wipe the sliding surface of the floating seal to prevent any dust or scratches.
8.
Apply engine oil to the floating seals (1) on the hubs (2) (3).
9.
After installing the O-ring (2) to the shaft (1), attach the shaft to the hub (3) and fasten it with the pin hub (4).
Install the floating seal (2) to the hub (1). Use jig C (3) to press it into position.
Use jig C (3) to install the floating seal (2) to the roller (1) side.
84402827B - May 2011 5005B-9
Assembly and Disassembly of Take-up Roller 10. Install the shaft (2) and O-ring (3) to the roller (1).
13. Fill engine oil (190 cc) into the roller main unit. â&#x20AC;˘ The roller main unit can be very unstable, so be careful in securing it.
11. After attaching the O-ring (4) to the shaft (1), attach the hub (2) and fasten it with the pin hub (3). 14. After filling the oil, use a hexagon wrench (6 mm) (2) to tighten the plug (1) with the nylon seal applied. â&#x20AC;˘ To reuse a plug, wrap it with seal tape.
12. Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.
84402827B - May 2011 5005B-10
Section 5005C
Removal and Installation of Grease Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of grease cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of grease cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 5005C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5005C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Grease Cylinder WARNING
3.
Jack up the side frame on the side where the grease cylinder is being removed as shown in the diagram. Jack up so that the shoe is floating about 5 cm, and insert wood plank (1) under the lower frame to prevent falling.
4.
Use a wrench (36 mm) to remove the bolts (1) and washers (2), and then remove the track guard (3). Tightening torque for bolt installation: 902 - 1049 N・m
5.
Install the wire (2) on the grease cylinder assembly (1), and then lift it with the liftcrane so that it is slightly tensed.
• When loosening the grease cylinder check valve, loosen it a little at a timec • The pressure inside the cylinder is very high, so there is a danger of grease being expelled and the plug flying off. The check valve adjustment procedure should not be done in front of the check valve. • Do not get under the machine when the main unit is jacked up. • Make sure to place the main unit on wood planks or the like to prevent falling. • Align the shoe assembly feed location and stop the engine except when working. Items to prepare • • • • • • • • •
Wrenches (24 mm, 36 mm) Hammer Lifting equipment Loctite #262 Striking jig Liftcrane Crowbar Wood plank Rag
Removal of grease cylinder 1. 2.
Remove the shoe assembly. See the "Removal and Installation of Shoe Assembly" procedure. Use a crowbar (3) to pull off the take-up roller (1) and recoil spring assembly about 100 mm from the side frame (2). When removing the grease cylinder, use a wood plank or the like (4) to prevent the take-up roller (1) and recoil spring assembly from coming out.
84402827B - May 2011 5005C-3
Removal and Installation of Grease Cylinder 6.
Use a wrench or box wrench (24 mm) to remove the bolt (1) and washer (2), and then remove the grease cylinder (3). Lower the liftcrane as is to lower to under the frame, and then take out from between the lower rollers.
Installation of grease cylinder To install, perform the reverse of the removal procedure. Grease cylinder installation bolt tightening torque: 267 312 Nă&#x192;ťm When installing bolts, coat the threaded sections with Loctite #262.
84402827B - May 2011 5005C-4
Section 5005D
Assembly and Disassembly of Grease Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 5005D-1
4 4 5 5 6
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 5005D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Grease Cylinder CAUTION • To ensure safe operations, wear protective gear before beginning work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Follow the precautions below when suspending the load. • The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the grease cylinder to determine whether it can be carried by hand or whether a liftcrane must be used. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling sliding parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. <General cautions> • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to deform any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare • • • • • • •
Hammer Wrench (19 mm) Box wrench (19 mm) Screwdriver Specialty jigs Special fiber cloth (Kimwipe) Marking pen
84402827B - May 2011 5005D-3
Assembly and Disassembly of Grease Cylinder Configuration Diagram
Code 1 2 3 4 5 6
Part name Dust seal Piston rod U-packing Retaining ring Grease cylinder High-strength bolt
Q'ty 1 1 1 1 1 2
Code 7 8 9
Part name Spring washer Bracket Check valve assembly
Dimension Diagram
84402827B - May 2011 5005D-4
Q'ty 2 1 1
Assembly and Disassembly of Grease Cylinder Jig Dimension Diagram
A B
Dust seal press-fit jig Removal jig
Disassembly Procedures 1.
Clean the grease cylinder with kerosene, remove the bolt (1) and washer (2), and remove the bracket (3). Remove the check valve (5) from the grease cylinder (4).
84402827B - May 2011 5005D-5
Assembly and Disassembly of Grease Cylinder 2.
Pull out the piston rod (2) from the grease cylinder (1).
Assembly Procedures 1.
Place parts in a rough cleaning container filled with kerosene to clean off any adhered matter that can form sharp points and cause scratches. • Immerse in kerosene until dust, grease, and other adhered matter comes off and floats to the surface.
2.
Place parts in a finish cleaning container filled with kerosene and clean while gently moving the parts. After cleaning, wipe away the kerosene with a clean rag. • Place the parts in a location free of dust and moisture and use compressed air to dry the parts. After drying, coat parts with engine oil.
3.
Use the removal jig (B) to remove the dust seal (2) from the grease cylinder (1).
3.
Install the U-packing (1) coated with grease onto the piston rod (2), and then install the snap ring (3). • Use a new U-packing (1). • Be careful that the U-packing (1) faces correctly.
4.
Remove the snap ring (2) from the piston rod (1), and then use the removal jig (B) to remove the U-packing (3).
84402827B - May 2011 5005D-6
Assembly and Disassembly of Grease Cylinder 4.
Use the jig (A) and hammer (C) to install the dust seal (2) on the grease cylinder (1). Apply grease to the lip section of the dust seal (2). Use a new dust seal (2).
5.
Coat the surface of the piston rod (1) with grease and insert into the grease cylinder (2).
6.
Tighten the check valve (1) to the grease cylinder (2) to the specified tightening torque. Install the bracket (3) and secure it with the spring washer (4) and the bolt (5). Check valve tightening torque: 48.99 - 68.61 Nă&#x192;ťm Bracket installation bolt tightening torque: 58.8 Nă&#x192;ť m
This completes the assembly.
84402827B - May 2011 5005D-7
Assembly and Disassembly of Grease Cylinder
84402827B - May 2011 5005D-8
Section 6001
Removal and Installation of Travel Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Travel Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 6001-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 6001-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Travel Motor WARNING
4.
Perform air bleeding for the hydraulic line. For details, see "Air Bleed Procedures" under Maintenance in the Service Text.
5.
Use a box wrench (19 mm) to rotate the grease cylinder check valve (5) and loosen the shoe tension.
• When loosening the check valve, loosen it a little at a time and stop when any grease appears. The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much. CAUTION • Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • •
Box wrenches (19 mm, 36 mm) Wrenches (19 mm, 27 mm, 30 mm, 41 mm) Hammer (to remove the master pin) Striking jig (to remove the master pin) Liftcrane (with the required lifting capacity) Wire rope (with the required breaking load) Loctite #262 Wood planks, etc. Rag Cleaning fluid
Removal of Travel Motor 1.
Allow the bucket (1) to touch the ground so as to elevate the shoe (2) of the side to be removed as in the diagram on the right.
• Grease will flow out, so have rag ready. If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.
2. 3.
Slowly rotate the shoe so that the shoe joint section (3) is aligned as in the diagram on the right. Place wood planks (4) under the shoe and return the bucket to its original position.
84402827B - May 2011 6001-3
Removal and Installation of Travel Motor 6.
Pull out the S-pin (6) from the rear of the joint section.
9.
Use a wrench (19 mm) to remove the 4 bolts (10), then remove the cover (11).
7.
Place a striking jig (9) against the master pin (7) and hit it with a hammer (8) to push the master pin out.
10. Use wrenches (27 mm for drain hose, 41 mm for high-pressure hose) to remove the drain hose (13) and 3 high-pressure hoses (12). â&#x20AC;˘ Be sure to use plugs on the removed drain and high-pressure hoses.
8.
Open the shoe (2) to the rear.
11. Use a wrench (19 mm) to remove the pilot hose (15) and a wrench (27 mm) to remove the elbow (14).
84402827B - May 2011 6001-4
Removal and Installation of Travel Motor 12. Attach the wire rope (17) to the travel motor (16) as in the diagram. Adjust the wire rope so that it is located at the center of mass and lift it with the liftcrane so that it is slightly tensed.
13. Use a box wrench (36 mm) to remove all 18 bolts (18).
Installation of Travel Motor 1.
Attach the travel motor to the lower frame as in the diagram. â&#x20AC;˘ Be careful of the installation angles.
2.
Apply Loctite #262 to the installation bolt (2) threaded sections and temporarily tighten them. Tighten top and bottom alternately to the specified torque so that an even tightening force acts on opposing corners as shown in the diagram below. Installation bolt tightening torque: 900 - 1051 Nă&#x192;ťm
14. Remove the travel motor (16).
84402827B - May 2011 6001-5
Removal and Installation of Travel Motor 3.
Use a wrench (27 mm) to remove the elbow (3) and a wrench (19 mm) to install the pilot hose (4).
4.
Use wrenches (27 mm for drain hose, 36 mm for high-pressure hose) to install the drain hose (6) and high-pressure hoses (5).
5.
Use a wrench (19 mm) to install the cover (8) with the 4 bolts (7). Installation bolt tightening torque: 63.7 - 73.5 Nă&#x192;ťm
6.
Wrap the shoe (9).
7.
Insert the master pin (11). Insert the S-pin (10) and bend it so that it cannot slip out.
8.
Tighten the check valve (12). While monitoring the track shoe tension, inject grease into the grease cylinder.
9.
When adjusting the track shoe tension, raise the lower side frame as shown in the diagram. Place a wood plank (13) under the lower frame to prevent falling. Adjust the tension so that the distance indicated with A between the frame bottom (14) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (15) is 340 - 360 mm.
84402827B - May 2011 6001-6
Removal and Installation of Travel Motor
84402827B - May 2011 6001-7
Removal and Installation of Travel Motor
84402827B - May 2011 6001-8
Section 6002
Assembly and Disassembly of Travel Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Tools for Assembly and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standard tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Secondary materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tool (jig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Measurement device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Motor Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Precautions before motor disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Removal of supplied valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly of overload relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Reduction gear disassembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation to receiving platform of reduction gear (unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal of reduction gear cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Removal of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassembly of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Removal of floating seal from motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Motor parts maintenance standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Reduction gear parts maintenance standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspection prior to reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Parts maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assembly of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Precautions before Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Motor Assembly Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Motor assembly procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly of the carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Assembly of the carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Installation of bearing and floating seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Assembly of the housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Determining the thickness of the angular bearing shim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation of housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Installation of carrier 2 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation of carrier 1 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Cover attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 84402827B - May 2011 6002-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Gear oil filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial pre-conditioning operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performing initial operation (pre-conditioning operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Causes of troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduction gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 6002-2
38 39 39 39 39 39 39 42 42 44
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Travel Motor Tools for Assembly and Disassembly Use the tools indicated below for assembly and disassembly of the motor.
Standard tools Secondary materials No.
Secondary name
1
Seal tape
2
Adhesive
3
Gear oil
4
Hydraulic oil
5
Grease
6
White kerosene
7
Liquid packing
8
Lapping plate
9
Lapping agent
10 11 12 13 14 15 16
Copper plate Tube brush Bamboo brush Oil pan Plastic container Rag Color check
Standardized materials No. Manufacturer name Loctite
Type and dimenPart used with sions
242 515
4, 25 24
GL-4#90 equivalent ISO VG46 equivalent Lithium series No.2 equivalent oil ThreeBond 1211 For sliding surface repair For sliding sur#1000 face repair For cleaning For cleaning For receiving oil For filling grease 9, 10, 11, 15, 16, 17, 18, 22, 23
84402827B - May 2011 6002-3
Assembly and Disassembly of Travel Motor Special Tool (jig) No.
Tool name
1
Gear (bearing) puller
Usage target part 10, 51
2
Holder fittings (2)
13, 51
3
Rear cover guide pins (2)
1, 24
4
Brake piston removal jig (2)
21
5
Shim thickness adjustment jig
52
6
Oil seal insertion jig
3
7
Rear bearing insertion jig
51
Type and dimensions
84402827B - May 2011 6002-4
Assembly and Disassembly of Travel Motor Type and dimensions
Usage target part
No.
Tool name
8
Brake piston insertion jig
21
9
Piston and shoe measurement jig
12, 18
84402827B - May 2011 6002-5
Assembly and Disassembly of Travel Motor Hexagon socket head bolt M6 x 100 t 10 mm or longer When the rear cover bolts are *1 used as is D1 2-20 notch 10 - Plain flat washer with D2 rounded finish 18 mm d
84402827B - May 2011 6002-6
Assembly and Disassembly of Travel Motor Measurement device No. 1 2 3 4
Tool name Dial gauge Micrometer caliper Micro depth gauge Caliper
Specifications
0 - 15 mm (JIS B7544) 0 - 150 mm (JIS B7507: 1997)
84402827B - May 2011 6002-7
Part used with
Assembly and Disassembly of Travel Motor Motor Disassembly Procedures Precautions before motor disassembly Begin motor disassembly only after thoroughly reading the precautions below. 1. 2. 3.
4.
When performing disassembly, always wear protective devices such as a helmet, goggles and safety shoes. Use the specified tools when performing disassembly. Remove all lines connected to the motor and remove the motor from the mother machine only after making sure that the machine is on a level surface and there are no external forces acting on rotating parts so that the mother machine does not operate uncontrollably when the motor is removed. To prevent foreign matter from entering the lines and motor when removing the motor from the mother machine, sufficiently clean off mud and dirt adhered around the motor before removing lines connected to the motor.
5.
When removing lines connected to the motor, hydraulic oil from inside the lines will spray out. For this reason, remove these lines only after removing pressure from inside the lines and preparing an oil pan. To prevent injuries due to the motor falling when transporting it by lifting the motor with a liftcrane, lift the machine with the eyebolts (a) mounted in the positions indicated in the diagram below. 6. The motor is filled with hydraulic oil. Before disassembling the motor, prepare an oil pan and drain the hydraulic oil from the motor. 7. To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on. 8. The motor comprises high-precision parts. For this reason, foreign matter adhering to parts can be damaging. Motor disassembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts. 9. The motor comprises high-precision parts. For this reason, dents and scratches on part surfaces can be damaging. Be very careful when handling parts during disassembly and do not create any dents or scratching. 10. To prevent personal injury and damage to parts during disassembly, do not force disassembly of parts which are especially tight to disassemble.
Motor lifting positions
Tightening torque Code
Part name
Dimensions
(4)
Hexagon socket head bolt
M18 x 110
(25)
Hexagon socket head bolt
M10 x 30
(26) (29) (35) (38) (42) (56) (57) (60)
Hexagon socket head plug Plug Pilot valve plug Plug Plug Hexagon socket head bolt Overload relief valve Plug
G3/4 M42 G3/8 G1/4 G1/8 M18 M27 G1/2
Tightening torque (N•m) 415.8 - 340.2 N・m (Loctite #242 coating) 75.5 - 61.7 N・m (Loctite #242 coating) 161.7 - 132.3 N・m 441 - 461 49.0 - 58.8 26.46 - 32.34 16.17 - 13.23 356.4 - 291.6 98.1 - 118 107.91 - 88.29
84402827B - May 2011 6002-8
Assembly and Disassembly of Travel Motor Disassembly procedure
However, the motor cannot be disassembled if the overload relief valve (57) is not removed first.
Removal of supplied valves
CAUTION
Remove the supplied valves before disassembling the motor parts.
Perform the disassembly procedure after the motor has reached its normal temperature, otherwise burns can occur.
â&#x20AC;˘ It is recommended not to remove any supplied valves other than those required for disassembly.
â&#x20AC;˘ Adhesive is applied to the thread sections to fix the spool assembly (26), so no further disassembly is possible.
Removal of supplied valves 1. 2.
Remove the M42 plug (29) and O-ring (30). Remove the spring (28), spring receiver (27), and spool assembly (26). â&#x20AC;˘ Make reference marks on the spool assembly (26) and rear cover (24), and when reassembling the parts, make sure that the assembly direction does not go in the opposite left-right direction.
3.
Remove the plug (42), O-ring (43), orifice spring (41), and orifice (40).
84402827B - May 2011 6002-9
Assembly and Disassembly of Travel Motor 4.
6.
Remove the overload relief valve (57). â&#x20AC;˘ When removing the overload relief valve (57), the valve seat (57-3) can easily come off, so be careful not to let it fall inside the rear cover (24), and check that it is not lost.
5.
Remove the coupling (58). CAUTION Be very careful not to get hands stuck between parts or drop the carried parts on feet.
Loosen the pilot valve plug (35), and remove the O-ring (36), spring (34), spring receiver (33), pilot valve spool (31), and pin (32).
84402827B - May 2011 6002-10
Assembly and Disassembly of Travel Motor Disassembly of motor 1. 2.
3. 4.
5.
Place the motor shaft horizontally and pull it out while leaving the 2 vertically-opposite hexagon socket head bolts M18 x 50 (56) in place. Install guide pins (a) at the 2 vertically-opposite locations. (Purpose: This prevents the rear cover from falling when removed and acts as a guide during assembly.) Slowly loosen the remaining 2 hexagon socket head bolts M18 x 50 (56) at the same time. Remove the rear cover (24) and brake spring (55) while making sure that the cylinder block (13) does not come out together with the rear cover (24).
Remove the valve plate (54) while making sure that the cylinder block (13) does not come off. • Make reference marks on the valve plate (54) and rear cover (24), and when reassembling the parts, be sure not to reverse the front and rear.
CAUTION Be very careful not to get hands stuck between parts or drop the carried parts on feet. • Be careful not to drop the valve plate (54), brake spring (55), rear bearing (51) outer race, shim (52), or O-rings (50) (47) (49). • There is a shim (52) under the rear bearing (51) outer race. Be very careful not to lose this during disassembly.
Removal of rear cover b 6.
Air feed source (left side hole) Using the removed hexagon socket head bolt M18 x 50 (56), press the holder fitting so as not to scratch the sliding surface of the cylinder block (13), and let the rear bearing (51) inner race come out. • Insert a rubber plate between the sliding surface and the holder fitting so as not to scratch the sliding surface of the cylinder block (13).
84402827B - May 2011 6002-11
Assembly and Disassembly of Travel Motor 7.
8.
Attach the gear (bearing) puller to the rear bearing (51) inner race and remove it.
• The piston and shoe are caulked and cannot be disassembled.
Removal of rear bearing While holding the brake piston (21) with the hand, fill compressed air from the brake release oil hole (c) and push out.
Casing matching surface enlargement
CAUTION Be very careful as the air pressure can cause the brake piston (21) to fly off. • When using a removal jig, install the removal jig to the M6 taps (2 locations) on the end of the brake piston (21), and pull out the brake piston (21). 9.
Insert a rod that will not scratch the cylinder block (13) (such as rolled-up cylindrical paper) into the piston (18) hole, and make a reference mark on the outer circumference of the cylinder block (13) for reference. 10. Remove the rotary group (cylinder block (13), piston assembly (18), shoe retainer (17), spherical joint (16), spring receiver (15), and cylinder spring (14)). CAUTION Be very careful not to get hands stuck between parts or drop the carried parts on feet.
11. Remove the separator plate (19) and friction plate (20). 12. Remove the 9 piston assemblies (18), shoe retainer (17), and spherical joint (16) from the rotary group at the same time. 13. Remove the spring receiver (15) and cylinder spring (14) from the cylinder block (13). • With the piston assembly (18) and shoe retainer (17) removed, align the alignment mark (e) and the reference mark (d) and insert them into the cylinder block (13). The purpose is to house the pistons into the same holes before disassembly when reassembling. • Be careful not to scratch each of the sliding surfaces. If the sliding surface is scratched, the part cannot be reused.
Removal of cylinder block [Tip] The preceding described how to disassemble the motor unit, but the disassembly is also the same if it comes with a reduction gear. Disassembling a motor with a reduction gear may be easier because the shaft does not swing as much. 14. Remove the shoe plate (12).
84402827B - May 2011 6002-12
Assembly and Disassembly of Travel Motor 15. Do not remove the tilting piston set (6), (7). If these parts must be removed, hold the tilting piston (6) with the hand and fill air from the tilting path hole (f) and push out the parts. CAUTION Be very careful as the air pressure can cause the tilting piston (6) to fly off. 16. The shaft (9) can be pulled out. 17. When replacing the front bearing (10), remove the inner race from the shaft (9) with the bearing puller, and replace with a new bearing. â&#x20AC;˘ When replacing parts related to the tightening margin of the bearing, such as the bearings (10) (51), shaft (9), casing (1), and rear cover (24), the thickness of the shim (52) needs to be adjusted. Correctly measure the shim gap when the shim is lightly positioned, replace with a shim (52) that matches the gap, and adjust the bearing gap to 0 - 0.1 mm. A separate jig or other tool is needed to determine the jig thickness. Contact us for details. â&#x20AC;˘ Do not remove the pivot (11). If removing the part, make a reference mark on the area aligned with the shoe plate (12). â&#x20AC;˘ Do not remove the oil seal (3). If the part is removed, always replace with a new part. If removing the oil seal, remove the retaining ring (4), and then remove the oil seal (3).
Removal of shoe plate 18. Determining the thickness of the taper roller bearing shim (52)
Casing matching surface enlargement
84402827B - May 2011 6002-13
Assembly and Disassembly of Travel Motor Disassembly of overload relief valve
Determining the shim thickness • This needs to be performed when replacing the motor casing (1), rear cover (24), shaft (9), or bearings (10) (51). 1)
Measure dimension E in the assembled condition indicated in the above diagram.
• The overload relief valve (57) is an important part in terms of performance and safety. Because resetting the pressure of this part is extremely difficult, the overload relief valve assembly should be replaced without disassembling if a problem occurs.
• Be careful not to allow the shaft (9) to fall. 2)
Measure dimension F on the rear cover side. • Use the average of the measurements of the 4 orthogonally intersecting points on the circumference.
3) 4)
When the thickness of the used shim (52) is "S," gap "Y" is as follows. Y = F - (E + S) In the case of this motor, select 1 or 2 shims (52) so that gap Y is 0 - 0.1 mm.
• The valve seat (57-3) fits into the socket (57-1) internal hole by a clearance fit and can easily come off, so when removing the overload relief valve (57) from the rear cover (24), be careful not to drop or lose the valve seat (57-3).When installing the overload relief valve (57) to the rear cover, apply grease (g) to the fitting section and install in a way that the valve seat (57-3) does not come off.
Valve seat fitting section
84402827B - May 2011 6002-14
Assembly and Disassembly of Travel Motor Reduction gear disassembly procedures
Disassembly procedure Installation to receiving platform of reduction gear (unit)
Disassembly preparations 1.
1.
The unit removed from the actual machine is dirty with dirt and debris. Clean the exterior of the unit and let it dry. CAUTION
Remove 3 hexagon socket head bolts M10 x 30 (25) screwed into the cover (24) at approximately the same distance apart, and instead, install and suspend the M10 eyebolts, and install the receiving platform with the cover in the raised position and the
Perform the disassembly procedure after the reduction gear has sufficiently cooled down, otherwise burns can occur. 2.
Loosen the drain and the feed plug G3/4 (26) to drain the gear oil inside the reduction gear. CAUTION When the gear oil is still hot, the pressure inside can cause the oil to spray out.
3.
Make reference marks (h) to the outside of each alignment surface so that the part can be assembled in its original form.
84402827B - May 2011 6002-15
CAUTION â&#x20AC;˘ Be very careful not to get hands stuck between parts or drop the suspended parts on feet. â&#x20AC;˘ Lift the part in a horizontal position.
Assembly and Disassembly of Travel Motor Removal of reduction gear cover 1.
2.
Remove the remaining hexagon socket head bolts M10 × 30 (25).
The contact surfaces of the cover (24) and ring gear (3) are coated with sealant, so place a metal pin against the projected part of the cover and use a hammer to strike it obliquely upward to remove the cover. CAUTION Be very careful not to get hands stuck between parts or drop the suspended parts on feet.
Removal of carrier 1 assembly 1. 2.
3.
Remove the sun gear 1 (22).
Remove the thrust plate (23). Install 3 M10 eyebolts on the carrier 1 (16), then remove the carrier 1 assemblies (16, 17, 18, 19, 20, 21). CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
84402827B - May 2011 6002-16
CAUTION Be very careful not to get hands stuck between gears.
Assembly and Disassembly of Travel Motor Removal of carrier 2 assembly 1.
2.
Remove the sun gear 2 (15).
Install 3 M10 eyebolts on carrier 2 (9), then remove the carrier 2 assemblies (9, 10, 11, 12, 13, 14). CAUTION
CAUTION Be very careful not to get hands stuck between gears.
• Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
Removal of housing assembly
CAUTION
1.
Remove the support ring (8).
• Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
2.
Place a screwdriver or other tool on the divided surface of the lock washer (7) and strike the tool with a hammer to remove the lock washer (7).
3.
Install 3 M10 eyebolts into the M10 threaded holes on the ring gear (3) at approximately the same distance apart, and remove the housing assembly (ring gear (3), housing (1), bearing (2), floating seal (5), hexagon socket head bolt M18 x 110 (4)) while lifting it in a horizontal position. 84402827B - May 2011 6002-17
Removal of housing assembly
Assembly and Disassembly of Travel Motor Disassembly of housing assembly 1.
Install 3 M20 eyebolts into the M20 threaded holes on the housing (1) at approximately the same distance apart, and place it on the receiving platform with the ring gear (3) in the lowered position and the housing (1) in the raised position. Make reference marks to the outer circumference of the housing and ring gear.
2. 3. 4.
Disassembly of housing assembly Remove the floating seal (5) from the housing (1). Remove the hexagon socket head bolts M18 x 110 (4) while leaving 2 diagonally opposite bolts. With the remaining 2 hexagon socket head bolts M18 x 110 (4) loosened, tap the heads of the bolts with a hammer to easily remove the ring gear (3) from the housing (1). CAUTION
CAUTION
Be very careful not to get hands stuck between parts or drop the suspended parts on feet.
• Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position. • Make the receiving platform 300 mm high or more.
Removal of floating seal • Be careful not to scratch the sliding surface of the floating seal (5) and its O-ring. • The bearing (2) outer race and housing (1) inner diameter form a very tight fit. Do not disassemble this unless it is necessary to replace the bearing (2). When removing the bearing (2) from the housing (1), replace with a new part instead of reusing the part.
84402827B - May 2011 6002-18
Assembly and Disassembly of Travel Motor Removal of floating seal from motor 1.
3.
Remove the floating seal (5) on the motor.
Remove the thrust washer 1 (18), planetary gear 1 (17), and needle bearing (19) from the carrier 1 (16).
Disassembly of carrier 1 assembly
CAUTION
â&#x20AC;˘ When reusing the carrier pin 1 (20), place codes on the carrier 1 (16) hole and carrier pin 1 (20) so that the parts can be reassembled in the same combination as before disassembly, and store the parts.
Be very careful not to get hands stuck between the gear and carrier.
1.
2.
Push the spring pin 6 x 36 (21) into the carrier pin 1 (20).
4.
Pull out the spring pin 6 x 36 (21) from the carrier pin 1 (20). â&#x20AC;˘ When replacing the carrier pin 1 (20) or planetary gear 1 (17), be sure to replace with 1 set of 3 parts.
Remove the carrier pin 1 (20) from the carrier 1 (16).
84402827B - May 2011 6002-19
Assembly and Disassembly of Travel Motor Disassembly of carrier 2 assembly
3.
â&#x20AC;˘ When reusing the carrier pin 2 (13), place codes on the carrier 2 (9) hole and carrier pin 2 (13) so that the parts can be reassembled in the same combination as before disassembly, and store the parts. 1.
Push the spring pin 10 x 50 (14) into the carrier pin 2 (13).
Remove the thrust washer 2 (11), planetary gear 2 (10), and needle bearing (12) from the carrier 2 (9). CAUTION Be very careful not to get hands stuck between the gear and carrier.
4.
Pull out the spring pin 10 x 50 (14) from the carrier pin 2 (13). â&#x20AC;˘ When replacing the carrier pin 2 (13) or planetary gear 2 (10), be sure to replace with a set of 3 parts.
2.
Remove the carrier pin 2 (13) from the carrier 2 (9).
84402827B - May 2011 6002-20
Assembly and Disassembly of Travel Motor Maintenance standards Motor parts maintenance standards The reference values indicating whether or not a part can be reused are indicated using the measurement values at the time a part is disassembled. However, this is a general reference, and when determining whether a part should be replaced, priority is given to performance prior to disassembly, the purpose of disassembly and the expected remaining life of the part if there is any damage or discoloration that significantly affects the part appearance. Measurement item and measurement method 1.
Sliding surfaces: cylinder block, valve plate, and shoe plate Judgment criteria and solution • Use a surface roughness gauge to measure the roughness of the sliding surfaces of these parts.
Part name and inspection Standard value item Surface roughness
Permissible limit value
• Cylinder block • Valve plate • Shoe plate
3.0 Zμ or lower Repair or replace.
0.4 Zμ or lower
Solution
(Perform common lapping to correct the surface roughness of the cylinder block and valve plate. (Lapping material #1200)) • Use a hardness gauge to measure the hardness of the shoe plate sliding surface. Part name and inspection Standard value item Shoe plate HS78 or higher • Sliding surface hardness
Permissible limit value
Solution
HS74
Replace
84402827B - May 2011 6002-21
Assembly and Disassembly of Travel Motor 2.
Clearance of piston and cylinder block Judgment criteria and solution • Use a micrometer caliper to measure the piston outer diameter and cylinder bore inner diameter at least 3 locations in the longitudinal direction. Maximum outer diameter value (piston) = d maximum Minimum outer diameter value (piston) = d minimum Minimum inner diameter value (cylinder bore) = D minimum Maximum inner diameter value (cylinder bore) = D maximum
Measurement locations Part name and inspection item Piston outer diameter d maximum - d minimum Cylinder bore inner diameter D maximum - D minimum Clearance D - d
Standard value
Permissible limit value
0.01 mm
0.05 mm
0.01 mm
0.022 mm
Solution
Replace the piston or cylinder block.
0.037 - 0.047 mm 0.065 mm
(Piston replacement should be performed 9 pistons at a time.) 3.
Piston and shoe backlash Judgment criteria and solution • Use a jig (d) (See "Measurement jig") to press the shoe (e) on the surface plate, slide the pistons (c) in an upward direction, and measure the piston and shoe backlash δ. (See "Caulking section backlash" and "Measuring backlash".)
Part name and inspection Standard value item Piston and shoe backlash 0 - 0.1 mm
Caulking section backlash
Permissible limit value 0.3 mm
Solution Replace piston.
Measuring backlash 84402827B - May 2011 6002-22
Assembly and Disassembly of Travel Motor a b f 4.
Magnet Dial gauge Surface plate
Parking brake force Judgment criteria and solution • After completing assembly, tighten the torque of the output shaft end with a torque wrench, and measure the torque when starting rotation.
Part name and inspection Standard value item
Permissible limit value
Solution
Parking brake torque
1055 N・m
• Separator plate • Friction plate • Spring Replace all.
1171 N・m
Guidelines for replacing the friction plates and partner plates To measure the brake torque, the motor must be separated to a single unit. It is extremely difficult to separate the motor by removing it from the mother machine or disassembling the reduction gear. Use the following method to determine whether to replace these parts when inspecting the parts during maintenance. (Replacement guidelines) Measure the pack length of the 6 friction plates and 7 separator plates, and if the value is less than the permissible value indicated below, replace all friction plates, separator plates, and springs. Reference value: 33.04 mm (nominal dimensions in the diagram) Permissible value: 31.5 mm 5.
Shaft Judgment criteria and solution • Use a roughness gauge to measure the wear on the oil seal contact areas of the shaft. The parts can be reused with a stepped wear of up to 0.05 mm. (When replacing the shaft (9), replace the oil seal (3) at the same time.)
6.
Bearing Judgment criteria and solution • Replace the bearings. Replace the bearings (10) (51) before the hour meter on the mother machine reaches 10000 hr. (When replacing the bearings (10) (51), replace the inner race and outer race at the same time. Also, when replacing the shaft (9) or bearings (10) (51), the shim (52) thickness must be adjusted.)
7.
Spline Judgment criteria and solution • Replace the spline when the spline wear exceeds the permissible limit value. The parts can be reused with a stepped wear of up to 0.3 mm on the contact surface.
8.
Overload relief valve Judgment criteria and solution • Pressure inspection and adjustments cannot be performed without a specialty test bench. Replace as a valve assembly every time the hour meter on the mother machine reaches 10000 hr.
84402827B - May 2011 6002-23
Assembly and Disassembly of Travel Motor Reduction gear parts maintenance standards Inspection prior to reassembly Thrust washer 1. 2.
Inspect for seizing, abnormal wear, and uneven wear. Inspect for wear that exceeds the permissible value.
Gears 1. 2.
Inspect for pitching or seizing on the tooth surfaces. Perform a color check for cracks in the tooth base.
Bearing Rotate by hand and inspect for abnormal noise or catching.
Floating seal Perform a color check for cracks in the tooth base.
84402827B - May 2011 6002-24
Assembly and Disassembly of Travel Motor Parts maintenance The reference values indicating whether or not a part can be reused are indicated below using the measurement values at the time a part is disassembled. However, this is a general reference, and when determining whether a part should be replaced, priority is given to performance prior to disassembly, the purpose of disassembly and the expected remaining life of the part if there is any damage or discoloration that significantly affects the part appearance. Parts with specified maintenance standards
Code
Item
A
Planetary shaft wear
B
Standard value
Permissible value
limit
Solution
Smooth with no abReplace using a set of 3 normal wear or seiz- â&#x2020;? parts. ing No pitching of D 1.6 Replace Smooth with no abmm or more, or no Tooth surface and tooth base con(Replace using a set of 3 normal wear or seizcracks in the tooth dition planetary gears.) ing base. 84402827B - May 2011 6002-25
Assembly and Disassembly of Travel Motor Permissible value
limit
Item
Standard value
D E F
Angular bearing (2) Inner race thrust gap Thrust washer 1 (18) thickness Thrust washer 2 (11) thickness Thrust plate (23) thickness
G
Gear oil
- 0.08 mm or more â&#x2020;? 0.02 mm or less 3.3 - 3.7 mm Wear of 0.1 mm 5.3 - 5.7 mm Wear of 0.1 mm 4.34 - 4.66 mm Wear of 0.15 mm Initial 250 hr. 2000 operating hr. (hour meter)
Code C
84402827B - May 2011 6002-26
Solution Shim adjustment Replace Replace Replace Replace
Assembly and Disassembly of Travel Motor Assembly of motor
Motor Assembly Procedure
Precautions before Motor Assembly
1.
Begin motor assembly only after thoroughly reading the precautions below. 1. 2. 3. 4.
5.
6. 7.
8. 9. 10. 11.
12. 13.
14.
When performing assembly, always wear protective devices such as a helmet, goggles and safety shoes. Use the specified tools when performing assembly. To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on. The motor comprises high-precision parts. For this reason, foreign matter adhering to parts can be damaging. Motor assembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts. The motor comprises high-precision parts. For this reason, dents and scratching on part surfaces can be damaging. Be very careful when handling parts during assembly and do not create any dents or scratching. Be sure to repair any damage discovered during disassembly and prepare replacement parts before beginning assembly. Remove metal fragments and foreign matters from all parts and check that there are no burrs or dents on parts before beginning assembly. If there are burrs or dents, use a whetstone to remove them. When performing assembly, apply clean hydraulic oil to each sliding and rotating sections before assembly. Thoroughly degrease areas where Loctite and liquid packing is used and remove oil and water before assembly. Replace all seal parts such as O-rings and backup rings with new parts. Be careful not to damage O-rings and backup rings during assembly. When assembling O-rings and backup rings, apply a small amount of grease for assembly. It is recommended that petroleum jelly or grease be used to prevent parts from falling during assembly. Tighten the bolts and other fastening sections to the tightening torque. Tightening torque should be controlled with a torque wrench. After assembly is complete, plug all ports leading into the motor to prevent dirt from entering.
2. 3.
Apply grease to the oil seal (3) outer circumference and casing (1) inner circumference, then use an insertion jig (h) to tap the oil seal (3) into the casing (1) evenly so that it does not fall down. Use a retaining ring (4) to fasten the oil seal (3). Insert the front bearing (10) outer race into the casing (1). (Clearance fit) Press fit the inner race into the shaft (9). (Tight fit) • Heating the inner race to 100°C or lower provides for easier press fitting. CAUTION Use caution to prevent burns.
4. 5.
Install the shaft (9) into the casing (1). Apply grease to the surface contacting the oil seal (3). Install the tilting piston sets (tilting piston (6), tilting piston seal (7), steel ball (8)). • Insert the tilting piston (6) so that it is not tilted. • When installing the tilting piston (6), apply grease to the seal parts and insert the piston carefully so as not to cut anything.
6.
7.
Install the pivot (11). Install it to the side matching the reference mark on the shoe plate (12). When operated for a long period of time, install it in the direction in which the slide imprints of the spherical section match the contact imprints of the shoe plate (12). Thoroughly grease the 3 spherical sections of the shoe plate (12) before installation.
Assembly procedure Perform assembly by observing the precautions listed in "Precautions before motor disassembly" and following the procedure indicated below.
84402827B - May 2011 6002-27
Assembly and Disassembly of Travel Motor 8.
After subassembling the piston assembly (18), shoe retainer (17), spherical joint (16), spring receiver (15), cylinder spring (14), and cylinder block (13), insert the entire subassembly into the shaft (9). CAUTION Be very careful not to get hands stuck between parts or drop the carried parts on feet. â&#x20AC;˘ The piston assembly (18) must be inserted into the same holes of the cylinder block (13) used before disassembly.
Installation of oil seal
Installation of piston assembly Use specialty rear bearing insertion jigs (A1, A2) to insert the rear bearing (51) inner race into the shaft (9). 10. Alternately install all of the separator plates (19) and friction plates (20) in turn. The separator plate (19) should be the first and last parts. 11. Use the brake piston insertion jig (B) to insert the brake piston (21) installed with D-rings (22) (23) in the casing (1). 9.
Installation of shoe plate
â&#x20AC;˘ Apply grease to the D-rings (22) (23). â&#x20AC;˘ Use the insertion jig to make sure the brake piston (21) is inserted evenly. The brake piston is equipped with 2 large and small D-rings (22) (23). First, the large-diameter D-ring (23) is inserted into the hole, then the small-diameter D-ring (22) is inserted. 84402827B - May 2011 6002-28
Assembly and Disassembly of Travel Motor The insertion condition of the small-diameter D-ring (22) cannot be visually checked, so do not forcefully insert this D-ring. This can cause chipping by the casing (1) hole. • The shim must be adjusted when replacing parts related to the shim adjustment. Perform the assembly after determining the shim thickness in advance by using the procedure in "Determining the thickness of the taper roller bearing shim (52)" page 25 in the disassembly procedure.
14. Insert the rear cover (24) into the casing (1) according to the guide pins, and tighten with hexagon socket head bolts M18 x 50 (56) at 2 vertically-opposite locations so that the rear cover is installed in a parallel orientation. After tightening the bolts, tighten with hexagon socket head bolts M18 x 50 (56) at the locations excluding the 2 locations with installed guide pins. After tightening the bolts, remove the guide pins and tighten the remaining 2 locations with hexagon socket head bolts M18 x 50 (56). CAUTION Be very careful not to get hands stuck between parts or drop the carried parts on feet.
Installation of brake piston i k
*1
Hammer 10 - Plain flat washer with rounded finish 18 mm When the rear cover bolts are used
12. Install guide pins (j) at 2 vertically-opposite locations on the casing (1). 13. Install the valve plate (54) in the rear cover (24) according to the reference mark made at the time of disassembly, then mount the shim (52), rear bearing (51) outer race, brake spring (55), and O-rings (50) (47) (49).
Installation of rear cover • If the outer race of the rear bearing (51) is removed, do not forget to install the shim (52). Check whether the O-rings (47) (49) (50) are installed in the rear cover (24). • The tightening torque for the hexagon socket head bolts M18 x 50 (56) is 291.6 - 356.4 N・m. 15. Install the coupling (58).
84402827B - May 2011 6002-29
Assembly and Disassembly of Travel Motor 16. Install the spring (34), spring receiver (33), pilot valve spool (31), and pin (32) in the rear cover (24), then tighten with the pilot valve plug (35) with the O-ring (36) installed.
17. Install the overload relief valve (57). • The valve seat (57-3) is fit with a clearance fit, so during installation, install the valve seat after making sure that it will not come off by applying grease to the fitting sections so that the valve seat does not fall off or become lost. • The tightening torque for the overload relief valve (57) is 98.1 - 118 N·m. 18. Install the orifice (40) and orifice spring (41) in the rear cover (24), then tighten with the plug (42) with the O-ring (43) installed. • The tightening torque for the plug (42) is 14.7 N·m. • When using a new orifice (40), adjust the seat section. (With a hammer, tap the orifice installed to the rear cover.) 19. Insert the spool assembly (26) into the rear cover (24) according to the reference mark made at the time of disassembly, then install the spring receiver (27) and spring (28) in that order. • The spool assembly (26) is directional, so insert it in the correct direction. 20. Tighten the M42 plug (29) with the O-ring (30) installed. • The tightening torque for M42 plug (29) is 441 446 N·m.
Installation of supplied valve • The tightening torque for the pilot valve plug (35) is 49.0 - 588 N·m.
84402827B - May 2011 6002-30
Assembly and Disassembly of Travel Motor Motor assembly procedure Assembly of the carrier 2 assembly 1.
Insert the planetary gear 2 (10), needle bearing (12), and thrust washer 2 (11) into the carrier 2 (9). CAUTION Be very careful not to get hands stuck between the gear and carrier.
2.
Align the carrier pin 2 (13) with the spring pin hole and insert it into the carrier 2 (9). Spring pin and caulking details *1 *2 *3 *4
3.
Insert the spring pin 10 x 50 (14) into the carrier pin 2 (9) and carrier pin 2 (13). (Hammer it 1 - 2 mm deeper than the striking surface.)
4.
Caulk at 2 opposing 180° locations. â&#x20AC;˘ For the direction of inserting the spring pin and the caulking method, see "Spring pin and caulking details".
84402827B - May 2011 6002-31
c
The spring pin opening section must be as in the diagram. 2 locations opposing each other at 180° must be caulked as in the diagram. The 0.5 mm spring pin must be hidden by the "caulking". Sink the spring pin tip 1.0 to 2.0 mm. Pinion side
Assembly and Disassembly of Travel Motor Assembly of the carrier 1 assembly
Installation of bearing and floating seal
1.
1.
Insert the planetary gear 1 (17), needle bearing (19), and thrust washer 1 (18) into the carrier 1 (16).
2. CAUTION Be very careful not to get hands stuck between the gear and carrier. 2.
Align the carrier pin 1 (20) with the spring pin hole and insert it into the carrier 1 (16).
3.
Insert the spring pin 6 x 36 (21) into the carrier pin 1 (16) and carrier pin 1 (20). (Hammer it 1 - 2 mm deeper than the striking surface.)
4.
Caulk at 2 opposing 180° locations.
Install the bearings (2) in the inner diameter of the housing (1). Install the floating seals (5) on the motor and housing (1). • Clean the floating seal installation section of any oil, dirt, paint, or other foreign matter. • Lightly apply gear oil to the sliding sections of the floating seals (5). (Do not coat the O-rings with gear oil.)
• Install in such a way that the O-rings do not become twisted. Check that the floating seal (5) is correctly installed between the housing (1) and motor in a parallel direction, as shown in the diagram.(Use of an insertion jig is recommended.)
• For the direction of inserting the spring pin and the caulking method, see "Spring pin and caulking details".
84402827B - May 2011 6002-32
Installation of floating seal
Assembly and Disassembly of Travel Motor Assembly of the housing assembly 1. 2.
Thoroughly coat the housing (1) surface that matches with the ring gear (3) with Loctite #515 (a). Install 3 housing (1) M20 eyebolts and lift with a wire, and install onto the ring gear (3) while aligning the reference marks.
Applying Loctite to the housing end surface CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position. 3.
Coat the 25 hexagon socket head bolts M18 x 110 (4) with Loctite #242, and tighten the bolts to the tightening torque of 340 - 416 N・m.
Assembly of the housing assembly
• Soak 20 mm from the bolt tip in Loctite #242. (*1)
Method of applying Loctite #242
84402827B - May 2011 6002-33
Assembly and Disassembly of Travel Motor Determining the thickness of the angular bearing shim • This needs to be performed when replacing the motor (casing), housing (1), (angular) bearing (2), or lock washer (7). Otherwise use the previous shim (6) as is. 1. 2.
Press the outer races of the 2 bearings (2) into the housing (1). Press the inner races of the 2 bearings (2) evenly and measure the inner race installation width (A). • Before measuring the inner race installation width, rotate the bearings at least 5 times to stabilize them.
3.
4. 5.
Measure the lock washer groove width (C) of the motor casing. Measure the lock washer (7) thickness (D). • Use the average of the measurements of the 4 orthogonally intersecting points on the circumference. Measure the dimensions with a precision of 0.01 mm.
6. 7.
When the thickness of the used shim (6) is S, gap X is as follows. X=(B+C)-(A+D+S) In the case of this unit, select 1 shim so that gap X is -0.08 - 0.02 mm. ((+) indicates a gap and (-) indicates pressing.)
Measure the bearing installation width (B) of the motor casing.
Determining the angular bearing shim thickness
Installation of housing assembly 1.
Place the motor shaft upwards on the work platform, and then place the shim (6) selected by (determining the thickness of the angular bearing shim) on the end surface of the bearing insertion part of the motor casing. CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
2.
Install and suspend 3 M10 eyebolts to the ring gear (3), slowly lower it vertically while aligning it with the motor core, and insert the bearings (2) installed in the inner diameter of the housing (1) into the motor. Use a pressing machine (b) to press the inner race parts of the bearings (2), and insert them completely to the bottom. CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
84402827B - May 2011 6002-34
Assembly and Disassembly of Travel Motor 3.
Insert the lock washer (7) into the groove while pressing the flange part of the housing (1).
4.
Insert the support ring (8) into the outside of the lock washer (7).
Press fitting of the housing assembly
84402827B - May 2011 6002-35
Assembly and Disassembly of Travel Motor Installation of carrier 2 assembly 1.
2.
Insert the sun gear 2 (15).
Insert the carrier 2 assembly into the ring gear (3) so that the 3 planetary gears 2 (10) are at the position indicated in "carrier 2 installation direction," and have the gears mesh with the spline of the motor casing.
CAUTION Be very careful not to get hands stuck between gears. • The carrier 2 assembly is assembled at the position indicated in "carrier 2 (c) installation direction" to improve oil lubrication, so be sure to observe this procedure.
Lift the part in a horizontal position. CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
Carrier 2 installation direction d *1
84402827B - May 2011 6002-36
Motor port Notching V into carrier 2
Assembly and Disassembly of Travel Motor Installation of carrier 1 assembly 1.
Install and suspend 3 M10 eyebolts to the carrier 1 assembly, insert it into the ring gear (3), rotate the planetary gear 1 (17) by hand to align it, and then have the gear mesh with the sun gear 2 (15). CAUTION • Be very careful not to get hands stuck between parts or drop the suspended parts on feet. • Lift the part in a horizontal position.
2.
After making sure that the coupling (See the motor parts Operator's Manual.) is at the end of the motor shaft, insert the sun gear 1 (22). CAUTION Be very careful not to get hands stuck between gears.
3.
Installation of carrier 1 assembly Install the thrust plate (23) on the carrier 1 (16). • Face the sharp edge toward the cover (24) side.
Thrust plate installation direction e f
84402827B - May 2011 6002-37
Reduction gear cover Sharp edge
Assembly and Disassembly of Travel Motor Cover attachment
2.
• The gear oil can be filled before installing the cover (24). 1.
Coat the 18 hexagon socket head bolts M10 x 30 (25) with Loctite #242 sealant, and tighten the bolts to the tightening torque of 61.7 - 75.5 N•m. • For details on applying Loctite #242 to the bolts, see "Method of applying Loctite #242".
Coat the cover (24) surface that matches with the ring gear (3) with Loctite #515 (g), and install the cover (24) on the ring gear (3). CAUTION Be very careful not to get hands stuck between parts or drop the suspended parts on feet.
Applying Loctite to the cover end surface
Gear oil filling 1. 2.
Fill the gear oil (SAE90, API GL-4 or GL-5, 9.5 L) into the filling port G3/4. Install the hexagon socket head plug G3/4 (26) to the cover (24) at a tightening torque of 132.4 - 161.8 N•m.
84402827B - May 2011 6002-38
Assembly and Disassembly of Travel Motor Initial pre-conditioning operation Drain charge After disassembly and assembly, completely fill the case of the motor casing with hydraulic oil. This motor has 2 drain ports (G1/2). Perform air bleeding from the port on the side without a line (top side).
Performing initial operation (pre-conditioning operation) Perform a pre-conditioning operation for about 5 min. at the motor tilting 1st speed and engine low idle, and check for abnormalities, such as abnormal noise or external leaks.
Troubleshooting See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind of problem occurs in the motor during operation.
General cautions Think before attempting to fix a problem. Determine the nature of the abnormality before beginning work, and think whether this same kind of problem has occurred before. Also, reconfirm whether the motor is the source of the problem. Be careful about dust and dirt. The cause of wear is very often dust and dirt. So take measures to prevent dust or dirt from entering the parts during disassembly. Parts handling Handle parts carefully, be especially careful with the drive section, and do not scratch the sliding sections. Seals handling Do not damage the seat surfaces of O-rings while performing work. Also, it is recommended that O-rings be replaced with new ones during disassembly.
Causes of troubles and countermeasures Hydraulic motor does not operate. Symptom Pressure does not rise.
Pressure rises.
Cause Countermeasure Operation problem with internal relief valve Repair or replace the relief valve. 1. The parking brake cannot be released. 1. Check the orifice clog, and (Orifice of release pressure path is then clean or replace the part. clogged.) 2. The parking brake cannot be released. 2. Install the spool in the correct (The spool assembly is inverted.) direction. 3. The friction plate or separator plate of 3. Replace the friction plate or the parking brake section is sticking. separator plate. 4. The brake piston of the parking brake 4. Repair or replace the brake section is sticking. piston outer diameter. 5. Inspect and then repair or replace the sliding parts (piston, 5. Seizing of sliding section shoe, shoe plate, cylinder block, valve plate, etc.) 6. Repair or replace. 6. Spool operation defect
Weak startup of the hydraulic motor Symptom The set pressure is normal, but there is a delay in the release of the parking brake. The parking brake is released, but startup is delayed.
Cause
Countermeasure
Spool operation defect (Spool sticking)
Repair or replace.
The hydraulic oil viscosity is too high.
Raise the oil temperature.
84402827B - May 2011 6002-39
Assembly and Disassembly of Travel Motor Symptom
Cause Countermeasure 1. The parking brake is not fully released. (Orifice of release pressure path is 1. Check the orifice clog. clogged.) The parking brake is released, 2. Clean the relief valve, and but startup is weak. 2. Debris is caught in the relief valve. then inspect or replace the seat surface. 3. Inspect and repair or replace 3. Seizing of sliding section the sliding parts. Rotation speed does not reach the setting value. Symptom Rotation speed does not reach the setting value.
Cause
Countermeasure 1. Check the pump discharge 1. Insufficient oil flow amount volume and the oil pressure path up to the motor. 2. The shoe, cylinder block, or valve plate 2. Inspect and repair or replace shows signs of wear or serious damage. the part (s).
The brake does not operate. Symptom The brake does not operate.
The reverse brake works.
Cause Parking brake operation problem a) Wear on the friction plate b) Broken spring Spool operation defect
Countermeasure Inspect and repair or replace the brake piston, friction plate, and spring(s).
a) Sticking of the spool and main unit b) Sticking of the check valve or debris is Repair or replace. caught in the check valve c) Orifice hole is clogged.
Oil leak Symptom
Cause 1. Bolt and plug loosening
Oil leak
2. Gouging of O-ring(s) 3. Leak inside gear casing
84402827B - May 2011 6002-40
Countermeasure 1. Retighten to the specified torque. 2. Replace the O-ring. 3. Replace the oil seal(s).
Assembly and Disassembly of Travel Motor Cannot shift from high speed to low speed. Symptom Cause Cannot shift from high speed to The pilot valve spool is sticking. low speed.
Countermeasure Inspect and repair or replace the pilot valve spool.
Abnormal noise emitted Symptom When braking slowly or braking at the same time as operating a circuit other than the motor circuit, a noise is emitted along with a strong vibration.
Cause Countermeasure Spool operation defect Air bleeding implementation Air is remaining in the circuit or valve section. Spool sticking
Repair or replace.
Hunting occurs when going down an incline Symptom
Cause Spool operation defect
Countermeasure
Repair or replace. a) Sticking of the spool and main unit Strong hunting occurs during b) Orifice seating problem inching operation. Interference with parking brake The springs in the spool end section are Repair or replace. worn or broken.
84402827B - May 2011 6002-41
Assembly and Disassembly of Travel Motor Structural diagram Travel motor
Diagram 1 Travel motor structural diagram Code 1 2 3 4 5 6 7 8 9 10
Part name Casing NPT 1/16 plug Oil seal Circle R retaining ring IRTW68 Expansion plug Tilting piston Tilting piston seal Steel ball Shaft Bearing HR32209J
Code 22 23 24 25 26 27 28 29 30 31
Part name D-ring (small diameter) D-ring (large diameter) Rear cover NPT 1/16 plug (mec) Spool assembly Spring receiver Spring M42 plug O-ring 1B G40 Pilot spool 84402827B - May 2011 6002-42
Code 43 44 45 46 47 48 49 50 51 52
Part name O-ring 1B P8 Check valve Check valve spring M6 orifice (D0.6) O-ring 1B P12.5 M6 orifice (D0.8) O-ring 1B P15 O-ring 215.57 x 2.62 Bearing HR32207C Shim
Assembly and Disassembly of Travel Motor Code 11 12 13
Part name Pivot Shoe plate Cylinder block
Code 32 33 34
Part name Pin Spring receiver Spring
Code 53 54 55
14
Cylinder spring
35
Pilot valve plug G3/8
56
15 16 17 18 19 20 21
Spring receiver Spherical joint Shoe retainer Piston assembly Separator plate Friction plate Brake piston
36 37 38 39 40 41 42
O-ring 1B P14 Joint G1/4 plug O-ring 1B P11 Orifice (brake valve) Orifice spring (brake valve) G1/8 plug
57 58 59 60 61
84402827B - May 2011 6002-43
Part name Parallel pin Valve plate Brake spring Hexagon socket head bolt M18 x 50 Overload valve Coupling C retainer ring 40 for hole G1/2 plug O-ring 1B P18
Assembly and Disassembly of Travel Motor Reduction gear
Diagram 2 Reduction gear structural diagram Code 1 2 3 4 5 6 7 8 9
Part name Housing Bearing Ring gear Hexagon socket head bolt Floating seal Shim Lock washer Support ring Carrier 2
Code 10 11 12 13 14 15 16 17 18
Part name Planetary 2 Thrust washer 2 Needle bearing Carrier pin 2 Spring pin 10 x 50 Sun gear 2 Carrier 1 Planetary 1 Thrust washer 1
84402827B - May 2011 6002-44
Code 19 20 21 22 23 24 25 26 27
Part name Needle bearing Carrier pin 1 Spring pin Sun gear 1 Thrust plate Cover Hexagon socket head bolt Plug G 3/4 O-ring
Section 6003
Removal and Installation of Swing Unit
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Swing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Swing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 6003-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 6003-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Swing Unit Job code
Removal of Swing Unit
35352AL08
1.
Use a hexagon wrench (5 mm) to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank. Tightening torque for bolt installation: 2.94 - 4.90 N•m
2.
Attach the specialty adapter (1) to the area where the air breather was removed, and set the vacuum pump. Create negative pressure in the hydraulic oil tank using the vacuum pump (2).
3.
Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the center cover (2).
4.
Use a hexagon wrench (8 mm) to remove the 8 hexagon bolts, and then remove the hoses (1) and (2). Next, use a wrench (41 mm) to remove the hose (3), use a wrench (36 mm) to remove the hoses (4) and (5).
WARNING • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. • When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 °C or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing injury or oil leak. Items to prepare • • • • • • • • • • • • • • • • •
Wrenches (14 mm, 19 mm, 27 mm, 36 mm, 41 mm) Hexagon wrenches (5 mm, 8 mm, 17 mm) Box wrench (36 mm) Pliers Hammer Grease Specialty adapter for vacuum pump connection Vacuum pump (vacuum pump power supply) Extension cable Wire rope (with the required breaking load) Marking pen Caps Plugs Liftcrane (with the required lifting capacity) Rag Cleaning fluid Wood planks, etc.
84402827B - May 2011 6003-3
Removal and Installation of Swing Unit • Mark the swing motor and hoses so that the connectors can be matched during assembly. • Attach caps or plugs to the swing motor and hoses to prevent any entry of water, dust or dirt. • Clean the swing motor and hoses by spraying them with a parts cleaner to prevent scratching and prevent dirt from accumulating on the connectors.
5.
Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the under cover (2).
6.
Use a wrench (13 mm) to remove the bolt (3) on the clamp (2) for the hose (1).
7.
Use a box wrench (36 mm) to remove the 12 bolts (1) from the swing unit. Tightening torque for bolt installation: 900 - 1050 N•m
8.
Wrap the wire rope (1) around the swing motor and lift it with a liftcrane. • A knock pin (2) is driven into the installation section of the swing unit. Apply lubricating oil to the knock pin and pull it out together with the main unit of the swing motor while hitting with a hammer.
9.
Thoroughly check that the location is safe before lowering the swing unit on wood planks (1). • Thoroughly secure the swing unit so that it does not fall over.
84402827B - May 2011 6003-4
Removal and Installation of Swing Unit Installation of Swing Unit 1.
2.
To install, perform the reverse of the removal procedure. When installing the swing unit, be careful with the position of the knock pin. Tighten bolts being installed to the specified torque For bolts for which the torque is not specified, check "Standard Torque Data for Cap Screws and Nuts" in the explanation in the materials.
Before driving, be sure to fill the inside of the motor casing with hydraulic oil from the drain port (1). Thoroughly perform air bleeding from the air bleed port (2). Use the level gauge (3) to check that gear oil for the reduction gear is filled to the stipulated volume.
84402827B - May 2011 6003-5
Removal and Installation of Swing Unit
84402827B - May 2011 6003-6
Section 6004
Assembly and Disassembly of Swing Unit
84402827B - May 2011
84402827B - May 2011
CONTENTS Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 6004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 6004-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Swing Unit Job code
Disassembly
35352AF10
1.
Making a reference mark on the unit matching surface It is useful to place a reference mark (*1) on the matching surface of the housing (1) and ring gear (2) with paint, etc.
2.
Removal of level gauge assembly Remove the level gauge assembly (3) and cap (4) (27 mm hexagon diameter).
CAUTION 1.
2. 3.
4.
5.
6.
7.
8.
Read and understand the contents of this Maintenance Manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. Handle this product according to the separate "Usage Precautions". When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 °C or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing injury or oil leak. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. Check performance after reassembly. Do not resume use unless performance is fully recovered. Use may result in damage to product. The cautions (mark !) listed in this Maintenance Manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.
84402827B - May 2011 6004-3
Assembly and Disassembly of Swing Unit 3.
Gear oil draining Loosen the drain hose (*2) end plug, and then drain the gear oil. â&#x20AC;˘ Gear oil cannot be reused.
5.
Removal of motor Use the hexagon wrench (17 mm) to loosen and remove the 12 hexagon socket head bolts (6). Use the make-up port (G1) to raise the motor and remove it. â&#x20AC;˘ Liquid packing has been applied to the matching surfaces of the housing (7) and ring gear (8), so use the notch sections (*3) in the diagram to remove the motor.
5 4.
Reduction gear
Removal of hose Remove the drain hose (*2). 5
Reduction gear
This completes the disassembly.
84402827B - May 2011 6004-4
Assembly and Disassembly of Swing Unit Assembly 1.
Application of liquid packing After cleaning and degreasing the reduction gear ring gear (1) and the motor housing matching surfaces, apply liquid packing (ThreeBond Co.,Ltd. "1215" gray or the equivalent) as shown in the diagram on the right (*1).
2.
Motor installation Lift the motor and gently install it in the reduction gear, and use the hexagon wrench (17 mm) to tighten the hexagon socket head bolts (2) to the tightening torque of 568 - 649 N・m.
Install a plug in the female side of the hose, and install a hose (*3) in the drain port on the side of the gear case (5). Fill with gear oil (6 L) from the housing (3) gear oil fill port.
• Align the housing (3) and ring gear (4) according to the reference mark (*2) made before disassembly.
4.
3.
Installation of level gauge assembly Install the cap (6) (27 mm hexagon diameter) into the housing by tightening it to a torque of 98 N・m, and insert the level gauge assembly (7).
Gear oil filling 84402827B - May 2011 6004-5
Assembly and Disassembly of Swing Unit 5.
Grease-up Remove the plug (8) (5 mm hexagon socket diameter) from the gear case (5) and inject grease (1 L) from the grease fill port (9). â&#x20AC;˘ When injecting grease, there is the possibility of the reduction gear oil seal being damaged by internal pressure, so remove the air bleed port plug before injecting grease. Tighten the plug to the gear case to a tightening torque of 20 Nă&#x192;ťm. After injecting grease, install the grease hose in the grease fill port.
This completes the assembly.
84402827B - May 2011 6004-6
Section 8001A
Overall view
84402827B - May 2011
84402827B - May 2011
CONTENTS Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 LAYOUT OF HYDRAULIC EQUIPMENT IN CAB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
84402827B - May 2011 8001A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Overall view Overall view
84402827B - May 2011 8001A-3
Overall view 1 2
Housing left side Swing body center section
3 4
Pomp chamber Hydrauric oil tank
84402827B - May 2011 8001A-4
5
Fuel tank
Overall view PUMP CHAMBER HYDRAULIC EQUIPMENT LAYOUT
84402827B - May 2011 8001A-5
Overall view 1
Hydraulic pump
5
N1 sensor
9
2
Accumulator
6
P2 pressure sensor
10
3
Pilot filter
7
P1 pressure sensor
11
4
5 stack solenid valve
8
Pilot pump
84402827B - May 2011 8001A-6
N2 sensor Horsepower control electromagnetic proportional Hydraulic oil temperature sensor
Overall view SWING BODY CENTER SECTION HYDRAULIC EQUIPMENT
84402827B - May 2011 8001A-7
Overall view 1 2 3
84402827B - May 2011 8001A-8
Swing motor Center joint Control valve
Overall view HOUSING LEFT SIDE HYDRAULIC EQUIPMENT LAYOUT
84402827B - May 2011 8001A-9
Overall view 1 2 3
84402827B - May 2011 8001A-10
Cushion valve (with heat circuit) Swing pilot pressure sensor Oil cooler
Overall view LAYOUT OF HYDRAULIC EQUIPMENT IN CAB
1 2
84402827B - May 2011 8001A-11
Travel remote control valve Upper operation remote control valve
Overall view
84402827B - May 2011 8001A-12
Section 8001B
Port Diagram
84402827B - May 2011
84402827B - May 2011
CONTENTS Hydraulic Pump (standard model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remote Control Valves (upper, travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remote Control Valves (left-right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remote Control Valve (travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Direction Valve/Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Direction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Relief Valve (electromagnetic proportional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Manifold Under Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Manifold (accumulator section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Manifold (hydraulic oil tank section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
84402827B - May 2011 8001B-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Port Diagram Hydraulic Pump (standard model)
*1
Discharge port
Port
Port name
A1, A2
Discharge port
B1
Suction port
Dr1
Drain port Proportional valve pressure port Servo assist port Negative control port
P1
Psv Pi1, Pi2 a1, a2, a4, a5, Gauge port a6 84402827B - May 2011 8001B-3
Port size SAE 6000psi 1 SAE 2000psi 3 G3/4-23 primary
G1/4-13 G1/4-15 G1/4-13 G1/4-15
Port Diagram Port A3 B3 a3 Dr3 A4 B4
84402827B - May 2011 8001B-4
Port name Gear pump discharge port Gear pump suction port Gauge port Drain port (gear pump) Gear pump discharge port Gear pump suction pump
Port size G1/2-19 G3/4-20.5 G1/4-14 G3/8-15 G1/2-16 G1-21
Port Diagram Control Valve Relief Valve
Detailed diagram of main relief valve adjustment 1 2 3
Boom up Arm in Boom down
5 6 7
Arm out Bucket open Main a (normal use)
9 10 11
4
Bucket close
8
Main b (pressure boost)
12
84402827B - May 2011 8001B-5
Standard lock nut Pressure boost lock nut Pressure boost adjusting screw Standard pressure adjusting screw
Port Diagram
Port Port size SAE P1 6000psi 1 SAE A1 5000psi 1 SAE B1 5000psi 1 SAE A2 5000psi 1 SAE B2 5000psi 1 SAE A3 5000psi 1 SAE B3 5000psi 1 SAE A5 5000psi 1
Port name
Port Port size
Port name
Pressure line
pb1
G1/4
Left travel backward pilot line
Left travel (forward) line
pb6
G1/4
Right travel backward pilot line
Left travel (backward) line
pb3
G1/4
Left swing pilot line
Option line
pb5
G1/4
Arm-in pilot line
Option line
pb7
G1/4
Bucket-close pilot line
Swing right line
pb8
G1/4
Boom-down pilot line
Swing left line
PH
G1/4
Pressure boost signal port
Arm-out line
Ps1
G1/4
Negative control line
84402827B - May 2011 8001B-6
Port Diagram Port Port size SAE B5 5000psi 1 T1
Port name
Port Port size
Port name
Arm-in line
T8
G1/4
Heat circuit line
Return line
Pb2
G1/4
Option line
Port Port size SAE P2 6000psi 1 SAE A6 5000psi 1 SAE B6 5000psi 1 SAE A7 5000psi 1 SAE B7 5000psi 1
Port name
Port Port size
Port name
Pressure line
pa3
G1/4
Right swing pilot line
Right travel (forward) line
pa8
G1/4
Boom-up pilot line
Right travel (backward) line
pa5
G1/4
Arm-out pilot line
Bucket-open line
PA
G1/4
Upper signal
Bucket-close line
PT
G1/4
Travel signal
84402827B - May 2011 8001B-7
Port Diagram Port Port size SAE A8 5000psi 1 SAE B8 5000psi 1 T2 pa1 G1/4 pa6 G1/4 DR3 G1/4 pa7 G1/4 DR4 G1/4 P3 G1/4
Port name
Port Port size
Port name
Boom-up line
Ps2
G1/4
Negative control line
Boom-down line
Pbu
G1/4
Return line Left travel forward pilot line Right travel forward pilot line Straight travel drain line Bucket-open pilot line Drain Backup confluence line
Pa2 DR2 DR4 P3
G1/4 G1/4 G1/4 G1/4
84402827B - May 2011 8001B-8
Swing priority variable orifice switch signal Option line Drain Drain Backup confluence line
Port Diagram 4 Stack Solenoid Valve
Port Port size C3 G1/4 C1 G1/4
Port Port size B G3/8 T G3/8
View from bottom
Port Port size C2 G1/4 P G3/8
84402827B - May 2011 8001B-9
Port Diagram
1 2
3 4
Swing lock Lever lock
84402827B - May 2011 8001B-10
Pressure boost Travel high speed
Port Diagram 2 Stack Solenoid Valve
B port side
A port side Port A1 B1 A2 B2 T
84402827B - May 2011 8001B-11
Port size G1/4 G1/4 G1/4 G1/4 G1/4
Port Diagram Remote Control Valves (upper, travel) Remote Control Valves (left-right)
Right side
Left side
Right side
Port name
Left side
1
Bucket close
1
2
Boom down
2
3
Bucket open
3
4
Boom up
4
P
Pressure
P
T
Return
T
84402827B - May 2011 8001B-12
Port Diagram Remote Control Valve (travel)
Port 1 2 3 4 P T
84402827B - May 2011 8001B-13
Port name Backward left Forward left Backward right Forward right Pressure Return
Port size G1/4 G1/4 G1/4 G1/4 G1/4 G1/4
Port Diagram Cushion Valve
Port E, F G, H O, P M, N C, D A, B K, L
Port name Boom up Boom down Bucket open Bucket close Arm out Arm in Swing left
Port size G3/8 G3/8 G3/8 G3/8 G3/8 G3/8 G3/8
Port I, J Q U S V T R
Port name Swing right Swing pressure sensor signal Swing priority orifice switch Return (drain line) Heat circuit
84402827B - May 2011 8001B-14
Port size G3/8 G1/4 G1/4 G1/4 G1/4 G1/4 G1/4
Port Diagram Direction Valve/Relief Valve (electromagnetic proportional) Direction Valve
Port A B
Port size G1 G1
Port T1 T2
Port size G1 G3/4
84402827B - May 2011 8001B-15
Port PP DR
Port size G1/4 G1/4
Port Diagram Relief Valve (electromagnetic proportional)
Port A B
Port size G1 G1
84402827B - May 2011 8001B-16
Port C T
Port size G3/4 G3/4
Port Diagram HBCV
B port opening side Port A B C DR PL
84402827B - May 2011 8001B-17
Port size SAE 6000psi 1 SAE J6000psi 1 SAE 6000psi 1 SAE J6000psi 1 G1/4 G3/8 G1/4
Remarks Arm HBCV Boom HBCV Arm HBCV Boom HBCV
Port Diagram Manifold Under Cab
Port P1 P2 P3 P4
Port size G3/8 G3/8 G3/8 G1/4
Port P5 T1 T2 T3
Port size G1/4 G3/8 G3/8 G3/8
84402827B - May 2011 8001B-18
Port T4 T5
Port size G1/4 G1/4
Port Diagram Manifold (accumulator section)
Port P P1 P2 P3 P0
84402827B - May 2011 8001B-19
Port size G1/2 G1/4 G1/4 G1/2 G3/8
Port Diagram Manifold (hydraulic oil tank section)
Port D1 D2 D3 D6 T T1 D7
84402827B - May 2011 8001B-20
Port size G3/8 G1/4 G1/4 G1/4 G1/2 G3/8 G3/8
Port Diagram Swing Motor
*1 Port M DB PG A B PA, PB Dr SGr
Air bleed port (when applying grease)
Port name Make up Drain Brake release Right swing Left swing Pressure measurement Gear oil drain port Grease-up port
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Port size G1 G1/2 G1/4 G1/4 PT3/8 PT1/8
Port Diagram Travel Motor
Port D1, D2 P MA, MB VA, VB
Port name
Port size
Drain port
G1/2
Pilot port
G1/4
Pressure detection port
G1/4
Main port
G1
84402827B - May 2011 8001B-22
Port Diagram Center Joint
Port A' B' C' D' P' T A B C D P
Port name Forward right (connected to travel motor) Forward left (connected to travel motor) Backward right (connected to travel motor) Backward left (connected to travel motor) Pilot port (connected to travel motor) Drain port Forward right (connected to control valve) Forward left (connected to control valve) Backward right (connected to control valve) Backward left (connected to control valve) Pilot port (connected to control valve)
84402827B - May 2011 8001B-23
Port size G1 G1 G1 G1 G1/4 G1/2 500psi 1 500psi 1 500psi 1 500psi 1 G1/4
Port Diagram
84402827B - May 2011 8001B-24
Section 8001D
Pressure Measurement and Adjustment Procedures
84402827B - May 2011
84402827B - May 2011
CONTENTS Procedures for Pressure Measurement from the Monitor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Monitor and switch panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pressure Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY . . . . . . 4 Hydraulic Oil Temperature Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Procedures for Pressure Measurement by Installing Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure Measuring Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Location of Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pressure Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Main Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A.Attachment pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Boom-down pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B.Travel pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 C.Swing pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 D.Option line pressure measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pilot Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Negative Control Pressure Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pressure gauge installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Main Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Main relief pressure adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Pressure measurement and adjustment preparation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Overload relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Swing relief pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Pilot Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
84402827B - May 2011 8001D-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Pressure Measurement and Adjustment Procedures Procedures for Pressure Measurement from the Monitor Display Monitor and switch panel
1 2
Liquid crystal monitor Switch panel
3 4
Design panel Diffuser
Pressure Measurement Method The P1, P2, N1, and N2 pressure can be measured from the monitor display. (The pilot pressure cannot be measured.)
Operating Method 1. 2. 3. 4.
If both the travel speed select switch and the attachement select switch on the switch panel are held down, the display switches to the service support screen. CHECK the select service support screen. MACHINE STATUS the select service support screen. The respective pressures are displayed "P1" (P1 pump main pressure), "P2" (P2 pump main pressure), "N1" (N1 negative control pressure), and "N2" (N2 negative control pressure) columns. * MENU switch is held down the display returns to the normal screen.
a b
84402827B - May 2011 8001D-3
Normal screen Service support screen
Pressure Measurement and Adjustment Procedures PROCEDURES FOR MEASURING HYDRAULIC OIL TEMPERATURE FROM THE MONITOR DISPLAY Hydraulic Oil Temperature Measurement Method The hydraulic oil temperature can be measured from the monitor display.
Operating Method 1. 2. 3. 4.
If both the travel speed select switch and the attachement select switch on the switch panel are held down, the display switches to the service support screen. CHECK the select service support screen.ã&#x20AC;&#x201A; MACHINE STATUS the select service support screen. The hydraulic oil temperature is displayed in the "Hyd.OIL TEMP" column.
