Fiat Kobelco E9sr Mini Crawler Excavator Service Repair Workshop Manual – PDF Download by www.heydownloads.com

INTRODUCTION

WORKSHOP MANUAL ENGLISH

14903 60413247

Print N. 604.13.247.00

Edition: 04/2003 English - Printed in Italy Printed by Studio ti

0-1

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 COMPLETE WORKSHOP MANUAL • The complete repair manual consists of two volumes: - E9SR EVOLUTION - Workshop Manual "Excavator"

14903 60413247

• "Excavator" and "Engine" Workshop Manuals contain the technical information necessary for machine/engine service and repair, service

VOLUME Workshop Manual - "Excavator"

equipment, information on maintenance standards, remove and install procedures, disassembly and assembly procedures. • The complete Workshop Manual for the excavator model E9SR EVOLUTION consists of the following volumes identified by print number as shown herebelow:

MACHINE TYPE

E9SR EVOLUTION

PRINT No. 604.13.247

0-3

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 â&#x20AC;&#x153;SAFETY RULESâ&#x20AC;? 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.

Product Support - Documentation Centre

0-4

14903 60413247

Strada di Settimo, 323 - S. Mauro T.SE (TO) ITALY

INDEX

INDEX SPECIFICATIONS Section 1 - Preliminary remarks Section 2 - Specifications Section 3 - Attachment dimensions

MAINTENANCE Section 11 - Tools Section 12 - Standard maintenance time table Section 13 - Maintenance standards and tests procedures

SYSTEM Section 22 - Hydraulic system Section 23 - Electrical system Section 24 - Components system

DISASSEMBLING Section 31 - Whole disassembly and assembly Section 32 - Attachments Section 33 - Upper slewing structure Section 34 - Travel system

TROUBLESHOOTING Section 42 - Hydraulic system Section 43 - Electrical system Section 44 - Engine

ENGINE

14903 60413247

Section 51 - Engine

0-5

SAFETY PRECAUTIONS

1.1 GENERAL SAFETY INFORMATION

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.

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.

Messages of safety appear in the manual and on the machine : All messages of safety are identified by eighter word of "DANGER", "WARNING" and "CAUTION".

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

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

0-6

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 Distributor.

While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur.

Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

1.2 SAFETY PRECAUTIONS

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

14903 60413247

WARNING 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 the operatorâ&#x20AC;&#x2122;s seat pocket. If it is missing or damaged, place an order with an authorized Distributor for a replacement. If you have any questions, please consult an authorized Distributor.

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

SAFETY PRECAUTIONS The following is a list of basic precautions that must always be observed. 1.

Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.

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.

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

14903 60413247

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.

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.

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.

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.

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

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 sure you understand how to use them before performing any service work. 14. Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary. 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.

0-7

SAFETY PRECAUTIONS 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.

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.

18. The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Donâ&#x20AC;&#x2122;t fail to lower the attachment and place the bucket to the ground before starting the work. 19. Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. 20. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.

14903 60413247

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

0-8

SECTION 1

PRELIMINARY REMARKS

TABLE OF CONTENTS 1. General precautions for repairs .............................................................................. 1-1 1.1 Preparation before disassembling .................................................................................................... 1-1 1.2 Safety in before disassembling and assembling .............................................................................. 1-1 1.3 Disassembling and assembling hydraulic equipment ....................................................................... 1-1 1.4 Electrical equipment ......................................................................................................................... 1-2 1.5 Hydraulic parts ................................................................................................................................. 1-3 1.6 Welding repair .................................................................................................................................. 1-3 1.7 Environmental measure ................................................................................................................... 1-3

2. Escaping procedure in case of emergency ............................................................ 1-4 2.1 When cab door does not open ......................................................................................................... 1-4 2.2 Towing the machine .......................................................................................................................... 1-4

14903 60413247

3. International unit conversion system ...................................................................... 1-5

PRELIMINARY REMARKS

1. GENERAL PRECAUTIONS FOR REPAIRS 1.1

PREPARATION BEFORE DISASSEMBLING (1) Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure. (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. (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. (4) Recording Record the following items for communication and prevention of recurring malfunction. 1) Inspection date and place 2) Model name, applicable machine number, and hour meter read 3) Trouble condition, place and cause, if any 4) Visible oil leakage, water leakage and damage 5) Clogging of filters, oil level, oil quality, oil contamination and loosening of connections 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. (5) 1) 2) 3)

Arrangement and cleaning in service shop Tools required for repair work. Prepare space to place the disassembled parts. Prepare oil containers for spilling oil etc.

14903 60413247

1.2

SAFETY IN DISASSEMBLING AND ASSEMBLING 1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses. 2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work.

3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine. 4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency. 5) Choose a hard, level and safe place, and place the attachment on the ground securely. 6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. 7) Use proper tools, and replace or repair defective tools. 8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

1.3

(1) 1)

2) 3) 4)

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT Removing hydraulic equipment Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter. Carefully drain oil of the removed pipes into a containers without spilling on the floor. Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion. Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

(2) Disassembling hydraulic equipment 1) Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after reassembling. 2) When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training. 3) Provide matching marks to facilitate reassembling work. 4) Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself. 5) Use the special jig and tools without fail if they are

1-1

PRELIMINARY REMARKS

(3) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact. 2) Measure and record wear condition of parts and clearance. 3) If the problem is found in a part, repair or replace it with a new one. (4) Reassembling hydraulic equipment 1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. 2) Perform rough and finish cleaning before assembling. 3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling. 4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance. 5) Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. 6) Remove rust preventive agent from the new parts before use. 7) Fit bearings, bushings and oil seals using special jigs. 8) Assemble the parts utilizing matching marks. 9) Ensure all the parts are completely assembled after the work. (5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied. 2) Perform air bleeding when: a. Hydraulic oil changed b. Parts of suction side piping replaced c. Hydraulic pump installed d. Slewing motor installed e. Travel motor installed f. Hydraulic cylinder installed

1-2

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

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. 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.

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

5) 6)

Perform air bleeding of pilot line by performing a series of digging, slewing and travel. Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary. Checking hydraulic oil level Level gauge

1.4

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

ELECTRICAL EQUIPMENT

(1) Do not disassemble electrical equipment. (2) Handle it carefully not to drop and give a shock. (3) Turn the key OFF prior to connecting and disconnecting work. (4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion. (5) Connect the connector and ensure it is completely locked.

14903 60413247

specified. 6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause. 7) Place the removed parts in order and attach tags to facilitate the reassembling. 8) Note the location and quantity of parts commonly applied to multiple locations.

PRELIMINARY REMARKS (6) Turn the key OFF prior to touching the terminal of starter or generator. (7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay. (8) Do not splash water on the electrical equipment and connectors during machine washing. (9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector. If moisture adhesion is found, dry it completely before the connection.

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

1.5 HYDRAULIC PARTS

14903 60413247

O-ring • Ensure O-rings have elasticity and are not damaged before use. • Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same. • Fit the O-rings without distortion and bend. • Always handle floating seals as a pair. 2) Flexible hose (F hose) • Use the appropriate parts. Different parts are

used depending on the working pressure even the size of fitting and the total length of the hose is same. • Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized. 1.6 WELDING REPAIR (1) Refer repair welding to qualified personnel according to the appropriate procedure. (2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment. (3) Move away the articles in advance that may cause fire if exposed to sparks. (4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks. 1.7 ENVIRONMENTAL MEASURE (1) Run the engine at the place that is sufficiently ventilated. (2) Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures: • When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes. • When swallowed: Do not let vomit, and receive medical treatment immediately. • When skin exposed: Wash with water and soap sufficiently. (4) Others Use replacement parts and lubricants authorized as the Distributor genuine parts.

1-3

PRELIMINARY REMARKS

2. ESCAPING PROCEDURE IN CASE OF EMERGENCY 2.1

WHEN CAB DOOR DOES NOT OPEN (CAB spec. only) (1) Escape from the front window. (2) Escape from skylight. (3) When front window and skylight do not open ; The life hammer is always reserved on the rear left side of cab. Break the glass on the rear side of cab, and escape from there. WARNING Break the window glass with care to protect eyes, and don't fail to break the window on which label "Emergency exit" is stuck.

Fig. 2-1 Life hammer and "Emergency exit" label

(4) In addition, the life hammer is equipped with a cutter on the lever side to cut the seat belt, etc. 2.2 TOWING THE MACHINE 1. If the machine should become stuck in soft soil areas it may be necessary to tow the machine. Attach a wire rope or chain, with the capacity to pull the machine out, to the lower frame axles. 2. Attach other end to the vehicle used to pull the machine. Operate the Machine’s Travel Lever in the proper direction while pulling with the other vehicle.

WARNING • While towing, do not enter between the machine and towing vehicle. • Do not apply a shock load onto the towing rope. • Do not use eyes on machine lower frame to tow machine. • Keep the wire rope horizontally, and perpendicularly to the crawler frame. • Tow the machine slowly at low speed mode. • For the towing of the machine body, provide pads to be applied to the corner of crawler frame to prevent the wire rope and crawler frame from any damages.

NOTE: Do not pull machine utilizing the brackets welded on the lower plates of the carbody. These brackets are provided for pulling lightweight objects. See figure for better reference.

1-4

14903 60413247

Fig. 2-2 Tow machine properly

PRELIMINARY REMARKS

3. INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS’ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS) Introduction Although this manual uses the gravitational unit system, if you need SI unit, refer to the following international system of units. are related to this manual : 1. Etymology of SI Units French :Le Systme International d’ Units English :International System of Units 2. Construction of SI Unit System Base units Table 3-1

SI unit system

SI units

Supplemen tary units Table 3-2 Derived units

Derived units of base units Table 3-3 Derived units bearing peculiar designations Table 3-4

Prefixes of SI (n-th power of 10, where n is an integer) Table 3- 5

(4) Derived Units bearing peculiar designations [ Table 3-4 ] 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 joule J N·m and Quantity of heat Power watt W J/s Quantity of coulomb C A·s electricity Electric volt V W/A potential difference, Voltage, and Electromotive force Quantity of farad F C/V static electricity and Electric capacitance ‰ V/A Electric ohm resistance Celcius celcius degree °C (t+273.15)K temperature or degree Illuminance lux lx l m/m2

14903 60413247

(1) Base Units [ Table 3-1 ] Given hereinafter is an excerpt of the units that (5) Prefixes of SI [ Table 3-5 ] QUANTITY UNIT SYMBOL Length metre m PREFIX SYMBOL Mass kilogram kg giga G Time second s mega M Electric current ampere A kilo k Thermodynamic kelvin K temperature hecto h Amount of substance mol mol deca da Luminous intensity candela cd deci d centi c (2) Supplementary Units [ Table 3-2 ] milli m QUANTITY UNIT SYMBOL micro µ Plane angle radian rad nano n Solid angle steradian sr pico p

(3) Derived Units [ Table 3-3 ] QUANTITY UNIT SYMBOL Area square metre m2 Volume cubic metre m3 Velocity metre per second m/s Acceleration metre per second squared m/s2 Density kilogram per cubic metre kg/m3

MULTIPLICATION FACTORS 10 9 10 6 10 3 10 2 10 10-1 10-2 10-3 10-6 10-9 10-12

(6) Unit Conversion [ Table 3-6 ] QUANTITY Gravitational SI CONVERSION FACTOR Weight kgf Mass kg 1 kgf=1 kg Force kgf N 1 kgf=9.807 N Torque kgf·m N·m 1 kgf·m=9.807 N·m Pressure kgf/cm2 MPa 1 kgf/cm2=0.09807 MPa Motive power PS kW 1 PS=0.7355 kW Revolution rpm min-1 r/min 1 F14747 1 Units that are allowed to use

1-5

PRELIMINARY REMARKS (7) Unit conversion logarithmic chart.

