Fiat Kobelco E40 2sr E50 2sr Mini Crawler Excavator Service Repair Workshop Manual – PDF Download

E40.2SR - E50.2SR WORKSHOP MANUAL ENGLISH Pubblication Nr. 604.13.368

Edition 08/2004 English - Printed in Italy Printed by Studio ti - 41204

INTRODUCTION

TO THE READER • This manual has been written for a skilled technician, in order to give him the information necessary to repair this machine. Read this manual carefully for correct information about repair procedures.

For any question or comment, or in case you notice a mistake in this manual content, please contact: FIAT KOBELCO CONSTRUCTION MACHINERY S.p.A. Strada Settimo, 323 San Mauro Torinese (TO) 10099 ITALIA PRODUCT SUPPORT Fax. ++39 011 0077357

ADDITIONAL REFERENCE MANUALS • In addition to this Workshop Manual, refer also to the following: Operation and maintenance instruction manual Spare parts catalog

DESCRIPTION OF THE WORKSHOP MANUAL

• The “Hydraulic exavator” Workshop Manual contains the technical information necessary for machine service and repair, the service equipment, the information • This repair manual consists of one single volume, on maintenance standards, the removal and installing identified with: procedures, and the disassembly and assembly proE40.2SR - E50.2SR - Workshop Manual “Hydraulic cedures. exavator” • The complete Workshop Manual for the model E40.2SR - E50.2SR consists of the following volume identified by print number as shown herebelow: VOLUME Workshop Manual - “Hydraulic exavator”

MACHINE TYPE E40.2SR E50.2SR

PRINT No. 604.13.368

INTRODUCTION

AVOID ACCIDENTS Most accidents, whether they occur in industry, on the farm, at home or on the highway, are caused by the failure of some individuals to follow simple and fundamental safety rules or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognising the real cause and doing something about it before the accident occurs. Regardless of the care used in the design and construction of any type of equipment there are conditions that cannot be completely safeguarded against without interfering with reasonable accessibility and efficient operation. Carefully read indications, cautions and safety warning quoted in the “SAFETY RULES� section. A careful operator is the best insurance against an accident. The complete observance of one simple rule would prevent many thousand serious injuries each year. That rule is: Never attempt to clean, oil or adjust a machine while it is in motion.

ATTENTION On machines having hydraulically, mechanically and/or cable controlled equipment (such as showels, loaders, dozers, scrapers etc.) be certain the equipment is lowered to the ground before servicing, adjusting and/or repairing. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and/or mechanical device used for controlling the equipment.

COPYRIGHT BY FIAT KOBELCO CONSTRUCTION MACHINERY Product Support - Documentation Centre

S.p.A.

Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY All rights reserved. Reproduction of text and illustrations in whole or in part, is strictly prohibited.

SAFETY PRECAUTIONS

0-1

SAFETY PRECAUTIONS

GENERAL SAFETY INFORMATION

alert against possible damage to the machine and its components and is represented as follows:

WARNING

CAUTION

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

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

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

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

WARNING 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to

0-2

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

WARNING

WARNING

Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.

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

(6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section: SPECIFICATIONS.

(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. (8)

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

(9)

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

The following is a list of basic precautions that must always be observed. (1)

(2)

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

(3)

Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys.

(4)

If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.

(5)

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

(10) To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11) Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely. (12) Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. (13) Always use the proper tools that are in good condition and that are suited for the job at hand. Be

0-3

SAFETY PRECAUTIONS sure you understand how to use them before performing any service work.

been damaged or altered should be checked for balance before reusing.

(14) Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

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

(15) Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. (16) Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. (17) Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18) The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work. (19) Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20) Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. (21) Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has

0-4

INDEX

E40.2SR E50.2SR

Title

Index No.

OUTLINE

1

SPECIFICATIONS

2

ATTACHMENT DIMENSIONS

3

TOOLS

11

STANDARD MAINTENANCE TIME TABLE

12

MAINTENANCE STANDARDS AND TEST PROCEDURES

13

HYDRAULIC SYSTEM

22

ELECTRICAL SYSTEM

23

COMPONENTS SYSTEM

24

WHOLE DISASSEMBLING & ASSEMBLING

31

ATTACHMENTS

32

UPPER SLEWING STRUCTURE

33

TRAVEL SYSTEM

34

HYDRAULIC SYSTEM

42

ELECTRICAL SYSTEM

43

ENGINE

44

ENGINE

51

SUPPORTING DATA

71

DATA

OPT.

E/G TROUBLESHOOTING

DISASSEMBLING

SYSTEM

MAINTENANCE

SPECIFICATIONS

SAFETY PRECAUTIONS

APPLICABLE MACHINES

0-5

SAFETY PRECAUTIONS

[MEMO]

0-6

1. OUTLINE TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR REPAIRS ..................................................... 1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING .............................................. 1-3 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING .................................... 1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ............ 1-3 1.1.4 ELECTRICAL EQUIPMENT .......................................................................... 1-4 1.1.5 HYDRAULIC PARTS ..................................................................................... 1-5 1.1.6 WELDING REPAIR ....................................................................................... 1-5 1.1.7 ENVIRONMENTAL MEASURE ..................................................................... 1-5 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM ............................................ 1-6

1. OUTLINE

1-1

1. OUTLINE

1-2

1. OUTLINE

1.1

GENERAL PRECAUTIONS FOR REPAIRS

(2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work.

1.1.1

PREPARATION BLING

(3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine.

BEFORE

DISASSEM-

(4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency.

(1) Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure.

(5) Choose a hard, level and safe place, and place the attachment on the ground securely.

(2) Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling.

(6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. (7) Use proper tools, and replace or repair defective tools. (8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

(3) Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance.

1.1.3

(4) Recording Record the following items for communication and prevention of recurring malfunction.

(1) Removing hydraulic equipment 1) Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter.

1) Inspection date and place. 2) Model name, applicable machine number, and hour meter read.

2) Carefully drain oil of the removed pipes into a containers without spilling on the floor.

3) Trouble condition, place and cause.

3) Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion.

4) Visible oil leakage, water leakage and damage. 5) Clogging of filters, oil level, oil quality, oil contamination and loosening of connections.

4) Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

6) Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date.

(2) Disassembling hydraulic equipment 1) Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after modification.

(5) Arrangement and cleaning in service shop 1) Tools required for repair work. 2) Prepare space to place the disassembled parts. 3) Prepare oil containers for draining oil etc. 1.1.2

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

2) When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training.

SAFETY IN DISASSEMBLING AND ASSEMBLING

3) Provide matching marks to facilitate reassembling work. (1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.

4) Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself.

1-3

1. OUTLINE 5) Use the special jig and tools without fail if they are specified.

WARNING

6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause.

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

7) Place the removed parts in order and attach tags to facilitate the reassembling.

3) Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug.

8) Note the location and quantity of parts commonly applied to multiple locations. (3) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact. 2) Measure and record wear condition of parts and clearance.

4) Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more than 5 minutes at low speed without load.

3) If the problem is found in a part, repair or replace it with a new one.

WARNING

(4) Reassembling hydraulic equipment

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

1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. 2) Perform rough and finish cleaning before assembling.

5) Perform air bleeding of pilot line by performing a series of digging, slewing and travel.

3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling.

6) Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

1.1.4

ELECTRICAL EQUIPMENT

5) Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. 6) Remove rust preventive agent from the new parts before use.

(1) Do not disassemble electrical equipment.

7) Fit bearings, bushings and oil seals using special jigs.

(3) Turn the key OFF prior to connecting and disconnecting work.

8) Assemble the parts utilizing matching marks.

(4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion.

(2) Handle it carefully not to drop and give a shock.

9) Ensure all the parts are completely assembled after the work.

(5) Connect the connector and ensure it is completely locked.

(5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied.

(6) Turn the key OFF prior to touching the terminal of starter or generator.

2) Perform air bleeding when:

(7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.

1. Hydraulic oil changed 2. Parts of suction side piping replaced

(8) Do not splash water on the electrical equipment and connectors during machine washing.

3. Hydraulic pump installed 4. Slewing motor installed

(9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector.

5. Travel motor installed 6. Hydraulic cylinder installed

1-4

1. OUTLINE 1.1.6

If moisture adhesion is found, dry it completely before the connection.

(1) Refer repair welding to qualified personnel according to the appropriate procedure.

WARNING

(2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment.

Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. •

When skin exposed: Wash with water and soap sufficiently.

•

When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes.

•

(3) Move away the articles in advance that may cause fire if exposed to sparks. (4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks. 1.1.7

When swallowed: Drink a large amount of milk or water.

•

When clothes exposed: Immediately undress and wash.

1.1.5

(2) Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures:

HYDRAULIC PARTS

•

When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes.

•

When swallowed: Do not let vomit, and receive medical treatment immediately.

•

When skin exposed: Wash with water and soap sufficiently.

(1) O-ring • •

Ensure O-rings have elasticity and are not damaged before use. Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same.

•

Fit the O-rings without distortion and bend.

•

Always handle floating seals as a pair.

(4) Others Use replacement parts and lubricants authorized as the genuine parts.

(2) Flexible hose (F hose) •

Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same.

•

Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

ENVIRONMENTAL MEASURE

(1) Run the engine at the place that is sufficiently ventilated.

When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water.

•

WELDING REPAIR

1-5

1. OUTLINE

1.2

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

(3) Derived Units Table 1-3

Introduction Although this manual includes International System of Unit and Foot-Pound System of Units, if you need SI unit, refer to the following international system of units. Given hereinafter is an excerpt of the units that are related to this manual.

Base units Table 1-1

SI units

Derived units

Derived units of base units Table 1-2 Derived units bearing peculiar designations Table 1-4

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

(1) Base units Table 1-1 QUANTITY

UNIT

SYMBOL

Length

meter

m

Mass

kilogram

kg

Time

second

s

Electric current

ampere

A

Thermodynamic temperature

kelvin

K

Amount of substance

mol

mol

Luminous intensity

candela

cd

(2) Supplementary units Table 1-2 QUANTITY

UNIT

SYMBOL

Plane angle

radian

rad

Solid angle

steradian

sr

SYMBOL

Area

square meter

m2

Volume

cubic meter

m3

Velocity

meter per second

m/s

Acceleration

meter per second squared

m/s2

Density

kilogram per cubic meter

kg/m3

Table 1-4

2. Construction of SI Unit System

SI unit system

UNIT

(4) Derived Units bearing Peculiar Designations

1. Etymology of SI Unites French: Le Systeme International d’ Unites English: International System of Units

Supplementary units Table 1-2

QUANTITY

1-6

QUANTITY

UNIT

SYMBOL

FORMULA

Frequency

hertz

Hz

1/s

Force

newton

N

kg • m/s 2

Pressure and Stress

pascal

Pa

N/m2

Energy, Work and Quantity of heat

joule

J

N•m

Power

watt

W

J/s

Quantity of electricity

coulomb

C

A•s

Electric potential difference, Voltage, and Electromotive force

volt

V

W/A

Quantity of static electricity and Electric capacitance

farad

F

C/V

Electric resistance

ohm

Celsius temperature

celsius degree or degree

C

(t+273.15)K

Illuminance

lux

lx

lm/m2

V/A

1. OUTLINE (5) Prefixes of SI Table 1-5 PREFIX

SYMBOL MULTIPLICATION FACTORS

giga

G

109

mega

M

106

kilo

k

103

hecto

h

102

deca

da

10

deci

d

10–1

centi

c

10–2

milli

m

10–3

micro

P

10–6

nano

n

10–9

pico

p

10–12

(6) Unit Conversion Table 1-6 QUANTITY Gravitational

SI

CONVERSION FACTOR

Mass

kg

kg

Force

kgf

N

1 kgf = 9.807 N

N•m

kgf•m = 9.807 N•m

Torque

kgf•m

Pressure

kgf/cm2

Motive Power

PS

kW

1 PS = 0.7355 kW

Revolution

rpm

min–1

r/min *1

MPa 1 kgf/cm2 = 0.09807 MPa

*1 Units that are allowed to use.

1-7

1. OUTLINE

[MEMO]

1-8

2. SPECIFICATIONS TABLE OF CONTENTS 2.1 COMPONENTS NAME ..................................................................................... 2-3 2.2 MACHINE DIMENSIONS .................................................................................. 2-4 2.3 SPECIFICATIONS AND PERFORMANCE ....................................................... 2-6 2.4 MACHINE & COMPONENTS WEIGHT (DRY) ................................................. 2-7 2.5 TRANSPORTATION ......................................................................................... 2-9 2.6 TYPE OF CRAWLER SHOES ........................................................................ 2-11 2.7 TYPE OF BUCKET ......................................................................................... 2-12 2.8 ENGINE SPECIFICATIONS ............................................................................ 2-14 2.8.1 SPECIFICATIONS ...................................................................................... 2-14 2.8.2 ENGINE PERFORMANCE CURVE ............................................................ 2-15

2. SPECIFICATIONS

2-1

2. SPECIFICATIONS

2-2

2. SPECIFICATIONS

2.1

COMPONENTS NAME

32 30 36

33

34 15 16

17

8 18

35 19

31

12 3

37 13

5

11

4

14

1

29 28 24 27

20 25

2

7 6

26 21

23

9 22 10

No.

NAME

No.

NAME

No.

NAME

No.

NAME

1 Engine

2 Oil filter

3 Radiator

4 Reservoir tank

5 Air cleaner

6 Muffler

7 Fuel tank

8 Hydraulic tank

9 Hydraulic pump

10 Slewing motor

11 Swing cylinder

12 Control valve

13 Travel lever

14 Safety lock lever

15 Canopy

16 Operating lever

17 Dozer operating lever

18 Throttle lever

19 Monitor panel (gauge cluster)

20 Battery

21 Swivel joint

22 Travel motor

23 Slewing bearing

24 Idler assy

25 Lower roller

26 Upper roller

27 Rubber crawler shoe

28 Dozer blade

29 Dozer cylinder

30 Boom

31 Boom cylinder

32 Arm cylinder

33 Light

34 Arm

35 Link

36 Bucket cylinder

37 Bucket

2-3

2. SPECIFICATIONS

2.2

MACHINE DIMENSIONS Unit: mm (ft•in)

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(1) E40.2SR (CANOPY)

115 {4.53"}

0

1940 {6'4.4"}

R980 } {3'2.6"

5000 {16'4.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

1940 {6'4.4"}

115 {4.53"}

R980 } {3'2.6"

0

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(2) E40.2SR (CAB)

5000 {16'4.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

2-4

2. SPECIFICATIONS Unit: mm (ft•in)

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(3) E50.2SR (CANOPY)

1940 {6'4.4"}

5230 {17'1.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(4) E50.2SR (CAB)

5230 {17'1.9"}

1940 {6'4.4"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

2-5

2. SPECIFICATIONS

2.3

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY Model Applicable Machines Shoe Type

E40.2SR

E50.2SR

PH05-03501~

PJ04-03001~

Rubber shoe Iron shoe (OPT) Rubber shoe Iron shoe (OPT)

Slewing Speed

min-1 {rpm}

8.8 {8.8}

Low km/h (mph) (1st) 2.8

Travel Speed Gradeability

8.8 {8.8}

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

4.6

2.8

4.6

2.8

4.6

2.8

4.6

% (degree)

58(30)

ENGINE Model (YANMAR)

4TNV88-XYB

Type

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

Number of cylinders-Bore u Stroke

4 - ø88 mm u 90 mm (3.46 in u 3.54 in)

Total Displacement

L

Output Rating

2.189 (134 cu•in)

kW/min {PS/rpm}

30.4 / 2400 {41.3 / 2400}

N•m/min (lbf•ft/rpm)

98.4 / 1440 (72.6 / 1440)

-1

-1

Maximum Torque Starting Motor Generator

V u kW

12 u 2.3

VuA

12 u 55

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gear pump

Hydraulic Motor

Axial piston

Hydraulic Motor w/Reducer (Travel)

2-Axial piston, 2-Speed motor

Control Valve

11-spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer)

Double action cylinder

Return Filter

Safety valve containing/Filter Type (30P)

SIDE DIGGING & DOZER Type Boom Swing Angle Stroke of Dozer (above/below)

Boom swing by hydraulic cylinder Right

60°

Left

70°

mm (in)

505 / 325 (19.9/12.8)

495 / 375 (19.5 / 14.8)

WEIGHT Rubber shoe

Iron shoe

Rubber shoe

Iron shoe

4200 (9260)

4300 (9480)

4630 (10200)

4730 (10400)

kg (lb)

1930 (4260)

m

2280 (5030)

m

Travel system

kg (lb)

1670 (3680)

1770 (3900)

1720 (3790)

1820 (4010)

Attachment (Boom+STD Arm+STD Bucket)

kg (lb)

505 (1110)

535 (1180)

Oil & Water

kg (lb)

95 (209)

m

Machine Weight

kg (lb)

Upper slewing body

Note: This figure is calculated with standard bucket.

2-6

2. SPECIFICATIONS

2.4

MACHINE & COMPONENTS WEIGHT (DRY) Unit: kg (lb) E40.2SR

MODEL

RUBBER SHOE CANOPY

CAB

IRON SHOE CANOPY

CAB

COMPLETE MACHINE

4200 (9260) 4340 (9570) 4300 (9480) 4440 (9790)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

1930 (4260) 2070 (4560) 1930 (4260) 2070 (4560)

UPPER FRAME

570 (1260)

CANOPY / CAB

85 (187)

ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK

m 220 (485)

m 85 (187)

m 220 (485)

170 (375)

m

m

m

35 (77)

m

m

m

5 (11)

m

m

m

37 (82)

m

m

m

4 (9)

m

m

m

110 (243)

m

m

m

SWING CYLINDER

39 (86)

m

m

m

SLEWING MOTOR

40 (88)

m

m

m

FUEL TANK SWING BRACKET

35 (77)

m

m

m

COUNTERWEIGHT

270 (595)

m

m

m

GUARD • BONNET

145 (320)

m

m

m

BOOM CYLINDER

47 (104)

m

m

m

1670 (3680)

m

1770 (3900)

m

525 (1160)

m

m

m

CONTROL VALVE

LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME

76 (168)

m

m

m

65u2 (143u2)

m

m

m

UPPER ROLLER

5u2 (11u2)

m

m

m

LOWER ROLLER

9u10 (20u10)

m

m

m

FRONT IDLER

42u2 (93u2)

m

m

m

IDLER ADJUSTER

30u2 (66u2)

m

m

m

SPROCKET

14u2 (31u2)

m

m

m

RUBBER CRAWLER SHOE

210 u2 (463u2)

m

—

—

400 mm (15.7") IRON SHOE

—

—

260u2 (573u 2)

m

SLEWING BEARING TRAVEL MOTOR

SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM BUCKET CYLINDER

22 (49)

m

m

m

170 (375)

m

m

m

27 (60)

m

m

m

505 (1110)

m

m

m

230 (507)

m

m

m

160 (353)

m

m

m

42 (93)

m

m

m

170 (375)

m

m

m

105 (232)

m

m

m

27 (60)

m

m

m

13 (29)

m

m

m

4u2 (9u2)

m

m

m

107 (236)

m

m

m

95 (210)

m

m

m

HYDRAULIC OIL

45 (99)

m

m

m

FUEL

44 (97)

m

m

m

BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD) FLUIDS (ASSY OF FOLLOWINGS)

Note: Bucket weight is shown with standard bucket weight.

2-7

2. SPECIFICATIONS Unit: kg (lb) E50.2SR MODEL

RUBBER SHOE CANOPY

COMPLETE MACHINE

CAB

IRON SHOE CANOPY

CAB

4630 (10200) 4770 (10500) 4730 (10400) 4870 (10700)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

2280 (5030) 2420 (5340) 2280 (5030) 2420 (5340)

UPPER FRAME

570 (1,260)

CANOPY / CAB

85 (187)

m 220 (485)

m 85 (187)

m 220 (485)

170 (375)

m

m

m

35 (77)

m

m

m

5 (11)

m

m

m

37 (82)

m

m

m

4 (9)

m

m

m

110 (243)

m

m

m

39 (86)

m

m

m

SLEWING MOTOR

40 (88)

m

m

m

CONTROL VALVE

35 (77)

m

m

m

COUNTERWEIGHT

580 (1,280)

m

m

m

GUARD • BONNET

145 (320)

m

m

m

ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER

BOOM CYLINDER LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

58 (128)

m

m

m

1720 (3790)

m

1820 (4010)

m

545 (1,200)

m

m

m

76 (168)

m

m

m

TRAVEL MOTOR

65u2 (143u2)

m

m

m

UPPER ROLLER

5u2 (11u2)

m

m

m

LOWER ROLLER

9u10 (20u10)

m

m

m

42u2 (93u2)

m

m

m

IDLER ADJUSTER

30u2 (66u2)

m

m

m

SPROCKET

14u2 (31u2)

m

m

m

RUBBER CRAWLER SHOE

210 u2 (463u2)

m

—

—

400 mm (15.7") IRON SHOE

—

—

275 u2 (606u2)

m

22 (49)

m

m

m

175 (386)

m

m

m

27 (60)

m

m

m

535 (1,180)

m

m

m

240 (529)

m

m

m

165 (364)

m

m

m

50 (110)

m

m

m

180 (397)

m

m

m

115 (256)

m

m

m

BUCKET CYLINDER

27 (60)

m

m

m

BUCKET LINK

13 (29)

m

m

m

LOWER FRAME SLEWING BEARING

FRONT IDLER

SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM

IDLER LINK BUCKET ASSEMBLY (STD)

4u2 (9u2)

m

m

m

112 (247)

m

m

m

95 (210)

m

m

m

HYDRAULIC OIL

45 (99)

m

m

m

FUEL

44 (97)

m

m

m

6 (13)

m

m

m

FLUIDS (ASSY OF FOLLOWINGS)

COOLANT

Note: Bucket weight is shown with standard bucket weight.

2-8

2. SPECIFICATIONS

2.5

TRANSPORTATION

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

WARNING Do not put chains over or against hydraulic lines or hoses. 6) Fasten machine to trailer with chains or cables. During transportation, the bucket or attachments may hit the canopy or the cab. Therefore, set the machine in the transporting position by observing following points: 1. Extend the bucket cylinder fully. 2. Extend the arm cylinder fully. 3. Lower the boom. 4. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment and extend arm cylinder. (2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT 1) BOOM WITH ARM CYLINDER Model

E40.2SR

E50.2SR

LuHuW mm (ft•in)

2790 u 1070 u 310 (9’1.8") (3’6.1") (12.2")

2910 u 1040 u 310 (9’6.6") (3’4.9") (12.2")

Weight w/arm cyl. kg (lb)

223 (492)

237 (523)

H

L 2) ARM & BUCKET (Standard bucket) Model

E40.2SR

E50.2SR

LuHuW mm (ft•in)

2630 u 510 u 600 (8’7.5") (20.1") (23.6")

2770 u 510 u 650 (9’1.1") (20.1") (25.6")

Weight kg (lb)

164 (362)

175 (386)

H

L

2-9

2. SPECIFICATIONS 3) ARM Model

E40.2SR

E50.2SR

LuHuW mm (ft•in)

1870 u 420 u 250 (6’1.6") (16.5") (9.84")

2010 u 420 u 250 (6’7.1") (16.5") (9.84")

Weight kg (lb)

164 (362)

175 (386)

H L

4) BUCKET (Standard bucket) Model

E40.2SR

E50.2SR

Heaped capacity m3(cu•yd)

0.14 (0.18)

0.16 (0.21)

LuHuW mm (ft•in)

780 u 690 u 650 (30.7") (27.2") (25.6")

780 u 690 u 750 (30.7") (27.2") (29.5")

Weight kg (lb)

89 (196)

98 (216)

H

L

5) DOZER w/o cylinder weight Model

E40.2SR

E50.2SR

LuHuW mm (ft•in)

1130 u 335 u 1960 (3’85") (13.2") (6’5.2")

1190 u 335 u 1960 (3’11") (13.2") (6’5.2")

Weight kg (lb)

170 (375)

175 (386)

H L

2-10

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER SHOES Type

Shoe width mm (in)

Total Crawler width mm (ft•in)

Number of Link

E40.2SR

400 (15.7")

1960 (6’5")

E50.2SR

400 (15.7")

E40.2SR

E50.2SR

Model

Ground pressure kPa (psi) CANOPY

CAB

68

26 (3.77)

27 (3.92)

1960 (6’5")

72

26 (3.77)

27 (3.92)

400 (15.7")

1960 (6’5")

36

26 (3.77)

27 (3.92)

400 (15.7")

1960 (6’5")

38

27 (3.92)

28 (4.06)

Rubber shoe

Iron shoe (option)

2-11

2. SPECIFICATIONS

2.7

TYPE OF BUCKET TYPE

ARM

Width mm (ft•in)

Heaped capacity m3 (cu.yd)

Weight kg (lb)

E40.2SR Length 1870 mm (6’1.62” ft•in)

E50.2SR Length 2010 mm (6’7.13” ft•in)

(ISO 7451)

Digging buckets

300 (11.81”)

0.050 (0.06)

56.14 (123.37)

V O

V O

Digging buckets

450 (17.72”)

0.090 (0.11)

74.01 (163.16)

V O

V O

Digging buckets

550 (21.65”)

0.120 (0.15)

82.43 (181.72)

V O

V O

Digging buckets

600 (23.62”)

0.130 (0.17)

85.89 (189.35)

V O

V O

Digging buckets

650 (25.59”)

0.140 (0.18)

89.33 (196.94)

V O

V O

Digging buckets

700 (27.56”)

0.160 (0.21)

92.79 (204.57)

V O

V O

Digging buckets

750 (29.53”)

0.180 (0.23)

97.73 (215.45)

V O

V O

Digging buckets

800 (31.49”)

0.200 (0.26)

101.22 (223.15)

V O

V O

Digging buckets

900 (35.43”)

0.220 (0.28)

109.64 (241.71)

V O

V O

Cleaning buckets

1200 (47.24”)

0.220 (0.28)

113.17 (249.49)

Q P X

Q P X

Cleaning buckets

1400 (55.11”)

0.240 (0.31)

126.22 (278.26)

Q P X

Q P X

Cleaning buckets

1500 (59.05”)

0.260 (0.34)

132.44 (291.98)

Q P X

Q P X

2-12

2. SPECIFICATIONS

WARNING ◆ The buckets with this length, during left arm slewing higher than 1 m from ground, can interfere with the cabin. For a safe use, consult the Dealer and ask for left slewing limiter of the arm support. ●: Width with lateral cutter ❍: Width without lateral cutter V: Generic digging for digging and sand loading operations, gravel, clay, earth in general, etc.. The specific weight of the material should not be higher than 1400 kg/m3. ■: Digging for light applications for operations of digging,sand loading/unloading of gravel, clay, earth in friabile and dry state, ditch cleaning, etc.