84402827B - May 2011 8001D-4
Pressure Measurement and Adjustment Procedures Procedures for Pressure Measurement by Installing Pressure Gauge Preparations Workers 2
Role (worker 1: work supervisor, pressure adjustment) Role (worker 2: operator)
Items to Prepare
2 3
Vacuum pump and power supply 5 (for vacuum pump) Pressure gauge (10 MPa-1) 6 7 Pressure gauge (60 MPa-2)
4
Hexagon wrench (8 mm, 6 mm) 8
1
Wrenches (17, 19, 24, 27 x 2, 32, 9 36 x 2) Rag 10 Extension cable 11 Hydraulic oil tank lid (for vacuum pump)
84402827B - May 2011 8001D-5
Recording sheet Pen Cleaning fluid
Pressure Measurement and Adjustment Procedures Pressure Measuring Ports There are the following 3 ports for pressure measurement. â&#x20AC;˘ Main pressure: pressure ports (P1, P2) (Remove the Main pressure sensor, then Install the pressure gauge.) â&#x20AC;˘ Negative control pressure: pressure ports (N1, N2) (Remove the negative control pressure sensor, then Install the pressure gauge.) â&#x20AC;˘ Pilot pressure: pressure port (P3)
84402827B - May 2011 8001D-6
Pressure Measurement and Adjustment Procedures
84402827B - May 2011 8001D-7
Pressure Measurement and Adjustment Procedures 1 2
Pump Pressure port: P2
3 4
Pressure port: P1 Pressure port: N1
84402827B - May 2011 8001D-8
5 6
Pressure port: N2 Pressure port: P3
Pressure Measurement and Adjustment Procedures Structure and Operation Explanation of Control Valve Location of Relief Valves Tool Position
Lock nut
2 3 4 5 6 7
Main (normal use) Main (boosted pressure) Boom up Boom down Arm in Arm out Bucket close Bucket open
8
Pilot
a 1 b
Adjusting screw
Pressure per of Measuring Set pressure rotation adjusting (MPa) port screw (MPa)
Hexagon diam- Hexagon diam34.3 eter 27 mm eter 27 mm
21.3
Monitor P1
Hexagon diam- Hexagon diam37.3 eter 32 mm eter 27 mm
28.4
Monitor P1
21.2 21.2 21.2 21.2 21.2 21.2
Monitor P2 Monitor P2 Monitor P1 Monitor P1 Monitor P2 Monitor P2
39.2 27.4 39.2 Hexagon diameter 17 mm Hexagon diam- 39.2 eter 6 mm 39.2 39.2 Hexagon diam3.92 eter 24 mm
2.0
Detailed diagram of main relief valve adjustment *1 *2 *3 *4
84402827B - May 2011 8001D-9
Pressure boost lock nut Pressure boost adjusting screw Standard lock nut Standard pressure adjusting screw
Pressure Measurement and Adjustment Procedures Pressure Measurement Preparations 1.
3.
Main unit installation Put the main unit on solid, level ground, put the bucket cylinder at its open stroke end, the arm cylinder at its out stroke end, lower the boom, and touch the arm top to the ground.
4.
Ignition key Switch OFF the ignition key (1), check that the engine has stopped, then switch the ignition key ON again. (Do not start the engine.)
5.
Oil temperature check Use the service check to check the hydraulic oil temperature.
Items to prepare For 10 MPa (for pilot and negative 1 ） Pres- control pressure measurement) sure gauge For 60 MPa (for main pressure measurement) Wrench (closed wrench) 17 mm 2）Tool Hexagon wrench 6 mm Rag 3）Others Cleaning fluid
2.
Monitor check Use the service check to check the no-load engine maximum speed and the SP mode pump input milliamp. Engine max. 2000 min-1
SP mode milli-amp 600 mA (during operation)
Oil temperature 45 - 55 °C
If the oil temperature is low, raise the oil temperature according to the warm-up operation procedure in the operator's manual.
6.
Bleeding pressure from inside circuits
84402827B - May 2011 8001D-10
Pressure Measurement and Adjustment Procedures Flip the gate lock lever (1) forward, then turn the upper operation lever (2) about 10 times to bleed out the pressure.
3
Gate lever
Move the travel lever (1) back and forth about 5 times to bleed out the pressure.
7.
Bleeding pressure from inside the hydraulic oil tank Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.
8.
Side door opening and closing Open the side door (1). At this time, be sure to use the lock (2).
This completes the preparations.
84402827B - May 2011 8001D-11
Pressure Measurement and Adjustment Procedures Pressure Measurement Main Pressure Measurement 1.
Pressure gauge installation Remove the pressure sensor (a1) (a2) installed on the hydraulic pump (1) and install the pressure gauge.
a1: Can be measured Travel left Option Swing Arm 1 pump flow Boom 2 pumps flow
a2: Can be measured Travel right Bucket Arm 2 pumps flow Boom 1 pump flow
Install the pressure gauge (2) on the adapter (1) and fasten it. Pressure gauge Port size
Install the adapter (2) on the gauge port (1).
84402827B - May 2011 8001D-12
for 60 MPa G1/4
Pressure Measurement and Adjustment Procedures A.Attachment pressure measurement Example: Arm-out pressure measurement Measure with the following operations. Engine speed Work mode Lever operation Oil temperature Measuring port Set pressure
1900 min-1 SP mode Arm-out relief 45 - 55 °C 1 pump: P1 port 2 pumps: P2 port Boosted pressure: 37.3 MPa Standard: 34.3 MPa
a
Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the pressure resulting from the pressure boost setting can be checked for about 8 sec. After 8 sec.or more, the standard set pressure can be checked. Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up. Lever operation
Arm out
Arm in
Engine speed Work mode Oil temperature 1 pump flow measuring port 2 pumps flow measuring port Pressure boost Standard pressure
1900 min-1 SP mode 45 - 55 °C P1 P1 P2 P2 37.3 MPa 34.3 MPa
Bucket open
Bucket close
Boom up
P2 No
P2 No
P2 P1
84402827B - May 2011 8001D-13
Boom down
P2 P1 27.4 MPa 27.4 MPa
Pressure Measurement and Adjustment Procedures Boom-down pressure measurement For pressure measurement with the boom down, put the arm cylinder at its out stroke end, open the bucket, put
a
Boom-down relief
the bucket tip on the ground, carry out the boom-down operation, and measure.
B.Travel pressure measurement 1. 2.
Install the stopper (1) on the crawler sprocket section (2) and lock the travel motor. Measure with the following operations. Engine speed Work mode Lever operation Oil temperature Measuring port Set pressure
84402827B - May 2011 8001D-14
1900 min-1 SP mode (1st speed) Travel relief 45 - 55 °C Left travel: P1 port Right travel: P2 port 34.3 MPa
Pressure Measurement and Adjustment Procedures C.Swing pressure measurement
D.Option line pressure measurement
1.
1.
Close the option line stop valve (1).
2.
Switch the attachment select switch of the monitor to the option line to be measured (breaker, crusher). Measure with the following operations.
2.
Do not let the bucket move even if swing pressure is relieved with a swing operation such as digging a hole. Measure with the following operations. Engine speed Work mode Lever operation Oil temperature Measuring port Set pressure
1900 min-1 SP mode Swing relief 45 - 55 °C P1 port 30.4 MPa
3.
Engine speed Work mode Pedal operation Oil temperature Measuring port
1900 min-1 SP mode Option relief 45 - 55 °C 1 pump: P2 port 2 pumps: P1 port
* Adjust the set pressure to match the specifications of the attachment used.
84402827B - May 2011 8001D-15
Pressure Measurement and Adjustment Procedures Pilot Pressure Measurement Pressure gauge installation Remove the plug with the wrench (1) to install a pressure gauge at the pump pressure measuring port (P3).
Install the adapter (1).
Install the pressure gauge (1) and measure the pressure. Engine speed Work mode Oil temperature Measuring port Set pressure
Pressure gauge Port size
1900 min-1 SP mode 45 - 55 °C P3 port 3.92 MPa
84402827B - May 2011 8001D-16
for 10 MPa G1/4
Pressure Measurement and Adjustment Procedures Negative Control Pressure Measurement Pressure gauge installation Remove the pump N1 pressure sensor (1) or N2 pressure sensor (2) connector (3), and then remove the pressure sensor.(N1, N2: pressure port) (The pressure sensor location becomes the measuring port.)
Install the adapter (1) of the pressure gauge at the port where the N1 or N2 pressure sensor was removed and install the pressure gauge (2).
Measure the negative control pressure for each operation.
84402827B - May 2011 8001D-17
Pressure Measurement and Adjustment Procedures
Pressure gauge Port size
for 10 MPa G1/4
Engine speed Work mode Oil temperature Measuring port Set pressure
84402827B - May 2011 8001D-18
1900 min-1 SP mode 45 - 55°C P1 pump side: N1 port P2 pump side: N2 port 3.92 MPa max.
Pressure Measurement and Adjustment Procedures Pressure Adjustment Main Pressure Adjustment Main relief pressure adjustment Engine speed Work mode Lever operation Oil temperature Measuring port
4 5
1900 min-1 SP mode Arm-in relief 45 - 55 °C P1 port
Boosted pressure:37.3 MPa Standard:34.3 MPa Boosted pressure:28.4 Pressure per rotation of MPa/rotation adjusting screw Standard:21.3 MPa/rotation Measurement pressure
Before adjusting, remove the pilot hose for the pressure boost signal (2) connected to the main relief valve (1), then insert the plug (3) into the hose side. The procedures for boosted pressure and standard pressure are different.
Control valve Wrench (19 mm)
84402827B - May 2011 8001D-19
Pressure Measurement and Adjustment Procedures Pressure measurement and adjustment preparation work
For boosted pressure 1.
Loosen the standard lock nut (27 mm) (1) and tighten the adjusting screw (27 mm) (2). Fasten with a wrench (27 mm) so that the pressure boost adjusting screw does not turn.
2.
After tightening until the adjusting screw stops turning, tighten the pressure boost lock nut (1).
3. 4.
Start the engine and run it at maximum rotation. Move the arm lever to the in side, set the relief state, and hold. Loosen the pressure boost lock nut (32 mm) (1) and adjust the set pressure with the adjusting screw (27 mm) (2).
Pressure is adjusted with control valves. The following preparations are required for adjusting with control valves. 1.
2.
Engine hood opening and closing Unfasten the 2 latches (2) on the engine hood (1) and open the engine hood (1).Pull the latches (2) to release the locks.
Cover removal Remove the 5 bolts (1), then remove the cover (2).
5.
â&#x20AC;˘ When lower than the set pressure, tighten.
â&#x20AC;˘ When higher than the set pressure, first lower below the set pressure, then adjust on the tightening side. 6.
After adjustment, fasten the adjusting screw with a wrench (27 mm), then tighten the lock nut.
84402827B - May 2011 8001D-20
Pressure Measurement and Adjustment Procedures 7.
After locking, check the pressure on the boosted pressure side.
For standard pressure 1.
Loosen the standard lock nut (27 mm) (1).
2.
Loosen the adjusting screw (1), lower below the set pressure, then adjust on the tightening side.
3.
After adjustment, tighten the lock nut while fastening the adjusting screw (1) with a wrench (2).
4.
After locking, check the pressure.
Repeat [1] - [7] until the set pressure is correctly adjusted.
Repeat [1], [2], and [3] until the set pressure is correctly adjusted. Stop the engine.
84402827B - May 2011 8001D-21
Pressure Measurement and Adjustment Procedures Overload relief pressure adjustment Engine speed Work mode Oil temperature Measuring port Measurement pressure
1900 min-1 SP mode 45 - 55 °C P1/P2 port Boom down: 27.4 MPa Others: 39.2 MPa
Since the overload relief pressure is set higher than the main relief pressure, it is necessary to provisionally set the main relief pressure higher than the overload relief pressure. (Except for boom down)
Pressure per rotation of adjust21.2 MPa/rotation ing screw
1 2 3 4
Control valve Boom down Bucket close Boom up
5 6
Arm-out Bucket open
Main relief pressure provisional setting 84402827B - May 2011 8001D-22
Pressure Measurement and Adjustment Procedures â&#x20AC;˘ Using the main pressure adjustment procedure for reference, temporarily set the boosted pressure and standard pressure to at least 39.2 MPa. * For boom down (1), since the overload set pressure is lower than the main relief set pressure, there is no need to temporarily set the main relief pressure.
Pressure adjustment Example: Arm-out (1) overload relief adjustment
1.
2.
After adjustment, lock the lock nut (1).
3.
After adjusting the overload relief pressure, adjust the boosted pressure and standard pressure to their normal values referencing the main pressure adjustment procedure.
Loosen the lock nut (1) with the wrench (2) and adjust by turning the adjusting screw (3) with the hexagon wrench (4). â&#x20AC;˘ When lower than the set pressure, tighten. â&#x20AC;˘ When higher than the set pressure, first loosen to a pressure lower than the set pressure, then adjust on the tightening side.
* For the position of each overload relief, see the "Control Valve Relief Locations".
84402827B - May 2011 8001D-23
Pressure Measurement and Adjustment Procedures Swing relief pressure adjustment Engine speed Work mode Oil temperature Measuring port Measurement pressure Pressure per rotation of adjusting screw 1. 2.
3.
After adjustment, lock the lock nut (1).
1900 min-1 SP mode 45 - 55 °C P1 port 30.4 MPa 11.6 MPa/rotation
Using the swing pressure measurement procedure for reference, lock the swing, and check the swing pressure. Use a wrench (1) to loosen the lock nut (2) and adjust by turning the adjusting screw (3). â&#x20AC;˘ When lower than the set pressure, tighten. â&#x20AC;˘ When higher than the set pressure, first loosen to a pressure lower than the set pressure, then adjust on the tightening side.
84402827B - May 2011 8001D-24
Pressure Measurement and Adjustment Procedures Pilot Pressure Adjustment 1.
Install the pressure gauge (1). While holding the plug with a wrench (24 mm) (2), adjust with a hexagon wrench (6 mm) (3). Engine speed Lever operation Measuring port Set pressure
1900 min-1 Neutral P3 3.92 MPa
84402827B - May 2011 8001D-25
Pressure Measurement and Adjustment Procedures
84402827B - May 2011 8001D-26
Section 8001E
Hydraulic Pump Flow Measurement Procedures
84402827B - May 2011
84402827B - May 2011
CONTENTS Hydraulic Pump Flow Measurement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Items to Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Work Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8001E-1
3 3 3 5 7
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001E-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Hydraulic Pump Flow Measurement Procedures Hydraulic Pump Flow Measurement Procedures Preparations Workers 3
Role (worker 1: work supervisor, pressure adjustment) Role (worker 2: operator) Role (worker 3: flow, pressure measurement, recording)
Items to Prepare
1
Vacuum pump and power supply 6
2
Flow meter
7
3
Pressure gauge (60 MPa x 2)
8
Extension cable 11 Hydraulic oil tank lid (for vacuum 12 pump) Adapter (flange type) 13 84402827B - May 2011 8001E-3
Pen Cleaning fluid Rag
Hydraulic Pump Flow Measurement Procedures 4
Hexagon wrench (6 mm, 10 mm) 9
Hydraulic hose (for flow measurement)
5
Wrenches (17, 19, 24, 27 x 2, 32, 10 36 x 2)
Recording sheet
84402827B - May 2011 8001E-4
Hydraulic Pump Flow Measurement Procedures Work Preparations 1. 2.
5.
Install the vacuum pump (1) on the hydraulic oil tank lid.
6.
After setting the vacuum pump (1) as in the diagram on the right, switch on the power.(If the cable is too short, use an extension cable.)
7.
Use a hexagon wrench (1) (10 mm) to remove the split flanges (2) and hydraulic hose (3). (This section explains flow measurement at the P2 pump.)
Check that the main unit is in its work posture (armvertical). Bleed out the pressure. (See the details on Bleeding Pressure in the Pressure Measurement and Adjustment Procedures.) * Perform a swing prevention check.
3.
4.
Use a wrench (17 mm) to remove the feed port cover (1).
Use the bolts removed in 3. to install the hydraulic oil tank lid (for vacuum pump) (1).
4
84402827B - May 2011 8001E-5
Bolt
Hydraulic Pump Flow Measurement Procedures 8.
Use the split flange (2) to install the adaptor (flange type (3)) on the tip of the hydraulic hose (1) removed in 7..
* When connecting, always check the connection positions. * Always have the metering valve (7) fully open. Remove the vavuum pump and re-install the hydraulic oil tank the same way it was. Install pressure gauges on P1 and P2.(See "Main Pressure Measurement".) Open the engine hood.(See "Main Pressure Adjustment".)
4 9.
Hydraulic hose
Install the adaptor (1) at the position from which the hydraulic hose was removed. If necessary, install an "elbow adaptor" (3) on the (prepared) hydraulic hose (2) connected to the flow meter IN side.
10. Install the hydraulic hose (3) on the flow meter (1) IN side(2), then fasten with the spanner. Install the (prepared) hydraulic hose (5) on the flow meter (1) OUT side (4), then fasten with the spanner. Installs the adapter (6) to have instralled in opposite in 8..
11. Remove the cover. 12. Remove the pilot hose for the boosted pressure signal, then plug the hose side. (See "Main Relief Pressure Adjustment".) This completes the preparation for flow measurement.
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Hydraulic Pump Flow Measurement Procedures Flow Measurement
5.
1.
6. 7. 8.
Measure the flow. When measuring the flow, position the workers as in the diagram on the right. (Worker 1 (1): Work supervisor, pressure adjustment) (Worker 2 (2): Operator) (Worker 3 (3): Flow, pressure measurement, recording)
Worker 2 lowers the arm-out port relief. (Min: 24 MPa P1+P2) Start of flow measurement The arm-out relief operation is carried out. Data measured in units of 2.0 MPa (P1+P2) * The measurement is carried out from 24.0 - 76.0 MPa and ends when the maximum pressure is reached.
9.
Remove the flow meter. * Because the maximum limit of the flow meter pressure gauge is exceeded starting from 40 MPa.
10. Reset the arm-in port relief valve to normal pressure.(For details on this adjustment, see "Pressure Adjustment".) 11. Remove the pressure gauges etc. and put everything back to normal. This completes the work.
2. 3.
4.
At the signal from the work supervisor, the operator starts the engine. Check the hydraulic oil temperature on the monitor. (50 °C) Check that the engine rotation and pump milli-amp is normal. The operator signals the arm-out relief operation to worker 1.
1 2
1
Ignition key
84402827B - May 2011 8001E-7
Lock nut 17 mm Hexagon wrench 6 mm
Hydraulic Pump Flow Measurement Procedures
84402827B - May 2011 8001E-8
Section 8001F
Drain Volume Measurement Procedures
84402827B - May 2011
84402827B - May 2011
CONTENTS Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Travel Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Swing Motor Drain Volume Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 8001F-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001F-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Drain Volume Measurement Procedures Preparations
4.
Use a wrench to remove the drain hose (5). (Always install a cap on the removed drain hose (5).)
Measuring conditions Engine speed Mode Oil temperature
1900 min-1 SP mode About 50°C
* Be careful. The drain volume varies greatly with the oil temperature.
Travel Motor Drain Volume Measurement 1.
Allow the bucket (2) to touch the ground so as to elevate one shoe crawler (1) as in the diagram on the right.
5.
Install the extension hose for measurement (1) on the side of the motor from which the drain hose was removed.
2.
Remove the bolts (2), then remove the cover (1).
6.
Prepare a waste oil can (1) and measuring container (2) and set them as in the diagram on the right.
3.
Always lay a rag (2) underneath before removing the drain hose (1).
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Drain Volume Measurement Procedures 7.
Forward 1st 2nd speed speed
Catch the stopper (1) between the sprocket section and the frame and lock the travel motor.
Backward 1st 2nd speed speed
Right Left * Measure at least 3 times each for left, right, forward, and backward.
8.
In SP mode at medium speed, relieve the travel operation, and move the extension hose to the measuring container (1) at the same time the motor starts. (At starting, start measurement with a stop watch (3).) 9. After 30 sec., move the extension hose to the waste oil can (1). 10. Measure the volume of oil in the measuring container (2) as the drain volume for 30 sec.
84402827B - May 2011 8001F-4
a
30 seconds
Drain Volume Measurement Procedures Swing Motor Drain Volume Measurement 1.
5. 6.
Remove the 2 drain hoses (1) and put plugs in the hose side of each. (wrench size: 27 mm, clamp 22 mm (hose side))
2.
Install the extension hose (1) for measuring the drain volume on one side of the T nipple. Install the hose facing in a direction that makes measurement easy and install a plug (2) on the other side.
3.
Prepare a waste oil receiver and measuring container (1) and set them as in the diagram on the right. For details on the method for locking the swing motor, see "Swing relief pressure adjustment". In SP mode, relieve the swing operation and move the extension hose to the measuring container (1) at the same time the motor starts.(At starting, start measurement with a stop watch (2).)
4.
After 60 sec., move the extension hose (3) to the waste oil can (4). Measure the volume of oil in the measuring container (1) as the drain volume for 60 sec. Measure at least 3 times each for left and right.
84402827B - May 2011 8001F-5
Right
Left
a
60 seconds
Drain Volume Measurement Procedures
84402827B - May 2011 8001F-6
Section 8001G
Air Bleed Procedure
84402827B - May 2011
84402827B - May 2011
CONTENTS Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Cylinder HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8001G-1
4 5 6 6 7 7 7
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8001G-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Air Bleed Procedure CAUTION Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or replacing hydraulic equipment, or removing hydraulic pipes. Air bleed procedure mode (when bleeding, follow the procedure below.) Hydraulic Cylinder air Swing motor Travel motor pump air Check bleeding air bleeding air bleeding bleeding Hydraulic oil or hydraulic pump replacement Cylinder replacement
Swing motor replacement
Travel motor replacement
* Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.
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Air Bleed Procedure Hydraulic Pump 1.
Loosen the air bleed plug (1) and check that oil oozes from the air bleed port (2)s. If oil does not ooze out, remove the air bleed plug (1), and fill hydraulic oil(3) from the air bleed port (2) into the pump (4) case. Temporarily tighten the air bleed plug (1). Run the engine at low idle, slightly loosen the air bleed port, and run until oil oozes from the air bleed port (2) section. Completely tighten the air bleed plug (1).
84402827B - May 2011 8001G-4
Air Bleed Procedure Travel Motor
5.
1.
Remove the bolts (2), then remove the cover (1).
6.
2.
Remove the hose (1) of drain port and elbow (2).
3. 4.
Pour in of hydraulic oil (1) from the air bleed port. When inside the motor is filled with hydraulic oil, tighten the elbow and hose.
Start the engine and execute a slow travel operation. Repeatedly travelling forward and backward bleeds off the air.
84402827B - May 2011 8001G-5
Air Bleed Procedure Swing Motor 1.
3.
Temporarily tighten the tee (1) of drain hose (3). Run the engine at low idle, slightly loosen the tee (1) of drain hose, and run until oil oozes from the port section (2). Completely tighten the tee (1) of drain hose.
4.
With the engine at low idle, slowly swing evenly left and right at least 2 rotations.
Run the engine at low idle, loosen the tee (1) of drain hose (3), and check that oil oozes from the air bleed port section (2). * Do not execute a swing operation.
2.
If oil does not ooze out, stop the engine for now, remove the tee (1) and fill hydraulic oil (2) into the motor case.
Check After the air bleeding is complete, stop the engine for at least 5 minutes to allow any air bubbles in the hydraulic oil tank to dissipate.
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Air Bleed Procedure Arm Cylinder HBCV
HBCV CAUTION The HBCV air bleeding work requires 2 workers: an operator and an air bleed worker. Decide the signals beforehand and work safely. Set the main unit so that the arm HBCV is at the highest position.
For arm-in operations, bleed the air from the arm cylinder HBCV (1) using the same procedure as for boom cylinder HBCV air bleeding.
Boom Cylinder HBCV 1. 2.
Start the engine and lower the boom without jacking up the main unit. In the above state, loosen the hose mouthpiece (1) at the position in the figure. Foaming hydraulic oil comes out from the hose mouthpiece section. When foaming hydraulic oil stops coming out, tighten the hose mouthpiece (1).
2 3. 4.
HBCV
Execute steps 2. for the opposite side boom cylinder too. Check boom operations. If there is a delay in the operation response, bleed the air again with the same procedure.
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Air Bleed Procedure
2
Hose mouthpiece
84402827B - May 2011 8001G-8
Section 8002
Removal and Installation of Hydraulic Oil Tank
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 8002-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8002-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Hydraulic Oil Tank Removal of Hydraulic Oil Tank
WARNING • Keep away from fire. • Bleed off the pressure in the hydraulic oil tank before beginning work. • The temperature of the hydraulic oil is high immediately after stopping the engine. Wait until the hydraulic oil temperature has decreased (to 40°C or less) before beginning work.
1. 2.
Drain the oil from the hydraulic oil tank. (For details, see "Draining Oil from Hydraulic Oil Tank".) Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the under cover (2). Tightening torque for bolt installation: 63.7 - 73.5 N•m
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • Wrenches (7 mm, 19 mm, 22 mm, 24 mm, 27 mm, 36 mm, 40 mm) • Eyebolts (M12 x 2) • Shackle (with the required lifting capacity) x 2 • Wire rope (with the required breaking load) • Liftcrane (with the required lifting capacity) • Marking pen • Caps • Plugs • Waste oil can • Rag • Cleaning fluid • Wood planks, etc.
3.
Prepare a waste oil can (1) under the hydraulic oil tank.
4.
Use a wrench (36 mm) to remove the bolt (1), and then remove the seal washer (2). • Cover the seal washer to prevent the entry of water, dust or dirt. • Tightening torque for bolt installation: 233.0 276.0 N•m
84402827B - May 2011 8002-3
Removal and Installation of Hydraulic Oil Tank 5.
6.
7.
â&#x20AC;˘ Attach caps or plugs to the hydraulic oil tank and hoses to prevent any entry of water, dust or dirt. â&#x20AC;˘ Clean the hydraulic oil tank and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
After closing the engine hood (1), use a wrench (19 mm) to remove the 10 bolts (2), and then remove the top covers (3) and (4).
Use a wrench (7 mm) to loosen the hose band (1), and then remove the drain hoses (2) and (3). Use caps to cover the lines to prevent any entry of water, dust or dirt.
8.
Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the stay (2).
9.
Use a wrench (19 mm) to remove the 7 bolts (1), and then remove the top cover (2) from the hydraulic oil tank.
Use wrenches (19 mm, 22 mm, 27 mm, 36 mm, 40 mm) to remove the drain hoses (1). â&#x20AC;˘ Mark the hydraulic oil tank and hoses so that the connectors match at the time of assembly.
84402827B - May 2011 8002-4
Removal and Installation of Hydraulic Oil Tank 10. Use a wrench (24 mm) to remove the 6 bolts (1) and 6 spacers (2) from the bottom of the hydraulic oil tank. â&#x20AC;˘ Depending on the machine, there may be height adjustment shims between the tank and the frame. Do not lose them. Also, mark or write down the locations where they are and how many.
11. Use a wrench (19 mm) to remove the 2 bolts (1) from the fuel tank front cover (tank) (2), and then remove the cover (tank).
13. Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the side covers (tank) (2).
12. Use a wrench (19 mm) to remove the 5 bolts (1) from the fuel tank side cover, and then remove the side cover (2). 14. Connect the 2 eyebolts (M12) (1) to the top of the hydraulic oil tank, and then use the shackles (2), wire rope (3) and liftcrane to lift the hydraulic oil tank (4). â&#x20AC;˘ When lifting, be careful that the level gauge (5) does not interfere with the frame at the side of the hydraulic oil tank. â&#x20AC;˘ Fully tighten the eyebolts, and then loosen them by a half turn.
84402827B - May 2011 8002-5
Removal and Installation of Hydraulic Oil Tank 15. Thoroughly check that the location is safe before lowering the hydraulic oil tank on wood planks (1). Thoroughly secure the hydraulic oil tank so that it does not fall down.
Installation of Hydraulic Oil Tank To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts"
84402827B - May 2011 8002-6
Section 8003
Removal and Installation of Hydraulic Pump
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of hydraulic pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
84402827B - May 2011 8003-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8003-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Hydraulic Pump WARNING
3.
Tighten the cock (3).
4.
Prepare the waste oil can (1). Use a wrench (10 mm) to loosen the air bleed plug (2).
• Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • Wrenches (10 mm, 13 mm, 17 mm, 19 mm, 27 mm, 36 mm, 41 mm) • Hexagon wrenches (10 mm, 14 mm) • Nylon sling (with the required breaking load) • Liftcrane (with the required lifting capacity) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Wood planks, etc.
Removal of hydraulic pump 1.
Use a wrench (19 mm) to remove the 6 bolts (1), and then remove the under cover (2).
2.
Remove the engine hood. For the procedure, see "Removal and Installation of Engine Hood".
84402827B - May 2011 8003-3
Removal and Installation of Hydraulic Pump 5.
Remove the drain plug (1).
6.
Drain the fuel.
7.
Loosen the hose bands (1), and then remove the 2 hoses (2). Use a wrench (13 mm) to remove the 3 bolts (3), and then remove the fuel filter (4).
8.
Remove the charge fuel pump filter. For the procedure, see "Charge Fuel Pump Filter in Procedures for Replacing Consumable Parts".
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Removal and Installation of Hydraulic Pump 9.
Use a wrench (10 mm) to loosen the air bleed plug (1) of the fuel pre-filter (2). Loosen the cap (3) at the bottom and drain out any remaining fuel.
10. Loosen the hose clip (1), and then remove the 2 hoses (2). Use a wrench (13 mm) to remove the 2 bolts (3), and then remove the fuel pre-filter (4).
* Put a waste oil case (4) underneath.
11. Remove the engine oil filter hose (1). Use a wrench (13 mm) to remove the 4 bolts (2), and then remove the engine oil filter (3).
84402827B - May 2011 8003-5
Removal and Installation of Hydraulic Pump 12. Remove the 3 pilot filter (1) hoses (2). Use a wrench (17 mm) to remove the 2 bolts (3), and then remove the pilot filter (1).
14. Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the bracket (2). Use a wrench (19 mm) to remove the 8 bolts (3), and then remove the cover (4).
13. Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the stay (2).
15. Use a wrench (19 mm) to remove the 4 bolts (1) and the 4 washers (2), and then remove the bracket (3).
84402827B - May 2011 8003-6
Removal and Installation of Hydraulic Pump 16. Use a wrench (17 mm) to remove the 4 bolts (1). Use a wrench (19 mm) to remove the 4 bolts (2), and then remove the brackets (3) (4).
• Clean the pump and hoses by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
18. Secure the pump with a liftcrane and nylon sling (1) so that it does not fall during removal and installation operations.
17. Remove the hoses and connectors that are connected to the pump. • Use a hexagon wrench (10 mm) to remove the 8 hose bolts (1), and remove the pressure hoses (2). • Use a wrench (41 mm) to remove the drain hose (3). • Use a wrench (27 mm) to remove the pilot hose (4). • Use a wrench (36 mm) to remove the suction hose (5). • Remove the connectors (6). • Use a wrench (19 mm) to remove the hydraulic pilot hoses (7). • Use a hexagon wrench (14 mm) to remove the suction line 4 bolt and remove the suction line (8). • Mark the pump and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the pump and hoses to prevent any entry of water, dust or dirt.
84402827B - May 2011 8003-7
Removal and Installation of Hydraulic Pump 19. Use a wrench (17 mm) to remove the 8 bolts (1) from the pump. Tightening torque for bolt installation:63.8 - 73.6 Nâ&#x20AC;˘m
20. Use a liftcrane and the nylon sling (1) to pull the pump out from the shaft and lift the pump.
21. Thoroughly check that the location is safe before lowering the pump on wood planks (1). â&#x20AC;˘ Thoroughly secure the pump so that it does not fall over.
84402827B - May 2011 8003-8
Removal and Installation of Hydraulic Pump Installation of hydraulic pump To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
Fill the pump case with hydraulic oil from the drain port so that no air remains in the pump case. Additionally, when there is a 2nd option gear pump, bleed off air from the air bleed port on the top surface of the power take-off case.
84402827B - May 2011 8003-9
Removal and Installation of Hydraulic Pump
84402827B - May 2011 8003-10
Section 8004
Removal and Installation of Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 8004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8004-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Control Valve WARNING
3.
After opening the engine hood (1), use a wrench (19 mm) to remove the 10 bolts (2), and then remove the top covers (3) (4).
4.
Use a wrench (19 mm) to remove the 4 bolts (1), and then remove the under cover (2). Tightening torque for bolt installation: 63.7 - 73.5 N•m
• Keep away from fire. • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • Wrenches (7 mm, 17 mm, 19 mm, 22 mm, 24 mm, 25 mm) • Hexagon wrenches (8 mm, 10 mm) • Wire cutters • Eyebolts (M10 x 2) • Shackle (with the required lifting capacity) x 2 • Wire ropes (with the required lifting capacity) • Liftcrane (with the required lifting capacity) • Marking pen • Caps • Plugs • Rag • Cleaning fluid • Wood planks, etc.
Removal of Control Valve 1.
Extend the attachment and bring in contact with the ground.
2.
Drain the oil from the hydraulic oil tank.(For details, see "Draining Oil from Hydraulic Oil Tank")
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Removal and Installation of Control Valve 5.
Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the housing frame (2).
6.
Remove the connectors (1) and (2) from the pressure sensor.
7.
Use a wrench (7 mm) to remove the hose band (1), and then remove the low-pressure hose (2).
8.
Use wrenches (19 mm, 22 mm, 25 mm) and hexagon wrenches (8 mm, 10 mm) to remove the control valve lines and hoses. â&#x20AC;˘ Mark the lines and hoses so that the connectors match at the time of assembly. â&#x20AC;˘ Use caps or plugs to cover the lines and hoses to prevent any entry of water, dust or dirt. â&#x20AC;˘ Clean the lines by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8004-4
Removal and Installation of Control Valve 9.
Use a wrench (24 mm) to remove the 4 bolts (1) from the control valve. Tightening torque for bolt installation: 267 - 312 Nâ&#x20AC;˘m
11. Install the shackles (1) on the eyebolts, then use the liftcrane and wire ropes (2) to lift the control valve (3).
10. Install the 2 eyebolts (1) (M10) on the control valve.
12. Place the control valve (1) on wood planks (2).
Installation of Control Valve To install, perform the reverse of the removal procedure. Tighten bolts to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
84402827B - May 2011 8004-5
Removal and Installation of Control Valve
84402827B - May 2011 8004-6
Section 8005A
Removal and Installation of Bucket Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 8005A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8005A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Bucket Cylinder Job code
Removal of Bucket Cylinder
35738AA10
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
• Remove the bucket. (For details, see "Removal and Installation of Bucket".) • Remove the bucket link. (For details, see "Removal and Installation of Bucket Link".) 1.
Bring the arm (1) top in contact with the ground. Retract the bucket cylinder rod.
2.
Tie the cylinder rod with wire (1) so that it cannot come out.
3.
Turn the key switch (1) OFF and stop the engine.
Items to prepare • • • • • • • • • • •
Wrenches (30 mm) Hexagon wrench (8 mm) Hammer Striking rod Liftcrane (with the required lifting capacity) Nylon sling (with the required lifting capacity) Grease Rag Cleaning fluid Crosstie Wire
84402827B - May 2011 8005A-3
Removal and Installation of Bucket Cylinder 4.
Switch the key switch ON again, and then turn the control lever (1) about 10 times to bleed out any pressure.
Remove the hose (1) in the same way. • Use caps or plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
NOTE: Do not operate the bucket at this time.
5.
Move the travel lever (1) back and forth about 5 times to bleed off the pressure. Return the key switch to OFF.
6.
Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.
7.
8.
Use a liftcrane and nylon sling (2) to secure the bucket cylinder (1). • Wrap the nylon sling to the inside of the line so that it is not crushed.
Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (3) of the hose (2), and then remove the 2 split flanges (4) and O-ring (5).
84402827B - May 2011 8005A-4
Removal and Installation of Bucket Cylinder 9.
Use a wrench (30 mm) to remove the bolt (1) and spacer (2).
10. Use a hammer (2) and striking rod (3) to push the pin (1) out. â&#x20AC;˘ When removing the pin, be careful not to damage the installed O-rings or dust seals.
11. Lift the bucket cylinder (1) and then place it on the crosstie.
84402827B - May 2011 8005A-5
Removal and Installation of Bucket Cylinder Installation of Bucket Cylinder
4.
• Tighten lines and bolts being installed to the specified torque. • When the torque is not specified, check the "Bolt Size and Torque Table". 1.
2.
3.
Align the bucket cylinder (1) with the arm and use a hammer (3) to push in the pin (2). • If a pin is hard to insert, the cylinder is tilted. • When inserting the pin, be careful not to damage the installed O-rings or dust seals.
Clean each pin and pin hole.
5.
Use a wrench (30 mm) to install the bolt (1) and spacer (2).
6.
After setting the O-ring (5) on the line side, install the hose (2) with the 2 split flanges (4) and the 4 hexagon socket head bolts (3).
Tie the cylinder rod with wire (1) so that it cannot come out.
Use a liftcrane and nylon sling (2) to lift the bucket cylinder (1). • Wrap the nylon sling to the inside of the line so that it is not crushed.
• Install the hose (1) with the same procedure. • The O-rings cannot be reused. Replace them with new parts. • Install the bucket link. (For details, see "Removal and Installation of Bucket Link".) • Install the bucket. (For details, see "Removal and Installation of Bucket".)
84402827B - May 2011 8005A-6
Removal and Installation of Bucket Cylinder
84402827B - May 2011 8005A-7
Removal and Installation of Bucket Cylinder
84402827B - May 2011 8005A-8
Section 8005B
Removal and Installation of Arm Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Arm Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 8005B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8005B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Arm Cylinder Job code
Removal of Arm Cylinder
35737AA10
1.
Use a liftcrane and nylon sling (1) to secure the arm cylinder (2).
2.
Use a wrench (30 mm) to remove the bolt (1) and spacer (2).
3.
Use a hammer (2) and striking rod (3) to remove the pin (1). Be careful. The arm and arm cylinder rod may come out of place at this time.
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • • • • •
Wrenches (30 mm) Hexagon wrench (12 mm) Nylon sling (with the required lifting capacity) Liftcrane (with the required lifting capacity) Cap Plug Hammer Striking rod Grease Rag Cleaning fluid Crosstie Wire
84402827B - May 2011 8005B-3
Removal and Installation of Arm Cylinder 4.
5.
6.
Start the engine, move the arm out at idle, and retract the arm cylinder (1) rod.
7.
Move the travel lever (1) back and forth about 5 times to bleed off the pressure.
8. 9.
Switch the key switch OFF. Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.
Tie the cylinder rod with wire (1) so that it cannot come out.
Switch the key switch (1) OFF to stop the engine. Switch the key switch ON again, then turn the control lever (2) about 10 times to bleed off any pressure. Switch the key switch OFF.
10. Use a hexagon wrench (12 mm) to remove the 4 hexagon socket head bolts (1) of the hose (2), and then remove the 2 split flanges (5) and O-ring (4). • Remove the hose (3) with the same procedure. • Use caps or plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. • Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8005B-4
Removal and Installation of Arm Cylinder â&#x20AC;˘ If a pin is hard to remove, there is a load on the pin. â&#x20AC;˘ When removing the pin, be careful not to damage the installed O-rings or dust seals.
11. Use a wrench (19 mm) to remove the grease hose (1). â&#x20AC;˘ Use caps or plugs to prevent any entry of water, dust or dirt. 14. Lift the arm cylinder (1), and then place it on the crosstie.
12. Use a wrench (30 mm) to remove the bolt (1) and spacer (2).
13. Use a hammer (2) and striking rod (3) to push the pin (1) out.
84402827B - May 2011 8005B-5
Removal and Installation of Arm Cylinder Installation of Arm Cylinder
• If a pin is hard to insert, there is a load on the pin. • When inserting the pin, be careful not to damage the installed dust seals.
• Tighten lines and bolts being installed to the specified torque. • When the torque is not specified, check the "Bolt Size and Torque Table". 1.
2.
3.
Clean each pin and pin hole.
5.
Use a wrench (30 mm) to install the bolt (1) and spacer (2).
6.
Use a wrench (19 mm) to attach the grease hose (1).
7.
After setting the O-ring (4) on the line side, install the hose (2) with the 2 split flanges (5) and the 4 hexagon socket head bolts (1).
Tie the cylinder rod with wire (1) so that it cannot come out.
Use a liftcrane and nylon sling (2) to lift the arm cylinder (1). • Wrap the nylon sling to the inside of the line so that it is not crushed.
• Install the hose (3) with the same procedure. • The O-rings cannot be reused. Replace them with new parts. 4.
Align the arm cylinder with the boom and use a hammer (2) to push in the pin (1).
Tightening torque for installation: 85.2 - 101.2 N·m
84402827B - May 2011 8005B-6
Removal and Installation of Arm Cylinder 9.
8.
Align the arm cylinder (1) with the arm pin hole and use a hammer (3) to insert the pin (2). Be careful. The arm and arm cylinder rod may come out of place at this time.
Start the engine, move the arm in at idle, and extend the arm cylinder (1) rod.
10. Use a wrench (30 mm) to tighten the bolt (1) and spacer (2). â&#x20AC;˘ Grease up.
84402827B - May 2011 8005B-7
Removal and Installation of Arm Cylinder
84402827B - May 2011 8005B-8
Section 8005C
Removal and Installation of Boom Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 8005C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8005C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Boom Cylinder Job code
Removal of Boom Cylinder
35736AA10
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
• When removing only the boom cylinder, put the attachments in the temporary decommissioning posture. • When removing as far as the boom, first remove the bucket, bucket link, bucket cylinder, arm, arm cylinder according to their respective removal and installation procedures. Bring the boom top in contact with the ground. 1.
Use a liftcrane and nylon sling (1) to secure the boom cylinders (right) (left) (2) (3).
2.
Use a wrench (19 mm) to remove the grease hoses on the left and right sides (1).
Items to prepare • • • • • • • • • • • • • • • •
Wrenches (19 mm, 30 mm, 36 mm) Hexagon wrench (8 mm) Crowbar Wire rope (with the required lifting capacity) Liftcrane (with the required lifting capacity) Nylon sling Marking pen Cap Plug Hammer Striking rod Grease Rag Cleaning fluid Crosstie Wire
• Use caps or plugs to prevent any entry of water, dust or dirt.
3.
Use 2 wrenches (36 mm) to remove the 2 double nuts (1) and bolt (2), and then remove the fastening ring (3). Also, remove the cab side in the same way.
84402827B - May 2011 8005C-3
Removal and Installation of Boom Cylinder 4.
Use a hammer (2) and striking rod (3) to push the pin (1) out. Start the engine, lower the boom at idle, and retract the boom cylinder (right) (left) rods.
5.
Tie the cylinder rods on the left and right sides with wire (1) so that they cannot come out.
6.
Turn the key switch (1) OFF and stop the engine.
7.
Switch the key switch ON again, and then turn the control lever (1) about 10 times to bleed out any pressure.
8.
Move the travel lever (1) back and forth about 5 times to bleed off the pressure. â&#x20AC;˘ Switch the key switch OFF.
9.
Press the air breather button (1) on top of the hydraulic oil tank to release the pressure inside the tank.
10. Use a hexagon wrench (8 mm) to remove the 8 hexagon socket head bolts (2) of the hose (1), and then remove the 4 split flanges (3) and 2 O-rings (4). Also, remove the cab side in the same way. â&#x20AC;˘ Mark the lines and hoses so that the connectors match at the time of assembly. â&#x20AC;˘ Use caps or plugs to cover the hoses and lines to prevent any entry of water, dust or dirt.
84402827B - May 2011 8005C-4
Removal and Installation of Boom Cylinder â&#x20AC;˘ Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
11. Use a wrench (30 mm) to remove the bolt (1) and spacer (2). Also, remove the cab side in the same way.
12. Use a crowbar to remove the pin (1). Also, remove the cab side in the same way.
13. Use a liftcrane and nylon slings (1) to lift the boom cylinders (right) (left) (2) (3) and remove. â&#x20AC;˘ Place the boom cylinders (right) (left) (2) (3) on crossties.
84402827B - May 2011 8005C-5
Removal and Installation of Boom Cylinder Installation of Boom Cylinder
4.
• Tighten bolts being installed to the specified torque. • When the torque is not specified, check the "Bolt Size and Torque Table". 1.
Clean each pin and pin hole.
2.
Tie the cylinder rods on the left and right sides with wire (1) so that they cannot come out.
3.
Use a liftcrane and nylon slings (1) to lift the boom cylinders (right) (left) (2) (3).
Align the boom cylinders (right) (left) with the swing frame pin holes and use a hammer (2) to push in the pin (1). • When inserting the pin, be careful not to damage the installed dust seals.
5.
Use a wrench (30 mm) to tighten the bolt (1) and spacer (2). Also, attach the cab side in the same way.
6.
After setting the 2 O-rings (4) on the line side, install the hose (1) with the 4 split flanges (3) and the 8 hexagon bolts (2). • The O-rings cannot be reused. Replace them with new parts.
84402827B - May 2011 8005C-6
Removal and Installation of Boom Cylinder 7.
Start the engine, raise the boom at idle, and extend the boom cylinder (right) (left) (1) (2) rods. Align the boom cylinder (right) (left) (1) (2) with the boom pin holes and use a hammer (4) to push in the pin (3). â&#x20AC;˘ If the insertion of a shim is possible according to the tolerance adjust the shim.
8.
9.
Use a wrench (19 mm) to attach the grease hoses on the right and left sides (1). â&#x20AC;˘ Grease up. â&#x20AC;˘ When installing as far as the boom, first install the bucket, bucket link, bucket cylinder, arm, arm cylinder according to their respective removal and installation procedures.
Use 2 wrenches (36 mm) to attach the 2 double nuts (1) and bolt (2), and install the fastening ring (3). Also, install the cab side in the same way.
84402827B - May 2011 8005C-7
Removal and Installation of Boom Cylinder
84402827B - May 2011 8005C-8
Section 8006
Removal and Installation of Center Joint
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Center Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 8006-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8006-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Center Joint Removal of Center Joint
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
1.
Use a hexagon wrench (5 mm) to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank. Tightening torque for bolt installation: 2.94 - 4.90 N•m
2.
Attach the specialty adapter (1) to the area where the air breather is removed, and set the vacuum pump (2). Create negative pressure in the hydraulic oil tank using the vacuum pump.
3.
Use a box wrench (19 mm) to remove the 8 bolts (1), and then remove the lower under covers (2).
Items to prepare • • • • • • • • • • • • • •
Wrenches (19 mm, 27 mm, 41 mm) Hexagon wrenches (5 mm, 8 mm) Box wrench (19 mm) Specialty adapter for vacuum pump connection Vacuum pump (vacuum pump power supply) Extension cable Marking pen Cap Plug Wire rope (with the required breaking load) Liftcrane (with the required lifting capacity) Wood planks, etc. Rag Cleaning fluid
84402827B - May 2011 8006-3
Removal and Installation of Center Joint 4.
Prepare a waste oil can (1) to receive the oil that spills out under the center joint.
5.
Use a wrench (41 mm) to remove the 4 travel hoses (1) and a wrench (27 mm) to remove the 2 drain hoses (2).
7.
Use a wrench (24 mm) to remove the 3 bolts (1), and then remove the center joint lock bar (2). Tightening torque for installation: 267 - 312 N•m
8.
Use a hexagon wrench (8 mm) to remove each group of 4 hexagon bolts (1), and then remove the 4 travel hoses (2).
• Mark the center joint and hoses so that the connectors match at the time of assembly. • Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. • Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
• Mark the hoses so that the connectors can be matched during assembly. • Attach caps or plugs to the hoses to prevent any entry of water, dust or dirt. • Clean the hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. Tightening torque for bolt installation: 37.2 - 47.2 N•m
6.
Use a wrench (27 mm) to remove the drain hose (1). • Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. • Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
9.
Wrap wire ropes (1) around the center joint and suspend it with a liftcrane so that the center joint does not fall during removal and installation operations.
84402827B - May 2011 8006-4
Removal and Installation of Center Joint 10. Use a wrench (19 mm) to remove the 3 bolts (1) from the center joint. Tightening torque for installation: 109 - 127 Nâ&#x20AC;˘m
Installation of Center Joint To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For bolts for which the torque is not specified, see "Standard Torque Data for Cap Screws and Nuts".
11. Use the wire ropes (1) and liftcrane to lift the center joint (2).
12. Thoroughly check that the location is safe before lowering the center joint on wood planks.
84402827B - May 2011 8006-5
Removal and Installation of Center Joint
84402827B - May 2011 8006-6
Section 8007A
Removal and Installation of Travel Remote Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8007A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8007A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Travel Remote Control Valve Job code
35356AK19
3.
Use a hexagon wrench (8 mm) to remove the 2 bolts (2) on both the left and right sides of the lever, and then remove the levers (1).
4.
Use a wrench (19 mm) to remove the 6 bolts (2), and then remove the under cover (1).
5.
Use a wrench (19 mm) to remove the 6 hoses (1).
WARNING • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • • • • •
Wrench (19 mm) Hexagon wrench (8 mm) Phillips screwdriver Marking pen Cap Plug Rag Cleaning fluid
Removal of Travel Remote Control Valve 1.
2.
Remove the floor mat (1).
Use a hexagon wrench (8 mm) to remove the 2 bolts (2) on both the left and right sides, and then remove the left and right travel pedals (1).
• Mark the valve and hoses so that the connectors match at the time of assembly. • Install caps or plugs to the valve and hoses to prevent any entry of water, dust or dirt. • Clean the valve and hoses by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8007A-3
Removal and Installation of Travel Remote Control Valve 6.
Use a wrench (19 mm) to remove the 2 hose adapters (1).
Installation of Travel Remote Control Valve Be careful not to connect the hydraulic hoses in incorrect locations. Before installing the hoses, check that the hose adapters are not loose and retighten them to the specified torque. When the torque is not specified, check the "Bolt Size and Torque Table".
7.
8.
1.
Pull down the travel remote control valve (1) into the cab, then install the travel remote control valve.
2.
Use a hexagon wrench (8 mm) to install the 2 bolts (1) on both the left and right sides of the travel lever.
3.
Use a wrench (19 mm) to install the 2 hose adapters (1).
Use a hexagon wrench (8 mm) to remove the 2 bolts (1) on both the left and right sides of the travel lever.
Pull up the travel remote control valve (1) into the cab, and then remove the travel remote control valve.
84402827B - May 2011 8007A-4
Removal and Installation of Travel Remote Control Valve 4.
Use a wrench (19 mm) to install the 6 hoses (1). Tightening torque: 25.4 - 31.4 Nă&#x192;ťm/44.0 - 54.0 Nă&#x192;ť m
7.
Use a hexagon wrench (8 mm) to install the 2 bolts (2) on both the left and right sides, then install the left and right travel pedals (1).
5.
Use a wrench (19 mm) to install the 6 bolts (2) and install the under cover (1).
8.
Install the floor mat (1).
6.
Use a hexagon wrench (8 mm) to install the 2 bolts (2) on both the left and right sides of the lever, then install the levers (1).
84402827B - May 2011 8007A-5
Removal and Installation of Travel Remote Control Valve
84402827B - May 2011 8007A-6
Section 8007B
Removal and Installation of Operation Remote Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Operation Remote Control Valve (left side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Operation Remote Control Valve (left side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Operation Remote Control Valve (right side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8007B-1
3 5 7 9
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8007B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Operation Remote Control Valve Job code
35355AA12
3.
Use a hexagon wrench (5 mm) to remove the 2 bolts (2), and remove the grip (1) of the gate lock lever.
4.
Use the Phillips screwdriver to remove the 2 screws (1) of the console top cover.
5.
Remove the 3 connectors (2) and remove the console top cover (1).
WARNING • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • • • • • •
Wrenches (19 mm, 22 mm) Box wrench (10 mm) Hexagon wrench (5 mm) Phillips screwdriver Marking pen Cap Plug Rag Cleaning fluid
Removal of Operation Remote Control Valve (left side) 1.
2.
Roll up the boot (1) of the control lever and use the Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (2) of the console top cover.
Use the Phillips screwdriver to remove the 2 screws (2), and then remove the handle of the tilt lever (1).
84402827B - May 2011 8007B-3
Removal and Installation of Operation Remote Control Valve 6.
Use the Phillips screwdriver or box wrench (10 mm) to remove the 5 bolts (2), then remove the cover (1).
7.
Roll up the boot (1) of the control lever, remove the connector (2) of the horn switch, and cut the wire band (3).
8.
While securing the nut (2) with a wrench (22 mm), use a wrench (19 mm) to remove the lock nut (3) and remove the control lever (1).
9.
Roll back the hose cover (1).
10. Use a wrench (22 mm) to remove the 6 hoses (1). â&#x20AC;˘ Mark the joystick remote control valve and hoses so that the connectors match at the time of assembly. â&#x20AC;˘ Use caps and plugs to cover the joystick remote control valve and hoses to prevent any entry of water, dust or dirt. â&#x20AC;˘ Clean the joystick remote control valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
11. Use the hexagon wrench (5 mm) to remove the 3 bolts (1) and 3 washers (2).
84402827B - May 2011 8007B-4
Removal and Installation of Operation Remote Control Valve 12. Remove the joystick remote control valve (1).
Installation of Operation Remote Control Valve (left side) 1.
Clean all the parts with a rag.
2.
Install the joystick remote control valve (1).
3.
Use the hexagon wrench (5 mm) to install the 3 bolts (1) and 3 washers (2).
4.
Use a wrench (22 mm) to install the 6 hoses (1). • P port Hose adapter tightening torque: 25.4 - 31.4 N·m Hydraulic hose tightening torque: 44 - 54 N·m • T port, 1 - 4 ports Hose adapter, hydraulic hose tightening torque: 44 - 54 N·m
84402827B - May 2011 8007B-5
Removal and Installation of Operation Remote Control Valve
5.
6.
8.
Use the Phillips screwdriver or box wrench (10 mm) to install the 5 bolts (2), then install the cover (1).
9.
Install the 3 connectors (2) and install the console top cover (1).
Put the hose cover (1) in place.
While securing the nut (2) with a wrench (22 mm), use a wrench (19 mm) to install the lock nut (3) and install the control lever (1). 10. Use the Phillips screwdriver to install the 2 screws (1) of the console top cover.
7.
Install the horn switch connector (2), bundle with the wire band (3), then cover the control lever boot (1).
84402827B - May 2011 8007B-6
Removal and Installation of Operation Remote Control Valve 11. Use a hexagon wrench (5 mm) to install the 2 bolts (2), and install the grip (1) of the gate lock lever.
Removal of Operation Remote Control Valve (right side) 1.
Roll up the boot (1) of the control lever and use the Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (2) of the console top cover.
2.
Use the Phillips screwdriver to remove the 2 screws (2), and then remove the handle of the tilt lever (1).
3.
Use the Phillips screwdriver to remove the 2 screws (1) of the console top cover.
12. Use the Phillips screwdriver to install the 2 screws (2), then install the handle of the tilt lever (1).
13. Use the Phillips screwdriver or box wrench (10 mm) to install the 2 bolts (2) for the console top cover and cover the control lever boot (1).
84402827B - May 2011 8007B-7
Removal and Installation of Operation Remote Control Valve 4.
Remove the 3 connectors (2) and remove the console top cover (1).
5.
Use the Phillips screwdriver or box wrench (10 mm) to remove the 5 bolts (2), then remove the cover (1).
6.
Roll up the boot (1) of the control lever, remove the connector (2) of the horn switch, and cut the wire band (3).
7.
While securing the nut (2) with a wrench (22 mm), use a wrench (19 mm) to remove the lock nut (3) and remove the control lever (1).
8.
Roll back the hose cover (1).
9.
Use a wrench (22 mm) to remove the 6 hoses (1). â&#x20AC;˘ Mark the joystick remote control valve and hoses so that the connectors match at the time of assembly. â&#x20AC;˘ Use caps and plugs to cover the joystick remote control valve and hoses to prevent any entry of water, dust or dirt. â&#x20AC;˘ Clean the joystick remote control valve and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8007B-8
Removal and Installation of Operation Remote Control Valve 10. Use the hexagon wrench (5 mm) to remove the 3 bolts (1) and 3 washers (2).
Installation of Operation Remote Control Valve (right side) 1.
Clean all the parts with a rag.
2.
Install the joystick remote control valve (1).
3.
Use the hexagon wrench (5 mm) to install the 3 bolts (1) and 3 washers (2).
4.
Use a wrench (22 mm) to install the 6 hoses (1).
11. Remove the joystick remote control valve (1).
• P port Hose adapter tightening torque: 25.4 - 31.4 N·m Hydraulic hose tightening torque: 44 - 54 N·m • T port, 1 - 4 ports Hose adapter, hydraulic hose tightening torque: 41 - 54 N·m
84402827B - May 2011 8007B-9
Removal and Installation of Operation Remote Control Valve
5.
6.
8.
Use the Phillips screwdriver or box wrench (10 mm) to install the 5 bolts (2), then install the cover (1).
9.
Install the 3 connectors (2) and install the console top cover (1).
Put the hose cover (1) in place.
While securing the nut (2) with a wrench (22 mm), use a wrench (19 mm) to install the lock nut (3) and install the control lever (1). 10. Use the Phillips screwdriver to install the 2 screws (1) of the console top cover.
7.
Install the horn switch connector (2), bundle with the wire band (3), then cover the control lever boot (1).
84402827B - May 2011 8007B-10
Removal and Installation of Operation Remote Control Valve 11. Use the Phillips screwdriver to install the 2 screws (2), then install the handle of the tilt lever (1).
12. Use the Phillips screwdriver or box wrench (10 mm) to install the 2 bolts (2) for the console top cover and cover the control lever boot (1).
84402827B - May 2011 8007B-11
Removal and Installation of Operation Remote Control Valve
84402827B - May 2011 8007B-12
Section 8007C
Removal and Installation of 4 Stack Solenoid
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of 4 Stack Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8007C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8007C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of 4 Stack Solenoid Job code
35350AL06
3.
Remove the 4 connectors (1).
4.
Use a wrench (19 mm) to remove the hoses (1) (2).
WARNING • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • • •
Wrenches (13 mm, 17 mm, 19 mm, 22 mm) Marking pen Cap Plug Rag Cleaning fluid
• Mark the solenoid valve and hose so that the connector matches at the time of assembly. • Use a cap or a plug to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hose by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connector.
Removal of 4 Stack Solenoid Valve 1.
Attach the specialty adapter (1) to the area where the air breather is removed, and set the vacuum pump (2). Create negative pressure in the hydraulic oil tank using the vacuum pump.
5. 2.
Use a wrench (13 mm) to remove the bolts (1) on the clamp. Remove the 2 bolts (2) on the cover and remove the cover (3).
Use a wrench (22 mm) to remove the hoses (1) (2). • Mark the solenoid valve and hose so that the connector matches at the time of assembly. • Use a cap or a plug to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hose by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connector.
84402827B - May 2011 8007C-3
Removal and Installation of 4 Stack Solenoid Installation of 4 Stack Solenoid Valve
6.
1.
Use a wrench (17 mm) to install the 4 stack solenoid valve (1) with the 2 bolts (2).
2.
Use a wrench (22 mm) to install the hoses (1) (2).
Use a wrench (22 mm) to remove the hoses (1) (2). • Mark the solenoid valve and hose so that the connector matches at the time of assembly. • Use a cap or a plug to cover the solenoid valve and hose to prevent any entry of water, dust or dirt. • Clean the solenoid valve and hose by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connector.
• The hose connections are as follows.
7.
Use a wrench (17 mm) to remove the 2 bolts (2), and then remove the 4 stack solenoid valve (1).
84402827B - May 2011 8007C-4
Removal and Installation of 4 Stack Solenoid
1 2
Assembly hose Solenoid valve
*1
Code Solenoid valve (left side) details Solenoid valve (right side) details
*2 *3
3.
Use a wrench (22 mm) to install the hoses (1) (2).
4.
Use a wrench (19 mm) to install the hoses (1) (2).
5.
Install the 4 connectors (1). Connect the connectors with the matching color ID tape.
84402827B - May 2011 8007C-5
Removal and Installation of 4 Stack Solenoid 6.
Use a wrench (13 mm) to install the cover (3) with the 2 bolts (2). Fasten the clamp with the bolt (1).
7.
Use a hexagon wrench (5 mm) to tighten the 4 bolts (1), then remove the air breather (2) on the hydraulic oil tank. â&#x20AC;˘ Bolt (1) tightening torque: 2.94 - 4.9 N¡m
84402827B - May 2011 8007C-6
Section 8007D
Removal and Installation of Cushion Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Cushion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 8007D-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8007D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Cushion Valve Job code
35350AF50
2.
Use a wrench (19 mm) to remove the 5 bolts (2), and then remove the under cover (1).
3.
Prepare the waste oil can (1).
4.
Remove the sensor (1). Use wrenches (19 mm, 22 mm) to remove the hoses connected to the ports.
WARNING • Be sure to release hydraulic pressure before beginning work. CAUTION • Be sure to stop the engine before beginning work. Items to prepare • • • • • • • •
Wrenches (17 mm, 19 mm, 22 mm) Hexagon wrench (5 mm) Marking pen Cap Plug Waste oil can Rag Cleaning fluid
Removal of Cushion Valve 1.
Attach the specialty adapter (1) to the area where the air breather is removed, and set the vacuum pump (2). Create negative pressure in the hydraulic oil tank using the vacuum pump.
• Mark the cushion valve, hoses and lines so that the connectors match at the time of assembly. • Use caps or plugs to cover the cushion valve, hoses and lines to prevent any entry of water, dust or dirt. • Clean the cushion valve, hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8007D-3
Removal and Installation of Cushion Valve 5.
*2 *3
Use a wrench (17 mm) to remove the 4 bolts (1) on the cushion valve bottom, and then remove the cushion valve.
Use 22 mm wrench Use 19 mm wrench
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Removal and Installation of Cushion Valve Installation of Cushion Valve 1.
Use a wrench (17 mm) to tighten the 4 bolts (1) on the cushion valve bottom, and then install the cushion valve.
2.
Install the sensor (1). Use wrenches (19 mm, 22 mm) to connect the hoses to the nipples and elbows on the ports.
2 3
Use 22 mm wrench Use 19 mm wrench
â&#x20AC;˘ The hose connections are as follows.
84402827B - May 2011 8007D-5
Removal and Installation of Cushion Valve 3 4 5 6 7 8 9 10 11 12
Swing right Bucket close Heat circuit line Arm out Boom down Swing left Bucket open Pressure sensor (swing) Swing priority switching pilot line Drain line
3.
Use a wrench (19 mm) to tighten the 5 bolts (2) and install the under cover (1).
4.
Use a hexagon wrench (5 mm) to tighten the 4 bolts (1) and install the air breather (2) on the hydraulic oil tank. â&#x20AC;˘ Bolt (1) tightening torque: 2.94 - 4.9 N¡m
1 2
Arm in Boom up
84402827B - May 2011 8007D-6
Section 8008
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit
84402827B - May 2011
84402827B - May 2011
CONTENTS Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 8008-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8008-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit Tools
4.
The table below shows the tools required for assembly and disassembly of the K3V/K5V pump.The bolts and plugs may vary by pump type.
Tool name Hexagon wrench
• See "Procedures for Assembly and Disassembly of Regulator" in the manual for the regulator for how to disassemble the regulator.
Tool dimensions 4, 5, 6, 8, 14, 17 (B dimension, mm)
Socket wrench, double-head (single- 19, 27 mm head) wrench Monkey wrench Medium-sized Flathead screwdriver Screwdriver (medium size) x 2 Plastic hammer With adjustable specified Torque wrench torque tightening Snap ring pliers For stop ring, TSR-160 Key material steel rod, 10 x Steel rod 8 x 200 Tweezers Bolt M8, L = about 50
5.
When disassembling the pump, read the disassembly procedures all the way to the end before disassembling according to the sequence below. The numbers in the parentheses after the part names indicate part numbers in the pump structural diagram. This manual lists the disassembly procedures for the tandem pump. Perform disassembly using the type column as reference. Also, be careful that parts from the front pump and rear pump do not get mixed together.
Loosen the hexagon socket head bolts (401) that fasten together the swash plate support boards (251), pump casings (271), and valve block (312). • When a gear pump, etc. is attached to the pump rear surface, remove the gear pump, etc. first before performing work.
6.
Disassembly Procedures
1.
Remove the hexagon socket head bolts (412, 413), and remove the regulator.
Face down the pump regulator installation surface horizontally on the work platform, and separate the pump casing (271) and valve block (312). • When placing the regulator installation surface facedown, be sure to place a rubber plate or similar material on the work platform so as not to damage the regulator installation surface. • When separating the pump casings and valve block, remove the 1st gear at the same time.
Select a location for disassembly. • Select a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts.
2. 3.
Use cleaning oil to remove any dirt or rust from the surface of the pump. Remove the drain port plug (468) and drain the oil from the pump casing. • Remove the plugs from both the front and rear pumps and drain the oil.
84402827B - May 2011 8008-3
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 7.
Remove the cylinder blocks (141) out from the pump casings (271) in a straight line in relation to the drive shafts (111), and remove the pistons (151), holder plates (153), spherical bushings (156), and cylinder springs (157) at the same time.
9.
Tap the installation flange section of the swash plate support board (251) on the pump casing side, and separate the swash plate support board and the pump casing.
• Be careful not to damage the sliding surfaces of the cylinders, spherical bushings, shoes, and swash plates.
10. Remove the shoe plate (211) and the swash plate (212) from the pump casing (271).
8.
Remove the hexagon socket head bolts (406) and remove the seal cover (F) (261). • Removal can be performed easily by inserting a bolt into the hole on the seal cover (F) and then pulling the bolt out. • The seal cover (F) has an oil seal, so be careful not to damage the oil seal when removing the seal cover.
11. Lightly strike the shaft end sections of the drive shafts (111) (113) with a plastic hammer, etc. to remove the drive shafts from the swash plate support board.
84402827B - May 2011 8008-4
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 12. Remove the valve plates (313) (314) from the valve block (312).
Assembly Procedures The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below.
• These can also be removed in Step 6.
1. 2. 3. 4. 5. 6. 7. 13. If necessary, remove the stopper (L) (534), stopper (S) (535), servo piston (532), and tilting pin (531) from the pump casing (271), and remove the needle bearing (124) and 1st gear (116) from the valve block (312).
Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. Thoroughly clean all parts with cleaning oil and air blow them before assembly. Be sure to apply clean hydraulic oil to sliding parts and bearings before assembly. As a rule, replace all O-rings, oil seals, and other seal parts with new parts. Use a torque wrench to tighten all installation bolts and plugs to the torque specified in "Maintenance Standards." Be careful not to mix up the pump parts for the front and rear. Install the swash plate support board (251) on the pump casing (271) by lightly striking it with a hammer. • If the servo pistons, tilting pin, stoppers (L), and stoppers (S) have been removed, install these parts on the pump casings in advance. • To avoid damaging the heads of the tilting pins and the feedback pins, use a jig when tightening the servo pistons and tilting pins. Also be sure to apply Loctite (moderate strength) to the threaded sections.
• To avoid damaging the head of the tilting pin, use a jig when removing it. • Loctite has been applied to the section where the tilting pin and the servo piston are bonded, so be careful not to damage the servo piston. • Try to avoid removing the needle bearings unless they are at the end of their service life. • Do not loosen the hexagon nuts of the valve block or swash plate support board. This changes the flow setting.
8.
Face down the regulator installation surface of the pump casing, insert the tilting bushing of the swash plate onto the tilting pin (531), and correctly mount the swash plate (212) and swash plate support board (251). • Use the fingertips of both hands to check that the swash plate moves smoothly. • Coat the swash plates, swash plate support boards, and all sliding sections with grease for easier installation of the drive shaft.
84402827B - May 2011 8008-5
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 11. Assemble the piston cylinder subassembly [cylinders (141), pistons (151, 152), holder plates (153), spherical bushings (156), spacers (158), cylinder springs (157)], and then insert it into the pump casing in alignment with the phase of the splines of the spherical bushings and cylinder blocks.
9.
Install the drive shaft (111) with a bearing (123), bearing spacers (127), and stop ring (824) attached to the swash plate support board (251). • Do not strike the drive shaft with a hammer, etc. • Lightly strike the outside ring of the bearing with a plastic hammer to install it, and use a steel rod, etc. to tightly insert it all the way in.
12. Install into the valve block (312) while aligning the valve plate (313) with the pin (885). • Be careful not to mistake the suction and discharge directions of the valve plates.
10. Attach the seal cover (F) (261) to the pump casing (271), and secure with the hexagon socket head bolts (406). • Apply a thin layer of grease to the oil seal inside the seal cover (F). • Be careful not to damage the oil seal when attaching it.
13. Install the valve block (312) into the pump casing (271) and tighten it with the hexagon socket head bolts (401). • Assembly is easier when starting with the rear side pump. • Install the valve block in the correct direction. (Install the valve block so that the regulator faces up and the suction flange faces right when looking at the valve block from the front.) • Insert the 1st gear into the valve block beforehand and couple it with the drive shaft joint section spline.
84402827B - May 2011 8008-6
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit 14. Insert the feedback pins of the tilting pins into the feedback lever of the regulators, install the regulators, and tighten the hexagon socket head bolts (412, 413). â&#x20AC;˘ Install the regulator, making sure not to mistake the front and the rear of the regulator.
15. Install the drain port plug (468) to finish assembly.
84402827B - May 2011 8008-7
Procedures for Assembly and Disassembly of Hydraulic Pump Main Unit
84402827B - May 2011 8008-8
Section 8010
Pump Main Unit Maintenance Standards
84402827B - May 2011
84402827B - May 2011
CONTENTS Replacement standards for worn parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Standards for repairing cylinders, valve plates, and swash plates (shoe plates) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Attached diagram 1. pump assembly cross-section diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Drive Shaft Front Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Drive Shaft Rear Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Part Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Procedures for Assembly and Disassembly of Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassembly procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
84402827B - May 2011 8010-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8010-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Pump Main Unit Maintenance Standards Replacement standards for worn parts If wear on any part exceeds the standard values below, replace or readjust that part. If, however, the appearance of the part shows significant damage, replace that part. RecomReference mended replacedimenment sions value 0.038 mm 0.065 mm 0 - 0.1 mm 0.3 mm 5.4 mm 5.0 mm 40.9 mm 40.1 mm
Part name and inspection item
Piston and cylinder bore clearance (D - d) Piston and shoe caulking section backlash (δ) Shoe thickness (t) Free height of cylinder spring (L) Assembled height of holder plate and spherical 23.8 mm bushing (H - h) Cylinder opening diameter(spline in cylinder) 35.17 mm Spherical bushing spline
22.8 mm 35.57 mm
Solution Replace piston or cylinder. Replace piston and shoe assembly. Replace piston and shoe assembly. Replace cylinder spring. Replace holder plate or spherical bushing. Replace cylinder and spherical bushing.
Clearance between the piston and cylinder bore : D-d
Free height of cylinder spring : L
Loseness of piston, shoe, and caulking : δ Thickness of shoe : t
Combined height of pressure plate and spherical bush : H-h
Standards for repairing cylinders, valve plates, and swash plates (shoe plates) Valve plate (sliding section) Swash plate (shoe plate section) Cylinder Surface roughness
Surface roughness re3-Z quiring repair Standard surface rough0.4 Z or lower (lapping) ness (repair value)
84402827B - May 2011 8010-3
Pump Main Unit Maintenance Standards Tightening torque Part name
Size
Hexagon socket head bolt
Rc plug NOTE: Wrap seal tape around the plug 1.5 - 2 times
PO plug
M5 M6 M8 M10 M12 M14 M16 M18 M20 R 1/16 R 1/8 R 1/4 R 3/8 R 1/2 G1/4 G1/2 G3/4 G1 G1 1/4 G1 1/2
Tightening torque (Nâ&#x20AC;˘m) 6.9 11.8 29.4 56.9 98.1 156.9 235.4 333.4 431.5 6.9 10.3 17.2 34.3 49.0 29.4 98.1 147.1 186.3 264.8 274.6
Tool name (mm) B=4 5 6 8 10 12 14 14 17 4 5 6 8 10 6 10 14 17 17 17
Hexagon wrench
Overall View Attached diagram 1. pump assembly cross-section diagram
Drive shaft front side
Drive shaft rear side
84402827B - May 2011 8010-4
Pump Main Unit Maintenance Standards Drive Shaft Front Side
84402827B - May 2011 8010-5
Pump Main Unit Maintenance Standards Drive Shaft Rear Side
84402827B - May 2011 8010-6
Pump Main Unit Maintenance Standards Part Table a
b c
Adhesion agent (ThreeBond Co., Ltd. No. 130SN) applica- d tion Oil seal outer circumference Lubricant (Sealub L101) coat- e ing Right rotation valve plate
f
Code
Part name
Q'ty
04 011 013 014 030
Gear pump Piston subassembly Cylinder subassembly (R) Cylinder subassembly (L) Swash plate subassembly
1 set 2 set 1 set 1 set 2 sets
041
Check valve 1 subassembly
2 sets
042
Check valve 2 subassembly
2 set
079 530
Electromagnetic proportional pressure reducing valve, cas- 1 set ing subassembly Tilting pin subassembly 2 sets
Code 111 113 114 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313 314 326 401 406 414
Part name Drive shaft (F) Drive shaft (R) 1st gear Cylinder roller bearing Needle roller bearing Bearing spacer Cylinder block Piston Shoe Holder plate Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support board Seal cover (F) Pump casing Valve block Valve plate (R) Valve plate (L) Cover Hexagon socket head bolt Hexagon socket head bolt Hexagon socket head bolt
Q'ty 1 1 1 2 2 4 2 18 18 2 2 18 2 2 2 2 1 2 1 1 1 1 8 4 4
Code 531 532 534 535 541 543 544 545 548 702 710 714 717 724 725 728 732 774 789 792 808 824 885 886 901
466
VP plug
2
953
467 468 490 492
VP plug VP plug Insert plug Insert plug
2 4 27 12
954 981 983
84402827B - May 2011 8010-7
Left rotation valve plate Tightening torque Flange socket (4-M10 x 1.5): 33 N¡m Tightening torque Hexagon bolt (3-M6 x 1.0): 12 N¡m Component part no. (q'ty) or type ZX15LHRZ2-07A-V 151 (9PC), 152 (9PC) 141 (1PC), 313 (1PC) 141 (1PC), 314 (1PC) 212 (1PC), 214 (1PC) 541 (1PC), 543 (1PC), 545 (1PC) 541 (1PC), 544 (1PC), 545 (1PC) KDRDE5KR-V3-V 531 (1PC), 548 (1PC)
Part name Q'ty Tilting pin 531 532 Servo piston Stopper (L) 534 Stopper (S) 535 541 Seat 543 Stopper 1 544 Stopper 2 545 Steel ball Feedback pin 548 O-ring 702 O-ring 710 O-ring 714 O-ring 717 O-ring 724 O-ring 725 O-ring 728 O-ring 732 774 Oil seal Backup ring 789 Backup ring 792 Hexagon nut 808 Stop ring 824 Valve plate pin 885 Spring pin 886 Eyebolt 901 Hexagon socket head stop 953 screw 954 Stop screw Nameplate 981 Driving tack 983
Pump Main Unit Maintenance Standards Bolt, plug, nut, servo piston tightening torque Tightening Part torque Screw size No. N¡m 401 M20 430 406 M8 29 414 M12 98 466 36 G1/4 468 170 G3/4 490 8.8 NPTF 1/16 492 9.8 Rc 1/8 531, M30 430 532 808 M20 240
84402827B - May 2011 8010-8
Pump Main Unit Maintenance Standards Procedures for Assembly and Disassembly of Regulator Tools Tool name Hexagon wrench Socket wrench, double-head (single-head) wrench Monkey wrench Screwdriver Plastic hammer Torque wrench Pliers Steel rod Tweezers Bolt
Tools dimensions 4, 5, 6 (B dimension, mm) Small-sized (maximum 36 mm)
For stop ring, x 2 Diameter D4 or less, L = 100 M4, L = about 50
Disassembly preparations 1. 2. 3.