FORCE

1 N=0.10197 kgf

100

500

1,000

100

5,000 10,000 20,000 N 500

1,000 2,000 kgf

1 kgf=9.807 N TORQUE

1 N · m=0.102 kgf · m 10

100

5,000 10,000 20,000 N • m

500

1,000 2,000 kgf • m

1 kgf · m=9.807 N · m PRESSSURE

1 MPa=10.197 kgf/cm2 0.1

100

1,000

kgf/cm2 F14748

14903 60413247

1 kgf/cm2=0.09807 MPa

MPa

1-6

SECTION 2

SPECIFICATIONS

TABLE OF CONTENTS 1. Components name ................................................................................................ 2-1 2. Machine dimensions ............................................................................................... 2-2 3. Specifications and performance ............................................................................. 2-3 4. Machine and components weight (dry) .................................................................. 2-4 5. Transportation dimension and weight ..................................................................... 2-5 6. Type of crawler shoes ............................................................................................. 2-7 7. Type of buckets ....................................................................................................... 2-7 8. Machine lifting procedure ....................................................................................... 2-8 9. Attachment working ranges ................................................................................... 2-9 10. Lifting capacities .................................................................................................. 2-10 11. Engine specifications ........................................................................................... 2-11

14903 60413247

11.1 Specifications ............................................................................................................................... 2-11 11.2 Engine performance curve ........................................................................................................... 2-12

SPECIFICATIONS

1. COMPONENTS NAME

3 4 5 6

7 8 9

39 10 11 38

12 13 14

32 s

19 30 29

20 28 21 27

F19333

23 25

14903 60413247

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

Arm cylinder Boom Boom cylinder Left operating lever Travel lever Safety lock lever (right) Right operating lever Adj. crawler frame width/ dozer operating lever Monitor panel Throttle lever Radiator Air cleaner Control valve Reserve tank

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.

Hydraulic tank Fuel tank Engine Muffler Slewing bearing Swivel joint Slewing motor Hydraulic pump Rubber crawler shoe Travel motor Shoe slide Adj. crawler frame widthcylinder 27. Lower roller

28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

Idler adjuster Idler Swing cylinder Solenoid valve Dozer blade cylinder Dozer blade Battery Safety lock lever (left) Pilot valve Canopy Bucket Bucket link Arm Bucket cylinder

2-1

SPECIFICATIONS

2. MACHINE DIMENSIONS E9SR EVOLUTION model (LONG ARM)

˝) .3 ´7

(2´5.5˝)

(3.5˝)

RET. EXT.

(1´6.7˝)

(3´2.6˝)

(1´8.7˝)

(11.0˝)

Unit: mm (ft·in)

RET. EXT.

(7.9˝)

(7.1˝) (2´5.5˝) (3´2.6˝)

(7´3.0˝) (9´5.0˝)

(3´3.8˝) (4´4.8˝) (2´11.0˝)

(9.4˝)

(6.1˝)

(7.5˝) (1.3˝)

(4´9.9˝)

(2´5.5˝)

TOTAL LENGTH EXCLUDING DOZER

14903 60413247

• Dimension does not include height of grouser Shoe lug: 18mm (0.7in)

2-2

SPECIFICATIONS

3. SPECIFICATIONS AND PERFORMANCE SPEED AND GRADEABILITY Model

E9SR EVOLUTION

Item

(Rubber Crawler Shoe)

Slewing Speed

9.0 rpm

Travel Speed Gradeability

%(degree)

Low (1st.)

High (2nd.)

2.0 km / h (1.2mph)

3.5 km / h (2.2mph) 58% (30)

SIDE DIGGING & DOZER Type

Boom swing by hydraulic cylinder

Boom Swing Angle

Right

50°

Left

80°

Strokes of Dozer (above/below) mm(in)

190 / 240 (7.5 / 9.4)

ENGINE YANMAR 2TNE68-YB

Model Type

Vertical,4-cycle,water cooled diesel engine

Number of cylinders-Bore X Stroke Total Displacement Output Rating Maximum Torque Starting Motor Generator (Dynamo)

2-68 mm X 72 mm (2.68 in x 2.83 in) 0.52 liters (31.7 cu·in) 7.8PS (5.7kW) / 2000 rpm 3.1 kgf·m/1500rpm (22 lbf·ft / 1500rpm) 12V X 0.9 kW 12V X 20A

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gearpump

Hydraulic Motor

Orbit motor

Hydraulic Motor w/Reducer (Travel) Control Valve Cylinder

Boom,Arm,Swing Bucket,Dozer,Frame width

Return filter

Axial piston, 2 speed motor 9-function multiple control valve Double acting cylinder Safety valve containing / Filter Type (30 )

NOISE LEVEL Sound power level

87 dB (A)

14903 60413247

F22286

2-3

SPECIFICATIONS

4. MACHINE AND COMPONENTS WEIGHT (DRY)

E9SR

COMPLETE MACHINE (LONG ARM)

950

(2090)

UPPER SLEWING BODY (ASSY OF FOLLOWINGS) UPPER FRAME ENGINE RADIATOR HYDRAULIC PUMP HYDRAULIC TANK FUEL TANK CONTROL VALVE SLEWING MOTOR SWING BRACKET SWING CYLINDER COUNTER WEIGHT

426 75 65 2.8 10 16 1.4 17 15 16 15 46

(939) (165) (143) (6.2) (22) (35) (3.1) (37) (33) (35) (33) (101)

377 12 17 33 x 2 17 x 2 3.8 x 6 4.5 x 2 5.2 x 2 2.8 x 2 42 8 7.5

(831) (26) (37) (73 x 2) (37 x 2) (8.4 x 6) (9.9 x 2) (11.5 x 2) (6.2 x 2) (93) (18) (17)

HOE ATTACHMENT (ASSY OF FOLLOWINGS) BOOM ARM (LONG) BUCKET (STANDARD) BUCKET CYLINDER ARM CYLINDER BUCKET CYLINDER

122 35 25 17 7 9 7

(269) (77) (55) (37) (15) (20) (15)

FLUIDS HYDRAULIC OIL COOLING WATER ENGINE OIL FUEL

25 15 l 2.2 l 1.7 l 9l

(55) (4.0 gal) (0.58 gal) (0.45 gal) (2.4 gal)

TRAVEL SYSTEM (ASSY OF FOLLOWINGS) SWIVEL JOINT SLEWING BEARING CRAWLER SHOE TRAVEL MOTOR LOWER ROLLER IDLER SPROCKETS IDLER ADJUSTER DOZER DOZER CYLINDER CRAWLER WIDTH CYLINDER

F22287

2-4

14903 60413247

MODEL

SPECIFICATIONS

5. TRANSPORTATION DIMENSIONS AND WEIGHT (1) MACHINE AND 1-TON TRUCK

E9SR EVOLUTION (LONG ARM) Machine Weight 950 kgf (2090 lbs)

14903 60413247

Unit: mm (ftÂ·in)

2-5

SPECIFICATIONS (2) BOOM WITH ARM CYLINDER

Model L X H X W mm (ft-in)

E9SR Evolution 1440 X 515 X 220 (4´-8.7˝ X 1´-8.3˝ X 8.7˝)

Weight w/Arm cyl.kg(lb)

45 (99) F21487gb

(3) LONG ARM & STANDARD BUCKET

Model

E9SR Evolution

L X H X W mm (ft-in)

1535 X 265 X 350 (5´-0.4˝ X 10.4˝ X 1´-1.8˝)

Weight kg(lb)

58 (128) F21488gb

(4) LONG ARM Model

E9SR Evolution

L X H X W mm (ft-in)

1150 X 255 X 175 (3´-9.3˝ X 10.0˝ X 6.9˝)

Weight kg(lb)

42 (93) F21489gb

(5) STANDARD BUCKET (REFERENCE ONLY) Model

E9SR Evolution

Heaped capacity m3 (cu·yd)

0.022 (0.029) 380 X 355 X 350 (1´-3.0˝ X 1´-2.0˝ X 1´-1.8˝)

L X H X W mm (ft-in) Weight kg (lb)

16.5 (36.4) F21490gb

(6) DOZER

Model L X H X W Ret/Ext mm (ft-in) Weight kg(lb)

E9SR Evolution 660 X 195 X 750/980 (2´-2.0˝ X 7.7˝ X 2´-2.5˝) 42 (93) F21533gb

2-6

14903 60413247

W/o cylinder weight

SPECIFICATIONS

6. TYPE OF CRAWLER SHOES

Type

Model

Shoe width mm (in)

E9SR

180 (7.1)

Total crawler width mm (ft-in)

Ground pressure kgf/cm2 (psi)

Rubber shoe

Retracted: 1450 (2´-5.5˝) 0.25 (3.6)

Extended: 980 (3´-2.6˝)

F21536gb

7. TYPE OF BUCKET (Reference only) Heaped capacity m3 (cu·yd)

Outside width of bucket mm (ft-in)

Number of teeth

Weight kg (lb)

Remarks

0.022 (0.028)

350 (1'-2")

16,5 (36)

Standard

0.018 (0.023)

300 (1'-1.2")

15,5 (34)

Optional

0.014 (0.018)

250 (1'-1")

14,5 (32)

Optional

14903 60413247

F21535gb

2-7

SPECIFICATIONS

8. MACHINE LIFTING PROCEDURE LIFTING PROCEDURES FOR THE MACHINE COMPLETE WARNING • The wire ropes to be used for lifting the machine should have sufficient strength against the machine weight. • Improper lifting method and/or roping manner might cause for a movement or slip of the machine while it is lifted up, resulting serious injury or damages on the machine. • Do not impose a load suddenly on the wire ropes and slings. • When the lifting work is carried out in cooperation with plural persons, make sure to ensure every situations with exchanging signals with each other. • During the lifting work, keep any persons away from around the lifting machine, especially under the machine.

Carry out the lifting work at a level ground. [1] Manipulate each operating lever to take the machine a position as shown in the figure. [2] Operate the boom swing pedal to face the boom directly in front. [3] Stop the engine, and make the safety lock lever to "LOCKED" position. Then take off the machine after confirmation for no abnormalities around the operator’s seat. [4] Rope the wires to the shackles under the floor mat (Location is this side of slewing lock lever and crawler frame width / dozer selector lever).

14903 60413247

[5] Slightly lift the machine to confirm the balance, then lift up the machine.