2-13

2. SPECIFICATIONS

2.8

ENGINE SPECIFICATIONS

2.8.1

SPECIFICATIONS Model

E40.2SR, E50.2SR

Engine Model

4TNV88-XYB

Type

Vertical, 4-cycle water-cooled diesel engine

No. of cylinders - Bore u Stroke

4 - 88 mm (3.46 in) u 90 mm (3.54 in)

Total displacement

2.189 liter (134 cu•in)

Compression ratio

19.1

Rated output

30.4 kW (41.3 PS) at 2400 rpm

Maximum torque

139.3 ~ 147.1 N•m (103 ~ 109 lbf•ft) at 1440 rpm

Low idling

1175 ± 25 rpm

High idling

2600 ± 25 rpm

Fuel consumption rate

Less than 242 g / kWh (178 g / PS•h)

Allowable tilting angles

Continuous ; 30 for all direction

Rotating direction

Counterclockwise as seen from flywheel side

Firing order

1-3-4-2-1

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

15.5±1

Fuel injection pressure Valve action

Valve clearance

19.6

MPa (2840

psi)

Open

Close

Intake valve

b.T.D.C. 15 ± 5

a.B.D.C. 45 ± 5

Exhaust valve

b.T.D.C. 56 ± 5

a.B.D.C. 18 ± 5

Intake valve

0.2 mm (0.008 in) in cold condition

Exhaust valve

0.2 mm (0.008 in) in cold condition

Thermostat action

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

Compression pressure

3.4 ± 0.1 MPa (500 ± 14 psi) at 250 rpm

Lubrication oil pressure

0.44 MPa (64 psi) at 2300 rpm

Dimensions L u W u H

684 u 554 u 662 mm (26.9 u 21.8 u 26.1 in)

Dry weight

170 kg (375 lb)

Governor

Mechanical centrifugal governor (All speed type)

Fuel filtration

cartridge type paper filter

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Liquid cooling / Radiator

Starter capacity

12 V u 2.3kW 12 V u 55 A

Generator capacity Starting aid

Air heater (12 V - 400 W)

Cooling water capacity: Max / Engine

6.0 / 2.7 liter (1.59 / 0.71 gal)

Engine oil volume: Max / Effective

7.4 / 4.0 liter (1.96 / 1.06 gal)

2-14

2. SPECIFICATIONS 2.8.2

ENGINE PERFORMANCE CURVE

E40.2SR, E50.2SR Model: 4TNV88A-XYB Rated Output: 30.4 kW / 2400 min-1 (41.3 PS / 2400 rpm) [Sd] 4

Sd

2 0

GT

600

[GT]

500 (148) 200 400

[T]

(129) 175 300 (111)

150

T

(92) 125

50

(68)

(74) 100

45

(61)

(55)

75

40

(54)

(37) 50 g/kWh

35

(48)

[ F ] (235) 320

30

(41)

25

(34)

PS

(221)

300

(206)

280

20

(27)

(191)

260

15

(20)

(177)

240

10

(14)

(162)

220

5

(7)

(147)

200

F

kW g/PSh

800

0

1000

1200

1400

1600

1800

2000

2200

2400

2600

min-1{rpm} F Fuel consumption volume =

U X 1000

XPXD

242 = X 21.2 X D 0.835 X 1000 = 8.81 D F. Fuel consumption rate (g/kwh) P. Shaft output (kw)

U Specific gravity D. Standard load factory (0.60 ~ 0.70) Fuel consumption in normal operation; 5.29 ~ 6.17 L/h (load factor: (0.60 ~ 0.70))

T. Shaft torque F. Fuel consumption rate PS.Power output GT. Exhaust temperature Sd. Smoke: Bosch

2-15

2800

PS

[PS]

2. SPECIFICATIONS

[MEMO]

2-16

3

3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS 3.1 BOOM ............................................................................................................... 3-3 3.1.1 BOOM DIMENSIONAL DRAWINGS ............................................................. 3-3 3.1.2 BOOM MAINTENANCE STANDARDS ......................................................... 3-4 3.2 ARM .................................................................................................................. 3-7 3.2.1 ARM DIMENSIONAL DRAWINGS ................................................................ 3-7 3.2.2 ARM MAINTENANCE STANDARDS ............................................................ 3-9 3.3 BUCKET .......................................................................................................... 3-13 3.3.1 BUCKET DIMENSIONAL DRAWINGS ....................................................... 3-13 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-14 3.4 DOZER ............................................................................................................ 3-15 3.4.1 DOZER DIMENSIONAL DRAWINGS ......................................................... 3-15 3.4.2 DOZER MAINTENANCE STANDARDS ..................................................... 3-16 3.5 SWING ............................................................................................................ 3-18 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ........................................ 3-18 3.5.2 SWING PORTION MAINTENANCE STANDARDS .................................... 3-19

3. ATTACHMENT DIMENSIONS

3-1

3. ATTACHMENT DIMENSIONS

3-2

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWINGS

Fig. 3-1 Boom Dimensional Drawings Table 3-1 Unit: mm (ft•in) No.

DIMENSIONS

NAME

E40.2SR

E50.2SR

2670 (8'9.12")

2790 (9'1.84")

Distance between pins of boss

R1406 (4'7.35")

R1434 (4'8.46")

C

Distance between pins of bracket

R1475 (4'10.1")

R1487.5 (4'10.6")

D

Height of boom cylinder rod pin

E

Height of arm cylinder (head side) pin

F

A

Boom length

B

470 (18.5")

457.5 (18.0")

941.5 (37.1")

908 (35.7")

Boom width

250 (9.84")

m

G

Inner width of bracket for boom cylinder (rod side) mounting

76 (2.99")

m

H

Boom end inner width

175 (6.89")

m

J

Boom end outer width

265 (10.4")

m

K

Inner width of bracket for arm cylinder (head side)

66 (2.60")

m

d1

Boom pin dia. [Bushing outer dia.]

ø50 (1.97") [ø60 (2.36")]

m

d2

Boom cylinder (rod side) pin dia.

ø50 (1.97")

m

d3

Pin dia. of arm end

ø60 (2.36")

m

d4

Arm cylinder (head side) pin dia.

ø45 (1.77")

m

3-3

3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section

Fig. 3-2 Clearance of pin and bushing on boom section Table 3-2 Unit: mm (in) Standard dimensions Pos.

Item

A

Boom

B

Boom cylinder (Head side)

C

Boom cylinder (Rod side)

D

Arm cylinder (Head side)

Pin dia.

Clearance

Tolerance Tolerance on bushing on pin dia. bore dia. +0.061 0 (+0.0024) ( 0 )

ø50 (1.97)

–0.02 –0.08 (-0.0008) (-0.0031)

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

Standard value

Standard value for repair

Serviceabili ty limit

0.7 (0.028)

1.0 (0.039)

0.02~ 0.141 (0.0008~0.0 056)

0.07~ 0.33 (0.0028~ 0.0130)

ø45 (1.77)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

•

The part number for pins may be changed owing to improvement, use them only for reference.

3-4

Remedy

Replace bushing or pin

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

Fig. 3-3 Clearance in thrust direction on boom section

3-5

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

Item No. Dimensions

L1 Swing bracket

Boom cylinder B-B (Head side)

C-C

Boom cylinder (Rod side)

(9.84

(9.84

Remedy Standard Serviceabilvalue for No. Dimensions ity limit repair

0.1~0.5 (0.004~ 0.020)

PL1

377 (14.8)

0.1~0.5 (0.004~ 0.020)

PL2

264 (10.4)

0.5~0.9 (0.020~ 0.035)

PL3

213 (8.39)

0.1~0.5 (0.004~ 0.020)

PL4

200 (7.87)

)

75

Boom cylinder L2 Swing bracket

(2.95

)

77 (3.03

)

1.0 (0.039)

75

Boom cylinder L3

(2.95

)

76 (2.99

1.5 (0.059)

Adjusted with shim

)

65

Arm cylinder L4 Boom

)

250

Boom

Arm cylinder D-D (Head side)

Standard value

Pin length

250

Boom A-A Boom

Clearance X adjusted with shim (total of both sides)

(2.56

)

66 (2.60

)

3-6

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWINGS

Fig. 3-4 Arm dimensional drawings

3-7

3. ATTACHMENT DIMENSIONS Table 3-4 Unit: mm (ft•in) No.

Dimensions

Name

E40.2SR

E50.2SR

1430 (4'8.30")

1560 (5'1.42")

A

Arm length

B

Distance between pins of boss and bracket

R405 (15.9")

m

C

Distance between pins of boss and bracket

R1118 (3'8.02")

m

D

Distance between pins of boss and boss

R230.5 (9.07")

m

E

Height between pins of boss and bracket

311 (12.2")

m

F

Height between pins of boss and bracket

211 (8.31")

191.5 (7.54")

G

Height between pins of boss and center

12 (0.472")

m

H

Boss width

150 (5.91")

m

J

Boss width

175 (6.89")

m

K

Bracket inner width

61 (2.40")

m

L

Bracket inner width

61 (2.40")

66 (2.60")

M

Idler link dimension

320 (12.6")

m

N

Bucket link dimension

310 (12.2")

m

D1 I.D. of boss

ø55 (2.17")

m

D2 I.D. of boss

ø55 (2.17")

m

D3 I.D. of boss

ø75 (2.95")

m

d1

Pin dia.

ø45 (1.77")

m

d2

Pin dia.

ø45 (1.77")

m

d3

Pin dia.

ø60 (2.36")

m

d4

Pin dia.

ø45 (1.77")

m

d5

Pin dia.

ø45 (1.77")

m

3-8

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Fig. 3-5 Clearance of pin and bushing on arm section Unit: mm (in) Standard dimensions Pos.

Item

A

Arm point (Connected part of bucket)

B

Bucket link (Bucket side)

C

Idler link (Connected part of arm)

Pin dia.

ø45 (1.77)

Bucket link (Idler link side)

D

Tolerance on pin dia.

–0.02 –0.05 (-0.0008) (-0.0020)

D’

Bucket cylinder (Rod side)

E

Bucket cylinder (Head side)

F

Arm foot (Connected part of boom)

ø60 (2.36)

G

Arm cylinder (Rod side)

ø45 (1.77)

Clearance

Tolerance on bushing bore Standard value dia. +0.064 +0.005 (+0.0025) (+0.0002)

0.025~ 0.114 (0.0010~ 0.0045)

+0.076 +0.035 (+0.0030) (+0.0014)

0.055~ 0.126 (0.0022~ 0.0050)

+0.073 +0.032 (+0.0029) (+0.0013)

0.052~ 0.123 (0.0020~ 0.0048)

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

0.07~ 0.30 (0.0028~ 0.0118)

+0.061 0 (+0.0024) ( 0 ) +0.25 +0.05 (+0.0098) (+0.0020)

Standard value for repair

Serviceability limit

0.7 (0.028)

1.0 (0.039)

0.02~ 0.111 (0.0008~ 0.0044) 0.07~ 0.30 (0.0028~ 0.0118)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

•

The part number for pins may be changed owing to improvement, use them only for reference.

3-9

Remedy

Replace bushing or pin

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

Fig. 3-6 Clearance in thrust direction on arm section

3-10

3. ATTACHMENT DIMENSIONS Table 3-6 • E40.2SR

Unit: mm (in) Standard dimensions

Sec.

Item No.

L1 Bucket

Bucket link (Rod side)

L2

(5.91

(5.94

Arm L3 Link side

L4

L5

150 (5.91)

0.1~0.5 (0.004~ 0.020)

— (—)

(2.165

)

(5.91

0.6~1.0 (0.024~ 0.039)

—

1.5 (0.059)

0.1~0.5 (0.004~ 0.020)

)

— (—)

Idler link

287.5 (11.3)

PL3

210.5 (8.29)

PL5

210.5 (8.29)

PL6

183 (7.20)

PL7

265 (10.4)

PL8

183 (7.20)

2.0 (0.079) Adjusted with shim

—

60

Head side L6

(2.36

0.5~0.9 (0.020~ 0.035)

)

61

Arm

(2.40

)

175

Arm L7

(6.89

Less than 0.5 (0.020)

)

175

Boom

(6.89

1.0 (0.039)

1.5 (0.059)

)

60

Rod side L8 Arm

PL2

)

150

Bucket link

Arm cylinder G-G (Rod side)

287.5 (11.3)

See "NOTE"

)

57±0.4 (2.24±0.016)

D-D

F-F Arm foot

0.7~2.2 (0.028~ 0.087)

55

Rod side

Bucket cylinder E-E (Head side)

)

PL1

151

Link side

Bucket link (Idler link side)

151

150

Bucket

Idler link C-C (Connected part of arm)

Standard Service- Remedy Standard value for ability No. Dimensions Dimensions value repair limit

(5.94

Link side B-B Bucket link

Pin length

150 (5.91)

Arm A-A Arm point

Clearance X adjusted with shim (total of both sides)

(2.362

)

61 (2.402

0.5~0.9 (0.020~ 0.035)

)

(Note) •

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

3-11

3. ATTACHMENT DIMENSIONS Table 3-7 • E50.2SR

Unit: mm (in) Standard dimensions

Sec.

Item No.

L1 Bucket

Standard Service- Remedy Standard Dimensions value for ability No. Dimensions value repair limit

151 (5.94

L2

(5.91

(5.94

Bucket link (Rod side)

Arm L3 Link side

L4

150 (5.91)

L5

— (—)

(2.165

L6

(5.91

(2.36

(2.40

0.6~1.0 (0.024~ 0.039)

—

PL3

210.5 (8.29)

1.5 (0.059)

0.1~0.5 (0.004~ 0.020)

2.0 (0.079) Adjust- PL5 ed with shim

—

L7

)

0.5~0.9 (0.020~ 0.035)

PL6

183 (7.20)

PL7

265 (10.4)

PL8

183 (7.20)

)

(6.89

)

175

Boom

(6.89

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

)

65

Rod side L8

(2.56

)

66 (2.60

0.5~0.9 (0.020~ 0.035)

)

(Note) •

210.5 (8.29)

175

Arm

Arm

)

61

Arm

Arm cylinder (Rod side)

287.5 (11.3)

60

Head side

G-G

)

— (—)

Idler link

F-F Arm foot

0.1~0.5 (0.004~ 0.020)

150

Bucket link

Bucket cylinder (Head side)

PL2

)

57±0.4 (2.24±0.016)

D-D

E-E

287.5 (11.3)

See "NOTE"

)

55

Rod side

Link side

Bucket link (Idler link side)

PL1

151

Bucket

Idler link C-C (Connected part of arm)

0.7~2.2 (0.028~ 0.087)

)

150

Link side B-B Bucket link

Pin length

150 (5.91)

Arm A-A Arm point

Clearance X adjusted with shim (total of both sides)

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

3-12

3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

BUCKET DIMENSIONAL DRAWINGS

Fig. 3-7 Bucket dimensional drawings Table 3-8 Unit: mm (in) No.

Model

E40.2SR

E50.2SR

Heaped Capacity m3 (cu.yd)

0.14 (0.17)

0.16 (0.20)

A

Distance between pin and bracket

228.5 (9)

m

B

Distance between bucket pin and tooth end

R802 (31.6)

m

C

Inner width of bucket top end

568 (22.36)

668 (26.29)

D

Inner width of lug

181 (7.12)

m

E

Inner width of bracket

151 (5.94)

m

F

Outer width of side cutter

650 (25.59)

700 (27.56)

G

Outer width of bucket bottom plate

510 (20.08)

610 (24.01)

H

Outer tooth distance

500 (19.68)

600 (23.62)

J

Pitch between teeth

166 (6.53)

200 (7.87)

J0

Pitch between teeth

166 (6.53)

200 (7.87)

d1

Pin dia.

ø45 (1.77)

m

d2

Pin dia.

ø45 (1.77)

m

3-13

3. ATTACHMENT DIMENSIONS 3.3.2

DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Fig. 3-8 Dimension of lug section Table 3-9 Unit: mm (in) Portion

Dimensions

Plate outer dia. øA

Boss thickness B

ø75 (2.95)

15 (0.59)

3-14

Pin bore dia. øC ø45 (1.77

)

Lug plate thickness D 10 (0.39)

3. ATTACHMENT DIMENSIONS

3.4

DOZER

3.4.1

DOZER DIMENSIONAL DRAWINGS

Fig. 3-10 Dozer dimensional drawings Table 3-10 Unit: mm (ft•in) No.

Dimensions

NAME

E40.2SR

E50.2SR

A

Blade width

1960 (6'5.17")

m

B

Blade height

346 (1'1.62")

m

C

Distance from dozer attaching pin center to cutting edge end

R1092 (3'6.99")

R1149 (3'9.24")

D

Inner width of dozer attaching bracket

531 (20.9")

m

E

Width of dozer attaching bracket

69 (2.72")

m

F

Distance from dozer attaching pin center to attaching pin on dozer cylinder head side

R712 (28.0")

m

62 (2.44")

m

1046 (3'5.18")

1105.3 (3'5.72")

Vertical distance from dozer attaching pin center to edge end

313 (12.3")

m

d1

Dozer attaching pin dia.

ø40 (1.57")

m

d2

Attaching pin dia. on dozer cylinder head side

ø55 (2.17")

m

G

Attaching bracket inner width on dozer cylinder head side

H

Horizontal distance from dozer attaching pin center to edge end

J

3-15

3. ATTACHMENT DIMENSIONS 3.4.2

DOZER MAINTENANCE STANDARDS

Fig. 3-11 Dozer maintenance standards A-B-C = Pin (1) Clearance of pin and bushing Table 3-11 Unit: mm (in) Standard dimension Pos.

Item

A

Dozer blade cylinder (Head side)

B

Dozer blade cylinder (Rod side)

C

Dozer blade foot

Pin dia.

ø55 (2.17)

ø40 (1.57)

Clearance

Tolerance on Tolerance on Standard val- Standard val- Serviceabilipin dia. bushing bore ue ue for repair ty limit dia. –0.15 –0.21 (-0.0059) (-0.0083)

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

0.20~ 0.46 (0.0079~0.01 81)

–0.06 –0.09 (-0.0024) (-0.0035)

+0.215 +0.115 (+0.0085) (+0.0045)

0.175~ 0.305 (0.0069~0.01 20)

1.5 (0.059)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

•

The part number for pins may be changed owing to improvement, use them only for reference.

3-16

2.0 (0.079)

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the dozer and cylinder installation section Table 3-12 Unit: mm (in) Standard dimensions Pos.

A

Item

Dozer blade cylinder (Head side)

No.

Dimensions

Dozer blade cylinder (Rod side)

L1

Dozer blade foot

(2.362

)

)

60

Rod side L2 Lower frame

Lower frame

Remedy

No. Dimensions

PL1

141 (5.55)

PL2

141 (5.55)

PL3

137 (5.39)

62

Dozer blade

(2.362

2.0~3.5 (0.079~0.035) Adjusted with shim

)

62 (2.441

)

69±0.5 (2.72±0.020)

Dozer blade C

Pin length

60

Head side

(2.441

B

Clearance X adjusted with shim (total of both sides)

L3

72 (2.83

2.5~4.5 (0.079~0.177)

)

(NOTE) •

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

3-17

3. ATTACHMENT DIMENSIONS

3.5

SWING

3.5.1

SWING BRACKET DIMENSIONAL DRAWINGS

E

H

d3

D

B

G

A

d2

C F1

F J

F2 d4

d1 Fig. 3-12 Swing bracket dimensional drawings Table 3-13

Unit: mm (in) No.

NAME

DIMENSION

A

Distance between swing center pin and boom foot pin

67 (2.64)

B

Distance between boom foot pin and boom cylinder pin

207.6 (8.17)

C

- ditto -

320.7 (12.6)

D

Distance between swing center pin and swing cylinder pin

E

- ditto -

290 (11.4)

F

Inside width of swing center

329 (13.0)

F1 - ditto -

R307.5 (12.1)

78.5 (3.09)

F2 - ditto -

76 (2.99)

G

Inside width of boom foot

250 (9.84)

H

Inside width for installing boom cylinder

77 (3.03)

J

Inside width for installing swing cylinder

73 (2.87)

d1

Pin dia. of swing center

ø80 (3.15)

d2

Pin dia. of boom foot

ø50 (1.97)

d3

Pin dia. of boom cylinder

ø50 (1.97)

d4

Pin dia. of swing cylinder

ø50 (1.97)

3-18

3. ATTACHMENT DIMENSIONS 3.5.2

SWING PORTION MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

B

C

A

D Fig. 3-13 Clearance of pin and bushing on swing portion Table 3-14 Unit: mm (in) Standard dimension Pos.

Item

A

Swing cylinder (Rod side)

B

Swing cylinder (Head side)

C

Swing center (Upper side)

D

Swing center (Lower side)

Pin dia.

ø50 (1.97)

ø80 (3.15)

Tolerance on Tolerance on bushing bore pin dia. dia.

–0.02 –0.05 (-0.0008) (-0.0020)

+0.150 0 (+0.0059) ( 0 ) +0.061 +0.009 (+0.0024) (+0.0004)

Clearance Standard value 0.02~ 0.20 (0.0008~0.00 79) 0.029~ 0.111 (0.0001~0.00 44)

Standard value for repair

Serviceability limit

1.5 (0.059)

2.0 (0.079)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

•

The part number for pins may be changed owing to improvement, use them only for reference.

3-19

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

PL1 X

PL2

L1

X

L2

B-B

A-A

1

C-C, D-D Fig. 3-14 Clearance in thrust direction on swing portion 1. Washer - To be install the groove to the lower side [t=2.3 (0.091�)]

3-20

3. ATTACHMENT DIMENSIONS Table 3-15 Unit: mm (in) Standard Dimension Sec.

Item No.

Swing A-A cylinder (Rod side)

Dimensions

L1

(2.76

L2

0.5~0.9 (0.020~ 0.035)

1.5 (0.059)

(2.76

)

(2.83

PL1

146.5 (5.77)

PL2

151 (5.94)

Replace PL3 washer

155 (6.1)

Adjusted with PL4 shim

142 (5.59)

— Adjusted with shim

)

72

0.5~0.9 (0.020~ 0.035)

1.0 (0.039)

—

)

73

Upper frame L3

(2.87

)

—

78.5

Bracket

(3.09

)

73

Upper frame L4 Bracket

Remedy Standard Serviceability value for No. Dimensions limit repair

70

Cylinder

Swing center D-D (Lower side)

)

73

Bracket

Swing B-B cylinder (Head side) Upper frame

Standard value

Pin length

70

Cylinder

(2.87

Swing center C-C (Upper side)

Clearance X adjusted with shim (total of both sides)

(2.87

)

78.5 (2.99

Less than 0.5 (0.020)

)

3-21

1.5 (0.059)

—

3. ATTACHMENT DIMENSIONS

[MEMO]

3-22

11. TOOLS TABLE OF CONTENTS 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS ........................... 11-3 11.1.1 METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES.................................................................................... 11-3 11.1.2 METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES. .................................................................................. 11-4 11.2 SCREW AND TOOL SIZES ............................................................................ 11-5 11.2.1 CAPSCREW ............................................................................................. 11-5 11.2.2 CAPSCREW (SOCKET BOLT) ................................................................ 11-5 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ............................. 11-5 11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ................................... 11-5 11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................. 11-5 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ............ 11-6 11.4.1 SLEEVE TYPE TUBE FITTINGS ............................................................. 11-6 11.5 SPECIAL SPANNERS FOR TUBES ............................................................... 11-7 11.6 SPECIAL TOOLS ............................................................................................ 11-7 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ......... 11-7 11.8 COUNTERWEIGHT LIFTING JIG ................................................................... 11-8 11.9 UPPER FRAME LIFTING JIG ......................................................................... 11-9

11. TOOLS

11-1

11. TOOLS

11-2

11. TOOLS

11.1

TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

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

1

1. Classification 11.1.1

Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews & Nuts to proper torque values. Torque value Unit: N•m (lbf•ft)

Classification Nominal size

4.8T

7T

10.9T

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

M6

P=1

4.4±0.5 (3.2±0.4)

3.7±0.4 (2.7±0.3)

9.6±1.0 (7.1±0.7)

8.1±0.8 (6.0±0.6)

17.4±1.8 (12.8±1.3)

14.7±1.5 (10.8±1.1)

M8

P=1.25

10.7±1.1 (7.9±0.8)

9.0±0.9 (6.6±0.7)

23.5±2.0 (17.3±1.5)

19.6±2.0 (14.5±1.5)

42.2±3.9 (31.1±2.9)

35.3±3.9 (26.0±2.9)

M10

P=1.5

21.6±2.0 (15.9±1.4)

17.9±1.8 (13.2±1.3)

46.1±4.9 (34.0±3.6)

39.2±3.9 (28.9±2.9)

83.4±8.8 (61.5±6.5)

70.6±6.9 (52.1±5.1)

M12

P=1.75

36.3±3.9 (26.8±2.9)

31.4±2.9 (23.2±2.1)

79.4±7.8 (58.6±5.8)

66.7±6.9 (49.2±5.1)

143±15 (105±11)

121±12 (89.2±8.9)

M14

P=2

57.9±5.9 (42.7±4.4)

49.0±4.9 (36.1±3.6)

126±13 (92.9±9.6)

106±10 (78.2±7.4)

226±20 (167±15)

191±19 (141±14)

M16

P=2

88.3±8.8 (65.1±6.5)

74.5±6.9 (55.0±5.1)

191±20 (141±15)

161±16 (119±12)

343±39 (253±29)

284±29 (209±21)

M18

P=2.5

122±12 (90.0±8.9)

103±10 (75.8±7.2)

265±29 (195±21)

226±20 (167±15)

481±49 (355±36)

402±39 (297±29)

M20

P=2.5

172±17 (127±13)

144±14 (106±10)

373±39 (275±29)

314±29 (232±21)

667±69 (492±51)

559±59 (412±44)

M22

P=2.5

226±20 (167±15)

192±20 (142±15)

500±49 (369±36)

422±39 (311±29)

902±88 (665±65)

755±78 (557±58)

M24

P=3

294±29 (217±21)

235±29 (173±21)

637±69 (470±51)

520±49 (383±36)

1160±118 (856±87)

941±98 (694±72)

M27

P=3

431±39 (318±29)

353±39 (260±29)

941±98 (694±72)

765±78 (564±58)

1700±167 (1250±123)

1370±137 (1010±101)