These regulators comprise small precision parts, so assembly and disassembly operations are somewhat complex. The pressure-flow settings of the front side regulator and the rear side regulator differ, so mark the regulators when disassembling to differentiate between the drive side and the driven side. When disassembling the regulators, read this disassembly procedure thoroughly before following the sequence below. The numbers in parentheses after the part names are the codes indicated in "Diagram 1. Front-side regulator assembly cross-section diagram" "Diagram 2. Rear-side regulator assembly cross-section diagram".
84402827B - May 2011 8010-9
Pump Main Unit Maintenance Standards Disassembly procedures 1.
5.
Select a location for disassembly. • Select a clean location. • Place a rubber plate or cloth on the work platform so as not to damage the parts.
2. 3.
After removing the cover (C) (629) subassembly, remove the outer spring (625), inner spring (626), and spring seat (C) (624) from the compensation section, and pull out the adjusting ring (Q) (645), pilot spring (646), and spring seat (644) from the pilot section. • The adjusting ring (Q) (645) can be easily removed by pulling it out with an M4 bolt.
Use cleaning oil to remove any dirt or rust from the surface of the regulator. Remove the hexagon socket head bolts (412, 413), and remove the regulator from the pump main unit. • Be careful not to lose the O-rings.
4.
6.
Remove the hexagon socket head bolts (436, 438), and remove the pilot cover (641). When the pilot cover is removed, remove the set spring (655) from the pilot section.
7.
Remove the stop ring (814), and remove the spring seating (653), return spring (654), and sleeve (651).
Remove the hexagon socket head bolts (438), and remove the cover (C) (629). • The cover (C) is assembled with an adjusting screw (C) (628), adjusting ring (C) (627), lock nut (630), hexagon nuts (801, 802), and hexagon socket head locking screw (924). Do not loosen these screws and nuts. Loosening causes the adjusted pressure and flow setting to change.
• The sleeve (651) is assembled with a retaining ring (836). • When removing the stop ring (814), the return spring (654) will fly out, so be careful not to lose it.
84402827B - May 2011 8010-10
Pump Main Unit Maintenance Standards 8.
9.
Remove the locking rings (858), and remove the fulcrum plug (614) and adjusting plug (615).
10. Pull out the pin (874), and remove the feedback lever (611).
• The fulcrum plug (614) and adjusting plug (615) can be easily removed by pulling them out with an M6 bolt.
• Use a fine steel rod to push out the pin (874) (pin diameter D4) from above without touching lever 1 (612).
Remove lever 2 (613). Do not pull out the pin (875). • It can be easily removed by using a pair of tweezers.
11. Remove lever 1 (612). Do not pull out the pin (875). 12. Pull out the pilot piston (643) and spool (652). 13. Pull out the piston case (622), compensation piston (621), and compensation rod (623) to complete disassembly of the regulator. • The piston case (622) can be removed by pushing out the compensation rod (623) from the opposite side of the piston case. * The component parts are small, so be very careful not to lose them.
84402827B - May 2011 8010-11
Pump Main Unit Maintenance Standards Assembly procedures The assembly procedure is the reverse of the disassembly procedure. However, follow the precautions below. 1. 2.
3. 4. 5. 1. 2. 3.
Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. Any foreign matter entering the equipment can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and perform assembly in a clean location. Make sure to tighten bolts and plugs of each section to the specified torque. Be sure to apply clean hydraulic oil to sliding sections before assembly. As a rule, replace all seals such as O-rings with new parts. Install the compensation rod (623) into the compensation hole on the casing (601). Insert the pin press fit in lever 1 (612) into the groove on the compensation rod, and install lever 1 on the pin press fit in the casing. Install the spool (652) and sleeve (651) in the casing spool hole.
a b 5.
4.
Install the pilot piston (643) into the flow control hole on the casing. • Check that the pilot piston slides smoothly without catching.
6.
Insert the pin press fit in lever 2 (613) into the groove on the pilot piston, and assemble lever 2.
7.
Assemble the fulcrum plug (614) and install the locking ring (858) so that the pins press fit in the fulcrum plug are inserted into the pin holes on lever 2.
8.
Insert the adjusting plug (615), and install the locking ring.
• Check that the spool and sleeve slide smoothly in the casing without catching. • Be careful to assemble the spool in the correct direction.
*1 *2
Lever (1) side Lever (2) side (Fulcrum plug, adjusting plug side)
Spool Feedback lever
Install the feedback lever (611), and insert the pin (874) in alignment with the pin hole on the feedback lever. • This is easier to assemble by inserting the pin into the feedback lever to a small degree in advance. • Be careful to assemble the feedback levers in the correct direction.
• Be careful to insert the fulcrum plug and adjusting plug into the correct openings. 84402827B - May 2011 8010-12
Pump Main Unit Maintenance Standards
9.
â&#x20AC;˘ At this time, check that the backlash from the movement of the feedback lever is not too great and that the feedback lever does not catch on anything.
11. Install the spring seating (644), pilot spring (646), and adjusting ring (645) into the pilot hole, and install the spring seating (624), inner spring (626), and outer spring (625) into the compensation hole.
Install the return spring (654) and spring seating (653) into the spool hole, and install the stop ring (814).
â&#x20AC;˘ Be careful to install the spring seating in the correct direction.
10. Assemble the set spring (655) into the spool hole, assemble the compensation piston (621) and piston case (622) into the compensation hole, install the pilot cover (641), and tighten the hexagon socket head bolts (436, 438).
12. Assemble the cover (C) (629) set with the adjusting screw (628), adjusting ring (C) (627), lock nut (630), hexagon nuts (801, 802), and the hexagon socket head locking screw (924), and tighten the hexagon socket head bolts (438).
This completes the assembly.
84402827B - May 2011 8010-13
Pump Main Unit Maintenance Standards
84402827B - May 2011 8010-14
Section 8011
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cautions for disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Removal of long cap and pull out of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Disassembly of arm 1 parallel-tandem spool, neutral cut spool section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly of arm regeneration release valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly of load check valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly of antidrift valve section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly of valve housing union bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cautions for assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cautions for O-Ring handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cautions for spool handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adhesive application method (for male thread section and female thread section of parts requiring adhesion)8 Procedure for assembly of sub-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly of spool assembly (main spool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly of arm 1 parallel-tandem spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly of neutral cut spool assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly of antidrift valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Procedure for assembly of control valve main unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly of relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly of load check valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly of antidrift valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly of option section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly of arm regeneration release valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly of arm 1 parallel-tandem spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly of neutral cut spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly of main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly of straight travel signal control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly of add-on section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly of other plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Part list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Procedures for assembly and disassembly of main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Procedures for assembly and disassembly of overload relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Procedures for assembly and disassembly of low-pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Procedures for assembly and disassembly of add-on main relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Relief valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 84402827B - May 2011 8011-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Troubles and countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
84402827B - May 2011 8011-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Procedures for Assembly and Disassembly of Control Valve Disassembly Cautions for disassembly 1.
On level ground, bring all the operating machines into contact with the ground. When doing this, have the main machine in a horizontal position. Check that the machine is in such a state that it will not travel or swing on its own. Then stop the engine and bleed out the pressure from each actuator. CAUTION Do not replace a valve assembly or disassemble a valve with pressure remaining in the system. This would be dangerous. High-pressure oil might spray out or parts might suddenly come out. For disassembly, bring the bucket to the ground and adequately bleed out any pressure in the circuits.
2. 3. 4. 5. 6.
Bleed the air pressure from the tank. Clean well around the location to be disassembled and keep foreign matter from getting into the valve during disassembly. Identify disassembled parts with shipping tags to show their position for re-assembly. Do not reuse any disassembled seals (O-rings, backup rings). Replace them with new ones. The spool was selected to fit with the valve housing and sleeve, so do not replace the spool.
Disassembly procedure Removal of long cap and pull out of main spool 1.
2. 3. 4.
Loosen the hexagon socket head bolts (74) (8 mm hexagon socket diameter) for the 9 caps (8) and the 1 cap (9), and remove them. When pulling out the spool only, do not loosen the M6 screws on the plate except for the 4 hexagon socket head bolts (75) and the 1 hexagon socket head bolt (94) fastening the plate assemblies. Loosen and remove the plugs (91) (19 mm hexagon diameter) attached to the ports as necessary. Remove the O-rings (7) (1 in each section) from the plate assemblies (10) and (11). Pull out each spool from the valve housing still in the sub-assembly state. CAUTION 1) 2)
5.
6. 7. 8.
When pulling out the spool, be careful not to cause any dents or scratches. 2Identify each spool with a shipping tag so that there will be no mistake about their positions when they are re-assembled.
Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) and hexagon socket head bolts (94) (5 mm hexagon socket diameter) those fastens the plate assemblies (10), (11), (28) and (29) to the housing. Remove the plate assemblies still in the assembly state. Do not disassemble them. Loosen and remove the plugs (91) (19 mm hexagon socket diameter) as necessary. Remove the O-rings (7) and (41) from the valve housings (1) and (13). Disassembly of spool assembly
84402827B - May 2011 8011-3
Procedures for Assembly and Disassembly of Control Valve CAUTION 1) 2) 3) 4)
In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks (as in the diagram on the right) and fasten with a vise before starting the work. Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool thread section to break down the adhesive. ℃. Heat so that the spool heating temperature is 200 - 250℃ Heat until the spool end loosens easily immediately after the heating. If overheating occurs, replace the spring with a new one. (Wooden blocks for spool assembly/ disassembly)
(Wooden blocks for spool assembly/disassembly) 1) 2)
Loosen the spool assembly (2) - (6) and (14) - (17) spool ends (8 mm hexagon socket diameter) and disassemble the spring seat and spring. The spools in spool assemblies (3), (4), (6) and (14) have poppets, springs, plugs, and filters in the spools, but do not disassemble them unless necessary. When disassembly is required, heat up the outer edge of the spool to break down the adhesive on the thread section, then remove the plug. When assembling, always replace O-rings and backup rings with new ones.
Disassembly of arm 1 parallel-tandem spool, neutral cut spool section 1. 2. 3. 4.
Loosen and remove the hexagon socket head bolts (78) (5 mm hexagon socket diameter) for the caps (18) and (86). Remove the O-ring (23) from the cap (18). Remove the O-rings (65) from the housing (1). Pull out the spools (19) and (84) from the valve housing still in the sub-assembly state. Disassembly of spool assembly CAUTION 1) 2) 3) 4) 1)
In order to avoid damaging the outer edge of the spool, sandwich the spool with wooden blocks for assemble (as in the diagram) and fasten with a vise before starting the work. Since adhesive is applied to the spool end thread section, heat up the outer edge of the spool thread section to break down the adhesive. ℃. Heat so that the spool heating temperature is 200 - 250℃ Heat until the spool end loosens easily immediately after the heating. If overheating occurs, replace the spring with a new one.
Loosen the spool (19) spool end (22) (5 mm hexagon socket diameter) and disassemble the spring seat (20) and spring (21).
Disassembly of arm regeneration release valve section Sub-parts in the assembly are expressed as [main number - sub-number].
84402827B - May 2011 8011-4
Procedures for Assembly and Disassembly of Control Valve CAUTION 1. 2. 1. 2. 3. 4.
When removing the plug, pressure left within can make parts fly out dangerously. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassemble.
Loosen and remove the plug (24) (32 mm hexagon diameter) and remove the O-ring (25). Remove the spring (26) and spool (27-1) from the sleeve (27-2). Pull out the sleeve (27-2) from the valve housing. Remove the piston (27-3), O-ring (30), and backup ring (31) from the sleeve (27-2).
Disassembly of load check valve section CAUTION 1. 2. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
When removing the plug, pressure left within can make parts fly out dangerously. Slowly loosen the plug to check that there is no resistance due to residual pressure, then disassemble.
Loosen and remove the hexagon socket head bolts (75) (4 in each section, 8 mm hexagon socket diameter) for the flanges (37) (6 locations) and (61) (1 location). Only (61) has a different shape from the others, so keep it separate from (37). Remove the spring (35), poppets (34) and (51) and O-ring (36) from the valve housing. Remove the arm 2 (E-E cross section) poppet (59), spring (60), and sleeve (58). Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the flanges (52) (2 locations) . Remove the spacer (53) from the valve housing and remove the O-ring (54) and backup ring (55) from the spacer (53). Remove the spring (35) and poppet (34) from the valve housing. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section) Remove the spring (33) and poppet (32) from the valve housing. Loosen and remove the plug (72) (8 mm hexagon socket diameter). (D-D cross section) Remove the spacer (57), spring (33), and poppet (32) from the valve housing. Loosen and remove the plug assembly (92) (36 mm hexagon diameter). (P4 section, cross section H-H ) Loosen and remove the hexagon socket head bolts (74) (4 locations, 8 mm hexagon socket diameter) for the flange (43) . Remove the spring (45), poppet (44), and O-ring (36) from the valve housing. Loosen and remove the plug (46) (27 mm hexagon diameter) and remove the O-ring (47). (H-H cross section) Remove the spring (48) and poppet (49) from the valve housing.
Disassembly of antidrift valve section Sub-parts in the assembly are expressed as [main number - sub-number]. CAUTION 1. 2. 1. 2. 3. 4.
When removing the antidrift valve assembly, pressure left within can make seals and other parts fly out dangerously. Slowly loosen the hexagon socket head bolt to check that there is no resistance due to residual pressure, then disassemble.
Loosen and remove the hexagon socket head bolts (74) (4 in each section, 8 mm hexagon socket diameter) for the 2 antidrift valve assemblies (67). Remove the O-rings (36) and (41) from the valve housing. Remove the spring (39) and poppet (38) from the valve housing. Disassembly of antidrift valve assembly CAUTION 1) 2) 1) 2)
If parts inside the antidrift valve are disassembled with the antidrift valve installed in the valve housing, pressure left within can make parts fly out dangerously. Slowly loosen the plug assembly (67-12) to check that there is no resistance due to residual pressure, then disassemble.
Loosen and remove the plug assembly (67-14) (38 mm hexagon diameter) and remove the O-ring. Remove the piston (67-3), spool (67-4), and spring (67-6). 84402827B - May 2011 8011-5
Procedures for Assembly and Disassembly of Control Valve 3) 4) 5)
Loosen and remove the plug (67-14) (12 mm hexagon diameter). Remove the sleeve (67-5) and poppet (67-2) from the body and remove the O-rings (67-8) and (67-9), backup rings (67-10) and (67-11) from the outer edge of the sleeve. Remove the spring seat (67-13) and spring (67-7) from deep in the hole.
84402827B - May 2011 8011-6
Procedures for Assembly and Disassembly of Control Valve Disassembly of relief valve CAUTION 1. 2. 3. 1. 2. 3.
When removing the relief valve, loosen and remove the main unit installation section plug. Do not loosen the set pressure adjustment plug or lock nut. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug turns.
Loosen and remove the overload relief valve (69) (32 mm hexagon diameter). Loosen and remove the main relief valve (68) (32 mm hexagon diameter). Loosen and remove the 2 relief valve assemblies (70) (32 mm hexagon diameter). Remove the O-rings (70-5) and (70-8).
Disassembly of option section 1. 2.
Loosen and remove the hexagon socket head bolts (75) (8 mm hexagon socket diameter) for the 2 caps (88), and remove the O-rings (89). Loosen and remove the 2 plug assemblies (93) (24 mm hexagon diameter), and remove the O-rings and backup rings.
Disassembly of straight travel signal control valve 1. 2. 3. 4.
Remove the hexagon socket head bolts (83) (5 mm hexagon socket diameter) and remove the body assembly (42). Loosen and remove the plug assembly (42-5) (5 mm hexagon socket diameter) and remove the O-ring. Pull out the spools (42-2) and (42-3) and spring (42-4). Loosen the orifice plug (42-7) (36 mm hexagon diameter) and remove it from the body (42-1).
Disassembly of other plugs 1. 2. 3. 4. 5.
Loosen and remove the plug assembly (71) (10 mm hexagon socket diameter) and remove the O-ring. Loosen and remove the plug assembly (72) (8 mm hexagon socket diameter) and remove the O-ring. Loosen and remove the orifice plug (40) (5 mm hexagon socket diameter). (D-D cross section) Loosen and remove the plug assembly (92) (36 mm hexagon diameter) and remove the O-ring. Loosen and remove the plug assembly (73) (6 mm hexagon socket diameter) and remove the O-ring.
Disassembly of add-on section 1. 2. 3. 4. 5. 6. 7.
Loosen and remove the 4 hexagon nuts (97) (22 mm hexagon diameter). Remove the outlet housing (95). Execute Steps [3] - [5] below as necessary. Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11). Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4). Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11). Remove the main unit body matching surface O-rings (56) and (64). Loosen the tie rod (96) and remove it from the main unit valve housing (1). (Use a pipe wrench.) CAUTION When removing the add-on section, be careful not to cause any dents, scratches, or the like on matching surfaces. Any dents, scratches, or the like on matching surfaces have a danger of allowing oil to leak from those surfaces and causing malfunction. Also, be careful not to let any foreign matter enter the oil path. Such foreign matter has a danger of the spool sticking due to biting of the spool sliding section or a load check seat defect making the actuator run wild or stop disabled.
Disassembly of valve housing union bolt CAUTION 1. 2. 3.
Do not disassemble the union bolt (77) unless necessary. If such disassembly is necessary, place the main unit on a flat table to do the work. Prepare the replacement O-rings (65) and (66). 84402827B - May 2011 8011-7
Procedures for Assembly and Disassembly of Control Valve 1.
Loosen and remove the 8 hexagon socket head bolts (77) (14 mm hexagon socket diameter). Tightening torque: 166 - 177 N•m
2.
Remove the valve housing matching surface O-rings (65) and (66).
Cleaning Completely clean all the disassembled parts with clean mineral oil. Dry with compressed air and place each part on clean paper or vinyl for inspection.
Inspection Inspect all surfaces of each part for burrs, scratches, gouges, and other defects. 1. 2. 3. 4. 5. 6. 7.
Inspect the valve housing load check seat surface for scratches, gouges, and also for debris, dents, rust. Repair any minor scratches with an oilstone. Check that there are no scratches, dents, etc. on the outer edge of the spool. Repair any small scratches with an oilstone. Sliding parts must all move easily. Also, all grooves and paths must be free of foreign matter. If a spring is broken or extremely deformed or worn, replace it. If relief valve operation is poor, inspect according to "Troubles and countermeasures Relief valve". Replace all O-rings and backup rings from disassembled parts. After removing caps or plugs, check for any paint fragments around the body opening or plug seating surface. (If paint fragments were to get inside the valve, they could jam up or clog up the valve, resulting in operation defects and oil leaks.)
Cautions for assembly Cautions for O-Ring handling 1. 2. 3. 4.
Do not use any O-ring with a molding defect or damage caused by handling. Apply enough grease or hydraulic oil to the O-ring and the section where it is mounted so that it can be mounted smoothly. Do not stretch an O-ring so far that this causes permanent deformation. When assembling an O-ring, be careful not to roll the O-ring into place.(If an O-ring is mounted twisted, it is difficult for it to naturally recover to its normal state and that twist causes oil leaks.)
Cautions for spool handling 1. 2.
Excessive torque on thread sections causes spool operation defects, so always tighten to just the specified torque. Be careful to assemble all spools, springs, and spool ends in the same combinations as before disassembly.
Adhesive application method (for male thread section and female thread section of parts requiring adhesion) 1. 2. 3.
Cleaning (degreasing) Either use vapor degreasing with acetate, ether or clean with an alkali cleaning agent. Drying Dry the surface to be glued, either by blowing clean air on it or letting it dry naturally. Inadequate drying reduces the effectiveness of the adhesive. Applying the adhesive Apply a small amount of adhesive (equivalent to Loctite #638) to the first 2 - 3 threads at the entrance of the spool female threads. At this time, install being careful that the application section does not touch the spring seat. CAUTION Do not use "Loctite Primer T" hardening accelerator. It causes insufficient adhesion strength.
4.
Adhesive hardening time In order to ensure the hardening of the adhesive, after fastening the spool end, leave the part out in the air for the following period of time. - Ambient temperature around 22℃: 8 hr. or longer - Ambient temperature around 40℃: 3 hr. or longer - Ambient temperature around 5℃: 24 hr. or longer
84402827B - May 2011 8011-8
Procedures for Assembly and Disassembly of Control Valve CAUTION If the parts are not left out in the air for the above period, adequate adhesive strength may not be achieved.
Procedure for assembly of sub-assembly CAUTION Before starting the assembling, check the quantity of each part, the installation location, the required tools, etc.
Assembly of spool assembly (main spool) 1. 2.
Apply adhesive to the thread sections of the spools (2) - (6), (14) - (17) and assemble the spring seat, spring, and spool end. Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 20 - 22 N•m
3.
For spools (3), (4), and (14), insert the poppets and springs from the end opposite from the spool end, then apply adhesive to the thread sections of the plugs with the O-rings and backup rings mounted, and tighten. Also, for spool (5), the plug with filter is mounted at this location. Tightening torque: 10 - 12 N•m CAUTION 1) 2) 3)
Be careful not to apply so much adhesive that it drips into the spool. Be careful not to tighten any spool end with excessive torque. Excessive torque there would deteriorate spool operation. There are 2 types of spring. Be careful to assemble each in its correct location. (only boom 2 different)
Assembly of arm 1 parallel-tandem spool assembly 1. 2.
Apply adhesive to the thread sections of the spool (19) and assemble the spring seat (20), spring (21), and spool end (22). Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 19 - 22 N•m CAUTION 1) 2)
Be careful not to apply so much adhesive that it drips into the spool. Be careful not to tighten any spool end with excessive torque. Excessive torque there would deteriorate spool operation.
Assembly of neutral cut spool assembly 1. 2.
Apply adhesive to the thread sections of the spool (84-1) and assemble the spring seat (84-2), spring (84-3), and spring end (84-4). Sandwich the spool with the wooden blocks (the same ones used for disassembly), fasten in place with a vise, then tighten the spool ends to the specified torque. Tightening torque: 19 - 22 N•m CAUTION 1) 2)
Be careful not to apply so much adhesive that it drips into the spool. Be careful not to tighten any spool end with excessive torque.
84402827B - May 2011 8011-9
Procedures for Assembly and Disassembly of Control Valve Assembly of antidrift valve assembly 1.
Assemble the O-rings (67-8) and (67-9) and backup rings (67-10) and (67-11) into the grooves on the outer edge of the sleeve (67-5). CAUTION 1) 2)
2. 3.
Be careful to assemble O-rings and backup rings in the correct locations. If they are assembled backwards, there is a danger of an O-ring being damaged and the drop of the actuator from its own weight increasing.
Insert the poppet (67-2) and spool (67-4) in the sleeve hole. Be careful to assemble the spool in the correct direction. Install the spring seat (67-13) at the small-diameter section at the tip of the poppet, mount on the spring (67-7), and insert into the body (67-1) together with the sleeve. CAUTION Apply grease to the poppet seat so that the spring and spring seat can be installed correctly on the poppet seat.
4.
Screw the plug (67-14) into the body (67-1) and tighten it. Tightening torque: 78 - 88 N•m
5. 6.
Assemble the spring (67-6) and piston (67-3) on the plug (67-14). Tighten the plug assembly (67-12) with O-ring mounted to the body (67-1). Tightening torque: 147 - 157 N•m
Procedure for assembly of control valve main unit Assembly of relief valve CAUTION 1. 2. 3. 1.
When installing the relief valve, be sure to tighten the main unit installation section plug. Do not tighten the set pressure adjustment plug or lock nut. Doing so would be dangerous because the set pressure changes if the set pressure adjustment plug turns.
Screw in and tighten the main relief valve (68). Tightening torque: 78 - 88 N•m
2.
Screw in and tighten the 6 overload relief valves (69) at each section. Tightening torque: 78 - 88 N•m
3.
Screw in and tighten the 2 relief valve assemblies with O-rings mounted (70). Tightening torque: 103 - 113 N•m
Assembly of load check valve 1.
Mount the O-rings (36) in the arm 1 section (E-E cross section), Boom 1 and 2 sections (F-F cross sections), swing section, and bucket section (G-G cross sections) and assemble the poppets (34) and springs (35). Mount the flanges (37) and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m For the arm 2 section (E-E cross section), assemble the sleeve (58), poppet (59) and spring (60), mount the flange (61), and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m
2.
Mount the O-ring (36) in the travel section (I-I cross section) and assemble the poppet (51) and spring (35). Tighten the flange (37) with the hexagon socket head bolt (75). Tightening torque: 58 - 64 N•m
3.
Assemble the poppet (34) and spring (35) on the common check section (J-J cross section), then insert the spacers (53) with the O-ring (54) and backup ring (55) mounted. 84402827B - May 2011 8011-10
Procedures for Assembly and Disassembly of Control Valve Tighten the flange (52) with the hexagon socket head bolt (75). Tightening torque: 39 - 44 N•m CAUTION 1) 2) 4.
Be careful to assemble O-rings and backup rings in the correct locations. If they are assembled backwards, there is a danger of an O-ring being damaged and causing external leaks.
Mount the O-ring (36) in the option section (H-H cross section) and assemble the poppet (44) and spring (45). Mount the flange (43) and tighten with the hexagon socket head bolts (74). Tightening torque: 58 - 64 N•m
5.
Assemble the poppet (49) and spring (48) in the travel section (H-H cross section). Screw in and tighten the plug (46) with O-ring (47) mounted. Tightening torque: 107 - 117 N•m
6.
Assemble the poppet (32) and spring (33) in the arm 1 parallel-tandem section (D-D cross section). Screw in and tighten the plug assembly (72) with O-ring mounted. Tightening torque: 73 - 79 N•m
7.
Assemble the poppet (32), spring (33), and spacer (57) in the arm 2 parallel-tandem section (D-D cross section). Screw in and tighten the plug assembly (72) with O-ring mounted. Tightening torque: 73 - 79 N•m
Assembly of antidrift valve 1. 2. 3.
Mount the O-rings (36) and (41) on the antidrift valve installation surfaces in the arm 1 section (E-E cross section) and boom 1 section (F-F cross section). Assemble the poppet (38) and spring (39). Install the 2 antidrift valve assemblies (67) and tighten with the hexagon socket head bolts (74). Tightening torque: 39 - 44 N•m
Assembly of option section 1.
Install the 2 caps (88) with O-rings (89) mounted and tighten with the hexagon socket head bolts (75). Tightening torque: 58 - 64 N•m
2.
Screw in and tighten the 2 plug assemblies (93) with O-rings and backup rings mounted. Tightening torque: 78 - 88 N•m
Assembly of arm regeneration release valve 1. 2. 3.
Mount the O-ring (30) and 2 backup rings (31) in the sleeve (27-2). Assemble the piston (27-3) and spool (27-1) in the sleeve and insert into the valve housing. Put the spring (26) into the plug (24) with O-ring (25) mounted, then screw into the valve housing and tighten. Tightening torque: 103 - 113 N•m
Assembly of arm 1 parallel-tandem spool 1.
Assemble the spool (19) in the sub-assembly state into the valve housing. CAUTION After inserting the spool, slide it to check for any sticky or rough feeling.
2.
Mount the cap (18) with O-ring mounted (23) and tighten with the hexagon socket head bolt (78). Tightening torque: 8.8 - 10.8 N•m
84402827B - May 2011 8011-11
Procedures for Assembly and Disassembly of Control Valve Assembly of neutral cut spool 1.
Assemble the spool assembly (84) into the valve housing. CAUTION After inserting the spool, slide it to check for any sticky or rough feeling.
2.
Mount the O-ring (65) into the housing and tighten the cap (86) with the hexagon socket head bolt (78). Tightening torque: 8.8 - 10.8 N•m
Assembly of main spool 1. 2.
Mount the O-rings (7) and (41) on the valve housing cap matching surface. Assemble the spool assemblies (2) - (6), (14) - (17) in the sub-assembly state into the same location as before disassembly. CAUTION 1) 2) 3)
3.
Line up the spool straight with the opening and insert it slowly. After inserting the spool, slide it to check for any sticky or rough feeling. If a spool is left inserted that feels sticky or rough, there is a danger of a spool operation defect.
Install the plate assemblies (28) and (29) and tighten the hexagon socket head bolts in the order (75), (94). Be careful not to apply excessive tightening torque to (94). Tightening torque: (75) 39 - 44 N•m (94) 8.8 - 10.8 N•m
4.
Install the plate assemblies (10) and (11), and tighten with the hexagon socket head bolts (75). Tightening torque: 39 - 44 N•m
5.
Install the caps (8) and (9), and tighten with the hexagon socket head bolts (74). Tightening torque: 39 - 44 N•m
6.
Screw in the plug assembly (110) with O-ring mounted into the option section (H-H cross section) short cap and tighten it. Tightening torque: 19 - 22 N•m
7.
Screw in the plugs (91) with O-rings (90) mounted into the option section (H-H cross section) and straight travel section (I-I cross section) long caps and tighten them. Tightening torque: 19 - 22 N•m CAUTION 1) 2)
Be careful not to apply excessive torque when tightening a plug to a cap. Applying excessive torque could crush the cap threads.
Assembly of straight travel signal control valve 1.
Screw the orifice plug (42-7) (36 mm hexagon diameter) into the body (42-1) and tighten it. Tightening torque: 3.0 - 3.8 N・m
2. 3.
Being careful about the insertion orientation, assemble the spools (42-2) and (42-3) and spring (42-4). Tighten the plug assembly (42-5) (5 mm hexagon socket diameter) with O-ring mounted to the body. Tightening torque: 13.5 - 16.5 N・m
4.
Install the body assembly (42) with the hexagon socket head bolts (83) (5 mm hexagon socket diameter). Tightening torque: 8.8 - 10.8 N・m
Assembly of add-on section 1. 2.
Screw the tie rod (96) into the main unit valve housing (1). Install the main unit body matching surface O-rings (56) and (64). Execute Steps [1] - [3] below as necessary. 84402827B - May 2011 8011-12
Procedures for Assembly and Disassembly of Control Valve 1) 2) 3) 4) 5)
Remove the spool section assembly (111) and remove the matching surface O-rings (110-10) and (110-11). Remove the inlet section assembly (99) and remove the matching surface O-rings (99-3) and (99-4). Remove the spool section assembly (98) and remove the matching surface O-rings (98-10) and (98-11). Install the outlet housing (95). Tighten the 4 hexagon nuts (97) (22 mm hexagon diameter).
84402827B - May 2011 8011-13
Procedures for Assembly and Disassembly of Control Valve Assembly of other plugs 1.
Screw in and tighten the plug assembly (71) with O-ring mounted. Tightening torque: 116 - 128 N・m
2.
Screw in and tighten the plug assembly (72) with O-ring mounted. Tightening torque: 39 - 44 N・m
3.
Screw in and tighten the orifice plug (40). ightening torque: 14 - 18 N・m
4.
Screw in and tighten the plug assembly (92) with O-ring mounted. Tightening torque: 205 - 227 N・m
5.
Screw in and tighten the plug assembly (72) with O-ring mounted. Tightening torque: 73 - 79 N・m
6.
Screw in and tighten the plug assembly (73) with O-ring mounted. Tightening torque: 31 - 41 N・m
84402827B - May 2011 8011-14
Procedures for Assembly and Disassembly of Control Valve Internal structure diagram
84402827B - May 2011 8011-15
Procedures for Assembly and Disassembly of Control Valve a b *1 *2
[FOR HOOK BOLT] 2-M10 x 1.5 c THREAD DEPTH 14 [FOR HOOK BOLT] 5-M10 x 1.5 d THREAD DEPTH 17
M10 x 1.5,THREAD DEPTH 12 e
ARM 1 BOOM 2
SWING OPTION
*3 *4
RETIGHTEN LOCKED
AFTER
84402827B - May 2011 8011-16
4-M16 x 2 THREAD DEPTH 27
NO.75
*5
TRAVEL
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-17
Procedures for Assembly and Disassembly of Control Valve a b *1 *2
ARM 2 BOOM 1
*3 *4
BUCKET TRAVEL
84402827B - May 2011 8011-18
RETIGHTEN AFTER NO.75 LOCKED 6.6 - 7.2 Nã&#x192;»m M10 x 1.5 THREAD DEPTH 17 *5
STRAIGHT TRAVEL
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-19
Procedures for Assembly and Disassembly of Control Valve *1 *2 *3 *4
PARALLEL LINE TANK DRAIN PILOT
*5 *6 *7 *8
CYLINDER PORT ATTACHMENT 1 ARM 2 IN Û OUT BOOM 1 DOWN Û UP
84402827B - May 2011 8011-20
*9 BUCKET CLOSE Û OPEN *10 TRAVEL *11 STRAIGHT TRAVEL
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-21
Procedures for Assembly and Disassembly of Control Valve *1 *2 *3 *4 *5 *6
ARM 1 OUT Û IN BOOM 2 UP Û DOWN SWING OPTION TRAVEL DRAIN
*7 *8 *9 *10 *11 *12
CYLINDER LINE PILOT (SUB VALVE) (CAP) TANK BRIDGE LINE
84402827B - May 2011 8011-22
*13 *14 *15 *16
CYLINDER STRAIGHT TRAVEL LINE COMMON CHECK LINE PARALLEL
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-23
Procedures for Assembly and Disassembly of Control Valve *1 *2 *3
TANK BOOM 2 UP Ã&#x203A; DOWN
*4 *5 *6
BOOM 1 TRAVEL STRAIGHT TRAVEL
84402827B - May 2011 8011-24
*7
OPTION
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-25
Procedures for Assembly and Disassembly of Control Valve *1 *2
SWING OPEN Ă&#x203A; CLOSE
*3 *4
BUCKET ARM 1
*5 *6
OUT Ă&#x203A; IN ARM 2
Part list Code 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
Part name Valve housing Spool assembly Spool assembly Spool assembly Spool assembly Spool assembly O-ring Cap Cap Plate assembly Plate assembly Valve housing Spool assembly Spool assembly Spool assembly Spool assembly Cap Spool Spring seat Spring Spool end O-ring Plug O-ring Spring Spool assembly Plate assembly Plate assembly O-ring Backup ring Poppet Spring Poppet Spring O-ring Flange Poppet Spring Orifice plug O-ring Body assembly Flange Poppet Spring Plug O-ring
Q'ty 1 1 1 1 2 1 20 9 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 2 2 7 8 10 6 2 2 1 27 1 1 1 1 1 1
Code 48 49 51 52 53 54 55 56 57 58 59 60 61 64 65 66 67 68 69-1 69-2 70 71 72 73 74 75 77 78 79 80 82 83 84 86 88 89 90 91 92 93 94 95 96 97 110
Part name Spring Poppet Poppet Flange Spacer O-ring Backup ring O-ring Spacer Sleeve Poppet Spring Flange O-ring O-ring O-ring Antidrift valve assembly Relief valve kit Relief valve kit Relief valve kit Relief valve assembly Plug assembly Plug assembly Plug assembly Socket head bolt Socket head bolt Socket head bolt Socket head bolt Name plate Drive screw Metal plug Socket head bolt Spool assembly Cap Cap O-ring O-ring Plug Plug assembly Plug assembly Socket head bolt Outlet housing Tie rod Nut Plug assembly
84402827B - May 2011 8011-26
Q'ty 1 1 1 2 2 2 2 1 1 1 1 1 1 3 14 12 2 1 5 1 2 3 10 3 32 66 8 4 1 2 5 4 1 1 2 2 2 2 2 2 2 1 4 4 1
Procedures for Assembly and Disassembly of Control Valve Relief valve Procedures for assembly and disassembly of main relief valve
1 2
Plug (32 mm hexagon diameter) 5 O-ring 6
3
O-ring
7
4
Hexagon nut (36 mm hexagon diameter)
8
1.
2.
O-ring 9 Plug (27 mm hexagon diameter) 10 Hexagon nut 11 (30 mm hexagon diameter)
1-1/16-12UN-2A Piston PF1/4 JIS O-ring type
Plug (27 mm hexagon diameter)
Disassembly This part is replaced as an assembly. When replacing, loosen the plug (1) (32 mm diameter) with a wrench and remove the O-ring (2). If oil leaks from the nut (4) (36 mm hexagon diameter), loosen the nut (4) (36 mm hexagon diameter) and the plug (1) (32 mm hexagon diameter), and replace the O-ring (3). If oil leaks from the nut (7) (30 mm hexagon diameter), loosen the nut (7) (30 mm hexagon diameter) and the plug (8) (27 mm hexagon diameter), and replace the O-ring (5). Assembly Carefully check to make sure there is no debris, paint fragments around the thread sections of the plugs (1) (32 mm hexagon diameter), (6) (27 mm hexagon diameter), (8) (27 mm hexagon diameter) and nuts (4) (36 mm hexagon diameter), (7) (30 mm hexagon diameter) and assemble the new O-rings. Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the plug (1) (32 mm hexagon diameter). Tightening torque: 78 - 88 Nă&#x192;ťm When the plug has been disassembled, adjust the pressure according to the Main relief valve item in 5).
Procedures for assembly and disassembly of overload relief valve
1
Cap
5
Poppet
9
2
O-ring
6
Spring
10
84402827B - May 2011 8011-27
Lock nut (17 mm hexagon diameter) Adjuster (6 mm hexagon diameter)
Procedures for Assembly and Disassembly of Control Valve 3
Adjuster kit section
7
4
O-ring
8
1.
1-1/16-12UN-2A Cap (31.75 mm hexagon diameter)
Disassembly This part is replaced as an assembly. When replacing, loosen the cap (1) (31.75 mm hexagon diameter) with a wrench and remove the O-ring (2). Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4). CAUTION Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet could be lost.
2.
Assembly Check carefully that there is no debris, paint fragments around the thread section of the cap and assemble a new O-ring (2). Also clean the valve housing relief valve installation section well, install the relief valve, and tighten the cap (1) (31.75 mm hexagon diameter). Tightening torque: 78 - 88 Nă&#x192;ťm When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure according to the Overload relief valve item in 5).
Procedures for assembly and disassembly of low-pressure relief valve
1 2 3 4 1. 2.
Plug Poppet Plug Spring
5 6 7 8
O-ring Piston Plug O-ring
9 10 11
PF1/4 PF3/4 1 3/16-12UN-2A
Disassembly Fasten the assembly with a vise, loosen the plug, and remove the piston (6), spring (4), and poppet (2). Then loosen the plug and take out the O-rings (5) and (8) from each part. Assembly Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a new O-ring. Install new O-rings (5) and (8) on the plug and install the plug. Assemble the poppet (2), spring (4), and piston (6) and screw in and tighten the plug. Tightening torque: 103 - 113 Nă&#x192;ťm Also clean the valve housing relief valve installation section well and tighten the relief assembly plug (1) (36 mm hexagon diameter). Tightening torque: 103 - 113 Nă&#x192;ťm
84402827B - May 2011 8011-28
Procedures for Assembly and Disassembly of Control Valve Procedures for assembly and disassembly of add-on main relief valve
1
Plug (32 mm hexagon diameter) 5
Poppet
9
2
O-ring
6
Spring
10
3 4
Adjuster kit section O-ring
7 8
1-5/16-12UN-2A Plug (24 mm hexagon diameter)
1.
Lock nut (17 mm hexagon diameter) Adjuster (6 mm hexagon diameter)
Disassembly This part is replaced as an assembly. When replacing, loosen the plug (1) (32 mm hexagon diameter) with a wrench and remove the O-ring (2). Also, if oil leaks from the adjuster kit section, loosen the adjuster kit and replace the O-ring (4). CAUTION Be careful disassembling the adjuster kit. The spring may make parts fly out and the poppet could be lost.
2.
Assembly Check carefully that there is no debris, paint fragments around the thread section of the plug and assemble a new O-ring (2). Also clean the valve housing relief installation section well, install the relief valve, and tighten the plug. Tightening torque: 59 - 69 Nâ&#x20AC;˘m When the adjuster kit has been disassembled, clean around the thread sections well and adjust the pressure according to the Add-on main relief valve item in 5).
Relief valve adjustment CAUTION This part is neither disassembled nor adjusted. (It is replaced as an assembly.) Therefore, be aware that proper operation is not guaranteed if pressure is adjusted.
Installation 1. 2. 3. 4.
Be careful that the line does not apply excessive force to the valve. Tighten all the bolts the same. Be careful. Welding close to a valve can damage its seal due to excess heat and sputter. In order to keep out debris, do not remove the cap for a port until it is time to work on the line.
Operation 1. 2. 3. 4.
Check that the hydraulic circuits and hydraulic oil are clean, then gradually raise the pressure (inch the operating machine in low idle) and check that no oil leaks to the outside. For the oil, use hydraulic oil with an aniline point of 82 - 113°C. Do not raise the relief valve above the specified set pressure. Set a difference of at least 2.0 MPa between the set pressure for the main relief valve and for the overload relief valve. 84402827B - May 2011 8011-29
Procedures for Assembly and Disassembly of Control Valve 5.
Warm up the machine adequately before starting the actual work. Pay attention to the following points in order to avoid sticking due to spool heat shock particularly when starting up with the hydraulic oil temperature or valve temperature low. â&#x20AC;˘ Do not operate the main relief valve and overload relief valve right too suddenly after each other. Raise the temperature of each section uniformly and operate in such a way that the hydraulic oil circulates within each actuator. â&#x20AC;˘ Fine operations and compound operations generate heat locally due to throttling of individual sections, so do not suddenly perform these operations with the machine still at low temperature.
Troubles and countermeasures Control valves overall Trouble content
Conceivable cause
Countermeasure Eliminate the section that is providing re1.The oil temperature is abnormally high. sistance to the oil flow in the line. Replace the hydraulic oil and at the same 2.Dirty hydraulic oil time, clean the circuits. 3.Line port joint tightened too much Check the torque. 4.The valve housing was warped during Loosen the installation bolts and check. installation. Attach a pressure gauge to the pump and The spool does not move 5.The pressure is too high. the cylinder port and check the pressure. through its stroke. Replace the spool as an assembly. 6.The spool is bent. 7.Return spring damage Replace the damaged part. Loosen the cap, center it, then tighten it. 8.The spring or cap is out of place. 9.The temperature distribution within the Warm up the circuits as a whole. valve is not uniform. 10.Debris is clogging inside the valve. Remove (flush out) the debris. Inspect for the pilot valve and pilot relief 11.Pilot pressure insufficient pressure. 1.Oil leak from cylinder Check the cylinder seal section. 2.Oil from the spool is bypassing. Check for spool damage. Clean the valve housing seat section and 3.Oil leak from overload relief valve relief valve seat section. Disassemble the antidrift valve and clean the seat section for each part. The load cannot be held. If a seat section is damaged, replace the poppet or lap the poppet and seat section. 4.Oil leak from antidrift valve If the antidrift valve spool is abnormal, since the spool and the sleeve are mating parts, replace them both at the same time. 1.There is debris jammed in the load Disassemble and clean the check valve. When the spool is switched check valve. from the neutral to the raise 2.The check valve poppet or seat section Replace the poppet or lap the poppet and position, the load falls. is damaged. seat section. Relief valve Trouble content Pressure does not rise at all.
The relief pressure is unstable.
The relief pressure is wrong.
Conceivable cause Countermeasure 1.Either the main poppet, sleeve, or pilot poppet is stuck open or there is debris jammed in the valve seat section. 1.The pilot poppet seat section is Replace the relief valve. damaged. 2.The piston or main poppet is stuck. 1.Seat section worn by debris Set the pressure again, then tighten 2.The lock nut and adjuster are loose. the lock nut to the specified torque. 84402827B - May 2011 8011-30
Procedures for Assembly and Disassembly of Control Valve Trouble content Oil leak
Conceivable cause 1.Relief valve seat section damage 2.Each part is stuck due to debris. 3.An O-ring is worn.
Countermeasure Replace the relief valve. Replace the adjuster or installation section O-ring.
Hydraulic system overall Trouble content
Conceivable cause 1.Pump trouble
2.Relief valve trouble 3.Cylinder trouble 4.Pump load pressure is high. The hydraulic system is not working 5.There is a crack in the valve. properly or is not working at all. 6.The spool does not move through its full stroke. 7.The tank oil level is too low. 8.The filter in the circuit is clogged. 9.The circuit line is throttled.
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Countermeasure Check the pressure or replace the pump. Replace the relief valve. Repair or replace. Check the circuit pressure. Replace the valve as an assembly. Check the spool movement. Fill the hydraulic oil. Clean or replace the filter. Check the line.
Procedures for Assembly and Disassembly of Control Valve
84402827B - May 2011 8011-32
Section 8012
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder
84402827B - May 2011
84402827B - May 2011
CONTENTS Specifications and structure diagram (including the assembly diagram and parts table) . . . . . . . . . . . . . . . . . . . . . . 3 Basic functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Function of Each Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cylinder Head Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pipe assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Precautions for Installing the Cylinder on the Machine Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Usage Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Maintenance and Inspection Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Maintenance Inspection and Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Trouble Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Storage Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Storing Parts Individually (In principle, store indoors.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 When Mounted on Vehicle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Recommended Anti-rust Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assembly and Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 General Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspection after Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Required Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 General Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wrench assembly (U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Piston Ring Expander . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Bushing Tool Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly of piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Disassembly of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assembly of Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assembly of Piston Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Piston Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Boom Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8012-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Specifications and structure diagram (including the assembly diagram and parts table) In this manual, explanation is done using a product with a representative structure for a construction machine hydraulic cylinder. Tighten bolts being installed to the specified torque.
Basic functions Hydraulic cylinders are a type of hydraulic actuator. A hydraulic cylinder converts the energy of pressure supplied from the hydraulic pump into a large force of linear motion. By operating the hydraulic pressure direction switchover valve, one can switch the direction of operation between extension and retraction. This linear motion with large force and the switchover of the operation direction are the basic functions.
Function of Each Location This manual explains the functions of each section of the cylinder using a product with a typical structure. There may be some slight differences with the product being used, but the functions are the same.
Cylinder Head Assembly The cylinder head assembly has the function of bearing the piston rod (2) by the bushing (4) press fit into the inner diameter of the cylinder head (3). The seal system of the inner diameter of the cylinder head prevents oil from leaking to the outside and prevents foreign matter from getting into the cylinder. The cylinder head assembly also has the function of supplying and discharging high-pressure oil from inside the cylinder tube to the retraction side port.
1 2 3 4
Cylinder tube Piston rod Cylinder head Bushing
5 6 7 8
Snap ring Buffer ring Rod packing Dust seal
9 10
Snap ring Collar
• Bushing The bushing is press fit to the inside surface of the cylinder head (3) and touches the piston rod (2). Together with the slide rings (18) (19) on the outer circumference of the piston, the bushing divides the lateral load applied to the cylinder and moves linearly relative to the piston rod. Furthermore, it supports one end of the piston rod and has the function of minimizing eccentricity which has a negative impact on the sealing. • Buffer ring/Rod packing The buffer ring (6), together with the rod packing (7), prevents cylinder oil leakage from the rod section to the outside. • Dust seal The dust seal (9) is positioned in the opening where the piston rod (2) comes out from and goes into the cylinder and prevents dust and water from getting into the cylinder from the outside. It also has the function of wiping off any mud sticking to the surface of the piston rod as the piston rod moves.
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Piston Assembly The piston assembly has the function of transmitting the propulsion of the cylinder. A piston ring (14) is mounted on the center of the piston (13) to prevent the flow of pressurized oil from either the left or right chamber to the other chamber. There are wear rings (15) mounted at each end of the piston ring. They have the function of a bearing to receive the cylinder lateral load. Cut off the oil on the extension side and retraction side and move the rod. 1. 2. 3. 4. 5. 6. 7. 8.
Piston ring (14) Cut off the oil on the extension side and retraction side. Wear ring (15) Prevent metal contact of the cylinder tube and piston. Ring (16) Prevent damage to the piston ring due to diesel ignition or foreign matter. Screw (19) Retain the piston. Plunger (11) Narrow the flow path of the oil by plunging to the collar near the extension stroke end and establish the containment pressure. (To alleviate the shock on the extension stroke end) Plunger (12) Narrow the flow path of the oil by plunging to the bottom near the retraction stroke end and establish the containment pressure. (To alleviate the shock on the retraction stroke end) Ball (18) Holds in the plunger. Also support plunger eccentricity. Cap (17) Holds in the ball.
1 2 11 12
Cylinder tube 13 Piston rod 14 Cushion ring (plunger exten15 sion side) Cushion seal (plunger retrac16 tion side)
Piston Piston ring
17 18
Cap Ball
Wear ring
19
Screw
Ring 84402827B - May 2011 8012-4
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder â&#x20AC;˘ Piston ring The piston ring (14) is positioned at the center of the piston (13) and seals the ring-shaped gap between the piston and the cylinder tube (1) and forms chambers with a high-pressure side and a low-pressure side with the piston as the boundary. â&#x20AC;˘ Wear ring Wear rings are positioned at both ends of the piston ring (14) and contact the inside surface of the cylinder tube (1). Together with the bushing (4) positioned on the inside surface of the cylinder head (3), the wear ring divides the lateral load applied to the cylinder and moves linearly relative to the inside surface of the cylinder tube. Furthermore, it supports one end of the piston rod (2) and has the functions of minimizing eccentricity, which has a negative impact on the sealing, and buries and captures any impurities trapped between the cylinder tube and the wear rings (15). â&#x20AC;˘ Plunger When the cylinder is fully extended, the cylinder head (3) and the plunger (11) fit together. When it is fully retracted, the cylinder bottom and the plunger (12) fit together. In both cases, this forms a ring-shaped gap and squeezes the oil to reduce the cylinder collision speed at full extension or full retraction and thus soften the impact.
Pipe assembly The pipe assembly is mounted on the extension side and retraction side ports of the cylinder tube assembly. It has the function of supplying and discharging high-pressure oil by connecting with the hydraulic circuits of the machine body.
20 21
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Pipe assembly Pipe assembly
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Handling Precautions Precautions for Installing the Cylinder on the Machine Body • When installing the cylinder on the machine body or removing it from the machine body, secure the piston rod at the fully retracted position, check safety, and suspend. CAUTION Never suspend the cylinder from the line section. This would not only pose the danger of falling but could also damage the cylinder. Use a band to secure the piston rod in the fully retracted state. If the piston rod is not in the fully retracted state, it could be easily damaged. This could create the need for repair or make the piston rod unusable. Also, not securing the piston rod is dangerous because the piston rod might fly out unexpectedly. • Do not weld after the cylinder has been mounted on the machine body. CAUTION Electric welding on the cylinder or even at a position separated from the cylinder can generate a spark within the cylinder and damage parts. This could cause extensive damage, making it necessary to replace parts or replace the cylinder. • When painting the machine body, mask the piston rod and wiper ring. CAUTION If the cylinder is operated with paint sticking to the piston rod surface and the wiper ring, the wiper ring does not function adequately, greatly interfering with cylinder functions. For example, dirt and paint from the outside may get into the cylinder easily and damage seal parts and cause an oil leak. • Clean the cylinder before installing it.
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Usage Cautions • Use under the determined conditions. CAUTION Use of hydraulic oil other than that specified can cause rapid deterioration of and damage to seal parts. If the relief valve is set to a value higher than that on the assembly diagram, there is a danger of this leading to cylinder damage. ℃ or higher) or low amGeneral sealing materials cannot handle high ambient temperature (about 100℃ ℃ or lower), so the cylinder would be damaged if used at such temperatures. bient temperature (-20℃ Such temperatures require special seal materials, so check if the cylinder being used complies with this requirement. The number one cause of cylinder trouble is oil leaks due to piston rod scratches. Operate very carefully to avoid scratching. If the piston rod is scratched, handle this according to "Trouble Diagnostics". • Warm up the equipment adequately before work. CAUTION After the cylinder has been stopped for a long time, the seal parts inside the cylinder are stuck to the metal of sliding surfaces, so do not suddenly pressurize or operate such a cylinder. A new cylinder or one that has been left unused for a long time has much air built up inside, so it does not operate smoothly. Also, if the cylinder is suddenly operated or pressurized without bleeding out the air, the adiabatic compression of the air generates high temperatures, which may burn and carbonize seal parts, leading to a drastically reduced functionality. Before starting work, always warm up the cylinder by moving slowly through a few full strokes under no load to bleed off any air in the cylinder. • For stopping the machine temporarily or storing it, always have the machine in a safely secure posture. CAUTION When extended, the cylinder cannot hold a load for a long time in a fixed position. This is because the cylinder is extended and retracted by very minor oil leaks from hydraulic circuits and from inside the cylinder and changes in the volume of the hydraulic oil due to oil temperature variation. This results in the danger of machine moving unexpectedly, which can lead to serious accidents. For stopping the machine temporarily or storing it, always have the machine in a safely secure position.
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Maintenance and Inspection Cautions • Always carry out daily maintenance inspections. CAUTION The most important point for realizing the cylinder functions for a longer time is "daily maintenance inspections". In order to ensure adequate functioning, execute "Maintenance Inspection and Service". Constantly clean off any mud, water, dust, oil or grease stuck to the piston rod and keep the piston rod in a clean state. However, do not use water or the like to clean the wiper ring section and seal section. Wipe with a rag. When leaving the machine unused for a week or longer, apply anti-rust oil to the surface of the piston rod in order to prevent rusting. • Use genuine parts for replacement parts. CAUTION If replacement parts are used that are not genuine parts, adequate functioning cannot be attained. Always use genuine parts. Specialty jigs have been produced so that assembly work and disassembly work can be done safely and quickly, so order them. • Be careful about assembly and disassembly too. CAUTION Disassembling a cylinder still installed on the machine body is extremely dangerous because it can cause unexpected movement of the machine body. Always remove the cylinder from the machine body before disassembling it. Assembling with dirty hands can get dirt inside the cylinder and not only reduce the cylinder service life but also damage other hydraulic equipment. Assemble under clean conditions. Use the thread part tightening torque indicated in the diagram. If the torque is either too low or too high, this can cause thread damage. • Strictly observe the cylinder storage standards. CAUTION Execute according to "Assembly and Disassembly Procedures".
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Maintenance Inspection and Service In order to ensure that hydraulic cylinders function properly for a long time, periodically carry out maintenance inspection and service based on the "Autonomous inspection table". Repair any trouble locations quickly based on the Trouble Diagnostics. CAUTION For periodic inspection and service, first work to prevent any hazard to operators. Strive to prevent hazards by working with an attitude based on good sense. Inspection and serInspection and service detail vice location Is the cylinder clean (especially rod sliding sections)? Appearance Is any oil leaking from line installation sections or other fixed sections? Is there missing or peeling paint or rust? Is operation smooth and free of abnormal noise and any other abnormality? Is the responsiveness good? Is any oil leaking from sliding sections? Operation Are there internal leaks? Is the operating pressure normal? Is the overload relief valve set pressure normal? Is hydraulic oil dirty or deteriorated? Hydraulic oil Is hydraulic oil replaced periodically? Are filters inspected periodically? Is the supply of grease to pins adequate? Do pin sections have any abnormal noises or seizing? Section for installa- Do pin sections have any backlash or wear? tion with main unit Are pin seals normal? Are any installation screws loose or fallen out? Retighten installation screws. Are sliding sections worn? Are sliding sections scratched or dented? Is sliding section plating peeling off? Piston rod section Are sliding sections bent? Are there any welding section cracks or damage? Are there any loose bolts or nuts (screws)? Retighten installation screws (bolts and nuts Cylinder tube section (screws)). (including line secAre there any welding section cracks or tions) damage? Are there large dents on the tube?
Daily
Monthly
Yearly
Remarks
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
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When leaving piston rod sliding sections exposed for long periods, apply anti-rust oil to the piston rod.
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Trouble Diagnostics Hydraulic cylinder trouble, countermeasure and solution It is not easy to discover trouble locations. The table below shows general symptoms, suggested causes and also solutions. For repairs, see the suggested causes and solutions in the table. The cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. In some cases, solutions are required other than those given in the table. In such a case, contact with our company to investigate the problem and its cause further and take appropriate measures. Item Symptom Piston rod sliding section oil leak 1 (For the judgment values, see "Inspection after Assembly".) 2 Cylinder head matching section oil leak Pipe and cylinder tube welding section oil leak 3 4 Operation defect
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Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Item Symptom
Related part
Cause
A sliding surface has rust and scratches that catch on a fingernail. Piston rod
Plating is peeling off.
1
Countermeasure and solution 1. Remove the scratches with a whetstone to make the sliding surface smooth (1.5 s max.). If the oil leak continues, the rod scratches may have damaged the U-ring or other seal, so disassemble and inspect. 2. If the scratches or rust cover too large an area to be repaired with a whetstone, replace the piston rod and the U-ring, wiper ring, or other seal and the piston rod bearing part. 1. Replate or replace the piston rod. 2. At this time, inspect the seals and piston rod bearing part as well and replace any that are damaged. 1. Remove the foreign matter. 2. If the packing is damaged, replace it.
There is foreign matter caught in the inner or outer diameter section. There are scratches on the inReplace. ner or outer diameter section. 1. This may be scorching due to adiabatic compression of air remaining in the cylinder. Piston rod sliding The lips and groove section are 2. When operating the cylinder for section oil leak locally carbonized (scorched). the first time after replacing a packing, run at low pressure and low speed to adequately bleed off the air. The packing has lost its rubber 1. Replace. elasticity and is in tatters. 2. This may be the end of the packing service life, deterioration of the hydraulic oil, or high temperRod packing ature of the hydraulic oil. (Buffer ring and U-ring) 1) Replace with a new hydraulic oil. The lip section is defective all 2) Check the temperature of the way around. the hydraulic oil.(The oil temperature should be no higher than 80â&#x201E;&#x192;.) 3) Check for local high temperature. 1. Replace. 2. Abnormally high pressure may be operating on the packing. There is major extrusion of the packing heel section.
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1) 2)
Check the pressure during operation. There may be trouble with the buffer ring section. Inspect the buffer ring section.
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Item Symptom
1
Related part
Cause
Backup ring
The part is greatly deformed.
Countermeasure and solution 1. As a rule, replace the rod packing too at the same time. 2. Abnormally high pressure is often the cause. The check items for this are the same as those given above for packing heel section extrusion.
There is foreign matter caught Remove the foreign matter. in the lip. Wiper ring The lip is damaged. There is other abnormal dam- Replace. age. Piston rod sliding There is major wear of the section oil leak bushing and the gap with the piston rod exceeds the limit on Replace. Bearing part inner diameter wear in "Usage Limits". (bushing) 1. Replace. There are large scratches on a 2. Inspect the piston rod sliding sursliding surface. faces for scratches and rust. 1. Remove the scratches or rust with a whetstone. A seal mounting section has Cylinder head 2. If the repair does not solve the scratches and rust. problem, replace the cylinder head. 1. Remove the foreign matter. 2. If the O-ring is damaged, replace it. 3. Tube interior surface inspection: If there are any scratches or rust, use a whetstone to make the surThere is foreign matter caught face smooth. O-ring in the inner or outer diameter. 4. Cylinder head O-ring groove inThere is damage to the O-ring. spection: Same as above 5. Backup ring inspection: If the backup ring is deformed or extruded, replace it. Check the above and replace the O-ring. Backup ring
2
Cylinder head matching section oil leak Cylinder head
Bolt
Cylinder tube
The part is deformed or exReplace together with the O-ring. truded. 1. Disassemble the cylinder head and inspect the O-ring and backup ring. If there is damage, replace. 2. Check the tube and cylinder head threads for damage and if there is A part is loose. any damage, replace. 3. When the inspection is complete, tighten to the specified torque. See "Assembly Procedures". 4. Stop rotation. There is looseness, stretching Replace all the bolts and tighten to the or breakage. specified torque. 1. Replace with a new one. 2. Oil leaks at matching sections may be caused by abnormally high pressure (including cushThere is abnormal swelling. ion pressure), so if the tube is swollen or deformed, replace it with a new one. Also inspect the circuit pressure. 84402827B - May 2011 8012-12
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Item Symptom
Related part
Cause
Countermeasure and solution CAUTION
3
4
Replace with a new one. Pipe and cylinder Pipe and cylinder There are cracks on the weld- The crack progresses and ultimately tube welding secing section. tube the part fractures. tion oil leak A fracture is extremely dangerous, so if a crack is seen, quickly stop work and replace that part. Welding over a crack is ineffective. Tighten to the specified torque acLine fastening bolt is loose. cording to the work procedure. Oil leak from cylinThe line is bent. Replace with a new one. der line connec- Pipe assembly 1. Use a whetstone to make the surtion section There are scratches on a conface smooth. tact surface. 2. If the oil leak does not stop, replace. 1. Replace with a new one. The bending is large and ex2. There may also be damage to ceeds the stipulated bend Piston rod seals and sliding parts, so inspect warp. Cylinder tube them. (Bend warp: See "MainteIf there is any abnormality, renance Standards".) place. Replace with a new one. Operation defect Inspect the seal and sliding parts the There are dents. Movement is not Cylinder tube same as above. smooth. 1. Replace with a new one. Abnormal wear of sliding parts Inspect the seal and sliding parts Piston rod and damage the same as above. Cylinder tube Foreign matter caught at the 2. Remove the foreign matter. Sliding part piston section or the cylinder Inspect the seal and sliding parts head sliding section the same as above. Replace with a new one. There are scratches, wear, or Also inspect the cylinder tube interior Piston seal other damage. surfaces. 1. Use honing or a whetstone to eliminate the scratches and rust and make the surface smooth. There are scratches and rust Internal oil leak If the scratches cover too large an Cylinder tube on interior surface. The piston rod exarea to be repaired, replace the tends and retracts cylinder tube with a new one. on its own and 2. Replace with a new piston seal. drops abnormally 1. Tighten to the specified torque. during operation. See "Assembly Procedures". Also, the stipu2. The piston rod thread section lated speed is not could be stretched. output. Piston nut Tightening is insufficient. Measure the diameter where the rod and piston fit together and if this area is tapered, replace the piston rod assembly. Inspect the amount of valve leakage Valves Leak from valve. and perform maintenance.
84402827B - May 2011 8012-13
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Item Symptom
Related part
Cause
Countermeasure and solution Bleed out the air. 1.
2. Operation is unAir steady.
There is air remaining in the cylinder.
Cylinder with no air bleeding Bleed out the air by moving the cylinder back and forth at few times at low pressure and low speed. Cylinder with air bleeding (air breather) After securing the machine so that the cylinder does not move, bleed the air from the air breather.
HINT The cylinder may extend or retract somewhat when the cylinder stops suddenly. This phenomenon occurs due to the compressibility of the hydraulic oil. This occurs particularly easily for cylinders with long strokes.
4
The impact is high when switching Pin bushing over between exPin tension and retraction.
The gap between the installa- Measure the pin and pin bushing dition section and the pin bushing mensions and replace any part that is enlarged. exceeds its specified dimension.
Cylinder sliding Pin bushing operations make Pin sounds.
The oil or grease feed is inadeApply oil or grease. quate. There is seizing at matching Replace with a new part and apply oil or grease. section.
CAUTION The hydraulic oil expands and contracts with changes in temperature and pressure. This causes the cylinder to extend and retract too, so it can be mistaken for an internal oil leak. For internal oil leaks, always check the temperature and pressure under the same conditions.
84402827B - May 2011 8012-14
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Storage Standards When a hydraulic cylinder is shipped from the plant, every measure is taken, but in order to prevent trouble during storage and to extend the product service life, pay attention to the following items.
Storing Parts Individually (In principle, store indoors.) • Store parts off the floor and do not store in any location with high temperature and humidity, corrosive gas or liquids. • Before shipment, we operate the cylinder with hydraulic oil to which a fixed quantity of vaporizing anti-rust agent has been added (in order to prevent rust within the cylinder), carry out the pre-shipping inspection, retract the piston rod with ultra-dry air (condensation point -35℃ or lower) (in order to prevent condensation due to temperature difference), and then put caps on the ports and line joints before shipping the cylinder. • Any product that has been in storage in our product warehouse longer than the standard storage period is disassembled and inspected before being shipped. Therefore, do not store or leave a cylinder unused with a cap removed or with the remaining oil in the cylinder drained. Storage for 1 month or longer Clean any dust from the cylinder, and then apply anti-rust oil to the 1 pin bushings, flange sections, piston rod, and other sections that rust easily.
Storage for 6 month or longer (3 months for cylinder alone) Operate the cylinder back and forth with clear hydraulic oil, and then pour anti-rust oil into the cylinder and store in compliance with the items on the left for storage of 1 month.
Storage for 1 year or longer Since there is a danger of packings deterioration, disassemble, inspect, and replace packings. Also, check for rust inside the cylinder.
If a cylinder that has been stored for If the cylinder cannot be operated, a long time is used as is, oil may leak 2 seal in anti-rust oil. due to temporary running-in defects of seals. 3 When storing, be extremely careful not to let parts drop, let them collide with anything, or let anything strike them.
When Mounted on Vehicle Body 1. 2. 3. 4. 5.
Operate the cylinder at least once per month. Retract the cylinder so that as much as possible outside air does not touch the piston rod and apply anti-rust oil at least once per month to the exposed part of the piston rod. Handle carefully to absolutely avoid scratching the piston rod. When putting the cylinder into an environment where rust occurs particularly easily, for example due to exposure to sea breezes during export, always apply anti-rust oil to the piston rod and as much as possible protect with polyethylene sheets or VCI paper (vaporizing anti-rust paper). Anti-rust oil and other solvents can have negative impacts on seals, so select anti-rust oil carefully and as much as possible keep it off dust seals etc.(For details on anti-rust oil to select, see "Recommended Anti-rust Oil".)
Recommended Anti-rust Oil
For inside cylinder
Vaporizing anti-rust oil a. Ferro Gard #1009 (from USC Limited) b. Knuckle Oil #105S (from Parker Industries, Inc.) For both a. and b., add 3 - 5 % of the hydraulic oil. By volume, Ferro Gard: 5/100 Knuckle Oil: 3/100 Anti-rust P-1300 (from the Nippon Oil Corporation)
For piston rod For machine worked surfaces other than parts with Select from JIS K 2246 (anti-rust oil) NP-1 through NP-6. oil sealed in
84402827B - May 2011 8012-15
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Assembly and Disassembly Procedures Preparations Prepare the Following before Starting Disassembly: 1. 2.
Work platform preparation Prepare a sufficiently spacious, solid and stable work surface so that parts will not fall or move during work. Tool and materials preparation Prepare the tools and materials shown on the following pages.
General Work Precautions 1. 2. 3. 4.
Thoroughly clean any dirt or mud from the outside walls of the cylinder before starting disassembly. Each part has been manufactured with a high degree of precision, so be careful not to let parts bump each other or fall when handling them. If parts are struck or pried off with excessive force during work because they are tight, this may cause burrs or damage which causing reduction in performance or oil leaking. Perform work carefully and thoroughly. If a cylinder is left disassembled, humidity and dirt can cause rust on parts. If a pause in the work is unavoidable, be careful to prevent rust and keep off dust.
Maintenance Standards Replace sliding parts and seal parts as follows. 1. 2. 3. 4.
Bushing When 1/4 of the circumference is worn brown over the entire length. Seals and slide rings Replace with new parts when the cylinder is disassembled. Pin bushing When there is severe seizing. Piston rod When the piston rod is bent 0.5 mm/1 m or more.
84402827B - May 2011 8012-16
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Inspection after Assembly Dimension inspecCheck the maximum retracted length and stroke as instructed on the diagram. tion Pressure with- Check for looseness, permanent deformation, and external leaks when the test pressure instand inspection structed on the diagram is applied to each stroke end for at least 3 min. Check the amount of oil leak at the rod section. • Judgment value for rod section oil leak amount Move the piston rod back and forth 20 times with the oil at a temperature from 20℃ to 40℃, then judge by the state of the oil ring formed on the rod surface. If the oil ring is in a broken down A state, this is judged to be trouble. See "Trouble Diagnostics" for information on how to solve this.
External leak inspection
Oil leak amount unit: ml/10 min. Inner diameter Oil leak Inner diameter Oil mm mm amount amount 0.4 100 4.0 Internal leak in- 32 spection 40 0.6 125 5.6 50 1.0 140 6.0 63 1.6 80 2.3
84402827B - May 2011 8012-17
leak Inner diameter Oil mm amount 160 10.0 180 12.6 200 15.6 220 20.0 250 22.0 1
Oil ring
a b
Acceptable Not acceptable
leak
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Required Tool General Tool
No.
Tool name
Q'ty
1
Screwdriver (flathead screwdriver)
1
2
Hexagon wrench
1 set
3
Vise
1
4
Wrench (for piston nuts)
1 set
5
Punch
1
6
Torque wrench
1 set
84402827B - May 2011 8012-18
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder No.
Tool name
Q'ty
7
Hammer (plastic hammer)
1
8
Monkey wrench
1
9
Scoop
1 set
84402827B - May 2011 8012-19
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Wrench assembly (U1) Part number: KRV10620 Application: Use for removal and installation of screw-type piston.
Component parts No. Part name 1 Arm 2 Arm 3 Center pin 4 Pin 5 Set screw
Q'ty Remarks 1 Each drive 3/4" 1 1 2 Diameter 1/4", 5/16" 2
Adjustment 2" (50.8 mm) - 6" (152.4 mm) Usage example
84402827B - May 2011 8012-20
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder a b c
Piston Wrench Torque wrench
Piston Ring Expander
Component parts Tools Part name U2 Expander U3
Clamp
U4
Ring (rubber band)
Part No. KRV10570 KRV10600 KRV10610 KRV10580 KRV10590
Q'ty 1 1 1 1 1
Remarks Piston outer diameter D120 - D135 Piston outer diameter D100 - D115 Piston outer diameter D120 - D135 Piston outer diameter D100 - D115
Characteristics A teflon ring is used on the piston of the hydraulic cylinder, but this cannot be installed as is. By simply rotating the handle, the ring expander can be used to expand the ring smoothly and easily for mounting on the piston without creating any damage. With the use of a compression ring, the teflon ring to be installed on the piston can be mounted exactly at the specified position.
Bushing Tool Kit Part number: KRV10630 Application: Each bushing tool can be installed to the grip by bolts and be used as striking tool when press fitting the wrapping bearing on the attachment cylinder.
84402827B - May 2011 8012-21
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Disassembly Procedures Piston Rod Assembly 1. 2. 3.
Remove the line from the cylinder assembly. Remove the installation bolts and separate the head assembly (1). Remove the piston rod assembly (2). • Place a drip pan or other object under the cylinder to receive the oil.
4.
Disassemble the piston rod assembly with the procedure below. 1)
Set the piston rod assembly (2) on the stand (*1).
3)
Use tool U1 to remove the piston assembly (4). • When not using tool U1, use the 2 notch holes (D10) (*3) to loosen the piston assembly.
2)
Remove the piston assembly rotation stopper screw (3). • If the screw (3) caulking is so strong the screw cannot be removed, screw the screw all the way in and then insert the tap (*2) in the threaded section and try to remove the screw.
4)
Remove the plunger (5). • Boom cylinder • Arm cylinder • Bucket cylinder
5)
Remove the collar (6). • Boom cylinder • Arm cylinder • Bucket cylinder
84402827B - May 2011 8012-22
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder 6)
Disassembly of piston assembly
Remove the head assembly (7).
1. 2. 3. 4.
7)
Remove the rings (11). Remove the wear rings (12). Remove the piston ring (13). Remove the O-ring and backup ring (14).
Remove the cap (8), remove the 12 balls (9), and then remove the cushion plunger (10). â&#x20AC;˘ Arm cylinder
84402827B - May 2011 8012-23
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Disassembly of Cylinder Head Assembly 1. 2.
Remove the O-ring and backup ring (15). Remove the snap ring (16), and then remove the dust seal (17).
3. 4. 5. 6.
Remove Remove Remove Remove
84402827B - May 2011 8012-24
the the the the
rod packing (18). buffer ring (19). snap ring (21). bushing (20).
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Assembly Procedures
Assembly of Piston Assembly
• Be careful not to scratch the packing, dust seal, or O-ring. • Insert the backup ring after heating with hot water at about 50°C - 60°C without forcing it in.
1.
Assembly of Piston Rod Assembly 1. 2. 3. 4.
Use tool U2 to widen the piston ring (13). • Set the piston ring on tool U2 and widen the piston ring by rotating the handle 8 - 10 times.
2.
Set tool U3 and retract the piston ring (13).
3. 4. 5.
Install the backup ring and O-ring (14). Install the wear rings (12). Install the rings (11).
Use a tool to press fit the bushing (20) and install the snap ring (21). Install the buffer ring (19). Install the rod packing (18). Use a tool to install the dust seal (17) and secure with the snap ring (16).
• Be careful not to widen the ring abutment section too much. Ring groove: grease (G2-L1) 5.
Install the backup ring and O-ring (15).
84402827B - May 2011 8012-25
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Piston Rod Assembly 1.
Set the piston rod assembly (2) on the stand (*1).
1) 2. 3.
Install the head assembly (7). Attach the O-ring and backup ring to the collar (6) and install it.
• Use a file to remove burrs and barbs on the thread section.
• Boom cylinder • Arm cylinder • Bucket cylinder 4.
2)
Boom cylinder Arm cylinder Bucket cylinder Check that the top of the plunger has slight backlash.
a
2-D10 notch hole 3)
5.
Set the cushion plunger (10) on the piston rod, install the 12 balls (9), and then secure with the cap (8). • Arm cylinder only
6.
Tighten the screw (3). Tightening torque: 58.85 - 73.55 N·m
Install the plunger (5). • • • •
Screw in the piston assembly (4) and use tool U1 to tighten the piston assembly (4) until it matches the position of the screw threaded hole.
Assemble the piston assembly (4) with the procedure below. • When reusing the rod and piston assembly (4) Thoroughly clean and remove all shavings and debris.
84402827B - May 2011 8012-26
Use a punch (*3) to caulk the threaded section at 4 locations. • When using new parts for the rod and/or piston assembly (4) Mark the cushion plug position on the end surface of the rod with bottom cushion. • Arm cylinder only
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder 4)
Screw in the piston assembly (4) until it touches the end surface of the rod (*4), and use tool U1 to tighten the piston assembly.
6) 7)
• After tightening the piston, check that the plunger (5) has backlash. • Boom cylinder • Arm cylinder • Bucket cylinder
8)
After creating holes, thoroughly clean and remove all shavings and debris. Tighten the screw (3). Tightening torque: 58.85 - 73.55 N·m Use a punch to caulk the threaded section at 4 locations.
Tightening torque: 264.6 - 323.4 N·m
7.
5)
• Set the ring abutment section (*5) at a horizontal position and insert the ring abutment section while aligning the cylinder tube and shaft. • After inserting, check that the ring is not damaged or fallen out, and push it all the way in.