2-8

SPECIFICATIONS

9. ATTACHMENT WORKING RANGES (LONG ARM/STANDARD BUCKET)

14903 60413247

Unit: mm (ft-in) Model

E9SR

Attachment Arm Item Bucket A Max. digging reach A' Max. digging reach at ground level B Max. digging depth C Max. digging height D Max. dumping clearance E Min. dumping clearance F Max. vertical wall digging depth G Min. front slew radius H Height at min. slew radius Stroke K Horizontal digging stroke at ground level Minimum L Above X Dozer strokes Below Y

Long 925 mm (3´-0.4˝) Standard 0.022 m3(0.029 cu.yd) 3300 (10´-9.9˝) 3210 (10´-6.4˝) 1750 (5´-8.9˝) 3160 (10´-4.4˝) 2320 (7´-7.3˝) 740 (2´-5.1˝) 1460 (4´-9.5˝) 1390 (4´-6.7˝) 2240 (7´-4.2˝) 1520 (4´-11.8˝) 1060 (3´-5.7˝) 190 (7.5˝) 240 (9.4˝) F21486gb

2-9

SPECIFICATIONS

10. LIFTING CAPACITIES (1) Conditions of calculation 1) The lifting load shows the lower value either 87% of lifting capacity by hydraulic pressure, or 75% of tipping load. 2) The load point is on the bucket lift point, and the bucket cylinder is extended (bucket IN). 3) Weight of hooks, slings, and all other lifting equipment shall be considered a part of the load. 4) The values in the upper rows show the lifting capacity at a machine facing sideways, and values in the lower rows show a machine facing longitudinally. 5) Unit: ton Crawler: 180 mm (7.1 in), Rubber crawler shoe. 6) Set hydraulic pressure 210 kgf / cm2 (2990 psi) (2) Reference No. list of lifting conditions E9SR EVOLUTION Attachment Crawler width Dozer blade position Figure No.

Long Arm + Standard Bucket 0.925m (3'0.4") + 0.022m3 (0.029 cuÂˇyd) EXPANDING 980mm (3'2.6")

Up and Front

Up and Rear

(1)

(2)

WARNING Hydraulic excavator whose crawler can be changed its width, is dangerous due to losing its side-way stability when the crawler is retracted. Lifting work is prohibited for the machine with contracted crawler width.

E9SR EVOLUTION (1) LONG ARM Crawler width: Expanding Dozer blade: Up and Front

Unit: ton

14903 60413247

Unit: ton

(2) LONG ARM Crawler width: Expanding Dozer blade: Up and Rear

2-10

SPECIFICATIONS

11. ENGINE SPECIFICATIONS 11.1 SPECIFICATIONS

E9SR EVOLUTION Engine Model Type mm x mm No. of cylinders - BoreXStroke L Total displacement Compression ratio Rated output Maximum torque Low idling High idling Fuel consumption rate Allowable tilting angles Rotating direction Firing order Fuel injection timing ( FID b.T.D.C.) degree (° ) Fuel injection pressure degree (° ) Intake valve Exhaust valve Intake valve Valve clearance Exhaust valve °C Thermostat action Start/ Full open Compression pressure Lubrication oil pressure Dimensions L X W X H Dry weight Governor Lubrication system Cooling system Starter capacity Generator capacity Cooling water capacity : Max / Engine Engine oil volume : Max / Effective Valve action

2TNE68-YB Vertical, 4-cycle water-cooled diesel engine 2-68 (2.68 in) X 72 (2.83 in) 0.52 (31.7 cu·in) 23.0 7.8 PS (5.7 kW) at 2000 rpm 3.1~3.4 kgf·m (22.4~24.6 ftl·bs) at 1500 rpm 1300 ± 25 rpm 2180 ± 25 rpm Less than 200 g / PS·h Back and forth, left and right 25° (momentary 30°) Counterclockwise as seen from flywheel side 1-2-1 14±1 120+100 kgf/cm2(1710+1400 psi) Open Close b.T.D.C 10±5 a.B.D.C 42±5 b.T.D.C 42±5 a.B.D.C 10±5 0.2 mm (0.008 in) in cold condition 0.2 mm (0.008 in) in cold condition 71±1.5 (160±3°F) / 85 (185°F) 33 ± 1 kgf / cm2 (469 ± 14psi) at 250 rpm 3.5 ± 0.5 kgf / cm2 (50 ± 7psi) at 2000 rpm 389 X 405 X 505 mm (15.3 X 15.9 X 19.9 in) 65+50 kgf (143+110 lbs) Mechanical centrifugal governor (All speed type) Forced lubrication with trochoid pump Liquid cooling / Radiator 12V X 0.9 kW 12V X 20A 2.2/0.6 l (0.58/0.16 gal) 1.7/0.7 l (0.45/0.18 gal)

14903 60413247

F22310

2-11

SPECIFICATIONS 11.2 ENGINE PERFORMANCE CURVE

(T) kgf·m

SHAFT TORQUE

3.1 ~ 3.4

(T) (N·m)

(30.4 ~ 33.3)

E9SR EVOLUTION Model: 2TNE68-YB Rated Output: 7.8 PS / 2000 rpm (5.7 kW / 2000 min-1)

(P) PS

POWER OUTPUT

(P) (kW)

(5.7 ± 3%)

7.8 ± 3%

1500 ± 100

<= 200 (<= 272)

FUEL CONSUMPTION RATE

(F) g/PS·h

FUEL CONSUMPTION RATE

(F) (g/kW·h)

Fuel consumption volume =

F X1000

200 X 7.8 X 0.835 X 1000

= 1.87 2-12

XPX

F : Fuel consumption rate (g / PS·h) P : Shaft output (ps) : Specific gravity : Standard load factor (0.60 ~ 0.70) Fuel consumption in normal operation; 1.1 ~ 1.3 / h (load factor : (0.60 ~ 0.70)

14903 60413247

Engine speed rpm x 100

SECTION 3

ATTACHMENT DIMENSIONS

TABLE OF CONTENTS 1. Boom ...................................................................................................................... 3-1 1.1 Boom dimensional drawings ........................................................................................................... 3-1 1.2 Boom maintenance standards ........................................................................................................ 3-2

2. Arm ......................................................................................................................... 3-4 2.1 Arm dimensional drawings (long arm) ............................................................................................. 3-4 2.2 Arm maintenance standards ............................................................................................................ 3-5

3. Bucket..................................................................................................................... 3-8 3.1 Bucket dimensional drawings ........................................................................................................... 3-8 3.2 Detail dimension of lug section ........................................................................................................ 3-9 3.3 Detail dimensional drawings of boss section ................................................................................. 3-10

4. Dozer .................................................................................................................... 3-11 4.1 Dozer dimension ............................................................................................................................ 3-11 4.2 Dozer maintenance standards ....................................................................................................... 3-12

5. Swing .................................................................................................................... 3-14

14903 60413247

5.1 Swing bracket dimensional drawings ............................................................................................. 3-14 5.2 Swing maintenance standards ....................................................................................................... 3-15

ATTACHMENT DIMENSIONS

1. BOOM 1.1

BOOM DIMENSIONAL DRAWINGS

Fig. 1-1 Boom dimensional drawings

Table 1-1

14903 60413247

No. A B C D E F G H J K d1 d2 d3 d4

Unit: mm (ft·in) NAME Boom length Boom foot width Boom end inner width Boom end outer width Height of boom cylinder rod pin Height of arm cylinder (head side) pin Distance between pins of boss Distance between pins of bracket Arm cylinder (head side) inner width Inner width bracket for boom cylinder (rod side) mounting section

Boom foot pin dia. Boom cylinder (head side) pin dia. Pin dia. of arm end Arm cylinder (head side) pin dia.

DIMENSIONS 1,380 (4' 6.33") 140 (5.51") 103 (4.06") 143 (5.63") 188 (7.40") 440 (1'5.32") R751.3 (2'5.58") R720.1 (2'4.35") 42 (1.65") 47 (1.85") ø30 (1.18") ø30 (1.18") ø30 (1.18") ø30 (1.18") F22313

3-1

ATTACHMENT DIMENSIONS 1.2 BOOM MAINTENANCE STANDARDS (1) Clearance of pin and bushing on boom section

Fig. 1-2 Clearance of pin and bushing on boom section

Table 1-2 POS.

Unit: mm (in) ITEM

Boom foot

Boom cylinder (Head side)

Boom cylinder (Rod side)

Arm cylinder (Head side)

STANDARD DIMENSIONS CLEARANCE REMEDY Tolerance Standard Pin dia. Tolerance on bushing Standard value for Service value on pin dia. limit bore dia. repairl

( Ø30 (1.1811)

-0.02 -0.05 -0.0008 -0.0020

) (

+0.11 +0.06 +0.0043 +0.0024

)

0.08 ~0.16 (0.0031 ~ 0.0063)

[( )] ( ) [( )] (

-0.03 -0.05 -0.0012 -0.0020 -0.03 -008 -0.0012 -0.0031

+0.18 +0.05 +0.0071 +0.0020

)

(

0.08~ 0.23 0.0031~ 0.0091 0.08~ 0.26 0.031~ 0.0102

Replace 0.5 0.8 bushing (0.020) (0.031) or pin

) F22315

ITEM

Boom foot

Boom cylinder (Head side)

Boom cylinder (Rod side)

Arm cylinder (Head side)

STANDARD DIMENSIONS CLEARANCE REMEDY Tolerance Standard Pin dia. Tolerance on bushing Standard value for Service value on pin dia. limit bore dia. repairl

( Ø30 (1.1811)

-0.02 -0.05 -0.0008 -0.0020

) (

-0.03 ( -0.0012 -0.08 ) -0.0031

(

+0.05 0 +0.0020 0

)

+0.18 +0.05 +0.0071 +0.0020

)

0.02 ~0.10 (0.0008 ~ 0.0039)

0.08 ~ 0.26 (0.0031 ~ 0.0102)

Replace 0.5 0.8 bushing (0.020) (0.031) or pin

F22316

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

3-2

14903 60413247

POS.

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

SECTION A-A

SECTION C-C

SECTION B-B

SECTION D-D

Table 1-3

Unit: mm (ftÂ·in) STANDARD DIMENSIONS

Pos.

ITEM

14903 60413247

No. A

Boom foot

Boom cylinder (Head side)

Boom cylinder (Rod side)

Arm cylinder (Head side)

Boom Swing bracket Boom cylinder Swing bracket Boom cylinder Boom Arm cylinder Boom

Dimensions

CLEARANCE X RECONDITIONED WITH SHIM (Total of both sides)

Standard Standard Service value value for repair limit

-0.004 140 -0.1 -0.2 (5.51 -0.008 ) 0.1~0.5 L1 +0.012 (0.004~0.020) ) 140+0.3 0 (5.51 0 0 0 (1.77 45 -0.5 -0.020 ) 0.1~2.5 L2 +2.0 +0.079 (0.039~0.098) 46 0 (1.81 0 ) 0 0 (1.77 -0.020 ) 45 -0.5 +1.0 +0.039 47 0 (1.85 0 ) 0 0 (1.57 -0.020 ) 40 -0.5 L4 +1.0 +0.039 42 0 (1.65 0 )

Less than 0.5 (0.020)

Pin length REMEDY No. Dimensions 189 (7.44) 111 2 (4.37) Reconditioned 139 by shim 3 (5.47) 134 4 (5.28) 1

See "NOTE"

1.0

1.5

(0.039)

(0.059)

F22318

NOTE: Clearance "X" shall be adjusted with shims, if clearance exceeds the standard value.