11-3

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

4.8T

7T

10.9T

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

M30

P=3.5

588±59 (434±44)

490±49 (361±36)

1285±127 (948±94)

1079±108 (796±80)

2300±235 (1700±173)

1940±196 (1430±145)

M33

P=3.5

794±78 (586±58)

667±69 (492±51)

1726±177 (1270±131)

1451±147 (1070±108)

3110±314 (2290±232)

2610±265 (1930±195)

M36

P=4

1030±98 (760±72)

863±88 (637±65)

2226±226 (1640±167)

1863±186 (1370±137)

4010±402 (2960±297)

3360±333 (2480±246)

11.1.2

Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews & Nuts to proper torque values. Torque value Unit: N•m (lbf•ft)

Classification Nominal size

4.8T

7T

10.9T

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

M8

P=1.0

11.3±1.1 (8.3±0.8)

9.5±1.0 (7.0±0.7)

24.5±2.0 (18.1±1.5)

20.6±2.0 (15.2±1.5)

44.1±3.9 (32.5±2.9)

37.3±3.9 (27.5±2.9)

M10

P=1.25

22.6±2.0 (16.7±1.5)

18.7±1.9 (13.8±1.4)

48.1±4.9 (35.5±3.6)

41.2±3.9 (30.3±2.9)

87.3±8.8 (64.4±6.5)

73.5±6.9 (54.2±5.1)

M12

P=1.25

39.2±3.9 (28.9±2.9)

33.3±2.9 (24.6±2.1)

85.3±8.8 (62.9±6.5)

71.6±6.9 (52.8±5.1)

154±16 (114±12)

129±13 (95.2±9.6)

M16

P=1.5

92.2±8.8 (68.0±6.5)

77.5±7.8 (57.2±5.8)

196±20 (145±15)

169±17 (125±13)

363±39 (268±29)

304±29 (224±21)

M20

P=1.5

186±19 (137±14)

155±16 (114±12)

402±39 (297±29)

333±29 (246±21)

726±69 (535±51)

608±59 (448±44)

M24

P=2

314±29 (232±21)

265±29 (195±21)

686±69 (506±51)

569±59 (420±44)

1240±118 (915±87)

1030±98 (760±72)

M30

P=2

637±59 (470±44)

530±49 (391±36)

1390±137 (1030±101)

1157±118 (853±87)

2500±255 (1840±188)

2080±206 (1530±152)

M33

P=2

853±88 (629±65)

706±70 (521±52)

1860±186 (1370±137)

1550±155 (1140±114)

3350±334 (2470±246)

2790±275 (2060±203)

M36

P=3

1070±108 (789±80)

892±88 (658±65)

2330±226 (1720±167)

1940±196 (1430±145)

4200±422 (3100±311)

3500±353 (2580±260)

11-4

11. TOOLS

11.2

SCREW AND TOOL SIZES

11.2.1

Capscrew

Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

M6

10

M24

36

M8

13

M30

46

M10

17

M36

55

M12

19

M42

65

M16

24

M48

75

M20

30

11.2.2

d

Tool size

B

Capscrew (Socket bolt)

Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

d

Tool size

M6

5

M20

17

M8

6

M24

19

M10

8

M30

22

M12

10

M36

27

M14

12

M42

32

M16

14

M48

36

(M18)

14

B

11.3

TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1

JOINTS FOR PIPING (O-RING SEALING TYPE)

Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

14

17±2 (12±1)

1/4

19

36±2 (27±1)

3/8

22

74±5 (54±4)

1/2

27

108±9.8 (80±7)

3/4

36

162±9.8 (119±7)

1

41

255±9.8 (188±7)

11.3.2

HYDRAULIC HOSE (30° FLARE TYPE)

Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

17

15±2.0 (11±1)

1/4

19

29±4.9 (22±4)

3/8

22

49±4.9 (36±4)

1/2

27

78±4.9 (58±4)

3/4

36

118±9.8 (87±7)

1

41

137±15 (101±11)

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

11-5

11. TOOLS

11.4

TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1

SLEEVE TYPE TUBE FITTINGS

Tube size OD u Thickness (mm)

Spanner size (mm)

Tightening Torque N•m (lbf•ft)

10 u 1.5

19

44±4.9 (33±4)

15 u 2.0

27

147±20 (110±14)

18 u 2.5

32

177±20 (130±14)

22 u 3.0

36

216±20 (160±14)

28 u 4.0

41

275±29 (200±22)

35 u 5.0

55

441±44 (330±33)

11-6

11. TOOLS

11.5

SPECIAL SPANNERS FOR TUBES

Applicable tube diameter mm (in)

Part No.

HEX mm (in)

27

15 (0.591)

(1.063)

32

18 (0.709)

(1.26)

36

22 (0.866)

(1.417)

41

28 (1.102)

11.6

Dimensions of a special spanner mm

(1.614)

SPECIAL TOOLS Unit: mm (in)

No.

Tools name

1

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

11.7

Tools No.

Shape

Use

4.4 (0.17")

For instrument R.H cover

—

APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS Service

Screw locking compound Sealing compound

Manufacturer

Features

Loctite

Three-Bond

#242

1360 K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

11-7

11. TOOLS

11.8

COUNTERWEIGHT LIFTING JIG

Q’ty: 2 set Material: Mild steel UNIT: mm (in)

49 9 (1.93") (0.35")

(2.36")

40 (1.57")

") .95 0 ( 24

45(

C

12 (0.47")

112 (4.41") 60

30 (1.12")

170 (6.69")

") 20

0.

310 (12.2")

40

(1.5

8")

0 R15 ) 1" 9 . (5 100 (3.94")

477 (18.8")

527 (20.7")

10 (0.39") (539) {21.2"}

20(4)-90 {0.79"(0.16")-3.54"}

10

C

70 (2.76") 10 (0.39")

3 (0.12") 10 (0.39")

R50 (1.9 7")

)

9"

.3

(0

12 (0.47")

300 (11.8")

3 (0.12")

100 (3.94")

R

R (1 50 .9 7" )

135 (5.32")

50 (1.97")

Fig. 11-1 Counterweight lifting jig

11-8

160 (6.30")

11. TOOLS

11.9

UPPER FRAME LIFTING JIG

Q’ty: 2 set Material: Mild steel UNIT: mm (in)

(1.97")

) 9" .7

50

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

24( 0.9 5")

(0 20

C 2-

5 (0.20")

244 (9.61")

16 (0.63")

310 (12.2")

100 (3.94") 4

1. 0(

58

15 (0.59")

")

40(2)-120 {1.58"(0.079")-4.72"}

12 (0.47")

420 (16.5")

(536) {21.1"}

167 (6.58") 50 (1.97")

5 ) C2 .98" (0

Fig. 11-2 Upper frame lifting jig

11-9

0 R2 9") .7 (0

C (0 10 .3 9" )

50

0 R3 8") .1 (1

5 (0.20")

(1.97")

12 (0.47")

470 (18.5")

5 (0.20")

16 (0.63")

R

11. TOOLS

[MEMO]

11-10

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

12. STANDARD MAINTENANCE TIME TABLE

12-1

12. STANDARD MAINTENANCE TIME TABLE

12-2

12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1) Technicians: One or more technicians qualified (with five years or more of field experience and having completed the training in the operation of vehicle type construction machinery) to be provided. 2) Facilities: General jigs, tools, apparatus, testers to be provided. The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection instruments necessary for specific self inspection activities. 3) Place: The workshop to be located on a flat land at which the work is able to perform and to which a service car or truck crane is accessible. (2) Applicable Range of Standard Maintenance Time 1) Standard maintenance time: Direct maintenance time plus spare time. 2) Direct maintenance time: Net time actually spent for maintenance. 3) Spare time: Time for transportation of the machine for maintenance, preparation for safety work, meeting for the work and physiological time for the needs of body. (3) Excluded Time (not included in the standard maintenance time) 1) Repairing time: Time for machining, sheet metal processing, welding, gas cutting, removing broken screw, taking care of parts and painting. 2) Items excluded from maintenance time because of uncertainty in time: Receiving the vehicle into shop, transportation, delivery, final inspection and investigation of causes for trouble, diagnosis and inspection. 3) Indirect time: Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user’s convenience at the site and paper work for reports, bills, etc. 4) Special time: Working time at early morning, at mid night and on holidays shall be separately calculated. 5) Separate calculation: The cost for service cars, trucks with crane and truck cranes shall be separately calculated. (4) Applicable Machine for Estimation of Standard Maintenance Time 1) Standard machine. 2) A well maintained machine combined with standard attachments which has operated in a normal circumstances.

12-3

12. STANDARD MAINTENANCE TIME TABLE

12.1

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

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

Assembly

SOL :

Solenoid

Rem. :

Removal

ATT

Attachment

SW

:

Switch

Inst. :

Installation

Bearing

V

:

Valve

O/H

Overhaul

:

BRG : C/V

:

Control valve

F hose:

Flexible hose

Cyl

:

Cylinder

E/G

Engine

:

:

(2) Classification of work code No.

GROUP

01

Attachment

02

Canopy and Guard

03

Upper Structure

04

Under carriage

GROUP No.

REMARKS To indicate removing, installing, replacement and overhaul.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

00 Bucket portion Rem.l/Inst.

1 pc.

02 • Bucket removing / installing position

Preparation

1 pc.

04 • Bucket drive pin

01 Attachment

05 • Bucket sling and transfer 06 Bucket (Single) 07 • Bushing

Include adjustment

0.4 0.1

Rem./Inst.

1 pc.

- ditto -

1 pc.

0.1

Preparation

1 pc.

0.1

O/H

1 pc.

Replace

1 pc.

10 Arm portion 11 Arm ASSY

UNIT: HOUR

Refer to 32.1.2

01 Bucket ASSY 03 • Bucket installing pin

REMARKS

Include stopper pin.

Not include removal / inst.

0.1

0.6 0.5

Refer to 32.1.3 Rem./Inst.

1 pc.

0.8

Preparation

1 pc.

0.2

Rem./Inst.

1 pc.

Include stopper pin.

0.1

14 • Bucket cylinder head pin

- ditto -

1 pc.

Include stopper pin.

0.1

15 • Bucket cylinder assy

- ditto -

1 pc.

16 • Arm cylinder rod pin

- ditto -

1 pc.

17 • Boom top pin

- ditto -

1 pc.

0.1

18 • Arm sling and transfer

- ditto -

1 pc.

0.1

12

• Bucket cylinder removing / installing position and piping

13 • Bucket cylinder rod pin

12-4

0.1 Include stopper pin.

0.1

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

20 Boom portion 21 Boom ASSY

UNIT: HOUR

Refer to 32.1.4 1 pc.

1.0

Preparation

1 pc.

0.1

- ditto -

1 pc.

0.1

24 • Boom cylinder rod pin

Rem./Inst.

1 pc.

25 • Boom cylinder piping

- ditto -

1 pc.

0.1

22 • Boom removing / installing position 23 • Boom cylinder temporary slinging

26 • Arm & Bucket piping

Rem./Inst.

Include stopper pin.

0.1

- ditto -

1 pc.

0.2

Rem. / Inst.

1 pc.

0.1

28 • Boom foot pin

- ditto -

1 pc.

29 • Boom assy slinging

- ditto -

1 pc.

0.1

30 Arm cylinder removing / installing

- ditto -

1 pc.

0.3

31 • Arm cylinder piping

- ditto -

1 pc.

0.1

32 • Arm cylinder head pin

- ditto -

1 pc.

33 • Arm cylinder slinging

- ditto -

1 pc.

0.1

40 Boom cylinder removing / installing

- ditto -

1 pc.

0.3

41 • Boom cylinder piping

- ditto -

1 pc.

0.1

42 • Boom cylinder head pin

- ditto -

1 pc.

0.1

43 • Boom cylinder slinging

- ditto -

1 pc.

0.1

27 • Boom assy temporary slinging

01 Attachment

REMARKS

50 Bucket cylinder

O/H

1 pc.

51 • Pin bushing

Replace

1 set

O/H

1 pc.

Replace

1 set

60 Arm cylinder 61 • Pin bushing 70 Boom cylinder

O/H

1 pc.

71 • Pin bushing

Replace

1 set

80 Swing portion 81 Swing bracket assy

Include stopper pin.

Include stopper pin.

0.1

0.1

2.5 Include seal.

1.0 2.5

Include seal.

1.0

Include seal.

1.0

2.5 Refer to 32.1.5

Rem. / Inst.

1 pc.

After removing boom.

0.4

82 • Swing cylinder rod pin

- ditto -

1 pc.

0.1

83 • Swing bracket slinging

- ditto -

1 pc.

0.1

84 • Swing center pin

- ditto -

1 pc.

0.1

85 Swing cylinder removing / installing

- ditto -

1 pc.

Rem. / Inst.

2 pcs.

0.2

- ditto -

1 pc.

0.1

88 Swing cylinder

O/H

1 pc.

89 • Pin bushing

Replace

1 pc.

Include seal.

1.0

Rem. / Inst.

1 set

Panel assy (3)

0.1

86 • Swing cylinder hose 87 • Swing cylinder head pin

Other necessary works 90 Dozer portion 91 Dozer ASSY

After removing swing bracket.

0.3

2.5

Refer to 32.1.6 Rem. / Inst.

1 pc.

0.6

92 • Dozer cylinder hose

- ditto -

2 pcs.

0.2

93 • Dozer cylinder rod pin

- ditto -

1 pc.

0.1

94 • Dozer installing pin

- ditto -

2 pcs.

0.2

95 Dozer cylinder

O/H

1 pc.

96 • Pin bushing

Replace

1 set

12-5

2.5 Include seal.

1.0

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

00 Canopy portion 01 Canopy assy 02 • Hand rail

Rem. / Inst.

1 pc.

- ditto -

1 pc.

0.2 0.1 Refer to 33.1.1

Rem. / Inst.

1 pc.

0.4

- ditto -

1 pc.

0.1

21 Cover assy (1)

Rem. / Inst.

1pc.

0.1

22 Bonnet assy (2)

- ditto -

1pc.

0.1

23 Cover assy (3)

- ditto -

1pc.

0.1

12 • Harness 20 Bonnet & Guard

Refer to 33.1.2

24 Cover assy (4)

- ditto -

1pc.

0.1

25 Cover assy (5)

Rem. / Inst.

1pc.

0.1

30 Control stand portion 31 Control stand ASSY 02 Canopy & Guard

UNIT: HOUR

Refer to 33.1.1

10 Cab portion 11 Cab assy

REMARKS

Refer to 33.1.14 Rem. / Inst.

1 pc.

1.0

32 • Air cleaner

- ditto -

1 pc.

0.1

33 • E / G control cable

- ditto -

1 pc.

0.2

34 • Deceleration motor (OPT)

- ditto -

1 pc.

0.1

35 • Filler neck

- ditto -

1 pc.

0.1

36 • Fuel air bleed hose

- ditto -

1 pc.

0.1

37 • Harness

- ditto -

1 set

0.3

Rem. / Inst.

1 set

Canopy

0.2

- ditto -

1 set

Floor cover

0.1

- ditto -

1 set

Guard (Cover, support)

0.4

- ditto -

1 pc.

Counterweight

0.4

- ditto -

1 pc.

Negative terminal of battery

0.1

Other necessary works

40 Floor plate portion 41 Floor plate assy Other necessary works

Refer to 33.1.3 Rem. / Inst.

1 set

- ditto -

1 pc.

50 Counterweight portion

0.5 Canopy removal / inst

0.2

Refer to 33.1.5

51 Counterweight ASSY

Rem. / Inst.

1 pc.

0.4

52 • Lifting tools

Preparation

1 set

0.1

53 • Slinging

Rem. / Inst.

1 pc.

0.1

54 • Counterweight fixing bolt

- ditto -

1 set

0.1

Other necessary works

- ditto -

3 pcs.

Rem. / Inst.

1 pc.

0.2

02 Swing yoke

- ditto -

1 pc.

0.1

03 Swing cable

- ditto -

1 pc.

0.1

04 Other necessary works

- ditto -

1 set

Guards

0.3

00 Control portion

03 Upper structure

01 E / G control cable

10 Intake portion 11 Air cleaner ASSY

Cover and Hose

0.4

Refer to 33.1.11 Rem. / Inst.

1 pc.

0.3

- ditto -

1 pc.

0.1

13 • Hose (2)

- ditto -

1 pc.

0.1

14 • Element

Replace

1 pc.

0.1

12 • Hose (1)

20 Exhaust portion 21 Muffler ASSY

Refer to 33.1.13 Rem. / Inst.

12-6

1 pc.

0.4

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

WORK TO BE DONE

UNIT

22 • Clamp

- ditto -

1 pc.

0.1

23 • Exhaust manifold attaching nuts

- ditto -

4 pcs.

0.1

24 • Muffler fixing bolt

- ditto -

4 pcs.

0.1

- ditto -

1 set

Rem. / Inst.

1 pc.

0.6

32 • Connector

- ditto -

1 pc.

0.1

33 • Generator fixing bolt

- ditto -

2 pcs.

0.1

34 •

- ditto -

1 pc.

Include tension adjusting

0.3

- ditto -

1 set

Covers

0.1

- ditto -

1 pc.

Negative terminal of battery

0.1

Rem. / Inst.

1 pc.

0.5

37 • B-terminal

- ditto -

1 pc.

0.1

38 • S-terminal connector

- ditto -

1 pc.

0.1

39 •

Starter fixing bolt

- ditto -

2 pcs.

0.2

Other necessary works

- ditto -

1 set

Cover and Floor plate

0.1

- ditto -

1 set

Seat and Stand cover

0.3

- ditto -

1 pc.

Negative terminal of battery

0.1

Rem. / Inst.

1 pc.

0.6

Replace

1 pc.

0.2

Rem. / Inst.

1 pc.

0.1

44 • Hose (Return; filter side)

- ditto -

1 pc.

0.1

45 • Level sensor connector

- ditto -

1 pc.

0.1

46 • Fuel tank fixing bolt

- ditto -

4 pcs.

0.1

- ditto -

1 pc.

Rem. / Inst.

1 pc.

After removing fuel tank ;

1.6

52 • Return filter

Replace

1 pc.

Include pressure releasing & replacing O-ring

0.2

53 • Hydraulic oil

- ditto -

1 pc.

0.2

54 • Suction hose

Rem. / Inst.

1 pc.

0.2

Replace

1 pc.

56 • Pilot return hose

Rem. / Inst.

1 pc.

0.1

57 • Swivel drain hose

- ditto -

1 pc.

0.1

58 • SOL. valve return hose

- ditto -

1 pc.

0.1

59 • Slewing, C / V return hose

- ditto -

2 pcs.

0.2

EQUIPMENT PORTION

Other necessary works 30 E / G Accessory portion 31 Generator

V-belt

Other necessary works 36 Starter

03 Upper structure

42 • Fuel 43 • Hose (Supply; water separator side)

Other necessary works

55 • Strainer

60 • Tank fixing bolt Other necessary works

72 • Hydraulic oil 73 • Pilot delivery oil hose

Covers

0.2

Refer to 33.1.10

Include replacing O-ring

0.1

- ditto -

4 pcs.

- ditto -

1 pc.

Covers

0.2

- ditto -

1 pc.

Control valve

1.6

- ditto -

1 pc.

Solenoid valve

0.1

Preparation

1 pc.

Hyd. oil tank pressurizing

0.1

70 Pump portion 71 Pump ASSY

0.1

Refer to 33.1.9

50 Hydraulic oil tank portion 51 Hydraulic oil tank ASSY

Heat insulation cover

UNIT: HOUR

Refer to 33.1.12 & 33.1.15

40 Fuel portion 41 Fuel tank ASSY

REMARKS

0.2

Refer to 33.1.6 Rem. / Inst.

1 pc.

After removing counterweight

1.2

Replace

1 pc.

Include pressure releasing

0.2

Rem. / Inst.

1 pc.

12-7

0.1

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

WORK TO BE DONE

UNIT

74 • Suction hose

- ditto -

1 pc.

0.2

75 • Suction tube (pump side)

- ditto -

1 pc.

0.2

76 • Main pump delivery hose

- ditto -

3 pcs.

0.2

77 • Pump fixing bolt

- ditto -

2 pcs.

0.2

O/H

1 pc.

3.0

Feed

1 pc.

Hyd. oil in pump

0.1

Preparation

1 pc.

Hyd. oil tank pressurizing

0.1

EQUIPMENT PORTION

78 Pump ASSY Other necessary works

80 Radiator portion 81 Radiator ASSY 82 • Coolant (LLC)

UNIT: HOUR

Refer to 33.1.16 Rem. / Inst.

1 pc.

1.2

Replace

1 pc.

0.2

83 • • Coolant density

Measuring

1 pc.

(0.2)

84 • Reserve tank hose

Rem. / Inst.

1 pc.

0.1

- ditto -

2 pcs.

0.2

85 • Radiator hose

03 Upper structure

REMARKS

86 • Cooler hose

- ditto -

2 pcs.

0.2

87 • Radiator fixing bolt

- ditto -

3 pcs.

0.1

88 • Radiator lifting or slinging

- ditto -

1 pc.

0.1

Other necessary works

- ditto -

1 pc.

Counterweight

0.4

- ditto -

1 set

Covers

0.2

- ditto -

1 pc.

Duct

0.1

90 Engine (E / G) Installing portion

Refer to 33.1.17

91 Engine ASSY

Rem. / Inst.

1 pc.

92 • Fuel hose

- ditto -

4 pcs.

Rem. / Inst.

1 set

0.3

94 • Engine fixing nut

- ditto -

1 pc.

0.2

95 • Engine slinging

- ditto -

1 set

0.2

- ditto -

1 set

Covers

0.2

- ditto -

1 pc.

Canopy

0.2

93 • Harness, connector and cable

Other necessary works

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

0.2

- ditto -

1 set

Control stand

1.0

- ditto -

1 pc.

Counterweight

0.4

- ditto -

1 pc.

Air cleaner

0.2

- ditto -

1 pc.

Muffler

0.4

- ditto -

1 pc.

Pump

1.2

- ditto -

1 pc.

Radiator

1.0

- ditto -

1 pc.

Battery negative terminal

0.1

100 Control valve portion 101 Control valve ASSY

1.0

Refer to 33.1.7 Rem. / Inst.

1 pc.

1.6 Include attaching hose’s tag and plug

102 • Piping connector, hose

- ditto -

1 set

103 • Control cable, Yoke

- ditto -

1 set

0.2

104 • Fixing bolt

- ditto -

1 set

0.1

O/H

1 pc.

3.0

Rem. / Inst.

1 set

Covers

0.1

- ditto -

1 set

Hoses

0.2

105 Control valve ASSY Other necessary works 110 Slewing motor portion 111 Slewing motor ASSY

1.0

Refer to 33.1.19 Rem. / Inst.

12-8

1 pc.

1.0

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

112 • Piping connector, hose

- ditto -

7 pcs.

Include attaching hose’s tag and plug

0.5

113 • Fixing bolt

- ditto -

1 pc.

0.3

O/H

1 pc.

3.0

Rem. / Inst.

1 set

Floor plate, Covers

0.2

Feed

1 pc.

Hyd. oil in motor

0.1

EQUIPMENT PORTION

114 Slewing motor ASSY Other necessary works 120 Swivel joint portion

03 Upper structure

121 Swivel joint ASSY

Refer to 33.1.20 2.5

1 pc.

122 • Under cover

- ditto -

1 pc.

123 • Piping connector, hose

- ditto -

1 set

124 • Stopper

- ditto -

1 pc.

0.1

125 • Fixing bolt

- ditto -

1 set

0.2

O/H

1 pc.

2.0

Preparation

1 pc.

Removal / Inst. position. (Secure working space.)

0.1

1 pc.

Canopy removal / inst. (for easy working)

0.2

1 pc.

Floor plate cover (2) removal / inst.

0.1

126 Swivel joint ASSY Other necessary works

130 Upper frame portion 131 Upper frame ASSY 132 •

Fixing bolt

133 • Upper frame slinging 134 • Cleaning Other necessary works

01 Rubber crawler

0.1 Include attaching hose’s tag and plug

1.5

Refer to 33.1.21 Rem. / Inst.

1 pc.

- ditto -

1 set

1.0 Apply sealant

0.3

- ditto -

1 pc.

0.3

Cleaning

1 pc.

0.2

Rem. / Inst.

1 pc.

Canopy

0.2

- ditto -

1 pc.

Guard (Cover, support)

1.5

- ditto -

1 pc.

Counterweight

0.4

Drain / Feed

1 pc.

Hydraulic oil

0.2

Rem. / Inst.

1 set

Swivel joint hose

0.5

- ditto -

1 set

Boom, Swing bracket

1.5

00 Travel portion

04 Under carriage

After removing slewing motor

Rem. / Inst.

Refer to 34.1.2 Rem. / Inst. One side

0.6

02 • Rubber shoe removing / inst. position. Preparation One side

0.1

03 • Tension adjusting

0.2

04 • Crawler shoe

Adjusting

One side

Rem. / Inst. One side

10 Upper roller portion 11 Upper roller ASSY 12 Upper roller

Rem. / Inst.

1 pc.

O/H

1 pc.

Rem. / Inst.

1 pc.

0.2

O/H

1 pc.

1.0

20 Lower roller portion 21 Lower roller ASSY 22 Lower roller

32 Idler & Idler adjuster ASSY

After removing crawler shoe

0.2 1.0

Refer to 34.1.6

30 Front idler & Idler adjuster portion 31 Idler & Idler adjuster ASSY

0.2 Refer to 34.1.3

Refer to 34.1.7 & 34.1.8 Rem. / Inst. One side After removing crawler shoe O/H

12-9

One side

0.5 0.1

12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

33 Idler ASSY 34 Idler adjuster ASSY

WORK TO BE DONE

UNIT

O/H

One side

1.0

- ditto -

One side

0.5

40 Sprocket portion 41 Sprocket

04 Under carriage

UNIT: HOUR

Refer to 34.1.9 Replace

One side

50 Travel motor portion 51 Travel motor ASSY

REMARKS

After removing crawler shoe

0.5

Refer to 3 34.1.10 Rem. / Inst. One side After removing crawler shoe

1.0

52 • Motor cover

- ditto -

One side

53 • Hydraulic connector, hose

- ditto -

One side

54 • Motor fixing bolt

- ditto -

One side

0.3

55 • Motor slinging

- ditto -

One side

0.1

O/H

One side

3.0

- ditto -

One side

3.0

One side Hyd. oil in motor

0.1

56 Travel motor 57 Travel reduction unit Other necessary works

Feed

60 Slewing bearing portion 61 Slewing bearing ASSY 62 • Slewing bearing fixing bolt 63 • Slewing bearing 64 • Slewing bearing slinging

0.1 Include attaching hose’s tag and plug

0.6

Refer to 34.1.11 Rem. / Inst.