Create a threaded hole for mounting the screw (3). • Align the drill of the V groove on the threaded section of the rod (2) with the piston (4) and create a threaded hole horizontally. • Create a threaded hole on the cylinder with bottom cushion (arm cylinder) while avoiding the position of the cushion plug.
Threaded hole dimensions (mm) Drill diBottom ameUsed Cylinder ter of hole tap name bottom depth hole Book and 10.3 24 12×1.75 bucket Arm 10.3 36 12×1.75
Install the piston rod assembly (2). Ring groove: grease (G2-L1)
Depth of tap 20 29
8.
Tighten the head assembly (1) with installation bolts.
Installation bolt tightening torque Cylinder Tightening torque name Boom 451.2 - 608.2 N·m Arm 755 - 1029 N·m Bucket 451.2 - 608.2 N·m
84402827B - May 2011 8012-27
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder 9.
Install the line.
84402827B - May 2011 8012-28
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Structural Diagram Boom Cylinder
* This diagram shows the parts for the left side.The parts for the right side are symmetrical. *1
*2
*3 L1 L2
Sumitomo Part No. + manufacturing number stamping range Sumitomo Part No. + manufacturing number stamping position (For the range on the circumference, see the side diagram.) Sumitomo Part No. (KRV1925 right, KRV1926 left) Dimensions after press fitting Stroke 1495 mm Maximum retracted 2090 mm
Code 01 02 03 04 05 06 07 08 09 10
Part name Cylinder tube Rod Cylinder head Snap ring Dust seal Rod packing Buffer ring Backup ring O-ring Bushing
length
Q'ty 1 1 1 1 1 1 1 1 1 1
Code 16 17 18 19 20 21 22 23 24 26
Part name Backup ring O-ring Ring Piston ring Wear ring Screw Snap ring Line Line Band 84402827B - May 2011 8012-29
Q'ty 2 1 2 1 2 1 1 1 1 1
Code 31 32 33 34 35 36 37 38 39 40
Part name Clip Nut Washer Bolt Washer Bolt Washer Grease nipple O-ring Bushing
Q'ty 2 4 4 12 12 4 4 1 2 1
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Code 11 12 13 14 15
Part name Collar Backup ring O-ring Plunger Piston
Q'ty 1 2 1 1 1
Code 25 27 28 29 30
Part name Bracket Bolt Washer Bolt Washer
84402827B - May 2011 8012-30
Q'ty 1 4 4 4 4
Code 41 42 43
Part name Dust seal Bushing Dust seal
Q'ty 2 1 2
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Arm Cylinder
*1
*2 *3 L1 L2
Sumitomo Part No. + manufacturing number stamping range Sumitomo Part No. + manufacturing number stamping position (For the range on the circumference, see the side diagram.) Dimensions after press fitting Stroke 1748 mm Maximum retracted 2445 mm
length
84402827B - May 2011 8012-31
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20
Part name Cylinder tube Rod Cylinder head Snap ring Dust seal Rod packing Buffer ring O-ring Backup ring Bushing Collar O-ring Backup ring Plunger Piston O-ring Backup ring Ring Piston ring Wear ring
Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 2
Code 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Part name Screw Plug O-ring Spring Valve Plunger Ball Cap O-ring Grease nipple Snap ring Bolt Washer Line O-ring Bolt Washer Line Bolt Washer
84402827B - May 2011 8012-32
Q'ty 1 1 1 1 1 1 12 1 1 1 1 12 12 1 1 4 4 1 4 4
Code 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58
Part name Bracket Band Bolt Washer Clip Nut Washer Bolt Washer Clamp Band Bracket Bolt Washer Bushing Dust seal Bushing Dust seal
Q'ty 1 1 4 4 2 4 4 2 2 1 1 1 2 2 1 2 1 2
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Bucket Cylinder
*1
*2 *3 *4
L1 L2
Sumitomo Part No. + manufacturing number stamping range Sumitomo Part No. + manufacturing number stamping position (For the range on the circumference, see the side diagram.) Dimensions after press fitting (Bottom center)
Stroke 1210 mm Maximum retracted 1870 mm
length 84402827B - May 2011 8012-33
Procedures for Operation/Assembly and Disassembly of Hydraulic Cylinder Code 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15
Part name Cylinder tube Rod Cylinder head Snap ring Dust seal Rod packing Buffer ring Backup ring O-ring Bushing Collar Backup ring O-ring Plunger Piston
Q'ty 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1
Code 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Part name Backup ring O-ring Ring Piston ring Wear ring Screw Snap ring Line Line Clamp Bracket Bolt Washer Bolt Washer
84402827B - May 2011 8012-34
Q'ty 2 1 2 1 2 1 1 1 1 2 2 4 4 4 4
Code 31 32 33 34 35 36 37 38 39 40 41 42 43
Part name O-ring Bolt Washer Bolt Washer Grease nipple Bushing Dust seal Bushing Dust seal Bolt Washer Band
Q'ty 2 12 12 4 4 2 1 2 1 2 4 4 2
Section 8013
Procedures for Assembly and Disassembly of Operation Remote Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Procedures for Assembly and Disassembly of Operation Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Required Tools and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Causes of Trouble and Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402827B - May 2011 8013-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8013-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Procedures for Assembly and Disassembly of Operation Remote Control Valve Procedures for Assembly and Disassembly of Operation Remote Control Valve Job code
35355AA18
CAUTION To ensure safe operations, wear protective devices before beginning work and follow all precautions. Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. If any parts are significantly rusted or dirty, clean them before disassembling. Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling sliding parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. • • • •
General cautions • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare
Maintenance Procedures Required Tools and Tightening Torque Tools
Wrench Special jig
Dimension Part No. (mm) 22
312
32 24
302 301
Tightening Part name Screw size torque (N·m) Adjusting M14 63.7 - 73.5 nut Disk M14 Joint M14 44.2 - 50.0
Other • • • • • • • •
Vapor corrosion inhibitor White kerosene Heat-resistant grease Sandpaper (#1000, #2000) Whetstone Vise Screwdriver Torque wrench
84402827B - May 2011 8013-3
Procedures for Assembly and Disassembly of Operation Remote Control Valve Maintenance Standards Maintenance inRemarks Standard spection item When handle is in neutral 1000 cc/min or more Conditions During operation 2000 cc/min or more Leak amount Primary pressure 2.94 MPa If either condition occurs, replace the remote Oil viscosity 23 mm2/S control valve as one unit. When wear on the sliding sections exceeds The same approximate conditions as those wear on the non-sliding sections by 10 Îźm or listed above for leak amount are expected when Spool more, replace the remote control valve as one the condition on the left occurs. unit. If the end section is worn by 1 mm or more, perform replacement.
Push rod
Replace the operation section disk (302) and Make adjustments if the backlash is due to Operation section joint section (301) if there is backlash of 2 mm looseness in the tightening sections. backlash or more due to wear. If abnormal noise, hunting, or a drop in primary pressure occurs and the problem cannot be reOperation stability solved with "Causes of Trouble and Countermeasures", replace the remote control valve as a unit. NOTE: It is desirable for seal materials such as O-rings to be replaced with each disassembly, but it is acceptable to reuse these after it is confirmed that they are not damaged.
84402827B - May 2011 8013-4
Procedures for Assembly and Disassembly of Operation Remote Control Valve Disassembly Procedures 1.
4.
If the return springs are strong, the plate (2), plugs, and push rods (3) will rise at the same time the joint (1) is loosened, so be careful of parts flying off when removing the joint.
5.
Remove the plate (1).
6.
If the return springs are weak, the plugs (1) will remain in the casing due to the sliding resistance of the O-rings, so use a flathead screwdriver to remove it.
Use copper plate (or lead plate) to secure the remote control valve in a vise, then remove the bellows (1). â&#x20AC;˘ Be careful not to tear the bellows.
2.
3.
Use a wrench on the bolt width of the adjusting nut (1) and disk (2) to loosen them, then remove the adjusting nut and disk.
Use a jig (1) to remove the joint.
â&#x20AC;˘ Use the groove in the outer circumference of the plugs and remove them while making sure they are not damaged by an unbalanced load. â&#x20AC;˘ Use caution as plugs may fly off when they are being removed due to the return springs.
84402827B - May 2011 8013-5
Procedures for Assembly and Disassembly of Operation Remote Control Valve 7.
Remove the push rods (1), plugs (2), pressure reducing valve assembly, and the return springs (3) from the casing.
10. Remove push rods (2) from the plugs (1).
• Record the relation of parts to the casing hole positions through marking, etc.
11. Remove the O-rings (2) from the plugs (1). • The O-ring cannot be reused. Replace it with new part. 8.
For disassembly of pressure reducing valve, press in the spring seating (1), move the spring seating to the side while bending the secondary pressure spring (2), and remove the spring from the spools (3) by passing through the larger hole. • Do not press in the spring seating by 6 mm or more.
12. Remove the seal (1). Use a small flathead screwdriver, etc. to remove seals. • The seal cannot be reused. Replace it with new part.
9.
Separate the spool (1), spring seating (2), secondary pressure spring (3), and washer (4). • Be careful not to scratch the surface of the spools. • Handle as an assembly until assembly is performed.
13. Cleaning parts Clean all parts by placing them in a rough cleaning container filled with white kerosene. (rough cleaning) Clean each part by placing it in a finish cleaning container filled with white kerosene, and thoroughly clean each part, including the interior, while slowly rotating the part. (finish cleaning) Use a clean rag to thoroughly remove any white kerosene stuck to parts. 84402827B - May 2011 8013-6
Procedures for Assembly and Disassembly of Operation Remote Control Valve • Scratching can easily occur if cleaning of a part is begun just after parts are immersed in white kerosene, so let each part sit in white kerosene until debris and grease sufficiently loosen from the surface of the part and float to the surface. • If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene. • Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture being dispersed into the atmosphere.
Assembly Procedures 1.
Insert washer (4), secondary pressure spring (3) and spring seating (2) onto each of the spool (1) in that order.
2.
Press in the spring seating (1) and move it to the side while bending the secondary pressure spring (2) to pass the seating over the larger hole and install it on each of the spools.
Preventing rust on parts Apply an anti-rust agent to each part. • Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions after reassembly.
• Do not press in the spring seating by 6 mm or more.
3.
Install the return springs (1) in the casing (2). Install the pressure reducing valve assembly (3) in the casing (2). • Install them in the positions they were in before disassembly.
84402827B - May 2011 8013-7
Procedures for Assembly and Disassembly of Operation Remote Control Valve 4.
Install O-rings (2) on the plugs (1).
6.
Install push rods (1) into the plugs (2). • Apply hydraulic oil to surface of the push rod.
5.
Install seal (1) on the plug (2). • Install so that the seal lips are as shown in the diagram below.
7.
Install the plug assembly (1) in the casing (2). If the return spring is weak, it will be stopped by the sliding resistance of the O-ring. • Be careful not to scratch the casing hole by forcing in the spool.
3
Push rod 8.
a
Hydraulic oil application
If the return spring is strong, use the plate (1) to install all 4 plug assemblies at the same time and temporarily tighten them with the joint (2). • Be careful of the plug assemblies and plate flying off.
84402827B - May 2011 8013-8
Procedures for Assembly and Disassembly of Operation Remote Control Valve 9.
• Tightening torque: 63.7 - 73.5 N·m • During tightening, do not move the disk position.
Install the plate (1).
10. Use a jig, and tighten the joint (1) to the casing (2) to the specified torque. Tightening torque: 44.2 - 50.0 N·m
13. Apply grease to the rotating section of the joint and to the top of the push rods (1).
11. Install the disk (1) onto the joint (2).
14. Install the bellows (1).
• Screw the disk in until it is equally touching each of the 4 push rods (3). Secondary pressure will cause faulty operation of the machine if the disk is screwed in too much, so pay attention to adjustment of the tightening position.
• Be careful not to tear the bellows. • Inject vapor corrosion inhibitor into each port, and then place plugs in the ports.
12. Install the adjusting nut, use a wrench on the bolt width of the disk (1) to secure it, and tighten the adjusting nut to the specified torque.
84402827B - May 2011 8013-9
Procedures for Assembly and Disassembly of Operation Remote Control Valve Causes of Trouble and Countermeasures It is not easy to discover trouble locations. A few problems that may sometimes occur are listed in the table below. Repairs are difficult, so refer to the possible causes and solutions in the table. The table below shows general symptoms, suggested causes, and also solutions. However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary. The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control valve assembly cross-section diagram". The table below does not include all possible causes and countermeasures. Further investigation of problems and causes should be done by an experienced and qualified repair person, as necessary. Symptom
Cause 1. Insufficient primary pressure 2. Secondary pressure spring (241) is broSecondary pressure is ken or worn. not rising. 3. The gap between spool (201) and the casing (101) is abnormally large. 4. There is backlash in the handle section. 1. Secondary pressure is 2. unstable. 3.
Sliding parts are sticking. Tank line pressure is variable. Air is getting into lines.
Secondary pressure is 1. 2. high.
Tank line pressure is high. Sliding parts are sticking.
84402827B - May 2011 8013-10
Solution 1. Maintain primary pressure. 2. Replace it with new part. 3. Replace the remote control valve as one unit. 4. Assemble and disassemble and/or replace the handle section. 1. Repair the sticking sections. 2. Return directly to the oil tank. 3. Perform operation several times and let out air. 1. Return directly to the oil tank. 2. Repair the sticking sections.
Procedures for Assembly and Disassembly of Operation Remote Control Valve
Attached diagram 1. Remote control valve assembly cross-section diagram a
Grease application to top
c
Grease application to rotating sliding sections. Be careful with the installation direction.
b
Secondary pressure adjustment shim Design central value t = 0.4 1 shim
d
Hydraulic symbol
Code 101 151 201 211 212-1 212-2 213 214
Part name Casing Plate Spool Plug Push rod (ports 1, 3) Push rod (ports 2, 4) Seal O-ring
Q'ty 1 1 4 4 2 2 4 4
Code 217 221-1 221-2 221-3 241-1 241-2 301 302
Part name Washer Return spring (port 1) Return spring (port 3) Return spring (ports 2, 4) Secondary pressure spring (ports 1, 3) Secondary pressure spring (ports 2, 4) Joint Disk
84402827B - May 2011 8013-11
Q'ty 4 1 1 2 2 2 1 1
Procedures for Assembly and Disassembly of Operation Remote Control Valve Code 216-1 216-2
Part name Spring seating (ports 1, 3) Spring seating (ports 2, 4)
Q'ty Code 2 312 2 501
Part name Adjusting nut Bellows
Q'ty 1 1
Tightening torque Code
Screw size
301 302 312
M14
Tightening torque 44.2 - 50.0 N¡m
M14
63.7 - 73.5 N¡m
Detailed diagram of jig main unit (1) and (2) are inserted by tightening. Attached diagram 2. Jig main unit *1
(1) Material: SCM415 (N) carburized
*3
*2
(2) Material: S45C
*4
84402827B - May 2011 8013-12
(Bolt width) Hole H6 + 0.13 Shaft n6 + 0.028
Procedures for Assembly and Disassembly of Operation Remote Control Valve
Detailed diagram of bushing Material: SCM415 (N) carburized Quantity: 2 Attached diagram 3. Joint disassembly jig
Joint installation state
c
84402827B - May 2011 8013-13
Bushing
Procedures for Assembly and Disassembly of Operation Remote Control Valve
84402827B - May 2011 8013-14
Section 8014
Procedures for Assembly and Disassembly of Travel Remote Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Procedures for Assembly and Disassembly of Travel Remote Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Causes of Trouble and Countermeasures and Cross-section Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
84402827B - May 2011 8014-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8014-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Procedures for Assembly and Disassembly of Travel Remote Control Valve Procedures for Assembly and Disassembly of Travel Remote Control Valve Job code
35356AK20
CAUTION • To ensure safe operations, wear protective devices before beginning work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Follow the precautions below when suspending the load. • The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane must be used. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling sliding parts, be sure to coat them with new hydraulic oil. • As a rule, replace all O-rings and other seal parts with new parts. General cautions • Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. Items to prepare • • • • • • •
Wrench Screwdriver Specialty jigs Vise Loctite 262 Special fiber cloth (Kimwipe) White kerosene
84402827B - May 2011 8014-3
Procedures for Assembly and Disassembly of Travel Remote Control Valve Maintenance Procedures Disassembly Procedures 1.
4.
Use a shock plate to secure the remote control valve in a vise, then remove the bellows (1) from the cover (2).
• Be careful when removing, as the push rods (3) may fly off.
• Be careful not to tear the bellows.
2.
3.
Remove the cams (1) as an assembly with the locking screws and lock nuts left attached. Record the positions of the cams in relation to the covers (2).
Use a hexagon wrench (1) on the hexagon socket head locking screws to loosen them. Be careful, as application of Loctite #241 makes the loosening torque high.
Place a round rod (D8 mm or less) against one end of the cam shafts (1) and lightly strike it with a hammer to remove the shafts.
5.
Use a hexagon wrench (1) on the hexagon socket head bolts to loosen and remove them.
6.
Remove the cover (1). • Record the positions of the covers in relation to the casings (4). Be careful when removing, as the push rods (2) or plugs (3) may fly off due to the damping springs. (The plugs are only kept in the casing by the sliding resistance of the O-rings.)
84402827B - May 2011 8014-4
Procedures for Assembly and Disassembly of Travel Remote Control Valve 7.
Remove push rods (2) from the plugs (1). Record the positions of the plugs in relation to the push rods. Be careful not to scratch the surface of the push rods. Be careful when removing, as the plugs may fly off.
10. Remove the damping springs (2) (3) from the casing (1). Record the positions of the damping springs in relation to the casing holes.
11. Remove the spring seating (2) from the casings (1). 8.
Remove the plugs (1) with the grease caps and NHU packings left attached. Record the positions of the plugs in relation to the casing holes. Be careful when removing parts, as the pistons (3) may fly off due to the damping springs (2).
â&#x20AC;˘ Record the positions of the spring seating in relation to the casing holes.
12. Use a magnet, etc. to remove steel balls (1). Be careful not to lose the steel balls.
9.
Remove the pistons (1). Record the positions of the pistons in relation to the casing holes.
84402827B - May 2011 8014-5
Procedures for Assembly and Disassembly of Travel Remote Control Valve 13. Use the hexagon wrench to remove the hexagon socket head bolts (1).
14. Remove the damper casing (1) and remove the O-rings (4) (3) from the casing. • Record the positions of the damper casing in relation to the casing (2). • Be careful when removing parts, as the pressure reducing valve assembly may fly off due to the return springs.
16. Remove the return spring (1) from the casing (2).
17. Lay the covers (1) on their sides on a level surface, place special tool 1 against the bushings, and remove the bushings by lightly striking them with a hammer.
18. Secure each cam assembly (1) in a vise, use a wrench to loosen the lock nuts (2), and remove the lock nuts and locking screws (3). 15. Remove the pressure reducing valve assembly (1) from the casing (2).
• As neutral adjustment of locking screws is necessary during assembly, handle them as part of the cam assembly as long as replacement of locking screws is not necessary.
• Record the positions of these parts in relation to the casing holes.
84402827B - May 2011 8014-6
Procedures for Assembly and Disassembly of Travel Remote Control Valve 19. For disassembly of the pressure reducing valve assemblies, place the bottom end of the spools (1) perpendicular on a level work platform, lower the spring seating (2), and use the end of a small flathead screwdriver to remove the 2 half-circle washers 1 (3). Be careful not to scratch the surface of the spool. Do not press in the spring seating by 4 mm or more.
22. Remove the NHU packings (2) from the plugs (1). Use a small flathead screwdriver, etc. to remove. • Be careful not to scratch the inner surface of the plugs.
23. Remove the O-rings (2) from the plugs (1).
20. Separate the spools (1), spring seating (2), secondary pressure springs (3), washers 2 (4), and washers 3 (5). Handle as an assembly until assembly is performed. Washers 2 are used for pre-set adjustment of the secondary pressure springs, so thickness is different for each spool assembly. Additionally, these are sometimes not used, so record the status for each assembly.
24. Cleaning parts
21. Remove the grease cups (2) from the plugs (1).
• Clean all parts by placing them in a rough cleaning container filled with white kerosene. (rough cleaning) • Scratching can easily occur if cleaning of parts is begun just after parts are immersed in white kerosene, so let each part sit in white kerosene until debris and grease sufficiently loosen off from the surface of parts and float to the surface. • If the white kerosene is dirty, this will encourage damage to parts and result in reduced performance after reassembly. Thoroughly manage the level of cleanliness of the white kerosene. • Clean each part by placing it in a finish cleaning container filled with white kerosene, and thoroughly clean each part, including the interior, while slowly rotating it (finish cleaning). Use a clean rag to thoroughly remove any white kerosene stuck to parts. • Do not dry parts with compressed air, as this will damage parts and cause rust to form due to debris and moisture being dispersed into the atmosphere. • Preventing rust on parts Apply an anti-rust agent to each part. Rust will form on parts if they are left as is after cleaning, and this will cause reduced performance of functions after reassembly.
84402827B - May 2011 8014-7
Procedures for Assembly and Disassembly of Travel Remote Control Valve Assembly Procedures 1.
Install the washers 3 (5), washers 2 (4), secondary pressure springs (3), and the spring seating (2) onto each of spools (1) in that order. Washers 2 are used for pre-set adjustment of the secondary pressure springs, so thickness is different for each spool assembly. Additionally, these are sometimes not used. Check the status recorded during disassembly and attach parts accordingly.
3.
Install the return springs (1) in the casing (2). • Install them in the positions they were in before disassembly.
2.
Place the bottom end of the spools (1) perpendicular on a level work platform, push the spring seating (2) down, and install the 2 half-circle washers 1 (3) onto the spring seating in such a way that they are not on top of each other.
4.
Install the pressure reducing valve subassemblies (1) assembled in steps 1) and 2) above into the casing (2). • Install them in the positions they were in before disassembly.
• Install the washers 1 so that the sharp edge side (a) faces up and the washer catches the head of the spool. Do not press in the spring seating by 4 mm or more.
• When installing the pressure reducing valve subassemblies, be careful not to strongly strike the casing corners (b) with the bottom ends of the spools.
84402827B - May 2011 8014-8
Procedures for Assembly and Disassembly of Travel Remote Control Valve
5.
7.
Install the steel balls (1) into the bushings.
8.
Install the spring seating (1) into the bushings.
Install O-rings (1) (2) on the casing (3). • Install them in the positions they were in before disassembly.
6.
Tighten the damper casing (1) and casing (2) with the hexagon socket head bolts (3) to the specified torque. • Install them in the positions they were in before disassembly. • Tighten the 2 hexagon socket head bolts (3) evenly, and tighten the damper casing (1) in a parallel orientation.
9.
Install the damping springs (2) (3) in the casing (1). • Install them in the positions they were in before disassembly.
• Hexagon socket head bolt (3) tightening torque: 7.8 - 9.8 N·m
84402827B - May 2011 8014-9
Procedures for Assembly and Disassembly of Travel Remote Control Valve 10. Install the pistons (1). â&#x20AC;˘ Install them in the positions they were in before disassembly.
13. Install grease cups (2) into the plugs (1).
11. Install O-rings (2) on the plugs (1).
14. Install push rods (2) into the plugs (1). â&#x20AC;˘ Before installing push rods, apply hydraulic oil to the rod surfaces. Do not press the rods in strongly, as this may damage the NHU packing lip sections.
12. Install NHU packings into the plugs (1).
â&#x20AC;˘ When installing the NHU packings (1), be careful of the installation direction. (See the diagram.) Before installing NHU packings, apply a thin layer of grease.
84402827B - May 2011 8014-10
Procedures for Assembly and Disassembly of Travel Remote Control Valve 15. Install the push rod subassemblies assembled in steps 11), 12), 13), 14) above into the casing (1).
18. Tighten the hexagon socket head bolts to the specified torque. • Be careful that the cover is horizontal. • Hexagon socket head bolt tightening torque: 45.2 - 64.8 N·m
16. Use special tool 1 on the covers (1) to press down the bushings, and lightly strike the bushings with a hammer to press fit them. • Be careful that the ends of the bushings do not stick out from within the cover.
17. Install the covers (1) on the casing (2).
19. Temporarily install the locking screws (3) and lock nuts (2) on the cams (1).
20. Install the cams (1) on the covers (2).
• Install them in the positions they were in before disassembly. • Be careful of the cover rising up due to the damping springs.
• Install them in the positions they were in before disassembly.
84402827B - May 2011 8014-11
Procedures for Assembly and Disassembly of Travel Remote Control Valve 21. While holding the cams (1), insert the cam shafts (2) from the outside.
24. Adjust the height of the locking screws so that the top surface of the cams (1) and the bottom surface of the covers (2) are parallel, and tighten the lock nuts to the specified torque after rotating the cams left and right to check if there is any neutral backlash. Even if the push rods are pressed in too much by the locking screws, backlash during neutral will occur. Use caution as this may cause sudden movement when starting the engine. • Locking screw tightening torque: 29.9 - 36.7 N·m
22. Apply Loctite #241 or the equivalent to the surfaces of the hexagon socket head locking screws (1).
25. Tilt the cams (1) and fill the grease cups of the plugs with grease while coating the top of the push rods with grease. • For grease application and filling, use a flat object made of soft material so as to not scratch the push rod or plug surfaces. 23. Tighten the hexagon socket head locking screws to the specified torque. • Hexagon socket head locking screw tightening torque: 5.9 - 7.9 N·m
26. After mounting the top end of the bellows (1) on the cams, mount the bottom end into the grooves on the covers (2). • Before mounting the bottom end of the bellows into the grooves of the covers, spray anti-rust oil on the parts within the bellows. • Be careful that the bellows are properly mounted in the grooves and not twisted, as this may reduce anti-rust and anti-moisture protection.
84402827B - May 2011 8014-12
Procedures for Assembly and Disassembly of Travel Remote Control Valve
84402827B - May 2011 8014-13
Procedures for Assembly and Disassembly of Travel Remote Control Valve Causes of Trouble and Countermeasures and Cross-section Diagram It is not easy to discover trouble locations. A few problems that may occur are listed in the table below. Repairs are difficult, so refer to the possible causes and solutions in the table. The table below shows general symptoms, suggested causes, and also solutions. However, the cause of machine problems are often not rooted in just a single part. Problems are often due to the relationship of one part with another. Also keep in mind that solutions other than those listed in the table may sometimes be necessary. The numbers in parentheses after the part names are the codes indicated in "Attached diagram 1 Remote control valve assembly cross-section diagram". Also, the table below does not include all possible causes and countermeasures. Further investigation of problems and causes should be done by an experienced and qualified repair person, as necessary. Symptom
Cause 1. Insufficient primary pressure 2. Secondary pressure spring (324) is worn. Secondary pressure is 3. The gap between spool and the casing is not rising. abnormally large. 4. There is backlash in the operation section. 1. Secondary pressure is 2. unstable. 3. Secondary pressure is 1. 2. high.
Damping is not working.
1. 2. 3. 4. 5. 6.
Damping torque is high.
1. 2.
Solution 1. Maintain primary pressure. 2. Replace it with new part. 3. Replace spool and casing assembly. 4. Disassemble and assemble or replace operation section parts. 1. Repair the sticking sections. Sliding parts are sticking. 2. Return directly to the oil tank. Tank line pressure is variable. 3. Perform operation several times and Air is getting into lines. let out air. Tank line pressure is high. 1. Return directly to the oil tank. Sliding parts are sticking. 2. Repair the sticking sections. 1. Perform operation several times and Air is gathering in the piston chamber. let out air. Sliding parts are sticking. 2. Repair the sticking sections. Damping springs (336) (337) are worn. 3. Replace it with new part. The gap between piston (224) and the cas4. Replace piston and casing asseming is abnormally large. bly. There are check valve operation problems. 5. Disassemble and adjust the check The piston metering hole is abnormally valve section. large. 6. Replace piston. Sliding parts are sticking. 1. Repair the sticking sections. Piston metering hole is clogged. 2. Repair or replace piston.
84402827B - May 2011 8014-14
Procedures for Assembly and Disassembly of Travel Remote Control Valve
Hydraulic symbols
Cross section B-B
Attached diagram 1. Remote control valve assembly cross-section diagram 84402827B - May 2011 8014-15
Procedures for Assembly and Disassembly of Travel Remote Control Valve ANNOTATION: Since hydraulic equipment is crucial to safety, we cannot guarantee performance and functions if disassembly and reassembly are performed. Code 101 102 201 202 203 210 211 212 213 214 245
Part name Casing Casing (damper) Cover Plug Grease cup NHU packing O-ring O-ring O-ring Push rod Washer 1
Q'ty 1 1 2 4 4 4 2 4 4 4 8
Code 271 301 311 313 324 335 336 337 412 413 420
217
Washer 2
4
423
218 220 224 225
Spring seating Hexagon socket head bolt Piston 2D085 Steel ball
4 2 4 2
471 472 501
Part name Hexagon socket head bolt Spool Spring seating Washer 3 Spring Spring Spring Spring Bushing Camshaft Cam Hexagon socket head locking screw Locking screw Lock nut Bellows
Q'ty 2 4 4 4 4 4 4 4 4 2 2 2 4 4 2
Tightening torque list Code Screw size Tightening torque 220 M6 7.8 - 9.8 N路m 271 M12 45.2 - 64.8 N路m 423 M6 5.9 - 7.9 N路m (Loctite coating) 472 M10 29.9 - 36.7 N路m a b
Grease application to top Filling of grease cup with grease
Attached diagram 2. Jig dimension diagram
84402827B - May 2011 8014-16
1
Bushing removal jig
c
Center hole possible (D2 or less)
Section 8016
Assembly and Disassembly of Cushion Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Operation Spool Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check Plunger Section with Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shuttle Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Written Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8016-1
3 3 3 4 5 5 6 6 7
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8016-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Cushion Valve Disassembly Procedures This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as possible. If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.) • • • •
Only disassemble in a clean location with minimal dirt. Use only clean tools and cleaning oil and handle them with care. Use plugs, caps to cover ports to prevent any entry of dirt and clean the outside of the assembly. Check the internal structure before starting work, and carefully study the disassembly objective and scope.
Reverse Operation Spool Section
Check Plunger Section with Throttle
1.
1.
Remove the plugs (1) and O-rings (2). • Remove the springs (3). • Remove the spools (4) with the cap screws and O-rings assembled in them.
Remove the plugs (1) and O-rings (2). • Remove the springs (3) and remove the check plungers (4). CAUTION The check plungers have similar shapes, so identify them in such a way that no one will mix them up with each other.
Diagram 1 2.
Fasten the spool (3) assemblies taken out in 1. in a vise. CAUTION
Diagram 3
Use a piece of wood (jig) (4) to prevent scratches. • Remove the cap screws (1) and O-rings (2).
Diagram 2
84402827B - May 2011 8016-3
Assembly and Disassembly of Cushion Valve Shuttle Valve Section 1.
Remove the plugs (1) and O-ring (2), and then remove the seat (4) and O-ring (3). â&#x20AC;˘ Remove the steel balls (5).
Diagram 4
84402827B - May 2011 8016-4
Assembly and Disassembly of Cushion Valve Assembly Procedures This valve has a structure that forms small gaps. It is precision processed and the parts are carefully selected and fit together, so do not disassemble it as much as possible. If assembly and disassembly is unavoidable, pay attention to the following. (The product warranty may be invalidated.) • • • •
Only assemble in a clean location with minimal dirt. Use only clean tools and cleaning oil and handle them with care. Clean the disassembled parts and prepared parts. Study the internal structure before starting the work and prepare the parts required by the disassembly objective and scope.
Reverse Operation Spool Section
CAUTION
1.
The spool assemblies are symmetrical left/ right, so the insertion direction does not matter.
Assemble the cap screw (1) with O-ring (2) on the spool (3). • Tightening torque: 9.8 - 14.7 N·m CAUTION Use a piece of wood (jig) (4) to prevent scratches.q
• Insert the springs (2) and assemble the plugs (3) with the O-rings (4) attached. • Tightening torque: 39.2 - 49.0 N·m
Diagram 6 2.
Diagram 5 Insert the spool assemblies (1) assembled in 1. into the body.
84402827B - May 2011 8016-5
Assembly and Disassembly of Cushion Valve Check Plunger Section with Throttle
Shuttle Valve Section
1.
1.
Insert the check plungers (1). CAUTION The check plungers have similar shapes, so be careful to insert each one in its correct position.
Insert the steel balls (1). • Assemble the seat (2) with the O-ring (3) attached and the plug (4) with the O-ring (5) attached. • Tightening torque: 39.2 - 49.0 N・m
• Insert the springs (2) and assemble the plugs (4) with the O-rings (3) attached. • Tightening torque: 29.4 - 31.4 N・m
Diagram 8
Diagram 7
84402827B - May 2011 8016-6
Assembly and Disassembly of Cushion Valve Written Materials 1.
2.
Check plunger table Part No.
Name
65301-11705 65301-11706 65301-11707 65301-11708 65301-11709 65301-11710 65301-11711 65301-11712 65301-11713 65301-11714 65301-11715
Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger Check plunger
Metering orifice diameRemarks ter (D) 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5
Cushion valve assembly diagram
External shape diagram
84402827B - May 2011 8016-7
Assembly and Disassembly of Cushion Valve
Cross section X -
Cross section Y -
Cross section V Cross-section diagram Code 1 2 3 4 5 6 7 8
Part name Body Spool Spring Plug O-ring Cap screw O-ring Plug
Code 9 10 11 12 13 14 15 16
Part name Check plunger Check plunger Check plunger Check plunger Spring Plug O-ring Steel ball
84402827B - May 2011 8016-8
Code 17 18 19 20 21 22 23 24
Part name Seat O-ring Plug O-ring Name plate Drive screw Plug Plug
Section 8017A
Removal and Installation of Arm HBCV
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Arm HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8017A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8017A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Arm HBCV 2.
CAUTION • Stop the machine in the temporary decommissioning posture on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Be sure to release hydraulic pressure before beginning work.
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (1), and then remove the line (2) and O-ring (3). • Use caps or plugs to cover the HBCV and line to prevent any entry of water, dust or dirt. • Clean the HBCV and line by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
Items to prepare • • • • • • •
Wrench (22 mm) Hexagon wrench (10 mm) Marking pen Caps Plugs Rag Cleaning fluid
Removal of Arm HBCV 1.
3.
Use a wrench (22 mm) to remove the line (1) and (2).
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (1), and then remove the arm HBCV (2) and O-ring (3).
• Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps or plugs to cover the line and HBCV to prevent any entry of water, dust or dirt. • Clean the line and HBCV by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
84402827B - May 2011 8017A-3
Removal and Installation of Arm HBCV Installation of Arm HBCV 1.
2.
Set the O-ring on the arm HBCV, and then install with 4 hexagon socket head bolts (1).
Set the O-ring (3) on the line (2), and then install with 4 hexagon socket head bolts (1). • The O-ring cannot be reused. Replace with a new part.
• The O-ring cannot be reused. Replace with a new part.
Tightening torque: 74.9 - 109.9 N・m
Tightening torque: 74.9 - 109.9 N・m
3.
Install the line assemblies (1) (2). • Install at the position where the HBCV and hoses are marked so that the connectors match at the time of assembly.
84402827B - May 2011 8017A-4
Section 8017B
Removal and Installation of Boom HBCV
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Boom HBCV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8017B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8017B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Boom HBCV • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Be sure to release hydraulic pressure before beginning work. Items to prepare • • • • • • • •
Wrenches (19 mm, 22 mm, 27 mm) Hexagon wrench (10 mm) Marking pen Caps Plugs Rag Cleaning fluid Crossties
3.
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (1), and then remove the boom HBCV (2).
4.
Use wrenches (19 mm, 22 mm) to remove the hoses (1) (3) (4) (5) of the cab side boom HBCV in step 1, and use a wrench (27 mm) to remove the boom bottom pressure sensor (6).
Removal of Boom HBCV 1.
Use wrenches (19 mm, 22 mm) to remove the hoses from the tool box side boom HBCV (1), (2), (3) and (4). • Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps or plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
• Mark the HBCV and hoses so that the connectors match at the time of assembly. • Use caps or plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. • Clean the HBCV and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
1 2 3 4 2.
Pilot hose (use 19 mm wrench) Drain hose (use 22 mm wrench) Drain hose (use 22 mm wrench) Pilot hose (use 22 mm wrench)
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (1), and then remove the line (2). • Use caps or plugs to cover the HBCV and lines to prevent any entry of water, dust or dirt. 84402827B - May 2011 8017B-3
Removal and Installation of Boom HBCV 1 3 4 5 5.
Pilot hose (use 22 mm wrench) Drain hose (use 19 mm wrench) Pilot hose (use 22 mm wrench) Pilot hose (use 22 mm wrench)
Installation of Boom HBCV 1.
Set the O-ring (1) on the boom HBCV (2), and then install with 4 hexagon socket head bolts (3). • The O-ring cannot be reused. Replace with a new part.
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (3), and then remove the line (2) and O-ring (1).
Tightening torque: 74.9 - 109.9 N・m
• Use caps or plugs to cover the HBCV and line to prevent any entry of water, dust or dirt. • Clean the HBCV and line by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
2.
Set the O-ring (1) on the line (2), and then install with 4 hexagon socket head bolts (3). • The O-ring cannot be reused. Replace with a new part. Tightening torque: 74.9 - 109.9 N・m
6.
Use a hexagon wrench (10 mm) to remove the 4 hexagon socket head bolts (3), and then remove the boom HBCV (2) and O-ring (1).
84402827B - May 2011 8017B-4
Removal and Installation of Boom HBCV 3.
Use wrenches (19 mm, 22 mm) to install the hoses (1) (3) (4) (5) of the boom HBCV, and use a wrench (27 mm) to install the boom bottom pressure sensor (6).
5.
• The O-ring cannot be reused. Replace with a new part.
• Install at the position where the HBCV and hoses are marked so that the connectors match at the time of assembly.
Tightening torque: 74.9 - 109.9 N・m
6. 1 3 4 5 4.
Pilot hose (use 22 mm wrench) Drain hose (use 19 mm wrench) Pilot hose (use 22 mm wrench) Pilot hose (use 22 mm wrench)
Set the O-ring (1) on the line (2), and then install with 4 hexagon socket head bolts (3).
Use wrenches (19 mm, 22 mm) to install the hoses from the tool box side boom HBCV (1) (2) (3) (4). • Install at the position where the HBCV and hoses are marked so that the connectors match at the time of assembly.
Set the O-ring (1) on the boom HBCV (2), and then install with 4 hexagon socket head bolts (3). • The O-ring cannot be reused. Replace with a new part. Tightening torque: 74.9 - 109.9 N・m
1 2 3 4
84402827B - May 2011 8017B-5
Pilot hose (use 19 mm wrench) Drain hose (use 22 mm wrench) Drain hose (use 22 mm wrench) Pilot hose (use 22 mm wrench)
Removal and Installation of Boom HBCV
84402827B - May 2011 8017B-6
Section 8018
Assembly and Disassembly of Center Joint
84402827B - May 2011
84402827B - May 2011
CONTENTS Configuration Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Jig Dimension Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8018-1
4 5 6 7 8
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8018-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Center Joint Job code
35354AE28
CAUTION General cautions
CAUTION
• Be careful not to drop precision parts or let bump them with other parts during work. • Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. • Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. • Make sure that foreign matter such as debris and moisture does not enter. • The work platform used should be solid, stable, and sufficiently spacious. Also, items should be clean and free of debris and moisture. Remove debris and moisture before performing work. • Inspect, remove debris and moisture, and clean tools and jigs before work. • Jigs and tools that are appropriate to the contents of work should be used.
• The following cautions for hydraulic equipment should be observed with these parts. • To ensure safe operations, wear protective devices for the work and follow all precautions. • When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. • Make sure that the jig is used for disassembly of the axle and rotor. • Follow the precautions below when suspending the load. • The liftcrane must be operated by a qualified operator. • Do not stand or pass under the suspended load. • Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane must be used. • Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. • If any parts are significantly rusted or dirty, clean them before disassembling. • Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. • When assembling V-rings, O-rings, and other sliding parts, be sure to coat them with new grease. • As a rule, replace all O-rings and other seal parts with new parts.
Items to prepare • • • • • • •
Hexagon wrenches (6 mm, 8 mm, 14 mm, or 17 mm) Torque wrench Socket wrenches (6 mm, 8 mm, 14 mm, or 17 mm) Lights Mirror Brush (plastic) Specialty jigs
84402827B - May 2011 8018-3
Assembly and Disassembly of Center Joint Configuration Diagram
Code 1 2 3 4
Part name Axle V-ring Rotor O-ring
Code 5 6 7 8
Part name Packing ring Thrust plate Hexagon socket head bolt O-ring
84402827B - May 2011 8018-4
Code 9 10 11
Part name Cover Hexagon socket head bolt Loctite #262
Assembly and Disassembly of Center Joint Dimension Diagram
*1 *2
Maximum gap 10.0 Minimum gap 8.5 Maximum gap 0.7 Minimum gap 0.3
84402827B - May 2011 8018-5
*3 *4
3 - M16 screw depth 22 mm, bottom hole depth 27 mm 4 x 4 - M10, screw depth 16 mm, bottom hole depth 18 mm
Assembly and Disassembly of Center Joint Jig Dimension Diagram Axle removal jig
a *1 *2 *3
b
Axle removal jig
*4
M16 - M20 full threaded bolt L = 370 - 420 mm M16 - M20 female thread Cover (9) installation dimensions
Removal jig (for O-ring and V-ring) 84402827B - May 2011 8018-6
*5
Hexagon socket head bolt (7) M10 x 25 Backing plate Axle (1) outer diameter - about 5 mm t = about 5 mm
Assembly and Disassembly of Center Joint Disassembly Procedures 1.
2.
3.
Use a hexagon wrench (6 mm) to remove the 4 hexagon socket head bolts (7), and then remove the thrust plate (6).
4.
Use the axle removal jig (a) to push out the axle (1) from the rotor (3).
Use a hexagon wrench (8 mm) to remove the 4 hexagon socket head bolts (10), and then remove the cover (9).
Remove the O-ring (8).
â&#x20AC;˘ Do not strike it with the hammer at this time.
84402827B - May 2011 8018-7
Assembly and Disassembly of Center Joint 5.
Use the removal jig (b) or the like to remove the V-ring (2) from the axle (1).
Assembly Procedures 1.
Place parts in a rough cleaning container filled with kerosene to clean off any adhered matter that can form sharp points and cause scratches. • Immerse in kerosene until dust, grease, and other adhered matter comes off and floats to the surface.
6.
Use the removal jig (b) or the like to remove the O-ring (4) and packing rings (5) from the rotor (3).
2.
Place parts in a finish cleaning container filled with kerosene and clean while gently moving the parts. After cleaning, wipe away the kerosene with a clean rag. • Place the parts in a location free of dust and moisture and use compressed air to dry the parts. After drying, coat parts with engine oil. • Polish away burrs, barbs, and scratches with a whetstone.
84402827B - May 2011 8018-8
Assembly and Disassembly of Center Joint 3.
Use cleaning fluid or compressed air to clean the rotor (3). After cleaning, check inside the rotor and in the groove sections for burrs, barbs and scratches and for scratches caused by striking.
5.
After installing the O-ring and packing rings, use the mirror to check for any parts that are sticking out or are twisted. Also, check for installation mistakes. After checking, coat with grease. After coating with grease, check again for any parts sticking out,etc.
4.
Check the quantity of packing rings (5) and O-ring (4). Coat with grease and install in the sequence below.
6.
Install the V-ring (2) on the axle (1) and coat sufficiently with grease. Be careful that no water or dirt gets into the grease.
• Set one packing ring (5) in each of the 7 grooves from the 2nd groove on the axle insertion side to the thrust plate side. • Set the O-ring (4) in the front-most groove on the axle insertion side. • Use new packing rings (5) and a new O-ring (4).
• Use a new V-ring (2).
7.
Install the axle (1) on the rotor (3). • Set in a way that the V-ring (2) will not be cut or damaged.
84402827B - May 2011 8018-9
Assembly and Disassembly of Center Joint 8.
Using a hexagon wrench (6 mm), coat the hexagon socket head bolts (7) with Loctite, install the thrust plate (6) on the axle (1), and tighten to the specified tightening torque. Installation bolt tightening torque: 31.4 - 37.3 N•m
9.
Install the O-ring (8) on the rotor (3).
10. Using a hexagon wrench (8 mm), coat the hexagon socket head bolts (10) with Loctite #262, install the cover (9) on the rotor (3), and tighten to the specified tightening torque. Installation bolt tightening torque: 62.7 - 72.5 N•m
This completes the assembly.
• Use new O-ring (8).
84402827B - May 2011 8018-10
Section 8019
Assembly and Disassembly of Swing Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Causes of Trouble and Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance Standard Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Swing Motor Internal Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
84402827B - May 2011 8019-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8019-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Swing Motor Job code
35352AF10
CAUTION 1.
2. 3.
4.
5.
6.
7.
8.
Read and understand the contents of this maintenance manual before performing disassembly, reassembly, inspection, repair, or other such work of this product. Handle this product according to the separate "Usage Precautions". When removing this product from the equipment it is mounted on, stop that equipment system and wait for the surface temperature of this product to fall to about 40 °C or below before removing it. Working on this product while it is still hot can cause burns. Additionally, always bleed out the pressure before removing any line from this product. Removing a pressurized line can result in oil spraying out and causing injury or oil leak. Use the specialty tools and measurement instruments for disassembly, reassembly, inspection, and repair, etc. of this product. Using an inappropriate tool may result in injury or product damage. Be careful of parts falling when performing disassembly, reassembly, inspection or repair, etc. of this product. This may result in injury or parts damage. Do not directly touch with bare hands the machined edges or threaded sections of parts during disassembly, reassembly, inspection, or repair etc. of this product. This may result in injury. Check performance after reassembly. Do not resume use unless performance is fully recovered. Using this product at a sub-par performance level may result in product damage. The cautions (mark !) listed in this maintenance manual do not cover all possible dangers. Always think of safety first during disassembly, inspection, reassembly, repair, or other such work.
84402827B - May 2011 8019-3
Assembly and Disassembly of Swing Motor Causes of Trouble and Solutions This list consists of actions to be taken when an abnormality is sensed or there are problems with functions during use of the hydraulic motor. Additionally, details concerning disassembly inspection and reassembly are listed after this, but sufficient caution should be exercised in handling during these actions so as to prevent scratching of sliding parts of the motor. 1.
General cautions This list consists of actions to be taken when an abnormality is sensed during use of the hydraulic motor. General cautions are listed below. 1)
2) 3) 4) 2.
Think before attempting to fix a problem. Determine the nature of the abnormality before beginning work and think whether this same kind of problem has occurred before. Also, reconfirm whether the motor is the source of the problem. Be careful about dust and dirt. The cause of wear is very often dust and dirt. So be careful that dust and dirt do not get into parts during disassembly. Parts handling Parts are manufactured with a high degree of precision, so be careful not to scratch them during handling. Do not damage O-rings or gasket surfaces while performing work. Also, it is recommended that O-rings are replaced for new ones during disassembly.
Investigating abnormalities in the motor main unit It is very difficult to search for the source of troubles in the hydraulic circuits. Inspect the following items and thoroughly investigate whether the motor is the source of troubles. 1) 2) 3) 4)
Inspecting oil within the casing Remove the drain plug and inspect the hydraulic oil within the casing. If a large amount of metal particles come out at the same time as oil, it is very likely that there is damage with parts within the motor. Existence of abnormal noise Check whether abnormal noise is coming from the motor main unit. Measure pressure for each part. Do not perform disassembly inspection carelessly. Measure pressure for each part and look for abnormalities in each area. Measure the amount of oil drained from the motor. 1) 2)
3.
Operation is normal if about 6 L/min or less of oil drains from the motor when pressure oil is applied after the swing is locked. 2 L/min or less of drained oil at constant swing is normal.
Trouble conditions and countermeasures 1)
Hydraulic motor does not rotate. Symptom
Cause Solution 1) Incorrect setting of the circuit safety 1) Reset safety valve correctly. valve 2) Disassemble and inspect. 2) Operation problems with relief 1) Repair or replace sticking valve Pressure does not section. rise. 1) Plunger sticking 2) Disassemble and clean. 2) Clogged plunger orifice 3) Check seating sections and replace 3) Plunger seating problem scratched part. 1) Eliminate load. 1) Overload 2) Inspect and repair piston/shoe, 2) Seizing of driving part cylinder/valve plate, etc. 3) No release pressure acting on the 3) Inspect and repair circuit. brake Pressure rises. 4) Disassemble and inspect. 4) Piston sticking to the brake 5) Disassemble and inspect. 5) Spool for brake release sticking 6) Disassemble and inspect. Replace 6) Friction plate seizing seizing part.
84402827B - May 2011 8019-4
Assembly and Disassembly of Swing Motor 2)
Rotation direction is reversed. Symptom
Cause
Reversed rotation di- 1) rection 2) 3)
Motor rotation direction reversed. Input and output for line reversed.
Motor speed is not reaching the set value. Symptom
Cause 1) Insufficient oil flow amount Motor speed is not 2) High temperature and severe leak reaching the set of oil value. 3) Wear or damage on each sliding section 4)
Insufficient torque
1) 2) 3)
Check the pump discharge volume and the circuit up to the motor. Lower the temperature of the oil. Replace.
Cause 1) 2) braking 3) 4) 5)
Solution 1) Disassemble and inspect. Replace Wear on the friction plate parts worn beyond the limit. Brake piston sticking 2) Disassemble and inspect. Brake release pressure cannot be 3) Inspect and repair circuit. released. 4) Disassemble and inspect. Spool for brake release sticking 5) Disassemble and inspect. Replace Damaged friction plate spline damaged part.
Severe hydraulic motor slipping Investigate the amount of oil drained from the hydraulic motor. Motor operation is normal if the amount is 500 cc/min or less. Symptom
Cause 1)
Slipping is severe when an external driving torque acts on the hydraulic motor.
Operation problems with relief valve 1) 2)
2) 6)
Solution
Hydraulic motor does not rotate. Symptom
5)
Solution 1) Check the rotation direction and assemble correctly. 2) Correct line configurations.
Solution 1) Disassemble and inspect. 1)
Plunger sticking Clogged plunger orifice
Plunger seating problem
2) 2)
Repair or replace sticking section. Disassemble and clean.
Check seating section and replace scratched part.
Oil leak 1)
Oil leak from oil seal
Symptom
Cause 1) Debris lodged in lip causing scratching. 2) Shaft scratched or worn Pressure within the casing becomOil leak from oil seal 3) ing abnormally high caused oil seal lip to turn up. 4) Shaft rusted. 2)
Solution 1) 2) 3) 4)
Replace oil seal. Stagger the position of the lip and shaft or replace. Repair any clogged drain line. Disassemble and repair.
Oil leak from matching surface
Symptom
Cause
1) Oil leak from match- 2) 3) ing surface 4)
O-ring has not been inserted. Scratched O-ring Scratched seal surface Loosened or damaged bolt 84402827B - May 2011 8019-5
Solution 1) Insert O-ring and assemble correctly. 2) Replace. 3) Disassemble and repair. 4) Tighten to the specified torque or replace.
Assembly and Disassembly of Swing Motor Maintenance Standard Table 1.
Replacement standards for worn parts If wear on any part exceeds the standard values below, replace or readjust. However, parts should be replaced regardless of these standards if they appear to be extremely damaged based on appearance.
Item
Clearances between piston and cylinder bore (D-d) Piston and shoe caulking section backlash (δ) Shoe thickness (t) Friction plate thickness
Clearance (D-d)
Standard dimensions (mm)
Recommended replacement value (mm)
Solution
0.028
0.058
Replace the piston or cylinder.
0
0.3
Replace the piston and shoe assembly.
5.5 2.0
5.3 1.6
Replace the piston and shoe assembly. Replace.
Piston and shoe backlash (δ)
Shoe thickness (t)
84402827B - May 2011 8019-6
Assembly and Disassembly of Swing Motor 2.
Sliding surface repair standards If the roughness of the sliding surface in any section exceeds the standard values below, repair or replace. Part name
Standard surface roughness
Shoe Shoe plate Cylinder Valve plate
0.8 - Z (Ra = 0.2) (lapping) 0.4 - Z (Ra = 0.1) (lapping) 1.6 - Z (Ra = 0.4) (lapping) 0.8 - Z (Ra = 0.2) (lapping)
Surface roughness requiring repair 3 - Z (Ra = 0.8) 3 - Z (Ra = 0.8) 12.5 - Z (Ra = 3.2) 6.3 - Z (Ra = 1.6)
Note: 1) 2)
Using lapping, make the degree of surface roughness of each sliding surface equal to or lower than the standard value. If the plate spring and cylinder spherical surface sliding section are rough, these should be replaced as a set.
84402827B - May 2011 8019-7
Assembly and Disassembly of Swing Motor Disassembly 1.
5.
Remove the ROH plug (469) from valve casing H0 (303) and take out the springs and plungers. Be careful not to scratch the plunger seating sections.
6.
Loosen the hexagon socket head bolt (401) and remove valve casing H0 (303) from casing JA1 (301).
Wrap the wire rope around the outer circumference of the motor, lift the motor with a liftcrane, and clean with white kerosene. After cleaning, dry the motor using compressed air. • To prevent foreign matter from entering the motor, mask each port with tape, etc. Also clean off adhered dirt and dust.
2. 3.
From the drain plug, drain the oil inside the housing. Point the shaft end of the drive shaft downwards and place a reference mark (*1) on the matching surface of valve casing H0 (303) and casing JA1 (301) with paint, etc. • Select a clean location. Place a rubber plate or cloth on the work platform so as not to damage the parts.
• The valve casing H0 (303) will rise up from the casing JA1 (301) when the bolts are removed due to the force of the brake springs (712). 7.
Remove valve plate B (131) from valve casing H0 (303). • Do this carefully so as not to let valve plate B (131) fall from valve casing H0 (303). (Valve plate B (131) may be attached to the cylinder side.) • When prying open the matching surface with a screwdriver, be careful not to scratch the surface.
4.
Loosen the relief valves (051) and remove them from valve casing H0 (303). • Be sure to replace the O-ring (051-1). The O-ring (051-1) is damaged when the relief valve is loosened.
8.
Take out the brake springs (712) from the brake piston (702).
84402827B - May 2011 8019-8
Assembly and Disassembly of Swing Motor 9.
Use a jig and remove the brake piston (702) from casing JA1 (301). • Apply the tips of the jig to the grooves of the brake piston, and pull straight up.
10. Reposition the motor on its side, and remove the cylinder (111) from the drive shaft. Next, remove the pistons (121), holder plate (123), plate spring (114), and shoe plate (124). • Be careful not to scratch the sliding surfaces of the cylinder (111), shoe (122), etc.
13. Perform the following as necessary. Do not reuse a removed bearing.
11. Take out the friction plate (742) and separator plate (743) from casing JA1 (301).
• Use a press to remove the inner race of the roller bearing (443) from the drive shaft (101). When using a steel rod to hit the inner race of the roller bearing, hit the inner race evenly while being careful not to damage the bearing. • Using a steel rod, tap from the housing section side of the oil seal, and pull out the outer race of the roller bearing from the housing. • Use a slide hammer bearing puller (*3) to remove the roller bearing (404) from valve casing H0 (303).
12. Take out the drive shaft (101) and shoe plate (124). • The spline will damage the oil seal (491) when the drive shaft is removed, so wrap the spline section of the drive shaft with vinyl tape, etc. (*2).
84402827B - May 2011 8019-9
Assembly and Disassembly of Swing Motor Assembly 1) Check each part for scratches from use or from disassembly. If there are any scratches, remove them with a whetstone or sandpaper of the necessary grain, clean with pure cleaning oil, then dry off with an air blower. 2） Replace seal parts with new ones. 3） Thoroughly clean all parts with cleaning fluid and dry with compressed air. 4 ） When assembling sliding sections, apply clean hydraulic oil before assembling. 1. This completes the disassembly.
2.
Place the housing on an appropriate platform with the cover on top. If the roller bearing (443) was removed, shrink fit the inner race of the roller bearing to the drive shaft (101). • Be careful with the direction of the flange of the roller bearing.
3.
Use a jig to insert the oil seal (491) into casing JA1 (301). • Be careful with the direction of the oil seal. • Apply a thin layer of grease to the oil seal lip section. • Be careful to evenly hit it without scratching the outer circumference.
84402827B - May 2011 8019-10
Assembly and Disassembly of Swing Motor 4.
Use a steel rod to install the outer race of the roller bearing (443) into casing JA1 (301).
7.
Set the plate spring (114) on the holder plate (123), and then set the pistons (121).
5.
Mount the drive shaft (101) in casing JA1 (301).
8.
Install the piston subassembly (10) on the cylinder (111).
9.
Align the piston subassembly (10) and cylinder (111) with the drive shaft spline and insert into the housing.
• Carefully insert it so as not to scratch the lip section of the oil seal (491). • Wrap vinyl tape, etc. around the shaft spline section to protect it.
6.
Lay casing JA1 (301) horizontal and insert the shoe plate (124). • Install with the larger chamfered side of the shoe plate (124) on the casing JA1 side. • Apply a thin layer of grease to the matching surface to prevent it from falling out.
10. Set the housing down with the oil seal side facing downwards, and alternately install separator plates (743) and friction plates (744) in that order to the housing. Install the 4 separator plates and 3 friction plates.
84402827B - May 2011 8019-11
Assembly and Disassembly of Swing Motor 13. Install the brake springs (712) into the brake piston (702).
14. If the roller bearing (444) was removed, use a hammer and steel rod to insert it into valve casing H0 (303).
11. Mount the O-rings (706) (707) on casing JA1 (301). â&#x20AC;˘ If grease is applied to the O-ring, it will not break easily when inserting the brake piston. 15. Install valve plate B (131) in valve casing H0 (303). â&#x20AC;˘ Apply a thin layer of grease to the matching surface (*1) of the valve plate.
12. Install the brake piston (702) into the housing.
84402827B - May 2011 8019-12
Assembly and Disassembly of Swing Motor 16. Mount the O-ring (472) to the cover.
19. Mount the relief valve (051) in valve casing H0 (303). Tightening torque: 177 N·m
• Apply grease to the O-ring.
17. Install valve casing H0 (303) on casing JA1 (301) and tighten with the bolt (401). • Be careful with the installation direction of the valve. • Make sure that valve plate B (131) does not fall over. • Make sure that the brake springs (712) do not fall over.
20. Assembly confirmation Open the input/output ports, apply 3.2 - 4.9 MPa of pilot pressure to the brake release port to check if the output shaft rotates smoothly for at least 1 rotation with about 30 - 40 N·m of torque. There is an assembly problem if it does not rotate, so disassemble again and adjust it. • At this time, have the drain port open.
Tightening torque: 430 N·m
18. Insert plungers H2 (351) and springs (355) into valve casing H0 (303) and tighten the ROMH plugs (469) with the O-rings (488) mounted on them. • Check that plunger H2 (351) moves smoothly.
This completes the assembly. • Check that the set pressure of the relief assembly is at the correct pressure after the hydraulic motor is installed in the actual machine.
Tightening torque: 539 N·m
84402827B - May 2011 8019-13
Assembly and Disassembly of Swing Motor
6 7 8 9 10 11
Relief internal structural diagram 1 2 3 4 5
Seat Poppet Spring Spring seat Shim
84402827B - May 2011 8019-14
Liner Piston Cap Backup ring O-ring Holder
Assembly and Disassembly of Swing Motor Jig
84402827B - May 2011 8019-15
Assembly and Disassembly of Swing Motor 1 2 3
Brake piston removal jig Brake piston Casing
84402827B - May 2011 8019-16
Assembly and Disassembly of Swing Motor Swing Motor Internal Structural Diagram
84402827B - May 2011 8019-17
Assembly and Disassembly of Swing Motor a
Brake spring layout diagram
Code 052 100 151 161 162 163 171
Part name Reverse prevention valve subassembly Casing ROH plug O-ring O-ring O-ring Hexagon socket head bolt
400
Reverse prevention valve
400-1 400-2
O-ring Backup ring
Code
Part name
051
Relief valve
051-1 10 101 111 114 121 122 123 124 131 20 301 303 351 355 390 391 401 443 444 451 469 472 488 491 702 706 707 712 742 743
O-ring Piston subassembly Drive shaft Cylinder Plate spring Piston Shoe Holder plate Shoe plate Valve plate B Valve casing H0 subassembly Casing JA1 Valve casing H0 Plunger H2 Spring H2 Nameplate Driving tack Hexagon socket head bolt Cylinder roller bearing Cylinder roller bearing Pin ROMH plug O-ring O-ring Oil seal Brake piston O-ring O-ring Brake spring Friction plate Separator plate
983
Masking plug
984 985 986 994
Masking plug Masking plug Masking plug Insert plug
84402827B - May 2011 8019-18
Q'ty 1 set 1 2 2 2 2 4 2 sets 2 2 Q'ty 2 sets 2 1 set 1 1 1 9 9 1 1 1 1 set 1 1 2 2 1 2 4 1 1 2 2 1 2 1 1 1 1 14 3 4 2 sets 1 set 1 set 1 set 1 set
Assembly and Disassembly of Swing Motor Bolt and plug tightening torque Part Screw size No. 051 M33 x 1.5 151 G1/4 171 M8 400 M22 x 1.5 401 M20 469 M36 x 1.5 984 G1/2 985 G1 986 G1/4 994 Rc3/4
・m) Tightening torque (N・
Width across flat (mm)
177 36 29 69 430 539 2.7 5.6 0.9 98
41 6 6 24 17 17 8 14 6 14
84402827B - May 2011 8019-19
Assembly and Disassembly of Swing Motor
84402827B - May 2011 8019-20
Section 8020A
Explanation of Hydraulic Circuit and Operations (standard model)
84402827B EN - May 2011
84402827B EN - May 2011
CONTENTS Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Travel low-speed circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Travel high-speed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Straight travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Straight travel circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Swing Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Swing speed limit control circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Swing relief cut-off control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Swing priority circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Swing priority circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Swing brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Swing parking circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Swing parking circuit (brake release) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Swing parking circuit (machine stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Boom Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Boom-up circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Boom-up circuit (independent operation) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Boom-up circuit (compound boom-up + arm-in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Boom-up circuit (compound boom-up + arm-in) (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Boom-down regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Boom-down regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Boom-down tilting prevention circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
84402827B EN - May 2011 8020A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Boom-down tilting prevention circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom-down load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom-down load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-out circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-out circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-in forced regenerative circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-in forced regenerative circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-in load holding valve circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-in load holding valve circuit (with HBCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket-open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bucket-close regenerative circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horsepower Boost Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arm-in Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel Horsepower Boost Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cushion circuit (arm-out operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cushion circuit (arm-out operation stopped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cushion circuit (arm-out → arm-in operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heat circuit (lever in neutral) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto pressure boost circuit (bucket close) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 42 44 46 46 48 50 52 54 56 58 58 60 62 62 64 64 66 68 68 70 72 74 76
Explanation of Hydraulic Circuit and Operations (standard model) Travel Circuit Travel low-speed circuit
84402827B EN - May 2011 8020A-2
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Travel motor Travel high-speed select switch Computer A Control valve Travel (left) Travel (right)
Pilot tank line Electric line
7 8 9 10 11 12
Travel high speed Lever lock 4 stack solenoid valve Console lever lock switch Hydraulic pump Travel remote control valve
13 14 15 16 17 18
Check valve Oil cooler Backward left Forward left Backward right Forward right
As an example, this section explains the forward travel operation. The travel motor 2-stage tilting angle is a large angle side.Even if the travel switchover is set to the high-speed side, switching the key switch OFF and then ON again always returns the system to this state. By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and switches the left travel spool to the forward side. At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched. The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank. The travel high-speed solenoid valve goes OFF, the travel motor Ps port oil connects with the tank line, and the travel motor tilting angle moves to the large tilting side.
84402827B EN - May 2011 8020A-3
Explanation of Hydraulic Circuit and Operations (standard model) Travel high-speed circuit
84402827B EN - May 2011 8020A-4
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Travel motor Travel high-speed select switch Computer A Control valve Travel (left) Travel (right)
Pilot tank line Electric line
7 8 9 10 11 12
Travel high speed Lever lock 4 stack solenoid valve Console lever lock switch Hydraulic pump Travel remote control valve
13 14 15 16 17 18
Check valve Oil cooler Backward left Forward left Backward right Forward right
As an example, this section explains the forward travel operation. Sets the travel motor 2-stage tilting angle to a small angle to set high speed. The travel motor has an automatic switchover function that switches the speed to low speed according to the load pressure on the travel motor only during high-speed travel conditions. By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and switches the left travel spool to the forward side. At the same time, the oil is also fed to the pa6 port to switch the right travel spool to the forward side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched. The return oil from the travel motor goes through the left and right travel spools and returns to the hydraulic oil tank. Electrical signals are sent to the computer A by operation of the travel high-speed select switch and the computer A sends electrical signals to the travel high-speed solenoid valve. Due to the switching of the travel high-speed solenoid valve, the pilot pressure (3.9 MPa) from the C1 port enters the left and right travel motor Ps ports through the center joint and sets the travel motor tilting angle to a small angle to raise the speed.
84402827B EN - May 2011 8020A-5
Explanation of Hydraulic Circuit and Operations (standard model) Straight travel circuit
84402827B EN - May 2011 8020A-6
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Travel motor Boom (up) Boom (down) Cushion valve Remote control valve (boom, bucket) Control valve Travel (left) Travel (right) Straight travel valve
Pilot tank line Electric line
10 11 12 13
Straight travel signal (left) Straight travel signal (right) Travel high-speed select switch Computer A
19 20 21 22
Boom cylinder Travel remote control valve Check valve Oil cooler
14 Travel high speed
23 Backward left
15 16 17 18
24 Forward left 25 Forward right 26 Backward right
Lever lock 4 stack solenoid valve Console lever lock switch Hydraulic pump
As an example, this section explains simultaneous forward travel and boom-up operations. By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and switches the left travel spool to the forward side. In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side. Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight travel signal (right). On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left) via the straight travel signal (right). The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched. If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4 port and switches the boom (1) and (2) spools to the up side. The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to the straight travel valve via the straight travel signal (left) and the straight travel spool is switched. The amount of switching of the straight travel spool varies with the upper pilot pressure. (Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to prevent sharp reduction in the travel speed.) Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right travel motors and for the control valve P2 pressurized oil to drive the boom. Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel is possible. Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize the drop in speed. The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
84402827B EN - May 2011 8020A-7
Explanation of Hydraulic Circuit and Operations (standard model) Straight travel circuit (with HBCV)
84402827B EN - May 2011 8020A-8
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Travel motor Boom (up) Boom (down) Cushion valve Remote control valve (boom, bucket) Control valve Travel (left) Travel (right) Straight travel valve
Pilot tank line Electric line
10 11 12 13
Straight travel signal (left) Straight travel signal (right) Travel high-speed select switch Computer A
19 20 21 22
Boom cylinder Travel remote control valve Check valve Oil cooler
14 Travel high speed
23 Backward left
15 16 17 18
24 Forward left 25 Forward right 26 Backward right
Lever lock 4 stack solenoid valve Console lever lock switch Hydraulic pump
As an example, this section explains simultaneous forward travel and boom-up operations. By operating the travel remote control valve to the forward side, the pilot pressure oil is fed to the control valve pa1 port and switches the left travel spool to the forward side. In the same way, oil is also fed to the pa6 port to switch the right travel spool to the forward side. Furthermore, the right forward travel pilot pressure oil separated internally from the control valve pa6 port switches the straight travel signal (right). On the other hand, the travel pilot pressure oil separated internally from the pa1 port switches the straight travel signal (left) via the straight travel signal (right). The discharge oil from hydraulic pump A1 enters the control valve P1 port and the discharge oil from hydraulic pump A2 enters the control valve P2 port. Each flows to the respective travel motor and causes forward travel through the left and right travel spools being switched. If a boom-up operation is carried out during travel, the pilot pressure oil is fed via the cushion valve to the control valve pa4 port and switches the boom (1) and (2) spools to the up side. The upper (boom, arm, bucket, swing, option) pilot pressure oil separated internally from the control valve pa4 port is fed to the straight travel valve via the straight travel signal (left) and the straight travel spool is switched. The amount of switching of the straight travel spool varies with the upper pilot pressure. (Because the pilot pressure is low for slight upper operation, the amount of switching of the straight travel spool is slight to prevent sharp reduction in the travel speed.) Through the straight travel valve being switched, it is possible for the control valve P1 pressurized oil to drive the left and right travel motors and for the control valve P2 pressurized oil to drive the boom. Because the left and right motors are driven by 1 pump, the left and right motors have the same pressure and straight travel is possible. Furthermore, the P2 excess pressurized oil is fed to the travel side via the check valve with travel merge orifice to minimize the drop in speed. The same operations are carried out when travel and an upper actuator other than for the boom are operated simultaneously.
84402827B EN - May 2011 8020A-9
Explanation of Hydraulic Circuit and Operations (standard model) Swing Circuit Swing speed limit control circuit
84402827B EN - May 2011 8020A-10
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2
Swing motor Swing
9 Travel pilot pressure sensor 10 Upper pilot pressure sensor
3
Cushion valve
11 Computer A
4 5 6 7 8
Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing) Control valve
12 13 14 15 16
Lever lock Swing brake 4 stack solenoid valve Console lever lock switch P1 pressure sensor
17 P1 flow control proportional valve 18 Hydraulic pump Horsepower control proportional 19 valve 20 P2 pressure sensor 21 Check valve 22 Oil coolere
This control is for suppressing increases in the swing speed accompanying increased pump flow. (Only in SP mode) For independent swing operation, due to the swing pilot pressure sensor and P1 pressure sensor input electric signal, the computer A outputs a signal to the P1 flow control proportional valve. The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve. The hydraulic pump A1 side discharge flow is reduced to 280 L/min by the signal output from the computer A to the P1 flow control proportional valve.
84402827B EN - May 2011 8020A-11
Explanation of Hydraulic Circuit and Operations (standard model) Swing relief cut-off control circuit
84402827B EN - May 2011 8020A-12
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2
Swing motor Swing
9 Travel pilot pressure sensor 10 Upper pilot pressure sensor
3
Cushion valve
11 Computer A
4 5 6 7 8
Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing) Control valve
12 13 14 15 16
Lever lock Swing brake 4 stack solenoid valve Console lever lock switch P1 pressure sensor
17 P1 flow control proportional valve 18 Hydraulic pump Horsepower control proportional 19 valve 20 P2 pressure sensor 21 Check valve 22 Oil cooler
This control aims for an energy-saving effect by controlling the pump in such a way as to minimize the excess oil drained from the swing motor relief valve for the starting pressure boost for a independent sharp swing operation. When a swing operation starts, due to the swing pilot pressure sensor and P1 pressure sensor input electrical signals, computer A outputs a signal to the hydraulic pump P1 flow control proportional valve. The discharge oil from the hydraulic pump A3 is fed to the P1 flow control proportional valve. The output signal from computer A to the P1 flow control proportional valve controls the pilot pressure to reduce the hydraulic pump A1 side discharge flow. Also, the input signal from hydraulic pump P1 pressure sensor controls the pilot pressure to gradually increase the discharge flow.
84402827B EN - May 2011 8020A-13
Explanation of Hydraulic Circuit and Operations (standard model) Swing priority circuit
84402827B EN - May 2011 8020A-14
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Swing motor Arm (in) Arm (out) Right swing Left swing Cushion valve Swing pilot pressure sensor Shuttle valve Computer A
Pilot tank line Electric line
10 11 12 13 14 15 16 17 18
Remote control valve (arm, swing) Lever lock Swing brake 4 stack solenoid valve Console lever lock switch Arm cylinder Arm (1) Swing Arm load holding valve spool
19 20 21 22 23 24 25 26 27
Arm load holding valve check valve Regeneration release valve Control valve Swing priority variable orifice Arm (2) Upper pilot pressure sensor Hydraulic pump Check valve Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side. By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing force for pressing digging. As an example, this section explains the right-swing and arm-in operation. By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve pa3 port and switches the spool to the right swing side. At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pb5 port and switches the spool to the arm-in side. At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing priority variable orifice to the right side and hold it. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out. The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool and merges upstream of the arm (1) spool. Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out. When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
84402827B EN - May 2011 8020A-15
Explanation of Hydraulic Circuit and Operations (standard model) Swing priority circuit (with HBCV)
84402827B EN - May 2011 8020A-16
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Swing motor Arm (in) Arm (out) Right swing Left swing Cushion valve Swing pilot pressure sensor Shuttle valve Computer A
Pilot tank line Electric line
10 11 12 13 14 15 16 17 18
Remote control valve (arm, swing) Lever lock Swing brake 4 stack solenoid valve Console lever lock switch Arm cylinder Arm (1) Swing Arm load holding valve spool
19 20 21 22 23 24 25 26 27
Arm load holding valve check valve Regeneration release valve Control valve Swing priority variable orifice Arm (2) Upper pilot pressure sensor Hydraulic pump Check valve Oil cooler
The swing pilot pressure is fed to the Pc3' port via the shuttle valve and holds the swing priority variable orifice to the right side. By metering the parallel circuit, for arm and swing simultaneous operation, the swing pressure is boosted to secure the swing force for pressing digging. As an example, this section explains the right-swing and arm-in operation. By moving the remote control valve to the right swing side, the pilot pressure oil is fed via the shuttle valve to the control valve pa3 port and switches the spool to the right swing side. At this time, by moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pb5 port and switches the spool to the arm-in side. At the same time, the pilot pressure oil from the shuttle valve S port is fed to the control valve Pc3' port to move the swing priority variable orifice to the right side and hold it. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor B port and the right swing operation is carried out. The discharge oil from hydraulic pump A2 enters the control valve P2 port, is fed from the parallel oil path to the arm (2) spool and merges upstream of the arm (1) spool. Switching the spool lets the oil flow into the arm cylinder bottom and the arm-in operation is carried out. When the right swing and arm-in operations are carried out at the same time, the swing priority variable orifice on the control valve P1 port parallel oil path moves and narrows, so the pressure is boosted to secure the swing force for pressing digging.