3-3

ATTACHMENT DIMENSIONS

2. ARM 2.1

ARM DIMENSIONAL DRAWINGS (LONG ARM)

SECTION ZZ

SECTION XX

SECTION YY

Fig. 2-1 Arm dimensional drawings (long arm)

No. A B C D E F G H J K L

3-4

Unit: mm (ft·in) NAME

Arm length Distance between pins of boss and bracket Distance between pins of boss and bracket Distance between pins of boss and boss Height between pins of boss and bracket Height between pins of boss and bracket Height between pins of boss and center Boss width Boss width Bracket inner width Bracket inner width

DIMENSIONS

No.

925 (3'0.42") R190 (7.48") R625 (2'0.61") R80 (3.15") 167 (6.57") 107 (4.21") 6 (0.24") 107 (4.21") 103 (4.06") 42 (1.65") 42 (1.65")

M N D1 D2 D3 d1 d2 d3 d4 d5

NAME Link dimension Link dimension I.D. of boss I.D. of boss I.D. of boss Pin dia. Pin dia. Pin dia. Pin dia. Pin dia.

DIMENSIONS 160 (6.30") 145 (5.71") ø35 (1.38") ø35 (1.38") ø40 (1.57") ø25 (0.98") ø25 (0.98") ø30 (1.18") ø25 (0.98") ø30 (1.18")

14903 60413247

Table 2-1

ATTACHMENT DIMENSIONS 2.2 ARM MAINTENANCE STANDARDS (1) Clearance of pin and bushing

Fig. 2-2 Clearance of pin and bushing on arm section

Unit: mm (in)

14903 60413247

Table 2-2

3-5

ATTACHMENT DIMENSIONS Clearance of pin and bushing

Fig. 2-3 Clearance of pin and bushing on arm section

Unit: mm (ft·in)

14903 60413247

Table 2-3

3-6

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

SECTION AA SECTION DD SECTION EE * SECTION GG

SECTION BB

SECTION CC

SECTION FF

Fig. 2-4 Clearance in thrust direction

14903 60413247

* Total clearance of both sides to be 0.2 ~ 0.5 mm (0.0079˝ ~ 0.020˝) or less after adjusting by shims. Table 2-4 Unit: mm (ft·in)

NOTE: Clearance "X" shall be adjusted by shims, if clearance exceeds the standard value for repair. 3-7

ATTACHMENT DIMENSIONS

3. BUCKET 3.1

BUCKET DIMENSIONAL DRAWINGS

Fig. 3-1 Bucket dimensional drawings

Table 3-1 CODE A B C D E F G H I d1 d2

Unit: mm (ft·in) HEAPED CAPACITY m3(cu.yd)

0.014 (0.018)

0.018 (0.024)

Distance between pin and bracket Distance between bucket pin and tooth end Inner width of bucket top end Inner width of lug Inner width of bracket Outer width of side cutter Inner width of bracket bottom Outer tooth distance Pitch between teeth Pin dia. Pin dia.

100 (3.94") R420 (16.54") 216 (8.50") 141 (5.55") 109 (4.29") 250 (9.84") 187 (7.36") 170 (6.69") 85 (3.35") ø25 (0.98") ø25 (0.98")

← ← 266 (10.47") ← ← 300 (11.81") 237 (9.33") 220 (8.66") 110 (4.33") ← ←

NAME

S.T.D. 0.22 (0.029) ← ← 316 (1'0.44") ← ← 350 (1'1.78") 287 (11.30") 236 (9.29") 118 (4.65") ← ← F22328

14903 60413247

NOTE: Standard bucket.

3-8

ATTACHMENT DIMENSIONS 3.2

DETAIL DIMENSION OF LUG SECTION

DETAIL OF Y

SECTION XX Fig. 3-2 Dimension of lug section

14903 60413247

Dimension

Spot facing Bore dia./ Bore depth

Bore dia.

Spring pin dia.

Plate outer dia.

Screw dia.

Plate width

Boss end outer dia.

Boss outer dia.

Boss width

Capscrew P.C.D.

No.

Lug plate thickness

Portion

Unit: mm (in)

Pin bore dia.

Table 3-2

øA

øC1/C2

øD

øE

øF

øI

øN

25+0.08 0 (0.98+0.003 0 )

12 18/2.5 35+0.11 6 Refer (0.472) (0.709/ (0.236) to +0.09 0.098) (1.378 Fig.Z

6 (0.24)

47 (1.85)

55 (2.17)

16 (0.63)

57 (2.24)

+0.0043

)

-0.0035

F22330

NOTE: Standard bucket.

3-9

ATTACHMENT DIMENSIONS 3.3

DETAIL DIMENSIONAL DRAWINGS OF BOSS SECTION

DETAIL X

Fig. 3-3 Dimension of boss section

Table 3-3 No.

øA

øB

øC

øD

øG

50.8

26.8

44.5

48.5

(2.00)

(1.055)

(1.75)

(1.91)

(0.472)

(0.945)

(0.433)

14903 60413247

Dimension

Unit: mm (in)

3-10

ATTACHMENT DIMENSIONS

4. DOZER 4.1

DOZER DIMENSION

“X”

VIEW “X”

Fig. 4-1 Dozer dimensional drawings

Table 4-1

14903 60413247

No. A A0 B C D E F G d1 d2

Unit: mm (ft·in)

NAME Blade width (Extended) Blade width (Retracted) Blade height Distance from dozer attaching pin center to cutting edge end Inner width of dozer attaching bracket Width of dozer attaching bracket Distance from dozer attaching pin center to attaching pin on dozer cylinder head side Attaching bracket inner width on dozer cylinder head side Dozer attaching pin dia. Attaching pin dia. on dozer cylinder head side

DIMENSION 980 (3'2.58") 750 (2'5.53") 200 (7.87") 616 (2'0.25") 262 (10.31") 38 (1.50") R500 (1'7.69") 37 (1.46") ø25 (0.984") ø25 (0.984") F22334

3-11

ATTACHMENT DIMENSIONS 4.2

DOZER MAINTENANCE STANDARDS

0.5~1.0 (0.02”~0.04”)

PIN C PORTION

PIN A PORTION

PIN B PORTION

(1) Clearance of pin and bushing Table-4-2

Unit: mm (in)

14903 60413247

3-12

ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the dozer and cylinder installation section Table 4-3

Unit: mm (in)

14903 60413247

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

3-13

ATTACHMENT DIMENSIONS

5. SWING 5.1

SWING BRACKET DIMENSIONAL DRAWINGS

Fig.5-1 Swing bracket dimensional drawings

Table 5-1

A B C D E F G H J d1 d2 d3 d4

ITEM Distance between swing center pin and boom foot pin Distance between boom foot pin and boom cylinder pin - ditto Distance between swing center pin and swing cylinder pin - ditto Inside width of swing center Inside width of boom foot Inside width for installing boom cylinder Inside width for installing swing cylinder Pin dia. of swing center Pin dia. of boom foot Pin dia. of boom cylinder Pin dia. of swing cylinder

DIMENSIONS 40 (1.57) 98 (3.86) 150 (5.91) R161 (R6.34) 124 (4.88) 180 (7.09) 140 (5.51) 46 (1.81) 47 (1.85) ø40 (1.57) ø30 (1.18) ø30 (1.18) ø40 (1.57)

14903 60413247

NO.

Unit: mm (in)

F22339

3-14

ATTACHMENT DIMENSIONS 5.2

SWING MAINTENANCE STANDARDS Place steel shim to lower side. Clearance of upper side to be 2.0 mm (0.079 in) or less. Shims placed on one place must be one.

SECTION AA

Place steel shim to cylinder side.

Place 1 mm (0.039in) thick.steel shim to upper side.Clearance of upper side to be 0.5 mm~1.0 mm (0.020~0.039 in)

SECTION CC

Fig.5-2 Clearance of pin and bushing

SECTION BB

(1) Clearance of pin and bushing

14903 60413247

Table 5-2

Unit: mm (in)

3-15

ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on swing bracket and cylinder installation section. Table 5-3

Unit: mm (in) STANDARD DIMENSIONS

Pos.

B C

PIN LENGHT

Standard value

Standard value for repair

Service limit

No. Dimensions

Less than 2.0 (0.079)

2.5 (0.098)

99 (3.90)

0.5~1.0 1.5 (0.020~0.039) (0.059)

90 (3.54)

233 (9.17)

ITEM No.

CLEARANCE X RECONDITIONED WITH SHIMS (total of both sides)

Swing cylinder (Rod side) Swing cylinder (Head side) Swing center (Upper)

Rod side Bracket Cylinder Upper frame Upper frame Bracket

Dimensions

0 45 -0.5 +2 47 0 0 45 -0.5 L2 +1 47 0 180±0.5 L3 180±0.5

0 (1.772 -0.020 ) +0.079 (1.850 0 ) 0 (1.772 -0.020 ) +0.039 (1.850 0 ) (7.087±0.020) (7.087±0.021)

0~1.0 (0~0.039)

REMEDY

Reconditioned with shim

F22342

14903 60413247

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

3-16

SECTION 11

TOOLS

TABLE OF CONTENTS 1. Torque specifications for capscrews and nuts ....................................................... 11-1 2. Screw size to tool sizes ......................................................................................... 11-2 3. Torque specifications for joints and hoses ............................................................. 11-2 4. Torque specifications for sleeve type tube fittings.................................................. 11-3 5. Plugs ..................................................................................................................... 11-4 6. Special spanners for tubes .................................................................................... 11-6

14903 60413247

7. Application of screw locking and sealing compounds ........................................... 11-6

TOOLS

1. TORQUE SPECIFICATIONS FOR CAPSCREWS AND 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. • Numerical indication on the capscrew head shows Refer to the table below for the tightening and retightening of capscrews. the classification for strength (e.g., 7 = 7 T). No • The table below is not applicable for the capscrews indication is provided for smaller size of capscrews, to fix the cover, etc., made of plastic. For the tightM 5 or less. ening torque for such capscrews, consult with an CLASSIFICATION 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. 2.Metric caorse thread standard tightening torque values. Make certain to tighten all capscrews & nuts to proper torque values. Classification NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION

TORQUE VALUE UNIT-kgf·m (lbf·ft)

2.Metric fine thread standard tightening torque values. Make certain to tighten all capscrews ans nuts to proper torque values. Classification

14903 60413247

NOMINAL SIZE NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION NO LUBRICATION OIL LUBRICATION

TORQUE VALUE UNIT-kgf·m (lbf·ft)

11-1

TOOLS

2. SCREW SIZE TO TOOL SIZES 1) Capscrew

2) Socket bolt

Table 2-1 Nominal screw size (d) M6 M8 M10 M12 M16 M20 M24 M30 M36

Table 2-2 Nominal screw size (d) M6 M8 M10 M12 M14 M16 (M18) M20 M24 M30 M36

B mm Tool size 10 13 17 19 24 30 36 46 55

B mm Tool size 5 6 8 10 12 14 14 17 19 22 27

3. TORQUE SPECIFICATIONS FOR JOINTS AND HOSES A. JOINTS FOR PIPING (O-RING SEALING TYPE) Nominal screw

Spanner

Tightening

size (PF) 1/8 1/4 3/8 1/2 3/4 1

size (mm) 14 19 22 27 36 41

torque kg·m(lb·ft) 1.7 ± 0.2 (12.3 ± 1.4) 3.7 ± 0.2 (26.8 ± 1.4) 7.5 ± 0.5 (54.2 ± 3.6) 11 ± 1.0 (79.6 ± 7.2) 16.5 ± 1.0 (119 ± 11) 26.0 ± 1.0 (188 ± 7.2)