1 pc.

- ditto -

1 pc.

Cleaning

1 pc.

Rem. / Inst.

1 pc.

12-10

After removing upper frame

0.6 0.3

Decreasing / Replenishment

0.1 0.2

13. MAINTENANCE STANDARDS AND TEST PROCEDURES TABLE OF CONTENTS 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ........... 13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE .................................... 13-5 13.2.1

STANDARD VALUE TABLE .................................................................. 13-5

13.3 MEASURING ENGINE SPEED ....................................................................... 13-7 13.3.1

ENGINE SPEED MEASUREMENT ....................................................... 13-7

13.4 MEASURING HYDRAULIC OIL PRESSURE ................................................. 13-9 13.4.1

STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ..... 13-9

13.4.2

PRESSURE MEASUREMENT AND ADJUSTMENT ............................. 13-9

13.5 MEASURING TRAVEL PERFORMANCES .................................................. 13-13 13.5.1

TRAVEL ............................................................................................... 13-13

13.5.2

TRAVEL DEVIATION ........................................................................... 13-13

13.5.3

MOVEMENT DRIFT DUE TO GRAVITY ............................................. 13-14

13.5.4

DRAIN RATE ON TRAVEL MOTOR .................................................... 13-14

13.6 MEASURING SLEW PERFORMANCES ...................................................... 13-15 13.6.1

SLEW TIME ......................................................................................... 13-15

13.6.2

OVERRUN WHEN SLEWING STOPS ................................................ 13-15

13.6.3

SLEW DRIFT DUE TO GRAVITY ........................................................ 13-15

13.6.4

DRAIN RATE OF TRAVEL MOTOR .................................................... 13-16

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .................. 13-17 13.7.1

CYLINDER SPEED .............................................................................. 13-17

13.7.2

GRAVITY DRIFT OF CYLINDERS ...................................................... 13-18

13.8 MEASURING SLEW BEARING PERFORMANCES ..................................... 13-19 13.8.1

SLEW BEARING-BUCKET TIP PLAY ................................................. 13-19

13.8.2

SLEW BEARING PLAY ........................................................................ 13-19

13.9 MEASURING CRAWLER TENSION ............................................................. 13-20 13.9.1

CRAWLER TENSION .......................................................................... 13-20

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13-1

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13-2

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1) For New Machine: This manual is to be used to check the actual performance and functions of the machine compared with the PERFORMANCE STANDARDS. 2) At Specific Self-Inspection (as per LOCAL RULES); The maintenance standards are used to make them as the criteria to determine the time for reconditioning, adjustment and replacement. 3) At Deterioration of Performance; This manual is of the criteria of safe and economical judgment whether the deterioration of performance on the machine would be caused by any faults or normal deterioration due to machine operation for a long period. 4) For Replacement of Major Components; This manual is of the standard to determine the time for replacement to recover the performance of major components such as pump, etc. (2) Terminology 1) Standard Values: These are of the standard values to assemble and regulate a new machine. Where special notes are not given, these values are based on the machine with standard structure (the machine with standard attachments and shoes). 2) Standard Values for Repair: These are of the values at which the reconditioning is required. In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and components being over the standard values. 3) Serviceability Limit: This is of the service limit for each part and component at which the reconditioning is impossible and they must be replaced to new ones. All the parts and components which are estimated to exceed the serviceability limit up to the next periodical inspection and maintenance, should be also replaced to new ones. The machine operation with the parts and components which have exceeded the serviceability limit, causes increase of troubles and down time of the machine, and also causes safety problems. (3) Precautions for Judgment: 1) Evaluation for Measured Data: It is inevitable some variation on the measured data due to differences between measuring conditions, peculiar variability on a new machine, old and new versions of the machine and measuring characteristics. The judgment for the measured data should be comprehensively conducted based on the extent of level of the measured data, instead of mere comparison with the standard values. 2) Determination for Reconditioning, Adjustment or Replacement: There are two kinds of deterioration of machine performance; one is due to normal wear with time elapsing of operation, and the other is recoverable to the standard values with the adjustment for pressure, etc. Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various factors into consideration such as operating hours, working conditions and maintenance conditions of the machine, so that the machine is able to be operated at the optimum performance level. (4) Other Precautions 1) Parts with Aging Effect: The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the aging effect. It is necessary to replace them to new ones at periodical intervals or at every overhaul. 2) Parts required Periodical Replacement: It is recommendable to designate the important hoses critical to secure the safety as Very Important Parts (V.I.P.), and periodically replace with new ones.

13-3

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 3) Inspection & Replacement of Lubricants: It is necessary for the user of the machine to fully familiarize himself with the procedures and precautions to handle the machine in safe and carry out the maintenance, as well as the procedures for inspection and lubrication. Refer to the OPERATION & MAINTENANCE MANUAL as well.

13-4

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.2

PERFORMANCE INSPECTION STANDARD TABLE

13.2.1

STANDARD VALUE TABLE Table 13–1(1/2)

[TEMPORARY]

Model Item

Unit

Standard value

Hyd. oil cleanliness

Class

8±1

—

8±1

—

50~60 (122~140)

—

50~60 (122~140)

—

60~90 (140~194)

—

60~90 (140~194)

—

1150±50

—

1150±50

—

2550±50

—

2550±50

—

1150±50

—

1150±50

—

Coolant temperature (Radiator surface)

*2 Port (Over load) relief valve pressure

°C (°F)

Low idle

Engine speed

Measuring condition

Hyd. oil temperature (Tank surface)

High idle

rpm

Deceleration Boom • Bucket • Travel (LH)

P1

Arm • Swing • Travel (RH) • Service

P2

Dozer

P3

Pilot relief valve Pilot Line pressure

MPa (psi)

—

Boom

Head Rod

Arm

Head Rod

Bucket

Standard value

Repairable value

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

23.0

(3340

)

—

3.5±0.4 (508±58)

—

3.5±0.4 (508±58)

—

27.5

(3990

)

—

27.5

(3990

)

—

(3700

)

—

25.5

(3700

)

—

Head

25.5 kgf/cm2 (psi) 25.5

(3700

)

—

25.5

(3700

)

—

Dozer

Head

25.5

(3700

)

—

25.5

(3700

)

—

*1 Slew

LH/RH

21.0

(3050

)

—

21.0

(3050

)

—

Crawler Speed (5 rev.) Travel

E50.2SR

Repairable value

Div.

Main relief valve pressure

E40.2SR

Travel Speed 10 m (32.8 ft)

Low

Rubber crawler

37.5±2.1

48

40.2±2.3

51

21.9±1.1

28

23.5±1.2

30

35.1±2.0

45

37.5±2.1

48

High

20.5±1.0

26

21.9±1.1

28

Low

13.7±0.7

18

13.7±0.7

18

8.1±0.4

10

8.1±0.4

10

15.0±0.7

19

15.0±0.7

19

8.8±0.4

11

8.8±0.4

11

high Low

Iron crawler Rubber crawler

High Low

Iron crawler

sec.

High

Travel deviation Drift due to gravity

sec.

W/P.B. (5 min)

mm (in) mm (in)

140

(5.5 0 (0)

)

280 (11.0)

140

1 (0.04)

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

13-5

(5.5 0 (0)

)

280 (11.0) 1 (0.04)

13. MAINTENANCE STANDARDS AND TEST PROCEDURES Table 13–1(2/2)

[TEMPORARY]

Model Div.

E40.2SR

Item

Unit

Standard value

Repairble value

Standard value

Repairable value

13.9±0.7

17

13.9±0.7

17

0

—

0

— 3.8

Slew

Slew time per 2–revolution sec. Overrun when slewing stops Drift due to gravity

Boom Cylinder speed Cylinders

2.3±0.4

2.9

3.0±0.4

2.1±0.4

2.7

2.6±0.4

3.3

Ext.

2.2±0.4

2.8

2.9±0.4

3.7

Ret.

2.0±0.4

2.6

2.5±0.4

3.2

Ext.

2.8±0.4

3.6

3.3±0.4

4.2

2.1±0.4

2.7

2.5±0.4

3.2

2.8±0.4

3.6

2.8±0.4

3.6

Ret.

1.8±0.4

2.3

1.8±0.4

2.3

Ext.

5.5±0.8

7.0

5.5±0.8

7.0

Ret.

4.0±0.6

5.1

4.0±0.6

5.1

Ext.

2.7±0.4

3.5

2.7±0.4

3.5

Ret.

1.9±0.4

2.4

1.9±0.4

2.4

Arm

Ret. Ext.

Bucket Swing Dozer

Cylinder Gravity move

mm (in)

Cano- Ext. py Ret. Cab

Crawler Slew bearing

E50.2SR

sec.

Boom

12

Arm

6

(0.24

6

(0.24

(10 min) Dozer

mm (in)

Bucket tip

150

Bucket tip play

40

18 (0.71)

12

)

12 (0.47)

6

(0.24

)

12 (0.47)

)

12 (0.47)

6

(0.24

)

12 (0.47)

260 (10.2)

150

80 (3.1)

40

(0.47

)

(5.9

(1.6

)

)

(0.47

)

(5.9

(1.6

)

)

18 (0.71)

260 (10.2)

80 (3.1)

mm (in)

Crawler tension

Rubber Steel

mm (in)

85~95 (3.35~3.14) 130~150 (5.12~5.91)

13-6

—

85~95 (3.35~3.14)

—

—

130~150 (5.12~5.91)

—

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.3

MEASURING ENGINE SPEED

13.3.1

ENGINE SPEED MEASUREMENT

(1) Measuring Instruments

2

1) Diesel Speedometer (1) (Measuring engine speed by means of applying a pick-up (2) to one of injection pipes)

1

2) Surface Thermometer (Measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator) (2) Engine Warming up Operation Start up the engine, and make the coolant temperature within the range of 60 to 90 째C (140 to 194 째F). Check the coolant temperature with the coolant thermometer on the monitor panel. The white color zone shows approx. 67 to 105 째C (153 to 221 째F) of temperature range. Therefore, when the indicator is located at around center of the white zone, it is suitable for the engine operation.

Fig. 13-1 Engine Speed measurement (The above figure shows concept)

(3) Engine Speed Measurement 1) Apply the pick up of speedometer to one of convenient injection pipes. (Refer to Fig. 13-1)

WATER TEMPERATURE

2) Measure the engine speed at idling with no load, and compare it to the figure in the STANDARD VALUE TABLE.

13-7

13. MAINTENANCE STANDARDS AND TEST PROCEDURES (4) Speed Adjustment 3

1) Low (3) / High (4) Idling Speed is low ; The proper engine speed is obtained with the length of accelerator wire as shown in the right sketch. When the engine speed is lower than the standard speed, adjust the length of wire with loosening the capscrew (9) of throttle lever side.

(5.28") 134

4

Y

CAUTION

A 9

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

6 15

30

5

Y

32

Z [WATER TEMPERATURE (OPT)] 5. Decel cable 6. Throttle cable

Z

A Fig. 13-2 Accelerator wire adjustment

13-8

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.4

MEASURING HYDRAULIC OIL PRESSURE

13.4.1

STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT

(1) Hydraulic Instruments • 6.86 MPa (1000 psi) pressure gauge: 1 set • 49 MPa (7100 psi) pressure gauge: 3 sets • Surface Thermometer: 1 set • Pressure Measuring Kit and Oil Analyzing

P3 (G3)

• Equipment: 1 set (2) Measuring cleanliness of hydraulic oil

P2 (G2)

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

13.4.2 13.4.2.1

P1 (G1)

PRESSURE MEASUREMENT AND ADJUSTMENT Main Circuit Pressure

(1) Measuring Conditions Engine speed: High idling Hydraulic oil temperature: 50 ~ 60 °C (122 ~ 140 °F) Coolant temperature (on radiator surface): 60~90 °C (140 ~ 194 °F)

OR9

OR8 OR3

OR1

(2) Pressure Measuring Procedures 1) After releasing pressure in the hydraulic oil tank, and setting a 49 MPa (7100 psi) pressure gauge to either of pressure detecting ports (G1, G2 or G3, PF1/4 with plug), operate the circuit to be measured to measure the relief pressure. 2) When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted.

OR7

OR4

Fig. 13-3 Main hydraulic oil pressure measurement

3) If the main relief pressure is lower than the standard range, tighten up the main relief valve by half turn [pressure increase by 12.2 MPa (1770 psi)], then measure the pressure at overload relief valve. 4) After adjustment for the overload relief pressure, return back the main relief pressure within the standard range.

13-9

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

Press.Detecting Port Operating Circuit

Port Location

Boom, Bucket & Travel (left)

G1

Arm, Travel (right) Swing & Service

G2

Dozer & Slew

G3

Size

2

Relief Valve

1

MR1 PF1/4

MR2 Main relief valve (MRV2)

MR3

2

Attaching position of overload relief valve 1

OR1

BUCKET DIGGING

OR3

BOOM UP

OR4

BOOM DOWN

OR7

ARM IN

OR8

ARM OUT

OR9

DOZER DOWN

Fig. 13-4 Main relief valve (MRV1)

(3) Pressure Adjustment 1) Control Valve: Main Relief Valve and Overload Relief Valve a.Loosen the lock nut (2), and adjust the setting pressure turning the setscrew (1). Roughly with one full turn: Main relief valve & Overload relief valve: Approx. 12.2 MPa (1770 psi) CW turning: Increasing setting pressure CCW turning: Decreasing setting pressure b.After the adjustment, tighten up the lock nut holding the setscrew not to turn around. c.Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2): 19.6 N•m (14.5 lbf•ft) 2) Slewing Motor: Relief Valve a.The adjustment of setting pressure for relief valve of slewing motor is not available. If the adjustment is required by fatigue of spring and so on, replace with the new rekief valve in an assembly. b.Therefore the port of detecting pressure is not equipped on the slewing motor.

13-10

Fig. 13-5 Relief valve (Slewing motor)

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.4.2.2

Pilot Circuit Pressure

(1) Measuring Conditions Engine: High idling Hydraulic oil temp.: 50 ~ 60 °C (122 ~ 140 °F) Coolant temp.: 60 ~ 90 °C (140 ~ 194 °F) at radiator surface

4 5

(2) Measurement Releasing pressure in the hydraulic oil tank of hydraulic system, and setting a 6.86 MPa (1000 psi) pressure gauge to the pressure detecting port (G4, PF 1/4 with plug) (4), measure the pilot relief pressure. Pressure Detecting Port Port Location

Size

G4

PF1/4

Relief Valve PR1 Fig. 13-6 Pilot oil pressure measurement Unplug PF1/4, and set a 6.86 MPa pressure gauge

(3) Pressure Adjustment Adjust it with the relief valve attached to the solenoid valve (5). 1) Loosen the lock nut (2), then turn the setscrew (1) to adjust the set pressure. CW screwing: Set pressure is increased. CCW screwing: Set pressure is decreased.

1

2 3

PR1

2) After the adjustment, lock the setscrew with the lock nut holding the setscrew not to allow its turning. 3) Again actuate the relief valve, and verify that the set pressure is being stable. Tightening Torque: Lock Nut (2): 7.8 N•m (5.8 lbf•ft) Relief valve (PR1): 44 N•m (32 lbf•ft) Capscrew (3): 7.8 N•m (5.8 lbf•ft)

13-11

Fig. 13-7 Relief valve

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.5

MEASURING TRAVEL PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.5.1

Travel

(1) Travel Speed (5 Revolutions) • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Machine Body is raised using both hoe attachment and dozer blade. • Set crawler shoes in motion. Starting after one full revolution, measure the time required for 5 revolutions. (To measure speed after it has stabilized.) (2) Travel Speed (10 m) • Engine: Rated r.p.m. • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Travel Posture • Set machine in motion. Starting after a running of 5 meters, measure the time required to travel 10 meters. Do this on level and hard ground. • Travel Posture: Fully extend the arm and bucket cylinders and place the hoe attachment so that its lowest part is even with the machine’s minimum ground clearance level. The hoe attachment must be in a no-load and the dozer blade must not touch the ground.

13.5.2

Travel Deviation

•

Engine: Rated r.p.m.

•

Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F)

•

Measurement Posture: Travel Posture

•

Measure the deviation "X" at the point of half of 10 m (32.8 ft) travel after 5 m preliminary running. Measure on level and hard ground.

13-12

5m(16.4ft)

10m(32.8ft)

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.5.3

Movement drift due to gravity

Measure the movement distance of machine on a slope due to machine’s own weight, holding the machine for 5 minutes on the slope. Measuring Conditions: •

Engine: Stopped

•

Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F)

•

Gradient: 15° (Approx. 1/3.73)

•

Machine posture: Fully extending the boom, arm and bucket cylinders, and fully contracting the dozer cylinder.

13.5.4

DRAIN RATE ON TRAVEL MOTOR

(1) Preparation 1) Apply stopper pins (1) for both travel sprockets of left and right. 2) Stop the engine, and release air in the hydraulic oil tank.

A

3) Connect a hose to the drain port of travel motor, and receive the drained oil in a container. 4) Apply a plug to the drain piping at tank side.

1 (2.36") (0.47") 60 12

WARNING Make sure of the rotating direction of travel motor referring to the right sketch. Otherwise, the rib (A) may be broken by the stopper pin (1).

80 (3.15")

1

Ø 40 (1.57")

(2) Measurement: • Engine: At rated speed • Hydraulic oil temp.: 50 ~ 60 °C (122 ~ 140 °F) • Machine posture: Locking the traveling, and allowing relief on the travel motor • Measure the drained volume of oil for 30 seconds of relief. Unit: liter (gal) /30 sec DRAIN DATE OF TRAVEL MOTOR SPEED SHIFT

1 st

Standard value

Standard value for repair

Serviceability limit

1.5 (0.40) or less

-

3 (0.79) or more

13-13

12 (0.47") 70 (2.76")

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.6

MEASURING SLEW PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.6.1

Slew Time

•

Engine: High Idle

•

Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F)

•

Measurement Posture: Completely retract the arm cylinder, fully extend the bucket cylinder and place so that boom foot pin (B) and bucket pin (A) are at matching height. Place the dozer blade on the ground.

•

With the hoe attachment in a no-load, drive 1 rotation, then measure the time required for the next 2 rotations.

13.6.2

Overrun When Slewing Stops

•

Engine: High Idle

•

Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F)

•

Measurement Posture: Same as that for measuring slew time.

•

Prior to measuring, draw matching marks on the outer race of the slew bearing and lower frame at exactly 180 degrees slew from the starting point. Then with the hoe attachment in a no-load, slew 180 degrees from starting point (A). At which point return the operating lever to neutral (B). Measure the distance between the position marks and the point the hoe attachment stops (C).

13.6.3

Slew Drift due to Gravity

•

Engine: Stopped

•

Hydraulic Oil Temp.: 50 ~ 60 °C(122 ~ 140 °F)

•

Gradient: 15° (Approx. 1/3.73)

•

Measurement Posture: Same as that for measuring slew time.

•

Slew the upper slewing structure and stop at right angle to the slope, then draw matching marks on the slew bearing’s outer race and the lower frame. Then measure the distance (A) that develops between the marks after 5 minutes. Measure for both RH and LH directions.

13-14

13. MAINTENANCE STANDARDS AND TEST PROCEDURES 13.6.4

Drain Rate of Travel Motor

(1) Preparation 1) Stop the engine, and release air inside the hydraulic oil tank. 2) Disconnect the slew motor drain hose at the return side to the hydraulic oil tank. Then receive the drain oil to a container. Install plug on bore of tank after removing drain hose. (2) Measurement: • Engine: At rated speed • Hydraulic oil temp.: 50 ~ 60 °C (122 ~ 140 °F) • Machine posture: Pushing a fixture with the side of bucket, operating the engine. • Measure the drained volume of oil for 30 seconds relieving at full stroke of the slewing operation. Unit: liter (gal) /30sec DRAIN RATE OF SLEW MOTOR Standard Value

Standard value for repair

Serviceability

3.0 (0.79) or less

-

-

13-15

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.7

MEASURING ATTACHMENT OPERATING PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.7.1

Cylinder Speed

(1) Boom Cylinder Speed • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Completely retract the arm cylinder, fully extend the bucket cylinder and place the dozer blade on the ground. • Then measure the time required for the bucket to reach its highest point (lowest point) from its lowest point (highest point) placing on the ground. (Do not include the cushioning time.) (2) Arm Cylinder Speed • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Completely retract the arm cylinder, fully extend the bucket cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the arm cylinder to completely retract (extend) from a fully extended state (retracted state). (3) Bucket Cylinder Speed • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Completely retract the arm cylinder, position the arm horizontally and place the dozer blade on the ground. • Then measure the time required for the bucket cylinder to completely retract (extend) from a fully extended state (retracted state). (4) Swing Cylinder Speed • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Same as that for measuring slew time. • While swinging the boom left (right) to right (left), measure the time required for a full stroke each way.

13-16

13. MAINTENANCE STANDARDS AND TEST PROCEDURES (5) Dozer Cylinder Speed • Engine: High Idle • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Using the hoe attachment lift up the dozer blade side. • Then, up and down the dozer blade with full stroke, measure the time required per stroke in each direction. 13.7.2

Gravity drift of Cylinders

(1) Boom, Arm, Bucket, Dozer, Bucket Tip • Engine: Stopped • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture: Completely retract the dozer and arm cylinders, fully extend the bucket cylinder and position the bucket pin to the same height as the boom foot pin. • Maintain the position for 10 minutes then measure the change of rod length and distance of the bucket tip. (2) Swing Cylinder • Engine: Stopped • Hydraulic Oil Temp.: 50 ~ 60 °C (122 ~ 140 °F) • Gradient: 15° (Approx. 1/3.73) • Measurement Posture: Same as that for measuring slew time. • Slew the upper slewing structure and stop at right angle to the slope, then measure the change in rod length after 5 minutes.

13-17

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.8

MEASURING SLEW BEARING PERFORMANCES

•TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement. 13.8.1

Slew Bearing-Bucket Tip Play

•

Measurement Posture: Completely retract the arm cylinder and fully extend the bucket cylinder.

•

Move the tips of the bucket teeth from side to side (left and right) and measure the play.

13.8.2

Slew Bearing Play

(1) Attach a dial gauge to the bottom face of the slew bearing’s outer-race located in front of the upper slewing structure.

(2) Raise the crawler on one side off the ground and set the dial gauge to zero.

(3) Then raise the opposite crawler and read the dial gauge.

13-18

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.9

MEASURING CRAWLER TENSION

13.9.1

Crawler Tension

•

Raise the machine completely off the ground using the hoe attachment and dozer blade. Then measure the distance (A) (of sag) between the center point on the crawler frame and top of the crawler shoe.

B A

CAUTION C

In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or " mark) in the top center position.

"

A

A. Distance B. Rubber C. Iron

13-19

13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13-20

22. HYDRAULIC SYSTEM TABLE OF CONTENTS 22.1 SUMMARY ...................................................................................................... 22-3 22.1.1 FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT ....................... 22-3 22.2 HYDRAULIC CIRCUITS AND COMPONENT MODELS ................................ 22-4 22.3 HYDRAULIC CIRCUIT OPERATION .............................................................. 22-6 22.3.1 COLOR CODING STANDARD FOR HYDRAULIC .................................. 22-6 22.3.2 NEUTRAL CIRCUIT ................................................................................. 22-6 22.3.3 TRAVEL OPERATING CIRCUIT .............................................................. 22-7 22.3.4 SLEW OPERATING CIRCUIT ................................................................. 22-8 22.3.5 BUCKET OPERATING CIRCUIT ............................................................. 22-8 22.3.6 BOOM OPERATING CIRCUIT ................................................................. 22-9 22.3.7 ARM OPERATING CIRCUIT .................................................................... 22-9 22.3.8 SWING OPERATING CIRCUIT ............................................................. 22-10 22.3.9 DOZER OPERATING CIRCUIT ............................................................. 22-10 22.3.10TRAVEL / DOZER COMBINED OPERATING CIRCUIT ........................ 22-11 22.3.11TRAVEL / BOOM COMBINED OPERATING CIRCUIT ......................... 22-11

22. HYDRAULIC SYSTEM

22-1

22. HYDRAULIC SYSTEM

22-2

22. HYDRAULIC SYSTEM

22.1

SUMMARY

22.1.1

FUNCTION AND FEATURES OF HYDRAULIC CIRCUIT

The hydraulic circuits are built up with the following functions and features in order to achieve easy operation, safety and high working efficiency.

Slew Attachment Others

Easy Operation and Safety

Travel

PerformDevice ance

Function

Features

• Straight traveling

• Straight traveling secured by independent travel function in combined operations

• Preventing overrunning of travel motor

• Preventing overrunning on a slope

• Parking brake • Slewing (with dozer) independent circuit

• Automatic braking at parking • Constant slewing speed when operating in simultaneous operation condition

• Auto slewing parking brake

• Protecting against slewing drift on a slope

• Slewing shockless function

• Smooth feeling when starting and stopping slewing operation • Responsive operability

• Hydraulic pilot control system • Dozer (with slewing) independent circuit.

• Secure the travel straight when travelling and working with dozer.

• Multi-control valve (Note: Option) • Closed pressurized hydraulic oil tank

• Capable of selecting operation pattern from four types using one lever • Preventing contamination of hydraulic oil and improving self sucking up efficiency

• Suction strainer

• Removing dirt of suction side

• Line filter in pilot circuit

• Preventing malfunction in pilot operating circuit

Travel Pump Attachment Electricity

Low fuel Consumption

High Working Performance

• Return filter

• Preventing contamination of hydraulic oil • Total power control (Pumps:: P1 + P2 + P3) • Effective use of engine power with variable pump (Power shifting by P3 pump) • 2 speeds traveling

• Improving working efficiency with 2 travel speeds shifting

• P3 pump oil flow conflux in arm or N & B op- • Speed increased by conflux P3 pump oil piperation ing (when no dozer or slewing used) • Push button deceleration (Note; Option)

• When waiting for dump truck, the engine speed is repeatedly changed and the fuel consumption and noise are reduced

22-3

22. HYDRAULIC SYSTEM

22.2 •

HYDRAULIC CIRCUITS AND COMPONENT MODELS

For the Hydraulic circuit diagram, refer to Fig. 71-1 of Supporting Data that is provided at the and of this Shop Manual. STANDARD SPECIFICATION No.

E40.2SR

NAME

MODEL No.