84402827B EN - May 2011 8020A-17
Explanation of Hydraulic Circuit and Operations (standard model) Swing brake circuit
84402827B EN - May 2011 8020A-18
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Swing motor Cushion valve Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing)
Pilot tank line Electric line
7 8 9 10 11 12
Hydraulic pump Check valve Lever lock Swing brake 4 stack solenoid valve Console lever lock switch
13 14 15 16
Computer A Control valve Oil cooler Upper pilot pressure sensor
As an example, this section explains the brake circuit operation after the end of a right swing operation. When the remote control valve is returned to neutral from a right swing operation, the pilot pressure oil is cut off and the control valve swing spool returns to neutral. The pressurized oil fed to the swing motor A port from the control valve A3 port is cut. At the same time, the destination location is eliminated for the pressurized oil flowing from the swing motor B port to the control valve B3 port, so the pressure rises to the swing motor relief valve set pressure. The pressure generated here becomes a brake force and stops the motor. When the swing is stopped, the swing motor continues to rotate for a while due to inertial force.In order to make up the shortfall in the oil volume, oil is supplied from the make-up line connected to the swing motor Mu port from the control valve T3 port to open the make-up check valve and oil is suctioned in to prevent cavitation.
84402827B EN - May 2011 8020A-19
Explanation of Hydraulic Circuit and Operations (standard model) Swing parking circuit (lever in neutral)
84402827B EN - May 2011 8020A-20
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Swing motor Cushion valve Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing)
Pilot tank line Electric line
7 8 9 10 11 12
Check valve Oil cooler Lever lock Swing brake 4 stack solenoid valve Console lever lock switch
13 14 15 16
Computer A Control valve Upper pilot pressure sensor Hydraulic pump
When the key is switched ON, the swing brake solenoid valve is switched by the electrical signal from computer A. The swing motor P port oil goes from the 4 stack solenoid valve C2 port through the swing brake solenoid, and returns to the hydraulic oil tank to hold the swing parking brake.
84402827B EN - May 2011 8020A-21
Explanation of Hydraulic Circuit and Operations (standard model) Swing parking circuit (brake release)
84402827B EN - May 2011 8020A-22
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Swing motor Cushion valve Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing)
Pilot tank line Electric line
7 8 9 10 11 12
Swing Lever lock Swing brake 4 stack solenoid valve Console lever lock switch Computer A
13 14 15 16 17
Control valve Upper pilot pressure sensor Hydraulic pump Check valve Oil cooler
When the engine is started and the swing lever is in neutral, the swing brake solenoid valve comes ON (24 V input), the pressure to the swing motor P port is cut, and the swing parking brake works. When the lever operation raises the reading to 0.5 MPa or higher at the pressure sensor in the swing pilot line, the output from computer A to the swing brake solenoid valve goes OFF, the swing motor PR port pressure rises, the swing parking brake is released, and swing becomes possible. As an example, this section explains the right swing operation. By carrying out the right swing operation on the remote control valve, the pilot pressure oil is fed to the control valve pa3 port via the shuttle valve and switches the swing spool to the right swing side. At the same time, computer A detects the swing pilot pressure sensor signal, judges that there is a swing operation, the electrical signal output from computer A goes OFF, and the swing brake solenoid valve is switched.The pilot pressure oil is fed to the swing motor PR port from the swing brake solenoid valve C2 port to release the swing parking brake. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the swing spool. Switching the spool lets the oil flow into the swing motor A port and the right swing operation is carried out. The pressurized oil from the swing motor B port goes through the swing spool and returns to the hydraulic oil tank. When this is followed by an attachment operation, the pilot pressure is detected by the control valve PA port pressure sensor and the swing parking brake continues to be released. After the swing operation ends, if about 5 sec. pass with no upper operation, the swing brake solenoid valve output from computer A comes ON and the swing parking brake works again. After the swing ends, if this is followed by an upper operation or there is an upper operation within about 5 sec., when about 1 sec. passes after the end of the upper operation, the swing parking brake works again. The swing parking brake is also released for independent upper operations and when about 1 sec. passes after the end of the upper operation, the swing parking brake works again. Key switch OFF ON ON ON ON
Swing pilot pressure Upper pilot pressure Swing brake solenoid Swing motor mechanisensor sensor valve cal brake 0 MPa 0 MPa OFF ON 0 MPa 0 MPa ON ON 0.5 MPa min. 0 MPa OFF OFF 0 MPa 0.5 MPa min. OFF OFF 0.5 MPa min. 0.5 MPa min. OFF OFF
Pilot pressure sensor judgment standard Operation is judged when at 0.5 MPa or above. Non-operation is judged when at 0.3 MPa or below.
84402827B EN - May 2011 8020A-23
Explanation of Hydraulic Circuit and Operations (standard model) Swing parking circuit (machine stop)
84402827B EN - May 2011 8020A-24
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Swing motor Cushion valve Right swing Left swing Swing pilot pressure sensor Remote control valve (arm, swing)
Pilot tank line Electric line
7 8 9 10 11 12
Check valve Oil cooler Lever lock Swing brake 4 stack solenoid valve Console lever lock switch
13 14 15 16
Computer A Control valve Upper pilot pressure sensor Hydraulic pump
When the machine is stopped (the key is switched OFF), the swing motor P port oil goes from the swing brake solenoid C2 port through the lever lock solenoid and returns to the hydraulic oil tank, holding the swing parking brake hold status.
84402827B EN - May 2011 8020A-25
Explanation of Hydraulic Circuit and Operations (standard model) Boom Circuit Boom-up circuit (independent operation)
84402827B EN - May 2011 8020A-26
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2
Cushion valve Boom (up)
3
Boom (down)
4
Boom (2) Remote control valve bucket) Lever lock Boost pressure relief
5 6 7
Pilot tank line Electric line
4 stack solenoid valve 15 Monitor display 16 Computer A Control valve Boom load holding valve check 17 P1 pressure sensor 10 valve 11 Boom cylinder 18 P2 pressure sensor 8 9
(boom,
12 Travel pilot pressure sensor
19 Hydraulic pump
13 Upper pilot pressure sensor 14 Console lever lock switch
20 Check valve 21 Oil cooler
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control valve pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the pa4 port separated in the internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side. The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2) spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge oil from boom (2), flows through the boom load holding valve check valve and into the boom cylinder bottom side and the boom-up operation is carried out. The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84402827B EN - May 2011 8020A-27
Explanation of Hydraulic Circuit and Operations (standard model) Boom-up circuit (independent operation) (with HBCV)
84402827B EN - May 2011 8020A-28
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1
Cushion valve
2
Boom (up)
3 4
Boom (down) Boom (2) Remote control valve bucket) Lever lock Boost pressure relief 4 stack solenoid valve
5 6 7 8
Pilot tank line Electric line
9
17 P1 pressure sensor Control valve Boom load holding valve check 18 P2 pressure sensor 10 valve 11 Boom cylinder 19 Hydraulic pump 12 Travel pilot pressure sensor 20 Check valve (boom,
13 Upper pilot pressure sensor
21 Oil cooler
14 Console lever lock switch 15 Monitor display 16 Computer A
22 Boom HBCV check valve
By operating the remote control valve to the boom-up side, the pilot pressure oil is fed via the cushion valve to the control valve Pa4 port and the boom (2) spool is switched. At the same time, the pilot pressure oil from the Pa4 port separated in the internal path is fed to the boom (1) pilot port and switches the boom (1) spool to the up side. The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the boom (2) spool and merges downstream of the boom (1) spool. The discharge oil from hydraulic pump A2 is fed to the boom (1) spool via the parallel oil path, merges with the discharge oil from boom (2), pushes open the boom load hold valve check valve, flows through the boom cylinder HBCV check valve and into the bottom side, and the boom-up operation is carried out. The boom cylinder rod side return oil goes through the boom (1) spool and returns into the hydraulic oil tank.
84402827B EN - May 2011 8020A-29
Explanation of Hydraulic Circuit and Operations (standard model) Boom-up circuit (compound boom-up + arm-in)
84402827B EN - May 2011 8020A-30
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
8
Arm cylinder Arm (in) Arm (out) Boom (up) Boom (down) Cushion valve Remote control valve (boom, bucket) Remote control valve (arm, swing)
9
Lever lock
1 2 3 4 5 6 7
10 Boost pressure relief 11 4 stack solenoid valve
Pilot tank line Electric line
12 13 14 15 16 17
Arm (1) Boom (up) Arm load holding valve spool Load holding valve check valve Regeneration release valve Control valve
18 Swing priority variable orifice
23 24 25 26 27 28
Upper pilot pressure sensor Console lever lock switch Monitor display Computer A P1 pressure sensor P2 pressure sensor
29 Hydraulic pump
19 Arm (2) 30 Check valve Boom load holding valve check 20 31 Oil cooler valve 21 Boom cylinder 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work). For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left side and the restriction on the flow to the arm is released to smooth the arm movement. By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools. At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port and the swing priority variable orifice spool is switched to the left side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2) and arm (1) spools. Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released and the oil flows through the arm (1) spool and into the arm cylinder bottom side. This makes arm-in operation movement smooth. The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the hydraulic oil tank. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side and the boom-up operation is carried out. When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the boom cylinder bottom side and the boom-up operation is carried out. The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-31
Explanation of Hydraulic Circuit and Operations (standard model) Boom-up circuit (compound boom-up + arm-in) (with HBCV)
84402827B EN - May 2011 8020A-32
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
8
Arm cylinder Arm (in) Arm (out) Boom (up) Boom (down) Cushion valve Remote control valve (boom, bucket) Remote control valve (arm, swing)
9
Lever lock
1 2 3 4 5 6 7
10 Boost pressure relief 11 4 stack solenoid valve
Pilot tank line Electric line
12 13 14 15 16 17
Arm (1) Boom (up) Arm load holding valve spool Load holding valve check valve Regeneration release valve Control valve
18 Swing priority variable orifice
23 24 25 26 27 28
Upper pilot pressure sensor Console lever lock switch Monitor display Computer A P1 pressure sensor P2 pressure sensor
29 Hydraulic pump
19 Arm (2) 30 Check valve Boom load holding valve check 20 31 Oil cooler valve 21 Boom cylinder 32 HBCV check valve 22 Travel pilot pressure sensor
As an example, this section explains the boom-up + arm-in compound operation (leveling work). For leveling work, the boom-up pilot pressure oil is fed to the pbu port, the swing priority variable orifice is moved to the left side and the restriction on the flow to the arm is released to smooth the arm movement. By operating the remote control valve to the boom-up side and arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pa4 port and pb5 port and switches the boom (1) and arm (1) spools. At the same time, pressurized oil separated from the boom (1) side pilot internal path is fed from the pa8 port to the pbu port and the swing priority variable orifice spool is switched to the left side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the parallel oil path to the boom (2) and arm (1) spools. Because the swing priority variable orifice spool in the parallel oil path is moved, the restriction on flow to the arm is released and the oil flows through the arm (1) spool and into the arm cylinder bottom side. This makes arm-in operation movement smooth. The arm cylinder rod side return oil goes through the load holding valve check valve and the arm (1) spool and returns to the hydraulic oil tank. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow through the boom load holding valve check valve and into the boom cylinder bottom side and the boom-up operation is carried out. When the circuit has an HBCV, the discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow through the boom load holding valve check valve and HBCV check valve and into the boom cylinder bottom side and the boom-up operation is carried out. The boom cylinder rod side return oil goes through the boom (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-33
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down regenerative circuit
84402827B EN - May 2011 8020A-34
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1
Load holding valve check valve
Pilot tank line Electric line
9
2
Check valve
10
3 4 5 6 7 8
Oil cooler P1 pressure sensor Orifice Bleed-off Cushion valve Boom (up)
11 12 13 14 15 16
Boom (down) Remote control valve bucket) Lever lock Boost pressure relief 4 stack solenoid valve Control valve P2 pressure sensor Hydraulic pump
17 Boom cylinder (boom,
18 Boom (1) 19 20 21 22 23
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display Computer A
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control valve pb8 port and switches the boom (1) spool to the down side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out. The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches the spool. This opens the HBCV check valve. The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom (1) spool regeneration orifice. Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side. The lower the cylinder rod side load pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes through the boom spool (1) without regeneration and returns to the hydraulic oil tank. Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with regeneration and engine output can be used effectively.
84402827B EN - May 2011 8020A-35
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down regenerative circuit (with HBCV)
84402827B EN - May 2011 8020A-36
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1
Load holding valve check valve
Pilot tank line Electric line
9
2
Check valve
10
3 4 5 6 7 8
Oil cooler P1 pressure sensor Orifice Bleed-off Cushion valve Boom (up)
11 12 13 14 15 16
Boom (down) Remote control valve bucket) Lever lock Boost pressure relief 4 stack solenoid valve Control valve P2 pressure sensor Hydraulic pump
17 Boom cylinder (boom,
18 Boom (1) 19 20 21 22 23 24
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display Computer A Boom HBCV check valve
By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control valve pb8 port and switches the boom (1) spool to the down side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1) spool. Switching the spool lets the oil flow into the boom cylinder rod side and the boom-down operation is carried out. The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. When the circuit has an HBCV, the pilot pressure oil separated in the internal path operates on the HBCV PL port and switches the spool. This opens the HBCV check valve. The boom cylinder bottom side pressurized oil goes through the load holding valve check valve (passes through the HBCV check valve and goes through the load holding valve check valve when the circuit has an HBCV) and is metered by the boom (1) spool regeneration orifice. Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder rod side. The lower the cylinder rod side load pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom return oil goes through the boom spool (1) without regeneration and returns to the hydraulic oil tank. Because the circuit is configured in such a way that, even if the boom (1) spool is at full stroke, negative control pressure is generated by the center bypass bleed-off oil path and the pump does not discharge full flow, the shortfall is made up for with regeneration and engine output can be used effectively.
84402827B EN - May 2011 8020A-37
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down tilting prevention circuit
84402827B EN - May 2011 8020A-38
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Load holding valve check valve Check valve Oil cooler Bleed-off Cushion valve Boom (up) Boom (down) Remote control valve (boom, bucket)
Pilot tank line Electric line
9 10 11 12 13 14 15
Lever lock Boost pressure relief 4 stack solenoid valve Control valve P2 pressure sensor Hydraulic pump Boom cylinder
17 18 19 20 21 22
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display Computer A P1 pressure sensor
16 Boom (1)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke, negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced. Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84402827B EN - May 2011 8020A-39
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down tilting prevention circuit (with HBCV)
84402827B EN - May 2011 8020A-40
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Load holding valve check valve Check valve Oil cooler Bleed-off Cushion valve Boom (up) Boom (down) Remote control valve (boom, bucket)
Pilot tank line Electric line
9 10 11 12 13 14 15
Lever lock Boost pressure relief 4 stack solenoid valve Control valve P2 pressure sensor Hydraulic pump Boom cylinder
17 18 19 20 21 22 23
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display Computer A P1 pressure sensor Boom HBCV check valve
16 Boom (1)
By operating the remote control valve all the way to the boom-down side at once, even if the boom spool goes its full stroke, negative control pressure is generated by the center bypass bleed-off oil path and the circuit is such that the hydraulic pump does not discharge full flow, so the generation of high pressure is restrained and main unit tilt is reduced. Since the shortfall in the oil volume is compensated by the regenerative circuit, the engine output can be used effectively.
84402827B EN - May 2011 8020A-41
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down load holding valve circuit
84402827B EN - May 2011 8020A-42
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Boom load holding valve check valve Load holding valve spool Cushion valve Boom (up) Boom (down) Remote control valve (boom, bucket) Lever lock Boost pressure relief
Pilot tank line Electric line
9
4 stack solenoid valve
17 Console lever lock switch
10 11 12 13
Control valve Check valve Oil cooler Boom cylinder
18 19 20 21
14 Boom (1)
Monitor display Computer A P1 pressure sensor P2 pressure sensor
22 Hydraulic pump
15 Travel pilot pressure sensor 16 Upper pilot pressure sensor
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom. By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control valve pb8 port and switches the boom spool to the down side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1). Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out. The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-43
Explanation of Hydraulic Circuit and Operations (standard model) Boom-down load holding valve circuit (with HBCV)
84402827B EN - May 2011 8020A-44
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Boom load holding valve check valve Load holding valve spool Cushion valve Boom (up) Boom (down) Remote control valve (boom, bucket) Lever lock Boost pressure relief
Pilot tank line Electric line
9
4 stack solenoid valve
17 Console lever lock switch
10 11 12 13
Control valve Check valve Oil cooler Boom cylinder
18 19 20 21
Monitor display Computer A P1 pressure sensor P2 pressure sensor
14 Boom (1)
22 Hydraulic pump
15 Travel pilot pressure sensor 16 Upper pilot pressure sensor
23 Boom HBCV check valve
When the remote control valve boom operation lever is in neutral, the oil at the boom cylinder bottom side is sealed by the load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the boom. By moving the remote control valve to the boom-down side, the pilot pressure oil is fed via the cushion valve to the control valve pb8 port and switches the boom spool to the down side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the boom (1). Switching the spool lets the oil flow into the boom cylinder bottom side and the boom-down operation is carried out. The pilot pressure oil from the pb8 port separated in the internal path is fed to the load holding valve spool and moves the spool to the left. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. The boom cylinder bottom side pressurized oil goes through the load holding valve check valve and the boom (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-45
Explanation of Hydraulic Circuit and Operations (standard model) Arm Circuit Arm-out circuit
84402827B EN - May 2011 8020A-46
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Arm cylinder Arm (in) Arm (out) Cushion valve Remote control valve (arm, swing) Lever lock Boost pressure relief 4 stack solenoid valve
Pilot tank line Electric line
9 10 11 12 13 14 15 16
Control valve Load holding valve check valve Arm (1) Arm (2) Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display
17 18 19 20 21 22
Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve Oil cooler
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying out the arm-out operation. When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation. The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-47
Explanation of Hydraulic Circuit and Operations (standard model) Arm-out circuit (with HBCV)
84402827B EN - May 2011 8020A-48
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Arm cylinder Arm (in) Arm (out) Cushion valve Remote control valve (arm, swing) Lever lock Boost pressure relief 4 stack solenoid valve
Pilot tank line Electric line
9 10 11 12 13 14 15 16
Control valve Load holding valve check valve Arm (1) Arm (2) Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display
17 18 19 20 21 22 23 24
Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve Oil cooler Arm HBCV check valve Arm HBCV
By moving the remote control valve to the arm-out side, the pilot pressure oil is fed via the cushion valve to the control valve pa5 port and pa9 port and switches the arm (1) and (2) spools to the out side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow through the load holding valve check valve and into the arm cylinder rod side, carrying out the arm-out operation. When the circuit has an HBCV, switching the arm spool lets the oil flow through the load holding valve check valve to push open the arm cylinder HBCV check valve and flow into the rod side, carrying out the arm-out operation. The arm cylinder bottom side return oil goes through the arm (1) and (2) spools and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-49
Explanation of Hydraulic Circuit and Operations (standard model) Arm-in forced regenerative circuit
84402827B EN - May 2011 8020A-50
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Load holding valve spool Load holding valve check valve Oil cooler Regeneration check valve Metering large Metering small Forced regeneration release valve Arm (in) Arm (out)
Pilot tank line Electric line
10 11 12 13 14 15 16 17 18
Cushion valve Remote control valve (arm, swing) Lever lock Boost pressure relief 4 stack solenoid valve Control valve Arm cylinder Arm (1) Arm (2)
19 20 21 22 23 24 25 26 27
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out. The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the spool to the right. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc. When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering side and the opening becomes larger. Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the arm spool (1) and forced regeneration release valve without being regenerated.
84402827B EN - May 2011 8020A-51
Explanation of Hydraulic Circuit and Operations (standard model) Arm-in forced regenerative circuit (with HBCV)
84402827B EN - May 2011 8020A-52
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9 10
Load holding valve spool Load holding valve check valve Oil cooler Regeneration check valve Metering large Metering small Forced regeneration release valve Arm (in) Arm (out) Cushion valve
Pilot tank line Electric line
11 12 13 14 15 16 17 18 19 20
Remote control valve (arm, swing) Lever lock Boost pressure relief 4 stack solenoid valve Control valve Arm cylinder Arm (1) Arm (2) Travel pilot pressure sensor Upper pilot pressure sensor
21 22 23 24 25 26 27 28 29
Console lever lock switch Monitor display Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve Arm HBCV check valve Arm HBCV
By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out. The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the spool to the right. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and is metered by the forced regeneration release valve.Through this, the return oil pushes open the check valve in the arm (1) spool and is forcibly regenerated on the cylinder bottom side, securing the arm speed for leveling work etc. When the cylinder bottom load pressure becomes high, the forced regeneration release valve is switched to the large metering side and the opening becomes larger. Through this, the check valve in the spool is closed and the cylinder rod side return oil returns to the hydraulic oil tank via the arm spool (1) and forced regeneration release valve without being regenerated.
84402827B EN - May 2011 8020A-53
Explanation of Hydraulic Circuit and Operations (standard model) Arm-in load holding valve circuit
84402827B EN - May 2011 8020A-54
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Load holding valve spool Load holding valve check valve Oil cooler Arm (in) Arm (out) Cushion valve Remote control valve (arm, swing) Lever lock
Pilot tank line Electric line
9 10 11 12 13 14 15 16
Boost pressure relief 4 stack solenoid valve Control valve Arm cylinder Arm (1) Arm (2) Travel pilot pressure sensor Upper pilot pressure sensor
17 18 19 20 21 22 23
Console lever lock switch Monitor display Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load holding valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm. By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve pb5 port and pb9 port and switches the arm (1) and (2) spools to the in side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow into the arm cylinder bottom side and the arm-in operation is carried out. The pilot pressure oil from the pb5 port separated in the internal path is fed to the load holding valve spool and moves the spool to the right. In this way, the load holding valve check valve spring chamber oil is connected to the tank line through the load holding valve spool, the spring chamber pressure drops, and the load holding valve check valve is opened. The arm cylinder rod side pressurized oil goes through the load holding valve check valve and the arm (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-55
Explanation of Hydraulic Circuit and Operations (standard model) Arm-in load holding valve circuit (with HBCV)
84402827B EN - May 2011 8020A-56
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8 9
Load holding valve spool Load holding valve check valve Oil cooler Arm (in) Arm (out) Cushion valve Remote control valve (arm, swing) Lever lock Boost pressure relief
Pilot tank line Electric line
10 11 12 13 14 15 16 17 18
4 stack solenoid valve Control valve Arm cylinder Arm (1) Arm (2) Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display
19 20 21 22 23 24 25
Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve Arm HBCV check valve Arm HBCV
When the remote control valve arm operation lever is in neutral, the oil at the arm cylinder rod side is sealed by the load hold valve check valve, reducing internal leakage from the main spool and reducing the natural drop of the arm. By moving the remote control valve to the arm-in side, the pilot pressure oil is fed via the cushion valve to the control valve Pb5 port and Pb9 port and switches the arm (1) and (2) spools to the in side. The discharge oil from hydraulic pump A1 enters the control valve P1 port and is fed from the center bypass oil path to the arm (1) spool. The discharge oil from hydraulic pump A2 enters the control valve P2 port, flows from the center bypass oil path and through the arm (2) spool front arm merge oil path and merges upstream of the arm (1) spool. Switching the arm spool lets the oil flow into the arm cylinder bottom side and carries out the arm-in operation. The pilot pressure oil from the Pb5 port separated in the internal path flows into the HBCV PL port and switches the spool. This opens the HBCV check valve. The pilot pressure oil from the Pb5 port separated in the internal path is fed to the load hold valve spool and moves the spool to the right. In this way, the load hold valve check valve spring chamber oil is connected to the tank line through the load hold valve spool, the spring chamber pressure drops, and the load hold valve check valve is opened. The arm cylinder rod side pressurized oil goes through the HBCV check valve, load hold valve check valve and the arm (1) spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-57
Explanation of Hydraulic Circuit and Operations (standard model) Bucket Circuit Bucket-open circuit
84402827B EN - May 2011 8020A-58
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7
Cushion valve Bucket (close) Bucket (open) Remote control valve bucket) Lever lock Boost pressure relief 4 stack solenoid valve
Pilot tank line Electric line
(boom,
8 Control valve 9 Bucket 10 Bucket cylinder
15 Computer A 16 P1 pressure sensor 17 P2 pressure sensor
11 Travel pilot pressure sensor
18 Hydraulic pump
12 Upper pilot pressure sensor 13 Console lever lock switch 14 Monitor display
19 Check valve 20 Oil cooler
By moving the remote control valve to the bucket-open side, the pilot pressure oil is fed via the cushion valve to the control valve pa7 port and switches the bucket spool to the open side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylinder rod side and the bucket-open operation is carried out. The bucket cylinder bottom side pressurized oil goes through the bucket spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020A-59
Explanation of Hydraulic Circuit and Operations (standard model) Bucket-close regenerative circuit
84402827B EN - May 2011 8020A-60
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7 8
Regeneration check valve 9 Boost pressure relief 10 4 stack solenoid valve Oil cooler 11 Control valve Orifice 12 Bucket Cushion valve 13 Bucket cylinder Bucket (close) 14 Travel pilot pressure sensor Bucket (open) Remote control valve (boom, 15 Upper pilot pressure sensor bucket) Lever lock 16 Console lever lock switch
Pilot tank line Electric line
17 18 19 20 21 22
pressure, the greater the volume of regeneration. When the cylinder rod side load pressure becomes high, the check valve is closed and the cylinder bottom side return oil goes through the bucket spool without regeneration and returns to the hydraulic oil tank.
Monitor display Computer A P1 pressure sensor P2 pressure sensor Hydraulic pump Check valve
By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control valve pb7 port and switches the bucket spool to the close side. The discharge oil from hydraulic pump A2 enters the control valve P2 port and is fed from the parallel oil path to the bucket spool. Switching the spool lets the oil flow into the bucket cylinder bottom and the bucket-close operation is carried out. The bucket cylinder rod side pressurized oil is metered by the bucket spool regeneration orifice.Through this, the return oil pushes open the check valve in the spool and is regenerated on the cylinder bottom side. The lower the cylinder rod side load
84402827B EN - May 2011 8020A-61
Explanation of Hydraulic Circuit and Operations (standard model) Negative Control Circuit Negative Control Circuit
84402827B EN - May 2011 8020A-62
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line Negative control line
1
P1 negative control relief
7
2 3 4 5
P2 negative control relief Control valve Travel pilot pressure sensor Upper pilot pressure sensor
8 9 10 11
6
Computer A
Console lever lock switch
Lever lock 4 stack solenoid valve P1 pressure sensor P2 pressure sensor N2 negative control pressure sen12 sor
13 14 15 16 17
Horsepower control proportional valve P1 flow control proportional valve Hydraulic pump Check valve Oil cooler
When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from the control valve P1 and P2 ports through the center bypass oil path, and through the negative control relief valve, and returns to the hydraulic oil tank. The negative control pressure oil separated from the center bypass oil path is fed from the Ps1 and Ps2 ports to the hydraulic pump Pi1 and Pi2 ports, moves the pump tilting to the minimum flow side, and the pump discharge flow is reduced.
84402827B EN - May 2011 8020A-63
Explanation of Hydraulic Circuit and Operations (standard model) Horsepower Boost Circuits Arm-in Horsepower Boost Circuit
84402827B EN - May 2011 8020A-64
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2 3
Arm (in) Arm (out) Cushion valve
9 Arm pilot pressure sensor 10 Control valve 11 Arm (1)
4
Remote control valve (arm, swing)
12 Arm (2)
5 6 7 8
Lever lock Boost pressure relief 4 stack solenoid valve Arm cylinder
13 14 15 16
Travel pilot pressure sensor Upper pilot pressure sensor Console lever lock switch Monitor display
17 Computer A 18 P1 pressure sensor 19 P2 pressure sensor N2 negative control pressure sen20 sor 21 Hydraulic pump 22 Check valve 23 Oil cooler
For the arm-in operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve from computer A by the arm pilot pressure sensor input signal and P1 pressure sensor and P2 pressure sensor input signals. The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional valve from computer A. Condition under which the arm-in horsepower boost control is entered Arm-in pilot pressure 0.5 MPa {72.5 psi} or higher (arm-in operation) P1ďź&#x2039;P2 45 MPa {6527 psi} Conditions under which the arm-in horsepower boost control is ended Arm-in pilot pressure 0.3 MPa {43.5 psi} or lower (arm-in operation end) P1ďź&#x2039;P2 45 MPa {6527 psi} When either occurs
84402827B EN - May 2011 8020A-65
Explanation of Hydraulic Circuit and Operations (standard model) Travel Horsepower Boost Circuit
84402827B EN - May 2011 8020A-66
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2 3
Travel motor Travel remote control valve Travel high speed
9 Control valve 10 Travel (left) 11 Travel (right)
4
Lever lock
12 Travel pilot pressure sensor
5 6 7 8
4 stack solenoid valve Console lever lock switch Travel high-speed select switch Computer A
13 14 15 16
P1 pressure sensor P2 pressure sensor Console lever lock switch Monitor display
17 Computer A 18 P1 pressure sensor 19 P2 pressure sensor N2 negative control pressure sen20 sor 21 Hydraulic pump 22 Check valve 23 Oil cooler
Travel Horsepower Boost Circuit For travel single operation, the horsepower boost signal is output to the hydraulic pump horsepower control proportional valve from computer A by the travel pilot pressure sensor input signal. The hydraulic pump discharged volume is increased by the horsepower boost signal to the horsepower control proportional valve from computer A. Conditions under which the travel horsepower boost control is entered Travel pilot pressure 0.5 MPa {72.5 psi} or higher. SP mode Conditions under which the travel horsepower boost control is ended Travel pilot pressure 0.3 MPa {43.5 psi} or lower. AUTO mode, H mode
84402827B EN - May 2011 8020A-67
Explanation of Hydraulic Circuit and Operations (standard model) Other Circuits As examples, this section explains the cases when an arm-out operation is carried out, when an arm-out operation is stopped, and when an arm-out operation is followed by an arm-in operation.
Cushion circuit (arm-out operation)
84402827B EN - May 2011 8020A-68
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6
Arm (in) Arm (out) Cushion spool Orifice Check valve Cushion valve
Pilot tank line Electric line
7 8 9 10 11 12
Remote control valve (arm, swing) Lever lock 4 stack solenoid valve Control valve Arm (1) Arm (2)
13 14 15 16
Console lever lock switch Hydraulic pump Check valve Oil cooler
When a remote control valve arm-out operation is carried out, the pilot pressure oil enters from the remote control valve 2 port into the cushion valve, pushes up the internal check valve, and is fed to the control valve pa5 and pa9 ports. At the same time, the cushion valve cushion spool is switched to the left. The arm-in side oil pushed out from the control valve pb9 and pb5 ports passes from the cushion valve B port through the cushion spool switched to the left and returns to the hydraulic oil tank. At this time, the warmed oil from the return line enters the remote control valve through the cushion spool from the cushion valve R port and returns to the hydraulic oil tank, so heat performance is improved.
84402827B EN - May 2011 8020A-69
Explanation of Hydraulic Circuit and Operations (standard model) Cushion circuit (arm-out operation stopped)
84402827B EN - May 2011 8020A-70
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5
Arm (in) Arm (out) Cushion spool Orifice Cushion valve
Pilot tank line Electric line
6 7 8 9 10
Remote control valve (arm, swing) Lever lock 4 stack solenoid valve Control valve Arm (1)
11 12 13 14 15
Arm (2) Console lever lock switch Hydraulic pump Check valve Oil cooler
When the remote control valve arm-out operation is returned to neutral, the oil pushed out from the control valve pa5 and pa9 ports flows to the cushion valve D port through the cushion orifice and returns from the remote control valve to the hydraulic oil tank. Through this orifice, the arm spool moves to the neutral position without returning sharply, so the cushioning is improved.
84402827B EN - May 2011 8020A-71
Explanation of Hydraulic Circuit and Operations (standard model) Cushion circuit (arm-out â&#x2020;&#x2019; arm-in operation)
84402827B EN - May 2011 8020A-72
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5
Arm (in) Arm (out) Cushion spool Orifice Cushion valve
Pilot tank line Electric line
6 7 8 9 10
Remote control valve (arm, swing) Lever lock 4 stack solenoid valve Control valve Arm (1)
11 12 13 14 15
Arm (2) Console lever lock switch Hydraulic pump Check valve Oil cooler
When the lever is operating all at once from an arm-out operation to an arm-in operation (arm rattling operation), the pilot pressure oil is fed from the remote control valve 2 port into the cushion valve A port, pushes up the internal check valve, and reaches the control valve pb5 port and pb9 port. At the same time, the cushion valve cushion spool is switched to the right. At this time, the oil pushed out from the pa5 and pa9 ports does not pass through the cushion orifice, but passes through the cushion spool that has been switched to the right and returns to the hydraulic oil tank, so response is improved.
84402827B EN - May 2011 8020A-73
Explanation of Hydraulic Circuit and Operations (standard model) Heat circuit (lever in neutral)
84402827B EN - May 2011 8020A-74
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4
Arm (in) Arm (out) Cushion valve Remote control valve (arm, swing)
Pilot tank line Electric line
5 6 7 8
Lever lock 4 stack solenoid valve Control valve Console lever lock switch
9 Hydraulic pump 10 Check valve 11 Oil cooler
The pilot line is equipped with a heat circuit to prevent response delay at low temperatures. When the remote control valve operation lever is set to neutral, the discharge oil from hydraulic pumps A1 and A2 goes from the control valve P1 and P2 ports through the center bypass oil path, and returns to the hydraulic oil tank. The pressurized oil from the control valve T8 port is fed to the cushion valve R port and returns through the cushion spool to the hydraulic oil tank. By circulating the oil inside the cushion spool, the temperature of the oil in the cushion valve is raised to improve heat performance.
84402827B EN - May 2011 8020A-75
Explanation of Hydraulic Circuit and Operations (standard model) Auto pressure boost circuit (bucket close)
84402827B EN - May 2011 8020A-76
Explanation of Hydraulic Circuit and Operations (standard model) Pressure line Tank line Pilot pressure line 1 2 3 4 5 6 7
Cushion valve Bucket (close) Bucket (open) Remote control valve bucket) Lever lock Boost pressure relief 4 stack solenoid valve
Pilot tank line Electric line
(boom,
8 Control valve 9 Bucket 10 Bucket cylinder
15 P1 pressure sensor 16 P2 pressure sensor 17 Hydraulic pump
11 Upper pilot pressure sensor
18 Check valve
12 Console lever lock switch 13 Monitor display 14 Computer A
19 Oil cooler
When an attachment is operated, this circuit boosts the control valve main relief set pressure from 34.3 MPa to 36.8 MPa according to the engine load ratio and hydraulic load pressure, then ends the pressure boost after 8 sec. As an example, this section explains bucket-close operations. By moving the remote control valve to the bucket-close side, the pilot pressure oil is fed via the cushion valve to the control valve pb7 port and switches the bucket spool to the close side. At the same time, the output signal from the upper pilot pressure sensor that detected the pressurized oil separated from the pilot internal path is input to computer A, which judges that there is upper operation. Furthermore, computer A judges that there is a boost in the main pump P1 and P2 pressure, outputs the ON (24 V) signal to the pressure boost relief solenoid, switches the valve, and the pilot pressure oil is fed to the control valve main relief valve PH port to hold the pressure boost relief set pressure for 8 sec. There is no boost for the option circuit and during travel operation.
84402827B EN - May 2011 8020A-77
Explanation of Hydraulic Circuit and Operations (standard model)
84402827B EN - May 2011 8020A-78
Section 8020B
Explanation of Hydraulic Circuit and Operations (option)
84402827B EN - May 2011
84402827B EN - May 2011
CONTENTS Option Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Breaker circuit (independent operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
84402827B EN - May 2011 8020B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Double-acting circuit (hydraulic fork). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Multi-purpose circuit (breaker Q control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Multi-purpose circuit (2 pumps flow crusher) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2nd option circuit (hydraulic rotation fork) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Explanation of Hydraulic Circuit and Operations (option) Option Circuits Breaker circuit (independent operation)
84402827B EN - May 2011 8020B-2
Explanation of Hydraulic Circuit and Operations (option) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
Monitor display Breaker switch
1 2
Control valve Manifold
8 9
3
Relief valve
10 Option remote control valve
4 5 6 7
Breaker Travel pilot pressure sensor Upper pilot pressure sensor Computer A
11 12 13 14
Option pilot pressure switch Console lever lock switch Lever lock 4 stack solenoid valve
15 P1 pressure sensor 16 P2 pressure sensor N2 negative control pressure sen17 sor 18 P1 flow control proportional valve 19 Hydraulic pump 20 Check valve 21 Oil cooler
By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and switches the option spool. The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the option spool. Switching the spool lets the oil flow from the relief valve A port through the B port and into the breaker. The breaker set pressure is set by this relief valve. At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output signals from the computer A to adjust the discharge flow. The return oil from the breaker goes through the manifold and returns to the hydraulic oil tank. Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display with the ON signal from the breaker switch in the cab, the optimum operating flow can be selected.
84402827B EN - May 2011 8020B-3
Explanation of Hydraulic Circuit and Operations (option) Double-acting circuit (hydraulic fork)
84402827B EN - May 2011 8020B-4
Explanation of Hydraulic Circuit and Operations (option) Pressure line Tank line Pilot pressure line 1 2 3 4 5
Control valve Hydraulic fork Travel pilot pressure sensor Upper pilot pressure sensor Monitor display
Pilot tank line Electric line
6 7 8 9 10
Computer A Lever Lock 4 stack solenoid valve Console lever lock switch Hydraulic pump
11 12 13 14
Option remote control valve Option pilot pressure switch Check valve Oil cooler
As an example, this section explains the case in which the hydraulic fork attachment is used. By operating the option remote control valve to the fork close side, the pilot pressure oil is fed to the control valve pa2 port and switches the option spool to the close side. The discharge oil from hydraulic pump A1 enters the control valve P1 port, is fed from the parallel oil path to the option spool, flows into the hydraulic fork because of the option spool switching and operates to the close side. At this time, the option pilot pressure switch signal is detected and the auto idle function is released. The return oil from the hydraulic fork goes through the option spool and returns to the hydraulic oil tank.
84402827B EN - May 2011 8020B-5
Explanation of Hydraulic Circuit and Operations (option) Multi-purpose circuit (breaker Q control)
84402827B EN - May 2011 8020B-6
Explanation of Hydraulic Circuit and Operations (option) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2
Control valve 3-direction valve
8 9
3
Shut-off valve
10 Option switchover solenoid valve
4 5 6
Breaker Option remote control valve Option pilot pressure switch
7
Multi-purpose circuit switch
11 Console lever lock switch 12 Lever lock 13 4 stack solenoid valve Horsepower control proportional 14 21 Oil cooler valve
Computer A Monitor display
15 P1 pressure sensor 16 P2 pressure sensor N2 negative control pressure sen17 sor 18 P1 flow control proportional valve 19 Hydraulic pump 20 Check valve
When the switch in the cab is flipped to the breaker side, the ON signal (24 V) is output from the computer A to the option switchover solenoid valve to switch the valve. The pilot pressure oil flows from the option switchover solenoid valve B1 port to the A1 port and is fed to the 3-direction valve PP port and shut-off valve PP port and each valve is switched. Always switch the 2 pumps flow select switch to the 1 pump side. By operating the option remote control valve to the breaker side, the pilot pressure oil is fed to the control valve pa2 port and switches the option spool. The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the breaker. The breaker set pressure is set by the relief valve built into the shut-off valve. At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output signals from the computer A to adjust the discharge flow. The return oil from the breaker returns from the 3-direction valve A1 port through the T1 port and to the hydraulic oil tank. Because the breaker operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum operating flow can be selected.
84402827B EN - May 2011 8020B-7
Explanation of Hydraulic Circuit and Operations (option) Multi-purpose circuit (2 pumps flow crusher)
84402827B EN - May 2011 8020B-8
Explanation of Hydraulic Circuit and Operations (option) Pressure line Tank line Pilot pressure line
Pilot tank line Electric line
1 2
3-direction valve Shut-off valve
10 Monitor display 11 Computer A
3
Crusher
12 Multi-purpose circuit switch
4 5
Option switchover solenoid valve 2 pumps flow solenoid valve
13 2 pumps flow select switch 14 Control valve
6
Option remote control valve
15 Neutral cut valve
7 8 9
Check valve Oil cooler Option pilot pressure switch
16 Travel pilot pressure sensor 17 Upper pilot pressure sensor 18 Lever lock
19 4 stack solenoid valve 20 Console lever lock switch Horsepower control proportional 21 valve 22 P1 pressure sensor 23 P2 pressure sensor N2 negative control pressure sen24 sor 25 P1 flow control proportional valve 26 Hydraulic pump
When the 2 pumps flow select switch in the cab is flipped to the 2 pumps flow side, the ON signal (24 V) is output from the computer A to the 2 pumps flow solenoid valve to switch the valve. When the multi-purpose circuit switch is flipped to the crusher side, the crusher circuit is formed without outputting a signal from the computer A to the option switchover solenoid valve and without switching the valve. At this time, the pilot signal does not go to the 3-direction valve or to the shut-off valve and the 3-direction valve forms the A â&#x2021;&#x201D; B circuit. By operating the option remote control valve to the crusher close side, the pilot pressure oil is fed to the control valve pa2 port and switches the option spool. At the same time, the pilot pressure oil flows from the solenoid valve for 2 pumps flow B2 port to the A2 port and is fed to the control valve pcc port and the control valve neutral cut valve is switched. The discharge oil from hydraulic pump A2 enters the control valve P2 port and goes through the center bypass oil path and since the neutral cut valve has closed the port to the tank, the oil goes from the P3 port via the P4 port and merges on the upstream side of the option spool. The discharge oil from hydraulic pump A1 is fed from the control valve P1 port through the parallel oil path and fed to the option spool. Switching the spool lets the oil flow from the shut-off valve A port through the B port and into the crusher. At this time, the option pilot pressure switch signal is detected, the P1 flow control proportional valve is controlled by the output signals from the computer A to adjust the discharge flow. The return oil from the crusher returns from the 3-direction valve A port through the B port and the option spool and returns to the hydraulic oil tank. Because the crusher operating flow can be set to 5 levels on the service support screen of the monitor display, the optimum operating flow can be selected.
84402827B EN - May 2011 8020B-9
Explanation of Hydraulic Circuit and Operations (option) 2nd option circuit (hydraulic rotation fork)
84402827B EN - May 2011 8020B-10
Explanation of Hydraulic Circuit and Operations (option) Pressure line Tank line Pilot pressure line 1 2 3 4 5
Control valve Travel pilot pressure sensor Upper pilot pressure sensor Lever lock 4 stack solenoid valve
Pilot tank line Electric line
6 7 8 9 10
Console lever lock switch 2nd option remote control valve Check valve Oil cooler Hydraulic rotation fork
11 12 13 14 15
2nd option pilot pressure switch Monitor display Computer A 4th pump Hydraulic pump
As an example, this section explains the case in which the hydraulic rotation fork attachment is used. By operating the 2nd option remote control valve to the right swing side, the pilot pressure oil is fed to the control valve par1 port. The 4th hydraulic pump OUT discharge oil is fed to the control valve Pr port, goes through the 2nd option spool and flows to the hydraulic rotation fork to operate to the right swing side. At this time, the 2nd option pilot pressure switch signal is detected and the auto idle function is released. The return oil from the hydraulic rotation fork goes through the 2nd option spool and returns to the hydraulic oil tank. The oil in the 2nd option drain line returns to the hydraulic oil tank without going through the control valve.
84402827B EN - May 2011 8020B-11
Explanation of Hydraulic Circuit and Operations (option)
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84402827B EN - May 2011 8020B-12
Section 8030A
Structure and Operation Explanation of Hydraulic Pump
84402827B - May 2011
84402827B - May 2011
CONTENTS Structure and operation explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Pump Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overall view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft front side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive shaft rear side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear pump internal structure diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structure and Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8030A-1
3 4 4 4 5 6 7 7 8
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Hydraulic Pump Structure and operation explanation This pump has a structure in which 2 pumps are coupled by the 1st gear (116) and the 2 pumps can be driven at the same time through the rotation of the power source being transmitted to the drive shaft F (111) on the front side. The oil suction and discharge port are located in the connection section of the 2 pumps (specifically, the valve block (312)), and the suction port is used in common by the front pump and rear pump. Pump structure and operation principles are the same for the front and rear pumps. The front pump is explained below. The pump can be roughly divided into the rotary group, which is the main part of the pump that performs rotation, the swash plate group, which changes the discharge flow, and the valve cover group, which switches between oil suction and discharge. The rotary group is made up of the drive shaft F (111), cylinder block (141), piston shoes (151) (152), holder plate (153), spherical bushing (156), and cylinder spring (157). The drive shaft is supported at both ends with bearings (123) (124). Along with being caulked to the piston to form a spherical joint, the shoe has a pocket section for balancing the hydraulic pressure in order to reduce the thrust force generated by the load pressure and allow the shoe to slide lightly on the shoe plate (211).The piston shoe sub-group is pressed against the shoe plate by the cylinder spring via the holder plate and spherical bushing so that it can slide smoothly on the shoe plate. Also, in the same way the cylinder block is pressed against the valve plate (314) by the cylinder spring. The swash plate group comprises the swash plate (212), shoe plate (211), swash plate support board (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is supported by the swash plate support board at the cylindrically shaped section formed by the opposite side of the shoe sliding surface. By leading the hydraulic pressure force controlled by the regulator into the hydraulic pressure chambers on both sides of the servo piston, the servo piston moves left and right. This moves the swash plate on the swash plate support board via the tilting pin spherical section and changes the tilting angle (α). The valve cover group comprises the valve block (312), valve plates (313) (314), and valve plate pin (885). The valve plate, which has 2 oval-shaped ports, is installed on the valve block. Its function is to feed oil to the cylinder block and recover it from the cylinder block. The oil switched by the valve plate is connected through the valve block to the outside lines. Now when the drive shaft is driven by the power source (motor, engine, etc.), the cylinder block is also rotated at the same time via the spline coupling. When the swash plate tilts, the piston located at the center of the cylinder block moves reciprocally relative to the cylinder while turning with the cylinder block. Therefore, if just one piston is looked at, during one cylinder block rotation the piston moves away from the valve plate (oil intake stroke) for 180° and then moves toward the valve plate (oil discharge stroke) for the remaining 180°. When the swash plate tilting angle is 0°, the piston does not move through a stroke and oil is not discharged.
84402827B - May 2011 8030A-3
Structure and Operation Explanation of Hydraulic Pump Hydraulic Pump Internal Structure Diagram Overall view
Drive shaft front side
Drive shaft rear side
Drive shaft front side
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Structure and Operation Explanation of Hydraulic Pump Drive shaft rear side
84402827B - May 2011 8030A-5
Structure and Operation Explanation of Hydraulic Pump Part table a
b
Adhesion agent (ThreeBond Co., Ltd. No. 130SN) applica- c tion Oil seal outer circumference Lubricant (Sealub L101) coat- d ing
Right rotation valve plate
e
Left rotation valve plate
f
Code
Part name
Q'ty
04
Gear pump
1set
011 013 014 030
Piston subassembly Cylinder subassembly (R) Cylinder subassembly (L) Swash plate subassembly
2set 1set 1set 2set
041
Check valve 1 subassembly
2set
042
Check valve 2 subassembly
2set
079 530
Tightening torque Flange socket (4-M10 x 1.5): 33 Nâ&#x20AC;˘m Tightening torque Hexagon bolt (3-M6 x 1.0): 12 Nâ&#x20AC;˘m Component part no. (q'ty) or type ZX15LHRZ2-07AVZX15LHRZ2-07A-V 151 (9PC), 152 (9PC) 141 (1PC), 313 (1PC) 141 (1PC), 314 (1PC) 212 (1PC), 214 (1PC) 541 (1PC), 543 (1PC), 545 (1PC) 541 (1PC), 544 (1PC), 545 (1PC)
Electromagnetic proportional pressure reducing valve, cas- 1set KDRDE5KR-V3-V ing subassembly Tilting pin subassembly 2set 531 (1PC), 548 (1PC)
Code 111 113 114 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313 314 326 401 406 414 466
Part name Drive shaft (F) Drive shaft (R) 1st gear Cylinder roller bearing Needle roller bearing Bearing spacer Cylinder block Piston Shoe Holder plate Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support board Seal cover (F) Pump casing Valve block Valve plate (R) Valve plate (L) Cover Hexagon socket head bolt Hexagon socket head bolt Hexagon socket head bolt VP plug
Q'ty 1 1 1 2 2 4 2 18 18 2 2 18 2 2 2 2 1 2 1 1 1 1 8 4 4 2
Code 492 531 532 534 535 541 543 544 545 548 702 710 714 717 724 725 728 732 774 789 792 808 824 885 886 901
467
VP plug
2
953
468 490 492
VP plug Insert plug Insert plug
4 27 12
954 981 983
84402827B - May 2011 8030A-6
Part name Q'ty Insert plug 12 Tilting pin 2 2 Servo piston Stopper (L) 2 Stopper (S) 2 4 Seat 2 Stopper 1 2 Stopper 2 4 Steel ball Feedback pin 2 O-ring 2 O-ring 1 O-ring 1 O-ring 2 O-ring 16 O-ring 6 O-ring 4 O-ring 2 1 Oil seal Backup ring 2 Backup ring 2 Hexagon nut 2 Stop ring 2 Valve plate pin 2 Spring pin 4 Eyebolt 2 Hexagon socket head stop 2 screw 2 Stop screw Nameplate 1 Driving tack 2
Structure and Operation Explanation of Hydraulic Pump Gear Pump Gear pump internal structure diagram
Hydraulic circuit a b
Front case side Gear case side
Code
Part name
350
Gear case subassembly 84402827B - May 2011 8030A-7
c
To main pump
*1
(2PLACES)
Component part No. (q'ty) or type 307 (1PC), 308 (1PC), 351 1set (1PC), 353 (1PC), 354 (1PC), 361 (1PC), 887 (2PC) Q'ty
Structure and Operation Explanation of Hydraulic Pump Code 307 308 309 310 311 312 351 353 354 355 361
Part name Poppet Seat Ring Spring Adjusting screw Lock nut Gear case Drive gear Driven gear Filter Front case
Q'ty 1 1 1 1 1 1 1 1 1 1 1
Code 433 434 435 466 700 710 725 732 850 887
Part name Flange socket Flange socket Flange socket VP plug Angle ring O-ring O-ring O-ring Locking ring Pin
Q'ty 2 2 4 1 1 1 1 1 1 2
Structure and Operation Explanation Structure The casing comprises the front case (361) and gear case (351). Inside the casing the drive gear (353), driven gear (354) pair and the relief valve for setting the discharge pressure are installed. The relief valve comprises the filter (355), poppet (307), seat (308), spring (310), ring (309), adjusting screw (311), and lock nut (312). In order to prevent oil leaking to the outside, an angle ring (700) and O-ring (710) are mounted on the front case (361). Operation Oil suctioned in from suction port B3 is discharged from discharge port A3 by the drive and driven gears. The discharge oil is held at the set pressure of 3.9 MPa by the relief valve. Unnecessary discharge oil is drained from the drain port via the relief valve.
84402827B - May 2011 8030A-8
Section 8030B
Structure and Operation Explanation of Travel Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Travel motor operation explanation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Summary explanation of component parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rotary group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overload Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Brake Valve Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Motor operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Parking Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation of Variable Capacity Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overload Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Brake Valve Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
84402827B - May 2011 8030B-1
Copyright Š 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Travel Motor Travel motor operation explanation Structure
Diagram 1 Travel motor structural diagram Code 1 2 3 4 5 6 7 8 9 10
Part name Casing NPT 1/16 plug Oil seal Circle R retaining ring Expansion plug Tilting piston Tilting piston seal Steel ball Shaft Bearing
Code 22 23 24 25 26 27 28 29 30 31
Part name D-ring (small diameter) D-ring (large diameter) Rear cover NPT 1/16 plug (mec) Spool assembly Spring receiver Spring M42 plug O-ring Pilot spool 84402827B - May 2011 8030B-3
Code 43 44 45 46 47 48 49 50 51 52
Part name O-ring Check valve Check valve spring M6 orifice O-ring M6 orifice O-ring O-ring Bearing Shim
Structure and Operation Explanation of Travel Motor Code 11 12 13 14 15 16
Part name Pivot Shoe plate Cylinder block Cylinder spring Spring receiver Spherical joint
Code 32 33 34 35 36 37
Part name Pin Spring receiver Spring Pilot valve plug O-ring Joint
Code 53 54 55 56 57 58
17
Shoe retainer
38
G1/4 plug
59
18 19 20 21
Piston assembly Separator plate Friction plate Brake piston
39 40 41 42
O-ring 1B P11 Orifice (brake valve) Orifice spring (brake valve) G1/8 plug
60 61
Part name Parallel pin Valve plate Brake spring Hexagon socket head bolt Overload valve Coupling C-shaped retaining ring for hole G1/2 plug O-ring
Summary explanation of component parts The motor is made up of the following main components. • • • • •
Rotary group producing rotational force Parking brake that prevents self-travel when the machine is parked Variable mechanism section that switches the motor capacity between high and low Overload relief valve installed to the rear cover Brake valve section (counter balance valve) that plays a critical role in controlling the hydraulic circuits
Rotary group The cylinder block (13) is fit into the teeth grooves on the spline of the shaft (9), which is supported at both ends by the bearings (10), (51). This cylinder block (13) is pressed against the rear cover (24) together with the valve plate (54) by the cylinder spring (14). The nine piston assemblies (18) slide along the surface of the shoe plate (12) while moving in and out of the cylinder block (13). There are static pressure bearings at the end surface of the piston assembly (18) shoe to reduce the sliding resistance. The spring force of the cylinder spring (14) is transmitted through the spring receiver (15), spherical joint (16), and shoe retainer (17) to press the end surface of the piston assembly (18) against the shoe plate (12) so that the piston moves without separating from the surface of the shoe plate (12).
Parking Brake A separator plate (19) and friction plate (20) are fit into the spline groove around the outer edge of the cylinder block (13) in an alternating pattern and are pressed against the casing (1) by the 14 brake springs (55) via the brake piston (21).
Variable Capacity Mechanism Section This section comprises the pivot (11), which is fit into the 2 semispherical indentations on the shoe plate (12) and support the shoe plate (12), the tilting piston (6), which revolves the shoe plate (12) around the pivot (11), the tilting stopper (1-1), which supports this revolution at the determined position, the pilot valve section, which brings the pressure oil to the tilting piston (6) according to the external command, and the 3 check valves (44), which take out and send to the pilot valve section the highest of the 3 pressures among the external command pilot pressure, the motor inlet pressure, and the motor outlet pressure.
84402827B - May 2011 8030B-4
Structure and Operation Explanation of Travel Motor Overload Relief Valve This comprises the socket (57-1), which holds the valve seat (57-3) that seats metal to the motor rear cover (24) internal hole section and which screws it into the rear cover (24) to secure it, the valve (57-2), which is contacted to the valve seat (57-3) by the adjusting spring (57-9) and which is fit into the socket (57-1) internal hole, the linking piston (57-4), which is inserted into the valve internal hole and serves as the oil path to the pilot section body (57-6), the piston (57-7), which is inserted into the pilot section body (57-6) and is pressed against the lid (57-5), and the spring adjusting shims (57-8).
Diagram 2 Overload relief valve structural diagram Code 57-1 57-2 57-3 57-4 57-5
Part name Socket Valve Valve seat Linking piston Lid
Code 57-6 57-7 57-8 57-9 57-10
Part name Pilot section body Piston Shim Adjusting spring O-ring 1B P7
84402827B - May 2011 8030B-5
Code 57-11 57-12 57-13
Part name Backup ring T2 P7 O-ring 1B G25 Backup ring T2 G25
Structure and Operation Explanation of Travel Motor Brake Valve Section Spool switchover pressure: 0.59 - 0.95 MPa Check valve cracking pressure: 0.015 MPa
Diagram 3 Brake valve section *1 1. 2.
Check valve
Spool Shut-off of hydraulic motor discharge oil and orifice operation are automatically performed by switchover of this spool (26), and holding, acceleration, stop, and counter balance operations affect the hydraulic motor. Check valve (built into spool) This is the oil feed path of the hydraulic motor and provides a discharge oil locking function. Therefore, this is the hydraulic motor suction valve as well as the holding valve.
84402827B - May 2011 8030B-6
Structure and Operation Explanation of Travel Motor Function
Diagram 4 Port position Inflow port VB VA
Discharge port VA VB
Direction of rotation (view from rear cover side) Right (clockwise) Left (counter-clockwise) *1 *2
84402827B - May 2011 8030B-7
VA port VB port
Structure and Operation Explanation of Travel Motor Motor operation The high-pressurized hydraulic oil sent from the hydraulic pump flows from the inflow ports (VA and VB) passes the brake valve section, rear cover (24), and valve plate (54), and is led into the cylinder block (13). The table shows the inflow port, the discharge port, and the direction of rotation of the output shaft.
Diagram 5 As in Diagram 5 (a), this high-pressure oil operates on each piston during 180°, with the Y-Y line connecting the piston top dead center and bottom dead center as the boundary, and generates force of . F1 = P x A (P)
(P: Pressure, A: Piston area)
This force F1 becomes a thrust force F2 and radial forces F31 - F34 (or F35) due to the shoe plate (12), which has a tilting angle of α. (See Diagram 5 (b).) These radial forces operate as the rotation force of the Y-Y shaft and generate a torque of . T = r1・F31 + r2・F32 + r3・F33 + r4・F34 (When high pressure operates on 5 pistons, r5/F35 is added.) This torque is transmitted to the shaft (9) spline via the cylinder block (13) and is transmitted to the shaft (9).
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Structure and Operation Explanation of Travel Motor Parking Brake Operation The parking brake is released when the high hydraulic pressure selected by the counter balance section installed in the rear cover operates on the brake piston (21). When this pressure does not operate on the piston, brake torque is always generated. This brake torque is generated by the force of friction between the separator plate (19) coupled by the casing (1) and spline and the friction plate (20) coupled with the cylinder block (13) by the spline. When pressure is not operating on the brake piston section, the brake piston (21) is pressed by the brake spring (55) and the brake piston (21) sandwiches the friction plate (20) and separator plate (19) against the casing (1). This sandwiching force generates friction force between the friction plate (20) and the separator plate (19), serving as brake torque that constrains the cylinder block (13) as well as the shaft (9).
Diagram 6 Parking brake section
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Structure and Operation Explanation of Travel Motor Operation of Variable Capacity Mechanism Section
Diagram 7 Operation of variable capacity mechanism section
a b c
To counter balance valve (brake valve) High-speed travel command line (external pilot) Adhesion force point
Diagram 7 shows a model of the variable capacity mechanism section. When pressure overcoming the spring (34) enters the high-speed travel command line PA, the spring (34) is compressed, the spool (31) moves to the right, the P and C ports are connected, the highest of the 3 pressures (motor pressure MA, motor pressure MB, and the high-speed travel command line pressure) is selected by the check valve (44), and the tilting piston (6) is pressed. Therefore, the shoe plate (12) tilts as shown by the broken line with line L connecting the 2 pivots (11) as the axis center, and tilting stops and is held at the point where it contacts the tilting stopper (1-1). As a result, the amount of the piston (18) coming in and out is reduced and the motor capacity becomes small, so the motor rotates at high speed without increasing the amount of oil sent from the hydraulic pump. For this machine, the capacity ratio is about 1.71 times. On the other hand, when the high-speed travel command line PA pressure disappears, the spool (31) is returned to the left by the spring (34), the oil that had been pressing against the tilting piston (6) is released to the tank via the orifice (46), and the force pressing against the piston disappears. There are 9 pistons (18) distributed uniformly on the shoe plate (12), and they press against the shoe plate (12). The adhesion force point for the total force of these 9 pistons is positioned pretty much at the center of the shoe plate (12) as in the diagram, and the pivots (11) are at a position S away from the center, so a rotational force that is the product of S and the piston pressing force is generated, returning the motor to its original status and switching to low-speed travel. Also, when the engine power is exceeded, for example when steering or climbing a steep hill at high speed, in order to prevent the engine stalling, the motor is automatically switched to low-speed when the engine load exceeds the stipulated value. When the hydraulic pump pressure (VA or VB) is led to the PB port of Diagram 7, this pressure operates on the pin (32), and when the stipulated pressure is exceeded, the spool (31) is returned to the left by the reaction force of the 84402827B - May 2011 8030B-10
Structure and Operation Explanation of Travel Motor pin (32), the oil that had been pressing against the tilting piston (6) is released to the tank, and the shoe plate (12) tilts to configure the high-capacity motor, resulting in low-speed travel. When this pressure falls to the stipulated pressure, the spool (31) moves to the right, resulting in high-speed travel.
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Structure and Operation Explanation of Travel Motor Overload Relief Valve Operation There are 2 overload relief valves. They have a crossover configuration and operate as follows. 1. 2.
When the hydraulic motor is stopped, in order to prevent load inertia, the brake pressure generated on the motor discharge side is held to no greater than a certain value. In order to get sharp acceleration with driving at the stipulated set pressure when starting the hydraulic motor and to attenuate the brake shock when stopping, what is called boost attenuation operation is carried out. The pressure generated is held at low pressure for a short time and the reduction gear, travel crawler sprocket section, etc. mesh smoothly, then the circuit pressure is held at the stipulated set pressure.
When the A port pressure for the overload relief valve rises at the time the hydraulic motor starts, this pressure is applied to the effective diameter section seated to the valve seat (57-3) of the valve (57-2) and it is also applied to the linking piston (57-4) of the valve interior through the small hole in the valve (57-2). The A port pressure rises and the valve (57-2) resists the adjusting spring (57-9) with the surface area difference between the linking piston hole diameter section and the valve seat effective diameter section and the stipulated set pressure is set. When the hydraulic motor brakes, the piston (57-7) in the rear section is on the left side due to the drive pressure, and when the A port pressure rises, it is also applied to the piston (57-7) through the small hole in the valve and the small hole in the linking piston (57-4), moving the piston to the right until it contacts the lid (57-5). During this time, the valve (57-2) resists the adjusting spring (57-9) and holds the A port pressure comparatively low and releases oil to the B port. After the piston (57-7) contacts the lid (57-5), operation is the same as when the motor starts.
Diagram 8 Operation of overload relief valve a b c
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From the A port To the B port Small hole
Structure and Operation Explanation of Travel Motor Brake Valve Operation 1.
Hold status (See Diagram 9.) In the switchover valve neutral state, the VA and VB ports are connected to the tank and the spool (26) is held in a central position by springs at both ends. Because the paths from the VA port to the MA port and from the VB port to the MB port are closed, the MA and MB ports connecting to both sides of the hydraulic motor are both blocked. Also, because the parking brake release path is connected to the tank, the parking brake is operating and rotation of the hydraulic motor is mechanically stopped by the brake spring force. If an external force is acting on the hydraulic motor, normally the rotation of the motor is stopped by the parking brake. When a torque larger than the parking brake force is generated, the parking brake slips, but hold pressure is generated on the MA port or MB port side, and the hold pressure holds the motor to minor rotation. When the hydraulic motor has minor rotation, high-pressure oil escapes from the closed circuit and cavitation can occur on the low-pressure side of the closed circuit. The check valve built into the spool operates in order to prevent this cavitation, a VA â&#x2020;&#x2019; MA or VB â&#x2020;&#x2019; MB path is formed, and an oil volume equal to the leaked volume is filled into the closed circuit from the tank.
Diagram 9 Hold status 1
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Spring
Structure and Operation Explanation of Travel Motor 2.
When accelerating (See Diagram 10.) When the VA port is connected to the hydraulic pump and the VB port is connected to the tank as a result of the switchover of the switchover valve, pressure oil from the hydraulic pump pushes up the check valve inside the spool from the VA port, is fed to the hydraulic motor via the MA port, aiming to rotate the hydraulic motor. The pressure oil is fed to the pilot chamber on the VA port side, overcoming the spring pressure of the VB port side and moving the spool (26) to the left. When this happens, a return path from the MB port to the VB port is formed, pressure oil is fed to the parking brake release line, and the parking brake is released. This causes the hydraulic motor to rotate. If the inertial load of the hydraulic motor is large, the pressure required for acceleration will reach the overload relief valve set pressure, and the rotation speed will increase as the hydraulic motor relieves the pressure oil. As the rotation of the hydraulic motor increases, the relief volume decreases and a constant speed is finally reached.
Diagram 10 When accelerating 1 2 84402827B - May 2011 8030B-14
Spring Pilot chamber
Structure and Operation Explanation of Travel Motor 3.
When stopping (See Diagram 11.) When the switchover valve returns to the neutral position during hydraulic motor rotation, the feed oil is cut off, and the VA and VB ports connect to the tank, the pressure in the pilot chamber of both ends of the spool becomes equal and the spool (26) is returned to the neutral position by the spring force. As a result the path from the MB port to the VB port is closed. However, because the hydraulic motor tries to continue to rotate by the inertial force of the load, the hydraulic motor causes pump operation and continually discharges hydraulic oil to the MB port. Because the path is cut off, the pressure rises, the overload relief valve operates, and the hydraulic motor gradually decelerates and finally comes to a stop. Also, because the parking brake release pressure is narrowed, the pressure slowly decreases, the brake finally operates, and rotation of the hydraulic motor is mechanically stopped.
Diagram 11 When stopping 1 2
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Spring Pilot chamber
Structure and Operation Explanation of Travel Motor 4.
When the counter balance is operating (Diagram 12) When the rotating hydraulic motor decelerates by the load inertia, the counter balance must be operated. As the hydraulic oil that is currently fed from the hydraulic pump to the VB port is gradually reduced, the hydraulic motor tries to rotate in excess of the feed flow due to inertia. As a result, the pressure in the pilot chamber on the VB port side is reduced and the spool (26) is pressed to the left side by the spring (28) and moved to the neutral position. Consequently, the area of the path from the MA port to the VA port decreases and path resistance increases, causing a rise in the pressure on the MA port side and the brake to operate for the hydraulic motor. When the rotation speed is decreased to or below the rotation speed equivalent to the oil feed volume, the pressure in the pilot chamber on the VB port side rises, the spool (26) moves to the right, and the area of the path from the MA port to the VA port increases, thereby decreasing the braking operation and controlling the rotation speed of the hydraulic motor to the rotation speed equivalent to the oil feed volume. To ensure stable counter balance operation, orifices (40) that provide a damping effect on the spool (26) are installed in the pilot chambers on both ends. The parking brake is released during pressure adjustment of the spool (26).
Diagram 12 When the counter balance is operating
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Structure and Operation Explanation of Travel Motor 1 2 3
Spring Pilot chamber Check valve with orifice
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Structure and Operation Explanation of Travel Motor
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Section 8030C
Structure and Operation Explanation of Swing Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Swing Motor Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Motor Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Casing Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relief Valve Operation Explanation (relief valve model: KRD22EK10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Motor Internal Structure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8030C-1
3 3 4 4 5 8
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Swing Motor Swing Motor Operation Explanation Hydraulic Motor Section As the diagram below shows, when the high-pressure oil passes through the valve plate (1) inlet-side port (a) and flows into the cylinder, the hydraulic pressure operates on the piston (5) and a force F is generated in the axial direction. This force F is divided into 2 vectors, a force F1 perpendicular to the swash plate (3) via the shoe (2) and a force F2 perpendicular to the shaft. This force F2 is transmitted to the cylinder block (4) via the piston (5), generating a rotational couple around the output shaft. 9 pistons (5) are arrayed in the cylinder block. Rotation torque is transmitted sequentially to the output shaft (6) by multiple pistons (5) linked with the high-pressure oil inlet-side port. When the oil in and out directions are reversed, the rotation of the output shaft (6) also reverses. The theoretical output torque T [N¡m] is given by the following equation.
Diagram 1 Motor section operation explanation diagram q p *1 *2
Low-pressure oil High-pressure oil
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*3 *4
Compartments per rotation [cm3] Effective pressure difference [MPa] Outlet Inlet
Structure and Operation Explanation of Swing Motor Valve Casing Section 1.
Anti-cavitation check section Because the system using this type of motor does not have a valve with a counter-balance function, the motor sometimes rotates more than the quantity of oil fed. In order to prevent cavitation due to insufficient oil, there is a check valve to take in the oil shortfall.
Diagram 2 Hydraulic circuit diagram 1 2
M port Control valve
Brake Section The cylinder (111) is coupled with the drive shaft (101) by the gear. Also, the separator plate (743) is constrained for circumferential rotation by the arc groove cut into the casing (301). When the friction plate (742) that is gear coupled to the cylinder outer circumference section is pressed to the casing (301) by the brake spring (712) via the separator plate (743) and the brake piston (702), friction force is generated between the friction plate and casing and between the separator plate and the brake piston. The drive shaft is constrained and braked by this friction force. On the other hand, when brake release pressure is applied to the oil chamber (1) formed between the brake piston and the casing and the hydraulic pressure (3) wins out over the spring force (2), the brake piston moves, the force pressing the friction plate against the casing disappears, and the brake is released.
84402827B - May 2011 8030C-4
Structure and Operation Explanation of Swing Motor
Diagram 3 Brake operation diagram
Relief Valve Operation Explanation (relief valve model: KRD22EK10) 1.
Operation explanation for when the relief valve is pressurized In the case where the P port is pressurized with the tank pressure,the P and R ports are initially at the tank pressure and the valve status is as shown in Diagram 4 (1). At the pressure where there is balance between the hydraulic pressure determined by the product of the pressure P and the pressurized area A1 of the plunger (301) on the one hand and the hydraulic pressure determined by the product of the spring (321) load FSP and plunger (301) pressurized area A2 and the g chamber pressure Pg on the other, the relief valve starts to operate. After that, the g chamber pressure rises and the piston (302) starts its stroke. Accompanying this movement, the load on the spring (321) increases. Through the operation above, the relief pressure P is increased from P1 to Ps in the pressure boost time t1. This process is explained below in terms of the relationship between the movement state of the parts in diagrams 4-(2) - (4) and the relief pressure. 1)
2)
State shown in Diagram 4-(2) When the relief valve P port is pressurized, pressure is generated in the g chamber via the orifice m in the plunger (301). When the hydraulic pressure operating on the plunger (301) increases and reaches the pressure at which it balances the spring (321) load FSP, the relief valve carries out the relief operation at pressure P1. The relationship at this time is expressed by the following equation. P1 x A1 = FSP1 + Pg1 x A2 FSP1: Initial set load for the spring (321) State shown in Diagram 4-(3) The g chamber pressure operates on pressurized areas A3 and A4 of the piston (302). When this hydraulic pressure becomes larger than the load on the spring (321), the piston starts to move to the left. At this time, the oil in the h chamber formed between the piston and the adjusting plug (401) is discharged into the g chamber via the orifice n set up on the piston (302) while the piston moves to the left, so the h chamber functions as a damping chamber. Through this, the spring load gradually increases until the piston reaches the adjusting plug end section and the relief pressure P rises smoothly.
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Structure and Operation Explanation of Swing Motor 3)
2.
State shown in Diagram 4-(4) When the piston (302) reaches the adjusting plug (401) end section, it does not move farther to the left, so the constant relief state is reached and the relief pressure is held at P2. Through the processes (1) - (4) above, the relief pressure varies as in Diagram 5.
Operation explanation for when the relief valve is depressurized In the case where the P port pressure falls,the P port pressure and the g chamber pressure fall together to the tank pressure when the pressurization of the P port ends. Through this process, the plunger (301) which was open moves to the left and is placed in the seat (401). At the same time, the piston (302) also is moved to the right by the spring (321) and returns to the state in Diagram 4-(1).
Diagram 4 Relief valve operation explanation diagram a b
Orifice m h chamber
c d
A1 pressurized area Orifice n
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e
g chamber
Structure and Operation Explanation of Swing Motor
Diagram 5 Pressure boost characteristics
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Structure and Operation Explanation of Swing Motor Swing Motor Internal Structure Diagram
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Structure and Operation Explanation of Swing Motor
Brake spring layout diagram
84402827B - May 2011 8030C-9
Structure and Operation Explanation of Swing Motor Code Part name Reverse prevention 052 valve subassembly 100 Casing 151 ROH plug 161 O-ring 162 O-ring
Q'ty
Code Part name
Q'ty
Code Part name
Q'ty
1 set
121
Piston
9
469
ROMH plug
2
1 2 2 2
122 123 124 131
472 488 491 702
O-ring O-ring Oil seal Brake piston
1 2 1 1
163
2
20
9 Shoe Holder plate 1 1 Shoe plate Valve plate B 1 Valve casing H2 sub1 set assembly
706
O-ring
1
4
301
Casing JA1
1
707
O-ring
1
2 sets 303
Valve casing H2
1
712
Brake spring
18
2 2 2 sets 2
351 355 390 391
Plunger H2 Spring H2 Nameplate Driving tack Hexagon socket head bolt Cylinder roller bearing Cylinder roller bearing Pin
2 2 1 2
742 743 984 985
Friction plate Separator plate Masking plug Masking plug
2 4 1 set 1 set
4
986
Masking plug
1 set
1 1 2
994
Insert plug
1
O-ring
Hexagon socket head bolt Reverse prevention 400 valve 400-1 O-ring 400-2 Backup ring 051 Relief valve 051-1 O-ring 171
10
Piston subassembly
1 set
401
101 111 114
Drive shaft Cylinder Plate spring
1 1 1
443 444 451
a
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ID mark
Section 8030D
Structure and Operation Explanation of Control Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Structure and Operation Explanation of Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 8030D-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Control Valve Structure and Operation Explanation of Control Valve Basic configuration This valve is based on the main unit housing which combines the P1 side housing and P2 side housing with the rear surfaces against each other and has a configuration that makes it possible to mount the inlet, add-on section, and outlet on the P2 side housing top.
Operation 1.
When all spools in neutral 1)
Neutral path [Fig. 1, Fig. 2] 1)
2)
When Pn1 and Pn2 ports are pressurized The oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) through the lowpressure relief orifice (Lc1) and returns to ports T1 - T8. The oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) through the lowpressure relief orifice (Rc1) and returns to the T1 - T8 ports. The pressure in the pressure chambers (L2) and (R2) upstream from the low-pressure relief valve is led into the pump from the ps1 and ps2 ports and controls the P1 and P2 pump discharge volume. Also, if excess oil flows into the neutral path (L1), the poppet opens to provide low-pressure relief. This prevents the ps1 and ps2 port pressures from becoming abnormally high. When Pn1 and Pn2 ports are not pressurized In this case, the low-pressure relief poppets open at lower pressure than in (a). Therefore, the oil fed from the P1 port enters the tank path (Ta) from the neutral path (L1) primarily through the low-pressure relief valve discharge port (L3) and returns to the T1 - T8 ports. Also, the oil fed from the P2 port enters the tank path (Ta) from the neutral path (R1) primarily through the low-pressure relief valve discharge port (R3) and returns to the T1 - T8 ports.