O-RING

B. HYDRAULIC HOSE (30° FLARE TYPE) Spanner

Tightening

size (PF) 1/8 1/4 3/8 1/2 3/4 1

size (mm) 14 19 22 27 36 41

torque kg·m(lb·ft) 1.5 ± 0.2 (11 ± 1) 3 ± 0.5 (21.7 ± 3.6) 5 ± 0.5 (36.2 ± 3.6) 8 ± 0.5 (57.9 ± 3.6) 12 ± 1.0 (86.8 ± 7.2) 14 ± 1.5 (101 ± 11)

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

11-2

UNION UNIT

14903 60413247

Nominal screw

TOOLS

4. TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS A. SLEEVE TYPE TUBE FITTINGS Tube size

Spanner

Tightening

CD X Thickness (mm) 10 x 1.5 15 x 2.0

size (mm) 19 27

torque kg·m(lb·ft) 4.5 ± 0.5 (33 ± 4) 15 ± 2.0 (110 ± 14)

18 x 2.5 22 x 3.0 28 x 4.0 35 x 5.0

32 36 41 55

18 ± 2.0 (130 ± 14)) 22 ± 2.0 (160 ± 14) 28 ± 3.0 (200 ± 22) 45 ± 4.5 (330 ± 33)

B. PART NO. Tube size

SLEEVE

14903 60413247

Ød 6 8 10 12 15 18 22 28 32 35 38

Tube size

Opposing

Ød

flats (HEX) B 14 17 19 22 27 32 36 41 50 55 60

6 8 10 12 15 18 22 28 32 35 38

NUT

11-3

TOOLS

5. PLUGS (1) Plug for hydraulic pipe joint 1) Cap nut (joint plug)

Table 5-1 Applicable Tube O. D: A 6 8 10 12 15 18 22 28

T screw

2) Plug (tube plug)

T screw

Opposing flat

M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M26 x 1.5 M30 x 1.5 M36 x 1.5 M42 x 1.5 M45 x 1.5 M48 x 1.5

14 17 19 22 27 32 36 41 50 55 60

Table 5-2

Sleeve type joint body

Nut

3) Nut

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

Opposing flat

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

14903 60413247

Table 5-3

D srew

11-4

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

Opposing flat H1 H 14 14 17 17 17 19 19 22 24 27 27 32 32 36 38 41

T screw

TOOLS (2) Plug for hydraulic equipment 1) PF screw

Table 5-4 PF screw PF 1/4 PF 3/8 PF 1/2 PF 3/4 PF 1

O ring

B mm 19 22 27 36 41

Nominal O-ring 1B P11 1B P14 1B P18 1B P24 1B P29

PF screw

Table 5-5

2) PT screw

PT screw PT 1/8 PT 1/4 PT 3/8 PT 1/2 PT 3/4 PT 1 PT 1 1/4 PT 1 1/2

PT screw

(3) Plug for (F) flare hose

B mm 5 6 8 10 14 17 22 22

Table 5-6

PT screw

Opposing flat B

PF screw PF 1/4 PF 3/8 PF 1/2 PF 3/4 PF 1

B mm 14 17 22 27 36

14903 60413247

Table 5-7

PF screw Opposing flat F

Opposing flat E

PF screw PF 1/4 PF 3/8 PF 1/2 PF 3/4 PF 1 PF 1 1/4

E mm 14 17 23 27 36 40

F mm 19 22 27 36 41 50

11-5

TOOLS

6. SPECIAL SPANNERS FOR TUBES Table 6-1 Applicable tube diameter mm (in)

HEX mm

15 (0.591)

Dimensions of a special spanner mm (in)

42 (1.65)

18 (0.709)

11.5(0.453)

22 (0.866)

14.5(0.571)

7. APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS Table 7-1 Manufacturer Service

Screw locking compound

Three-Bond

#242

1360K

Low strenght

#262

1374

Middle strenght

#271

1305

Hight strenght

#515

1215

Sealing 14903 60413247

Sealing compound

Features Loctite

11-6

SECTION 12

STANDARD MAINTENANCE TIME TABLE

TABLE OF CONTENTS

14903 60413247

1. Standard working time table for the maintenance of excavator ............................. 12-1

STANDARD MAINTENANCE TIME TABLE

1. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

(1) Standard maintenance time table 1) Units of working time: 6 minutes = 0.1 hour

2) Calculating method of standard maintenance time: Maintenance time = Working time X Number of workers (Working time = Maintenance time / Number of workers) 3)

01 Attachment

; Flexible hose ; Installation ; Overhaul ; Solenoid ; Switch ; Valve

(2) Classification of work code

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 •

No. 01 02 03 04

GROUP REMARK Attachment To indicate removing, Canopy and Guard installing, replacement Upper Structure and overhaul. Under carriage F14813

O / H: The removing and installing time are not included.

GROUP No. 00 01 02 03 04 05 06 07 10 11 12

14903 60413247

Abbreviations in the table. ASSY ; Assembly F hose ATT ; Attachment Inst. BRG ; Bearing O/H C/V ; Control valve SOL Cyl ; Cylinder SW E/G ; Engine V

13 14 15 16 17 18 20 21 22 23 24 25 26

EQUIPMENT PORTION Bucket portion Bucket ASSY • Bucket removing/ installing position • Bucket installing pin • Bucket drive pin • Bucket sling and transfer Bucket (Single) • Bushing Arm portion Arm ASSY • Bucket cylinder removing/ installing position and piping • Bucket cylinder rod pin • Bucket cylinder head pin • Bucket cylinder assy • Arm cylinder rod pin • Boom top pin • Arm sling and transfer Boom portion Boom ASSY • Boom removing/ installing position • Boom cylinder temporary slinging • Boom cylinder rod pin • Boom cylinder piping • Arm & Bucket piping

WORK TO BE UNIT DONE

REMARK

Refer to sec. 32 item 2 Removal/Inst. 1 pc. Include adjustment Preparation 1 pc. Removal/Inst. 1 pc. Include stopper pin. 1 pc. - ditto Preparation 1 pc. 1 pc. Not include removal / inst. O/H 1 pc. Replace Refer to sec. 32 item 3 Removal/Inst. 1 pc. Preparation 1 pc. 1 pc. Include stopper pin. 1 pc. Include stopper pin. 1 pc. 1 pc. Include stopper pin. 1 pc. 1 pc. Refer to sec. 32 item 4 Removal/Inst. 1 pc. Preparation 1 pc. 1 pc. – ditto – Removal/Inst. 1 pc. Include stopper pin. 1 pc. – ditto – 1 pc. – ditto –

Removal/Inst. – ditto – – ditto – – ditto – – ditto – – ditto –

UNIT: HOUR 0.4 0.1 0.1 0.1 0.1 0.6 0.5 0.8 0.2 0.1 0.1 0.1 0.1 0.1 0.1 1.0 0.1 0.1 0.1 0.1 0.2 F14814

12-1

14903 60413247

STANDARD MAINTENANCE TIME TABLE

12-2

14903 60413247

STANDARD MAINTENANCE TIME TABLE

12-3

14903 60413247

STANDARD MAINTENANCE TIME TABLE

12-4

14903 60413247

STANDARD MAINTENANCE TIME TABLE

12-5

14903 60413247

STANDARD MAINTENANCE TIME TABLE

12-6

SECTION 13

MAINTENANCE STANDARDS AND TESTS PROCEDURES

TABLE OF CONTENTS 1. How to use maintenance standards and precautions ........................................... 13-1 2. Performance inspection standard table ................................................................ 13-2 2.1 Standard value ............................................................................................................................... 13-2

3. Measuring engine speed ...................................................................................... 13-4 3.1 Engine speed measurement .......................................................................................................... 13-4

4. Measuring hydraulic oil pressure .......................................................................... 13-6 4.1 Standard for hydraulic oil pressure measurement .......................................................................... 13-6 4.2 Pressure measurement and adjustment ........................................................................................ 13-6

5. Measuring travel performances ............................................................................ 13-9 5.1 Travel .............................................................................................................................................. 13-9 5.2 Travel deviation ............................................................................................................................... 13-9 5.3 Movement drift due to gravity ....................................................................................................... 13-10 5.4 Drain rate on travel motor ............................................................................................................. 13-10

6. Measuring slew performances ........................................................................... 13-11 6.1 Slew time ...................................................................................................................................... 13-11 6.2 Overrun when slewing stops ........................................................................................................ 13-11 6.3 Slew drift due to gravity ................................................................................................................ 13-11 6.4 Drain rate of travel motor .............................................................................................................. 13-12

7. Measuring attachment operating performances ................................................. 13-13

14903 60413247

7.1 Cylinder speed ............................................................................................................................. 13-13 7.2 Gravity drift of cylinders ................................................................................................................ 13-14

8. Measuring slew bearing performances .............................................................. 13-15 8.1 Slew bearing-bucket tip play ........................................................................................................ 13-15 8.2 Slew bearing play ......................................................................................................................... 13-15

9. Measuring crawler tension ................................................................................. 13-15 9.1 Crawler tension ............................................................................................................................ 13-15

MAINTENANCE STANDARDS AND TESTS PROCEDURES

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).

14903 60413247

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, Orings, 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. 3) Inspection and 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 AND MAINTENANCE MANUAL as well.

13-1

MAINTENANCE STANDARDS AND TESTS PROCEDURES

2. PERFORMANCE INSPECTION STANDARD TABLE 2.1 STANDARD VALUE

14903 60413247

E9SR

*1: The pressure for slew is controlled by the relief valve attached to the slew motor. The figures in [ ] show the setting pressure on single body of slew motor relief. 13-2

MAINTENANCE STANDARDS AND TESTS PROCEDURES

14903 60413247

E9SR

13-3

MAINTENANCE STANDARDS AND TESTS PROCEDURES

3. MEASURING ENGINE SPEED 3.1 ENGINE SPEED MEASUREMENT PICK UP

(1) Measuring instruments 1) Diesel speedmeter (measuring engine speed by means of applying a pick-up to one of injection pipes). 2) Surface thermometer (measuring the surface temperature getting contact of the probe with the surface of hydraulic oil tank and radiator).

(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 RED approx. 67 to 105 째C (153 to 221 째F) of temperature range. WHITE Therefore, when the indicator is located at around center of the BLUE white zone, it is suitable for the engine operation.

(3) Engine speed measurement 1) Apply the pick up of speedmeter to one of convenient injection pipes.

SPEED METER

Fig. 3-1 Engine speed measurement (The above figue shows concept)

14903 60413247

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

13-4

MAINTENANCE STANDARDS AND TESTS PROCEDURES (4) Speed adjustment 1) Low / High idling speeds is low; the proper engine speed is obtained with specified length of accelerator wire as shown in the lower sketch. When the engine speed is lower than the standard speed due to improper length of the wire, adjust it with the capscrew (8).