1

PUMP ASSY

AP2D25LV1RS7

2

CONTROL VALVE

BCV65-AQ10

3

SLEWING MOTOR

PLC-120-18B-1FS2-8284A

4

TRAVEL MOTOR

GM06VA

5

BOOM CYLINDER

6

ARM CYLINDER

ø80-ø50-717

7

BUCKET CYLINDER

ø75-ø45-546

8

SWING CYLINDER

ø90-ø50-567

9

DOZER CYLINDER

ø95-ø55-200

10

SWIVEL JOINT

11

PILOT VALVE (ATT)

PV48M2042

12

PILOT VALVE (TRAVEL)

PVD6P4001

13

SOLENOID VALVE

2KWE5G-30/G12WS-249A

14

PILOT VALVE (DOZER)

PV6P

15

SHUTTLE VALVE

16

CONTROL VALVE (OPT)

17

RETURN FILTER (ELEMENT)

18

SUCTION STRAINER

19

INLINE FILTER

Y-426800

20

CHECK VALVE

S15AO-K2

21

STOP VALVE

22

SELECTOR VALVE

23

OIL COOLER

24

HYDRAULIC OIL TANK

CANOPY

ø90-ø50-704

CAB

ø90-ø50-680

NOTE: This is for reference only, because the model number might be changed due to improvement.

22-4

22. HYDRAULIC SYSTEM •

For the Hydraulic circuit diagram, refer to Fig. 71-1 of Supporting Data that is provided at the and of this Shop Manual. STANDARD SPECIFICATION No.

E50.2SR

NAME

MODEL No.

1

PUMP ASSY

AP2D25LV1RS7

2

CONTROL VALVE

BCV65-AQ10

3

SLEWING MOTOR

PLC-120-18B-1FS2-8284A

4

TRAVEL MOTOR

GM06VA

5

BOOM CYLINDER

6

ARM CYLINDER

ø90-ø50-716

7

BUCKET CYLINDER

ø75-ø45-546

8

SWING CYLINDER

ø90-ø50-567

9

DOZER CYLINDER

ø95-ø55-200

10

SWIVEL JOINT

11

PILOT VALVE (ATT)

PV48M2042

12

PILOT VALVE (TRAVEL)

PVD6P4001

13

SOLENOID VALVE

2KWE5G-30/G12WS-249A

14

PILOT VALVE (DOZER)

PV6P

15

SHUTTLE VALVE

16

CONTROL VALVE (OPT)

17

RETURN FILTER (ELEMENT)

18

SUCTION STRAINER

19

INLINE FILTER

Y-426800

20

CHECK VALVE

S15AO-K2

21

STOP VALVE

22

SELECTOR VALVE

23

OIL COOLER

24

HYDRAULIC OIL TANK

CANOPY

ø100-ø55-699

CAB

ø100-ø55-666

NOTE: This is for reference only, because the model number might be changed due to improvement.

22-5

22. HYDRAULIC SYSTEM

22.3

HYDRAULIC CIRCUIT OPERATION

22.3.1

COLOR CODING STANDARD FOR HYDRAULIC

Blue:

Feed, drain circuit,

less than 0.34 MPa (50 psi)

Green:

Return, make-up circuit,

0.34~ 0.59 MPa (50~86 psi)

Purple:

Secondary pilot pressure,

0.59~3.5 MPa(85~508 psi)

Red:

Primary pilot pressure,

3.5~3.9 MPa (508~ 566 psi)

Orange:

Main pump drive pressure,

4.9~23 MPa (711~3340 psi)

Blue tone:

At valve selection

Red valve:

When proportional valve (reducing) is operating

Red solenoid:

In active and exciting

Displaying the flow circuit and standby circuit when operating. Regarding the electrical symbols in this manual, refer to the electric circuit diagram. NOTE: For the hydraulic circuit operation, refer to Fig. 71-4 to 11 of Supporting Data that is provided at the end of this Shop Manual. 22.3.2

NEUTRAL CIRCUIT (Refer to Fig. 71-4)

2) Pilot Secondary Pressure Circuit While the pilot valves (11), (12) and (14) are being in neutral, the pilot secondary pressure is not generated. By means of operating the operating lever, the secondary pressure is generated in accordance with its motion and led to the control valve (2) from the pilot valve to shift each spool of shifting valve.

(1) Pilot Circuit 1) Pilot Primary Pressure Circuit The oil delivered from the A4 port on pump assy (1) enters into the solenoid valve (13) through the line filter (19). The pressurized oil from the port A2 of the solenoid valve (13) with the safety lock lever released (in the operating condition) is supplied to the P ports of the pilot valves for attachment (11), travel (12) and dozer (14). Since the operating circuit is fully closed in the neutral position, the oil delivered by the pump other than the oil supplied to the Pp1 port of the control valve loses its flowing passage, and returns to the hydraulic tank (24) through the relief valve (set pressure: 3.5 MPa [508 psi]) built in the solenoid valve (13). The oil supplied to the Pp1 port is led to the tank passage through the pilot passages provided to the service spool and through the pilot passages provided to the right and left travel spools.

(2) Main Circuit

22-6

1) Variable Pump Circuit The delivered oil from A1 and A2 ports on variable pump enters into P1 and P2 ports on control valve (2) respectively. All the discharged oil from these two ports finally returns to the hydraulic oil tank (24), through each valve of travel left, boom and bucket for the P1 oil, and through each valve of travel right, swing, service and arm for the P2 oil. 2) Third Pump Circuit The oil delivered from A3 port on 3rd pump enters into P3 port on control valve (2). The whole amount of oil discharged through the port P3 returns to the hydraulic oil tank (24) through the selector valves for the dozer and slewing and the independent travel and flow conflux valves.

22. HYDRAULIC SYSTEM 22.3.3

spool moves to the neutral position with the spring force. As the results, the passage in return oil side is throttled, and the motor speed is suppressed by a back-pressure, then the motor is controlled to the speed corresponding to the supplied oil volume of the pump.

TRAVEL OPERATING CIRCUIT (Refer to Fig. 71-5)

Pilot oil hydraulic system with operating lever 22.3.3.1

2nd Speed Operating Circuit (Independent-forward travel)

(1) Pilot Circuit 1) Shifting signal for 2nd speed travel When the "Rabbit and Turtle" mark (at the power cut-off, it automatically takes back for 1st speed) on the nob of travel right lever is pushed down, it actuates the 1st and 2nd speed travel shifting valve of solenoid valve (13). The pressurized oil signal for 2nd speed is generated from the A1 port of solenoid valve(13), and led to the P port on travel motor (4) through swivel joint (10), and shifts the 2-speed shifting valve (404). 2) Changing travel valve spool The pilot secondary pressure is generated from pilot valve (12) by the operation for travel forward. The pressurized oil is led to the Pb7 and Pb6 ports on control valve (2) to shift the travel valve spool. (2) Main Circuit 1) Circuit up to Travel Motor (4) The delivered oil from A1 and A2 ports on variable pump enters into the P1 and P2 ports of control valve (2), and led to the B7 and B6 ports through the travel valve. Then it is led to the A and B ports on left and right travel motors respectively through the swivel joint (10). 2) Travel Motor a. The pressurized oil supplied to the travel motor shifts the spool of the counterbalance valve (brake valve) (408), releases the parking brake (403), opens the hydraulic circuit having closed by the check valve (407) and rotates the travel motor. It actuates the speed shifting valve (404) when the 2nd speed signal is sent. The high pressure oil pumped through the shuttle valve (406) passes the speed change valve (404), actuates the 2-speed shifting piston (401) and provides the motor with high speed and low torque. b. When the motor reaches near to a self-running condition (over-running) at going down a slope and so on, the oil pressure of supply side gets down to lower pressure, and the counter balance valve [brake valve] (408)

22-7

c. The counterbalance valve spool is so designed that it is gradually shifted by a throttle effect to stop or start the motor absorbing shock at the start and stop of the machine. d. When load increases during high speed travel, the speed automatically shifts to the 1st speed, resulting in low speed and high torque.

22. HYDRAULIC SYSTEM 22.3.4

22.3.5

SLEW OPERATING CIRCUIT

BUCKET OPERATING CIRCUIT

(Refer to Fig. 71-6)

(Refer to Fig. 71-7)

Pilot oil hydraulic system with operating lever

Pilot oil hydraulic system with operating lever

22.3.4.1

22.3.5.1

Slew (left) Operating Circuit

Bucket Digging Operation Circuit

(1) Pilot Circuit

(1) Pilot Circuit

1) Bucket Spool Shifting When the operating lever is put at bucket digging position, the pilot secondary pressure oil is generated from the pilot valve (11). The pressurized oil entered into the Pb9 port on control valve (2) shifts the bucket valve spool.

1) Slew Valve Spool Shifting With operation for slew (left), the pilot secondary pressure oil is generated from the pilot valve (11), and led to the Pb2 port of control valve (2) to shift the slew valve spool. 2) Releasing Parking Brake The pilot primary pressure is always led to PB port on the timer valve (303). With the slew operation, the operating pilot secondary pressure is led to PP port on the timer valve (303) through the shuttle valve (14) to shift the spool. It leads the pilot primary pressure 3.5 MPa (508 psi) to the parking brake to release it. (Similarly, the arm in operation releases the slew brake.) 3) Activating Parking Brake When the slew operating lever is returned to neutral position to stop slewing, the pilot secondary pressure disappears causing to shift the timer valve (303), then the pressurized oil is shut down. The oil in the brake cylinder is discharged due to spring force, and drained through the throttle in the timer valve (303). Thus the braking is activated with some time lag for 2.5 to 5.0 seconds to smoothly absorb the slewing inertia at its stop of motion.

(2) Main Circuit 1) Supply Circuit for Cylinder (7) The oil delivered from A1 port on variable pump of pump assembly (1) enters into P1 port on control valve (2). The pressurized oil from B9 port through bucket valve is supplied to the head side of bucket cylinder (7) to activate the digging work. The return oil from the rod side of cylinder (7) enters into A9 port on control valve (2) and returns into the tank through bucket valve. 22.3.5.2

Bucket Dumping Operating Circuit

(1) Pilot Circuit 1) Bucket Spool Shifting When the operating lever is moved to bucket dumping position, the pilot secondary pressure oil is supplied from pilot valve (11), and enters into Pa9 port on control valve (2) to shift the bucket valve spool. (2) Main Circuit

(2) Main Circuit 1) Supply Circuit for Slewing Motor (3) The oil delivered from the A3 port on hydraulic oil pump (1) is supplied to the B port on slewing motor (3) through the P3 port on control valve (2) and slew valve to drive the slewing motor. 2) Slewing Motor (3) a. The relief valve (304) relieves rapidly increased pressure at start and stop of the machine to ease shock. b. The make-up valve (check valve) (305) has a function to replenish oil from the return oil circuit that is led to the tank [T2 port on control valve (2)] to the slewing motor, to prevent the slewing motor from the cavitation due to negative pressure generated in it because of inertia on the slewing mass.

22-8

1) Supply Circuit for Cylinder (7) Similar to the case for bucket digging, the pressurized oil delivered from A1 port on variable pump enters into P1 port on control valve (2). The oil supplied from A9 port through bucket valve is entered into the rod side of bucket cylinder (7) to activate the bucket dumping.

22. HYDRAULIC SYSTEM 22.3.6

22.3.7

BOOM OPERATING CIRCUIT

(Refer to Fig. 71-9)

(Refer to Fig. 71-8)

Pilot oil system with operating lever With oil flow conflux function for the third pump.

Pilot oil hydraulic system with operating lever 22.3.6.1

Boom UP Operating Circuit

22.3.7.1

(1) Pilot Circuit 1) Boom Spool Shifting When the operating lever is put at boom up position, the pilot secondary pressure oil is generated from pilot valve (11). The pressurized oil entered into Pa8 port on control valve (2) shifts the boom valve spool.

Arm In Operating Circuit

(1) Pilot Circuit 1) Shift for Arm Spool At the arm in operation, the pilot secondary pressure generated from the pilot valve (11) is led to the Pa3 port on control valve (2) to shift the arm valve spool. Furthermore, the pilot secondary pressure acts to the PP port on timer valve (303) through the shuttle valve (15) to release the parking brake. Since the spool of the arm valve shifts to close the pilot passage, the pressure of pilot oil thru the Pp1 port equals to the supply pressure. Thus the pressure overcomes the spring forces of the independent travel and flow conflux valves to shift the valve spool.

(2) Main Circuit 1) Supply Circuit for Cylinder (5) The oil delivered from A1 port on variable pump of pump assy (1) enters into P1 port on control valve (2). The oil supplied from B8 port through boom valve and lock valve is entered into the head side of boom cylinder (5) to up the boom. 22.3.6.2

ARM OPERATING CIRCUIT

Boom Down Operating Circuit

(2) Main Circuit

(1) Pilot Circuit

1) Supply Circuit for Cylinder (6) The oil delivered from the A2 port on variable pump enters into P2 port on control valve (2). The pressurized oil from the P3 port joins with the oil from the P2 port through the independent travel and flow conflux valves. The joined oil flows out from the A3 port through the arm valve and is supplied to the head side of the arm cylinder (6) to perform arm in work.

1) Boom Spool Shifting When the operating lever is put at boom down position, the pilot secondary pressure oil is generated from pilot valve (11), and enters into Pa8 port on control valve (2) to shift the boom valve spool. At the same time, the pilot secondary pressure is led to the boom lock valve (206) to push up the check valve and open the oil path from closed condition.

2) Return Line from Cylinder (6) The return oil from the rod side of arm cylinder enters into the B3 port on control valve (2), and is led to the return line from the T1 port through arm valve, then return to the tank.

(2) Main Circuit 1) Supply Circuit for Cylinder (5) and Return Oil Circuit The pressurized oil delivered from A1 port on variable pump is led to boom valve provided on control valve (2), and supplied to the rod side of boom cylinder (5) to down the boom. The oil returned from the head side of cylinder (5) enters into B8 port on control valve (2), and returns to the tank through the boom lock valve (206) and boom valve. Its flow rate is restricted by the throttle effect in boom valve, accordingly the boom is lowered at a stable speed.

22.3.7.2

Operating Circuit for Arm Out

(1) Pilot Circuit At the operation for arm out, the pilot secondary pressure is generated from the pilot valve (11), and led to the Pb3 port on control valve (2) to shift the arm valve spool. The independent travel and flow conflux valves are actuated as in the excavating operation. (2) Main Circuit

a. Boom lock valve (206) This is of a check valve mechanism to prevent the boom from lowering due to its own weight while the boom valve is being at neutral position.

22-9

As in the case of excavating operation, the oil having flown into the control valve (2) joins with the pressurized oil from P2 and P3, flows out from the B3 port and is supplied to the rod side of the arm cylinder to perform arm out work.

22. HYDRAULIC SYSTEM 22.3.8

22.3.9

SWING OPERATING CIRCUIT

DOZER OPERATING CIRCUIT (Refer to Fig. 71-11)

(Refer to Fig. 71-10) Cable driving system with operating pedal

Pilot oil system with operating lever

22.3.8.1

22.3.9.1

Swing (left) Operating Circuit

Dozer Down Operating Circuit

(1) Dozer Operation

(1) Swing Operation When depress the left side of swing pedal, the swing valve spool in control valve (2) is shifted by the cabling mechanism. Since the pilot oil pressure is not utilized for it is activated regardless to the safety lock lever.

When the operating lever is pushed forward, the pilot secondary pressure is generated from the pilot valve (14) to shift the dozer valve spool through the Pb1 port of the control valve (2). (2) Main Circuit

(2) Main Circuit 1) Supply Circuit for Cylinder (8) The delivered oil from A2 port on variable pump enters into P2 port on control valve (2), and comes out from A5 port through cylinder valve, and is supplied to the head side of cylinder (8) to activate the swing (left). a. At activation of the swing valve spool for both left and right swing motions, a part of appropriate volume of oil is returned to the tank through the P2 bypass circuit due to the throttle effect on the spool. Then supplying volume of oil to the cylinder is restricted to ensure the slow and stable swing motions for both leftward and rightward.

22-10

1) Supply Circuit for Cylinder (9) The oil delivered from A3 port of the hydraulic pump (1) enters into P3 port on control valve (2), and is led to B1 port through dozer valve. The pressurized oil passed through swivel joint (10) is supplied to the head side of dozer cylinder (9) to activate dozer down motion.

22. HYDRAULIC SYSTEM 22.3.10

22.3.11

TRAVEL / DOZER COMBINED OPERATING CIRCUIT

TRAVEL / BOOM COMBINED OPERATING CIRCUIT (Refer to Fig. 71-13)

(Refer to Fig. 71-12) At the combined operation of travel and dozer at the same time, the straight traveling is secured with this function.

At the combined operation of travel and boom at the same time, the straight traveling is secured with this function.

22.3.10.1

22.3.11.1

Travel (1st speed forwarding) /Dozer Down Operating Circuit

(1) Pilot Circuit Both the travel and dozer are operated by the lever using the pilot oil system. The operation of each lever directly shifts the travel valve spool and dozer valve spool in the control valve (2) respectively. (2) Main Circuit The oil delivered from A1 and A2 ports on the variable pump (1) enters into P1 and P2 ports on control valve (2), and each flow of left and right is led to swivel joint (10) and travel motor (4) respectively through each travel valve of left and right. The oil delivered from A3 port on the third pump enters into P3 port on control valve (2), then it is led to the dozer cylinder (9) through dozer valve and swivel joint (10). 1) The dozer is operated by the pressurized oil supplied by the third pump which has no relation with travel circuit. Then there is no variation on the supply volume of pressurized oil for both travel motors of left and right even though the dozer is operated during traveling. Thus the straight traveling is secured. (The slewing is operated in the same way as the dozer.) 2) As the above mentioned, the traveling speed is not changed from the single operation for traveling securing the straight traveling.

Travel (1st speed forward) / Boom Up Operating Circuit

(1) Pilot Circuit The traveling/boom up is of the pilot oil hydraulic system with lever operation. By means of pushing forward of travel operating lever and pulling this side of boom up operating lever, the pilot secondary pressure shifts the travel valve spool and/or boom spool in the control valve (2). Thus the pilot passage of the boom valve is closed to make the pressure of the oil from the Pp1 port equal to the supply pressure. Therefore the hydraulic pressure overcomes the spring force of the independent travel and flow conflux valves to shift the valve spool. (2) Main Circuit The oil delivered from A1 and A2 ports on the variable pump enters into P1 and P2 ports on the control valve (2). The whole amount of oil from the P1 and P2 ports is supplied to the travel motor in the same way as operating the independent travel. The oil flows from the travel valve through the B7 and B6 ports and the swivel joint (10) to the right and left travel motor (4). The oil delivered from the port A3 of the hydraulic pump (1) is supplied to the boom cylinder. The oil through the P3 port of the control valve (2) flows through the dozer and slewing valves and through the shifted independent travel and flow conflux valves to the boom valve. The oil from the B8 port through the boom and block valves is supplied to the head side of the boom cylinder (5). 1) When the travel and other attachments (boom, arm, bucket, swing, and service (for N & B) are operated in combination, the independent travel and flow conflux valves are actuated. Thus the attachments are actuated only by oil supplied from the P3 port. Therefore the oil of the P1 and P2 ports is utilized only by the travel to secure stable travel in the combined operation.

22-11

22. HYDRAULIC SYSTEM

[MEMO]

22-12

23. ELECTRICAL SYSTEM TABLE OF CONTENTS 23.1 HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION ......... 23-3 23.1.1 ELECTRIC CIRCUIT DIAGRAM .............................................................. 23-3 23.1.2 HARNESS CONNECTION ....................................................................... 23-3 23.2 ELECTRICAL EQUIPMENT & HARNESS ...................................................... 23-4 23.2.1 ELECTRICAL EQUIPMENT LIST ............................................................ 23-4 23.2.2 HARNESS & CABLE LIST ....................................................................... 23-6 23.2.3 ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS .......... 23-8

23. ELECTRICAL SYSTEM

23-1

23. ELECTRICAL SYSTEM

23-2

23. ELECTRICAL SYSTEM

23.1

HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION

23.1.1

ELECTRIC CIRCUIT DIAGRAM

NOTE: For the electric circuit diagram, refer to Fig. 71–13 of Supporting Data that is provided at the end of this shop manual. (1) In the diagram, the number, size and color of wires are shown on the wiring line. The size of the wire is to be 0.75 sq (square mm = mm2) unless otherwise specified. Symbol B G L

Color BLACK GREEN BLUE

Symbol O Br Lg

Color ORANGE BROWN LIGHT GREEN

R

RED

Gr

GRAY

W Y

WHITE YELLOW

Sb V

SKY BLUE VIOLET

P

PINK

23.1.2

Example: 6 2 R 1 2 3

1. Wire color red 2. Wire size 2 sq (mm2) 3. Wire N. 6

HARNESS CONNECTION

(1) Indication for Connector 1

5

3

4 2

1) The figure for the connector pin arrangement is shown by putting the lock (1) (nail) to upper portion, and looking from the fitting face. 2) The numbers in the connector show the wire No. (3), and alphabetical letters show the wire color (2). 3) On the side face of connector, the connector name (4) and serial number of the connector No. (5) are indicated. 4) At the place indicated as "DOUBLE SPLICE", Two wires are connected to one place. (2) The connector is to be connected with engaging the male (M) and female (F) connectors of the same number. Example: CN-101M and CN-101F Where: M means for Male, and F for Female. (3)

mark means the connector with diode. The direction for diode is shown by the arrow.

(4) The AVSS wires are to be used for the size between 0.75 sq and 2 sq. AVS wires between 3 sq and 5 sq and others are AV wires, unless otherwise specified. (5) The wire size is 0.75 sq, unless otherwise specified. (6) The treatment for the harness end is to be as follows: 1)

: After roughly applying harness taping, wires are installed in a corrugated tube.

2)

: Harness taping by two plies.

3)

: No harness treatment for connection.

(7) The length for the above (6)-3) is to be 30 ± 10 mm. (1.2 ± 0.4 in), and the length includes in the total length of wire shown in the diagram.

23-3

23. ELECTRICAL SYSTEM

23.2

ELECTRICAL EQUIPMENT & HARNESS

23.2.1

ELECTRICAL EQUIPMENT LIST

Refer to Fig. 71–13 Group

Diode

Electrical Fittings

Light

Motor

Relay

Code D-1 D-2 D-3 D-4 D-12 D-13 D-14 E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-10 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-20 E-26 L-1 L-2 L-5 M-1 M-2 M-3 M-4 M-6 R-1 R-2 R-3 R-6 R-7 R-8 R-9 R-10 R-11 R-13 R-14 R-22 R-23 R-24 R-25

Part Name DIODE DIODE DIODE DIODE DIODE DIODE DIODE FUSE BOX GENERATOR (ALTERNATOR) HORN FUSIBLE LINK (45A) GAUGE CLUSTER POWER SOCKET AIR HEATER RADIO (OPT) HEATER (OPT) BATTERY SEQUENCE BOX FUSE BOX FOR COOLER (OPT) COOLING UNIT CONDENSER MOTOR COMPRESSOR TRAVEL ALARM HOUR METER ROOM LAMP BOOM WORKING LIGHT CAB / CANOPY WORKING LIGHT STARTER MOTOR WIPER MOTOR (CAB) WASHER MOTOR (CAB) DECELERATION MOTOR FUEL PUMP BATTERY RELAY SAFETY RELAY DECELERATION RELAY TIMER UNIT E/G STOP RELAY CHARGE INDICATOR RELAY CAB / CANOPY WORKING LIGHT RELAY CONDENSER SPEED SHIFT RELAY CONDENSER RELAY COOLER RELAY SLEW / SWING SELECT RELAY SW. SELECT RELAY SLEW / SWING PRESERVATION RELAY NIBBLER OPEN RELAY NIBBLER CLOSE RELAY

23-4

23. ELECTRICAL SYSTEM Group Sensor

Solenoid

Switch

Code SE-1 SE-2 SE-5 SV-1 SV-2 SV-3 SV-5 SV-9 SV-10 SV-12 SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-9 SW-10 SW-11 SW-14 SW-15 SW-16 SW-23 SW-24 SW-25 SW-26 SW-27 SW-28 SW-30 SW-31 SW-33 SW-34

Part Name FUEL SENSOR ENGINE THERMO SENSOR ENGINE WATER TEMPERATURE LEVER LOCK SOL. 2-SPEED SELECT SOL. E/G STOP SOL. POWER SHIFT SOL. (Cooler Spec) NIBBLER OPEN SOL. NIBBLER CLOSE SOL. SLEW/SWING SELECT SOL. KEY SWITCH WORKING LIGHT SW. 2-SPEED SELECT SW. WIPER WASHER SW. E/G COOLANT TEMP. SW. E/G OIL PRESSURE SW. HORN SW. LEVER LOCK SW. HEATER SW. (OPT) DECELERATION SW. AIR FILTER RESTRICTION SW. (NA) HI, LOW PRESS SW. CONDENSER SPEED SHIFT SW. TRAVEL ALARM SELECT SW. (OPT) TRAVEL RIGHT (FORWARD) PRESSURE SW. (OPT) TRAVEL RIGHT (REVERSE) PRESSURE SW. (OPT) TRAVEL LEFT (FORWARD) PRESSURE SW. (OPT) TRAVEL LEFT (REVERSE) PRESSURE SW. (OPT) SLEW/SWING SELECT SW. SLEW/SWING LEVER PRESS. SW. (LEFT) SLEW/SWING LEVER PRESS. SW. (RIGHT) NIBBLER OPEN SW. NIBBLER CLOSE SW.

NOTE: The part number may be changed owing to modification, use them only for reference.

23-5

23. ELECTRICAL SYSTEM 23.2.2 Code H-1 H-3 H-4 H-5 H-6 H-7 H-8 H-9 H-10 H-11

HARNESS & CABLE LIST Name Inst Main Harness Engine Harness Starter Cable (+) Battery Ground Cable (–) Engine Ground Cable Boom Harness Key Switch Harness Canopy Work Light Harness Boom Work Light Extension Harness Connection Harness with Cab

Remarks

(OPT.)

NOTE: The part number may be changed owing to modification, use them only for reference.

23-6

23. ELECTRICAL SYSTEM

This page is blank because of editing convenience.