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Structure and Operation Explanation of Control Valve
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Structure and Operation Explanation of Control Valve
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Structure and Operation Explanation of Control Valve 1 2 3 4 5
Low-pressure relief valve (L) Arm 1 Boom 2 Swing Option
6 7 8 9 10
Travel Outlet Attachment 2 Inlet Attachment 1
11 12 13 14 15
Arm 2 Boom 1 Bucket Straight travel Low-pressure relief valve (R)
a b c d e
(Section (Section (Section (Section (Section
f g h i j
P1 side (Section (Section (Section (Section
k l m n
(Section 7) (Section 6) (Section ST) P2 side
5) 4) 3) 2) 1)
R2 ) R1) 9) 8)
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Structure and Operation Explanation of Control Valve
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Structure and Operation Explanation of Control Valve
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Structure and Operation Explanation of Control Valve
2 3 4 5
Variable arm regeneration ori6 fice 7 Arm 1 Boom 2 8 Swing 9 10 Option
a b c d e f g h i
Open Close (Section Up Down (Section (Section (Section (Section
1
5)
4) 3) 2) 1)
j k l m n o p q r
Travel
11
Boom 1
Attachment 2 Attachment 1 Neutral cut Arm 2
12 13 14
Bucket Travel Straight travel
(Section R2 ) (Cylinder extension) (Cylinder retraction) Down Up (Section R1) Close Open (Section 9)
s t u v w x y z
Down Up (Section Close Open (Section (Section (Section
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8)
7) 6) ST)
Structure and Operation Explanation of Control Valve 2)
Signal, straight travel signal control valve, plate assembly [Fig. 3] There are 2 signals, (a) and (b) below. The pilot signal for each spool for which a lever is operated is used to generate the pressure that is output. The straight travel signal control valve integrates each signal pressure and controls straight travel spool switchover. Also, the plate assembly has a function for picking up the pilot pressures with the built-in shuttle. 1)
2)
Travel signal (PT) The highest of the pilot pressures applied to the travel section 1 (pa1, pb1) and travel section 6 (pa6, pb6) is selected and output to the PT port. Therefore, when the travel spool is in the neutral position (no-load pilot pressure), no pressure is generated at the PT port. Front signal (PA) The highest of the pilot pressures (pa2 - 9 and pb2 - 9) applied to sections 2 - 9 that use the pressurized oil from the P1 and P2 pumps, except for the travel sections, is selected and output to the PA port. (Note 1) Therefore, when all the spools are in the neutral position (no-load pilot pressure), no pressure is generated at the PA port.
<Note 1> When an add-on (main pump add-on) is used through the feed from P2, the branches for the add-on pilot signals par1 and pbr1 are connected to the respective main unit valves, prs1 and prs2 ports, and thus incorporated in the front signal PA selection area. Be careful. If the above line connection is not done, the PA pressure will not rise through add-on selection. Also, when using 2 main pump add-ons, set the circuit so that the maximum of the add-on pilot pressures (par1 and 2, pbr1 and 2) can be taken out as desired and connect to either prs1 or prs2.
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Structure and Operation Explanation of Control Valve
4
Straight travel signal control valve Travel Main unit housing section (option) Plate assembly
a b
RCV Remote control valve MCV
1 2 3
5
Boom
9
Option
6
Arm
10
Add-on (main pump)
7
Bucket
8
Swing
c d
RCV Remote control valve MCV
e f
RCV Remote control valve MCV
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Structure and Operation Explanation of Control Valve 2.
Independent operation 1)
Travel spool switchover [Fig. 4 and Fig. 5] When a travel spool is switched by pressurizing from the travel (section 1) pilot port Pb1 (Pa1), the oil fed from the P1 port flows from the neutral path (L1) through the spool neck section and into the B1 (A1) port. The return oil returns to the tank path (Ta) from the A1 (B1) port through the spool neck section. When a travel spool is switched by pressurizing from the travel (section 6) pilot port Pb6 (Pa6), the oil fed from the P2 port flows from the neutral path (R1) through the spool neck section or path (S6-1) and into the B6 (A6) port. For independent travel operation, the parallel path (R3) and the path (S6-1) have the same pressure, so the poppet (S6-2) does not open. The return oil returns to the tank path (Ta) from the A6 (B6) port through the spool neck section.
1 2
Switching state Neutral state
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3 4
Option Travel
a b
(Section 2) (Section 6)
Structure and Operation Explanation of Control Valve
1 2
Switching state Neutral state
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3 4
Travel Straight travel
a b
(Section 1) (Section ST)
Structure and Operation Explanation of Control Valve 2)
Option spool switchover [Fig. 4] When the option spool is switched by pressurizing from the option (section 2) pilot port Pb2 (Pa2), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load check valve (S2-2), path (S2-1), and the spool neck section, and into the B2 (A2) port. The return oil returns to the tank path (Ta) from the A2 (B2) through the spool neck section. Also, when oil is fed from the P4 port, it passes through the inside of the load check valve (S2-2) and merges with path (S2-1).
1 2
Switching state Neutral state
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3 4
Option Travel
a b
(Section 2) (Section 6)
Structure and Operation Explanation of Control Valve
1 2
Switching state Neutral state
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3 4
Travel Straight travel
a b
(Section 1) (Section ST)
Structure and Operation Explanation of Control Valve 3)
Swing spool switchover [Fig. 6] When the swing spool is switched by pressurizing from the swing (section 3) pilot port Pb3 (Pa3), the neutral path (L1) is closed. The oil fed from the P1 port flows from the parallel path (L3) through the load check valve (S3-2), path (S3-1), and the spool neck section, and into the B3 (A3) port. The return oil returns to the tank path (Ta) from the A3 (B3) through the spool neck section.
1 2
Switching state Neutral state
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3 4
Swing Bucket
a b
(Section 3) (Section 7)
Structure and Operation Explanation of Control Valve 4)
Bucket spool switchover [Fig. 7 and Fig. 8] 1)
Close (regeneration) [Fig. 7] When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pb7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load check valve (S7-2), path (S7-1), and the spool neck section, and into the B7 port. At the same time, the return oil from the A7 port returns to the tank path (Ta). After part of the return oil pushes open the poppet (S7-3) inside the bucket spool, it merges into the B7 port to prevent cylinder head side cavitation. Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the port pressure conditions.
Bucket close (regeneration) 1 2
Neutral state Switching state
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3 4
Swing Bucket
a b
(Section 3) (Section 7)
Structure and Operation Explanation of Control Valve 2)
Open [Fig. 8] When the bucket spool is switched by pressurizing from the bucket (section 7) pilot port Pa7, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load check valve (S7-2), path (S7-1), and the spool neck section, and into the A7 port. The return oil returns to the tank path (Ta) from the B7 port through the spool neck section.
Bucket open 1 2
Neutral state Switching state
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3 4
Swing Bucket
a b
(Section 3) (Section 7)
Structure and Operation Explanation of Control Valve 5)
Boom spool switchover [Fig. 9, Fig. 10, and Fig. 11] 1)
Neutral [Fig. 9] This valve mounts an anti-drift valve on the boom 1 cylinder head (A8) side. In neutral, the poppet (AD1) is reliably seated by the pressure of the A8 port itself led through path (AD2) and the spool (AD3) into the spring chamber (AD4) to cut off the return oil from the A8 port.
Neutral
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1 2
Boom 2 Boom 1
a b
(Section 4) (Section 8)
Structure and Operation Explanation of Control Valve 2)
Boom up (2 pumps flow) [Fig. 10] When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port Pa8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load check valve (S8-2), and the spool neck section and into the A8 port. When the boom 2 spool is switched by pressurizing from the boom 2 (section 4) pilot port Pa4, the neutral path (L1) is closed. The oil fed from the P1 port flows through the parallel path (L3), the load check valve (S4-2), the spool neck section, and path (4) and merges into the A8 port. The return oil returns to the tank path (Ta) from the B8 port through the spool neck section.
Up (2 pumps flow)
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1 2
Boom 2 Boom 1
a b
(Section 4) (Section 8)
Structure and Operation Explanation of Control Valve 3)
Boom down (regeneration) [Fig. 11] When the boom 1 spool is switched by pressurizing from the boom 1 (section 8) pilot port pb8, the neutral path (R1) is closed. The oil fed from the P2 port flows through the parallel path (R3), the load check valve (S8-2), and the spool neck section and into the B8 port. The pilot pressure applied to pb8 at this time moves the anti-drift valve spool (AD3) through the path built into the housing at the same time that the spool is switched and reduces the pressure of the spring chamber (AD4) to open the poppet (AD1). Through this movement, the cutoff of the A8 port is released before the spool is switched. After that, the return oil from the A8 port returns to the tank path (Ta). Part of the return oil pushes open the poppet (S8-3) inside the boom 1 spool, passes through path (S8-1), and merges into the B8 port to prevent cylinder rod side cavitation. Cylinder speed increase and P2 port pressure reduction effects also accompany depending on the port pressure conditions.
Down (regeneration)
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1 2
Boom 2 Boom 1
a b
(Section 4) (Section 8)
Structure and Operation Explanation of Control Valve 6)
Arm spool switchover [Fig. 12 - 15] 1)
Neutral [Fig.12] This valve mounts an anti-drift valve on the arm 1 cylinder rod side. In neutral, the poppet (AD1) is led through path (AD2) and the spool (AD3) into the spring chamber (AD4). It is reliably seated by the pressure of the A5 port itself to cut off the return oil from the A5 port.
Neutral
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1 2
Arm 1 Arm 2
a b
(Section 5) (Section 9)
Structure and Operation Explanation of Control Valve 2)
Arm in (2 pumps flow) [Fig. 13] When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pb5, the oil fed from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1), and the spool neck section and into the B5 port. When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pb9, the oil fed from the P2 port flows from the neutral path (R1) through the load check valve (S9-2), path (S9-1), the spool neck section, and path (6) and merges into the B5 port. The pilot pressure applied to pb5 at this time moves the anti-drift valve spool (AD3) through the path built into the housing at the same time that the spool is switched and reduces the pressure of the spring chamber (AD4) to open the poppet (AD1). Through this movement, the cutoff of the A5 port is released before the spool is switched. After that, the return oil from the A5 port splits into the flow through the regeneration check in the spool that is regenerated at the B5 port and the flow returning to the tank path (Ta) through the regeneration control valve. (For details on the regeneration function, see the regeneration valve operation explanation in next section 3).)
Arm in (2 pumps flow)
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1 2
Arm 1 Arm 2
a b
(Section 5) (Section 9)
Structure and Operation Explanation of Control Valve 3)
Arm in (variable regeneration) [Fig. 14] For an arm-in operation, after the return oil from the A5 port passes through the notch (a), it divides into 2 paths: 1. The return oil returns to the tank path (Ta) through the fixed orifice (d) in the regeneration control valve, path (e), and the variable orifice (f). 2. The return oil passes through the fixed orifice (b) in the arm 1 spool, the regeneration check (c), and the fixed orifice (i), then merges into the bridge path (S5-1). Here, when the bridge path (S5-1) pressure goes higher due to the port B5 load pressure, the regeneration control valve spool (h) is pressed through the regeneration control valve piston (g), and the variable orifice (f) section opening surface area increases, so the quantity of oil returning to the tank path (Ta) increases. On the other hand, the quantity of oil regenerated in the B5 port decreases. Though this variable mechanism, both the regeneration ratio for low loads is secured and reduction in the return back pressure for high loads is established.
Arm in (variable regeneration)
2
Regeneration (variable) Arm 1
a
(Section 5)
1
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control
valve
Structure and Operation Explanation of Control Valve 4)
Arm out (2 pumps flow) [Fig. 15] When the arm 1 spool is switched by pressurizing from the arm 1 (section 5) pilot port Pa5, the oil fed from the P1 port flows from the neutral path (L1) through the load check valve (S5-2), path (S5-1), and the spool neck section and into the A5 port. When the arm 2 spool is switched by pressurizing from the arm 2 (section 9) pilot port Pa9, the oil fed from the P2 port flows from the neutral path (R1) through the load check valve (S9-2) and path (S9-1), merges into the arm 1 section path (S5-1) and heads toward the A5 port through the arm 1 spool neck section. The return oil from the B5 port returns to the tank path (Ta) through the spool neck section.
Arm out (2 pumps flow)
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1 2
Arm 1 Arm 2
a b
(Section 5) (Section 9)
Structure and Operation Explanation of Control Valve 7)
Arm parallel orifice [Fig. 16] Metering by the spool is installed in the arm 1 parallel path of this valve to control the quantity of oil fed to arm 1 for compound operations. The oil fed from the arm 1 (Section 5) parallel path (L3) pushes open the poppet (S5-3) and passes through the variable metering spool orifice (Lc8), then is connected to path (L5). Here, the quantity metered by the orifice (Lc8) is adjusted by pressurizing the pilot port (Pbu).
1
Low-pressure relief valve (L)
3
2
Pbu signal path
4
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For boom up (for Pbu pressurization) For neutral
Structure and Operation Explanation of Control Valve 8)
Relief valve 1)
Main relief valve [Fig. 17] The oil fed from the P1 port passes through the poppet (LP) and the oil fed from the P2 port passes through the poppet (RP) and path (3) and is led to the main relief valve. The maximum pressure of the P1 and P2 side pumps is controlled by the operation of the main relief valve.
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Structure and Operation Explanation of Control Valve 2)
Overload relief valve [Fig. 18] There is an overload relief valve at the boom 1, arm 1, bucket, and add-on cylinder ports to prevent any abnormal rise in actuator pressure, for example due to an external force. This relief valve is also equipped with a function for preventing cavitation (suction function) by taking in oil from the tank when the cylinder port pressure becomes negative pressure.
a
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Suction function Operating
Structure and Operation Explanation of Control Valve 3.
Compound operation 1)
Travel compound operation [Fig. 19, Fig. 20] Under the conditions below when the travel left/right and the front system are operated at the same time, the straight travel spool is switched, and the straight travel characteristic is maintained. 1 When the front is operated during travel left/right simultaneous operation (forward, backward, or pivot turn) 2 When the left/right are operated simultaneously during front system operation Front system operation is not affected by the switchover section or quantity of switchovers. 1)
Signal circuit [Fig. 19] (A) When the [Travel 1] side lever is operated, the pressure branched off from the valve main unit pilot port passes through the filter and the shuttle, then switches the switchover valve [V1]. (B) When the [Travel 2] side lever is operated, the pressure branched off from the valve main unit pilot port passes through the filter and the shuttle, then if the switchover valve [V1] is switched, it switches the switchover valve [V2] through the path. On the other hand, if the switchover valve [V1] is in the neutral state, the path is cut off by the switchover valve [V1]. Therefore, if both (A) and (B) are established at the same time, the straight travel spool internal path (Pst) is connected to PA. Also, if either (A) or (B) are established, the travel signal (PT) pressure rises. (C) If at least one of the front systems is switched, the highest pressure of all the pilot pressures in the front system is selected and is connected to the front signal port (PA). Therefore, if (A), (B), and (C) are established at the same time, the straight travel spool switchover quantity is determined proportional to the front signal (PA) pressure through the internal straight travel signal path (Pst). [Fig. 19] shows the example of a case of travel left/right forward + boom up.
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Structure and Operation Explanation of Control Valve
2
Straight travel signal control 5 valve Travel 1 6
3
Travel 2
7
Bucket
4
Plate assembly
8
Swing
a b c
Advance Reverse Up
d e f
Down Close Open
1
Boom
9
Option
Arm
10 11
Add-on (main pump) Main unit housing section (option)
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g h
Right Left
Structure and Operation Explanation of Control Valve 2)
Main unit circuit [Fig. 20] When the straight travel spool is switched, the oil fed from the P1 port flows from the neutral path (L1) to travel (section 1) and at the same time passes through path (2), the straight travel spool neck section, and the neutral path (R1) and into travel (section 6) and feeding to travel left and right becomes possible. On the other hand, when the oil fed from the P2 port flows to the parallel path (R3), at the same time it passes through the straight travel spool neck section and path (1) and into the parallel path (L3), so it becomes possible to feed oil to the entire front system. When the front system is switched during travel and that pressure becomes higher than the load pressure on travel (section 6), part of the oil fed from the P2 port pushes up the poppet (S6-2) from the parallel path (R3) and the oil flows through the orifice at the poppet tip and merges into path (S6-1). This softens the shock on the machine body of the sharp drop in speed caused by the switchover to 1 pump travel. As described above, because travel (sections 1 and 6) operates with the oil fed from the P1 port and operations other than travel are operated with oil fed from the P2 port, travel curving is prevented and straight travel characteristics are maintained during compound operations.
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Structure and Operation Explanation of Control Valve 1 2
4.
Switching state Travel
3 4
Straight travel Travel
a b c
(Section 1) (Section 6) (Section ST)
Anti-drift valve The anti-drift valve is mounted on the arm rod (boom head) side cylinder port to prevent the arm (boom) cylinder from dropping naturally. Also, the release signal operates led by the internal path from the pilot signal. (The arm side (A5) is shown as a typical example.) 1)
Neutral (A5 port hold) 1) 2)
The A5 port hold pressure passes from path (a) through path (b), through path (c), and is connected to the poppet (1) spring chamber (d). Therefore, the A5 port pressurized oil is cut off by the seat section (S1) and the seat section (S2).
1
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Main spool
Structure and Operation Explanation of Control Valve 2)
Release signal application 1) 2) 3)
When the pi port is pressurized, the piston (2) moves and the spool (3) operates. Furthermore, the spool (3) operates the poppet (4). Then, the operation of the poppet (4) cuts off the connection between the A5 port and the spring chamber (d).
1 3)
Main spool
Ending hold state 1) 2)
When the piston (2) operates further, the spring chamber (d) passes from path (c) through path (e) and is connected to the drain chamber [DR] through the (T2) section. The spring chamber (d) pressure becomes the drain pressure and the main poppet (1) operates.
1
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Main spool
Structure and Operation Explanation of Control Valve 5.
Relief valve 1)
Main relief valve operation 1)
This relief valve is incorporated between the neutral path "HP" and the low-pressure path "LP". The oil passes through the metering hole of the main poppet (C) and charges the interior space (D). Also, the sleeve (E) and the main poppet (C) seat securely operating on the different surface areas [A] and [B].
2)
When the neutral path "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (F) opens. The oil flows around the poppet, passes through the notch hole (G), and is led to the lowpressure path "LP".
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Structure and Operation Explanation of Control Valve 3)
Because the pilot poppet has opened, the (D) pressure drops and the main poppet (C) opens, so the oil flows directly into the path "LP".
"Boosted pressure operation" When pressure is applied to the pilot port "PH", the piston (H) is moved to the set position by the plug (I). Because of this, the pilot spring force rises and the "HP" pressure rises.
2)
Overload relief valve operation 1)
This relief valve is incorporated between the cylinder port "HP" and the low-pressure path "LP". The oil passes through the metering hole of the piston (C) and charges the interior space (G). The sleeve (K) and the main poppet (D) seat securely operating on the different surface areas [A] and [B].
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Structure and Operation Explanation of Control Valve 2)
When the cylinder port "HP" pressure reaches the set pilot poppet spring force, the pilot poppet (E) opens. The oil flows around the poppet, passes through the notch hole (H), and is led to the lowpressure path "LP".
3)
Because the pilot poppet (E) has opened, oil flow is generated through the orifice (I) of the piston (C), a pressure difference is generated between the path "HP" and the rear side of the piston (C), and the piston (C) moves and seats with the poppet (E).
4)
The flow of oil from the path "HP" to the rear side of the poppet (D) is only through the ring-shaped gap between the poppet (D) and the piston (C) and through the orifice (F), so the pressure difference increases. Because of this, the poppet (D) opens and the oil flows directly into the path "LP".
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Structure and Operation Explanation of Control Valve 3)
Overload relief valve intake operation 1)
6.
This relief valve has a built-in anti-void unit that supplies oil if cavitation occurs at the cylinder port "HP". When the cylinder port "HP" pressure is lower than the low-pressure side "LP", the sleeve (K) is opened by the surface area difference between (A) and (B). Oil enters the cylinder port "HP" from the low-pressure side "LP" to prevent cavitation.
Neutral cut spool [Fig. 21] This valve is equipped as standard with a neutral cut spool in the P2 side housing neutral path (R1) minimum flow (low-pressure relief valve upstream). When the pcc port is pressurized and the neutral cut spool is switched, the path through the orifice [Lc7] to low-pressure relief is cut off and output to the outside from the P3 port becomes possible.
1
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Low-pressure relief valve (R)
Structure and Operation Explanation of Control Valve 7.
Plate assembly [Fig. 22] This valve is equipped with a plate assembly hermetically sealed with a gasket piling a plate on the housing side surface. The shuttle is built into the inside and this valve has a function for selecting and controlling the spool pilot pressure. Also, in order to protect the shuttle section from contamination from the outside, a filter is mounted between the plates. When removing, do not loosen the screws shown in the diagrams and be careful that internal parts are not dispersed.
[Short cap side]
[Long cap side] 1
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Subassembly screw
Structure and Operation Explanation of Control Valve 8.
Straight travel signal control valve [Fig. 19, Fig. 23] This valve integrates the pilot pressure for the spool of the front system and travel selected with each plate assembly and is used to switch the straight travel spool. When the Travel 1 pilot pressure is pressurized, the spool [V1] is switched. When the Travel 2 pilot pressure is pressurized at the same time, the spool [V2] can be switched. Here, when the front system pilot pressure [PA] is pressurized, the PA pressure flows into Pst and is led to the straight travel spool pilot chamber and the spool is switched.
a b
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Travel 2 Travel 1
Structure and Operation Explanation of Control Valve
2
Straight travel signal control 5 valve Travel 1 6
3
Travel 2
7
Bucket
4
Plate assembly
8
Swing
a b c
Advance Reverse Up
d e f
Close Open Right
1
Boom
9
Option
Arm
10 11
Add-on (main pump) Main unit housing section (option)
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g
Left
Structure and Operation Explanation of Control Valve 9.
Add-on [Fig. 24, Fig. 25] 1)
Add-on main relief valve The oil fed from the Pr port is led to the main relief valve. The Pr pump maximum pressure is regulated by the operation of the main relief valve.
a b c
Advance Reverse Up
2)
Spool section When the spool is pressurized from the add-on (Section 10) pilot port par1 (pbr1) and switched, the neutral path [Pg] is closed. The oil fed from the Pg port flows from the parallel path [Rg] through the load check valve [S10-1], the path [S10-2], and the spool neck section, and into the AR1 (BR1) port. The return oil returns to the tank path [Ta] from the BR1 (AR1) through the spool neck section.
d e f
Close Open Right
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g
Left
Structure and Operation Explanation of Control Valve 3)
4)
Low-pressure relief valve operation [Fig. 26, Fig. 27] 1)
Signal pressure generation (when pin1 (pin2) port pressurized) The oil fed from the pump port (P1 (P2)) flows through the neutral path (L1 (R1)), then flows from the low-pressure relief path (L2 (R2)) through the orifice (Lc1 (Rc1)) and out into the tank path (Ta). At this time, the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)) is led to the lowpressure relief signal port (Ps1 (Ps2)). When the (L2 (R2)) upstream main spool operates, the oil flowing through (L2 (R2)) is reduced, so the (Ps1 (Ps2)) signal pressure becomes lower.
2)
Relief operation When excess oil flows in path (L2 (R2)), the poppet is operated by the pressure generated in path (L2 (R2)) by the orifice (Lc1 (Rc1)). Through this poppet operation, the oil flows from the path, through the notch hole path, and out to the tank path [Ta]. This prevents the generation of excess pressure at the low-pressure relief signal port.
Add-on main relief valve 1)
Add-on main relief valve operation This relief valve is incorporated between the neutral path "HP" and the tank path "LP". The oil passes through the metering hole of the main poppet [1] and charges the interior space [C]. Also, the sleeve [2] and the main poppet [1] seat securely operating on the different surface areas "A" and "B".
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Structure and Operation Explanation of Control Valve 2)
When the neutral path "HP" pressure reaches the set pilot spring force, the pilot poppet [3] opens. The oil flows around the pilot poppet [3], passes from the notch hole [E] and through the ring-shaped gap [D] and is led to the tank path "LP".
3)
Because the pilot poppet [3] has opened, the interior space [C] pressure drops and the main poppet [1] opens, so the "HP" oil flows directly into the path "LP".
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Structure and Operation Explanation of Control Valve
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Section 8030E
4 Stack Solenoid Valve Operation Explanation
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84402827B - May 2011
CONTENTS External Shape Diagram and Component Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8030E-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030E-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
4 Stack Solenoid Valve Operation Explanation External Shape Diagram and Component Parts This valve is made up of the body and the electromagnetic switchover valve.
Normal closed type solenoid; SP, S1, S3
Normal open type solenoid; S2 1 2
Electromagnetic switchover valve Body
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4 Stack Solenoid Valve Operation Explanation Operation Explanation
Hydraulic circuit diagram The pressure oil fed from the P port feeds pressure oil to the C1 - C3 ports according to the excitation or non-excitation of electromagnetic switchover valves S3 - S4 resulting from exciting electromagnetic switchover valve SP. Electromagnetic switchover valves S1, S3 Electromagnetic switchover valve S2
â&#x2020;&#x2019; Oil passing through when valve excited â&#x2020;&#x2019; Oil passing through when valve not excited
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Section 8030F
Structure and Operation Explanation of Upper Pilot Valve (remote control valve)
84402827B - May 2011
84402827B - May 2011
CONTENTS Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 3 3 8
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030F-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) Structure The structure of the remote control valve is as shown in the Structural Diagram. There is a longitudinal axial hole in the casing and the pressure reduction valve is installed in it. The pressure reduction valve comprises the spool (201), secondary pressure setting spring (241), return spring (221), spring seating (216), and washer 2 (217). The secondary pressure setting spring (241) is set so that the secondary pressure calculation is 0.5 - 1 MPa (depending on the model). The spool (201) is pressed against the push rod (212) by the return spring (221). When the push rod (212) is pushed down by tilting the handle or another operation, the spring seating goes down at the same time and the secondary pressure setting spring (241) setting is changed. The casing (101) has the oil inlet (primary pressure) port P and the outlet (tank) port T and, furthermore, the secondary pressure is taken out from the ports 1, 2, 3, 4.
Function 1.
Basic functions The remote control valve is for controlling the control valve spool stroke quantity, direction, etc. This is done by operating the pilot valve output pressure on the control valve spool end section. In order to satisfy this function, the remote control valve is made up of the following elements. 1) 2) 3) 4) 5)
2.
Inlet port (P) to which the oil is fed from the hydraulic pump Multiple output ports (1, 2, 3, 4) for operating the feed pressure from the inlet port on the control valve spool end Tank port (T) required for controlling the above output pressure Spool connecting the output port to the inlet port or tank port Mechanical means including a spring operating on the above spool in order to control the output pressure
Main part functions The function of the spool (201) is to switch the oil path either to have the hydraulic pressure fed from the hydraulic pump received by the P port and lead the P port pressure oil to the output ports (1, 2, 3, 4) or to lead the output port pressure oil to the T port. The output pressure operating on this spool (201) is determined by the secondary pressure setting spring (241). In order to change the deflection quantity of the secondary pressure setting spring (241), the push rod (212) is inserted into the plug (211) in such a way that it can slide. The return spring (221) operates on the casing (101) and spring seating (216) and operates to return the push rod (212) in the displacement zero direction regardless of the output pressure and makes the spool (201) neutral return reliable. It also has the effect of a counter-force spring for giving an operator an appropriate operation feel.
Operation Operation of the remote control valve is explained based on the hydraulic circuit diagram (Diagram 1) and operation explanation diagrams (Diagram 2 - Diagram 4). Diagram 1 is a typical usage example for the remote control valve.
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Structure and Operation Explanation of Upper Pilot Valve (remote control valve)
Diagram 1 Remote control valve usage example 1 2
Pilot valve Pilot pump
3 4
Main pump Control valve
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5 6
Hydraulic motor Hydraulic cylinder
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) 1.
When the handle is in neutral (See Diagram 2.) The force of the secondary pressure setting spring (241) that determines the remote control valve output pressure does not operate on the spool (201). Therefore, the spool (201) is pushed up by the return spring (221) (spring seating (216)) and the output ports (2, 4) are connected with the T port. Therefore, the output pressure is the same as the tank pressure.
Diagram 2 When the handle is in neutral
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Structure and Operation Explanation of Upper Pilot Valve (remote control valve) 2.
When the handle is tilted (See Diagram 3.) When the handle is tiled and the push rod (212) is moved through a stroke, the (spring seating (216)) spool (201) moves down and the oil fed from the pilot pump flows out to the ports (2, 4) through the P port and the ports (2, 4) and pressure is generated.
Diagram 3 When the handle is tilted
84402827B - May 2011 8030F-6
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) 3.
When the handle is held (See Diagram 4.) When the handle is tilted and the pressure of the ports (2, 4) rises to a pressure equivalent to the set spring force (241), the hydraulic pressure and the spring force are in balance. When the ports (2, 4) pressure becomes higher than the set pressure, the ports (2, 4) and the P port close and the ports (2, 4) and the T port open. When the ports (2, 4) pressure becomes lower than the set pressure, the ports (2, 4) and the P port open and the ports (2, 4) and the T port close, so the secondary pressure is held constant.
Diagram 4 When handle held (secondary pressure at or above set pressure) 1 2 4.
T port P port
Operation in area in which the handle tilt is large (depends on the model) For certain models, when the handle is flipped down beyond a certain angle, the spool top end section touches the push rod bore bottom section and the output pressure goes into the state of still being connected with the P port pressure. Furthermore, with the structure in which the spring seating and spring are installed inside the push rod, when the handle is flipped down beyond a certain angle, the push rod bore bottom section and the spring touch. That spring force changes the 2nd pressure gradient and after that the push rod bore bottom section and the spring seating top end section touch, and the output pressure remains connected to the P port.
84402827B - May 2011 8030F-7
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) Structural Diagram
Code 101 151 201 211 212-1 212-2 213 214 216-1 216-2 217 221-1 221-2
Part name Casing Plate Spool Plug Push rod Push rod Seal O-ring Spring seating 1 Spring seating 1 Washer 2 Spring (port 1) Spring (port 3)
84402827B - May 2011 8030F-8
Q'ty 1 1 4 4 2 2 4 4 2 2 4 1 1
Structure and Operation Explanation of Upper Pilot Valve (remote control valve) Code 221-3 241-1 241-2 301 302 312 501
Part name Spring Spring Spring Joint Disk Adjusting nut Bellows
84402827B - May 2011 8030F-9
Q'ty 2 2 2 1 1 1 1
Structure and Operation Explanation of Upper Pilot Valve (remote control valve)
84402827B - May 2011 8030F-10
Section 8030G
Structure and Operation Explanation of Travel Pilot Valve (remote control valve))
84402827B - May 2011
84402827B - May 2011
CONTENTS Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Reduction Valve Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Section Damping Mechanism Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Structural Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 8030G-1
3 4 4 7
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030G-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) Operation The remote control valve with built-in damper (hereinafter, remote control valve with damper) is a remote control valve that incorporates into the remote control valve main unit a damping function for preventing the man-machine system hunting (lever hunting) phenomenon. Operation of the remote control valve with damper is divided into the Pressure Reduction Valve Section and the Operation Section Damping Mechanism Section. The explanations in these 2 sections are based on the hydraulic circuit diagram, assembly cross-section diagram, and damping operation explanation diagram below. The diagram below is a typical usage example for the remote control valve.
Hydraulic circuit diagram 1 2 3
Remote control valve Pilot pump Main pump
84402827B - May 2011 8030G-3
4 5 6
Control valve Hydraulic motor Hydraulic cylinder
Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) Pressure Reduction Valve Section 1.
2.
For the neutral state The spool (301) is pushed up by the return spring (335) via the spring seating (311) and washer 1 (215) and is in the neutral position shown in the assembly cross-section diagram. Therefore, since the output port is connected only to port T by the spool switching function, the pressure at output ports 1 and 2 is the same as the pressure at port T. When the remote control valve operation section is tilted from the neutral state In the assembly cross-section diagram, when the cam (420) is rotated clockwise, the port 1 side push rod (214) is pushed down, the spool moves down via washer 1, the spring seating, the secondary pressure setting spring (324), washer 2 (217), and washer 3 (313), the port P and port 1 are connected, and the oil fed from the pilot pump flows to port 1 and generates pressure. When the port 1 pressure rises to the pressure equivalent to the secondary pressure setting spring force that has been set by tilting the operation section, the hydraulic pressure on the spool and the spring force come into balance and the port 1 output pressure is held constant. The port 2 spool stays in the neutral state and the oil from the control valve is discharged via port T. Some specifications are of the type that near the maximum angle of the operation section, a push rod directly touches the spool top section and forcibly pushes in the spool to connect port P and the output port so that they have the same pressure.
Operating Section Damping Mechanism Section 1. 2.
3.
For the neutral state The push rod is pushed up by the damping springs (333, 337) via the piston (224) and is in the position shown in the assembly cross-section diagram. When the operation section is tilted from the neutral state (See Damping operation explanation diagram (1).) In the assembly cross-section diagram, when the cam is rotated clockwise, the port 1-side push rod is pushed down and the piston moves down (2-1). At this time, the oil in the damping piston chamber is discharged from the piston metering hole and the pressure generated at this time generates damping force. On the other hand, the port 2-side push rod is moved up by the damping spring via the piston. At this time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings (223) and steel balls (225) and into the damping piston chamber. The oil outside the piston chamber drains out from the path that leads from the casing top end section to port T. When the operation section is tilted back from a full tilt (See Damping operation explanation diagram (2).) In the assembly cross-section diagram, after the cam is fully tilted clockwise then rotated counter-clockwise, the port 2-side push rod is pushed down and the piston moves down. At this time, as described above, the oil in the damping piston chamber is discharged from the piston metering hole and the pressure generated at this time generates damping force (3-1). On the other hand, the port 1-side push rod is moved up by the return spring (335) and the damping spring (3-2). At the same time, the tank chamber oil is suctioned in through the 3 ball check sections made up of bushings and steel balls and into the damping piston chamber (3-3). Also, the oil outside the piston chamber drains out from the path that leads from the casing top end section to the tank port (3-4). In other words, the structure is such that damping force works for either tilt operation, from the neutral position to the full tilt position or from the full tilt position to the neutral position.
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Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) Damping operation explanation diagram 1.
Operation when lever is moved through its stroke from the neutral position
1 2
Push rod Orifice
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3 4
Piston Piston chamber
Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) 2.
Lever stroke state and operation when lever is moved back
*1 *2
Neutral Full stroke 12.5°
84402827B - May 2011 8030G-6
*3 *4
(Ă&#x17E; during operation) Oil drains to T.
Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) Structural Diagram
Code 101 151 201 202 203 210 212 214 215 217 218 221 223
Part name Casing Plug Cover Plug Grease cup NHU packing O-ring Push rod Washer 1 Washer 2 Spring seating Locking ring Bushing
Q'ty 1 2 2 4 4 4 4 4 8 4 4 4 4
Code 271 301 311 313 324 335 336 337 412 413 420 423 471
Part name Hexagon socket head bolt Spool Spring seating Washer 3 Spring Spring Spring Spring Bushing Camshaft Cam Hexagon socket head locking screw Locking screw
84402827B - May 2011 8030G-7
Q'ty 271 301 311 313 324 335 336 337 412 413 420 423 471
Structure and Operation Explanation of Travel Pilot Valve (remote control valve)) Code 224 225
Part name Piston 2D085 Steel ball
Q'ty 4 12
Code 472 501
Part name Lock nut Bellows
84402827B - May 2011 8030G-8
Q'ty 472 501
Section 8030H
Structure and Operation Explanation of Cushion Valve
84402827B - May 2011
84402827B - May 2011
CONTENTS Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operation Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 8030H-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 8030H-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Structure and Operation Explanation of Cushion Valve Structure This valve is made up of a shuttle valve section and cushion valve section with heat circuit. The cushion valve with a heat circuit is connected between the hydraulic shovel car control valve and the pilot operation valve to reduce body shaking (cushion function) caused by emergency stop operations by the operator. This valve is also equipped with a circuit with which the operator can deliberately disable the cushion function for reverse operations. The shuttle valve selects the high-pressure signal pressure from 2 signal pressure systems. This valve has 2 circuits.
*1 *2
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Arm Boom
Structure and Operation Explanation of Cushion Valve Operation Explanation 1.
Normal operation The pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) pushes up the check plunger and is sent to the B port (or D, F, or H port). The pressure oil that has passed through the B port operates on the control valve spool and operates the actuator. The oil pushed out from the control valve spool passes through the D port (or B, F, or H port) and flows out to the T port.
84402827B - May 2011 8030H-4
Structure and Operation Explanation of Cushion Valve 2.
Cushion operation When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is closed by the pilot operation valve, the pressure oil that has operated on the control valve spool is pushed back to the B port (or the D, F, or H port) by the return spring on the spool. The returned oil passes through the check plunger metering orifice, is sent to the A port (or the C, E, or G port), and is drained from the pilot operation valve. At this time, by passing through the metering orifice, the pressurized oil holds down the control valve spool speed, which prevents the sudden stopping of the actuator and reduces shaking of the body. (Cushion function)
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Structure and Operation Explanation of Cushion Valve 3.
Reverse operation When the pressure oil fed from the pilot operation valve to the A port (or C, E, or G port) is switched to the C port (or A, E, or G port), the pressure oil that has operated on the control valve spool is pushed back to the B port. Because the pushed back oil flows out to the T port without passing through the check plunger metering orifice, it does not hold down the control valve spool speed, so the cushion function does not work.
84402827B - May 2011 8030H-6
Structure and Operation Explanation of Cushion Valve 4.
Heat circuit When the pilot operation valve is in the neutral position, the oil fed to the R port passes through the inside of the reverse operation spool and flows out to the T port, which heats up the inside of the valve. When pressure oil is being fed from the pilot operation valve to the A port (or C, E, or G port), the oil fed to the R port flows out to the C port (or A, E, or G port) and heats up the circuit to the pilot operation valve and inside the valve.
5.
Shuttle valve The steel ball is pressed from the higher of the pressures between the I and J ports and the K and L ports to the lower of these pressures. Through this process, high-pressure oil is fed to the S port or the Q port. In the same way, oil of the higher pressure between the M and N ports and the O and P ports is fed to the U port.
84402827B - May 2011 8030H-7
Structure and Operation Explanation of Cushion Valve
84402827B - May 2011 8030H-8
Section 9002
Removal and Installation of Counterweight
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9002-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9002-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Counterweight 4.
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. • Thoroughly secure the removed counterweight with the wire ropes and liftcrane so that it does not fall over.
Use the wire ropes and liftcrane to lift and remove the counterweight. • Move the counterweight about 50 cm to the rear while lifting it so that it does not interfere with the housing, engine parts and pipes.
Items to prepare • • • • • • • •
Box wrench (50 mm) Balance lifting device Shackles (with the required lifting capacity) x 4 Wire rope (with the required breaking load) x 4 Liftcrane (with the required lifting capacity) Wood planks, etc. Rag Cleaning fluid
Removal of Counterweight 1.
Remove the following before beginning work.。 • Engine hood, gas damper and lock stay • Rear view camera and electrical parts bracket
2.
Install the shackles (1), and then use the wire ropes (2) and liftcrane to secure the counterweight so that it does not fall during removal and installation operations.
3.
Use a box wrench (50 mm) to remove the 4 bolts (1) at the bottom section of the counterweight.
84402827B - May 2011 9002-3
Removal and Installation of Counterweight 5.
Thoroughly check that the location is safe before lowering the counterweight on wood planks (1). • Thoroughly secure the counterweight with the wire ropes and liftcrane so that it does not fall over.
Installation of Counterweight 1.
Install the shackles (1), and then use the wire ropes (2) and liftcrane to secure the counterweight so that it does not fall during removal and installation operations.
2.
Use the wire ropes and liftcrane to lift and install the counterweight. • Suspend the counterweight so that it does not interfere with the housing, engine parts and pipes.
3.
Coat the threaded section of the bolt (1) with Loctite, and use a box wrench (50 mm) to fasten the counterweight using the 4 bolts (1) and 4 high-strength washers (2) at the bottom section of the counterweight. Tightening torque: 1862 - 2058 N·m
4.
Install the following after finishing work. • Engine hood, gas damper and lock stay • Rear view camera and electrical parts bracket
84402827B - May 2011 9002-4
Section 9003A
Removal and Installation of Bucket
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9003A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9003A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Bucket Job code
Installation of Bucket
84100AB20
1.
Clean each pin and pin hole.
2.
Place the back of the bucket parallel to the ground. Use a hammer (4) to press in the bucket side pin (3) and arm side pin (2), and then install the bucket (1).
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective gear (protective eyewear and safety shoes, etc.) when working with a hammer. Items to prepare • • • • • •
Hammer Striking rod Grease Rag Cleaning fluid Wrench (36 mm) x 2
• If a pin is hard to insert, there is a load on the pin. Do not force it in. Adjust the bucket installation position. • When inserting the pin, be careful not to damage the installed O-rings or dust seals.
Removal of Bucket • Place the back of the bucket parallel to the ground. 1.
Remove the bolts (1) and the nuts (2).
3. 2.
Use a hammer (4) and striking rod (5) to push the bucket side pin (3) and arm side pin (2) out, and then remove the bucket (1). • When removing the pin, be careful not to damage the installed O-rings or dust seals.
Install the bolts (1) and nuts (2) to the bucket and arm side pins. • When installing the pin bolts, leave about 1 to 2 mm of gap between both nuts and the retaining ring. • Grease up.
84402827B - May 2011 9003A-3
Removal and Installation of Bucket
84402827B - May 2011 9003A-4
Section 9003B
Removal and Installation of Bucket Link
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Bucket Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9003B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9003B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Bucket Link CAUTION
2.
Use 2 wrenches (36 mm) to remove the double nuts (1), and then pull out the bolts (2) (3).
3.
Use a hammer (3) and striking rod (4) to push the pin (2) out and remove the bucket link (1).
4.
Use a hammer (4) and striking rod (5) to push the pin (3) out and remove the arm links (1) (2).
• Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective gear (protective eyewear and safety shoes, etc.) when working with a hammer. Items to prepare • • • • • •
2 wrenches (36 mm) Hammer Striking rod Grease Rag Cleaning fluid
Removal of Bucket Link • Remove the bucket. (For details, see "Removal and Installation of Bucket".) 1.
Place the bucket link (1) parallel to the ground.
• When removing the pin, be careful not to damage the installed O-rings or dust seals.
84402827B - May 2011 9003B-3
Removal and Installation of Bucket Link Installation of Bucket Link 1.
Clean each pin and pin hole.
2.
Use a hammer (4) to push in the pin (1) and install the arm links (2) (3). • If a pin is hard to insert, there is a load on the pin. • When inserting the pin, be careful not to damage the installed O-rings or dust seals.
3.
Place the bucket link (1) parallel to the ground. Use a hammer (3) to push in the pin (2) and install the bucket link (1).
4.
Use 2 wrenches (36 mm) to attach the double nuts (1), and then install the bolts (2) (3). • When installing the pin bolts, leave about 1 to 2 mm of gap between both nuts and the retaining ring. • Grease up. • Install the bucket. (For details, see "Removal and Installation of Bucket".)
84402827B - May 2011 9003B-4
Section 9003C
Removal and Installation of Arm
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9003C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9003C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Arm Job code
39121AA10
2.
Use a wrench (30 mm) to remove the bolt (1) and spacer (2).
3.
Use a hammer (3) and striking rod (4) to push the pin (2) out and remove the arm (1).
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
• If a pin is hard to remove, there is a load on the pin. • When removing the pin, be careful not to damage the installed dust seals. • Be very careful. When the pin is removed, the arm may fall slightly. • Be very careful. The arm may fall over to the side.
Items to prepare • • • • • • • • •
Wrench (30 mm) Hammer Striking rod Nylon sling (with the required lifting capacity) Liftcrane (with the required lifting capacity) Grease Rag Cleaning fluid Crosstie
Removal of Arm • Remove the bucket. (For details, see "Removal and Installation of Bucket".) • Remove the bucket link. (For details, see "Removal and Installation of Bucket Link".) • Remove the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) • Remove the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) 1.
Bring the arm (1) top in contact with the ground and use a liftcrane and nylon sling (2) to secure it. At this time, insert the arm cylinder pin (3) and secure with the nylon sling.
4.
Lift the arm and then place it on the crosstie.
84402827B - May 2011 9003C-3
Removal and Installation of Arm Installation of Arm
• When inserting the pin, be careful not to damage the installed dust seals.
• Tighten bolts being installed to the specified torque. • When the torque is not specified, check the "Bolt Size and Torque Table". 1.
Clean each pin and pin hole.
4.
2.
Bring the arm (1) top in contact with the ground and use a liftcrane and nylon sling (2) to secure it. At this time, insert the arm cylinder pin (3) and secure with the nylon sling.
3.
Align the arm (1) with the boom and use a hammer (3) to push in the pin (2) and then install the arm (1).
Use a wrench (30 mm) to tighten the bolt (1) and spacer (2). • Install the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) • Install the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) • Install the bucket link. (For details, see "Removal and Installation of Bucket Link".) • Install the bucket. (For details, see "Removal and Installation of Bucket".)
• If a pin is hard to insert, there is a load on the pin.
84402827B - May 2011 9003C-4
Section 9003D
Removal and Installation of Boom
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
84402827B - May 2011 9003D-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9003D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Boom Job code
39105AB10
1.
Bring the boom (1) top in contact with the ground.
2.
Use a wrench (19 mm) to remove the grease hoses on the left and right sides (1).
CAUTION • Stop the machine on a level location with good footing. • Be sure to stop the engine before beginning work. • When working together with others, always be sure to exchange signals and pay adequate attention to safety. • Always wear protective devices (protective eyewear and safety shoes, etc.) when working with a hammer. • Be sure to inspect the nylon sling and other lifting equipment before beginning work. • Do not stand or pass under the suspended load.
• Use caps or plugs to prevent any entry of water, dust or dirt.
Items to prepare • Wrenches (10 mm、19 mm、22 mm、30 mm、36 mm、41 mm) • Hexagon wrench (12 mm) • Slide hammer (24 mm) • Nylon sling (with the required lifting capacity) • Liftcrane (with the required lifting capacity) • Marking pen • Cap • Plug • Rag • Striking rod • Cleaning fluid • Wood piece • Square wooden pieces • Wire
Removal of Boom • Remove the bucket. (For details, see "Removal and Installation of Bucket".) • Remove the bucket link. (For details, see "Removal and Installation of Bucket Link".) • Remove the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) • Remove the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) • Remove the arm. (For details, see "Removal and Installation of Arm".) • This section explains the procedure for when attaching the boom cylinder to the frame. When removing the boom cylinder too, see "Removal and Installation of Boom Cylinder".
3.
Use a wrench (36 mm) to remove the double nuts (1) and bolt (2), and then remove the fastening ring (3). Also, remove the cab side in the same way.
84402827B - May 2011 9003D-3
Removal and Installation of Boom 4.
Use a hammer (2) and striking rod (3) to push the pin (1) out. Use a liftcrane and nylon slings (4) to hold the boom cylinders (right) (left) so that they does not fall.
5.
Start the engine, lower the boom at idle, and retract the boom cylinder (1) (2) rod.
6.
Tie the cylinder rods on the left and right sides with wire (1) so that they cannot come out.
7.
Secure the base of the boom cylinder with the wood piece (1).
8.
Lower the boom cylinders (right) (left) and let them rest on the wood piece (1). â&#x20AC;˘ Remove the cab side boom cylinder from the boom in the same way.
9.
Install the pin (1) removed in Step 4. Use a wrench (36 mm) to tighten the bolt (3) with the 2 double nuts (2), and then install the fastening ring (4). Also, install the cab side in the same way.
10. Use wrenches (41 mm) to remove the hoses (1), (2), (3). Use a hexagon wrench (12 mm) to remove the 4 hexagon socket head bolts (5) and the 2 split flanges (6), and then remove the hose (4). â&#x20AC;˘ Mark the hoses and lines so that the connectors match at the time of assembly.
84402827B - May 2011 9003D-4
Removal and Installation of Boom â&#x20AC;˘ Use caps or plugs to cover the hoses and lines to prevent any entry of water, dust or dirt. â&#x20AC;˘ Clean the hoses and lines by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
12. Use a wrench (30 mm) to remove the bolt (1) and washer (2).
13. Use a slide hammer (1) (24 mm) to remove the pin (2). 11. Wrap nylon slings (1) around the pins on the left and right sides installed in Step 9 and secure with the liftcrane.
14. Back up the machine and remove the boom (1).
84402827B - May 2011 9003D-5
Removal and Installation of Boom Installation of Boom
4.
Tie the cylinder rods on the left and right sides with wire (1) so that they cannot come out.
5.
Align the boom with the swing frame pin hole and use a slide hammer (1) (24 mm) to tighten the pin (2).
• This section explains the procedure for when not installing the boom cylinder. • Tighten bolts being installed to the specified torque. • When the torque is not specified, check the "Bolt Size and Torque Table". 1.
2.
Clean each pin and pin hole.
• When inserting pins, be careful not to damage the dust seals. • If the insertion of a shim is possible according to the tolerance adjust the shim.
Install the pin (1). Use a wrench (36 mm) to tighten the bolt (3) with the 2 double nuts (2), and then install the fastening ring (4). Also, install the cab side in the same way.
6.
Use a wrench (30 mm) to tighten the bolt (1) and washer (2). • Grease up.
3.
Wrap the nylon slings (1) around pins on the left and right sides installed in Step 2 and secure with the liftcrane.
84402827B - May 2011 9003D-6
Removal and Installation of Boom 7.
Use a wrench (41 mm) to install the hoses (1) (2) (3). After setting the O-ring (4) on the line side, install the hose (4) with the 2 split flanges (6) and the 4 hexagon socket head bolts (5).
10. Use a wrench (36 mm) to attach the double nuts (1) and bolt (2), and install the fastening ring (3). Also, install the cab side in the same way.
• The O-ring cannot be reused. Replace them with new parts.
11. Use a wrench (19 mm) to attach the grease hoses on the right and left sides (1).
8.
Start the engine, raise the boom at idle, and extend the boom cylinder (1) (2) rod.
12. Bring the boom (1) top in contact with the ground.
9.
Use a hammer (2) to push in the pin (1). Use a liftcrane and nylon slings (3) to hold the boom cylinders (right) (left) so that they does not fall.
• When installing the boom cylinder too, see "Removal and Installation of Boom Cylinder". • Install the arm. (For details, see "Removal and Installation of Arm".) • Install the arm cylinder. (For details, see "Removal and Installation of Arm Cylinder".) • Install the bucket cylinder. (For details, see "Removal and Installation of Bucket Cylinder".) • Install the bucket link. (For details, see "Removal and Installation of Bucket Link".) • Install the bucket. (For details, see "Removal and Installation of Bucket".)
84402827B - May 2011 9003D-7
Removal and Installation of Boom
84402827B - May 2011 9003D-8
Section 9004
Removal and Installation of Operator's Seat
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Operator's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9004-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9004-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Operator's Seat Job code
90120AD17
3.
Use a wrench (13 mm) to remove the 2 bolts (1) from the rear of the seat. Tightening torque for bolt (1) installation: 19.6 N·m
4.
Remove the operator's seat (1).
Items to prepare • Wrench (13 mm)
Removal of Operator's Seat 1.
2.
Pull the slide lever (1) to slide the seat (2) to the rear. Use a wrench (13 mm) to remove the 2 bolts (3) from the front of the seat. Tightening torque for bolt (3) installation: 19.6 N·m
Pull the slide lever (1) to slide the seat forward, and then pull the reclining lever (2) to fold the seatback forward.
Installation of Operator's Seat To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque.
84402827B - May 2011 9004-3
Removal and Installation of Operator's Seat
84402827B - May 2011 9004-4
Section 9005A
Removal and Installation of Cab Assembly
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
84402827B - May 2011 9005A-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005A-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Cab Assembly Job code
90150AA08
2.
Use a box wrench (10 mm) to remove the 3 bolts (1), and then remove the air conditioner ducts on both sides (2) (3). Tightening torque for bolt (1) installation: 2.9 - 3.9 N·m
3.
Use a Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (1), and then remove the side front lower trim (2). Tightening torque for bolt (1) installation: 5.9 - 7.8 N·m
4.
Use a flathead screwdriver or longnose pliers to remove the clip pins (1), and then remove the air conditioner ducts (2) by pulling them forward.
CAUTION • Be sure to stop the engine before beginning work. • Be sure to inspect the wire rope and other lifting equipment before beginning work. • Do not stand or pass under the suspended load. Items to prepare • • • • • • • • • • •
Wrenches (10 mm, 12 mm, 13 mm, 19 mm, 41 mm) Box wrenches (10 mm, 13 mm, 19 mm) Longnose pliers Flathead screwdriver Eyebolt (M24 x 4) Chains (wire ropes) (with the required breaking load) Liftcrane (with the required lifting capacity) Lubricating oil Rag Cleaning fluid Wood planks, etc.
Removal of Cab Assembly • Remove the operator's seat. (For details, see "Removal and Installation of Operator's Seat".) 1.
Use a box wrench (13 mm) to remove the 6 bolts (1), and then remove the trim rear assembly (2). Tightening torque for bolt (1) installation: 5.9 - 7.8 N·m
84402827B - May 2011 9005A-3
Removal and Installation of Cab Assembly 5.
Use a wrench (13 mm) to remove the 2 bolts (2), and then remove the bracket (1) and air conditioner duct (3).
8.
Remove the connector (1) and wire band (2), and then use a wrench (13 mm) to remove the 2 bolts (3).
6.
Remove the radio antenna (1).
9.
Remove the washer fluid hose ( ).
7.
Use a wrench (13 mm) to remove the bolts (2) for the ground wire (1) connecting the cab and frame.
10. Use a wrench (13 mm) to remove the 4 bolts (1), use a wrench (12 mm) to remove the 3 bolts (4) and 2 nuts (2), and then remove the rear brackets (3) (5).
84402827B - May 2011 9005A-4
Removal and Installation of Cab Assembly 11. Use a wrench (13 mm) to remove the 3 bolts (1), and then remove the bracket (2).
12. Use a flathead screwdriver or longnose pliers to remove the 2 clips (1), and then remove the suction ducts (2) (3).
14. Remove the connector (1).
15. Remove the 4 connectors (1) and the 2 wire bands (2).
16. Remove the 4 caps (1) from the top of the cab. 13. Use a wrench (10 mm) to remove the 2 bolts (1), and then remove the bracket (2).
84402827B - May 2011 9005A-5
Removal and Installation of Cab Assembly 17. Install the 4 eyebolts (M24) (1) in place of the removed caps.
19. Use a wrench (19 mm) to remove the 8 cab bolts (1) and 4 nuts (2).
â&#x20AC;˘ Fully tighten the eyebolts, and then loosen them by a half turn.
18. Use chains (1) and liftcrane to secure the cab.
20. Use a wrench (41 mm) to remove the anchor bolt (1).
84402827B - May 2011 9005A-6
Removal and Installation of Cab Assembly 21. Use chains (1) and liftcrane to remove the cab (2).
22. Thoroughly check that the location is safe before lowering the cab on wood planks (1). â&#x20AC;˘ Thoroughly secure the cab with the chains and liftcrane so that it does not fall down.
84402827B - May 2011 9005A-7
Removal and Installation of Cab Assembly Installation of Cab Assembly To install, perform the reverse of the removal procedure.
Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Tightening Torque" section.
84402827B - May 2011 9005A-8
Section 9005B
Removal and Installation of Wiper
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9005B-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005B-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Wiper Items to prepare
Installation of Wiper
• Wrench (17 mm) • Phillips screwdriver
To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque.
Removal of Wiper 1.
Use a wrench (17 mm) to remove the 1 nut (1), and then remove the wiper arm (2). Tightening torque for nut (1) installation: 12 - 16 N·m
2.
Use the Phillips screwdriver to remove the 1 screw (1), and then remove the wiper (2).
84402827B - May 2011 9005B-3
Removal and Installation of Wiper
84402827B - May 2011 9005B-4
Section 9005C
Removal and Installation of Wiper Controller
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Wiper Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9005C-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005C-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Wiper Controller Job code
Installation of Wiper Controller
55518BH01
To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Tightening Torque" section.
Items to prepare • • • •
Wrench (10 mm) Box wrench (10 mm) Phillips screwdriver Flathead screwdriver
Removal of Wiper Controller 1.
Use the Phillips screwdriver or box wrench (10 mm) to remove the 4 bolts (1), and then remove the side rear B trim (2).
2.
Remove the connector (2) from the wiper controller (1).
3.
Use a flathead screwdriver to slightly bend the 4 installation clips (1), and then remove the wiper controller (2).
84402827B - May 2011 9005C-3
Removal and Installation of Wiper Controller
84402827B - May 2011 9005C-4
Section 9005D
Removal and Installation of Wiper Motor
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9005D-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005D-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Wiper Motor Job code
55518AZ46
3.
Use a Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (1), use a hexagon wrench (5 mm) to remove the 3 bolts (2) and 3 washers (3), and then remove the front upper trim assembly (4). Tightening torque for bolt (1) installation: 5.9 - 7.8 N·m
4.
Use a wrench (17 mm) to remove the 1 nut (1), and then remove the wiper arm (2). Tightening torque for installation: 12 - 16 N·m
5.
Use a wrench (17 mm) to remove the 1 nut (1). Tightening torque for installation: 11 - 13 N·m
Items to prepare • • • • •
Hexagon wrench (5 mm) Wrenches (10 mm, 17 mm) Box wrench (10 mm) Flathead screwdriver (longnose pliers) Phillips screwdriver
Removal of Wiper Motor 1.
2.
Use a Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (1), and then remove the side front lower trim (2). Tightening torque for bolt (1) installation: 5.9 - 7.8 N·m
Use a flathead screwdriver or longnose pliers to remove the clip pins (1), and then remove ducts B (2).
84402827B - May 2011 9005D-3
Removal and Installation of Wiper Motor 6.
Use a box wrench (10 mm) to remove the 4 bolts (1), and then remove the wiper motor assembly (2).
Installation of Wiper Motor To install, perform the reverse of the removal procedure. • Be careful about the wiper link and wiper arm installation location. • Check the wiper arm wipe location and stop location. • When installing the bolts, tighten them to the specified torque. If the torque is not specified for an installation bolt, see the "Tightening Torque" section.
84402827B - May 2011 9005D-4
Section 9005E
Removal and Installation of Monitor
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9005E-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005E-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Monitor Job code
55640AO14
3.
Remove the connector (1).
4.
Use a wrench (10 mm) to remove the 4 bolts (2), and then remove the monitor (1).
Items to prepare • Wrench (10 mm)
Removal of Monitor 1.
Use a Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (1), and then remove the side front lower trim (2). • Bolt (1) tightening torque: 5.9 - 7.8 N·m
2.
Use a Phillips screwdriver or box wrench (10 mm) to remove the 2 bolts (1), use a hexagon wrench (5 mm) to remove the 3 bolts (2) and 3 washers (3), and then remove the front upper trim assembly (4). • Bolt (1) tightening torque: 5.9 - 7.8 N·m
Installation of Monitor To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. For the tightening torques of the installation bolts, see the "Tightening Torque" section.
84402827B - May 2011 9005E-3
Removal and Installation of Monitor
84402827B - May 2011 9005E-4
Section 9005F
Removal and Installation of Cab Front Glass
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Cab Front Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Cab Front Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9005F-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005F-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Cab Front Glass Job code
90156AL10
3.
Use a wrench (10 mm) to remove the 3 bolts (1) each, and then remove the brackets (2) (3). Tightening torque for bolt (1) installation: 880 - 1270 N·cm
4.
Remove the covers (1) (2) for the bracket.
5.
Use a wrench (10 mm) to remove the 3 bolts (1), and then remove the front glass left lower bracket (2). Tightening torque for bolt (1) installation: 880 - 1270 N·cm
CAUTION Reinforced glass is used for the front window. Be extremely careful not to damage it when touching it during removal or installation. Items to prepare • • • •
Wrench (10 mm) Phillips screwdriver Rag Cleaning fluid
Removal of Cab Front Glass 1.
Use a Phillips screwdriver to remove the 8 clips (2), and then remove the cover (1).
2.
Use a Phillips screwdriver to remove the screw (1), and then install the removed screw (1) into the screw hole (2). • The assist spring is locked.
84402827B - May 2011 9005F-3
Removal and Installation of Cab Front Glass 6.
7.
Use a wrench (10 mm) to remove the 3 bolts (1), and then remove the front glass right lower bracket (2). Tightening torque for bolt (1) installation: 880 - 1270 N¡cm
Installation of Cab Front Glass To install, perform the reverse of the removal procedure. Tighten bolts being installed to the specified torque. If the torque is not specified, see the "Tightening Torque" section.
Remove the cab front glass (1).
84402827B - May 2011 9005F-4
Section 9005G
Window Lock Adjustment Procedures
84402827B - May 2011
84402827B - May 2011
CONTENTS Window Lock (front side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Window Lock (rear side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9005G-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005G-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Window Lock Adjustment Procedures Items to prepare • • • •
3.
Set the cab front glass (1) in place.
4.
Use a wrench (10 mm) to retighten the 2 bolts (1).
Wrench (10 mm) Phillips screwdriver Rag Cleaning fluid
Window Lock (front side) 1.
2.
Release the lock with the lever (1), and then remove the lock of the cab front glass.
Use a wrench (10 mm) to loosen the 2 bolts (1).
84402827B - May 2011 9005G-3
Window Lock Adjustment Procedures Window Lock (rear side) 1.
2.
3.
Set the cab front glass (1) in place.
4.
Use a wrench (10 mm) to retighten the 4 bolts (1).
Use a Phillips screwdriver to remove the 8 clips (2), and then remove the cover (1).
Use a wrench (10 mm) to loosen the 4 bolts (1).
84402827B - May 2011 9005G-4
Section 9005H
Tightening torque
84402827B - May 2011
84402827B - May 2011
CONTENTS Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
84402827B - May 2011 9005H-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9005H-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Tightening torque Tightening torque When installing cab inner and outer parts, for bolts and screws for which the torque is not specified, tighten according to the following. Bolt nominal diameter M3 x 0.5 (size) Nâ&#x20AC;˘m 0.59 - 0.79 kgfâ&#x20AC;˘m 0.06 - 0.08
M4 x 0.7
M5 x 0.8
M6 x 1.0
M8 x 1.25
M10 x 1.5
1.27 - 1.86 0.13 - 0.19
2.45 - 3.53 0.25 - 0.36
4.52 - 6.14 0.43 - 0.63
9.84 - 14.74 1.00 - 1.50
19.58 - 28.4 2.0 - 2.9
84402827B - May 2011 9005H-3
Tightening torque
84402827B - May 2011 9005H-4
Section 9006
Air Conditioner Overall Diagram
84402827B - May 2011
84402827B - May 2011
CONTENTS Air Conditioner Overall Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Equipment Layout Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Air Conditioner Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Explanation of Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Explanation of Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Air Mix Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Blow Mode Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Refresh/Recirculate Switch Motor Actuator Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Blower Amp Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Compressor Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 COOLMAX Control and HOTMAX Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Abnormality Detection and Control after Abnormality Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Door Switch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inside Air Filter Clogging Detection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Air Mix Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Refresh/Recirculate Switch Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Mode Motor Actuator Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Self-diagnosis Function with Panel Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Abnormality Display and Self-check Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Abnormality Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Explanation of Abnormality Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Motor Actuator Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Sensor Abnormality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Explanation of Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Monitor Mode Display Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Monitor Mode Display Operating Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Display Contents in Monitor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Part Function and Good/Poor Judgment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Air Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Refresh/Recirculate Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Blow Mode Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Dual Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Solar Radiation Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Inside Air Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
84402827B - May 2011 9006-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
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Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Air Conditioner Overall Diagram Air Conditioner Overall Diagram Frame
84402827B - May 2011 9006-3
Air Conditioner Overall Diagram
Code
Part name
1
Cooler hose (Liquid 2) 1
5
2
Cooler hose (Suction) 1 Rubber hose 16 x 2 5600 Cooler hose (Dis1 charge)
6
3 4
Q'ty Code
7 8
Part name Compressor; Air conditioner Slide shaft Tension pulley (With cover)
Q'ty Code
Part name
1
9
Dryer receiver (D60.5) 1
1
10
1
11
Cooler hose (Liquid 1) 1 Bracket receiver 1 (D60.5)
Air condenser
1
12
a
Air conditioner unit
e
Heater (Engine output)
b c
Engine Heater (Engine return)
f g
d
White marking
h
j Heater (Unit outlet) Heater (Unit inlet) Must be connected with the air conditioner unit. 84402827B - May 2011 9006-4
i
V belt B-45.5
Q'ty
1
White marking Must be connected with the air conditioner unit. Clamp
Air Conditioner Overall Diagram *
in the diagram indicates a clamp position. Figures indicate hose lengths.
84402827B - May 2011 9006-5
Air Conditioner Overall Diagram Cab
84402827B - May 2011 9006-6
Air Conditioner Overall Diagram
84402827B - May 2011 9006-7
Air Conditioner Overall Diagram Code 1 2 3 4 5 6 7
Part name Solar radiation sensor Duct; Face-A Duct; Def-A Grille; Air vent Duct; Face-B Duct; Def-C Duct; Face-C
Q'ty 1 1 1 7 1 1 1
Code 8 9 10 11 12 13 14
Part name Duct; H and C box Bracket; Box Box; Hot and cool Duct; Vent (Left) Duct; Vent (Right) Air filter (Fresh) Duct; Intake-A (Fresh)
Q'ty 1 1 1 1 1 1 1
Code 15 16 17 18 19 20 21
a
Monitor display
e
Heater hose (Eng.Out)
i
b c d
Trim side; Front (Right) Trim side; Front (Left) Heater hose (Eng.Return)
f g h
Cooler hose (Suction) Cooler hose (Liquid) Cover; Top (Console left)
j k
84402827B - May 2011 9006-8
Part name Duct; Intake-B (Fresh) Unit; Air conditioner Duct; Foot Duct; Def-B Control panel (AC) Drain hose Flange plate
Q'ty 1 1 1 1 2 1
Should be connected with the console harness. Wire harness (Console) Floor
Air Conditioner Overall Diagram Equipment Layout Diagram
84402827B - May 2011 9006-9
Air Conditioner Overall Diagram Code
Part name
Code
1
Motor actuator (mode)
4
2 3
Compressor relay Blower OFF relay
5 6
Part name Motor actuator (refresh/recirculate switch) Interior temperature sensor Blower motor
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Code
Part name
7
Blower amp
8 9
Motor actuator (air mix) Evaporator sensor
Air Conditioner Overall Diagram Circuit Diagram Air Conditioner Circuit Diagram
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Air Conditioner Overall Diagram
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Air Conditioner Overall Diagram 5 V system 5 V are always applied. Analog Signal:0 - 5 V are applied GND Lg Light green
O
Part name Compressor Blower OFF relay
Code 13 14
Part name Inside air sensor Motor actuator (air mix)
Blower motor
15
Motor actuator (mode)
P
W
B
R
Y
G
L
Br
Pink
White
Black
Red
Yellow
Green
Blue
Brown
Code 1 2
Part name Main key switch A/C main power supply Power supply for compressor clutch
Code 7 8 9
3 4
Power supply for controller 10
Blower amp
16
5
Sunlight sensor 11 Pressure switch (receiver 12 dryer)
Compressor relay
17
Evaporator sensor
18
6
Sb Sky Orange blue
V Violet
Motor actuator (refresh/recirculate switch) CAN signal Control panel (TKSCP208C0)
NOTE: • Wire diameters that are not indicated are 0.5. • Broken lines indicate wiring on the vehicle side. • Codes displayed on the connectors indicate the code colors seen from the connection ports of the connectors.
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Air Conditioner Overall Diagram Explanation of Functions Explanation of Control Back-up function Even when air conditioner operation is stopped (switched OFF) with the vehicle main key power supply or operation panel ON/OFF switch, the set temperature and all the other setting states are stored in memory, so the next time air conditioner operation starts, it goes into the same state as before it was stopped. When the vehicle main key power supply is cut off, the data is backed up by storing it in the internal EEPROM. However, if the main key power supply is cut off within 0.5 sec. of switch input, that switch input is not stored into memory. Also, the data read out from EEPROM when the power is switched ON is judged to see if it is within the valid range. If data outside the valid range was written into memory, for example due to noise, then operation starts from the default setting values to avoid abnormal operation. Fahrenheit temperature display To switch, hold down both the temperature setting UP and DOWN switches for 5 sec. The display toggles between Celsius and Fahrenheit display each time the switches are both held down for 5 sec. The Fahrenheit display is a 2-digit integer and below the decimal point is not used, so "F" is displayed. However, in case of trouble, this display takes priority. When this display is switched, the new status is backed up in memory, so even if the main key power supply is switched OFF, the display status is retained. Internal calculations are all done in Celsius. Only the operation panel display is in Fahrenheit. Therefore, the display may differ slightly from the exact Fahrenheit temperature. Below is shown the Fahrenheit temperature and the corresponding Celsius temperature used in internal processing. CAUTION These specifications are written with Celsius as the standard. Therefore, if the temperature is displayed in Fahrenheit, convert the temperature to centigrade by using the table below. Fahrenheit play [°F] 63 64 65 ： 77 ： 91
dis- Interior recognition set temperature (Celsius) [°C] 18.0 18.5 19.0 ： 25.0 ： 32.0
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Air Conditioner Overall Diagram Air Mix Motor Actuator Control 1.
2.
3.
4.
Summary explanation The provisional target degree of opening is determined from the target blow temperature and the current blow mode, various restrictions are applied, and the target degree of opening is calculated. Then drive is output to move the motor actuator position to the target degree of opening. Below are the details. Heater unit hysteresis correction operation (motor actuator one-direction stop) After the actuator moves to the target degree of opening, it returns to the specified position. However, if the target degree of opening is less than 0°, the actuator is treated as having reached the target degree of opening when it reaches 0°, then it moves to the specified position. (A stop in the fully-open direction is used as the reference.) Motor actuator operation priority order The operation priority for this motor actuator is No. 1. This means that if the target degree of opening for this motor actuator changes and operation becomes necessary, even if some other motor actuator is operating, that other motor operation is paused, and this motor actuator operates. Motor actuator retry control Even when there are no changes to the target values after the target is attained, if the difference between the current value and the target value once every 5 min. is equal to or greater than the operation start angle, the motor actuator is operated.
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Air Conditioner Overall Diagram Blow Mode Motor Actuator Control 1. 2.
Summary explanation The blow mode is switched by rotating the diffuser switching damper with the motor actuator. There are 2 types of control: auto and manual. Auto control When AUTO blow mode is set, the blow mode changes to auto control. During auto control, the diffuser is switched according to the target blow temperature Auto control continues until operation of the blow mode select switch is recognized.
*1 *2 3.
Target blow temperature Blow mode
*3 *4
MODE 2 VENT MODE 3 B/L
*5
Manual control 1)
2)
When operation of the blow mode select switch is recognized, the blow mode motor actuator is driven to attain the output shaft angle below and the display is switched too. Each time operation of the switch is recognized, the display switches MODE 1 → MODE 2 → MODE 3 → MODE 4 → MODE 1 →... However, if this switch is pressed during auto control, auto control is ended and the diffuser is fixed at its current position. MODE 5 in the table below only occurs when operation of the DEF select switch is recognized. After that, when operation of the blow mode select switch is recognized, the blow mode becomes the one that was in effect just before operation of the DEF select switch was recognized. Also, even if the DEF switch is pressed again during this mode, the mode is not canceled. Blow mode Blow mode motor actuator degree of opening
MODE 1 90° FACE
MODE 2 67° VENT
Panel display
4.
MODE 4 FOOT
Blow mode control priority order The priority order for auto control and manual control is as follows. Priority order 1 2
Control Manual control Auto control
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MODE 3 48° B/L
MODE 4 26° FOOT
MODE 5 0° DEF
Air Conditioner Overall Diagram Refresh/Recirculate Switch Motor Actuator Control 1.
2.
Recirculate mode In refresh mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been closed, the system goes into recirculate mode.At this time, the display switches to recirculate and the motor actuator operates to the refresh angle (damper angle) of 0째. Refresh mode In recirculate mode, when it is recognized that the refresh/recirculate select switch on the operation panel has been closed, the system goes into refresh mode. At this time, the display switches to refresh and the refresh/ recirculate switch motor actuator operates to the refresh angle. 1) 2)
3.
Refresh mode I When blow mode control is manual and is set to B/L or FOOT, the set temperature is set to 32 째C (HOTMAX), and air flow control is manual and is set to Hi, the refresh angle (damper angle) operates to 67째. Refresh mode II When in a mode other than refresh mode I, the refresh angle (damper angle) operates to 30째.
Operation stop judgment 1) 2)
The operating motor actuator stops when the current position comes within the target position range. The stopped motor actuator operates when the current position goes beyond the target position range. Refresh/recirculate mode and refresh/recirculate display Recirculate Refresh/recirculate mode Outside air Panel display
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Air Conditioner Overall Diagram Blower Amp Control 1.
2.
Summary explanation The air flow is controlled by outputting to the blower amp connected in series with the blower motor. The air flow is switched by varying the analog voltage output by changing the PWM output duty ratio and increasing or decreasing the blower motor speed. There are 2 types of air flow control: auto air flow control and manual air flow control. Also, in auto air flow control, the air flow is restricted by the cold blast prevention control etc. Manual air flow control Each time it is recognized that the air flow UP switch has been closed, the air flow is fixed to the next higher level of air flow from Lo → M1 → M2 → M3 → M4 → Hi. When Hi is already displayed, the air flow is not changed. In the same way, each time it is recognized that the air flow DOWN switch has been closed, the air flow is fixed to the next lower level of air flow from Hi → M4 → M3 → M2 → M1 → Lo. When Lo is already displayed, the air flow is not changed. The same is true when air flow control is switched from auto to manual. For example, when AUTO M1 is displayed, if it is recognized that the air flow DOWN switch has been closed, the display becomes Lo and AUTO is no longer displayed. Also, the change speed for air flow output switchover is the same as discussed for auto below. Relationship between air flow and display during manual operation Lo (minimum air M1 M2 M3 Air flow flow) Blower air 40 % 46 % 54 % 64 % flow %
M4
Hi (maximum air flow)
80 %
100 %
Display
3.
Auto air flow control When it is recognized that the AUTO switch has been closed, the air flow is controlled automatically and AUTO is displayed. 1) 2) 3) 4) 5) 6)
During auto air flow control, the air flow is set according to the target blowing temperature as shown in the diagram below. Auto air flow control continues until closing of either the air flow UP or air flow DOWN switch is recognized. The auto air flow amount calculation results are continuous, not divided into levels. When it is recognized that the AUTO switch has been closed, the display becomes as in the table below according to the results of the auto air flow amount calculation. The normal auto air flow output change is roughly 5 V/sec. Auto air flow control is restricted by the cold blast prevention control described in (4), which is the next item.