DECELERATION MOTOR (OPT)

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

9” )

VIEW A

DETAIL “Y” DETAIL “X”

DETAIL Y

14903 60413247

Fig. 3-2 Acelerator wire adjustment

13-5

MAINTENANCE STANDARDS AND TESTS PROCEDURES

4. MEASURING HYDRAULIC OIL PRESSURE 4.1 STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT (1) Hydraulic instruments 70 kgf/cm2 (1000 psi) pressure gauge ..... 1 set 500 kgf/cm2 (7110 psi) pressure gauge .. 3 sets Surface thermometer ............................... 1 set Pressure measuring kit and Oil analyzing equipment ........................ 1 set (2) Measuring cleanliness of hydraulic oil WARNING 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.

CONTROL VALVE

4.2 PRESSURE MEASUREMENT AND ADJUSTMENT 4.2.1 Main circuit pressure (1) Measuring conditions Engine speed: high idling Hydraulic oil temperature: 50 ~ 60 째C (122 ~ 140 째F). Coolant temperature (on radiator surface): 60~90 째C (140 ~ 194 째F).

13-6

SLEWING MOTOR

Fig. 4-1 Main hydraulic oil pressure measurement

Operating circuit

Press. detecting port Relief Port location Size valve

Boom, bucket, swing & travel (left)

Arm & travel (left)

RV1 RV2 PF 1/4

Dozer/crawler width, service P1, P2

RV1, RV2

Slew

SR4, SR5

14903 60413247

(2) Pressure measuring procedures 1) Set the pressure gauge to the pressure detecting port (plugged) and operate the circuit to be measured to measure the relief pressure. 2) When the main relief pressure is being within the standard range, the measurement for the overload relief pressure may be omitted. 3) If the main relief pressure is lower than the standard range, tighten up the main relief valve by half turn [pressure increase by 80~90 kgf/cm2 (1140~1280 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.

MAINTENANCE STANDARDS AND TESTS PROCEDURES (3) Pressure adjustment (A) Control valve: main relief valve and overload relief valve 1) Loosen the lock nut (2), and adjust the setting pressure turning the setscrew (1). Roughly with one full turn: main relief valve P1: approx. 160 kgf/cm2 (2280 psi) main relief valve P2: approx. 180 kgf/cm2 (2560 psi) Port relief valve: approx. 160 kgf/cm2 (2280 psi) CW turning ............ increasing setting pressure CCW turning ........ decreasing setting pressure 2) After the adjustment, tighten up the lock nut holding the setscrew not to turn around. 3) Again activate the relief valve to check the stable setting pressure. Tightening torque for nut (2): 3±0.2 kgf·m (22±1 lbf·ft)

Fig. 4-3 Relief valve (slewing motor)

14903 60413247

(B) Slewing motor: relief valve 1) Remove the cap nut (1), and loosen the lock nut (2) Then adjust the setting pressure turning the setscrew (3). Roughly with one full turn: approx. 37 kgf/cm2 (530 psi) CW turning ........... Increasing setting pressure CCW turning ....... Decreasing setting pressure 2) After the adjustment, tighten up the lock nut holding the setscrew not to turn around. 3) Again activate the relief valve to confirm the stable setting pressure.

Fig. 4-2 Main relief valve / Overload relief valve

13-7

MAINTENANCE STANDARDS AND TESTS PROCEDURES 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 (2) Measurement Setting pressure gauge to the pressure detecting port (plugged ), measure the pilot relief pressure.

Pressure detecting port Port location Size A PF1/4

Relief valve

SOLENOID VALVE Fig. 4-4 Pilot oil pressure measurement

PR F22376

Fig. 4-5 Relief valve

14903 60413247

(3) Pressure adjustment Adjust it with the relief valve attached to the solenoid valve. 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. 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): 0.8 ± 0.1 kgf·m (6 ± 0.7 lbf·ft) : Relief valve (PR1) 4.5 ± 0.5 kgf·m (33 ± 4 lbf·ft) : Solenoid valve (3)

13-8

MAINTENANCE STANDARDS AND TESTS PROCEDURES

5. MEASURING TRAVEL PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement.

5.1 TRAVEL (1) Travel speed (5 revolutions) • Engine • Hydraulic oil temp.

: high idle : 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).

Fig. 5-1

(2) Travel speed (10m) • Engine • Hydraulic oil temp.

: rated r.p.m. : 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.

START

5m (16.4 ft) PRELIMINARY RUNNING

10m (32.8 ft) MEASUREMENT DISTANCE

Fig. 5-2

• 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.

GROUND CLEARANCE 30 ~ 40 cm (12~16 in) Fig. 5-3

5.2 TRAVEL DEVIATION

14903 60413247

• Engine • Hydraulic oil temp.

: rated r.p.m. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement posture : travel posture • Measure the deviation "X" at the point of half of 10m (32.8 ft) travel after 5m preliminary running. Measure on level and hard ground. X 10m (32.8 ft)

Fig. 5-4

13-9

MAINTENANCE STANDARDS AND TESTS PROCEDURES

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.

(Approx.1/3.73)

Fig. 5-5 Machine posture for measurement FORWARD

5.4 DRAIN RATE ON TRAVEL MOTOR (1) Preparation 1) Apply stopper pins for both travel sprockets of left and right. 2) Stop the engine, and release air in the hydraulic oil tank. 3) Connect a hose to the drain port of travel motor, and receive the drained oil in a container.

RIB "A" ROTATING DIRECTION STOPPER PIN Fig. 5-6 Location of stopper pin applied to travel sprocket

(3.94")

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.

(0.47")

(0.47") (2.76") MARK MODEL

38 90 E9SR EVOLUTION (1.50) (3.54)

(2) Measurement: • Engine • Hydraulic oil temp.

: at rated speed : 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.

øD

F22383

Fig. 5-7 Stopper pin size

SPEED SHIFT

1 st 2 nd

Fig. 5-8 Measure drain

DRAIN RATE OF TRAVEL MOTOR Standard value

Standard value for repair

1.5 (0.40) 1.0 (0.26)

2.3 (0.61)

Service limit 3 (0.79)

1.5 (0.40)

2 (0.53) F22384

13-10

14903 60413247

Unit: liter (gal.) / 30 sec.

MAINTENANCE STANDARDS AND TESTS PROCEDURES

6. MEASURING SLEW PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement.

BUCKET PIN

BOOM FOOT PIN

6.1 SLEW TIME • Engine • Hydraulic oil temp.

: high idle : 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 and bucket pin 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.

Same level

Fig. 6-1

6.2 OVERRUN WHEN SLEWING STOPS • Engine • Hydraulic oil temp.

: high idle : 50 ~ 60 °C (122 ~ 140 °F) • Measurement posture: same as that for measuring slew time. • 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. At which point return the operating lever to neutral. Measure the distance between the position marks and the point the hoe attachment stops.

Fig. 6-2

6.3 SLEW DRIFT DUE TO GRAVITY

14903 60413247

• Engine • Hydraulic oil temp.

: stopped : 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 that develops between the marks after 5 minutes. Measure for both RH and LH directions.

DISTANCE

(Approx. 1/3.73)

Fig. 6-3

13-11

MAINTENANCE STANDARDS AND TESTS PROCEDURES

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 • Hydraulic oil temp.

: at rated speed : 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.

Fig. 6-4 Receiving drain oil

Unit: liter (gal.) / 30 sec. DRAIN RATE OF TRAVEL MOTOR Model

Standard Standard value Serviceability value

E9SR

for repair

limit

0.10 (0.026) 0.15 (0.040) 0.20 (0.053)

14903 60413247

EVOLUTION

13-12

MAINTENANCE STANDARDS AND TESTS PROCEDURES

7. MEASURING ATTACHMENT OPERATING PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement.

7.1 CYLINDER SPEED (1) Boom cylinder speed • Engine • Hydraulic oil temp.

: high idle : 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).

Fig. 7-1

(2) Arm cylinder speed • Engine • Hydraulic oil temp.

: high idle : 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).

Fig. 7-2

FULLY RETRACTED

(3) Bucket cylinder speed • Engine • Hydraulic oil pemp.

: high idle : 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).

Fig. 7-3

14903 60413247

(4) Swing cylinder speed • Engine • Hydraulic oil temp.

: high idle : 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 (do not include the cushioning time). Fig. 7-4

13-13

MAINTENANCE STANDARDS AND TESTS PROCEDURES (5) Dozer cylinder speed • Engine • Hydraulic oil temp.

: high idle : 50 ~ 60 °C (122 ~ 140 °F) • Measurement posture: using the hoe attachment lift up the dozer blade side. • Then, raising and lowering the dozer blade with full stroke, measure the time required per stroke in each direction. Fig. 7-5

(6) Adjustable crawler flame width Cylinder Speed • Engine : High Idle • Hydraulic Oil Temp. : 50 ~ 60 °C (122 ~ 140 °F) • Measurement Posture : Using the hoe attachment and dozer blade, lift up the machine. • Measure the time required for the crawler width cylinder to completely retracted (extended) state from fully extended (retracted) state.

Fig. 7-6

F22289

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.

Fig. 7-7

: stopped : 50 ~ 60 °C (122 ~ 140 °F) • Gradient : 15 °C (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.

13-14

(Approx. 1/3.73)

Fig. 7-8

14903 60413247

(2) Swing cylinder • Engine • Hydraulic oil temp.

MAINTENANCE STANDARDS AND TESTS PROCEDURES

8. MEASURING SLEW BEARING PERFORMANCES • TEST PROCEDURES Measure 3-time each. Apply average data of the above for judgement.

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. Fig. 8-1

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.

Fig. 8-2

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

Then raise the opposite crawler and read the dial gauge.

Fig. 8-3 Fig. 8-4

9. MEASURING CRAWLER TENSION

9.1 CRAWLER TENSION • Raise the machine completely off the ground using the hoe attachment and dozer blade. Then measure the distance (of droop) between the center point on the crawler frame and top of the crawler shoe.