23-7

23. ELECTRICAL SYSTEM 23.2.3 23.2.3.1

ARRANGEMENT DRAWING FOR COMPONENTS & HARNESS Upper Frame Portion

1

3

6 4

Fig. 23-1 Upper Frame Portion (1/8)

23-8

23. ELECTRICAL SYSTEM

8 2 9

10 2

11

5

12

13

14 15

16

2

7

14 17

20

18

16 19

Fig. 23-2 Upper Frame Portion (2/8)

23-9

23. ELECTRICAL SYSTEM 1. To canopy light

11. Relay assy

2. Clip

12. Connect with fuel sensor

3. Tighten after checking no paint Tightening torque 10.7 N·m (7.9 lbf·ft)

13. Fix white taping part. Clip

4. To boom

15. Connect with two-speed select sw.

5. Clip. Fix option connector 6. Fix with ring terminal gnd. connector

16. Capscrew tighten after checking no paint Tightening torque 46.1 N·m (34.0 lbf·ft)

7. Starter cable

17. B (-)

8. Main harness and eng. harness are connected by the machine center side so that a tube may not hit a bared part

18. PB (+)

14. Fix white taping part

19. Battery ground cable 20. Capscrew tightening torque 23.5 N·m (17.3 lbf·ft)

9. Connection with a heater relay harness 10. Tightening torque 23.5 N·m (17.3 lbf·ft)

23-10

23. ELECTRICAL SYSTEM

This page is blank because of editing convenience.

23-11

23. ELECTRICAL SYSTEM

1

2

E-26 3

11 A

10

9

4

5

8 6 7

Fig. 23-3 Upper Frame Portion (3/8) 1. Clip Fix white taping part Tightening torque 46.1 N·m (34.0 lbf·ft)

6. Clip. Harness is fixed to a plate using a hole of dozer pilot cover

2. Tightening torque 7.4~9.8 N·m (5.5~7.2 lbf·ft)

8. Fixed so that branch may become downward

3. Clip Fix white taping part Tightening torque 46.1 N·m (34.0 lbf·ft)

9. Fixed so that it may be attached to a wall.

4. Clip fusiblelink to connector

7. Fix white taping part

10. Fix white taping part 11. Tightening torque 9.6 N·m (7.08 lbf·ft)

5. Attachment of slit downward

23-12

23. ELECTRICAL SYSTEM M-1

10

11 SW-7

12 SW-11

19

SW-1

13

SW-4 SW-10 SW-2

14 15

B 20

16 18 17

15

10. To boom

15

Fig. 23-4 Upper Frame Portion (4/8) 15. Clip.

11. Connect with lever lock sw.

16. Clip. Fix white taping part.

12. Clip. After fixing harness of lever lock sw. and horn sw. it is fixed using a hole.

17. In decelles. Itt is bundles and fixec.

13. Through the slit.

18. It is installed so that slit of a grommet may be suitable in front.

14. Connect with lever lock sw.

19. Cluster gauge 20. Clip. Fix white taping part.

23-13

23. ELECTRICAL SYSTEM 3

M-4

1

2

M-6

4

5 6 7

Fig. 23-5 Upper Frame Portion (5/8) 1. Air cleaner 2. It depends perpendicularly and connects at 45 degrees. Tightening torque 3.4~4.9 N·m (2.5~3.6 lbf·ft) 3. Fix connector to plate

4. Tighten after checking no paint. Tightening torque 46.1 N·m (34.0 lbf·ft) 5. Eng. ground cable 6. Clip. Tichtening torque 23.5 N·m (17.3 lbf·ft) 7. Eng. harness

23-14

23. ELECTRICAL SYSTEM 8 9

10

11

12

13

Fig. 23-6 Upper Frame Portion (6/8) 8. To canopy light

11. Fix white taping

9. WG (+)

12. White taping is fixed to upp frame

10. P (-)

13. Clip. White taping part fixes to the joint of T port of a solenoid valve

23-15

23. ELECTRICAL SYSTEM

1

3

2

4

5 6

9 7

8

Fig. 23-7 Upper Frame Portion (7/8) 1. Connect with boom light harness

6. Breather tank

2. Clip

7. Connect main harness to cab harness

3. Inst¡Main harness (Vender connection)

8. Harness is fixed so that a plate may not be straddled

4. A white taping part is on a hose clamp.

9. Let hose&tube of breather tank back pass

5. It fixes so that harness may not swell to a breather tank side

23-16

23. ELECTRICAL SYSTEM 10 1

2 11

12

14 13 E-1

15

18 16

19

17

20

Fig. 23-8 Upper Frame Portion (8/8) 1. Connect with boom light harness

14. Fixed to seatstand clip.

2. Clip

15. Eng. harness

10. Clip. Boom light harness is fixed to boom hose.

16. Harness is fixed to a plate using a hole of dozer pilot cover.

11. It is the 230 mm (9.06�) thing done for clamp of the white taping part by the way from a boom hose mouthpiece part. 12. White taping part is fixed to the hose for boom cylinders.

17. Fusible link 18. Eng. harness 19. Fix white taping part. 20. Connect with main harness

13. Clip. Fix in 100 mm (3.94�) pitch.

23-17

23. ELECTRICAL SYSTEM 23.2.3.2

Engine Portion E-4 1

2

H-3

H-3

H-4

A

E-14 SE-5 E-2

3

M-1

4

5

H-3

6 H-4

Fig. 23-9 Engine Portion (1/2) 1. Clip. Fasten with a bolt for lifting lug. 4. Clip. Fix white taping part. 2. Clip. Fix white taping part.

5. Connect with main harness

3. Fasten with a bolt for starter motor. Tightening torque 1.7 ~ 2.4 N·m (1.3 ~ 1.8 lbf·ft)

6. Clip. Fix white taping part.

23-18

23. ELECTRICAL SYSTEM SE-2 8

7

10

9

B SV-3

E-4

10

10 SW-6

11 M-6

12

13 H-6

14

Fig. 23-10 Engine Portion (2/2) 7. Fix white taping part.

11. Fix white taping part.

8. Connect with main harness

12. Clip. Fix white taping part.

9. Fix the eyelet terminal to the side. Tightening torque 5.9 ~ 9.8 N·m (4.35 ~ 7.23 lbf·ft)

13. Clip. Fix white taping part. 14. Capscrew

10. Clip

23-19

23. ELECTRICAL SYSTEM 23.2.3.3

Relay Unit Portion

1. To decel. To air heater

1

2. To horn sw. lever lock sw.

2

3. Clip 4. To cab harness 5. Relay assy 6. Clip. It attaches so that the cut portion of clip may not be from the plate side.

3

4

R-2 R-6

R-1 R-7

R-6 E-14

R-3

R-8

6

5

Fig. 23-11 Relay Unit Portion (1/2)

23-20

23. ELECTRICAL SYSTEM

R-2

R-6 E-14

R-8

H-1 R-3 CN-32M

CN-61F CN-60F

Fig. 23-12 Relay Unit Portion (2/2)

23-21

23. ELECTRICAL SYSTEM 23.2.3.4

Fuel Tank Portion 2 SE-1

1

3

1

1

1

1 1

Fig. 23-13 Fuel Tank Portion (1/2) 1. Capscrew. Tightening torque 11.0 N路m (8.11 lbf路ft)

3.

2. Fuel sensor. Tightening torque 2.94 N路m (2.17 lbf路ft)

23-22

Fuel tank

23. ELECTRICAL SYSTEM

5 6 4

7

M-6

Fig. 23-14 Fuel Tank Portion (2/2) 4. Fuel filter

6. Inlet

5. Return

7. Water separator

23-23

23. ELECTRICAL SYSTEM 23.2.3.5

Work Light Portion

(1) Boom Work Light 2 1

H-7

3

L-2

4

5

6

7 8 9

11

10

1. Clip. White taping part is fixed on outside of the bar

7. To working light

2. Through to the hole 3. Connect with main harness

8. The electric wire by the side of work light is slacked so that water may not enter.

4. Lets harness pass so that a white taping part may come to a hose stop clamp.

9. Clip. A terminal is fixed to the hole of a bracket after clipping to the main line as this figure.

5. Clip. Harness is fixed of insulock under the tube.

10. Eyelet terminal to be binded to bolt.

6. Eyelet terminal to be binded to bolt.

11. Clip. Harness is bundled and it clips in the hole of a bracket.

23-24

23. ELECTRICAL SYSTEM (2) Cab / Canopy Work Light H-9

12

13

14

15

16

12. It is the sake of a temporary stop at the time of delivery. Tightening torque 7.0 ~ 8.0 N路m (5.16 ~ 5.91 lbf路ft)

15. To connect harness of upp frame side. 16. Fix to the welding clip.

13. It is the inside of the pillar of a canopy pass. 14. Cab / Canopy working light. Tightening torque 16.7 ~ 21.6 N路m (12.3 ~ 15.9 lbf路ft)

23-25

23. ELECTRICAL SYSTEM 23.2.3.6

Cab Portion (OPT)

1 2

H-11

3

4

B

M-3

Fig. 23-15 Cab Portion (OPT) (1/2) 1. Connects white cab harness.

3. Capscrew. Fix a terminal for ground.

2. Fix with plate.

4. Connects white light harness.

23-26

23. ELECTRICAL SYSTEM

A

5

A

B

Fig. 23-16 Cab Portion (OPT) (2/2) 5. Clip 6. Switch. Connect to connector of inst-main harness with “wiper” tag

NOTE: Tightening torque. Threads size tightening torque M8 23.5 N·m (17.3 lbf·ft)

23-27

6

23. ELECTRICAL SYSTEM

[MEMO]

23-28

24. COMPONENTS SYSTEM TABLE OF CONTENTS 24.1 HYDRAULIC COMPONENTS ......................................................................... 24-3 24.1.1 HYDRAULIC PUMP .................................................................................. 24-3 24.1.2 PILOT VALVE (ATT) ............................................................................... 24-14 24.1.3 2PILOT VALVE (TRAVEL) ...................................................................... 24-18 24.1.4 CONTROL VALVE .................................................................................. 24-24 24.1.5 SLEWING MOTOR .................................................................................. 24-42 24.1.6 TRAVEL MOTOR .................................................................................... 24-49 24.1.7 SWIVEL JOINT ........................................................................................ 24-60 24.1.8 CYLINDER .............................................................................................. 24-62 24.2 ELECTRICAL EQUIPMENT .......................................................................... 24-70 24.2.1 ELECTRICAL EQUIPMENT LIST ........................................................... 24-70 24.2.2 SPECIFICATIONS ELECTRICAL EQUIPMENT ......................................24-72

24. COMPONENTS SYSTEM

24-1

24. COMPONENTS SYSTEM

24-2

24. COMPONENTS SYSTEM

24.1

HYDRAULIC COMPONENTS

24.1.1

HYDRAULIC PUMP

24.1.1.1 SUMMARY 1. GENERAL VIEW A2 A1

R1

A1

A3

A2

A3 æ ]

ß

A4 S1

R1

A1 A2

A4

A3

S1 S1 No.

Ports Name

Size

S1

Suction port

SAE 11/2

A1, A2

Delivery port

PF 1/2

A3

Delivery port

PF 1/2

A4

Pilot delivery port

PF 3/8

R1

Air bleed port (with breather valve)

M10X1.0

Fig. 24-1 General view of hydraulic pump

24-3

24. COMPONENTS SYSTEM 2. SPECIFICATIONS Model (Type) Piston pump P1 + P2

Gear pump P3

Trochoid pump P4

23.0 (3340)

20.0 (2900)

3.5 (508)

cc/rev (cu•in/rev)

23.8 (1.45) × 2

14.1 (0.86)

5.1 (0.31)

L/min (gal/min)

57.1 (15.1) × 2

33.8 (8.93)

12.2 (3.22)

Item Working pressure Displacement Delivery flow

MPa (psi)

Control system Rated revolution Weight

AP2D18LV3RS7

Total power shift control by tilting angle (power shift) min (rpm)

2400

-1

kg (lb)

35.0 (77.2)

24-4

24. COMPONENTS SYSTEM 24.1.1.2 CONSTRUCTION • FUNCTION

No.

NAME

No.

No.

1

Shaft assy

6

Piston assy

2

Swash plate assy

7

Gear pump assy

3

Rotary group

8

Housing assy

4

Cover assy

9

Trochoid pump assy

5

Spring assy Fig. 24-2

1. Piston pump • This pump is a variable displacement double piston pump which delivers two equal flows with one cylinder block., and has only one inlet port, but the flow is separated into two flows by the control plate on the cover and is led to two delivery ports provided on the cover. • The hydraulic pressure produced by the delivery oil acts on the hanger, resists the spring force, and tilts the hanger. As the piston stroke is changed by the tilting of the hanger, the flow rate varies. • The 3rd pump or pilot pump is installed on the same shaft with a coupling.

24-5

24. COMPONENTS SYSTEM 2. Operation • Pump operation Displacement q (cm3) q=ΠXd2/4XtanαXDXZ/2X10-3 s (Stroke) (Number of piston)

1 12

2 3

4 5

13 11

9 10

8 7 6

1. 2. 3. 4. 5. 6. 7.

Piston Bottom dead point Cylinder block Control plate Suction port In side P2 Out side P1

8. 9. 10. 11. 12. 13.

Delivery port Suction stroke Delivery stroke Top dead point Hanger (Sliding surface) Hanger bearing

a. The cylinder block is fitted on the spline and rotates with the drive shaft. b. The piston fitted on the cylinder block follows the sliding surface of the hanger and moves to and from c. The piston moves to increase the capacity from the bottom dead point to the top dead point, the pressure oil flows from the inlet port into cylinder block through the control plate. (Suction stroke 9) d. But as the piston moves to decrease the capacity from the top dead point to the bottom dead point, the pressure oil is sent out to the delivery port. (Delivery stroke 10) e. By changing the tilting angle of the hanger (sliding surface), the displacement varies. f. The oil sucked from the inside port of the cylinder block is delivered from the delivery port inside of the control plate. g. The oil sucked from the outside port of the cylinder block is delivered from the delivery port outside of the control plate.

24-6

24. COMPONENTS SYSTEM • Control

13

14

17

15

16

15 S

13. Spring A 14. Hanger 15. Piston 16. Piston for P3 shift 17. Spring B

ÂŚPI.Total pressure ÂŚP

Q. Flow rate S. Shift control line

a. The delivery pressure P1 and P2 are directed to the piston which slides on the hanger and acts on the hanger. b. The spring is provided to act against the delivery pressure. c. When the oil pressure vie piston acting on the hanger exceeds the installation load of the spring, the hanger is fixed to the maximum tilting position. d. When the oil pressure via piston acting on the hanger exceeds the installation load of the spring, the hanger is tilted and kept tilted at a position where the oil pressure is balanced with the spring forces. (Region A in above figure) e. When the oil pressure acting on the piston rises further to reduce the tilting angle, the spring B which has been inactive up to now becomes active. f. To overcome the spring force of two springs, the oil pressure must be higher and the shifting line becomes more steep. (Regions A + B in the middle of the figure above) g. When the P3 oil pressure acts on the shift piston, the control shifting line is shifted.

24-7

24. COMPONENTS SYSTEM • Adjusting procedure of set torque 18

17

19

21

24 22

20

23 22

21

17. 18. 19. 20. 21.

Spring seat Cover Adjusting screw Spring guide Tighten

Q

22. Loosen 23. Hexagon nut 24. Starting pressure of tilting ÂŚP. Total pressure Q. Flow rate

a. Adjusting procedure 1. Loosen the hexagon nut. 2. Set the power line by tightening or loosening the adjusting screw.

24-8

24. COMPONENTS SYSTEM 24.1.1.3 INNER CONSTRUCTION Refer to Fig. 24-2 regarding the whole pump 1. Drive shaft

1

2 8 10 9 6

No.

NAME

3

7

11

Q’TY

No.

NAME

Q’TY

1

Shaft

1

8

Oil seal

1

2

Seal case

1

9

O-ring

1

3

Bearing

1

10

Snap ring

1

6

Snap ring (for Shaft)

1

11

Key

1

7

Snap ring (for Shaft)

1

2. Swash plate (Hanger)

1 2 5 6 3 4

No.

NAME

Q’TY

No.

NAME

Q’TY

1

Hanger

1

4

Bearing

2

2

Plate

1

5

Capscrew

4

3

Distance piece

1

6

O-ring

1

24-9

24. COMPONENTS SYSTEM 3. Rotary group

1

8

2

7

9

5

6

10

4

No.

NAME

Q’TY

No.

NAME

Q’TY

1

Piston

10

7

Spring

1

2

Cylinder block

1

8

Parallel pin

3

4

Retainer

1

9

Spring seat

2

5

Plate

1

10

Snap ring (for hole)

1

6

Guide

1

4. Control spring

1

No.

NAME

6

5

34, 44, 54, 64 2 7 9 4

Q’TY

No.

3

8

NAME

Q’TY

1

Spring seat

1

8

Capscrew

2

2

Spring seat

1

9

Nut

1

3

Cover

1

10

Spring

1

4

Setscrew

1

34

Shim

2

5

Spring

1

44

Shim

2

6

Spring

1

54

Shim

2

7

O-ring

1

64

Shim

2

24-10

24. COMPONENTS SYSTEM 5. Cover

4

X

3 10

2 Z Z 7

4

17

16

X

X-X

13

1

5

6

9 7

11

9 7 Z-Z

16 Y

9 11

Y

16

Y-Y

No.

NAME

Q’TY

No.

NAME

Q’TY

1

Cover

1

9

Orifice

3

2

Control plate

1

10

Bearing

1

3

Parallel pin

2

11

Plug assembly

2

4

Capscrew

3

13

Capscrew

1

5

O-ring

1

16

Plug: M8

2

6

O-ring

4

17

Plug: M5

1

7

Plug: M6

4

24-11

24. COMPONENTS SYSTEM 6. Gear pump

No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

3

Housing

1

10

Plate

2

16 Square ring

1

4

Cover

1

11

Guide

2

17 Square ring

2

5

Gear

1

12

Coupling

1

18 O-ring (1B P6)

1

6

Gear

1

14

O-ring

2

19 Capscrew (M12×25)

6

7

Side plate assy

2

15

O-ring

1

24-12

24. COMPONENTS SYSTEM 7. Housing

1

3

6

8

2

7

5

X

7

5 X

4 No.

NAME

9 Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

1

Cylinder

1

4

Parallel pin

1

7

Disk spring

3

2

Piston

1

5

Spring seat

1

8

O-ring

1

3

Piston

2

6

Capscrew

2

9

O-ring

1

8. Trochoid pump

No.

NAME

Q’TY

No.

NAME

Q’TY

1

Gear

1

6

Capscrew

3

2

Casing

1

7

Side plate (B)

1

3

Side plate (A)

1

8

Spring pin

1

4

O-ring

1

9

Plate

1

5

Spring pin

1

24-13

24. COMPONENTS SYSTEM 24.1.2

PILOT VALVE (ATT)

24.1.2.1 SUMMARY 1. General view 2 3 1 (3)

2 (4)

T

P

T

1

A 4 I

I OT

1 (3)

psi

lbf·ft

MPa

580

2.95

497 435

2.2

SP

300 22 290

1.48 1.35

0.74

145 78

0.69

0

0 mm

SP

PR 0

10

5

2 (4)

psi

580

15

19

OT deg.

OT

lbf·ft 2.95

MPa

497

OT

435

2.2

300 22 290

1.75

1.48 1.39

0.74

145 78

0.69

SP

0

0 mm

SP

PR 0

5

10

15

20

OA

24-14

OT

25 deg.

24. COMPONENTS SYSTEM A. The adjust nut (opposing flats: 22): Fix adjust nut by means of spanner (opposing flats: 22) when the lever is installed. Then tighten the mating lock nut to 41 ± 0.3 N⋅m (30 ± 2.2 lbf⋅ft) OA.Operation angle (degree) OT. Operation torque (N⋅m) (lbf⋅ft) PR.Push rod stroke mm SP. Secondary pressure (MPa) (psi) T. Tightening torque: 6-PF1/4 T= 29.4 ± 2.0 N⋅m Max primary pressure

6.9 MPa (1.000 psi)

Rated flow

15 L/min 4.0 (gal/min)

Weight

1.6 kg (3.5 lb)

24-15

24. COMPONENTS SYSTEM 24.1.2.2 CONSTRUCTION 1

2 2

3

2 (4)

1 (3)

Fig. 24-3 Pilot valve-Sectional view 3. Secondary pressure adjusting shims 1. Apply Loctite #277 (part of slant line) 2. Apply grease on top No.

NAME

Q’TY

No.

NAME

Q’TY

No.

NAME

Q’TY

101

Casing

1

213

Seal

4

241–1 Spring

2

151

Plate

1

214

O-ring; 1B P20

4

241–2 Spring

2

201

Spool

4

216–1 Spring seat

2

301

Joint; M14 (1)

1

211

Plug

4

216–2 Spring seat

2

302

Disk

1

212–1 Push rod (2)

2

217

Washer 2 (3)

4

312

Adjusting nut; M14

1

212–2 Push rod (2)

2

221

Spring

4

501

Bellows

1

RIGHT PILOT VALVE PORT No.

OPERATION

1

BUCKET DIGGING

2

BOOM DOWN

3

BUCKET DUMP

4

BOOM UP 1

LEFT PILOT VALVE PORT No. 1

SLEWING LEFT ARM OUT

3

SLEWING RIGHT

4

ARM IN

4 F25782

OPERATION

2

3 2

24-16

24. COMPONENTS SYSTEM 24.1.2.3 OPERATION • Lever in neutral position (See Fig. 24-4) In this case, the force of the secondary pressure setting spring (241) that determines the output pressure of the pilot valve is not transmitted to the spool (201). Accordingly, the spool (201) is pushed up by the return spring (221) and spring seat (216) permitting the output port 2, 4 to connect with the tank port T. This makes the output pressure equal to the tank pressure.

Fig. 24-4 Lever in neutral position • When the Lever is tilted (See Fig. 24-5) When the lever is tilted, the push rod (212) strokes. The spool (201) and spring seat (216) moves downward to make the port P to connect with the port 2, 4. With the result that the oil of the pilot pump flow out to the port 2, 4, to produce a pressure.

Fig. 24-5 When Lever is tilted • The Lever being held (See Fig. 24-6) When the lever is tilted till the pressure of the port 2, 4 rises to an oil pressure corresponding to the set spring force, the hydraulic pressure is balanced with the spring (241) force. And when the pressure of the port 2, 4 rises above a set pressure, the port P are closed and the port T are opened. When the pressure of the port 2, 4 falls below a set pressure, the port P are caused to open and the port T are caused to close, thus holding the second pressure constant.

Fig. 24-6 Lever being held

24-17

24. COMPONENTS SYSTEM 24.1.3

2PILOT VALVE (TRAVEL)

24.1.3.1 SUMMARY 1. General view

1. 4-M8 X P1.25

3. 4-PF1/4

T= 16.7 ± 1.5 N⋅m 2. 2-PF1/4

T= 29.4 ± 2.0 N⋅m

T= 29.4 ± 2.0 N⋅m 2. Specifications ITEM

SPECIFICATIONS

Model (Type)

PVD6P4001

Max. primary pressure

6.9 MPa (1000 psi)

Rated flow

10 L/min (2.6 gal/min)

Weight

3.9 kg (8.6 lb)

24-18

24. COMPONENTS SYSTEM 3. Performance Characteristics • Required operating torque (damper) 12.9 ± 1.9 N⋅m (9.5 ± 1.45 lbf⋅ft). Push rod speed 0.0275 m/ s. (The actual required torque is found by adding the operating torque of the damper in the valve operating torque in the left operating lines)

580

MPa

8.85

OT

7.69

435 340

6.64

21

4.48

4.43

290

4.27 3.58

SP. Secondary pressure (MPa) (psi) OT. Operation torque

145

(N⋅m) (lbf⋅ft) PR.Push rod stroke mm OA.Operation angle (degree)

2.21

SP

78

SP

PR OA

24-19

OT

24. COMPONENTS SYSTEM 24.1.3.2 CONSTRUCTION 472 501

1 1

1

471

413

214 210 202 271 201 212 224

402

414

203

213

336

102

218

225

311 211 252

324 335

217 313 251 261 301 101

Fig. 24-7 Pilot valve-Sectional view 1. Apply grease

Torque No. N•m (lbf•ft)

NAME

Q’TY

101 Casing

1

102 Casing (Damper)

1

201 Cover

2

202 Plug (1)

Torque No. N•m (lbf•ft) 6.9 (5.1)

NAME

Q’TY

252 Plug

2

261 O-ring

3

271 Capscrew

4

4

301 Spool

4

203 Grease cup

4

311 Spring seat

4

210 Packing

4

313 Washer

4

211 O-ring

4

324 Spring

4

212 O-ring

4

335 Spring

4

213 O-ring

2

336 Spring

4

214 Push rod (1)

4

413 Cam shaft

2

217 Shim

4

414 Bushing (1)

4

218 Spring seat

4

420 Cam

2

224 Piston

4

471 Steel ball

4

225 Steel ball

12

472 Set screw

2

29.4 (21.7) 251 RO Plug

3

501 Boots (Bellows)

2

8.8 (6.5)

6.9 (5.1)

24-20

24. COMPONENTS SYSTEM 24.1.3.3 OPERATION 1. Reducing valve • When the lever is at neutral position, (See Fig. 24-8) The spool is pushed up by the return spring (335) through spring seat (311), and is positioned at the neutral position in the right figure. Therefore, the pressure at delivery ports 1 and 2 is equivalent to that of port T because the delivery port is connected to only port T following the switched spool condition. 311

335

1. Port 1 2. Port 2

301

2,4

1,3

Fig. 24-8 • In case where the lever is tilted, (See Fig. 24-9) By rotating cam (420) in clockwise, push rod (214) on the port 1 side is pushed down, and the spool moves down by way of spring seat (311), spring (324) for setting the secondary pressure, shim (217) and washer (313) and consequently the port P is connected to the port 1 and the supplied oil from the pilot pump flows into port 1 and generates pressure. When the pressure at port 1 rises to the pressure equivalent to the spring pressure for the secondary pressure setting set by tilting the control section, the hydraulic pressure applied to the spool balances the spring force, and maintains port 1 at a constant delivery pressure. The spool on the port 2 side is held at neutral position, and the return oil from the control valve is discharged through port T.

A 24-9 B Fig.

A. B.

24-21

Neutral position Full stroke

24. COMPONENTS SYSTEM 2. Dumping mechanism • In case of neutral position, Push rod (214) is pushed up by dumping spring (336) through piston (224), and holds at the position shown in Fig. 24-7. • Where the control section is inclined from the neutral position, By rotating the cam clockwise, the push rod on the port 1 side is pushed down, and the piston also moves down. Then, the oil in the dumping piston chamber is discharged through the orifice, and the simultaneously generated pressure produces dumping force. On the other hand, the push rod on the port 2 side moves up by the dumping spring through the piston. Then, oil is sucked from the tank into the dumping piston chamber through three ball check valves. The oil outside of the piston chamber flows out through the passage leading to port T on the casing top end.