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Air Conditioner Overall Diagram *1 *2 *3
Target blow temperature Auto air flow Hi
*4 *5 *6
M4 M3 M2
*7 *8
M1 Lo
Relationship between air flow and target blow temperature Display refreshing and air flow output correspondence table Current display Item Target % (about) Lo display Output range changed to M1 When 44 % or higher Output range changed to Lo When 40 % or lower M1 display Output range changed to M2 When 52 % or higher Output range changed to M1 When 48 % or lower M2 display Output range changed to M3 When 61 % or higher Output range changed to M2 When 57 % or lower M3 display Output range changed to M4 When 74 % or higher Output range changed to M3 When 70 % or lower M4 display Output range changed to Hi When 88 % or higher Hi display Output range changed to M4 When 84 % or lower 4.
Cold blast prevention control The air flow is restricted according to the value of the coolant temperature data and other parameters sent from the vehicle side via CAN communication. The air flow restriction has 2 levels - air flow 0 and air flow Lo. Whether or not to use the restriction is determined from the judgment results. 1)
Conditions under which cold blast prevention control is used 1) 2) 3)
2)
3)
5.
Auto air flow When set temperature - inside air sensor temperature 11. When the coolant temperature signal from vehicle is the less than 30 °C signal or the 30 °C or higher but less than 45 °C signal
Under the condition above, the inside air sensor temperature is the value immediately after the vehicle main key power supply is switched ON and AUTO and Tset are according to the current switch states. Therefore, when the AUTO switch is pressed after the air flow has been set manually, if the coolant temperature is within the cold blast prevention range, the air flow is restricted. In the same way, even if the set temperature is changed, if the conditions are met, the air flow is restricted. While cold blast prevention control is being executed, the display corresponds to the restricted air flow. Air flow 0 control When the coolant temperature signal from vehicle is the less than 30 °C, the air flow is set to 0. This continues until a coolant temperature signal of 30°C or higher is received. Once a coolant temperature signal of 30 °C or higher is received and these conditions are no longer met, air flow 0 is ended. Air flow Lo control When the coolant temperature signal from vehicle is the 30 °C or higher but less than 45 °C signal, the air flow is set to Lo. This continues until a coolant temperature signal of 45 °C or higher is received. Also, the same as for [2], this shift is irreversible. Once a coolant temperature signal of 45 °C or higher is received, control is normal.
Blower air flow control when mode motor actuator angle switched When the mode motor actuator is operated with the blower air flow at M1 or higher, the mode motor actuator is operated with the blower air flow first set to Lo. After the end of operation, the original blower air flow returns. Changes to the blower output at this time are the same as normal auto air flow control. However, the blower display is not changed during control.
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Air Conditioner Overall Diagram 6.
Air flow control priority order The priority order for auto air flow control, manual air flow control, and cold blast prevention control is as follows. Priority orControl der Blower air flow control when mode motor actuator angle 1 switched 2 Manual air flow control 3 COOLMAX control 4 Cold blast prevention control 5 HOTMAX control 6 Auto air flow control
84402827B - May 2011 9006-20
Air Conditioner Overall Diagram Compressor Clutch Control 1.
2.
Summary explanation The compressor clutch is controlled by the power to the clutch coil being switched ON/OFF by an external relay. This control is executed by thermo operation and the fletching prevention function. Thermo operation has control mode 1 and control mode 2. These modes are applied according to the blow mode and other conditions. However, for blower air flow 0, the compressor clutch is switched OFF. The operation temperature does not include the thermistor variation. Thermo operation (AC switch ON) 1)
Control mode switchover â&#x20AC;˘ When the blow mode is B/L and the target blow temperature is as in the diagram below, control mode 2 is used. As the diagram shows, there is hysteresis between control modes 1 and 2. â&#x20AC;˘ Other than the above is all control mode 1.
*1 *2 *3 3.
Fletching prevention function 1)
2) 4.
Target blow temperature Control mode 1 Control mode 2
Operation conditions After the end of initial operation, if 4 - 5 min. continue with the air flow M3 or higher and the compressor clutch not coming ON even once, the compressor clutch is switched ON one time. This control is cleared by the vehicle main key power supply being switched OFF and this control starts again when this power supply is switched ON again. This control takes priority over all other control.
AUTO switch link function When operation of the AUTO switch is recognized, compressor clutch control comes ON and AUTO is displayed. 1) 2)
Compressor clutch control is the same control as for the AC switch being switched ON. When it is recognized that the AC switch has been switched OFF, the AUTO display goes out. Even when it is recognized that the AC switch has been switched ON again, AUTO is not displayed.
However, at this time, if the main key power supply is switched OFF, then ON again, since the AC ON, air flow AUTO, and blow mode AUTO conditions are all met, AUTO is displayed.
84402827B - May 2011 9006-21
Air Conditioner Overall Diagram COOLMAX Control and HOTMAX Control 1.
When the set temperature is 18.0 째C [COOLMAX] (or 18.E) 1) 2) 3)
2.
The air mix motor actuator is set to the 0째 limiter position (fully closed). For auto air flow control, the air flow is set to Hi. For AUTO blow mode control, the blow mode is set to VENT.
When the set temperature is 32.0 째C [HOTMAX] (or 32.E) 1) 2) 3)
The air mix motor actuator is set to the 90째 limiter position (fully open). For auto air flow control, the air flow is set to M4. For AUTO blow mode control, the blow mode is set to FOOT.
Abnormality Detection and Control after Abnormality Detected 1.
2.
Summary explanation If there is an abnormality in a motor actuator drive line or sensor computer input circuit, the abnormality is detected and control after detection is performed as described below. In all cases, abnormality control does not end once abnormality has been detected and the location is returned to normal. Trouble control is only ended when the vehicle main key power supply is switched OFF or when air conditioner operation is stopped with the ON/OFF switch on the operation panel. However, motor actuator restriction is only ended by switching OFF the main key power supply. Trouble in a motor actuator and its input/output circuits 1)
Disconnection detection After the main key power supply is switched ON, if a motor actuator potentio-meter line is disconnected or shorted, the display in the table below for that motor actuator is carried out and that motor actuator is not driven until the main key power supply is switched OFF, then ON again.
Abnormality location Air mix motor actuator Blow mode motor actuator Refresh/recirculate switch motor actuator
Abnormality display HL. E is displayed on the set temperature display LCD. See the diagram below. The passenger icon display flashes. The refresh/recirculate mark flashes.
84402827B - May 2011 9006-22
Air Conditioner Overall Diagram 2)
Motor lock detection If the output shaft rotation angle of a motor actuator does not reach the target value within 15 sec., locking is detected, output to that motor is stopped, and the abnormality is displayed on the computer according to the abnormality location.
Abnormality location
Abnormality display HL. E is displayed on the set temperature display LCD. See the diagram below. The passenger icon display flashes. The refresh/recirculate mark flashes.
Air mix motor actuator Blow mode motor actuator Refresh/recirculate switch motor actuator
3.
Trouble in a sensor or its input/output circuits (disconnection or short) 1)
Disconnection or short in the inside air sensor or its input/output circuits 1)
Operator compartment temperature control end • The operator compartment temperature control (all control related to target blow temperature) is stopped and the air mix degree of opening is directly adjusted according to the temperature adjustment switch input. • Accompanying this, the operation panel set temperature display changes as in the diagram below.
* is a value between 0 - 9, and each time the DOWN switch is closed, this value decreases by 1; each time the UP switch is closed, this value increases by 1. * value 0 1-8 9 2)
Motor actuator degree of opening (°) 0° * value × 10° 90°
Auto air flow control end • The air flow is temporarily fixed at the setting that was in effect when the inside air sensor abnormality was detected. • The AUTO display is set flashing. • After this, the air flow is switched by the manual air flow switch.
3)
AUTO blow mode control end • The blow mode is temporarily fixed at the setting that was in effect when the inside air sensor abnormality was detected. • The AUTO display is set flashing. • After this, the blow mode is switched by the manual blow mode switch.
4)
Air mix damper degree of opening display priority • Even if the trouble shown by one of the items below occurs during inside air sensor trouble, E is not displayed in the * section below the decimal point and the air mix damper degree of opening display is given priority. • HL. E is only displayed for air mix motor actuator trouble. 84402827B - May 2011 9006-23
Air Conditioner Overall Diagram 5)
Thermo operation control mode fixed • Switching of the control mode according to the blow mode and target blow temperature is stopped and the control mode is fixed at control mode 1.
2)
Disconnection or short in evaporator sensor or its input/output circuits 1) 2) 3)
Compressor control is not executed and the compressor clutch is always OFF. E is displayed in the first fraction position of the set temperature display LCD. See the diagram below. (The temperature setting is in 1 °C steps.) However, E is not displayed for inside air sensor trouble. The AC mark flashes.
Disconnection or short in evaporator sensor or its input/output circuits
*1 *2 3)
The AC mark flashes E is not displayed
Disconnection or short in solar radiation sensor or its input/output circuits 1) 2)
4) 4.
The solar radiation compensation data is set to 0. E is not displayed in the first fraction position of the set temperature display LCD as it is for other sensors. Coolant temperature signal trouble Cold blast prevention control does not work and normal control is used.
CAN communication abnormality processing 1)
Recovery from bus off 1) 2)
2)
Bus off retry processing is performed at the above rate. Receiving data abnormality 1) 2)
3)
Definition: The data field is outside the prescribed range regardless of whether the receiving data is operating normally or abnormally. Processing: In the case of the former, all data that time are discarded and the previous data are retained.
In the case of the latter, data is discarded only for those items determined to be abnormal. Communication interruption abnormality 1)
2) 3) 4) 4)
Initial retry processing: 5 msec. Re-retry processing: every 1 sec.
Interruption judgment Monitor Display: When normal reception is not possible 1 sec. or more since the previous normal reception Engine: When normal reception is not possible 10 sec. or more since the previous normal reception Internal use data: Shift to alternate data (processing) Sending process: Continue Recover: As soon as valid data is received
Alternate data (processing) ＜Sending mode: ENGINE ECU＞ 84402827B - May 2011 9006-24
Air Conditioner Overall Diagram 1)
2)
Outside air data abnormality Perform estimated outside air control. * However, once there is a shift to estimated outside air, estimated outside air control continues until the ignition is switched OFF. Coolant temperature data abnormality Control the internal coolant temperature data to 45 °C (the temperature at which to avoid cold air prevention control).
＜Sending mode: MONITOR DISPLAY ECU＞ 1) 2) 5)
Open window signal data abnormality Perform control with the internal open window data closed. Open door signal data abnormality Perform control with the internal open door data closed.
Alternate data (processing) up to initial normal reception ＜Send node: ENGINE ECU＞ 1) 2)
Outside air data abnormality Within 5 sec. after ignition is turned on: No data After 5 sec. after ignition is turned on: Perform estimated outside air control. Coolant temperature data abnormality Within 5 sec. after ignition is turned on: Perform control at 30 °C (the temperature at which to control cold air prevention) After 5 sec. after ignition is turned on: Perform control at 45 °C (the temperature at which to avoid cold air prevention control)
＜Send node: MONITOR DISPLAY ECU)＞ 1) 2)
Open window signal data abnormality Perform control with the internal open window data closed. Open door signal data abnormality Perform control with the internal open door data closed.
84402827B - May 2011 9006-25
Air Conditioner Overall Diagram Monitor Mode 1. 2. 3.
Summary explanation Monitor mode is a mode for understanding abnormalities in the operation panel itself or in other control. The system goes into monitor mode when there is the special switch input below on the operation panel. Starting monitor mode When the air conditioner is operating with basic control, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is started. Monitor contents 1) 2) 3)
4.
LCD segment diagnosis When monitor mode is entered, the target LCD lights up for 1 sec. An LCD with trouble does not light up. Sensor diagnosis The detection value (AD value or °C) for each sensor is displayed. Coolant temperature signal recognition value This displays the reception status for the coolant temperature signal sent from the vehicle.
Display contents in monitor mode In monitor mode, the data (detection value for each sensor, coolant temperature signal recognition, etc.) is displayed in the 3-digit of the 7-segment display for the temperature setting. The data displayed is selected with the blower UP/DOWN switches and AUTO switch. The blower UP/DOWN switches move the display on the dedicated monitor mode 7-segment display through 16 displays, 0 - F, and the corresponding data is displayed.(Table A) Hexadecimal data display and decimal data display can be selected with the AUTO switch. Only for the coolant temperature signal recognition value, the value detected immediately before entry into monitor mode is displayed. The difference between hexadecimal data and decimal data is indicated by the 3rd-digit of the 7-segment display for the temperature setting. For hexadecimal data, "H" is displayed there and for decimal data, numbers (0 - 9) are displayed there. 1)
Hexadecimal display AD values 00H - FFH are displayed. When the AD value corresponds to that in Table B (or Table C for the solar radiation sensor), this indicates a disconnection or short. In the hexadecimal display, when the value of a sensor changes in monitor mode, the hexadecimal display changes with it. If the display before entering monitor mode was , the error judgment value is displayed. (In other words, the detected value before the abnormality was detected) In the same way, if the display be-
2)
5. 6.
fore entering monitor mode was , the display becomes **.E and the error judgment value is displayed. Decimal display Decimal display is used from -99.9 °C to 99.9 °C. Also, the "-" minus display is displayed on the left side of the 3 digit segment.
Air conditioner operation in monitor mode When the system enters monitor mode, all output (operation) through control is stopped and until monitor mode is ended, operations and settings of basic control through all the switches are not possible. Ending monitor mode In monitor mode, if the operation panel ON/OFF switch closed path continues for 1 sec. while the refresh/recirculate select switch closed path is ongoing, monitor mode is ended and the system returns to the basic control state. The same also occurs if the vehicle main key power supply is switched OFF. Exclusively mode 7 seg 0 1 2 3 4
for
monitor Display contents Inside air sensor temperature data Evaporator sensor temperature data Solar radiation compensation data Outside air data -
84402827B - May 2011 9006-26
Air Conditioner Overall Diagram Exclusively mode 7 seg
for
monitor Display contents Coolant temperature signal status data
C 5-F
Abnormal
Lower than 30째C
4 1 Data (sensor diagnosis etc.) Sensor Short name Inside air F6H sensor Evaporator F6H sensor Sensor 5 V short name Solar radiaD5H tion sensor
30째C or higher Lower than 45째C 2
Disconnection 0CH 0CH
Ground short 0CH
84402827B - May 2011 9006-27
45째C or higher 3
Air Conditioner Overall Diagram Door Switch Control 1.
2.
Summary explanation This control adds a restriction to air conditioner operation with the door switch or front window switch. Its purpose is to prevent overheating of the vehicle main unit. Concretely, it suppresses condenser heating and controls in a way restricted in order to obtain a feeling of comfort. Door switch/front window switch signal Due to data sent from CAN communication. Message ID: 0x18FF1028 Sending mode: Monitor Display Send cycle: 10 ms Data: Open door signal and open window signal data Data judgment: Set with continuous 5 times of the same data for 20 ms cycle sampling
3.
Control restricted by door switch/front window switch 1)
2)
Starting restricted control When either the door or front window is open continuously for 1 sec. or longer, it is recognized that the switch is open. At the count of 60 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted control is starting and that control starts. Restricted control 1)
For both auto and manual blow mode control Regardless of being selected in either auto or manual blow mode, unless the blow mode is FACE, the following air flow restriction is executed. (If the blow mode is FACE, the air flow is not restricted.) Ⅰ. If the target blow temperature ＜ 20 °C, the air flow upper limit is set to M1. Ⅱ. If the target blow temperature 25 °C, the air flow restriction in I is ended.
2) 3)
3)
When the current blow mode control is AUTO Auto control with the AUTO blow mode VENT changed to FACE is used. When the current blow mode control is manual selection Only if the blow mode is VENT immediately after the open switch is recognized, that mode is changed to FACE. After this, all the blow modes can be selected with manual operation.
Ending the restriction When both the door and front window are closed continuously for 1 sec. or longer, it is recognized that the switches are closed. After a count of 1 sec., the buzzer buzzes the same way as for switch input to tell the operator that restricted control has been ended. When the restricted control is ended, the restriction on the air flow discussed in 1. above and the change from VENT to FACE in 3. are ended and control returns to normal. However, if the blow mode has been manually selected, even if the mode was changed from VENT to FACE by the above restriction, it does not return to VENT when the restricted control is ended.
84402827B - May 2011 9006-28
Air Conditioner Overall Diagram Inside Air Filter Clogging Detection Control 1.
2.
Summary explanation This control recognizes the blower current with the dedicated shunt resistor voltage input, judges from that value whether or not the A/C unit inside air filter is clogged and if it judges that that filter is clogged, it issues a warning to encourage the operator to replace the filter. Filter detection control 1)
2)
Starting detection control (detection timing) 5 sec. after the end of initial operation, if the air conditioner is operating and the cold blast prevention conditions are not present, this control is started. Also, this control is executed every 50 hours of air conditioner (blower) operation. However, during a temporary filter clog or filter clog, it is executed every time. Detection method Cooling / heating is judged from the operation mode and in this way the air mix motor actuator target position is determined. Also, the mode motor actuator target value is set to FOOT, the blower air flow target value is set to M1, and output is made to attain the target values. When all the target values are attained, the blower current from the shunt resistor voltage is recognized, and the filter clog is judged by comparing this current with the default current value. (cooling / heating judgment) When the operation mode is
FACE or VENT, When FOOT or DEF When B/L: Final inside air temperature When B/L: Final inside air temperature
(detection current threshold) Relative to the default current value
: Cooling (COOLMAX) : Heating (HOTMAX) If < 22 ÂşC, heating If â&#x2030;Ľ 22 ÂşC, cooling
For cooling
: 0.35 - 0.39 A min.
For heating
: 0.48 - 0.54 A min.
If the value is below this three times in a row, it is judged that there is a clog. (default current value) Current found in the initialization operation described below. 3)
Clog warning (buzzer) The buzzer buzzes intermittently at 1 Hz for 10 sec. (display) "FIL" is displayed on the 7-segment display for the set temperature for 10 sec. Other marks go out. However, if there is any switch input, the "FIL" display is ended immediately.
4) 5)
Alarm reset If a reset detection value is recognized during the clog state, the clog state is reset. The reset detection value is 50 % of the clog detection threshold. ON/OFF switching This function is switched ON/OFF by pressing the [Refresh / Recirculate], [MODE], and [DEF] switches at the same time. The factory setting for this function is OFF. This function does not come ON until the initialization operation discussed below is executed. (buzzer) When operation of this switch is recognized, there is the normal switch input sound. (display) ON or OFF is displayed on the set temperature 7-segment display, whichever is the state after switching. Other marks go out.
6)
Initialization operation When the [Refresh / Recirculate] and [DEF] switches are pressed at the same time, the default current value is detected and all the data for filter detection is initialized. Before executing this operation, make sure that the air conditioner unit (with a new inside air filter installed), ducts, and grilles (with all grilles fully open) are all installed in their normal states on the vehicle. If initialization is carried out in any other state, there is a danger of the clog detection judgment control making an incorrect judgment. Immediately after replacing the inside air filter with a new one, execute the initialization operation. (buzzer) When operation of the switch is recognized, the buzzer buzzes with the normal switch input sound. When the detection ends, the buzzer buzzes for 3 sec.
7)
Detection processing avoidance 84402827B - May 2011 9006-29
Air Conditioner Overall Diagram â&#x20AC;˘ When the inside / outside air damper is not at the recirculate position immediately before the current value is read â&#x20AC;˘ When the power supply voltage is not in the tolerance range for the voltage during the initialization operation â&#x20AC;˘ Trouble in any of the motor actuators
84402827B - May 2011 9006-30
Air Conditioner Overall Diagram Actuator Inspection Air Mix Motor Actuator Inspection • Structural diagram
Air mix damper operation defect ↓ See the chart. ↓ Specifying the trouble location 1 2
Control panel Air mix motor actuator
3 4
Connector 1 Connector 9
• Chart Step
1 2 3 4 5
6
7
Standard value
Action
Press the temperature setting switches and set to COOLMAX (18.0 °C). Does the actuator operate at all? Is an error displayed? Press the temperature setting switches and set to HOTMAX (32.0 °C). Does the actuator operate at all? Is an error displayed? Is there continuity in harness between the actuator and control panel? Remove the actuator connector (9). About Is the resistance between L/Y KΩ and B/L of the actuator about 4.7 KΩ? Is there continuity between the G/L and L/Y and between G/L and B/L of the actuator? Set temperature COOLMAX (18 °C) HOTMAX (32 °C)
Yes
No
Go to Step 2
Go to Step 3
Go to Step 6
Damper lock or link defect
Go to Step 2
Go to Step 4
Go to Step 5
Control panel defect
Actuator defect or damper Harness defect lock or link defect 4.7
Go to Step 7
Actuator defect
Control panel defect
Actuator defect
Air mix motor actuator position 0° 90°
84402827B - May 2011 9006-31
Air Conditioner Overall Diagram Refresh/Recirculate Switch Motor Actuator Inspection • Structural diagram
Inside/outside air mix damper operation defect ↓ See the chart. ↓ Specifying the trouble location 1 2
Control panel Refresh/recirculate motor actuator
3 4
Connector 1 Connector 11
• Chart Step 1 2 3 4
5
6
Action
Standard value
Press the refresh/recirculate switch. Does the actuator operate at all? Is an error displayed? Is an error displayed? Is there continuity in harness between the actuator and control panel? Remove the actuator connector (11). About Is the resistance between L/Y and KΩ B/L of the actuator about 4.7 KΩ? Is there continuity between the L/G and L/Y and between L/G and B/L of the actuator?
Yes
No
Go to Step 2
Go to Step 3
Go to Step 5 Go to Step 4
Damper lock or link defect Control panel defect
Actuator defect or damper Harness defect lock or link defect 4.7
Go to Step 6
Actuator defect
Control panel defect
Actuator defect
84402827B - May 2011 9006-32
Air Conditioner Overall Diagram Mode Motor Actuator Inspection • Structural diagram
Mode damper operation defect ↓ See the chart. ↓ Specifying the trouble location 1 2
3 4
Control panel Mode motor actuator
Connector 1 Connector 10
• Chart Step 1 2 3 4 5
6
Action
Standard value
Press the mode select switch. Does the actuator operate at all? Is an error displayed? Is there continuity in harness between the actuator and control panel? Is an error displayed? Remove the actuator connector (10). About Is the resistance between L/Y and KΩ B/L of the actuator about 4.7 KΩ? Is there continuity between the Y/L and L/Y and between Y/L and B/L of the actuator?
Yes
No
Go to Step 4
Go to Step 2
Go to Step 3
Control panel defect
Actuator defect or damper Harness defect lock or link defect
4.7
Blow mode MODE 1 Blow mode motor actuator degree of open90° ing FACE
Go to Step 5
Damper lock or link defect
Go to Step 6
Actuator defect
Control panel defect
Actuator defect
MODE 2
MODE 3
MODE 4
MODE 5
67°
48°
26°
0°
VENT
B/L
FOOT
DEF
Panel display
84402827B - May 2011 9006-33
Air Conditioner Overall Diagram Self-diagnosis Function with Panel Display Abnormality Display and Self-check Procedures Motor actuator and sensor abnormalities can be checked on the panel display.
Abnormality Display Position
a b
This segment is displayed only in the monitor mode below. Error is displayed on the 3-digit 7-segment display.
84402827B - May 2011 9006-34
Air Conditioner Overall Diagram Explanation of Abnormality Display Motor Actuator Abnormality 1.
HL. E displayed on 3-digit 7-segment display.
Check the air mix damper motor actuator for a harness disconnection or disconnected connector. This is also displayed when locked due to air mix motor actuator abnormality and link abnormality.
2. flashes.
Check the blow mode damper motor actuator for a harness disconnection or disconnected connector.
3. flashes.
Check the refresh/recirculate damper motor actuator for a harness disconnection or disconnected connector.
CAUTION The above display and flashing is displayed on the 3-digit 7-segment display when trouble occurs with the panel ON/OFF switch ON status. After trouble occurs, when the panel ON/OFF switch is switched ON, the function is displayed. After trouble is resolved, the abnormality display and flashing are not ended until the main switch is switched OFF â&#x2020;&#x2019; ON.
84402827B - May 2011 9006-35
Air Conditioner Overall Diagram Sensor Abnormality 1.
HL. * displayed on 3-digit 7-segment display
Check the inside air sensor and check its harness for disconnection, short, or connector connection defect.
a
(* is any number 0 - 9.)
2. mark flashing are flashing on the 3-digit 7-segment display. (** displays the set temperature **.E and the value at that time still remaining.)
Check the evaporator sensor and check its harness for disconnections, shorts, or connector connection defects.
CAUTION The display in 1 and 2 above is displayed on the 3-digit 7-segment display when trouble occurs with the panel ON/OFF switch ON status. After the trouble section is repaired, end the abnormality display by switching the panel ON/OFF switch OFF â&#x2020;&#x2019; ON.
84402827B - May 2011 9006-36
Air Conditioner Overall Diagram Explanation of Monitor Mode 2. When sensor abnormality is displayed, the sensor status (disconnection, short) can be checked in monitor mode.
Monitor Mode Display Position
a b
3-digit 7-segment 7-segment dedicated to monitor display
84402827B - May 2011 9006-37
Air Conditioner Overall Diagram Monitor Mode Display Operating Method
1 2 3 1. 2. 3. 4.
Refresh/recirculate select switch Blower switch UP/DOWN switch ON/OFF switch
Hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. or longer. Press the AUTO switch. (All the 7 segments light up for 1 sec., then the system enters monitor mode.) Numbers 0 - 9 or letters A - F are displayed in the 2nd and 3rd digit of the 3-digit 7-segment display. "H" is displayed in the 1st-digit. The display of 0 - 2 on the dedicated 7-segment display is carried out with the blower UP/DOWN switches. The necessary sensor is selected from the table below. 7-segment display table dedicated to monitor 0 Inside air sensor 1 Evaporator sensor 2 Solar radiation sensor (Display other than the above (3 - 9, B - F) is not used during service.)
5.
To end the monitor display, either hold down the refresh/recirculate select switch and the ON/OFF switch at the same time for 1 sec. again or longer or switch the vehicle main switch OFF. CAUTION 1. 2.
During monitor mode, operations and settings of basic control through all the switches are not possible until the air conditioner control operation is stopped and monitor mode ended. During monitor mode, even if a sensor is repaired, the abnormality display is recorded in memory, and until the ON/OFF switch is switched OFF, then ON again, the abnormality display is not ended.
84402827B - May 2011 9006-38
Air Conditioner Overall Diagram Display Contents in Monitor Mode See the dedicated monitor 7-segment display table and 3-digit 7-segment table. 1.
Display example 1
The dedicated monitor 7-segment display is 0 (indicates the inside air sensor state). From the 3-digit 7-segment table 3F → The sensor is normal. → The inside air sensor is normal.
2.
Display example 2
The dedicated monitor 7-segment display is 1 (indicates the evaporator sensor state). From the 3-digit 7-segment table 0C → The sensor is disconnected. → The evaporator sensor is disconnected.
3.
Display example 3
The dedicated monitor 7-segment display is 2 (indicates the solar radiation sensor state). From the 3-digit 7-segment table D5 → The sensor is shorted on the 5 V side. → The solar radiation sensor is shorted.
3-digit 7-segment table
84402827B - May 2011 9006-39
Air Conditioner Overall Diagram
a b c
2nd-digit of 7-segment display d Inside air sensor disconnection e OCH0 display Evaporator sensor disconnecf tion OCH1 display
Solar radiation sensor short g OCH2 display 3rd-digit of 7-segment display
h
Sensors normal
i
Solar radiation sensor 5 V side short D5H2 display Inside air sensor short F6H0 display Evaporator sensor short F6H1 display
Air conditioner troubleshooting The blow temperature does not go down. * M/A means motor actuator. Step
1
Action
When the AUTO switch or AC switch is pressed, HL. E is displayed in the panel set temperature display section.
Standard value
Yes
No
• The air mix motor actuator connector is disconnected or has a contact defect. • Air mix motor actuator defect Go to Step 2 • Main harness continuity defect Inspect and repair or replace part.
2
HL. * is displayed on the panel set temperature display section. * is No. 0 to 9.
Go to Step 3
84402827B - May 2011 9006-40
Go to Step 4
Air Conditioner Overall Diagram Step
Action
3
The panel snow mark flashes.
4
The panel snow mark flashes.
Standard value
Yes
No
• Inside air sensor or harness disconnection or • Inside air sensor and short evaporator sensor simulThe inside air sensor contaneous disconnection or • nector is disconnected or short has a contact defect. • Computer breakdown See the Monitor Mode secSee the Monitor Mode section too. tion too. Inspect and repair or replace part. • The evaporator sensor connector is disconnected or there is a contact defect. • Evaporator sensor simultaneous disconnection or Go to Step 5 short See the Monitor Mode section too. Inspect and repair or replace part.
5
When the set temperature is 18.0 and the blow mode is set 18.0 ﾟC to vent mode, the blow temperature drops.
6
Cool air is flowing into the inside air sensor section.
7
The air mix damper is at the COOLMAX position.
8
If motor actuator operation • Inspect, repair, or replace stops midway, remove the Motor actuator breakdown the motor actuator lever cause or correct the problem, 1.5 kgf or link section. or computer breakdown and then measure the operat- less Replacement • Clean the lever link secing force. tion, then apply grease. Is it 1.5 kgf or less?
Go to Step 6
Go to Step 7
Inspect the duct or eliminate the cause of the cool air infiltration. Switch compressor clutch ON/OFF and inspect and repair the power supply circuit. See the cooling cycle troubleshooting.
Computer breakdown or inside air sensor defect Inspect and replace.
The blow temperature does not go up.
84402827B - May 2011 9006-41
Go to Step 8
Air Conditioner Overall Diagram Step
1
2
Standard value
Action
HL. E is displayed on the panel set temperature display section.
Inspect and repair or replace part. • Inside air sensor or harness disconnection or short • The inside air sensor connector is disconnected or Go to Step 3 has a contact defect.
HL. * is displayed on the panel set temperature display section. * is No. 0 to 9.
See the Monitor Mode section too. Inspect and repair or replace part.
3
4
Warm air is flowing into the inside air sensor section.
6
No
• The air mix motor actuator connector is disconnected or has a contact defect. • Air mix motor actuator defect Go to Step 2 • Main harness continuity defect
When the set temperature is 32.0 and the blow mode is set 32.0 ﾟC to foot mode, the blow temperature rises.
5
Yes
Go to Step 4
Go to Step 5
Inspect the duct or eliminate the cause of the warm air infiltration. Inspect the warm coolant lines.
Computer breakdown or inside air sensor defect Inspect and replace.
The air mix damper is at the Go to Step 6 HOTMAX position. If motor actuator operation • Inspect motor actuator stops midway, remove the Motor actuator breakdown lever link section. cause or correct the problem, 1.5 kgf or Repair or replace. or controller breakdown and then measure the operat- less Replacement • Clean the lever link secing force. tion, then apply grease. Is it 1.5 kgf or less?
The blower motor does not rotate. Step 1
2
3
4
5
Action
Standard value
With the flow set to HI, battery voltage is applied to the terminals (+ and -) of the blower motor. (Note: 1) The battery voltage is applied between the blower motor (+) power supply red/blue and the body. Voltage of about 10 V is applied between the blower amp About 10 V brown/yellow line and ground. Remove the blower amp and refer to the section on Blower Amp Inspection. Is there any abnormality? No abnormality → Yes Abnormality → No Inspect the blower motor relay. When the blower motor relay white/red and blue/red are directly connected, the blower motor rotates. (Note: 2)
Yes
No
Replace the blower motor.
Go to Step 2
Go to Step 3
Go to Step 5
Go to Step 4
Replace computer.
Eliminate the cause of the Inspect and repair the wire trouble, then replace the harness. blower amp.
Go to Step 6
84402827B - May 2011 9006-42
Inspect, repair, or replace the wire harness.
Air Conditioner Overall Diagram Action
Step
Standard value
The battery voltage is applied between the blower motor relay white/red and the body. When the blower motor relay purple/white is dropped to ground, the blower motor rotates.
6
7
Yes
No
Go to Step 7
Inspect, repair, or replace the wire harness.
Inspect or repair the wire harness or replace the com- Replace the relay. puter.
NOTE: 1. 2.
Measure with the connector connected. For the sake of safety, have the air conditioner, vehicle key, and light switches all OFF when working with direct connections in place.
The blower motor speed does not change. Part 1 Step
1
Action
Yes No â&#x20AC;˘ Inside air sensor or harness disconnection or short â&#x20AC;˘ The inside air sensor connecHL. * is displayed on the panel set tor is disconnected or has a Replace the blower amp or contact defect. temperature display section. computer. * is No. 0 to 9. See the Monitor Mode section too. Inspect and repair or replace part.
Part 2 Step 1 2
Action Yes No Does the blower motor fail to change speed when the mode is other than Go to Step 2 See Part 1. FACE? While operating under restrictive control by door switch or See Part 1. Is the door or front window open? front window switch.
The magnetic clutch does not engage. Step
Action
1
When the AUTO switch or AC switch Go to Step 2 is pressed, the snow mark lights up.
2
3
4 5
Yes
No The snow mark flashes and E is displayed on the panel display section.
Clutch defect. Replace the Go to Step 3 compressor. Pressure switch defect or coolant pressure abnormally Voltage is applied between the harhigh or low Go to Step 4 ness and pressure switch. See the cooling cycle troubleshooting. Voltage is applied between the vehicle side harness connector blue/red and Go to Step 5 Inspect the clutch fuse. ground (black). Is there trouble in the air conditioner Replace computer. Replace the harness. harness? Voltage is applied to the clutch.
Refresh/recirculate mode does not switch 84402827B - May 2011 9006-43
Air Conditioner Overall Diagram Step
1
2
Action
Yes No The refresh/recirculate motor actuator connector is disconThe refresh/recirculate mode display nected, there is a contact deon the operation panel LCD display Go to Step 2 fect, or there is trouble with the section is flashing. motor actuator or the main harness. There is foreign matter on the refresh/ recirculate motor actuator lever sec- Remove the foreign matter or Replace the motor actuator. tion or the motor actuator lever sec- replace the part. tion is broken.
The mode is not switched. Step
1
2 3
4
Action
Standard value
Yes
No
The refresh/recirculate motor actuator connector is disconnected, there is a contact defect, or there is trou- Go to Step 2 ble with the motor actuator or the main harness. Inspect or replace.
The passenger icon display on the operation panel LCD display section flashes. The motor actuator rod is correctly in place. A damper lever is correctly in place.
When the cam with the rod re2 kgf moved is moved by hand, it is more sluggish (2 kgf or more).
Go to Step 3
Correction
Go to Step 4
Correction
• Foreign matter or breakage at cam section or damper shaft section • Operation defect due to soiling with grease or the Replace the motor actuator or like or computer. • Remove the foreign matter or replace the part. • Clean the cam section, then apply grease.
84402827B - May 2011 9006-44
Air Conditioner Overall Diagram Part Function and Good/Poor Judgment Control Panel Function of each switch
7
1
Main power switch
4
Air flow select switch
2
Auto control switch
5
Air conditioner ON/OFF switch 8
3
Temperature control switch
6
Defrost switch
Diffuser select switch Refresh/recirculate switch
select
Through the operation of its internal microcomputer, the control panel compares, operates on, and processes the sensor input signals and control panel switch input signals, switches the output side actuators (refresh/recirculate switching, mode switching, air mix) and comprehensively controls the fan motor and compressor. Also, it is equipped with self-diagnosis functions to make trouble diagnosis easier. (For details see the air conditioner troubleshooting.)
84402827B - May 2011 9006-45
Air Conditioner Overall Diagram Blower Amp The power transistor receives the base current from the control unit and changes the speed of the fan motor. Blower amp inspection The blower amp can be easily judged by removing the blower amp connector and checking for continuity across the blower amp terminals.
Tester
Terminal No. 1 2 --+ + +
3 -----
Continuity Yes (4.7 kΊ) No Yes (diode parallel forward direction)
a
84402827B - May 2011 9006-46
Temperature fuse: 132 - 138 °C
Air Conditioner Overall Diagram Relay
4-pole relays are used for the blower OFF relay and compressor relay. Blower OFF relay This relay receives the signal from the control amp and switches the blower OFF relay ON. When the blower OFF relay is switched ON, the power supply voltage is fed to the blower motor via the blower amp and the blower motor is started. Compressor relay The compressor relay is switched ON/OFF by the control amp compressor control. Relay inspection contents 1. 2. 3. 4. 5.
Relay Coil resistor: 320Ί Specification voltage: DC 20 - 30 V Be careful. The coil side of this relay must be installed with the poles facing correctly. Inspection: Inspect for continuity between 3 and 4 under the conditions below. 20 - 30 V applied between term8inals 1 and 2 No voltage applied between terminals 1 and 2
84402827B - May 2011 9006-47
: Continuity : No continuity
Air Conditioner Overall Diagram Air Mix Actuator CAUTION The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifications. The air mix actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and closes the air mix damper via the link. Built into the air mix actuator is the potentio-meter which switches linked with the actuator shaft. When the target air mix door position is determined by the temperature control switch, the control unit reads in the potentio-meter position in the actuator and determines whether the motor turns forward or reverse. The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF, the motor stops.
Motor actuator
Control panel
1 2
M/A 1 M/A 2
3 4
5
GND Potentio-meter
Direction of rotation Clockwise (forward) Counter-clockwise (reverse)
Terminal 1 + -
84402827B - May 2011 9006-48
2 +
5 VDC
Air Conditioner Overall Diagram Refresh/Recirculate Actuator
CAUTION The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifications. The refresh/recirculate switch actuator is installed on the blower intake unit. It opens and closes the refresh/recirculate door via the link. Built into the refresh/recirculate switch actuator is the potentio-meter that switches linked with the actuator shaft. When the refresh/recirculate door position is determined by the refresh/recirculate switch on the control panel, the control unit reads in the signal of the potentio-meter in the actuator and determines whether the motor turns forward or reverse. The position detection switch also rotates linked with the motor and stops the refresh/recirculate door at the set position.
84402827B - May 2011 9006-49
Air Conditioner Overall Diagram Blow Mode Actuator
CAUTION The air conditioning system voltage specifications are 24 V, but the motor actuator has 12 V specifications. The blow mode actuator is installed at the center of the air conditioner unit contained behind the link cover. It opens and closes the mode door via the link. Built into the blow mode actuator is the potentio-meter which switches linked with the actuator shaft. When blow mode is determined by the temperature control switch, the control unit reads in the potentio-meter position in the actuator and determines whether the motor turns forward or in reverse. The contacts move linked with the motor. When the contacts move open or the control unit output signal goes OFF, the motor stops.
84402827B - May 2011 9006-50
Air Conditioner Overall Diagram Evaporator Sensor In order to prevent the evaporator from freezing, the evaporator blow temperature is detected and the compressor ON/OFF is controlled.
• Evaporator sensor inspection method (specifications value) Disconnect the evaporator sensor from the main harness and measure the resistance between the sensor side connector terminals using the tester. Resistance between When the sensor section detection temperature is 0 °C terminals When the sensor section detection temperature is 25 °C
84402827B - May 2011 9006-51
: :
7.2 kΩ 2.2 kΩ
Air Conditioner Overall Diagram Dual Pressure Switch
â&#x20AC;˘ The dual pressure switch is installed on the receiver dryer. When there is pressure trouble in the coolant high-pressure side line (abnormally high pressure or abnormally low pressure), the dual pressure switch contacts open up to cut off the compressor power and protect the cooling cycle.
Dual pressure switch specifications 1 2
(Low-pressure side) (High-pressure side)
â&#x20AC;˘ Simple inspection method for dual pressure switch 1. 2.
3.
With the cooling cycle stopped, disconnect the connector from the switch and check the conductance between the switch side connector terminals using the tester. If there is conductance, the switch is normal. (When the outside air temperature is 0 °C or higher) Connect the gauge manifold high-pressure side hose to the high-pressure side charge port. With the cooling cycle operating, the condenser front surface is covered with a plate shaped object and the high pressure rises. If the compressor stops around 3.14 MPa, the switch is normal. With the coolant removed, check the conductance between the switch side connector terminals using the tester. If there is no conductance, the switch is normal.
84402827B - May 2011 9006-52
Air Conditioner Overall Diagram Solar Radiation Sensor This is the air conditioner solar radiation correct sensor. It detects the strength of sunlight with a photodiode, converts it into milli-amp and sends that to the controller.
â&#x20AC;˘ Solar radiation sensor inspection method Disconnect the solar radiation sensor connector from the harness and measure the voltage between the sensor side connector terminals using the tester's voltage measurement mode. The voltage must be different when light is striking the photoreceiver section and when it is not. (The voltage is about 0 V when absolutely no light is striking the photoreceiver.) CAUTION Always measure with the tester in voltage measurement mode (V mode). Measuring in resistance mode (Ί mode) would destroy the sensor.
84402827B - May 2011 9006-53
Air Conditioner Overall Diagram Inside Air Sensor
The inside air sensor is installed in the inside air side intake port of the air conditioner unit and switches the temperature inside the cab to the resistance. This resistance value is converted into a voltage value in the control panel and processed. Inside air sensor inspection method Remove the inside air sensor connector from the main harness and measure the resistance between the sensor side connector terminals using the tester. Inside air sensor inspection details (specifications) Resistance between terminals For 0 °C: 7.2 kΩ ± 3 % For 25 °C: 2.2 kΩ ± 3 %
84402827B - May 2011 9006-54
Section 9007
Assembly and Disassembly of Air Conditioner Units
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Blower Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of Blower Amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of Heater Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of Heat Case Right/Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of Evaporator and Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of Evaporator Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement of Motor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
84402827B - May 2011 9007-1
3 4 4 4 5 5 6 6
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9007-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Assembly and Disassembly of Air Conditioner Units 2.
CAUTION • Be sure to stop the engine before beginning work.
Remove the filter cover (1) and inside air filter (2). • Remove the 4 Phillips screws (3) and remove the intake case (4). Screw size Phillips screws (3): M5 x 16 (T1)
CAUTION • When replacing the evaporator, re-supply and check the compressor oil quantity.
Removal of Blower Unit 1.
Remove the connectors connected to the refresh/ recirculate motor actuator connector (1), blower motor connector (2), inside air sensor connector (3), evaporator sensor connector (4) and relay connector (5).
84402827B - May 2011 9007-3
Assembly and Disassembly of Air Conditioner Units Replacement of Blower Motor
1.
Replacement of Blower Amp
CAUTION
CAUTION
Do not remove the fan from the blower motor.
Never disassemble the blower amp. Removing with the power on can suddenly increase the blower amp temperature, damaging the part. Also, touching the surface could cause burns.
Remove the cooling hose (2) from the air conditioner unit (1). • Remove the 3 Phillips screws (3) and remove the blower motor (4). Screw size Phillips screws (3): M5 x 14 • The installation procedure is the reverse of the removal procedure.
1.
Remove the connector (1) from the blower amp (2). • Remove the 2 Phillips screws (3) and remove the blower amp (2). Screw size Phillips screws (3): M4 x 16 • The installation procedure is the reverse of the removal procedure.
Removal of Heater Core CAUTION Remove while being careful not to apply excessive force to the pipe. 1.
Drain the coolant. • Remove the 4 Phillips screws (1) and remove the link cover (2). Screw size Phillips screws (1): M5 x 16 • Remove the mode actuator connector (3), and remove the heater core (4). • The installation procedure is the reverse of the removal procedure.
84402827B - May 2011 9007-4
Assembly and Disassembly of Air Conditioner Units Removal of Heat Case Right/Left CAUTION
Replacement of Evaporator and Expansion Valve CAUTION
At this time, perform work with the heater core removed from the heater case. The evaporator sensor cord is sandwiched in the groove of the HVAC unit, so carefully check it and remove it while making sure not to damage it. 1.
Remove the 10 Phillips screws (1) and remove the heater case right (2) and heater case left (3). Screw size Phillips screws (1): M4 x 16
Be careful of the O-rings getting caught, etc. when installing the expansion valve. The evaporator sensor cord is sandwiched in the groove of the HVAC unit, so carefully check it and remove it while making sure not to damage it. 1.
Turn the HVAC unit upside down and place it on a stand. • Remove the 4 Phillips screws (1) and remove the drain case (2). • Remove the 1 Phillips screw (1) and remove the evaporator pipe stay (3). • Remove the evaporator sensor connector (4), and remove the evaporator (5).
2.
Use a hexagon wrench (4 mm) to remove the 2 hexagon socket head bolts (1), and then remove the expansion valve (2). • Install O-rings (3) on the new evaporator (4) (1 NF O-ring 5/8 and 1 NF O-ring 1/2). Bolt (1) tightening torque: 6.9 N·m
84402827B - May 2011 9007-5
Assembly and Disassembly of Air Conditioner Units Installation of Evaporator Sensor CAUTION Be careful that the sensor cord does not get squeezed in the case when the case is assembled.
a b c d e
Thermistor holder position 20 mm 73 mm 9th row 27th row
Make sure to install the harness holder (1) and thermistor holder (2) in the original position of the evaporator (4) as shown in the diagram. â&#x20AC;˘ Install the evaporator sensor (3) end and thermistor holder (2) as shown in the diagram.
Replacement of Motor Actuator 1.
Replacement of mode motor actuator Remove the link cover. Remove the connector (2) from the motor actuator (1). Remove the 3 Phillips screws (3) securing the motor actuator (1), remove the rod (4) attached to the motor actuator (1) from the rod hole on the mode cam, and then install the new motor actuator (1). The installation procedure is the reverse of the removal procedure.
Screw size Phillips screws (3): M4 x 16 (T1)
84402827B - May 2011 9007-6
Assembly and Disassembly of Air Conditioner Units 2.
Replacement of air mix motor actuator Remove the link cover. Remove the connector (2) from the motor actuator (1). Remove the 3 Phillips screws (3) securing the motor actuator (1), remove the rod (4) attached to the motor actuator (1) from the rod hole on the damper lever, and then install the new motor actuator (1). The installation procedure is the reverse of the removal procedure. Screw size Phillips screws (3): M4 x 16 (T1)
3.
Replacement of refresh/recirculate motor actuator Remove the link cover. Remove the connector (2) from the motor actuator (1). Remove the 3 Phillips screws (3) securing the motor actuator (1), remove the lever pin (4) attached to the motor actuator (1) from the slot hole, and then install the new motor actuator (1). The installation procedure is the reverse of the removal procedure. Screw size Phillips screws (3): M4 x 16 (T1)
84402827B - May 2011 9007-7
Assembly and Disassembly of Air Conditioner Units
84402827B - May 2011 9007-8
Section 9009
Removal and Installation of Compressor
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9009-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9009-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Compressor Job code
• Always remove the low-pressure side line (2) first. • Attach caps or plugs to the compressor and lines to prevent any entry of water, dust or dirt. Tightening torque for bolt installation: 19.6 - 24.5 N·m
50200AA26
WARNING • Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out. CAUTION • Be sure to stop the engine before beginning work. • When removing and installing the compressor, check the compressor oil quantity. Items to prepare • • • •
Wrench (13 mm) Box wrench (13 mm) Rag Cleaning fluid
3.
Removal of Compressor 1.
Remove the connector (1).
2.
Use a box wrench (13 mm) to loosen the bolts (1) on the lines in the 2 locations, and then remove the 2 lines (2) (3).
Use a wrench (13 mm) to remove the 4 bolts (1), and then remove the compressor (2). Tightening torque for bolt installation: 19.6 - 29.4 N·m
84402827B - May 2011 9009-3
Removal and Installation of Compressor Installation of Compressor 1.
2.
To install, perform the reverse of the removal procedure. When installing the bolts, tighten them to the specified torque.
3.
Check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause compressor seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Measure the oil quantity of the removed compressor. Only this oil quantity is necessary, so subtract this quantity from 135 cc to determine the amount by which the oil quantity of the new compressor should be reduced. Example) If the remaining oil quantity of the removed compressor is 30 cc: Remove 135 cc - 30 cc = 105 cc from the new compressor to be installed. Resupply oil: SP-10 or SP-20 (P.A.G. oil) Perform air conditioner gas charging. For details, see "Gas Filling Procedures".
84402827B - May 2011 9009-4
Section 9010
Removal and Installation of Condenser
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
84402827B - May 2011 9010-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9010-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Condenser Job code
50200AK72
2.
Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the stay (2). Use a wrench (19 mm) to remove the 5 bolts (3), and then remove the top cover.
3.
Use a wrench (10 mm) to remove the bolt (1), and then remove the line (2).
CAUTION • Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out. CAUTION • Be sure to stop the engine before beginning work. CAUTION • When removing and installing the condenser, resupply and check the compressor oil quantity. Items to prepare • • • • •
• Attach caps or plugs to the condenser and line to prevent any entry of water, dust or dirt. • Clean the lines by spraying with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.
Wrenches (10 mm, 13 mm, 19 mm) Cap Plug Rag Cleaning fluid
Tightening torque for line installation: 7.8 - 11.8 N·m
Removal of Condenser 1.
Remove the wing nut (1), and then remove the precleaner (2).
4.
Use a wrench (10 mm) to remove the bolt (1), and then remove the line (2).
84402827B - May 2011 9010-3
Removal and Installation of Condenser 5.
Use a wrench (13 mm) to remove the bolt (1), and then remove the clamp (2).
6.
Use a wrench (13 mm) to remove the 6 bolts (1), and then remove the condenser (2).
84402827B - May 2011 9010-4
Removal and Installation of Condenser Installation of condenser 1.
2.
To install, perform the reverse of the removal procedure. Tighten lines and bolts to the specified torque. For bolts for which the torque is not specified, check "Bolt Size and Torque Table" in the explanation in the materials.
3.
Make sure to resupply and check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause compressor seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Resupply quantity: 40 cc Resupply oil: SP-10 or SP-20 (P.A.G. oil) Perform air conditioner gas charging. For details, see "Procedures for Gas Filling".
84402827B - May 2011 9010-5
Removal and Installation of Condenser
84402827B - May 2011 9010-6
Section 9011
Removal and Installation of Receiver Dryer
84402827B - May 2011
84402827B - May 2011
CONTENTS Removal of Receiver Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Installation of receiver dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
84402827B - May 2011 9011-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9011-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Removal and Installation of Receiver Dryer Job code
50200AN92
3.
Remove the connector (1).
4.
Use a wrench (10 mm) to remove the 2 bolts (2) from the line (1).
WARNING • Be careful when loosening the lines. The air conditioner circuit is filled with high-pressure gas, so there is the danger of gas splaying out. CAUTION • Be sure to stop the engine before beginning work. CAUTION • When replacing the receiver dryer, resupply and check the compressor oil quantity.
• Install caps or plugs to the receiver dryer and line to prevent any entry of water, dust or dirt. • Clean the receiver dryer and line by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors. Tightening torque for line installation: 7.8 - 11.8 N·m
Items to prepare • • • • •
Wrenches (10 mm, 19 mm) Cap Plug Rag Cleaning fluid
Removal of Receiver Dryer 1.
Remove the wing nut (1), and then remove the precleaner (2).
5.
2.
Use a wrench (10 mm) to remove the 2 bolt (1), and then remove the receiver dryer (2).
Use a wrench (19 mm) to remove the 2 bolts (1), and then remove the stay (2). Use a wrench (19 mm) to remove the 5 bolts (3), and then remove the top cover (4).
84402827B - May 2011 9011-3
Removal and Installation of Receiver Dryer Installation of receiver dryer 1.
2.
To install, perform the reverse of the removal procedure. Tighten lines and bolts being installed to the specified torque. For bolts for which the torque is not specified, check "Bolt Size and Torque Table" in the explanation in the materials. 3.
Check the compressor oil quantity. The compressor contains 135 cc of oil. The oil quantity being low will cause compressor seizing and a reduction in durability. The oil quantity being high will cause a reduction in cooling capabilities. Make sure to check the oil quantity and adjust if needed. Resupply quantity: 20 cc Resupply oil: SP-10 or SP-20 (P.A.G. oil) Perform air conditioner gas charging. For details, see "Gas Filling Procedures".
84402827B - May 2011 9011-4
Section 9015
Work Precautions
84402827B - May 2011
84402827B - May 2011
CONTENTS Work Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Work Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Filling Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging Hose Connection Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Gauge Manifold Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Vacuuming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gas Filling Operation, High-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gas Filling Operation, Low-pressure Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
84402827B - May 2011 9015-1
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
84402827B - May 2011 9015-2
Copyright © 2011 CNH FRANCE S.A. PRINTED IN FRANCE
Work Precautions Work Precautions WARNING • Refrigerant gas filling involves handling dangerous high-pressure gas, so make sure that a experienced and qualified worker with the procedure performs this operation. • Always wear protective eyewear. • Gas entering the eyes may cause blindness. • Refrigerant in the liquid state is very cold (about -26 °C), so be very careful during handling. • Refrigerant coming in contact with skin may cause frostbite. Always use R134a refrigerant. • Storage Keep service cans (hereinafter, cans) with refrigerant in them at 40 °C or below. The insides of the cans are highly pressurized and filled with refrigerant, so if the temperature rises there is the danger of internal pressure rising sharply and an explosion occurring. Never store in direct sunlight, in a closed vehicle, or near open flames. Be careful not to drop cans or have them collide with other objects. • Filling operation When cans are heated in order to fill them with refrigerant, make sure that the service can valve and gauge manifold low-pressure valve are open and heat with water at 40 °C or below. Direct heating or heating to 40 °C or higher may cause explosions, so use caution. If refrigerant filling is done after the engine is started, never open the gauge manifold high-pressure valve. This is very dangerous, as the high-pressure gas will flow in the opposite direction and may cause a can or charging hose explosion. Be careful not to allow the entry of dust or dirt into the air conditioner circuit. Air, moisture and dirt are very bad for the cooling cycle. Perform work quickly and accurately, and be especially careful to prevent the entry of foreign matter. Be careful not to overfill with gas.
84402827B - May 2011 9015-3
Work Precautions Work Procedures Air Conditioner Refrigerant "Vacuum Operation" and "Gas Filling Operation". 1.
2.
The "vacuum operation" consists of eliminating moisture in the air conditioner circuit. If there is any moisture left inside the air conditioner circuit, various problems may occur during operation such as freezing in the small hole of the expansion valve causing the circuit to clog and rust developing in the circuit. For this reason, perform vacuuming before filling the circuit with refrigerant. This operation consists of eliminating moisture inside the circuit through boiling and evaporation. The "gas filling operation" consists of filling the circuit with refrigerant after the vacuum operation. Gas filling does not only affect the cooling capabilities of the air conditioner, it also affects the life of the parts which make up the circuit. Severely overfilling the circuit will cause pressure inside the circuit to be abnormally high, and this will cause reductions in the cooling ability of the air conditioner. Additionally, if pressure is extremely low, the circulation of lubricating oil within the compressor will be poor and this will cause seizing with sliding parts of the compressor. Because the gas filling operation itself involves handling high-pressure gas, performing the operation using an incorrect procedure is very dangerous. Follow the operation and observe all precautions indicated in this text to correctly perform refrigerant filling.
Operation Chart
Vacuuming operation
Vacuuming start ↓ Vacuuming stop ↓
30 min. or longer (750 mmHg or less) Let sit for 5 min.
Airtightness check
Gauge display abnormality (connectors check and repair)
↓ Refrigerant filling
Fill with refrigerant gas up to a gauge pressure of 0.098 MPa.
Refrigerant fill- ↓ ing operation Gas leak check ↓ Refrigerant filling
84402827B - May 2011 9015-4
Work Precautions Tools No.
Part name
Q'ty Shape
1
Gauge manifold
1
Application
Red: high-pressure side Blue: low-pressure side Yellow: vacuum pump side
2
Charging hose
3
3
Quick joint
1
4
Quick joint
1
Low-pressure side
5
T joint
1
For service can valve
6
Service can valve
2
For service can
7
Vacuum adapter
1
For vacuum pump
pump
84402827B - May 2011 9015-5
Work Precautions Filling Procedures CAUTION â&#x20AC;˘ Because gauge manifold specifications such as hose color are different depending on the manufacturer, read the operator's manual for the gauge manifold to be used for details.
Charging Hose Connection Positions
1 2
High-pressure side (DIS) ser3 vice valve Low-pressure side (SUC) ser4 vice valve
Air conditioner compressor
5
Receiver dryer
Condenser
6
Air conditioner unit
Gauge Manifold Connection 1. 2.
3.
Close the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13). Connect the charging hoses (red and blue) to the service valve. Red hose (14): Gauge manifold high-pressure side (HI) â&#x2020;&#x2019; compressor high-pressure side (DIS) service valve (1) Blue hose (15): Gauge manifold low-pressure side (LO) â&#x2020;&#x2019; compressor low-pressure side (SUC) service valve (2) Push in the connections for the high-pressure and low-pressure sides until a "click" is heard to make sure they are secure and in the correct position. Connect the charging hose (yellow) (7) to the vacuum pump (8).
84402827B - May 2011 9015-6
Work Precautions
9 10
84402827B - May 2011 9015-7
Low-pressure gauge High-pressure gauge
Work Precautions Vacuuming 1. 2. 3. 4. 5.
Open the high-pressure valve (HI) (12) and low-pressure valve (LO) (11) of the gauge manifold (13). Turn the vacuum pump (8) switch on and vacuum for at least 30 min. After the prescribed vacuuming time has elapsed (degree of vacuuming achieved: -750 mmHg or less), close the gauge manifold (13) high-pressure valve (12) and low-pressure valve (11). Next, turn the vacuum pump (8) switch off. Perform a check of air-tightness. Let the gauge manifold (13) sit for at least 5 min. with the high-pressure valve (12) and low-pressure valve (11) closed, and check that the gauge indicator does not go back to 0. If the gauge indicator starts to swing back to 0, this indicates there is a leak. Tighten the line connections, perform vacuuming again, and check to see if there is still a leak.
84402827B - May 2011 9015-8
Work Precautions Gas Filling Operation, High-pressure Side First, prepare the regulation amount of refrigerant, then start the filling operation from the high-pressure side. 1. 2.
3.
4.
After repeating vacuuming, switch the charging hose (yellow) (7) of the gauge manifold (13) from the vacuum pump to the service can (16). Air purging Open the valve for the service can (17). (However, keep the gauge manifold high-pressure and low-pressure valves closed.) Next, press the air purge valve (18) of the side service port on the gauge manifold low-pressure side with a screwdriver to discharge the air inside the charging hose using the refrigerant pressure. (Complete after the swooshing sound stops.) Open the high-pressure valve (12) of the gauge manifold (13), and fill with coolant. (Fill with refrigerant gas up to a gauge pressure of 0.098 MPa.) After filling, close the gauge manifold high-pressure valve and valve for the service can (17). Never operate the compressor. (This is very dangerous, as the refrigerant will flow in the opposite direction and may cause a service can or hose explosion.) Gas leak check Check for gas leaks in the cycle using the gas leak tester. If there are leaks, eliminate them through tightening. Always use the tester for R134a.
84402827B - May 2011 9015-9
Work Precautions Gas Filling Operation, Low-pressure Side CAUTION â&#x20AC;˘ Never open the gauge manifold high-pressure valve. â&#x20AC;˘ Never tip over the service can. This may cause damage to the compressor. After finishing the high-pressure side filling operation, perform the operation for the low-pressure side. 1. 2. 3. 4. 5.
Check that the high-pressure valve (12) and low-pressure valve (11) of the gauge manifold (13) and the valve for the service can (17) are closed. Start the engine, increase speed to 1400 - 1600 min-1, and completely open the cab door and window. Turn the air conditioner switch on, move the fan switch to the maximum position, and move the temperature adjustment switch to the maximum cooling position. During filling, set the degree of discharge for the compressor at 1.37 - 1.57 MPa. Open the low-pressure valve (11) of the gauge manifold (13) and valve for the service can (17), and fill with the regulation amount of refrigerant until the air bubbles in the receiver sight glass (19) are gone.
â&#x20AC;˘ Judging the amount of refrigerant from the receiver dryer sight glass After the AC is turned ON, a few air When the amount is bubbles are visible. The glass then becomes transparent and turns to a pale, correct milky-white color. When overfilling oc- After the AC is turned ON, no air bubbles curred at all are visible.
When filling was in- After the AC is turned ON, air bubbles are seen continuously. sufficient (Total gas filling amount: 950 - 1050 g) 6.
After refrigerant filling is complete, close the low-pressure valve (11) of the gauge manifold (13) and the valve for the service can (17), and stop the engine. 84402827B - May 2011 9015-10
Work Precautions • If the air conditioner is operated with very little refrigerant (R134a), this will have a damaging effect on the compressor. • If the air conditioner is filled with too much refrigerant (overcharge), this will actually cause insufficient cooling and there is the danger of pressure in the circuit becoming abnormally high. Be sure to use an appropriate amount of refrigerant. • Never open the gauge manifold high-pressure valve (12). • Never invert the service can. (Gas is suctioned in liquid form, so this may cause damage to the compressor valve.) 7.
After refrigerant filling and inspection, remove the gauge manifold and hoses. Quickly remove the low-pressure side charge hose (blue) (15) from the low-pressure side (SUC) service valve. Do not do anything on the high-pressure side until the high-pressure gauge indicator falls to 0.98 MPa or below. After confirming that the indicator has fallen below this point, quickly remove the high-pressure side charge hose (red) (14) from the high-pressure side (DIS) service valve.
84402827B - May 2011 9015-11
ITEM
28 P
MA
MB
P
21
21 27
PR
K2
K1
26
22
25
SINGLE ACTING CIRCUIT
DB
83
M PB
30.4 MPa at 253 L/min
J
G1
D1
PA
(G3)
RED
VA
C
D2
L1
DR
MA
B
A
23
RIGHT
16
A
T
B
B
*
1
A
A
G1
(G3)
76 A
MAIN RELIEF (STANDARD)
- 34.3 MPa / 343 bar / 4974 psi
A=
MAIN RELIEF (BOOST)
- 37.3 MPa / 373 bar / 5412 psi
B=
BOOM RAISING PORT SECONDARY RELIEF
- 39.2 MPa / 392 bar / 5688 psi
B1/B2 =
RELIEF ON BOOM HBCV
- 38.7 MPa / 387 bar / 5612 psi
C=
BOOM LOWERING PORT SECONDARY RELIEF
- 27.4 MPa / 274 bar / 3976 psi
D=
DIPPER OUT PORT SECONDARY RELIEF
- 39.2 MPa / 392 bar / 5688 psi
D1 =
RELIEF ON DIPPER HBCV
- 38.7 MPa / 387 bar / 5612 psi
E=
DIPPER IN PORT SECONDARY RELIEF
- 39.2 MPa / 392 bar / 5688 psi
F=
BUCKET OPEN PORT SECONDARY RELIEF
- 39.2 MPa / 392 bar / 5688 psi
G=
BUCKET CLOSE PORT SECONDARY RELIEF
- 39.2 MPa / 392 bar / 5688 psi
H=
PILOT PRESSURE RELIEF
- 3.92 MPa / 39.2 bar /
I=
RIGHT-HAND SWING PORT SECONDARY RELIEF
- 30.4 MPa / 304 bar / 4411 psi
J=
LEFT-HAND SWING PORT SECONDARY RELIEF
- 30.4 MPa / 304 bar / 4411 psi
K1/K2 =
TRAVEL REVERSE PORT SECONDARY RELIEF
- 37.8 MPa / 378 bar / 5485 psi
L1/L2 =
TRAVEL FORWARD PORT SECONDARY RELIEF
- 37.8 MPa / 378 bar / 5485 psi
N1/N2 =
NEGATIVE CONTROL RELIEF
- 2.55 MPa / 25.5 bar /
O/P =
SECONDARY RELIEF (2eme OPTION)
- 22.6 MPa / 226 bar / 3279 psi
R=
MAIN RELIEF (2eme OPTION)
- 20.6 MPa / 206 bar / 2987 psi
W4 =
BREAKER OPTION SECONDARY RELIEF VALVE
- 20.6 MPa / 206 bar / 2987 psi
B2 15 pb8
FORWARD R.H BACKWARD R.H
B1
43 D3
83
83
*
Y62 *
C
B
T
75 T2
A
76 A
O 15 pb7
A
MULTI-PURPOSE+3WAY VALVE (ELEC.MAG RELIEF)
Y61
B
C
Y60
15
Y59
0.5 MPa 72.5 psi 5 bar
S71
2
P1
42 ON 0.1 MPa 14.5 psi 1 bar OFF 0.08 MPa 11.6 psi 0.8 bar
10
0.004 MPa 0.54 psi 0.04 bar
0.007 MPa 1.02 psi 0.07 bar
ps1
T
0.1 MPa 14.5 psi 1 bar
43
T 0.103 MPa 14.94 psi 1.03 bar
pa4 B3 A3 pb3 pa3
83
*
* 165 T
1
pa2
T1
MULTI-PURPOSE + 3WAY VALVE
83 160 A2
162 P
160 B
76
*
T2 B
A
*
83
A DR
165 A
157 A
72 A
83
132 B1
58 P5
132 T
pa1
166 S2
15 DR3
159 T
134 A2
43 T
160 A1
D
IN
15 par1
10 OUT
* 134 43 D2
A2
15 pbr1
85
A1
P
Y26
pb9
T
54
P2 P1
T3
85
BOOM(1)
B
* 71
DOWN pb8
C
pa8
85
OUT 4
T
P
SWING LEFT RIGHT 3 1
58 T5
39.2MPa at 20L/min 39.2MPa at 20L/min
B7 A7
G
SWING
BUCKET
CLOSE
90
RIGHT
OPEN
F
OPTION
TRAVEL(R)
BACKWARD
BREAKER ON
FORWARD
pb7 pa7 B6 A6 pb6
FORWARD
B
T
Y4
C1
15 pb2
A
15 DR1
DOUBLE ACTING CIRCUIT
A1
*
Y23
Y24
* 161
T
BOOM DOWN 2
UP 4
59
15 pb5
15 T8
CLOSE
15 pa7
2-STAGE RELIEF
58 T5
1.5MPa
SWING BRAKE
Y5
58 P5
C2
164 P3
31
B
BUCKET OPEN CLOSE 3 1
OUT D
UP R
DOWN
F
RIGHT
H
J
L
U
P
85
8
15 pa9
E
T
G
I
Q
K
M
TRAVEL(L)
Y7 A1
FORWARD
BACKWARD
FORWARD
TRAVEL(R) FORWARD
Psv
a4
PILOT SYSTEM PUMP
10
a2
RETURN TO RESERVOIR
86
B44
A2
a1
(FRONT)
BACKWARD
P1
P2
0.15 MPa 21.75 psi 1.5 bar
LEAK-OFF RETURN SUPPLY CIRCUIT
(REAR)
PILOT SYSTEM CIRCUIT
B40
a7
C2 T
HOSE
Pi2
B
55
1
P
2
4
T
PIPING CROSS-OVER
85
A4
O
B2
P1 A3
A1
166
S4 15 pb1
S3
B1
15 pb6
S1 15 pa6
PIPING CONNECTION
3
A2
43 D7
B22
P2 PUMP P
0.02 MPa 0.29 psi 0.2 bar
85 C V
P1 PUMP
82
P3 P0
163 A P
N
60
COMPONENT BOUNDARY
LEFT
S
LEGEND
51
1.5 MPa 217.5 psi 15 bar
Y3
Pi1 C1
IN
15 pcc
OPEN
164 P1
15 pa5
A
P
T
OPTION
B27
BACKWARD
53
162 *
Y9
G
P
P2
PT
58 P5
T
ON 0.5 MPa 72.5 psi 5 bar OFF 0.3 MPa 43.5 psi 3 bar
T
HYDRAULIC RESERVOIR BREATHER BY-PASS VALVE SCREEN FILTER RETURN FILTER HYDRAULIC PUMP (OPTIONAL) MAIN HYDRAULIC PUMP MAIN CONTROL VALVE HYDRAULIC SWIVEL TRAVEL MOTOR SWING MOTOR TRAVEL MOTOR BRAKE RIGHT BOOM CYLINDER LEFT BOOM CYLINDER DIPPER CYLINDER BUCKET CYLINDER BOOM SAFETY VALVE DIPPER SAFETY VALVE DIPPER LOAD HOLDING VALVE BOOM LOAD HOLDING VALVE OIL COOLER RETURN MANIFOLD OIL COOLER BY-PASS VALVE NON-RETURN CHECK VALVE ACCUMULATOR BOOM & BUCKET CONTROL LEVER SWING & DIPPER CONTROL LEVER TRAVEL CONTROL PEDAL BOOM & DIPPER CONTROL SHOCK ABSORBER PILOT AND RETURN SYSTEM MANIFOLD FILTER PILOT SYSTEM MANIFOLD SECOND OPTION CONTROL VALVE (EU) CONTROL PEDAL (OPTIONAL) SECOND OPTION CONTROL VALVE HAMMER/CRUSHER SELECTOR HAMMER/CRUSHER SELECTOR PILOT CIRCUIT FILTER SHUT-OFF VALVE (OPTIONAL) PILOT FILTER PILOT FILTER BY-PASS VALVE HYDRAULIC BREAKER VERSION, PLUG 4 SOLENOID VALVE BANK STRAIGHT TRAVEL VALVE HAMMER/CRUSHER 2 SOLENOID VALVE BANK 2 SOLENOID VALVE BANK (SECOND OPTION) MANIFOLD BREAKER OPTION PORT SECONDARY RELIEF SHUT-OFF VALVE (OPTIONAL) 2 SOLENOID VALVE BANK (OPTION 1) 2 SOLENOID VALVE BANK 2 SOLENOID VALVE BANK (OPTION 1) 1 SOLENOID VALVE BANK STRAIGHT LINE TRAVEL PEDAL (NA) BOOM / ARM / BUCKET PRESS. PROPORTIONAL SOLENOID VALVE OPTION PRESS. PROPORTIONAL SOLENOID VALVE SHUTTLE VALVE BLOCK (NA) SWING PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SENSOR TRAVEL PILOT PRESSURE SENSOR SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH PUMP PRESSURE SENSOR (NEGA-CONT. P2) PUMP PRESSURE SENSOR (P1) PUMP PRESSURE SENSOR (NEGA-CONT. P1) PUMP PRESSURE SENSOR (P2) (BLUE BAND) OVERLOAD INDICATOR PRESSURE SWITCH PRESS. SENSOR (PILOT ARM CLOSE) PRESS. SENSOR (PILOT BUCKET CLOSE) PRESS. SENSOR (PILOT BOOM UP) PRESS.SWITCH (1ST OPTION) PRESSURE SWITCH FILTER INDICATOR (BREAKER OPTION) PILOT PRESSURE SOLENOID VALVE (PINK TAPE) SWING BRAKE SOLENOID VALVE (BLUE TAPE) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) POWER-UP SOLENOID VALVE (YELLOW BAND) MAIN PUMP POWER PROPORTIONAL SOLENOID OPTION 2 SPEED SOLENOID VALVE (BLUE TAPE) MAIN PUMP FLOW PROPORTIONAL SOLENOID OPTION 1 SOLENOID VALVE (BLUE TAPE) OPTION 1 SOLENOID VALVE (RED TAPE) OPTION 2 SOLENOID VALVE (BLUE TAPE) OPTION 2 SOLENOID VALVE (RED TAPE) OPTION SELECT SOLENOID VALVE (RED TAPE) BOOM DOWN PROPORTIONAL SOLENOID VALVE (NO TAPE) ARM CLOSE PROPORTIONAL SOLENOID VALVE (RED TAPE) BUCKET CLOSE PROPORTIONAL SOLENOID VALVE (BLUE TAPE) OPTION PRESS. PROPORTIONAL SOLENOID VALVE OPTION SELECT SOLENOID VALVE (BLUE TAPE) OPTION 2 SPEED SOLENOID VALVE (RED TAPE)
P
T5
B26
134 T
105
43 D1
Y9
DESCRIPTION
Y2
34.3MPa at 230L/min 37.3MPa at 210L/min
PH
Y27
85
LEVER LOCK
2-STAGE TRAVEL
C3
PA
B28 *
G
P
T
15 pbr1
58 T5
A1
15 pb2
A2 15 par1
166 S1
108
MAIN RELIEF V.
A
Y11
M ISUZU 6HK1X 210.0kW/1900min -1
28
A3
Dr
3.92 MPa 568.4 psi 39.2 bar
H
B1
S2
B3
OUT
15 Pr
15 pa1
Dr3
COMPONENT ITEM NO. COMPONENT NUMBER
a3
IN
36553068-0EN
Y24
160 *
15 pcc
A2
58 T5
15 pa2
A
166 S3
pst FOR MULTI-PURPOSE + 3WAY VALVE FOR DOUBLE ACTING CIRCUIT
T
58 P5
pa6
BACK -WARD
C2
* 85
57 P
DR4 DR2 DR3
TRAVEL(L)
C1 B P
B84
164 A
75 pp
OPTION (NA) < KNOB SWITCH TYPE >
B85
LEFT
*
G
* 159
SECOND OPTION
29 PL
UP
T4
57 ARM
85
A1
Y23
B8
27.4MPa at 280L/min
SINGLE ACTING CIRCUIT / MULTI-PURPOSE + 3WAY VALVE
T1
85
IN 2
A2
T5
T2
15 pb2
P
A8
1PEDAL TRAVEL
P
15 pa2
57 V
B42 P3
*
58 T5
OPTION < KNOB SWITCH TYPE >
58 P5
G
SECOND OPTION
OUT pa9
39.2MPa at 20L/min
BOOM(2)
T
A
15 ON 0.5MPa pb2 OFF 0.3MPa
162 A
Y25
ARM(2)
E
161 T
71 P
T
OPTION
P1 71 T
T4
166 S4
A2
C2
B P
OUT
161 A1
W4
134 G
B1 A1 pb1
45
161 A2
159 A1
T
PP
P4
159 A2
DR
B
P4
72 B
71 B
pcc
32
B2 A2 pb2 PP
165 C
par1
P3 ps2
ARM(1)
IN
* 85
15 pa2
20.6MPa at 63L/min
39.2MPa at 20L/min
pb4
164 C
158
75
T2
pc3 pbu
15 pcc
6
pa5
57 D
D2
4
pb5
30 PL
57 T
T1
T1
DR1
2.55MPa at 50L/min
prs1
D7
T7
134 A1
39.2MPa at 20L/min
B5
D3
6
T6
C1
*B94
71 A
Pr
31 A5
29 DR
133 T
T3
58 P5
ON 0.5 MPa / 72.5 psi / 5 bar OFF 0.3 MPa / 43.5 psi / 3 bar
pbr1
MAIN RELIEF V.