RUBBER CRAWLER

STEEL CRAWLER

14903 60413247

CAUTION In the case of rubber crawlers, measurements should be taken with setting the joint ("M" or "∞" mark) in the top center position. Fig. 9-1

Fig. 9-2

13-15

MAINTENANCE STANDARDS AND TESTS PROCEDURES

14903 60413247

NOTES

13-16

SECTION 22

HYDRAULIC SYSTEM

TABLE OF CONTENTS 1. Summary ............................................................................................................... 22-1 1.1 Function and features of hydraulic circuit ....................................................................................... 22-1

2. Hydraulic circuits and component models ............................................................. 22-3 2.1 Standard specifications .................................................................................................................. 22-3 2.2 Standard specifications .................................................................................................................. 22-4 2.3 Nibbler & breaker specifications (option) ........................................................................................ 22-5 2.4 Nibbler & breaker specifications (option) ........................................................................................ 22-6

3. Hydraulic circuit operation .................................................................................... 22-7 3.1 Outline of hydraulic circuit explanation ........................................................................................... 22-7 3.2 Neutral circuit ................................................................................................................................. 22-8 3.3 Travel operating circuit .................................................................................................................... 22-9 3.4 Slew operating circuit ................................................................................................................... 22-10 3.5 Bucket operating circuit ................................................................................................................ 22-11 3.6 Boom operating circuit ................................................................................................................. 22-12 3.7 Arm operating circuit .................................................................................................................... 22-13 3.8 Swing operating circuit ................................................................................................................. 22-14 3.9 Dozer and adjustable crawler frame width operating circuit ......................................................... 22-15 3.10 Travel / dozer combined operating circuit ................................................................................... 22-16

14903 60413247

4. Schematic piping for hydraulic system (standard & nibbler/breaker) ................... 22-17

HYDRAULIC SYSTEM

1. SUMMARY 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.

PERFORMANCE

DEVICE

• Straight traveling • Expansion and retraction of dozer width (one touch changing width of dozer)

ATTACHMENT

• Securing straight traveling at combined operations of travel and dozer • Improving working performance at narrow space of working area

• Preventing overrunning of travel motor

• Preventing overrunning on a slope

• Travel lock

• Safety lock lever locks operation of travel lever

• Slew lock (at parking)

• Preventing slewing drift at parking on a slope due to attachment's own weight

SLEWING

TRAVEL

(at combined operation with dozer)

EASY OPERATION AND SAFETY

FEATURES

FUNCTION

(Slew Lock with lever operation for 2 facing directions of forward and backward)

• Hydraulic pilot control system

• Easy handling

• Pilot lock system

• Safety lock lever also locks pilot circuit

• Closed pressurized hydraulic oil tank

• Preventing contamination of hydraulic oil and

• Suction strainer

• Removing dirt of suction side

• Line filter in pilot circuit

• Preventing malfunction in pilot operating circuit

• Return filter

• Preventing contamination of hydraulic oil

• Constant power control (Pump: P1 + P2)

• Effective use of engine power with variable

PUMP ATTACHMENT TRAVEL

HIGH WORKING PERFORMANCE

14903 60413247

OTHERS

improving self sucking up efficiency

pump (with 2 discharge ports)

• 2 speeds traveling

• Improving working efficiency with 2 travel speeds shifting

• Recirculation of return oil at light load digging • Speed-up for light load digging with arm with arm

22-1

HYDRAULIC SYSTEM

14903 60413247

NOTE:

22-2

HYDRAULIC SYSTEM

2. HYDRAULIC CIRCUITS AND COMPONENT MODELS

14903 60413247

2.1 STANDARD SPECIFICATIONS

Fig. 1 Hydraulic circuit diagram 22-3

HYDRAULIC SYSTEM

14903 60413247

2.2 STANDARD SPECIFICATIONS

Fig. 2 Hydraulic circuit diagram 22-4

HYDRAULIC SYSTEM

2.3 NIBBLER & BREAKER SPECIFICATIONS (OPTION) MO

(LEFT)

(RIGHT) 401

401

4, 5

RED

OPT

4, 5

RED

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

BREAKER

DOZER

6 405

302

303 95kgf/cm2 303 95kgf/cm2

404

1/4

405

ARM

B 1/4

1/4

PP 1/4

1/4

1/4 1/4

1/4

P DR

DR DR

NIBBLER G E A B C D

26 A B C D F

F PP

NIBBLER

BREAKER

1/4

A1 B1

3/16

Pb2

A3 B3

BOOM

TRAVEL RIGHT

A6 B6

A5 B5

DOZER / CRAWLER

B7 A7

B8 A8

TRAVEL LEFT

SERVICE

Pb8

1/4

A4 B4

SWING

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 2 210 kgf/cm

3/16 A

(LEFT) T

P (RIGHT)

P2 B

2 3/16 3/16

3/16

3/16 3/16

3/16

280kgf/cm

210kgf/cm

102 280kgf/cm2

103 2 250kgf/cm

2 103 250kgf/cm 103

102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED

14903 60413247

104 250kgf/cm 2

LEVER LOCK

P3 P2

20 T1

3/8

OPT

3/8

3/8 3/8

1/4

13 (LEFT) T

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 2 35kgf/cm

ISD 1

K 3

P P2

2 17

18 F22402

M O S1

22.6

1/4

Fig. 3 Hydraulic circuit diagram 22-5

HYDRAULIC SYSTEM

2.4 NIBBLER & BREAKER SPECIFICATIONS (OPTION) (LEFT)

(RIGHT) 401

401

4, 5

RED

OPT

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

DOZER

ARM BV

405

302

303 95kgf/cm2 303 95kgf/cm2

404

1/4

H A

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

A B C D F

F PP

1/4

A1 B1

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

3/16 3/16

3/16

3/16 3/16

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED 104 250kgf/cm 2

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

18 14903 60413247

OPT

3/8

(LEFT) T

3/8 3/8

1/4

M O S1

22.6

1/4 F22404

Fig. 4 Hydraulic circuit diagram 22-6

HYDRAULIC SYSTEM

3. HYDRAULIC CIRCUIT OPERATION 3.1 OUTLINE OF HYDRAULIC CIRCUIT EXPLANATION (1) The descriptions in this section are for the hydraulic circuits of standard Specifications. (2) Color Coding Standards Blue ························ Supply / return circuit (low pressure) Purple ···················· Secondary pilot pressure circuit Red ························ Primary pilot pressure circuit Orange ··················· Main pump drive pressure circuit (high pressure) Gray tone ··············· Shifted condition of valve (See Fig. 5) Red valve ··············· Indication for opened condition on valve Red solenoid ·········· Energized condition on pilot valve

F22291

Fig. 5 Shifted condition of valve

14903 60413247

(3) Operating Conditions in Circuit Diagram shown with Color Line 1) Neutral Circuit ········· Showing the hydraulic pressurized circuits with the above colors, while the safety lock lever is released. (operating conditions ) 2) Operating Circuits ··· Showing only the circuits with the above colors, in which hydraulic oil is flowed at operation. Therefore, the circuits which is pressurized but being no oil flow, are not shown with the above color. 3) Description for Operation ····Describing in order of pages omitting the repeated matters.

22-7

HYDRAULIC SYSTEM

3.2 NEUTRAL CIRCUIT (1) Pilot Circuit 1) Pilot Primary Pressure Circuit The oil discharged from the P3 pump on pump assy (2) enters into the solenoid valve (13) through the line filter (20). At releasing the safety lock lever (operating conditions), the pressuized oil discharged from the A1 port on solenoid valve (13) is divided its flowing into two directions. The one directs to the cylinder (23) to release the travel lock, and the other, as primary pilot pressure, directs to the P port on pilot valve (14). Because the operating circuit is closed at neutral position, the discharged oil from the pump loses its flowing passage, and returns to the hydraulic oil tank through the relief valve [setting pressure: 35 kg/cm2 (500 psi)] in the solenoid valve (13). 2) Pilot Secondary Pressure Circuit While the pilot valve (14) is 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 from the pilot valve to shift each spool of shifting valve.

(RIGHT)

401

4, 5

RED

OPT

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

404

6 405

1/4

302

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

ARM BV

405

B 1/4

1/4

PP 1/4

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

A B C D F

F PP

1/4

A1 B1

Pb2

A3 B3

BOOM

TRAVEL RIGHT

A6 B6

A5 B5

DOZER / CRAWLER

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

A4 B4

SWING

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

3/16

B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

2 3/16 3/16

3/16

3/16 3/16

3/16

(2) Main Circuit 1) Variable Pump Circuit The discharged oil from P1 and P2 ports on variable pump enters into P1 and P2 ports on control valve respectively. All the discharged oil from these two ports eventually joins together in the service valve and returns to the hydraulic oil tank, through each valve of bucket, boom, swing, right travel and dozer for the P1 oil, and through each valve of arm, slew and left travel for the P2 oil.

(LEFT)

4, 5

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

18 14903 60413247

OPT

3/8

(LEFT) T

3/8 3/8

1/4

M O S1

22.6

1/4 F22407

Fig. 6 Neutral circuit 22-8

HYDRAULIC SYSTEM

3.3 TRAVEL OPERATING CIRCUIT The operation is conducted by a lever, which operate link mechanism to operate valve. (Refer to item 3.10 Travel / Dozer Combined Operating Circuit regarding the travel straight function.)

(LEFT)

(RIGHT)

401

4, 5

401

4, 5

RED

OPT

301

OPT

402

403

T 302

3.3.1 2nd Speed Operating Circuit

14903 60413247

•

SWING

404

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

302

405

ARM

H A

B 1/4

1/4

PP 1/4

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

A B C D F

F PP

1/4

A1 B1

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

2 3/16 3/16

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa8

Pa9

3/16

21 15

OPT

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

3/8

(LEFT) T

3/8 3/8

1/4

3/8

•

CRAWLER WIDTH

405

3/16 3/16

2) •

BUCKET

3/16

(2) 1)

BOOM

3/16

(1) 1)

(Independent-forward travel) Pilot Circuit Shifting signal for 2nd speed travel When the "Rabbit and Tortoise" mark (at the power cutoff, 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 discharged from the A2 port of solenoid valve(13), and led to the PP port on travel motor (4) through swivel joint (6), and shifts the 2-speed shifting valve (404). Main Circuit Circuit up to Travel Motor (4) When shifting the travel lever to forward, it shifts the travel valve spool of control valve (1) through the link mechanism. The discharged oil from variable pump enters into the P1 and P2 ports of control valve, and led to the A4 and A7 ports through the travel valve. Then it is led to the B and A ports on right and left travel motors through the swivel joint. Travel Motor The pressurized oil supplied to the travel motor shifts the spool in counter balance valve (405), and opens the return oil line that is being closed by the check valve, then rotates the travel motor. When the 2nd speed signal is given, the pressurized oil passed through the 2-speed shifting valve (404) shifts shuttle valve (403) to high pressure, and actuates 2-speed shifting piston (401), and then makes the motor high speed with low torque. 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 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. The counter balance valve spool is so designed that it is gradually shifted by a throttle effect to stop or start the motor resulting shock absorption at the start and stop of the machine.

1/4

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

M O S1

22.6

1/4 F22408

Fig. 7 2nd speed operating circuit (Independent-forward travel) 22-9

HYDRAULIC SYSTEM

3.4 SLEW OPERATING CIRCUIT The operation is conducted by the pilot oil pressure. (LEFT)

4, 5

3.4.1Slew (left) Operating Circuit

401

4, 5

RED

OPT

(1) Pilot Circuit 1) Slew Valve Spool Shifting With operation for slew (left), the pilot secondary pressure oil is discharged from the pilot valve (14), and led to the Pb8 port of control valve(1) to shift the slew valve spool.

(RIGHT)

401

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

404

(2) Main Circuit 1) Supply Circuit for Slewing Motor (3) The oil discharged from the P2 port on variable pump (2) is supplied to the Bv port on slewing motor (3) through the control valve (1) to drive the hydraulic motor. And to avoid sudden and quick slew operation at the single (independent) operation of slew, an oil volume limiting mechanism (by-pass line) is provided in the control valve (1). Namely, part of pressurized oil enters into slew valve through arm valve at which appropriate volume of oil is returned to the tank circuit with a throttle effect to control the oil volume to the slewing motor.