1

3 2

4

4 A

5

2 (4)

1 (3)

Fig. 24-10 Operation when the lever is stroked from the neutral position 1. 2. 3. 4. 5.

Cam Orifice Push rod Piston Steel ball

A. When stroking from the neutral position towards the mark Â&#x;, the oil in the piston chamber on the right (left) side is discharged through the orifice, and the simultaneously generated pressure produces damping force.

24-22

24. COMPONENTS SYSTEM • Where the control section is inclined in the opposite direction from the full tilting After tilting the cam clockwise fully, if it is rotated counterclockwise, the push rod on the port 2 side is pushed down and the piston moves down. Then, the same as above, the oil in the damping piston chamber is discharged through restriction of piston, and the simultaneously generated pressure produces damping force. On the other hand, the push rod on the port 1 side is moved up by the force of the return spring and damping spring. Similarly oil is sucked from the tank into the damping piston chamber through three ball check valves. And the oil in the piston chamber flows out through the passage leading from the casing top end to the tank port. That is, either tilting operation from the neutral position to the full tilting position or the full tilting position to the neutral position is designed to produce the damping force. 7

8

1 3

B

4

6

D

C E

9 F

2 (4)

1 (3)

Fig. 24-11 Operation when the lever is stroked or operated in reverse 1. 3. 4. 6. 7. 8. 9. B.

Cam Push rod Piston Damping spring Neutral position Full stroke Return spring The oil outside of the piston is ows through the passage leading to port T on the casing top end.

D. When tilting in reverse direction from the neutral position, the push rod is pushed up by the force of the damping spring. (In operation in direction) E. Oil in T lines is sucked in the damper chamber through three ball check valves. (In operation in direction)

F. When shifting the lever in revese from direction to

(In operation in direction) C. The oil in the piston chamber is discharged through the restriction, and the simultaneously generated pressure produces the damping force. (In operation in direction)

24-23

( ) condition, the piston on the left side immediately performs the roles of the damper piston. The damping force is produced on both sides constantly.

24. COMPONENTS SYSTEM 24.1.4

CONTROL VALVE

24.1.4.1 GENERAL VIEW AND HYDRAULIC PORTS NO. B G

1

2

Pb1

Pb2

4

5

Pb3

Pb4

H 3

6

8

7

12

10

9

Pb8 Pb6

Pb7

Pb9 Pb8’

Pa1

Pa2

Pa4

Pa6

F 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Pa9

Pa7 Pa8

Pa3

D

A

13

C 12. Bucket 13. Manual operate

Dozer Slewing Supply and independent travel Arm Service Swing Travel right Supply Travel left Boom

A. Pilot port 16-PF1/4 (Pa1~Pa4 - Pa6 - Pa9 Pb1~Pb4 - Pb6 - Pb9) B. Drain port Dr1 PF1/4 C. Tank port T2 PF1/2 D. Pump port P1, P3-P2 3-PF1/2 F. Actuator port 18-PF3/8 (A1~A9 / B1~B9) G. Tank port T1 PF1/2 H. Pp1 PF1/4

24.1.4.2 SPECIFICATIONS Model (Type) Valve operation

BCV365–AQ10

Manual

Swing

Pilot

Travel left, Travel right, Boom, Arm, Bucket Slewing, Dozer, Service, Travel straight and conflux

Flow rate Setting pressure at main relief valve P1, P2, P3

P1, P2 – 57.1 L/min(15.1 gal/min), P3 → 33.8 L/min(8.9 gal/min) P1, P2: 23.0

P3:23.0 Setting pressure at over load relief valve

MPa (3340 psi) at 57.1 L/min (15.1 gal/min) (MR1, MR2)

MPa (2900

psi) at 33.8 L/min (8.9 gal/min) (MR3)

B1, A3, B3, B10 port (OR6, OR4, OR5, OR1) 25.5 at 5 L/min (1.3 gal/min) B8, B9 port (OR3, OR2) 27.5

24-24

MPa (4000

MPa (3700

psi)

psi) at 5 L/min (1.3 gal/min)

24. COMPONENTS SYSTEM 24.1.4.3 CONSTRUCTION 1. Control Valve: Overall composition 15

13

16

15

15

20

19 18

20 12

1

No.

2

3

14

NAME

15

4

5

Q’TY

No.

17

6

7

8

NAME

9

16

Q’TY

10

21

11

No.

NAME

Q’TY

1

Dozer section

1

8

P1, P2 inlet straight

1

15 Over load relief valve

4

2

Slewing section

1

9

Travel (left) section

1

16 Over load relief valve

2

3

P3 inlet, independent travel & conflux section

1

10 Boom section

1

17 Anti cavitation valve

1

4

Arm section

1

11 Boom lock section

1

18 Tie bolt

4

5

Service section

1

12 Bucket section

1

19 Tie bolt

4

6

Swing section

1

13

2

20 Nut

8

7

Travel (right) section

1

14 P3 Main relief valve

P1, P2 Main relief valve supply

24-25

1

24. COMPONENTS SYSTEM 2. Component Parts The control valve is roughly classified into the following four sections. • Manual operation section: Swing • Pilot operation section: Travel right and left, boom, arm, bucket, slewing, independent travel and conflux, dozer blade, service(nibbler & breaker • Accessory section: P1 and P2 inlets, and P3 inlet (common with independent travel and conflux) • Accessory section (valve): P1, P2, P3 main relief, overload relief, anti cavitation, boom lock * For respective operation section, only typical example is described. - Manual operation: Swing (No.6) No.

Name

Q’TY

1

Body

1

2a

Spool

1

2b

O-ring 1A P14.5

1

2c

Dust wiper

1

2d

Oil seat retainer

1

2e

Spring seat

2

2f

Spring

1

2g

Spool end

1

3

O-ring 1A P14.5

1

4

Dust wiper

1

5

Oil seat retainer

1

6

Socket bolt M6 X 12

2

7

Socket bolt M6 X 22

2

8

Cover

1

9

Load check valve

1

10

Spring (for check valve)

1

11

Plug (for check valve)

1

12

O-ring 1B P11

1

13

Plug PF3/8

1

14

O-ring 1B P14

1

15

Anti cavitation valve

1

15

12 11

9 10

14 13

7

8

2g 6

24-26

5

4

3

1

2a

2b 2c 2d 2e 2f

24. COMPONENTS SYSTEM - Pilot operation: Slewing (No.2) No.

Name

Q’TY

1

Body

1

2a

Spool

1

2b

Spring seat

1

2c

Spring

1

2d

Spool end

1

2e

Spring seat

1

3

O-ring AS 1B 119

2

4

Pilot cover “A”

1

5

Pilot cover “B”

1

6

Socket bolt M6 X 45

4

7

Loed check valve

2

8

Spring (for check valve)

1

9

Plug PF3/8

1

10

O-ring 1B P11

1

11

Plug PF3/8

1

12

O-ring 1B P14

1

10 9

7 8

12 11

6

4

6

5

1

2a

3

2b

2c

2d

2e

- Main relief valve (P1, P2, P3) and overload relief valve No.

Name

Q’TY

1

Socket

1

2

Pressure regulating valve

1

3

Piston

1

4

Body

1

5

Poppet

1

6

Adjust screw

1

7

Lock nut M14

1

8

Spring (Adjust valve)

1

9

Spring (Pressure regulating)

1

10

O-ring 1A P7

1

11

Back up ring

1

12

Seat (adjust section)

1

13

O-ring AS 1B 15

1

14

O-ring 1B P10

1

15

O-ring 1B P22

1

16

O-ring 1B S10

1

17

Back up ring

1

17

13

3

1

24-27

11

2

10

14

9

12

15

5

16

8

7

4

6

24. COMPONENTS SYSTEM - Anti cavitation valve No.

Name

Q’TY

1

Anticavitation valve

1

2

Body

1

3

Plug

1

4

Spring

1

5

Back up ring

1

6

O-ring 1A P10A

1

7

O-ring 1B P14

1

8

O-ring 1B P15

1

1

6

5

7

2

4

3

8

- Main relief valve (P3) No.

Name

Q’TY

1

Socket

1

2

Pressure regulating valve

1

3

Piston

1

4

Plug

1

5

Body

1

6

Poppet

1

7

Adjust screw

1

8

Lock nut M14

1

9

Spring (Adjust valve)

1

10

Spring (Pressure regulating)

1

11

O-ring 1B P15

1

12

O-ring 1B S10

1

13

O-ring 1A P7

2

14

Back up ring

2

15

O-ring 1B P14

1

15

14

13

5

11

4

8

7

1

24-28

2

10

3

6

12

9

24. COMPONENTS SYSTEM - Overload relief valve No.

Name

Q’TY

1

Socket

1

2

Pressure regulating valve

1

3

Piston

1

4

Plug

1

5

Body

1

6

Poppet

1

7

Adjust screw

1

8

Lock nut M14

1

9

Spring (Adjust valve)

1

10

Spring (Pressure regulating)

1

11

O-ring 1B P15

1

12

O-ring 1B S10

1

13

O-ring 1A P7

2

14

O-ring 1B P14

2

15

Back up ring

1

16

Spring guide

1

15

14

13

5

11

4

8

7

1

24-29

2

10

3

6

16

12

9

24. COMPONENTS SYSTEM 24.1.4.4 HYDRAULIC CIRCUIT

24-30

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

Dozer spool Swing spool Travel independent and conflux spool Arm spool Service spool Boom swing spool Travel right spool Travel left spool Travel left spool Boom spool Bucket spool P1 (RV1) relief valve P3 (RV3) relief valve B1 Over load relief valve A3 Over load relief valve B3 Over load relief valve

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.

24-31

A8 Over load relief valve B8 Over load relief valve B9 Over load relief valve Boom lock valve Anticavitation valve Over load relief plug P1 by-pass passage P2 by-pass passage P3 by-pass passage P1 parallel passage P2 parallel passage P3 parallel passage Pp1 Pilot passage Tank passage

24. COMPONENTS SYSTEM 24.1.4.5 EXPLANATION OF OPERATION 1. Neutral position P1: The oil delivered from the hydraulic pump flows from the P1 port of the control valve (hereafter called a C/V) into the left travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spool leading from the left travel to the boom because the spool does not cut off the by-pass and flows out to the tank circuit through the by-pass of the spool for the bucket and the by-pass leading to the tank. P2: The oil delivered from the hydraulic pump flows from the P2 port of C/V into the right travel spool section through the passage of the supply section. At the spool neutral position, the entered oil passes through the by-pass of the spools for the right travel, boom swing and service, and flows out to the tank circuit through the by-pass circuit leading from the by-pass of the spool for service. P3: The delivery from the hydraulic pump flows from the (C/V) P3 port into the parallel circuit of swing and dozer operation. Since the spool does not shut off the by-pass passage in the neutral spool condition, the oil having flown into the parallel passage flows out to the tank passage through the by-pass passages of the spools for the dozer and slewing and through the by-pass passage of the P3 supply section.

WARNING As the flow from the pump is fed into each line (P1, P2, P3), the switching sections of respective line shown below are in operable condition. Therefore, don’t operate them except when working. P1 line: Left travel, Boom, Bucket P2 line: Right travel, Boom Swing, Service and Arm P3 line: Dozer, slewing [Service and Arm] Pp1: The delivery oil from the gear pump flows from the (C/V) Pp1 port into the pilot circuit through the orifice provided on P3 supply section. (Two systems for shifting independent travel and for shifting arm and service flow conflux) In the neutral spool condition, the oil of the independent travel shifting side flows out to the tank passage through the passages provided to the right and left travel spool and the swing spool. Therefore the pilot circuit pressure becomes equal to the tank pressure, the received pressure of the independent travel valve is equal to the tank pressure, and consequently the independent travel spool does not switch. Moreover, the oil of the flow conflux shifting side flows out to the tank passage through the passage provided to the service spool. Since the pilot passage pressure equals to the tank pressure and the receiving pressure of the flow conflux piston equals to the tank pressure, the flow conflux spool is not shifted.

WARNING When the engine is stopped (when each hydraulic pump is stopped), the actuator does not function even when being loaded by the self weight, because the pilot pressure does not act on the pilot control spool (except for the condition where the accumulator, etc. is attached and the pressure remains due to the pipe volume). On the spool of boom swing which directly actuates the spool, the port on the loaded side is led to the tank circuit with the operating direction making it unable to hold the load, consequently the actuator may be actuated causing danger. Therefore, even if the engine is stopped, when there are people around the machine or it may be in contact with implements, don’t use the control lever.

24-32

24. COMPONENTS SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 12. B. C.

Fig. 24-12 Operation at neutral position D. Tank passage Dozer E. P3 side. By-pass passage Slewing F. Independent travel - flow conflux spool Supply and independent travel G. From P3 port Arm H. P2 side. By-pass passage Service I. From P2 port Swing L. Pilot passage for independent travel Travel (right) M. Orifice Supply N. Piston for conflux Travel (left) O. Pilot passage for conflux Boom P1. From P1 port Bucket Q. P1 side. By-pass passage P3 side. Parallel passage From by-pass passage of tank to tank passage

24-33

24. COMPONENTS SYSTEM 2. Pilot operating section • Operating boom raise With the boom raise operation, the pilot secondary pressure enters into the Pa8 port, and moves the spool for the boom operation. And with the movement of the spool, as the by-pass circuit is cut at the boom switching section, the oil received through the P1 port flows from the parallel circuit through the check valve installed on the upper part of the spool by-pass circuit for the travel operation into the parallel circuit on the boom switching section. With the movement of the spool, as the circuit from the passage leading to the boom lock section to the bridge passage is opened, the oil entered in the parallel circuit passes through the load check valve on the boom switching section and flows into the boom lock section through the bridge passage. The oil entered in boom section opens the lock valve and is fed into the boom cylinder head side. On the other hand, the return oil from the boom cylinder rod side flows into the B8 port, and with the movement of the spool the oil flows out into the tank circuit that is connected by the notch of the spool. Consequently, the boom cylinder extends and raises the boom. The oil from the Pp1 port passes through the orifice provided on the P3 supply section and flows into the pilot circuit. The oil entered into the pilot circuit flows from the travel switching section to the tank circuit, and the pilot circuit pressure becomes equal to the tank pressure, consequently the independent travel spool is not switched. 14

R T

W

U

5

11 11 P 9

10

Fig. 24-13 Operation at boom raising 9. 10. 11. 14. P. R.

Travel (left) Boom P1, P2 supplied port Boom cylinder From P1 pump Parallel passage

S. T. U. W.

24-34

Pilot passage Bridge passage By-pass passage The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit.

24. COMPONENTS SYSTEM 3. Manual operation section • Left swing operation With the left swing operation, the swing spool moves to the push–in direction. With the movement of the spool, as the by-pass circuit is cut off at the swing switching section, (a portion of the oil flows out to the by-pass (tank) circuit through the notch provided on the swing spool.), the oil entered through the P2 port flows into the parallel circuit through the check valve provided on the upper part of the travel spool by-pass circuit. With the movement of the spool, as the circuit from the A5 port to the bridge passage is open, the oil entered in the parallel circuit passes though the load check valve, flows into the A5 port through the bridge passage, and is fed into the swing cylinder head side. On the other hand, the return oil from the swing cylinder rod side flows into through the B5 port, and with the movement of the spool the return oil flows out to the tank circuit that is connected by the notch of the spool. Consequently, the swing cylinder extends, and the boom swings leftward. The oil entered through Pp1 port passes through the orifice provided on the P3 supply section, and flows into the pilot circuit. As the oil entered in the pilot circuit flows out from the travel switching section into the tank circuit, the pilot circuit pressure becomes equal to the tank pressure, and consequently the independent travel spool is not switched. 15

T R S

U

Z

6

7

I

R

I

w

Fig. 24-14 Operation of swing 6. 7. 15. I. R. S.

Swing Travel (right) Swing cylinder From P2 pump Parallel passage Pilot passage

T. Bridge passage U. By-pass passage W. The oil entered in through the Pp1 port flows out from the travel switching section into the tank circuit. Z. Some oil flows into the by-pass passage.

24-35

24. COMPONENTS SYSTEM 4. Arm flow conflux function This valve actuates the arm and service using joined flow amount of P2 and P3. The flow conflux circuit is used only for actuating the arm and service as explained below. The operation for the service shifts the spool for the arm by the secondary pressure from the remote control valve. Since the spool shifting results in shutoff of the pilot and tank passages for flow conflux, the pressure in the flow conflux pilot passage equals to the Pp1 port supply pressure, which acts on the flow conflux piston to move it to the position where the piston collar contacts with the inner shoulder the valve. At the same time, the flow conflux piston moves the flow conflux and independent travel spools. Once the spool is shifted, the pressurized oil supplied from P3 flows into the second by-pass passage of P2 side through the parallel and by-pass passages of the slewing and dozer shifting and through the check valve provided to the P3 supply section, which is connected to the by-pass passage of the P2 side at the upstream (between boom swing and service) of the service shifting section, and also connected to the by-pass passage of the P2 side through the check valve at the P3 supply section. Therefore the flow of oil supplied from P3 joins in the parallel passage of the P2 side in proportion to an operating amount of the arm or the service. (The drawing below shows service operation.)

N

K

S

Fig. 24-15 Actuation of flow conflux circuit in service operation `

3. 4. 5. G. H. I. N.

Supply and independent travel Arm Service From P3 port P2 side. By-pass passage From P2 pump Piston for conflux

K. The parallel passage of P2 side through the check valve P. From P1 pump R. Parallel passage S. Pilot passage V. From P3 pump W. By-pass passage W1.Bridge passage

24-36

24. COMPONENTS SYSTEM 5. Independent travel function When both right and left travels is shifted, and one of boom, bucket, boom swing and servise is shifted, the oil flows from the Pp1 port through the throttle into the pilot passage, in which pressure equals to the Pp1 port supply pressure because the pilot passage is shut off from the tank passage. Then the Pp1 port supply pressure acts on the travel straight spool, and the spool moves until it contacts with the pilot cap overcoming the spring force. Once the spool is shifted, the pressurized oil supplied from P3 passes through the parallel and by-pass passages of the slewing and dozer shifting sections, and passes through the spool of the P3 supply section and the land of main unit to flow into the second parallel passage of the P1 side and the parallel passage of the P2 side. In addition, if the pressure of pilot passage is equal to the pressure of Pp1 port, the spools in the P1/P2 supply section are shifted too. Thereby P2 parallel passage is connected with P1 parallel passage. After these shifting, the pressurized oil supplied to P1 and P2 actuates the right and left travel, and the pressurized oil supplied to P3 actuates the other attachments. Therefore even if the travel and other attachment are simultaneously operated, the travel is correctly performed without deviating. The arm or service operated in the flow conflux position without relating to the independent travel function can be simultaneously performed with the travel in the same operability as the independent travel function. K

G

S

1

2 G

P1

3

4

G P2 K

H

P3 P1, P2 P1 Q

Fig. 24-16 Independent travel actuation 1. 2. 3. 4. G. K. Q.

Dozer Slewing Supply and independent travel Arm From P3 pump The parallel passage of P2 side To the parallel passage of P1 side

S. Pilot passage P1. Pp1 pressure P2. Oil from P3 pump is cut off by both travel operation and attachment operation P3. Travel straight spool and P1/P2 supply spool are shifted simultaneously, and P1 parallel passage connects with P2 parallel passage.

24-37

24. COMPONENTS SYSTEM 6. Function of Lock Valve • Piston Holding When the boom spool is at neutral position, the pilot piston chamber (a) is connected to the drain passage through the pilot port (Pb8’) for releasing lock valve. And the piston chamber (b) is also connected to the drain passage through the drain port (Dr1). Therefore the piston (C) is held at the position shown in the figure. And the hydraulic pressure to hold the boom cylinder is applied to the lock valve chamber as shown in the figure, pressing the needle valve and lock valve to their seats respectively. Then it prevents leakage on the head side of boom cylinder, and also prevents the arm cylinder from its movement due to leakage.

14

16 17

20

19

18

Fig. 24-17 Function of Lock Valve (piston holding) 14. Boom cylinder 16. Lock valve chamber 17. Needle valve sheet

18. Needle valve 19. Lock valve 20. Body seat

24-38

b

a

A

C

24. COMPONENTS SYSTEM • Release When the pilot pressure is applied to the pilot port (Pb8’) for releasing lock valve, the piston (C) is moved to the right side opening the needle valve through piston (A). At that time, the return oil from boom cylinder passes through the throttle on lock valve, then lock valve chamber • → pilot piston chamber → drilled hole in turn, and flows into the tank path through the throttle hole (drilled hole) on boom spool pushing up the steel ball. The opening of the needle valve results in the pressure drop in the lock valve chamber. The return oil from the boom cylinder opens the lock valve, and flows into the tank passage through the notch (groove) of the boom spool and the throttle (drilled hole).

14

20

19

Fig. 24-18 Function of Lock Valve (release) 14. 16. 17. 18.

Boom cylinder Lock valve chamber Needle valve sheet Needle valve

19. 20. 22. 23.

24-39

Lock valve Body seat Pilot piston chamber Drilled hole

18

a

b

16 17

23 A

C

24. COMPONENTS SYSTEM 7. Operation of relief valve • Operation at relief condition - The pressure oil passes through the inside of the piston placed in the pressure regulating valve (main valve) and fills in "A" chamber inside of the piston through the orifice "B" to securely seat the pressure regulating valve and the socket, and the socket and the body seat. 25

"B"

24

26

P

27 28

30

"A"

29

Fig. 24-19 24. 25. 26. 27.

28. Socket 29. Pressure regulating valve 30. Adjust valve

Tank passage Piston Adjust valve spring Body seat

- When the pressure of the oil in the P port reaches to the set pressure of the spring, the pressure oil acts on the adjust valve through the piston and opens the adjust valve. Then, the pressure oil passes through the inside of the piston, orifice B, A chamber, ring orifice, and drilled hole D in order, and flows out to the tank circuit around the socket.

31

"D"

31. Ring orifice “C“ - The pressure in "A" chamber drops because the adjust valve is open, consequently the pressure oil in the P port flows out to the tank circuit through the drilled hole "E".

"E" - When the pressure on the P port drops lower than the spring set pressure of the adjust valve, the adjust valve is pushed against the seat by the adjust valve spring force of the adjust valve and the pressure in "A" chamber is equal to the pressure in the P port, consequently the adjust valve is also pushed against the seat and returns to the former condition(Fig. 24-19).

24-40

24. COMPONENTS SYSTEM • Suction operation When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure of the tank circuit from the P port rises, the socket is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank passage into the P port and the space fills with the oil.

"E" • Operation of anti-cavitation valve When the negative pressure is generated in the P port, the oil is supplied through the tank circuit. When the pressure from the P port rises, the valve is pushed up. Consequently, the space between the body seat and the socket opens, and the oil flows from the tank circuit into the P port and the space fills with the oil. 24

P

27 28

24. Tank passage 27. Body seat 28. Socket

24-41

24. COMPONENTS SYSTEM 24.1.5

SLEWING MOTOR

24.1.5.1 GENERAL VIEW

24.1.5.2 HYDRAULIC CIRCUIT Port

NAME

A

Main port

B

Main port

T

Tank port

DR

Drain port

PB

Slewing parking brake release port

PP

Slewing parking brake pilot port

Size PF3/8

PF1/4

Rotating direction: Inlet A port: Clocwise (Seen from shaft side): Inlet B port: Counter clockwise

24.1.5.3 SPECIFICATIONS Items Part No.

Specifications Type

Hydraulic motor Parking brake Relief valve Reduction unit

Slewing motor unit

PLC-120-18B-1FS2-8284A

Slewing motor Displacement Rated flow

PM-1B-22B-FS2-4572A 3

cm /rev (cu•in/rev)

22.1 (1.35)

L/min (gal/min)

33.8 (8.93)

Static friction torque

N•m (lbf•ft)

73.0 (54)

Release pressure

MPa (psi)

Min 2.5 (363), Max 4.9 (710)

Set pressure

MPa (psi) 21.0 (3045) at 34 L/min (9.0 gal)/min

Cracking pressure

MPa (psi) 16.5 (2393) at 1 L/min (0.26 gal/min)

Reducting ratio

17.7

Weight (with Reduction unit)

kg (lb)

24-42

Approx. 40 (88)

24. COMPONENTS SYSTEM 24.1.5.4 CONSTRUCTION 242

A

510

B

B

411 409 407 405 404 410 406 412

403

408

402

412

401

301 302 304 305 244

303

A A-A

235 236 245 238 223 218 231 224

201 217 225 221 215 205 232 212 204

237

213

234

206

233

209 505

507

306

208 503

506

203

207 501

511

226

210 502

214

130 504

124

202

107

129

118

127

111

105

106

216

117

103

110

109 123

119

113

125

102

136

108 114 101 116 128 115 112 104

24-43

512

508 509

B-B

24. COMPONENTS SYSTEM

No.

NAME

Q’TY

(Reduction assy)

No.

NAME

Q’TY

No.