2.55MPa at 50L/min
57 B
30 DR
D6
1 150MESH
R
N2 85
133 P
B83
10 Dr3
T8
370 psi
OPTION2
P3
57 N
D1
5
P2
175 T1
156
N1
76 A
BR1 AR1
22.6MPa at 20L/min 22.6MPa at 20L/min
Tr2
44
158 *
*
73
15 DR3
59
B43
568 psi
DOUBLE ACTING CIRCUIT
Tr1
P
164
15 pb4
1 2 4 5 6 9 10 15 16 21 22 23 25 26 27 28 29 30 31 32 42 43 44 45 51 53 54 55 57 58 59 60 71 72 73 75 76 82 83 85 86 90 105 108 132 134 156 157 158 159 160 161 162 163 164 165 166 B22 B26 B27 B28 B40 B42 B43 B44 B45 B83 B84 B85 B94 S71 Y2 Y3 Y4 Y5 Y7 Y9 Y11 Y23 Y24 Y25 Y26 Y27 Y59 Y60 Y61 Y62 Y67 Y68
A1 B2
Y68 75 B
75 A
ITEM
B1
Y67
BREAKER ON
*
157
*
132 *
OPTION
W4
DR
*
72
OPTION (EU) < PEDAL TYPE >
T DR
PRESSURE SETTING
A=
PL
D
P
A
B
C
PL
L2
23
B
FORWARD L.H BACKWARD L.H
165 *
D1
MB
C LEFT
(G3)
G1
PL
156 *
VB
A
1 D3
B45 * 29
*
29
B
C
15 pb5
I
*
VA
VB
RED
30 30.4 MPa at 253 L/min
*
DESCRIPTION
58 P5
*
--
CONNECTION ITEM NO. OPTIONAL ITEM NO.
1
9
CX350C - CX370C EXCAVATOR HYDRAULIC SCHEMATIC Lep 84402838EN
1 2 5R 002 5R 003
2 1
1.25W 107 1.25W 106
8R 105 8R 104
2 1 YAZAKI SDL (CN.A55)
YAZAKI SDL (CN.A54)
0.85Gr 419 0.85BW 429 0.85W 409 2 3 1
OPTION LINE (See page 2/2)
YAZAKI (CN.D18)
YAZAKI (CN.D19)
B
1.25G 501 1.25WR 511
1 2
YAZAKI 58 (CN.D27)
508 509
YAZAKI SDL (CN.A56)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
YAZAKI SDL (CN.A53)
0.85WR 149
50a,51a
YAZAKI SDL (CN.A57)
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
0.85BG 652 0.85YL 538
YAZAKI (CN.D80)
FLOOR
M8
1 2
1 2
1.25B 1.25R
S71
Y64 Y70 Y66
INJ3 (#3)
INJ2 (#5) 1 2
10
INJ6 (#4)
13 9
1 2
INJ4 (#6) 1 2
FUEL FILTER SENSOR 0.75WB 334 0.75GW 335 0.75BW 336
60B 798
0.85RB 290 0.85LgR 500 0.85BrR 010
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Br 834 4 2 5 3 6 1 0.85R 130
BUCK UP GND R(-) L(-) OW B Gr G RL 162 1.25B 728 0.85BY 982 0.85BL 983 0.85Br 834 0.85YR 223
0.85BG 622 0.85GW 536 0.85BG 621 0.85YL 558
0.75RG 394 0.75RG 395 0.75RW 396 0.75RW 397 1.25R 374 1.25G 375 1.25Br 382 1.25G 383 1.25R 378 1.25Br 379 1.25R 384 1.25RW 385 1.25R 376 1.25RW 377 1.25R 380 1.25RW 381 15 30 45 60 1 31 3 32 2 46 18 47 16 48 17 33 OP-SCVHI OP-SCVHI IA-SCVLO IA-SCVLO OP-COM1A OS-INJ1 OP-COM1C OS-INJ5 OP-COM1B OS-INJ3 OP-COM2C OS-1NJ6 OP-COM2A OS-1NJ2 OP-COM2B OS-INJ4
PRESS.SWICH (FILTER INDICATOR) 0.85BG 680 1.25B 780
3 1 2 5 4 1.25LW 200 1.25LW 201 WG 823 1.25Y 870 ACC R(+) L(+) R GrR GR
1 2 3 4 5 6 7 8 9 0.85RB 291 0.85Y 980 0.85L 981 0.85B 722 0.85LG 842
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
0.85BG 620 0.85LB 539 0.85YB 570 0.85BG 624 0.85V 571
SUMITOMO
3 1 2 5 4 1.25GrR 195 1.25GrR 196 WG 831 1.25GR 875
1 2 0.85VW 170 0.85RY 840
1 2 3 4 5 6 7 8 9 10 0.85LG 302 0.85WR 148
1 2 3 4 5 6 7 8 9 10
1 4 2 5 3
3 1 2 5 4 LgW 190 LgW 191 LW 841 LR 880
0.85Y 0.85L 0.85B 1 2 3
0.85BW 691a 0.75RW 319 0.75GW 320 0.75RG 321 0.75WB 322 0.75Y 323 0.75BY 324 0.75P 326 0.75RW 340 0.75YG 342 0.75B 344 0.75WR 365 0.75GW 366 0.75R 316 0.75L 317 0.75G 318 0.85BL 692a 58 6 13 26 23 12 40 14 25 9 10 8 55 22 56 42 43 SG-SLD8 SP-5V4 IA-MAP SG-5VRT4 SP-5V7 IA-OILPRESS SG-5VRT7 IA-IDMPOS IA-THW IA-THL IA-THBST IA-MAT SG-5VRT8 SP-5V6 IF-CAM SG-5VRT6 SG-SDL6
0.75L 314 11 IA-PFUEL
2 1
5RW 020
YAZAKI 58L (CN.A50
1 2 3 1 2 5 4 0.85GW 216 0.85GW 217 LG 842 0.85R 885
LR 881
3 1 2 5 4 G 888 RL 164 OR 826 RL 165 0.85RB 290
0.85LB 985
3 1 2 5 4 0.85L 981 0.85RB 293 LG 832
0.85YB 984
0.75WR 386 0.75WB 387 0.75WL 388 0.75GB 353 0.75GW 354 0.75GR 355 0.75B 392 0.75GR 393 0.75WB 310 0.75R 311 0.75G 312 0.85B 690a 35 20 5 52 53 54 49 50 21 57 41 28 OM-EBM1 OM-EBM2 OM-EBM3 IS-EBMPOS1 IS-EBMPOS2 IS-EBMPOS3 OM-IDM1 OM-IDM2 SP-5V5 IF-CRANK SG-5VRT5 SG-SDL5
1 YAZAKI CN-A (CN.D31)
1 2 3 4 5 6 7 8
YAZAKI SDL (CN.A52)
0.85GrR 012 0.85WR 512 0.85Br 516
520 521
118
3 1 2 5 4
0.85Y 011
0.85BrR 010 0.85GR 845 0.85B 706
0.85Y 011 1.25WR 145 0.85LR 373
3 1 2 5 4
3 1 2 5 4 1.25WR 146 1.25WR 147 0.85YL 808 0.85GW 303
3 1 2 5 4 0.85W 114 0.85W 115 0.85LY 824 0.85LR 890
3 1 2 5 4
0.85LgR 500 0.85LR 890 0.85B 705 0.85LR 891 0.85G 501
0.85W 112 0.85W 113 0.85O 804 0.85WR 511
3 1 2 5 4
3 1 2 5 4 1.25RW 140 0.85YR 370 0.85B 704 1.25WR 141
517 519 640 040a,041a 302
1.25WR 142 1.25WR 142 1.25WR 142 1.25WR 142 1.25B 780 1.25B 780a 1.25B 780b 1.25B 780c 1.25B 780d 1.25B 780e 0.85BG 680 0.85BG 680a 0.85BG 680b 0.85YR 370 0.85YR 371 0.85LR 373 0.85BrR 301 0.85LG 302 0.85GW 303 P 040 PG 041 V 050 VG 051 PB 082 PL 080 BrY 084 0.85G 305 0.85G 508 0.85L 372 0.85Y 328 0.85YL 329 0.85BY 330 0.75WB 331 0.75P 332 0.75BW 333 0.75GW 335 0.75Y 346 0.75RW 348 BrR 350 WG 337 LW 338 GY 339 67 89 111 133 61 62 63 64 65 66 97 119 137 114 136 152 100 121 122 154 132 110 88 141 72 142 139 134 153 69 87 135 70 84 112 83 79 80 81 117 82 113 PS-+B PS-+B PS-+B PS-+B PG-POWER(GND) PG-POWER(GND) PG-POWER(GND) PG-POWER(GND) PG-POWER(GND) PG-POWER(GND) PG-SIGNAL(GND) PG-SIGNAL(GND) PG-CASE(GND) OS-MAIN RL OS-MAIN RL OS-STARTER IS-IGKEY(ST) IS-ENGSTP IS-DPDREG CC-CAN-H CC-CAN-L CC-ISOCAN-H CC-ISOCAN-L IS-DIAG CC-KW2000 IS-MEMCL PS-MAFBAT IS-IGKEY(ON) OS-GLOW RL SP-5V2 IA-BARO SG-5VRT2 SP-5V3 IA-EXHP SG-5VRT3 IA-FIPRESS IA-THE1 IA-THE2 IA-IAT SP-12V IA-MAF SG-12VRT
YAZAKI SWP (CN.D6)
YAZAKI 58M (CN.A51)
60B 799
YAZAKI SDL (CN.A44)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16 17 18
BG 613 BG 614
1 2 3 4 5 6
3 1 2 5 4
0.85BG 623 0.85WG 537
YAZAKI CN-A (CN.C25)
YAZAKI SDL (CN.A29)
4 3 2 1
YAZAKI SDL (CN.A45)
YAZAKI SDL (CN.C3)
1 2 3 4
YAZAKI CN-A (CN.C23)
YAZAKI CN-A (CN.C24)
1 2 DEUTSCH DT (CN.A25)
6 5 4 3 2 1 7 8 9 10 11 12
EST CONNECTOR B
0.85Y 980 0.85RB 292 LG 825
4 5 6 1 2 3 7 8 9 10
YAZAKI CN-A (CN.C22)
1 2
1 2 3
YAZAKI CN-A (CN.C7)
YAZAKI SDL (CN.A23)
0.85Y 408 0.85LY 418 0.85BO 428
AMP 040 (CN.C5)
1 2
AMP (CN.C6)
1 2 3 4 5 6 7 8 9 10 11 12 13
1 2 3 4 5 6
1 2
1 2 3 4
AMP 070MIULTI (CN.C1)
1 2 3 4 5 6 7 8 9 10
1 2
A/D I/O
6 5 4 3 2 1 14 13 12 11 10 9 8 7
I/O AMP 040/070HYBRID I/O
11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12 6 5 4 3 2 1 12 11 10 9 8 7 8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9 13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
1 2 3 AMP ECO-J (CN.D5)
M8
ENGINE CONTROLLER
B85
1.25Y 1.25Y
Y65
1 2
A2
2 1
Y69
INJ5 (#2)
1 2
2 3 1
B88
M10
EXSHAUST PRESS SENSOR 0.75WB 331 0.75P 332 0.75BW 333
1 2 3
B89
EXSHAUST TEMP SENSOR(CNT) 0.75Y 346 0.75BW 347
1 2
t℃
B90
t℃
B91
EXSHAUST TEMP SENSOR(FNT) 0.75RW 348 0.75BW 349
1 2
AIR INTAKE SENSOR MASS & TEMP
M8
5B 796 AMP HYBRID I/O
1.25LR 1.25P 1.25B 1.25WL 1.25LR 1.25BR
Y63
1 2
154 132 110 88
6 2
1 2
153 131 109 87
1 2
1 2
152 130 108 86
INJ1 (#1)
3
1 2
151 129 107 85
5 1
Y35
1 2
150 128 106 84
0.85LW 533 0.85BG 650
1 2
149 127 105 83
1.25BW 1.25L 1.25R 1.25G 1.25R 1.25WB
SUMITOMO MT090 (CN.E19)
148 126 104 82
2 1
SUMITOMO MT090 (CN.E18)
147 125 103 81
B84
S62
B87
SUCTION CONT.VALVE
SUMITOMO MT090 (CN.E17)
146 124 102 80
Y T OB 0.75BL 0.75RB 0.75RW
Vcc OUT(PULSE) GND
SUMITOMO MT090 (CN.E16)
145 123 101 79
1 3 2
B1
X35
SUMITOMO MT090 (CN.E15)
144 122 100 78
PRESS.SWITCH (AIR CLEANER)
ISUZU(CN.A24)
SUMITOMO MT090 (CN.E14)
143 121 99 77
t℃
1 2 3
1 2
142 120 98 76
2 1
B86
3
141 119 97 75
B83
S55
1 2
140 118 96 74
LEVEL SWITCH (RESERVE TANK) 0.85GrR 532 0.85BG 651
PRESS
1 2
139 117 95 73
WATER TEMP.SENSOR
Y62
OPT
1 2
138 116 94 72
t℃
1 2
SUMITOMO MT090 (CN.E13)
137 115 93 71
1 2
B51
1 2 3 SUMITOMO (CN.E12)
136 114 92 70
0.85VR 910 0.85VG 911
B3
EGR INTAKE TEMP.SENSOR
SUMITOMO (CN.E11)
135 113 91 69
0.75G
YAZAKI (CN.E10)
134 112 90 68
t℃
1 2
PACKARD (CN.E9)
65 66 133 111 63 64 89 61 62 67
1 2
AMP ECO-J (CN.E8)
60 45 30 15
0.75BR 0.75RL
BrR 350 G 351 WG 337 LW 338 GY 339
2 1 5 3 4
t℃
1 2 3 4 5
59 44 29 14
1 2 3
0.85VR 910 0.85VG 911
B21
BOOST TEMP.SENSOR
0.75RB 0.75R
SUMITOMO (CN.D35)
58 43 28 13
0.85WL 432 0.85GW 444 0.85BL 452
0.75WR 0.75GY
2 1 YAZAKI (CN.D34)
57 42 27 12
PRESS. SENSOR (PILOT BOOM UP)
t℃
1 2
2 1 YAZAKI (CN.D33)
56 41 26 11
1 2 3
0.75YG 0.75LW
10 8 13 9 4
55 40 25 10
0.85WL 431 0.85LR 446 0.85BL 451
1 2 3
1 5 6 2 3
54 39 24 9
Y61
SOL1
B47
FUEL TEMP.SENSOR
0.75BR 0.75RL
1 2 3 SUMITOMO (CN.D32)
53 38 23 8
CLOSE (BLUE TAPE)
B52
0.75YG
YAZAKI (CN.E21)
52 37 22 7
PRESS. SENSOR (PILOT BUCKET CLOSE)
0.75WB 0.75LY 0.75BY
YAZAKI (CN.E20)
51 36 21 6
1 2 3
0.75WB 0.75LY 0.75BY
1 2 3
50 35 20 5
BUCKET
SOL2
B49
OIL PRESS SENSOR
4 3 2 1 9 8 7 6 13 12 11 16 15 21 20 19 18 26 25 24 23 31 30 29 28
49 34 19 4
0.85WL 430 0.85VG 445 0.85BL 450
1 2 3
0.75RW 0.75L 0.75RL
5 10 14 17 22 27 32
48 33 18 3
PRESS. SENSOR (PILOT ARM CLOSE)
Vcc OUT(PULSE) GND
8 4
PACKARD (CN.D36)
47 32 17 2
(CN.D2)
1 2 3
MITSUBISHI NMW (CN.D7)
46 31 16 1
(CN.D1)
1.25W 405 1.25Gr 425 1.25BW 445
0.75RW 0.75L 0.75RL
1 2
0.85Y 328 0.85YL 329 0.85BY 330
CLOSE (RED TAPE)
M25
BOOST PRESS SENSOR
1 2
1 3 2
1 2
ARM
M
1 2 3
L LW Br 0.75BW
1 2
PRESS. SENSOR (BARO)
Y60
1 2
1.25WR 144 0.85G 305
Y59
YAZAKI SWP (CN.D81)
B48
1 2
1 2
0.75RW 185 0.85YL 818
B45
1 2 3 AMP ECO-J (CN.D53)
YL 558 LB 559
RESISTOR(MAF)
0.75G 345
0.85G 906 0.85GB 907
B27
PRESS. SENSOR (HBCV)
1 3 2
4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 20 19 18 17 SUMITOMO D (CN.D10)
0.85WL 430 0.85BL 450
G 351 0.75W 313 0.75G 315
UP
SOL3
1 2
R7
1.25WR 142 0.85YR 370 0.85LR 373 0.85BrR 301 0.85LG 302 0.85GW 303 P 040 PG 041 V 050 VG 051 PB 082 PL 080 BrY 084
BOOM
PROPORTIONAL S/V 3 2 1 YAZAKI SDL (CN.D52)
1.25R 384 1.25RW 385 1.25R 376 1.25RW 377 1.25R 380 1.25RW 381
(NO TAPE)
1 2 3 AMP ECO-J (CN.D55)
0.85G 504
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2
YAZAKI SWP (CN.D80)
0.75WR 145
1.25WR 142 0.85YR 370 0.85LR 373 0.85Y 301 0.85LG 302 0.85GW 303 P 040a PG 041a V 050 VG 051 PB 082 PL 080 BrY 084
1 2 3
0.85O 902 0.85BO 903
1 2 3 AMP ECO-J (CN.D54)
0.85GW 444 0.85VG 445 0.85LR 446
0.85W 406 0.85YG 416 0.85BW 426
Y11
FLOW
GND U V W VCC
PROPORTIONAL S/V
B26
PRESS. SENSOR (PILOT TRAVEL)
P1
M24
CRANK ANG(MRE) SENSOR
0.75WR 0.75GY
17 18 19 15 20 16 11 5 1 7 3 6 2 12 14 10 8 4 13 9
1.25R 374 1.25G 375 1.25Br 382 1.25G 383 1.25R 378 1.25Br 379
1 2
CARLING VC2 (CN.B8)
1 2 3 4 5 6 7 8 9 10
1 2 3
1 2
Y7
POWER
YAZAKI SWP (CN.D43)
9 6 5 4 7
0.85W 405 0.85V 415 0.85BW 425
0.75L 904 0.75BL 905
PUMP
YAZAKI SWP (CN.D42)
(FOR FAN REVERSE)
10 3 2 1 8
PRESS. SENSOR (PILOT UPPER)
0.75R 316 0.75L 317 0.75G 318 0.75BL 692b 0.75RG 394 0.75RW 396
YAZAKI SWP (CN.D41)
X34
WL 260 LY 806 YR 805 VY 534 GY 535 G 850 O 851 GL 852 OL 853 BG 640
B22
1 2
U V W
M4
PUMP 0.75Y 900 0.75BY 901
Vcc OUT GND
CAM ANG(MRE) SENSOR
Y8
1.25G
1
M
OVER HEAT SW.
1 2
CARLING VC2 (CN.B9)
1 2 3
MAGNET CLUTCH (COMPRESSOR)
YAZAKI SWP (CN.D79)
CARLING VC2 (CN.B12)
10 3 2 1 8
0.85W 404 0.85GR 414 0.85BW 424
1.25RW 944
5 6 7 8 1 2 3 4
S52
2 1
B40
PRESS. SENSOR (PILOT SWING)
24V
1 2
9 6 5 4 7
9 6 5 4 7
1 2 3
0.85GW 943 1.25RW 944
0.75WR 0.75WB 0.75WL 0.75LW 0.75GB 0.75GW 0.75GY 0.75L
0.75RB 0.75BY 0.75R
1 2
LED
0.75WB 403 0.75G 413 0.75BW 423
M
DUAL SWITCH (RECIVER DRYER)
GW 953
B43
PRESS. SENSOR (N2)
1.25 B 1.25 BL
2 1
2 1 6 5 3 4
1 2
FREE SWING<NA>
1 2 3
1 2
CARLING VC2 (CN.B10)
0.85W 402 0.85Lg 412 0.85BW 422
0.85B 767 0.85GR 897
AMP ECO-J (CN.D40)
0.85BG 628
10 3 2 1 8
10 3 2 1 8
PRESS. SENSOR (N1)
0.75WB 400 0.75BW 420 0.75Y 410 0.75L 411 0.85Lg 412 0.75G 413 0.85GR 414 0.85V 415 0.85YG 416 0.85Gr 419 0.85WL 430 0.85BL 450 0.85GW 444 0.85VG 445 0.85LR 446 0.75Y 490 0.85GL 492 0.85BG 660 0.85GrR 532 0.85LW 533 0.85YL 538
BL G
E68
CONDENSER
B44
M23
INTAKE THROTTLE DC-MOTOR
BL G VW
(NOT USED)
YAZAKI SWP (CN.D39)
YAZAKI(CN.A43)
(FOR CRANE) (NOT USED)
9 6 5 4 7
1 2 3
1 2
AMP (CN.D89)
VG 051
X33
YAZAKI(CN.B24) YAZAKI(CN.B25)
0.85BG 629
S28
PRESS. SENSOR (P2) 0.75WB 401 0.75L 411 0.75BW 421
0.85GR 898 0.85B 768
X2
1 2
PG 041i PB 082
RL 167 0.85G 507 P 040k PG 041k 0.85Y 085
BEACON<EU>
B42
1 2
SUMITOMO 090 (CN.D77)
TO DRM
13 5 2 8 3 1 4 6 9 10 11 12 7
TRAVEL ALARM<NA>
M
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 2 3
YAZAKI(CN.D73)
0.85R 885 0.85B 762
PRESS. SENSOR (P1)
0.75RW 340
B93
YAZAKI SWP (CN.D74)
X32
S22
0.85W 400 0.85BW 420 0.85Y 410 0.85L 411 0.85Lg 412 0.85G 413 0.85GR 414 0.85V 415 0.85YG 416 0.85Gr 419 0.85WL 430 0.85BL 450 0.85GW 444 0.85VG 445 0.85LR 446 0.85YB 490 0.85GL 492 0.85BG 660 GrR 532 LW 533 YL 538 LB 559
R5
B92
HORN HIGH (RIGHT) 24V,333Hz 115dB BEACON
0.85YR 882 YAZAKI(CN.D72) 0.85B 761
AMP ECO-J (CN.D44-1)
M8
CARLING VC2 (CN.B11)
1.25R 1.25B
0.75Y 0.75B
0.75WR 365 0.75GW 366
HORN LOW (LEFT) 24V,303Hz 115dB
YAZAKI(CN.D71)
1 2
P 040f PG 041f 1.25B 740
P 040i BG 633 BG 632 V 050 PL 080
OVER LOAD WARNING<EU>
0.75WB 400 0.75Y 410 0.75BW 420
2 1
0.75B 344 0.75G 345
M4
24V
1 2 SUMITOMO MT090 (CN.D90F)
1.25RB 150 0.85G 506 0.85Br 517
A/C PANEL & A/C UNIT (See page 2/2)
10 3 2 1 8
CARLING VC2 (CN.B7)
0.85VG 911
FUEL LEVEL SENSOR
0.75RW 319 0.75GW 320 0.75RG 321
0.75YG 342
M
0.85LR 880
YAZAKI SWP (CN.D44)
1 2 3 4 5 6 7 8
9 6 5 4 7
10 3 2 1 8
0.85GL 492 0.85BG 660
0.75BW
VW GrB WB 0.75B
1 6 15 11 12 5 10 17 14 16 29 24 19 18 30 25 20 21 31 22 9 13 23 7 2 26 3 8 27 4 28 32
0.75W 313 0.75L 314 0.75G 315 0.75BW 691b
WASHER 1 2
YAZAKI(CN.D70) 0.85B 760
B2
H2
1 2 SUMITOMO MT090 (CN.D68)
X27
S13
9 6 5 4 7
0.75BY 901 0.85BO 903 0.75BL 905 0.85GB 907 0.85YL 818
AIR SUSPENSION
24V
S85
ENG STOP
0.85V 910
t℃
2 1
0.75WB 310 0.75R 311 0.75G 312 0.75B 690b
0.75WB 322 0.75Y 323 0.75BY 324
1 2
0.85V 829 0.85B 755
HYD.OIL TEMP SENSOR
E1 TRAVEL ALARM 24V,107dB
U V W VCC GND
COMMON RAIL PRESS SENSOR
REFUEL PUMP (See page 2/2)
0.85V 830 0.85B 756
0.85GR 897 B 769 GW 953 0.85LR 242
1 2 3 AMP ECO-J (CN.G6)
BL 064b
TO GPS UNIT
S9
1 2
X6
4 5 2 1 3
24V 70W
1 3 2
1
W 060b WL 061b
X4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
VR 230 1.25WR 235 0.85LR 240 0.85WR 148 0.85LG 302 0.85LB 539 0.85Y 408 0.85LY 418 0.85BO 428 P 040g PG 041g WB 949 BW 950 0.85GW 943
1 2
X36
1 2 3 4 5 6 7 8
2W 250 0.85VG 822 2B 764
K51
E2
1 2
BG 636
1.25B 749 1.25W 205
1 2 3 4 5 6 7 8 9 10 11 12 13 14
YAZAKI(CN.B14) YAZAKI(CN.B15) YAZAKI(CN.B16)
12V OUTPUT (FOR RADIO)
2ND.ACT S/V(L)
0.85WB 909 0.85VG 911
M8 YAZAKI (CN.B22)
0.85RY 280 0.85WR 281 0.85BW 709
S34
YAZAKI PA (CN.B13)
RELAY CONDENSER (CN.D86F)
0.75Y 490 0.75BW 491
L H
M
EGR VALVE 5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16
24V 70W
LAMP (HOUSE)
B R
1 2
YAZAKI SWP (CN.D78)
1 2 3 4
OPT POWER YAZAKI(CN.A32M) YAZAKI(CN.A32F)
2ND.ACT S/V(R)
0.85YR 222 0.85B 721
4 5 6 1 2 3 7 8 9 10 11 12 13
BG 630
7 12 4 11 1 3 6 8 9 5 10 2
WB 245
Y 065b YL 066b
YAZAKI(CN.A34F) YAZAKI(CN.A35F)
YAZAKI PA (CN.B23)
W 060a WL 061a WR 062 BL 064a Y 065a YL 066a YR 067 BY 069
X3
P 040j PG 041j
S33
3 4 1 2 5 6 7 8 9
Y18
SWING (NO TAPE)
1 2 3 AMP ECO-J (CN.D51)
X26
X31
CAN
BG 631 RL 166 P 040h PG 041h PL 081
1 2 3 4 5 6
RADIO MUTE
0.85BY 901 0.85BO 903 0.85BL 905 0.85GB 907 0.85YL 818
0.75Y 900 0.85O 902 0.75L 904 0.85G 906
FREE
1 2 3 AMP ECO-J (CN.D50)
X5
BG 631 RL 166 P 040 PG 041 PL 081
A B C D E F G H J
S69
0.75RW 185
0.75R 0.75B
1 2 3 AMP ECO-J (CN.D49)
X25
BG 634 PB 083
HORN
L L Y Y G G O O
6 7 4 5 3 8 1 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1.25B 703 1.25BG 603
1 2 3 4 5 6 7 8 9 10 11 12 13 14
YAZAKI (CN.C32)
DIAG SW YAZAKI(CN.A36M) YAZAKI(CN.A36F)
1 2 3 4 5 6
1.25W 110 WL 266 0.85G 505 0.85RY 521 YB 570 V 571 P 040e PG 041e YR 541 O 542 LG 833
YAZAKI (CN.C17)
X24
M8
0.85LW 841 0.85B 725 0.85YL 591 0.85BG 627 0.85GL 852 0.85B 726 0.85OL 853 0.85B 727
P2
S15
0.85YR 221 0.85B 720
VR 230 1.25WR 235 0.85LR 240 1.25WR 148 0.85LG 302 LB 539 0.85Y 408 0.85LY 418 0.85BO 428 P 040g PG 041g WB 949 BW 950 0.85GW 943
BG 635 BrY 084
1ST.ACT S/V(L)
0.75GR 180 0.75RW 181 0.75RW 182 0.75RW 183
1 2
0.85R 0.85B
1 2
0.85R 0.85B
1 2
0.85WL 807 0.85GW 215
1 2 3 AMP ECO-J (CN.D48)
TO CONTROLLER C
YAZAKI(CN.A29F)
YAZAKI SDL (CN.A26)
SW FAN REVERSE SW CTWT MOVE
M8
LAMP (CAB)
MEMORY CLEAR YAZAKI(CN.A37M) YAZAKI(CN.A37F)
DIAGNOSTIC CONNECTOR
AVcc AGND AGND
P 040d PG 041d
X9
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
SW KEY ON
PL 056 PW 055 Y 065a YL 066a BY 069
YAZAKI(CN.A33F) YAZAKI(CN.A33M)
0.85R 0.85W
24V 70W
X23
YAZAKI(CN.A28F) 1.25GR 876 1.25B 715
AMP DIAG (CN.A27)
SN_P BOOM UP SN_P ARM CLOSE SN_P BCKT CLOSE
2 15 21 9 22 10 23 12 24 13 25 26 7 20 8 11 1 14 16 3 17 4 18 5 19 6
YR 067 YR 068
IMMOBILIZER
E3
YAZAKI(CN.A26F) 1.25GR 875 1.25B 714 YAZAKI(CN.A27F)
3 2 1 8 7 6 5 4
SN_IN1 SN_IN2 POT_IN1 POT_IN2 POT_IN3 POT_IN4 POT_IN5 POT_IN6 POT_IN7 POT_IN8 POT_IN9 POT_IN10 COMP_IN1 COMP_IN2 COMP_IN3 SW_IN1 SW_IN2 SW_IN3 SW_IN4 SW_IN5 SW_IN6 SW_IN7 SW_IN8 SW_IN9 SW_IN10 SW_IN11 SW_IN12 SW_IN13
4 12 3 10 2 5 13 6 14 11 1 9 7 15 16 8
0.85G 906 0.85GB 907 0.85W 908 0.85WB 909 0.85V 910 0.85VG 911
VG 531 BG 637
24V 70W
LAMP (CAB)
0.85YL 818
0.85R 0.85W
YAZAKI SDL (CN.A24)
TXD RXD RS232C_TXD RS232C_RXD RS232C_GND GND GND CAN_H CAN_L +5V_OUT FREQUENCY_IN FREQUENCY_GND AVcc SW_1 SW_2 SW_3
0.85LR 881 0.85YR 882
E3
CARLING VC2 (CN.C12)
1.25GR 875 1.25B 714
YAZAKI SDL (CN.A48)
SW_IN12 SW_IN13
S70
WINDOW OPEN:CLOSE WINDOW CLOSE:OPEN
O 590 BG 614
EST CONNECTOR A
BOOT_CNT FWE
G 812 Lg 813
10 3 2 1 8
D E C F A B J G H DEUTSCH HD10 (CN.52)
S-G
3 6 1 4 2 5 8 7 11 12 9 10
9 6 5 4 7
6 3 2 5 1 4
S32
KNOB(LEFT)
X8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Y5
1.25Y 870 1.25B 757
1 2 3 AMP ECO-J (CN.D47)
ARM CLOSE(OUT) ARM CLOSE(RTN) FAN SPEED(OUT) FAN SPEED(RTN) OPT PRESS(OUT) OPT PRESS(RTN) SHLD GND
S54
HORN VOL.SW
YAZAKI(CN.A30F) O 590 BG 614 YAZAKI(CN.A31F)
1ST.ACT S/V(R)
0.85Y 900 0.85O 902 0.85L 904 0.85G 906 0.85W 908 0.85V 910
(S3)
1 2 3 AMP ECO-J (CN.D46)
BUCKET CLOSE(PWM)
YAZAKI (CN.C13)
S31
1 2
SOL POWER SAVE SOL FAN REVERSE
YAZAKI (CN.C14)
WIPER
YAZAKI SWP (CN.B17)
PWM_OUT1 PWM_RTN1 PWM_OUT2 PWM_RTN2 PWM_OUT3 PWM_RTN3
A-G
LIMIT SW （WINDOW）
0.85YR 220
RL 162 0.85YR 221 0.85GW 536 0.85WG 537 0.85YL 558 0.85YB 570 0.85V 571 0.85Br 834 0.85LG 842 0.85Y 980 0.85L 981 0.85BY 982 0.85BL 983 0.85RY 280 0.85WR 281 0.85BW 709
S11
P15
1 2 SUMITOMO MT090 (CN.B18)
NPN_OUT1 NPN_OUT2 NPN_OUT3 NPN_OUT4 NPN_OUT5 NPN_OUT6 NPN_OUT7 NPN_OUT8 NPN_OUT9 NPN_OUT10
GND_A
0.85B 713
L
0.85BL 983 0.85LB 985
YAZAKI SDL (CN.A49)
L-G
GND
CIGAR LIGHTER 24V,5A
1 2
0.85OR 225 RL 163 0.85B 708 0.85RY 280 0.85WR 281 0.85BW 709
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
5 6 7 8 1 2 3 4 9 10 11 12 13 14 15 16 17 18
N-G
GND_3
E51
YAZAKI (CN.C15)
GND 12V OUT(BACKUP) 12V OUT(MAIN) GND SHUT OFF
SPEAKER(L)
6 2 5 3 1 4 7
RL 162 0.85YR 221 GW 536 WG 537 YL 558 YB 570 V 571 Br 834 LG 842 0.85Y 980 0.85L 981 0.85BY 982 0.85BL 983 0.85RY 280 0.85WR 281 0.85BW 709
IDLE SW
L L Y Y G G O O
6 7 4 5 3 8 1 2
P3
S16
0.75RW 187 0.85Br 803
0.75RW 187
RADIO AM/FM STEREO 24V,2A<NA>
RELIEF (YELLOW TAPE)
Y4
1.25Y 871 1.25B 758
1 2
1 2 3 AMP ECO-J (CN.D45)
P-G
1.25BG 602 1.25BG 602a 0.85B 702 0.85B 702a
YAZAKI (CN.C16)
24V IN (MAIN) 24V IN (BACKUP)
0.85L 530 0.85BG 625 0.85YG 594 0.85BG 626 0.85G 850 0.85B 723 0.85O 851 0.85B 724
RL 167
DC/DC(24V/12V) CONVERTER
0.85BY 982 0.85YB 984 0.85BL 983 0.85LB 985
KNOB(RIGHT)
2 1
YAZAKI 62C (CN.B5)
GND_2
1.25W 109 1.25W 109a
0.85WR 282
12V
3 1 4 2
0.85RY 844 0.85GR 845
YAZAKI CN-A (CN.B1)
1 2 3 4 5 6 7 8
POWER 24V
1 12 11 22 2 13 5 16 9 20 10 21 6 4 7 3 8 14 15 18 17 19
H5
U1
0.85L 530 0.85YG 594 0.85G 850 0.85O 851 0.85LW 841 0.85YL 591 0.85GL 852 0.85OL 853
1 2 3 4 5 6
2 STAGE
(S1)
1.25Y 871 1.25B 758
SOLENOID VALVE
1 2
POWER 24V
R
0.85BY 982 0.85YB 984
X30
1 2 YAZAKI SWP (CN.B3)
0.75R 0.75B
1 2
0.85B 712
SPEAKER(R) 1 2
2 4 1 3
3 2 1 YAZAKI SDL (CN.B2)
1 2
YAZAKI SWP (CN.D57)
ACC SOCKET
X15
DOOR OPEN:CLOSE DOOR CLOSE:OPEN
H4
0.85G 485 0.85L 486 1.25B 711
1 2 3
OL 593 Y 843 BG 613
TO CAMERA 3 (BLUE TAPE)
OFF ACC ON ST
0.75RW 183 0.75Y 802
TRAVEL (RED TAPE)
LAMP (BOOM)
1 2
0.85LR 827 0.85LB 828
OL 593 Y 843 BG 613
1 2 3 4
ON HEAT ST
0.75R 0.75B
Y3
24V
1 2
S53
R 960 B 961 Y 962 W 963
1 2 3 4 5 6 7 8
B G1 G2 ACC M ST
0.75RW 182 0.75L 801
(S2)
M
1 2
LIMIT SW （DOOR）
L 530 YG 594 G 850 O 851 LW 841 YL 591 GL 852 OL 853
OFF ACC
1 2
2 STAGE
BRAKE (BLUE TAPE)
Y2
YAZAKI CN-A (CN.D67)
0.85LR 827 0.85LB 828 1.25B 710
24V
A13
ON
CONNECTION
0.85WL 807 0.85VG 822 0.85LR 880 0.85YR 882 0.85V 829 0.85R 885 0.85GW 943 0.85LR 242
SWING
YAZAKI SWP (CN.D56)
0.85G 0.85L 0.85B
DOOR
G 888 Y 843
1 2
TO CAMERA 2 (RED TAPE)
KEY SWITCH
LIMIT SWITCH (GATE)
YAZAKI 62C (CN.B4)
1 3 2 4 6 5
G 888 Y 843
2 1
1 2 3 4
THROTTLE VOL.
1 2 3 4 5 6 7 8
0.85LR 0.85LB
OFF ，10W
R 965 B 966 YB 967 WB 968
0.85R 130 0.85RB 290 0.85VW 170 0.85LgR 500 0.85BrR 010 0.85RY 840 0.85GR 845 0.85G 507 0.85B 720 0.85BG 620
0.75GR 180 0.75WB 800 0.75L 801 0.75Y 802 0.85Br 803
0.75R 0.75B
1 2
(SP)
2BY 2B
1 2
3
WIPER MOTOR
24
1 2 3 4 5 6 7 8 9 10
S1
S51
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
LOCK (PINK TAPE)
YAZAKI SWP (CN.D69)
M3
0.85G 485 0.85L 486
X29
ROOM LAMP
E4
0.85R 130 0.85RB 290 0.85VW 170 0.85LgR 500 0.85BrR 010 0.85RY 840 0.85GR 845 0.85G 507 0.85B 720 0.85BG 620
TO CAMERA 1 (NO TAPE)
1 2 3 4
GR 180 W 800 L 801 Y 802 Br 803 G 812 Lg 813 WL 807 VG 822 LR 880 YR 882 0.85WV 829 0.85R 885 0.85GW 943 0.85LR 242
0.75R 0.75B
YAZAKI 58W (CN.D76)
4 8 5 6 10
GR 820 Lg 821 V 809 0.85BrR 210 0.85WY 829
X28 R 970 B 971 YR 972 WR 973
0.75RW 181 0.75WB 800
2 1
829,834850,851,852,853,880,882,885,943
R3
1 2
LEVER
YAZAKI CN-A (CN.D65)
B61
SUMITOMO MT090 (CN.A30)
1.25W 118 1.25G 753
SOLENOID VALVE
1 2
11 12 13 1 2 3 9 7
WB 949 BW 950
1 2
YAZAKI (CN.D81)
6 7
L VW LW
0.75WR 386 0.75WB 387 0.75WL 388 0.75RG 356 0.75GB 353 0.75GW 354 0.75GR 355 0.75RW 352
M20
FUEL PUMP
1 2
SUNLOAD SENSOR
833 164,190,195,200,216
1 2
M8
1 2 3 4 5 6 7 8
WIPER SW.IN(INT) WIPER SW.IN(CNT) WASHER SW. IN POWER (24V) IN WASHER CONT.(+) WASHER CONT.(-) WINDOW CONTROL REV. SIG. STOP SIG. WINDOW LIMIT SW. WIPER MOTOR(CW) WIPER MOTOR(CCW) GND
M
RL ROOM LAMP
YG 594 0.85YB 984 0.85LB 985 0.85BY 982 0.85BL 983
1 2 3 4 5 6 7 8
0.85LY 418 0.85Gr 419 0.85G 503 0.85RY 520 0.85Br 515 0.85W 400 0.85BO 428 0.85BW 420 LW 533 VY 534 GY 535 GW 536 WG 537 YL 538 LB 539
WIPER CONTROLER
D-OUT7
1.25RW 119 1.25G 754
YAZAKI SWP (CN.D64)
A4
0.85YB 490 0.85GL 492 0.85Y 410 0.85L 411 0.85Lg 412 0.85G 413 0.85GR 414 0.85V 415 0.85YG 416
RL MUTE
K10
YAZAKI SWP (CN.D62)
0.85Y 408 L 530 VG 531 GrR 532
RL IDLE STOP
D-OUT6
RELAY LAMP:UPPER (CN.A17)
BrL L
U V W
1 2 3 SUMITOMO (CN.E7)
D-OUT5
K11
RELAY LAMP:CAB (CN.A18)
GND Vcc
1 2 3 SUMITOMO (CN.E6)
RL LAMP
K3
RELAY HORN (CN.A16)
1 2
RL FUEL PUMP
D-OUT4
K5
508,372
1 2
D-OUT3
RELAY BEACON (CN.A19)
1 2
2 3
1 2 3 AMP (CN.E5)
WIPER-CNT
RELAY ROOM LAMP (CN.A20)
0.85GrR 011 0.85B 750
0.75B 392 0.75GR 393 0.75P 326
0.75YR 0.75LR
1 2 3 YAZAKI (CN.E4)
WIPER-INT
D-OUT2
1 2
YAZAKI CN-A (CN.G2)
D-OUT1
YAZAKI SWP (CN.C18)
SPARE2
YAZAKI SWP (CN.C19)
SPARE1
D-IN7
K35
RELAY SPEAKER:L (CN.A22)
5L 021
1
1 2
P 040c PG 041c
D-IN6
1
0.85G 509 0.85L 372
0.75RG 840 0.75B 752
SUMITOMO
YAZAKI SWP (CN.C20)
ONE TIME WIPER
D-IN5
1 2 3 4
DOOR SW
4 5 6 7 2 3 1
CAMERA SW
D-IN4
K36
RELAY SPEAKER:R (CN.A21)
1 4 2 5 3
YAZAKI CN-A (CN.C11)
MUTE SW
D-IN3
1 2
D-IN2
0.85BrR 210 0.85YR 220 0.85WR 282 0.85WV 829 1.25GR 875 VG 822 WG 823 0.85LY 824 LG 825 OR 826 G 888 YL 591
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
5RW 020
GLOW PLUG
VGS TURBO&C/UNIT 1 2 3 8 5 6 7 9 4 10 12 13 11 14
VG 051a V 050a
5R 003 5Y 004
1 2
24V 5.0kw
R1
RELAY STARTER
K69
K2
M1
M5
5BW
1
0.75B 786 0.75WR 145
RELAY GLOW
YAZAKI (CN.D12)
1 2 3 4 5 6 7 8
F-WINDOW SW
K37
1 YAZAKI CN-A (CN.D22)
M
SUMITOMO DL090 (CN.E3)
CAMERA3 GND D-IN1
0.85BrR 210 0.85YR 220 0.85WR 282 0.85WY 829 1.25GR 875 VG 822 WG 823 LY 824 LG 825 OR 826 G 888 YL 591 V 592 YG 594 0.85YB 984 0.85LB 985 0.85BY 982 0.85BL 983
1 2 3 4
CAMERA3 SIG
Y 962 W 963 YB 967 WB 968 YR 972 WR 973 O 590 YL 591 V 592 OL 593 YG 594 VR 595 Br 596 GR 820 Lg 821 VG 822 WG 823 LY 824 LG 825 OR 826 WB 949 BW 950
1 2 3 4
CAMERA2 GND
1 11 2 12 3 13 4 5 6 7 8 9 10 14 15 16 17 18 19 20 11 22
704
YAZAKI PA (CN.A28)
CAMERA2 SIG
Y 962 W 963 YB 967 WB 968 YR 972 WR 973 O 590 YL 591 V 592 OL 593 YG 594 VR 595 Br 596 GR 820 Lg 821 VG 822 WG 823 LY 824 LG 825 OR 826
YAZAKI 090 (CN.C8)
CAMERA1 GND
1 11 2 12 3 13 4 5 6 7 8 9 10 14 15 16 17 18 19 20
1.25BG 611 1.25BG 610
YAZAKI (CN.C9)
CAMERA1 SIG
1.25BG 611 1.25BG 610
5L 021
STARTER MOTOR
4 3 2 1 8 7 6 5 12 11 10 9 16 15 14 13 YAZAKI SWP (CN.D8)
GND GND
YAZAKI (CN.C10)
SDA(12C)
12V
YAZAKI SWP (CN.D66)
S11 WIPER S12 WASHER S10 W.LAMP S2 TRAVEL MODE S4 IDLE MODE S86 DPF CLEAN S87 ATT SELECT S88 MENU S89 DIAPLAY SEL S90 TRIP/CAMERA
YAZAKI 1.0Ⅲ （CN.C4）
0.85BG 660
6 7 8 9 1 2 3 4 5 10 11 12 13 14 15 16 17 18 19 20 SCL(12C)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
AGND
12V
1 2
AMP 040MIULTI (CN.C2)
THERMO SN
+
(CN.D20) M4
1 2
WR 062 WR 063 YR 541 O 542
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
I/O
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
A/D-IN
SWITCH PANEL
-
B
M10 S
5Y 004
0.85B 751
YAZAKI SWP (CN.D58)
A/D
CAMERA GND
1 2 SUMITOMO MT090 (CN.B6)
I/O
P10
CAMERA+
0.85B 779
+
M10
0.5μF
B M6
1 2 3 4 5 AMP (CN.E2)
AMP 040/070HYBRID I/O
8V-OUT
140 804,808 500 112 515 010 840 845 824
1.25W 107 1.25G 501 1.25WR 511 1.25Br 515 0.85GrR 011 0.75RG 840
M10
G2
R L
3 2
RESET
373 303 142 370 301 501 511 515 012 840
1 2 3 4 5 6 7 8
YAZAKI (CN.D13)
YAZAKI 58W (CN.D37)
11 10 9 8 7 6 5 4 3 2 1 22 21 20 19 18 17 16 15 14 13 12
PGM_WRITE PGM_WRITE SW
-
8R 030
1 2
6 5 4 3 2 1 12 11 10 9 8 7
5V-OUT
WL 061b W 060b BL 064b V 097 VG 098 G 099 R 960 B 961
M10
0.75R 0.75L
1 2
7 6
GND(RS232C)
WL 061b W 060b BL 064b V 097 VG 098 G 099 R 960 B 961
M10
1.25W 107 0.85G 501 0.85WR 511 0.85Br 515 0.85GrR 012 0.85RY 840
1.25G 510 1.25Br 515
M8 YAZAKI (CN.D21) M4 YAZAKI
24V 50A
IC REGULATOR
60R 001 M8
E M6
YAZAKI (CN.D16)
60R 101
YAZAKI SWP (CN.D61)
8 7 6 5 4 3 2 1 16 15 14 13 12 11 10 9
RxD(RS232C)
K34
(CN.A15) RELAY STARTER CUT
M8
SUMITOMO
RL 161 1.25W 111 0.85BrW 519 LR 881 YR 882 V 809 P 040b PG 041b WL 061b W 060b BL 064b WB 949 BW 950 1.25BG 610
1 2 3 4 5 6 7 8 9 10 11 12 13 14
K68
(CN.A10) (CN.A14) RELAY RELAY DPF NEUTRAL START
RELAY BATTERY
YAZAKI (CN.D15)
M8
POSITION SENSOR
TxD(RS232C)
CPU
TFT FULL COLOR
0.85RL 161 1.25W 111 0.85BrW 519 0.85LR 881 0.85YR 882 V 809 P 040b PG 041b WL 061b W 060b BL 064b WB 949 BW 950 1.25BG 610
K67
YAZAKI SWP (CN.D60)
13 12 11 10 9 8 7 6 5 4 3 2 1 26 25 24 23 22 21 20 19 18 17 16 15 14
CAN L CAN GND
0.85RL 161 1.25W 111 0.85BrW 519 P 040b PG 041b
(CN.A12) RELAY IDLE STOP
8B 797
1 2 YAZAKI 58L (CN.D24)
ALTERNATOR
SUMITOMO (CN.E1)
H1
LCD DISPLAY
0.85Y 900 0.85BY 901 0.85O 902 0.85BO 903 0.85L 904 0.85BL 905
PW 055 PL 056 W 060a WL 061a BL 064a
CAN H
1 2 4 5 6 18 8 9 19 3 12 7 10 11 13 14 16 17 15 20
YAZAKI SDL (CN.A47)
SN_ANG THROTTLE SN_P OVER LOAD KEY ON SW GATE LEVER BATTERY CHARGE AVcc AGND AGND SW AIR CLEANER P-SW OPT1 P-SW OPT2 SW FREE SWING SW HBCV/TRVL ALM SW FILTER IND SW ENG STOP
2 15 21 9 22 10 23 12 24 13 25 26 7 20 8 11 1 14 16 3 17 4 18 5 19 6
W 800 L 801 Y 802 Br 803 0.85O 804 YR 805 LY 806 WL 807 0.85YL 808 V 809
P4
ALTERNATOR
0.85RL 161 1.25W 111 0.85BrW 519 P 040b PG 041b
1 2 3 4 5 6 7 8 9 10
SN HYD.TEMP SN FUEL LEVEL SN_P P1 SN_P P2 SN_P N1 SN_P N2 SN_P SWING SN_P UPPER SN_P TRAVEL
IGN D-IN8
1 2 4 5 6 18 8 9 19 3 12 7 10 11 13 14 16 17 15 20
K66
1 4 2 5 3
YAZAKI SDL (CN.A46)
SN_IN1 SN_IN2 POT_IN1 POT_IN2 POT_IN3 POT_IN4 POT_IN5 POT_IN6 POT_IN7 POT_IN8 POT_IN9 POT_IN10 COMP_IN1 COMP_IN2 COMP_IN3 SW_IN1 SW_IN2 SW_IN3 SW_IN4 SW_IN5 SW_IN6 SW_IN7 SW_IN8 SW_IN9 SW_IN10 SW_IN11 SW_IN12 SW_IN13
4 12 3 10 2 5 13 6 14 11 1 9 7 15 16 8
BATT.
(CN.A11) RELAY BATTERY RL
G1 60R 100
YAZAKI SWP (CN.D59)
TXD RXD RS232C_TXD RS232C_RXD RS232C_GND GND GND CAN_H CAN_L +5V_OUT FREQUENCY_IN FREQUENCY_GND AVcc SW_1 IDLE SW SW_2 ANTI-THEFT SW_3 COOLANT
BZ.
K65
K7
1 2 SUMITOMO MT090 (CN.D38)
BOOT_CNT FWE SW_IN12 LM MAG SW SW_IN13 LM MODE
MONITOR DISPLAY
1 2 3 4 5 6
(CN.A13) RELAY KEY ON
1 2 YAZAKI 58L (CN.D25)
1 2
S-G
3 6 1 4 2 5 8 7 11 12 9 10
P1
1.25BG 601 1.25BG 601a 0.85B 701 0.85B 701a
V 097 VG 098 G 099 VR 595 Br 596 BG 612
K64
1 2
DIESEL ENGINE
FUSIBLE LINK SAFETY RL 60A
1 2
PUMP POWER(OUT) PUMP POWER(RTN) BOOM DOWN(OUT) BOOM DOWN(RTN) P1 FLOW(OUT) P1 FLOW(RTN) SHLD GND
1.25W 108 1.25W 108a
(CN.A09) RELAY ECM
FUSIBLE LINK FUSE BOX 65A
YAZAKI CN-A (CN.D26)
YAZAKI SWP (CN.D28)
SOL SWING BRAKE NPN_OUT1 NPN_OUT2 SOL 2 STAGE TRAVEL NPN_OUT3 SOL 2 STAGE RELIEF NPN_OUT4 FREE SWING NPN_OUT5 RL BATTERY NPN_OUT6 SOL OPT 2 SPEED NPN_OUT7 SOL OPT SELECT NPN_OUT8 TRAVEL ALARM NPN_OUT9 RL DPF NPN_OUT10 SIG WASHER
PWM_OUT1 PWM_RTN1 PWM_OUT2 PWM_RTN2 PWM_OUT3 PWM_RTN3
K63
1 2 YAZAKI 58L (CN.D23)
F45
0.85GW 215 2W 250
1 2 3 4 5 6 7 8
0.85G 507
1.25Y 870
F43
FUSE CONT 15A
YAZAKI (CN.D17)
B 749 0.85B 708
2BG 600 2B 700
F42
5RW 103 5RW 102
8 7 6 5 4 3 2 1
1.25Y 870 WL 267 0.85GW 215 2W 250
1.25B 700 0.85B 701 0.85B 702 1.25B 703 0.85B 704 0.85B 720
1.25W 112 1.25W 111 1.25W 110 1.25W 109 1.25W 108 1.25W 107
1.25BG 600 1.25B 700
1 2 3 4 5 6
6 5 4 3 2 1
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PG 41a PG 41b PG 41c PG 41d PG 41e PG 41f PG 41g PG 41h PG 41i PG 41j 1.25BG 600 1.25BG 601 1.25BG 602 0.85BG 603 1.25BG 609 1.25BG 610 0.85BG 620 BG 630 BG 637 BG 640
1.25WR 141 1.25WR 142 1.25WR 145 1.25WR 146 1.25WR 147 1.25WR 148
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
KEY SWITCH 0.85R 130
1.25RW 140
1.25RB 150
P 40a P 40b P 40c P 40d P 40e P 40f P 40g P 40h P 40i P 40j RL 160 RL 161 RL 162 RL 163 RL 164 0.85G 502 0.85G 503 0.85G 504 0.85G 505 0.85G 506
15A
(F1)
20A
(F2)
ENGINE CONTROLLER
10A
(F3)
GPS CONTROLLER
10A BACK UP RL 160
0.85VW 170
GR 180
LgW 190
(F4)
10A
(F5)
LEVER LOCK (GATE)
10A
(F6)
SOLENOID
10A
(F7)
HORN
15A
(F8)
1.25GrR 195
1.25LW 200
LAMP (CAB)
LAMP (BOOM,HOUSE)
15A
15A
(F9)
1 2
3R 105a
3R 105b
(F10)
SPARE 1.25W 205
15A
(F11)
WIPER/WASHER 0.85BrR 210
10A
(F12) 3R 105c
TRAVEL ARALM BEACON 0.85GW 215 0.85GW 216
10A
(F13)
CIGAR LIGHTER SEAT SUS
DC/DC CONVERTOR 0.85OR 225
0.85YR 220 0.85YR 221
10A
(F14)
5A
(F15)
AIRCON UNIT VR 230
(F16) 3R 105d
AIRCON 15A BLOWER MOTOR
0.85LR 240 0.85LR 242
1.25WR 235
5A
(F17)
AIRCON COMPRESSOR
10A
(F18)
SPARE WB 245
15A REFUEL PUMP
YAZAKI M (CN.A40)
YAZAKI CN-A (CN.D29)
(CN.A4)
YAZAKI M (CN.A39)
FUSIBLE LINK BACK UP 50A
1 YAZAKI CN-A (CN.D30)
(CN.A3)
1 2 3 4 5 6
1 2 3 4 5 6
1 2 3 4 5 6 YAZAKI M (CN.A38)
F41
1 YAZAKI 58Y (CN.D11)
GND_A
1 12 11 22 2 13 5 16 9 20 10 21 6 4 7 3 8 14 15 18 17 19
8R 105 5RW 103
3 2 1 7 6 5 4 10 9 8 14 13 12 11 YAZAKI SWP (CN.D9)
GND
(CN.A2)
2 1
1 2
GND_3
(CN.A8)
SUMITOMO (CN.A42)
2 1 6 5 4 3
GND_2
(CN.A7)
SUMITOMO (CN.A41)
YAZAKI SDL (CN.C21)
POWER 24V
(CN.A6)
10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11
503,504,505,515,520,521,530,536,537,539,558,804,808,809
POWER 24V
(CN.A5)
8R 105 5RW 103
108,109,110 601,602,603,701,702,703
CONTROLLER A
79165894-1EN - 1/2
10 9 8 7 6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11
RL 166
A1
(CN.A1)
8R 105 5RW 103 180,215,242,250,260,267 400,410,411,412,413,414,415,416,419,420,430,444,445,446,450,490,492,532,534,535,538,559,660,800,801,802,803,805,0806,807,812,813,900,901,902,903,904,905,906,907,908,909,910,911
YAZAKI SWP (CN.D14)
WL 260 WL 266 WL 267 2W 250
OPTION
10A
(F20)
F34
(F19) 3R 105e
BOX FUSE(ATTACHMENT FOR CAB MAIN HARNESS)
B95
PLATFORM
CX350C / CX370C EXCAVATOR - ELECTRICAL SCHEMATIC Lep 84402837BEN - 1/2
AIR CONDITIONER SWITCH PANEL & UNIT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CAN L CAN H PG 041g P 040g
BrY 940 BrW 942 VW 936
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
L 947 Sb 945
LY 926 WB 949
RL 939 LG 931 YL 930 GL 929
TEMP SENSOR(EVA) TEMP SENSOR(REC)
GND SENSOR GND POTENTIO (GND)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 VR 231 LW 925 LR 924 YW 923 YR 922 GW 921 GR 920
B 731 BW 946 BL 932
S51 S52 S53 S54 S55 S61 S62 S69 S70 S71 S85 S86 S87 S88 S89 S90 U1 X2 X3 X4 X5 X6 X8 X9 X15 X23 X24 X25 X26 X27 X28 X29 X30 X31 X32 X33 X34 X35 X36 Y2 Y3 Y4 Y5 Y7 Y8 Y9 Y11 Y18 Y23 Y24 Y25 Y26 Y27 Y35 Y59 Y60 Y61 Y62 Y63 Y64 Y65 Y66 Y67 Y68 Y69 Y70
BLOWER GATE COMP_RL COIL BLOWER-OFF RELAY
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
BLOWER FEED-BACK R/F_POTENTIO (SIG) MODE_POTENTIO (SIG) AIR-MIX_POTENTIO (SIG)
AMP 040 (CN.B22)
POTENTIO (5V) SUNLOAD SENSOR2
AMP 040 (CN.B21)
P6
CCU POWER(IGN) R/F M_ACT.OUT1 R/F M_ACT.OUT2 MODE M_ACT.OUT1 MODE M_ACT.OUT2 AIR-MIX M_ACT.OUT1 AIR-MIX M_ACT.OUT2
A9
ITEM
AIR CONDITIONER SWITCH PANEL
E52 1 2 3 4 5 6
YAZAKI CN-A (CN.B19)
YAZAKI SDL (CN.A48)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
M
A6
BLOWER AMP
TEMP.SENSOR (RECIRCULATE)
LR 924 LW 925 LY 928 LG 931 BL 934
1 2
1 2
7 1 6 2 3 4 5
M
YAZAKI SDL (CN.B20)
M5
TEMP.SENSOR (EVAPORATOR)
B5
1 2
1 2
YAZAKI CN-A (CN.F6)
L 947 BW 948
MOTOR ACTUATOR (FRESH/RECIRCULATE)
R4 YAZAKI CN-A (CN.F5)
Sb 945 BW 946
M
M6
1 2 3 4 5 6 7
LY 926 GL 929 YL 930 LG 931 BL 932
3 2 1
1 2 3
2RL 938 BrY 940 2B 730
7 1 6 2 3 4 5
1 2 3 4 5 6 7
1 2
YW 923 LY 927 YL 930 BL 933
1 2
2LR 937 2RL 938
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
M8 YAZAKI (CN.B22)
M8
BLOWER MOTOR
M
M7
MOTOR ACTUATOR (MODE) YR 922
YAZAKI CN-A (CN.F4)
LY 926 GL 929 YL 930 LG 931 BL 932
Sb 945 L 947 BW 946 GR 920 GW 921 YR 922 YW 923 LR 924 LW 925
1 2 4 3
YAZAKI CN-A (CN.F3)
Sb 945 L 947 BW 946 GR 920 GW 921 YR 922 YW 923 LR 924 LW 925
K17
RELAY BLOWER OFF 2WR 235 VR 230 VW 936 2LR 937
GW 921 LY 926 GL 929 BL 932
7 1 6 2 3 4 5
1 2 3 4 5 6 7
BrW 942 VW 936 BrY 940 RL 939
GR 920
1 2 3 4
BrW 942 VW 936 BrY 940 RL 939
2B 730
YAZAKI CN-A (CN.F2)
P 040g PG 041g WB 949 BW 950 0.85GW 943
1 2 4 3
JAE IL-AG5 (CN.F9)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1.25B 730
0.85LR 240 0.85LR 241 BrW 942 0.85GW 943
MOTOR ACTUATOR (AIR MIX)
K6
RELAY COMPRESSOR
JAE IL-AG5 (CN.F8)
2WR 235 0.85LR 240 VR 230 0.85GW 943
JAE IL-AG5 (CN.F7)
1 2 3 4 5 6
1 2 3 4
1.25WR 235 0.85LR 240 VR 230 0.85GW 943
YAZAKI CN-A (CN.F1)
VR 230 1.25WR 235 0.85LR 240
1 2 3 4 5 6 7 8 9 10 11 12 13 14
AIR CONDITIONER UNIT
SOLENOID VALVE WL 260 LY 806
YAZAKI SDL (CN.A57)
1 2 3 4 5 6 7 8 9 10
OPTION
1 2
0.75R 0.75B
OPTION
SELECT (BLUE TAPE)
(S1)
Y67
2SPEED (RED TAPE)
(S2)
Y68
1 2
YAZAKI SWP (CN.57-2)
WL 260 LY 806 YR 805 VY 534 GY 535
0.75R 0.75B
ITEM
1 2
YAZAKI SWP (CN.57-1)
WL 261 YR 805
PRESS.SWITCH (1ST OPTION) BG 640 VY 534
BG 640
0.75W 0.75W
1 2
B94
1 2
YAZAKI SWP (CN.57-3)
1 2 3 4 5 6 7 8 9 10
1 2
DESCRIPTION HYDRAULIC FUNCTION CANCELLATION LEVER SWITCH AIR CONDITIONING COMPRESSOR CLUTCH SWITCH DOOR LIMIT SWITCH FRONT WINDOW LIMIT SWITCH RESERVE TANK LOW SWITCH REFUEL PUMP SWITCH AIR CLEANER SENSOR RADIO MUTE SWITCH HORN VOLUME SWITCH PRESSURE SWITCH FILTER INDICATOR (BREAKER OPTION) BEACON (EU) DPF CLEAN ATT SELECT MENU DISPLAY SELECT TRIP/CAMERA DC-DC (24V-12V) CONVERTER ROTARY LIGHT CONNECTOR OPTIONAL POWER CONNECTOR ENGINE TEST POINT CONNECTOR CONTROLLER TEST POINT CONNECTOR CAB SEAT COMPRESSOR MOTOR CONNECTOR RADIO CONNECTOR (NA) ANTI-THEFT SYSTEM CONNECTOR ACCESSORY SOCKET CLEAR MEMORY 1 CLEAR MEMORY 2 TO CONTROLLER C EST CONNECTOR B TO GPS UNIT TO CAMERA 1 (NO TAPE) TO CAMERA 2 (RED TAPE) TO CAMERA 3 (BLUE TAPE) CAN TO DRM FOR CRANE (NOT USED) FOR FAN REVERSE OVER HEAT SWITCH 12V OUTPUT (FOR RADIO EU) PILOT PRESSURE SOLENOID VALVE (PINK TAPE) SWING BRAKE SOLENOID VALVE (BLUE TAPE) 2 STAGE TRAVEL SOLENOID VALVE (RED BAND) POWER-UP SOLENOID VALVE (YELLOW BAND) MAIN PUMP POWER PROPORTIONAL SOLENOID AIR CONDITIONER MAGNET CLUTCH OPTION 2 SPEED SOLENOID VALVE (BLUE TAPE) MAIN PUMP FLOW PROPORTIONAL SOLENOID FREE SWING SOLENOID VALVE (LBX-NA) OPT.1 KNOB (R) -R SOLENOID VALVE (BLUE TAPE) OPT.1 KNOB (R) -L SOLENOID VALVE (RED TAPE) OPT.2 KNOB (L) -R SOLENOID VALVE (BLUE TAPE) OPT.2 KNOB (L) -L SOLENOID VALVE (RED TAPE) OPTION SELECT SOLENOID VALVE (RED TAPE) SUCTION CONTROL VALVE (SCV) BOOM DOWN PROPORTIONAL SOLENOID VALVE (NO TAPE) ARM CLOSE PROPORTIONAL SOLENOID VALVE (RED TAPE) BUCKET CLOSE PROPORTIONAL SOLENOID VALVE (BLUE TAPE) OPTION PRESS. PROPORTIONAL SOLENOID VALVE INJ1 (#1) INJ2 (#5) INJ3 (#3) INJ4 (#6) OPTION SELECT SOLENOID VALVE (BLUE TAPE) OPTION 2 SPEED SOLENOID VALVE (RED TAPE) INJ5 (#2) INJ6 (#4)
PRESS.SWITCH (2ND OPTION) BG 641 GY 535
B28 LEGEND
1 2
YAZAKI SWP (CN.57-4)
OPTION LINE CIRCUIT <PEDAL TYPE>
0.75W 0.75W
1 2
B OPTION LINE CIRCUIT <KNOB SWITCH TYPE>
1 2 G 854 VY 534
1 2
1 2
0.75R 0.75B
OPTION
1 2
0.75R 0.75B
OPTION
SELECT (RED TAPE)
(S2)
Y27
WL 261 YR 805
2SPEED (BLUE TAPE)
(S1)
WL 262 G 850
1 2 GL 856 GY 535
1 2 SUMITOMO MT090 (CN.57-11)
1 2
OPT.1
0.75R 0.75B
KNOB(R)-R (BLUE TAPE)
(S1)
Y23
1 2
OPT.1
0.75R 0.75B
KNOB(R)-L (RED TAPE)
(S2)
CONNECTOR (MALE)
CONNECTOR (FEMALE)
1 2
OPT.2
0.75R 0.75B
WL 265 OL 853
1 2
OPT.2
0.75R 0.75B
(S1)
Y25
CONNECTOR LETTER LOCATED (OUTSIDE CAB)
(S2)
K31
RELAY PUMP (CN.G4)
RELAY STOP (CN.G5)
S61 1 2 SUMITOMO MT090 (CN.175)
1 4 2 5 3
MANUAL/AUTO
1
1 2 3
2 3 YAZAKI CN-A (CN.G6)
0.85VR 866 0.85GW 216 0.85L 867
2 1 0.85WR 917 0.85VR 918
3 1 2 5 4 0.85L 867 0.85L 868 0.85YL 820 0.85BrR 916 0.85WR 917
3 1 2 5 4
SUMITOMO
60 B 001 CIRCUIT NUMBER TABLE OF COLOR SYMBOLS
Y26
REFUEL PUMP
K30
COLOR OF CONNECTOR (IF NOT INDICATED COLOR IS WHITE)
AREA COLOR
1 2
YAZAKI SWP (CN.57-8)
KNOB(L)-L (RED TAPE)
INDICATES POWER WHEN KEY SWITCH IS ON
CN12 (R)
1 2
YAZAKI SWP (CN.57-7)
KNOB(L)-R (BLUE TAPE)
1
CONNECTOR NUMBER (IN CAB)
SOLENOID VALVE WL 264 GL 852
INDICATES CONSTANT POWER
Y24
1 2
1 2 SUMITOMO MT090 (CN.57-12)
YAZAKI SWP (CN.57-6)
1 2
HARNESS
INSULATION AGAINST MAGNETISM
1 2
WL 263 O 851
OL 857 GY 545
SINGLE WIRE CONNECTOR
Y9
SOLENOID VALVE
1.25GW 215 0.85VR 866 0.85B 758 1.25LR 915
CABLE GROUND
1 2
O 855 VY 544
1 2 SUMITOMO MT090 (CN.57-9)
YAZAKI SWP (CN.57-5)
YAZAKI SDL (CN.A57)
1 2 SUMITOMO MT090 (CN.57-10)
YAZAKI SWP (CN.57-2)
1 2 3 4 5 6 7 8 9 10
BOOT GROUND
1 2
YAZAKI SWP (CN.57-1)
WL 260 LY 806 YR 805 VY 534 GY 535 G 850 O 851 GL 852 OL 853
NOT CONNECTED
SOLENOID VALVE WL 260 LY 806
1 2 3 4 5 6 7 8 9 10
CONNECTED
SYMBOL
COLOR
B
BLACK
W
WHITE
Br
BROWN
P
PINK
V
VIOLET
G
GREEN
O
ORANGE
R
RED
Y
YELLOW
Lg
LIGHT GREEN
Sb
SKY BLUE
L
BLUE
Gr
GRAY
A1 A2 A4 A6 A9 A13 B1 B2 B3 B5 B21 B22 B26 B27 B28 B40 B42 B43 B44 B45 B47 B48 B49 B51 B52 B61 B82 B83 B84 B85 B86 B87 B88 B89 B90 B91 B92 B93 B94 B95 E1 E2 E3 E4 E51 E52 E68 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20 F34 F41 F42 F43 F45 G1 G2 H1 H2 H4 H5 K2 K3 K5 K6 K7 K10 K11 K17 K30 K31 K34 K35 K36 K37 K51 K63 K64 K65 K66 K67 K68 K69 M1 M3 M4 M5 M6 M7 M8 M14 M20 M23 M24 M25 P1 P2 P3 P4 P6 P10 P15 R1 R3 R4 R5 R7 S1 S2 S4 S9 S10 S11 S12 S13 S15 S16 S22 S28 S31 S32 S33 S34
DESCRIPTION COMPUTER ENGINE CONTROLLER WIPER CONTROLLER BLOWER CONTROLLER AIR CONDITIONER CONTROLLER CONTROLLER B COOLANT TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR FUEL TEMPERATURE SENSOR EVAPORATOR SENSOR ENGINE OIL PRESSURE SWITCH SWING PILOT PRESSURE SWITCH UPPER PILOT PRESSURE SENSOR TRAVEL PILOT PRESSURE SENSOR SECOND OPTION PILOT CIRCUIT 1 PRESSURE SWITCH PUMP PRESSURE SENSOR (NEGA-CONT. P2) PUMP PRESSURE SENSOR (P1) PUMP PRESSURE SENSOR (NEGA-CONT. P1) PUMP PRESSURE SENSOR (P2) (BLUE BAND) OVERLOAD INDICATOR PRESSURE SWITCH BOOST PRESSURE SENSOR AMBIENT AIR (BAROMETRIC) PRESSURE SENSOR CRANKSHAFT POSITION SENSOR BOOST TEMPERATURE SENSOR COMMON RAIL PRESSURE SENSOR SUNLOAD SENSOR REFUEL PUMP STOP ALARM PRESS. SENSOR (PILOT ARM CLOSE) PRESS. SENSOR (PILOT BUCKET CLOSE) PRESS. SENSOR (PILOT BOOM UP) EGR INTAKE TEMP.SENSOR CAM ANG (MRE) SENSOR FUEL FILTER SENSOR EXSHAUST PRESS. SENSOR EXSHAUST TEMP. SENSOR (CNT) EXSHAUST TEMP. SENSOR (FNT) HORN LOW (LEFT) HORN LOW (RIGHT) PRESS.SWITCH (1ST OPTION) AIR INTAKE SENSOR MASS & TEMP WORKING LIGHT (UPPERSTRUCTURE) WORKING LIGHT (ATTACHMENT) WORKING LIGHT (CAB) CAB LIGHT CIGARETTE LIGHTER AIR CONDITIONER CONDENSER FUSE 15A ; KEY SWITCH FUSE 20A ; ENGINE CONTROLLER FUSE 10A ; GPS CONTROLLER FUSE 10A ; BACK UP FUSE 10A ; LEVER LOCK (GATE) FUSE 10A ; SOLENOID FUSE 10A; HORN FUSE 15A ; LAMP (CAB) FUSE 15A ; LAMP (BOOM, HOUSE) FUSE 15A ; SPARE FUSE 15A; WIPER AND WASHER FUSE 10A ; TRAVEL ALARM ; BEACON FUSE 10A ; CIGAR. LIGHTER ; SEAT SUSP. FUSE 10A ; DC /DC CONVERTER FUSE 5A ; AIR CONDITIONER HEATER UNIT FUSE 15A ; AIR CONDITIONER BLOWER FUSE 5A; AIR CONDITIONER COMPRESSOR FUSE 10A ; SPARE FUSE 15A; FUEL FILLER PUMP FUSE 10A ; OPTION LINE FUSE BOX FUSIBLE 50A ; LINK BACK UP FUSE 15A ; CONT FUSIBLE 65A ; LINK FUSE BOX FUSIBLE 60A ; LINK SAFETY RL BATTERY ALTERNATOR AUDIBLE WARNING DEVICE TRAVEL ALARM SPEAKER RIGHT SPEAKER LEFT RELAY-GLOW PLUG RELAY-HORN RELAY-ROTARY LIGHT RELAY-AIR CONDITIONER CONDENSER FAN RELAY BATTERY RELAY-WORKING LIGHT (UPPERSTRUCTURE / ATTACHMENT) RELAY-WORKING LIGHT (CAB) BLOWER OFF RELAY REFUEL PUMP RELAY REFUEL PUMP STOP RELAY RELAY STARTER CUT RELAY ROOM LAMP RELAY SPEAKER LEFT RELAY SPEAKER RIGHT RELAY CONDENSER RELAY ECM RELAY KEY ON RELAY BATTERY RL RELAY IDLE STOP RELAY DPF RELAY NEUTRAL START RELAY STARTER STARTER MOTOR WIPER MOTOR WASHER MOTOR MOTOR (AIR CHANGING) AIR VENT DIRECTION CONTROL MOTOR MOTOR ACT (AIR-MIX) BLOWER MOTOR FUEL FEED PUMP MOTOR ELECTRIC FUEL PUMP VGS TURBO INTAKE THROTTLE DC-MOTOR EXHAUST GAS RECIRCULATION VALVE INSTRUMENT PANEL SWITCH PANEL (LEFT-HAND) SWITCH PANEL (RIGHT-HAND) MONITOR DISPLAY AIR CONDITIONER CONTROL PANEL SWITCH PANEL RADIO SET (NA) GLOW PLUG THROTTLE VOLUME THERMISTOR INNER TEMPERATURE FUEL SENSOR RESISTOR (MAF) KEY SWITCH TRAVEL MODE SWITCH AUTO IDLE SWITCH ENGINE EMERGENCY STOP SWITCH WORKING LIGHT SWITCH WIPER SWITCH WASHER SWITCH OVERLOAD SWITCH (EU) HORN SWITCH IDLE SWITCH FREE SWING SWITCH (NA) ; OPTIONAL (EU) TRAVEL ALARM SWITCH (LBX-NA) OPTION 1 SOLENOID VALVE SWITCH OPTION 1 SOLENOID VALVE SWITCH OPTION 2 SOLENOID VALVE SWITCH OPTION 2 SOLENOID VALVE SWITCH
NOTE : 1. "BR" INDICATES BLACK CABLE WITH RED STRIPE. 2. WATERPROOF CONNECTORS USED OUTSIDE OF CAB.
0.85BrR 916 0.85B 759
R B
ALARM 24V,107dB
B82 0.85B 765
YAZAKI 58W (CN.D76)
2 1 3
2W 250 0.85VG 822 2B 764
1 2
YAZAKI 58W (CN.G7)
1 3 2
REFUEL PUMP 1.25LR 915 1.25B 757
2 1
2R 2B
10A
M
M14 24V
28488018-1EN - 2/2
CX350C / CX370C EXCAVATOR - ELECTRICAL SCHEMATIC Lep 84402837BEN - 2/2