NAME

Q’TY

204 Cylinder

1

302 Check valve

2

101 Casing

1

205 Valve plate

1

303 Plug

2

102 Carrier 1

1

206 Piston

9

304 Spring

2

103 Carrier 2

1

207 Shoe

9

305 O-ring ; 1B P11

2

306 O-ring ; 1B P18

2

104 Pinion shaft

1

208 Shoe holder

1

105 Internal gear A

1

209 Cylinder holder

1

106 Spur gear 1

4

210 Swash plate

1

401 Seat

2

107 Spur gear 2

3

212 Retainer

2

402 Retainer

2

108 Sun gear 1

1

213 Pin

3

403 Poppet

2

109 Sun gear 2

1

214 Filter

2

404 Piston

2

110 Pin 1

4

215 Spring

1

405 Cap

2

111 Pin 2

3

216 Ball bearing

1

406 Spring

2

112 Seal ring

1

217 Ball bearing

1

407 Spacer

*

113 Thrust collar

1

218 O-ring ; 1B G120

1

408 O-ring ; 1B P14

2

114 Pre-load collar (semi-circular)

2

221 Snap ring

1

409 O-ring ; 1B P18

2

115 Taper roller bearing

1

223 Socket bolt ; M12×35

5

410 O-ring ; 1B P22

2

116 Taper roller bearing

1

224 Spring pin

1

411 O-ring ; 1B P28

2

117 Roller

68

225 Parallel pin ; ø6×14

1

412 Backup ring

4

118 Roller

69

226 Parallel pin

1

(Timer assy)

119 Thrust washer

14

231 Piston

1

501 Valve block

1

(Relief valve assy)

123 Snap ring (for shaft 30)

1

232 Spring B

12

502 Spool

1

124 Snap ring (for shaft 20)

7

233 Friction plate

2

503 Piston

1

125 Spring pin

7

234 Separator plate

2

504 Stopper

1

127 Pin

4

235 O-ring ; 1B G100

1

505 Spring (1)

1

128 Oil seal

1

236 O-ring ; 1B G110

1

506 Spring (2)

1

129 O-ring

1

237 Backup ring

1

507 Spring seat

1

130 Socket bolt ; M8×25

5

238 Backup ring

1

508 Plug ; PF1/4

4

136 Ring

1

242 Socket bolt ; M6×15

4

509 O-ring ; 1B P11

4

244 Socket bolt ; M8×50

4

510 O-ring ; 1B P7

2

201 Body

1

245 O-ring ; 1B P18

2

511 Plug

2

202 Housing

1

512 Plug

1

203 Shaft

1

(Motor assy)

(Valve assy) 301 Cover

1

24-44

24. COMPONENTS SYSTEM 24.1.5.5

FUNCTION AND OPERATION

(1) Operating slewing motor This hydraulic motor, the axial piston (swash plate) type, converts hydraulic energy delivered by the pump into rotary motion. Oil supplied through the control valve from hydraulic pump is directed to the valve plate (1). This oil enters port A (7) of the valve plate and the oil flows into the cylinder bore in the cylinder (2) aligned with port A (7) and pushes the piston (3). The force on the piston is converted by the swash plate (4) into rotary motion, which is transmitted to the shaft (5) splined to the cylinder (2). Return oil from the cylinder bore flows out port B (6) of the valve plate (1). In the case of reverse rotation, the oil flows into port B (6), and the return oil flows out port A (7).

Fig. 24-20 Operation of hydraulic motor (2) Operation of parking brake The parking brake operates to fix the output shaft of the slewing motor mechanically when the slewing motor stops. • Operation when the brake release pressure is blocked: When the brake release pressure is blocked, brake piston (1) is pressed in the direction arrow of the above Fig. 24-21 by the action of spring (2). At this time, two friction plates (4) fixed by the crescent-shaped groove of cylinder (3) are sandwiched between three separator plates (6) fixed to housing (5). As the result, cylinder (3) is unable to turn by the frictional force between friction plates (4) and separator plates (6), thereby fixing the output shaft of the slewing motor. • Operation when the brake release pressure is continued: When the brake release pressure is through, it is directed to chamber (7) in Fig. 24-21 below. The pressure then overcomes the action of spring (2) and moves brake piston (1) in the direction of arrow in Fig. 24-21 below. The result is that friction plates (4) and separator plates (6) are released from frictional power, allowing cylinder (3) to rotate.

24-45

2 1 5 7 4 6 3

2 1 8 7 4 6 3

Fig. 24-21 Operation of parking brake

24. COMPONENTS SYSTEM (3) Operation of hydraulic valve 1) Shockless relief valve The shockless valve is made up of a poppetm (1), spring and the piston (2) that changes two steps stroke. The IN and OUT ports of the hydraulic motor are closed when the hydraulic motor stops. The motor attempts to keep slewing by inertia of the upper structure. This produces pressure (braking pressure) on the OUT port side by the pumping action of the motor. The shockless relief valve relieves the braking pressure by the following two step actions, in order to absorb the shocks at motor stop and prevent the motor from breaking down at the same time. The shockless relief valve also operates to absorb shocks the same way when the motor starts up. a) 1st Stage As pressure P1 flowing into the hydraulic motor increases, pressure corresponding to the spring action F1 causes the poppet (1) open. b) 2nd Stage The pressure P1 flows into "secondary chamber" (3) through the "orifice B and A" (4-5) which causes the piston to push to the stroke end (4). This reduces the length of the spring and increases the spring force. The pressure P1 rises to a set value Ps. The above-mentioned 2-step action absorbs shocks which occur when the hydraulic motor starts and stops. 2) Check Valve After accelerating slewing of the upper structure, when the speed is being reduced by half-lever, the supply flow rate from pump to port A (6) is lowered. But if the upper structure is slewed at a comparatively high speed, the pressure in the (C) section is lowered to negative pressure making lubrication necessary. However, when the pressure of port B (7) is equal to or lower than the working pressure of cushion relief valve the oil of (C) section led through port A (6) is discharged to the control valve through port B (7). As a result, the flow rate from the control valve does not satisfy the specialized oil quantity. To prevent this, the make-up check valve (8) is installed to supply necessary oil into the (C) section.

24-46

2

1

3

5

4

4

P

T

Fig. 24-22 Operation of shockless relief valve 6

9

8

C

Fig. 24-23

7

24. COMPONENTS SYSTEM 3) Action of hydraulic parking brake (P/B) timer When the parking brake operates as the upper structure produces inertia, the hydraulic parking brake timer operates to delay the operation of the parking brake for a certain time length. a) When the parking brake is released ; If the pressure flows into the brake release command secondary pilot pressure port (PP), it overcomes the force of spring (505) and pushes spool (502) to the positions in Fig. 24-24 and in the figure above. On that occasion, the brake release pressure at the brake releasing primary pressure port (PB) passes through the arrow in Fig. 24-24 above, is flowed into the chamber of the parking brake piston, and releases the parking brake. b) When the parking brake acts ; If the pilot pressure at the brake releasing command secondary pilot pressure port (PP) is blocked, spool (502) is pushed back to the position in the figure below by the force of spring (505). The brake release pressure at the brake releasing pressure port (PB) is blocked by spool (502) and block the pressure supply to the chamber of the parking brake piston. The pressure of the parking brake piston chamber is pushed out by the force of the spring in the parking brake and flows out to the DR port through the passage indicated by an arrow in the figure below: On that occasion, the oil that is flowing out is regulated by the orifice of piston (503), flows out to the DR port slowly, and delays the action of the parking brake for a certain time length.

Fig. 24-24 Operation of hydraulic parking brake timer When the brake releasing command secondary pilot pressure flow into port PP;

When the brake releasing command secondary pilot pressure is blocked at port PP; Fig. 24-25 Operation of hydraulic parking brake timer

24-47

24. COMPONENTS SYSTEM (4) Reduction Unit (Planetary 2 stage) This slewing reduction unit for the slewing motor is made up of two stage planetary gear sets. It converts highspeed rotary motion from the slewing motor (4) into low speed and high-torque motion to rotate the pinion shaft (3). Refer to the Fig. 24-25, sun gear 2 (S2) is splined on the output shaft of the slewing motor (4) and the rotation of sun gear 2 (S2) performs primary reduction through gears (S2), (b2), and (a2). After primary reduction, rotation performs secondary reduction through gears (S1) (splined to carrier 2), (b1), and (a1). After secondary reduction, rotation is transmitted to the pinion shaft splined to carrier 1 creating slewing force. The gear ratio of the two-stage planetary gear can generally expressed by:

R=

Zs1 Zs2 Zs1+Za1 Zs2+Za2

Where ; Zs1, 2 : S1, 2 Number of teeth Za1, 2 : a1, 2 Number of teeth 4

2

1 3

Fig. 25-26 Operation of slewing reduction

24-48

24. COMPONENTS SYSTEM

24.1.6

TRAVEL MOTOR

24.1.6.1 SPECIFICATIONS 1. General View

F

E

X

G

X

E. Oil filling port F. Oil level check port G. Drain port No. A, B D1, D2 P P2, P3

NAME

SIZE

The relation between rotating direction of reduction unit and oil inlet and outlet port (View from X side)

Hydraulic oil fill / drain port

PF1/2

Rotating direction

Oil inlet port

Oil outlet port

Drain port

PF1/4

Clockwise

A

B

1st/2nd speed select port

PF1/8

Counterclockwise

B

A

Pressure gauge port

PT1/8

24-49

24. COMPONENTS SYSTEM 2. Specifications Model (Type)

GM06VA

Rated output revolution (1st / 2nd) Reduction unit

rpm

Output torque (1st / 2nd)

N•m (lbf•ft)

Reduction ratio

Parking brake

5710 / 3280 (4211 / 1033) 1 / 68.6

cm3/rev (cu•in/rev)

Displacement (1st / 2nd)

Hydraulic motor

30.9 / 52.2

26.4 / 15.3 (1.61 / 0.93)

Rated operating pressure

MPa (psi)

23.0 (3340)

Rated output revolution (1st / 2nd)

min (rpm)

2119 / 3583

L/min (gal/min)

57.1 (15.1)

-1

Rated flow 2-Speed shifting pressure

MPa (psi)

3.5 (507)

Automatic 2-speed shifting pressure

MPa (psi)

18.5 (2680)

Static friction torque

N•m (lbf•ft)

64.7 (47.7)

Releasing pressure

MPa (psi)

0.89 (129)

Weight

kg (lb)

24-50

65 (143)

24. COMPONENTS SYSTEM 24.1.6.2 CONSTRUCTION 1. Construction (Outline)

R

H

I L M N

O

T

Q

H. I. L. M. N.

Reduction unit Hydraulic motor Brake valve Parking brake High and low speed change mechanism

O. Q. R. S. T.

24-51

Control valve Hydraulic pump High speed Low speed Hydraulic circuit

S

24. COMPONENTS SYSTEM 2. Sectional view

A

B

A

B-B

A-A

24-52

24. COMPONENTS SYSTEM No.

NAME

1

Hub

2 3

Q’TY

No.

NAME

Q’TY

1

108 Thrust ball

1

Spindle

1

109 Timing plate

1

Carrier

1

110

Washer

2

4

Sun gear (1)

1

112

Piston

1

5

Planetary gear (1)

3

113

Spring

8

6

Sun gear (2)

1

114

Spring

1

7

Planetary gear (2)

4

115

Friction plate

1

9

Thrust washer (1)

2

116

Separator plate

2

11

Thrust collar (4)

4

132 Oil seal

1

12

Thrust washer (3)

7

135 O-ring

1

13

Cover

1

139 O-ring

1

14

Coupling

1

145 Snap ring

1

22

Ring nut

1

149 Ball bearing

1

24

Ball bearing

2

150 Ball bearing

1

27

Needle roller bearing with retainer

3

151 Roller

3

28

Needle roller bearing with retainer

4

167 Pivot

2

29

Inner race

3

177 Parallel pin

2

190 Spring

30

Inner race

4

Floating seal kit

1

Rear flange assembly

1

31

Floating seal

2

• Rear flange kit

1

33

Plug with flange

1

201 •• Rear flange

1

35

O-ring

1

223 • Spool

1

37

O-ring

1

39

Plug

2

263 •• Spool

1

40

Hexagon head screw

7

264 •• Oil stopper

1

41

Steel ball

1

221 • Plug

2

42

Parallel pin

2

224 • Plug

2

43

O-ring

2

225 • Stopper

2

44

O-ring

1

226 • Plug

2

45

Ring

1

227 • Valve

2

47

Hexagon socket set screw

2

228 • Spring

2

1

230 • Spring

2

236 • O-ring

2

• Spool kit

Cylinder and piston kit 104 •Cylinder block

104

1

1

237 • O-ring

2

•Piston kit

252 • Hexagon socket plug

4

••Piston assembly

254 • Hexagon socket plug

4

105 •••Piston

105

266 • Spring

1

106 •••Shoe

106

268 • Steel ball

1

Piston kit

1

273 • O-ring

2

•Piston assembly

1

275 • Orifice

1

1

276 • Orifice

1

161 ••Piston 162 ••Shoe

1

279 • Filter

1

163 •Seal ring

1

280 • Plug with flange

1

102 Shaft

1

299 • Name plate

1

103 Swash plate

1

241 Parallel pin

2

107 Retainer plate

1

243 Capscrew

6

24-53

24. COMPONENTS SYSTEM 24.1.6.3 FUNCTION 24.1.6.3.1

Reduction Unit

1. Function This reduction gear unit is composed of two stage planetary gear mechanism. The reduction gear reduces the high speed of hydraulic motor and converts it low–speed, high– torque rotation. 2. Operating Description The rotation of hydraulic motor shaft is transmitted to sun gear (4) of the first stage which is linked with shaft (102) in spline. Sun gear (4) is meshed with three planetary gears (5), and three planetary gears (5) mesh with hub (1) while rotating on their axis. At that time, the hub is rotated by the rotation of the planetary gears (5). The hub rotation is transmitted to carrier (3) which connected to planetary gears (5), and that causes sun gear (6) rotation of the second stage. The rotation of sun gear (6) is transmitted to the hub via four planetary gears (7) of the second stage. The generated rotation of reduction gear is output rotation. (7)

(5) (4)

(102)

O

I

(6) (3)

(1)

24.1.6.3.2

Hydraulic Motor Section (Brake valve, parking brake, high and low speed change mechanism)

1. Function 1) Hydraulic motor Hydraulic motor is referred to as a swash plate type axial piston motor which converts the pressure oil power fed by pump into rotary motion. 2) Brake valve a. Travel motor controls the force of rotational inertia of the body to brake and stop the rotation smoothly. b. Check valve function to prevent hydraulic motor from cavitation. c. Open the port to release the parking brake force at travel motor operation, and close the port at a standstill. 3) Parking brake The parking brake is used to the prevent machine from running away or slipping while parking on a slope using the friction plate type brake mechanism, and is installed on the hydraulic motor. 4) High / Low 2-speed shifting mechanism By means of changing the tilt angle of the swash plate to change the stroke volume of piston with help of the function on the shifting valve and control piston, the speed is shifted to high speed with low torque or low speed with high torque.

24-54

24. COMPONENTS SYSTEM 2. Operation 1) Hydraulic motor Hydraulic oil fed by pump enters rear flange (201) of travel motor, and is led from timing plate (109) to cylinder block (104) through brake valve mechanism. This pressure oil is led to only the one side of Y1 - Y2 tied between top dead point and bottom dead point of piston (105) stroke. And the pressure led to one side of cylinder block pushes 4 or 5 pistons (105), generating the power {F (N) = 100 x P (MPa) x A (cm2)}. This power enters on swash plate (103), but swash plate (103) is fixed having an angle (Îą) against axis of drive shaft (102), and divided into component of force (F2, F3). And the radial component of force (F3) generated various torque (T = F3 x ri) against line Y1 - Y2. The total torque [T = ÂŚ (F3 x ri)] is connected to turning effort, and rotates cylinder block (104) through piston (105). This cylinder block (104) is connected with drive shaft (102) with spline, and rotates drive shaft (102) to transmit torque. 2) Brake valve a. Operation (Brake released) The pressure oil is led to through port (A), opens valve (227), and led to port (C) on the section side of hydraulic motor to rotate hydraulic motor. At the same time, the pressure oil enters chamber (b) through passage (a) from the small hole of spool (223), and exerts on the end of spool to generate the force. Then the force of spring (228) slides the spool placed on the neutral position leftward. The sliding of spool forms the space (passage) between spool and rear flange with spool groove. This passage is connected to port (D) and port (B) of the return circuit of the hydraulic motor, and the return oil returns to tank side, enabling hydraulic motor to rotate. Then, the sliding of spool (223) leads pressure oil to port (P). The pressure oil led to port (P) moves piston (112) of parking brake, and releases parking braking force. (For details, refer to item "Parking brake".) If pressurized oil is supplied from port (B) the movements of spool (223) and valve (227) are reversed so that the hydraulic motor is rotated reversely.

24-55

24. COMPONENTS SYSTEM b. Stop / Stall (braking action) If pressurized oil supply through the port (A) is suspended while travelling, the hydraulic force to push up the spool is lost, and the spool (223) which is slided to left side, tries to return to the neutral position through the stopper (225) due to the spring (228) force. At that time, through the oil in the chamber (b) tries to flow out to the port (A) side through the passage (a) in the spool, its flow is restricted and some back pressure is generated by the throttle effect in the passage (a) controlling the return speed of the spool. At the same time, the hydraulic motor tries to rotate with its inertia force even though the pressurized oil is suspended, and the return oil from the hydraulic motor tries to return to the port (B) side from the port (D) through the passages on spool groove and rear flange. When the spool entirely return to the neutral position, the passage on the hydraulic motor of the oil return side is completely closed by the spool, and the hydraulic motor ceases its rotation. While machine working, the brake valve smoothly stops rotation of the hydraulic motor which tries to rotate with its inertia force, by means of throttling the return side passage of the hydraulic motor, generating back pressure due to shape of the spool groove and controlling the return speed of the spool. On the other hand, when braking is operated, the hydraulic motor tries to rotate with its inertia force and to intake oil with its pumping function. However, because the intake side is closed its passage with the spool, the oil supply is suspended. This causes cavitation in the hydraulic motor. To prevent the cavitation, the valve (227) is operated by very slight negative pressure to open the passages of port (A) side and intake port (C) of the hydraulic motor. And when pressurized oil is supplied through the port (B), each motion of the above mentioned parts becomes symmetrical right and left to stop the hydraulic motor.

24-56

24. COMPONENTS SYSTEM c. Self-traveling While machine is being operated, as the travel speed is increased due to steep slope, the oil flow rate of the hydraulic motor is higher than the supply flow rate of the hydraulic oil pump. The rotation of the hydraulic motor in this case is called a self-traveling (Overrun). While self-traveling, the oil pressure is lowered similar to the stopping condition. Then brake valve is moved similar to the stopping condition, throttles passage in the return side of hydraulic motor, and generate backing pressure. In addition, the force of inertia decreases the revolution of hydraulic motor to revolution having a balance with the supply flow rate of pump.

3) Parking brake a. Traveling The pressure oil led trough brake valve actuates on spool (223) of brake valve on the hydraulic motor section, opens passage to parking brake, and is led to cylinder chamber (a) compressed of spindle (2) and piston (112) on the reduction gear section. If the pressure of oil which is 0.89 MPa(129 psi) or higher it exceeds the force of spring moving piston (112) toward rear flange (201) side. This movement of piston (112) reduces the push power to separator plate (116) and friction plate (115), and makes the movement of friction plate (115) which is installed to cylinder block (104) on hydraulic motor section free releasing the brake power to cylinder block (104).

24-57

24. COMPONENTS SYSTEM b. Stopping If pressure oil from brake valve is cut, and the pressure in cylinder chamber (a) lowers 0.89 MPa(129 psi) or less, the piston (112) goes to rightward by the force of spring (113). Also, the force of the spring pushes mating plate (116) and friction plate (115), which is in a free state because piston (112) is pushed, against spindle (2) on the reduction gear section. The frictional force produced by the push power stops the rotation of cylinder block (104), and transmits braking torque 32.4 N•m (23.9 lbf•ft) to hydraulic motor shaft. And since oil is controlled through the proper oil passage, it results in smooth operation.

4) High / Low 2-speed shifting mechanism a. Low speed When the pilot pressure (10) is not supplied through the port (D), the valve (263) is pushed up to the upper position due to the spring (266) force and pressurized oil through the port (A) or (B), the pressurized oil is cut off at port (C), and oil in the chamber (P) is released into the drain (D) (motor case) through the valve (263). Accordingly, the tilt angle of the swash plate (103) becomes the maximum mum stroke volume and low speed rotation of the hydraulic motor.

1 resulting the maxi-

10

Y P

D

D. Drain

24-58

24. COMPONENTS SYSTEM b. High speed When 3.5 MPa (507 psi) of the pilot pressure (10) is supplied through the port (D), it defeats the spring (263) force and pressurized oil through the port (A) or (B) to push down the valve (263) to lower position, the pressurized oil at the port (C) is led to the chamber (P) through the valve (263), and the piston (161) pushes the swash plate (103) up to the plane X and maintain it at its position. At that time, the tilt angle of the swash plate becomes the minimum draulic motor.

2 resulting the minimum stroke volume and high speed rotation of the hy-

10

X

P

D

D. Drain c. Automatic shifting to low speed during high speed operation If the load is increased while high speed operation, the oil pressure at the port (A) or (B) is also increased. And when the oil pressure reaches to 18.5 MPa (2680 psi), it excesses the pilot pressure (10) of 3.5 MPa (507 psi), and the valve (263) is pushed up to upper position, and oil in the chamber (P) is released into the drain (D) (motor case) through the valve (263). At that time, the swash plate (103) gets touch with the plane Y of spindle, and the tilt angle of swash plate becomes the maximum resulting low speed rotation.

1 and is maintained at its position

10

Y P

D

D. Drain

24-59

24. COMPONENTS SYSTEM 24.1.7

SWIVEL JOINT

24.1.7.1 GENERAL VIEW

B

G (P)

(F) D C (E) F

P D

A

B

E C A G

Fig. 24-27 General view 24.1.7.2 SPECIFICATIONS Port No.

A, B, C, D

E, F

P

G (Drain)

Rated working pressure

MPa (psi)

20.6 (2990)

←

3.4 (500)

0.5 (73)

Pressure test

MPa (psi)

30.9 (4480)

←

30.9 (4480)

1.0 (145)

70 (18.5)

40 (10.6)

10 (2.6)

←

PF1/2

PF3/8

PF1/4

PF3/8

Rated flow

L/min (gal/min)

Port size Revolution Weight

rpm

Less than 15

kg (lb)

Approx 22 (49)

24-60

24. COMPONENTS SYSTEM 24.1.7.3 CONSTRUCTION

14

5

1 11 10

16

8 6

P F E D C B A G

3

15 13 7, 17 4

12

9

2

Fig. 24-28 Construction No.

NAME

Q’TY

No.

NAME

Q’TY

1

STEM

1

10

DUST SEAL

1

2

BODY

1

11

DUST SEAL

1

3

FLANGE

1

12

SNAP RING

1

4

SPACER

1

13

BOLT (M10 X 30)

4

5

PIN

1

14

PLUG (PF1/4)

3

6

SLIPPER SEAL

4

15

SPRING WASHER

4

7

NAME PLATE

1

16

BACK-UP RING

1

8

O-RING

1

17

CLEVIS

2

9

O-RING

1

24.1.7.4 OPERATION The swivel joint is installed on the slewing center of the machine, and plays a role to continuously connect the oil circuit regardless of the slewing angle of the upper frame.

24-61

24. COMPONENTS SYSTEM 24.1.8

CYLINDER

24.1.8.1 SPECIFICATIONS 1. General View

B

A

C

Fig. 24-29 General view of cylinder A. Fully retracted length B. Fully extended length

C. Part No. and manufacturing No. stamp position

E40.2SR

Unit: mm (ft–in) Center distance of mounting pins Full extend B / Full retract A

Cushion

Dry weight kg (lb)

Boom (Canopy) ø90 / ø50 (3.54" / 1.97") 704 (2’3.7")

1743 / 1039 (5’8.6" / 3’4.9")

Rod side

47 (104)

Boom (Cab)

ø90 / ø50 (3.54" / 1.97") 680 (2’2.8")

1719 / 1039 (5’7.7" / 3’4.9")

Rod side

46 (101)

Arm

ø80 / ø50 (3.15" / 1.97") 717 (2’4.2")

1825 / 1108 (5’11.9" / 3’7.6") Rod & Head

Bucket

ø75 / ø45 (2.95" / 1.77") 546 (1’9.5")

1378 / 832 (4’6.3" / 2’8.8")

None

27 (60)

Swing

ø90 / ø50 (3.54" / 1.97") 567 (1’10.3")

1510 / 943 (4’11.4" / 3’1.1")

None

39 (86)

Dozer

ø95 / ø55 (3.74" / 2.17")

700 / 500 (2’3.6" / 1’7.7")

None

27 (60)

Cylinder

Cylinder Bore / Rod Dia.

Stroke

200 (7.87")

E50.2SR

42 (93)

Unit: mm (ft–in) Center distance of mounting pins Full extend B / Full retract A

Cushion

Dry weight kg (lb)

Boom (Canopy) ø100 / ø55 (3.94" / 2.17") 699 (2’3.5")

1768/ 1069 (5’9.6" / 3’6.1")

Rod side

57 (127)

Boom (Cab)

ø100 / ø55 (3.94" / 2.17") 666 (2’2.2")

1753 / 1069 (5’9.0" / 3’6.1")

Rod side

56 (123)

Arm

ø90 / ø50 (3.54" / 1.97")

716 (2’4.2")

1836 / 1120 (6’0.3" / 3’8.1")

Bucket

ø75 / ø45 (2.95" / 1.77")

546 (1’9.5")

1378 / 832 (4’6.3" / 2’8.8")

None

27 (60)

Swing

ø90 / ø50 (3.54" / 1.97") 567 (1’10.3")

1510 / 943 (4’11.4" / 3’1.1")

None

39 (86)

Dozer

ø95 / ø55 (3.74" / 2.17")

700 / 500 (2’3.6" / 1’7.7")

None

27 (60)

Cylinder

Cylinder Bore / Rod Dia.

Stroke

200 (7.87")

24-62

Rod & Head 49 (108)

24. COMPONENTS SYSTEM 24.1.8.2 CONSTRUCTION AND FUNCTION 24.1.8.2.1

Construction

1. Boom cylinder

21

3

4

20

17 16 15

19

14

18

2

1

13

5

6

12

Fig. 24-30 Construction of boom cylinder

No.

NAME

Q’TY

No.

NAME

Q’TY

1

TUBE ASSY

1

13 RING

1

2

ROD ASSY

1

14 ROD BUSHING

1

3

BUSHING

2

15 SEAL RING

1

4

HEAD

1

16 BACK-UP RING

1

5

CUSHION BEARING

1

17 DUST SEAL

1

6

PISTON

1

18 O RING

2

9

LOCK NUT

1

19 BACK-UP RING

3

10 WEAR RING

2

20 O RING

1

11 SEAL RING

1

21 DUST SEAL

4

12 SEAL RING

1

24-63

11

10

9

24. COMPONENTS SYSTEM 2. Arm cylinder

21

3 4

20

17 16 15

19

14

18

2

1

13

5

11

6

12

NAME

Q’TY

No.

NAME

Q’TY

1

TUBE ASSY

1

14 ROD BUSHING

1

2

ROD ASSY

1

15 SEAL RING

1

3

BUSHING

2

16 BACK-UP RING

1

4

HEAD

1

17 DUST SEAL

1

5

CUSHION BEARING

1

18 O RING

2

6

PISTON

1

19 BACK-UP RING

3

9

LOCK NUT

1

20 O RING

1

10 WEAR RING

2

21 DUST SEAL

4

11 SEAL RING

1

23 CUSHION BEARING

1

12 SEAL RING

1

24 PLATE RING