302

REPLENISH OIL 303 95kgf/cm2 303 95kgf/cm2

404

DOZER

R 405

1/4

405

ARM

H A

B 1/4

1/4

PP 1/4

B 1/4

1/4 1/4

A 1/4

P DR

DR DR G E A B C D

A B C D F

F PP

2) Slewing Motor (3) • The relief valve (303) relieves rapidly increased pressure at start and stop of the machine to ease shock.

1/4

A1 B1

BUCKET

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

2 3/16 3/16

3/16

3/16 3/16

The make-up valve (check valve) (302) has a function to replenish oil from the return oil circuit to hydraulic pump, to prevent the slewing motor from the cavitation due to negative pressure generated in it because of enertia on the slewing mass. The check valve (22) provided in the return circuit is to make up back pressure [approx. 2 kgf/cm2 (28 psi)] that is useful for easy replenishment.

3/16

•

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

18 14903 60413247

OPT

3/8

(LEFT) T

3/8 3/8

1/4

M O S1

22.6

1/4 F22409

Fig. 8 Slew operating circuit (Independent-left slewing) 22-10

HYDRAULIC SYSTEM

3.5 BUCKET OPERATING CIRCUIT The operation is conducted by the pilot oil pressure. (LEFT)

4, 5

3.5.1Bucket Digging Operation Circuit

401

4, 5

RED

OPT

(1) Pilot Circuit 1) Bucket Spool Shifting When the lever is put at bucket digging position, the pilot secondary pressure oil is discharged from the pilot valve (14). The pressurized oil entered into the Pa1 port on control valve (1) shifts the bucket valve spool to connect the circuits of variable pump and bucket cylinder.

(RIGHT)

401

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

404

DOZER

6 405

302

303 95kgf/cm2 303 95kgf/cm2

404

1/4

405

ARM

H A

1/4

1/4 1/4

1/4

P DR

DR DR

(2) Main Circuit 1) Supply Circuit for Cylinder (9) The oil discharged from P1 port on variable pump of pump assy (2) enters into P1 port on control valve (1). The pressurized oil discharged from A1 port through bucket valve is supplied to H side of bucket cylinder (9) to activate the digging work. The return oil from R side of cylinder (9) enters into B1 port on control valve (1) and returns into the tank through bucket valve.

G E A B C D

A B C D F

F PP

1/4

Pb2

A3 B3

TRAVEL RIGHT

A6 B6

A5 B5

DOZER / CRAWLER

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

1/4

A1 B1

BUCKET

3/16

B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

3/16 3/16

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa8

Pa9

3/16

3/16 3/16

3/16

(2) Main Circuit 1) Supply Circuit for Cylinder (9) Similar to the case for bucket digging, the pressurized oil discharged from P1 port on variable pump enters into P1 port on control valve (1). The oil discharged from B1 port through bucket valve is supplied to R side of bucket cylinder (9) to activate the bucket dumping.

3/16

(1) Pilot Circuit 1) Bucket Spool Shifting When the operating lever is put at bucket dumping position, the pilot secondary pressure oil is discharged from pilot valve (14) and enters into Pb1 port on control valve (1) to shift the bucket valve spool.

1/4

3.5.2Bucket Dumping Operating Circuit

1/4 1/4

21 A2

OPT

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

14903 60413247

20 T1

3/8

(LEFT) T

3/8 3/8

1/4

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

M O S1

22.6

1/4 F22410

Fig.9 Bucket digging operation circuit 22-11

HYDRAULIC SYSTEM

3.6 BOOM OPERATING CIRCUIT The operation is conducted by the pilot oil pressure. (LEFT)

3.6.1 Boom Raising Operating Circuit

4, 5

401

4, 5

RED

OPT

(1) Pilot Circuit 1) Boom Spool Shifting When the operating lever is put at boom raising position, the pilot secondary pressure oil is discharged from pilot valve (14). The pressurized oil entered into Pb2 port on control valve (1) shifts the boom valve spool to connect the circuits for variable pump and boom cylinder. (2) Main Circuit 1) Supply Circuit for Cylinder (7) The oil discharged from P1 port on variable pump of pump assy (2) enters into P1 port on control valve (1). The oil discharged from B2 port through boom valve is supplied to H side of boom cylinder (7) to raise the boom.

(RIGHT)

401

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

404

R 405

302

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

1/4

405

ARM

H A

B 1/4

1/4

PP 1/4

B 1/4

1/4 1/4

A 1/4

P DR

DR DR G E A B C D

A B C D F

F PP

3.6.2 Boom Lowering Operating Circuit

A3 B3

BOOM

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

1/4

Pb2

1/4

1/4 1/4

A2 B2

Pb1

B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

2 3/16 3/16

3/16

3/16 3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa8

Pa9

3/16

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

18 14903 60413247

OPT

3/8

3/8 3/8

1/4

3/8

3/16

3.6.3 Damper Cylinder (24)

22-12

A1 B1

BUCKET

3/16

(LEFT) T

The damper cylinder (24) is connected to pressure oil side of pilot valve and rod side of boom cylinder (7), and has a function so called accumulator effect to restrict and attenuate the pressure variation of rod side. Especially, this effectively acts for shock absorption and anti-hunt at stop of boom raising or lowering.

1/4

3/16

(1) Pilot Circuit 1) Boom Spool Shifting When the operating lever is put at boom lowering position, the pilot secondary pressure oil is discharged from pilot valve (14), and enters into Pa2 port on control valve (1) to shift the boom valve spool. (2) Main Circuit 1) Supply Circuit for Cylinder (7) and Return Oil Circuit The pressurized oil discharged from P1 port on variable pump is led to boom valve provided on control valve (1), and supplied to R side of boom cylinder (7) to lower the boom. The oil returned from H side of cylinder (7) enters into B2 port on control valve (1), and returns to the tank through boom valve. And to prevent rapid lowering of the boom at single operation for the boom, a flow rate restricting (by-pass) mechanism is provided on the spool of boom valve, as same as in the slew valve and swing valve.

M O S1

22.6

1/4 F22411

Fig.10 Boom raising operating circuit

HYDRAULIC SYSTEM

3.7 ARM OPERATING CIRCUIT The operating is conducted by a pilot oil pressure with a function to recirculate the return oil at digging works with light load.

(LEFT)

4, 5

(RIGHT)

401

4, 5

RED

OPT

301

OPT

402

403

T 302

3.7.1Arm Digging Operating Circuit

(1) Pilot Circuit 1) Shift for Arm Spool At the arm digging operation, the pilot secondary pressure discharged from the pilot valve (14) is led to the Pa9 port on control valve (1) to shift the arm valve.

BOOM

BUCKET

CRAWLER WIDTH

SWING

404

405

1/4

PP 1/4

1/4

1/4 1/4

B 1/4

P A

A B C D F

F PP

1/4

A1 B1

3/16

Pb2

A3 B3

TRAVEL RIGHT

A6 B6

A5 B5

DOZER / CRAWLER

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

P2 B

2 3/16 3/16

3/16 3/16

3/16

3 3/16

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa8

Pa9

3/16

21 15

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

3/8

(LEFT) T

3/8 3/8

1/4

3/8

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

OPT

14903 60413247

G E A B C D

(2) Main Circuit Similar to the case for digging, the oil entered into the control vale (1) is discharged from the B9 port, and supplied to the R side of arm cylinder to actuate the arm out.

3.7.2Operating Circuit for Arm Out (Dumping) (1) Pilot Circuit At the operation for arm out, the pilot secondary pressure is discharged from the pilot valve (14), and led to the Pb9 port on control valve (1) to shift the arm valve.

ARM

405

DR 1/4 1/4

(2) Main Circuit 1) Supply Circuit for Cylinder (8) The oil discharged from the P2 port on variable pump enters into the P2 port on control valve (1). The pressurized oil came out from the A9 port through the arm valve is supplied to the H side of arm cylinder (8) to actuate the digging works. 2) Return Line from Cylinder (8) The return oil from the R side of arm cylinder enters into the B9 port on control valve(1), and is led to the return line from the T port through arm valve, then return to the tank. At the low load operation, the oil returned from the cylinder is raised its pressure by a throttle effect in the arm valve, and a part of pressurized return oil pushes up the check valve which connects to the supply circuit. The working speed is increased by such recirculation system for the return oil.

302

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

1/4

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

M O S1

22.6

1/4 F22412

Fig.11 Arm digging operating circuit 22-13

HYDRAULIC SYSTEM

3.8 SWING OPERATING CIRCUIT (LEFT)

The operation is conducted by the operating pedal, which drives the cable to operate valve.

4, 5

(RIGHT)

401

4, 5

RED

OPT

301

OPT

402

403

T 302

3.8.1 Swing (left) Operating Circuit (1) Swing Operation By means of stepping down the swing (left) operating pedal, the swing valve spool in control valve (1) is shifted through the pulling up motion of the cable. Since the pilot oil pressure is not utilized for it, as the same case as the dozer, it is activated regardless to the safety lock lever.

BOOM

BUCKET

CRAWLER WIDTH

SWING

404

DOZER

302

303 95kgf/cm2 303 95kgf/cm2

404

405

ARM BV

405

H A

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

A B C D F

F PP

1/4

A1 B1

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

3/16 3/16

3/16

3/16 3/16

3/16

(2) Main Circuit 1) Supply Circuit for Cylinder (10) The discharged oil from P1 port on variable pump enters into P1 port on control valve (1), and is divided into 2 directions. One is discharged from B3 port through swing valve and supplied to the R side of cylinder (10) to activate the swing motion (left). The other enters into swing valve through bucket valve and boom valve, and part of appropriate volume of oil is returned to the tank due to the throttle effect on the swing valve to restrict the volume of oil to be supplied to the swing cylinder. Then the slow and stable swing motion is secured for both swings for leftward and rightward.

1/4

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

18 14903 60413247

OPT

3/8

(LEFT) T

3/8 3/8

1/4

M O S1

22.6

1/4 F22413

Fig.12 Swing (left) operating circuit 22-14

HYDRAULIC SYSTEM

3.9 DOZER AND ADJUSTABLE CRAWLER FRAME WIDTH OPERATING CIRCUIT

401

301

OPT

402

403

T 302

7 BOOM

BUCKET

CRAWLER WIDTH

SWING

404

6 405

1/4

302

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

ARM BV

405

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

A B C D F

F PP

1/4

A1 B1

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

BUCKET

1/4

1/4 1/4

1/4

25 B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

3/16 3/16

3/16

3/16 3/16

3/16

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

3.9.2 Adjustable Crawler Frame Width (Crawler width) Operating Circuit

14903 60413247

4, 5

RED

OPT

(1) Dozer Operation Put the shifting lever provided under the operator seat, to down side. Then shift the selector valve provided on the swivel joint (6), to dozer side. When the operating lever is pushed forward, the dozer spool in control valve (1) is shifted by the pulling up motion of the cable. Since the pilot oil pressure is not utilized for it, as the same case as the swing, this is activated regardless to the safety lock lever.

Pa8

Pa9

3/16

21 15

OPT

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

3/8

(LEFT) T

3/8 3/8

1/4

3/8

Put the selector valve on swivel joint (6) to crawler width side (shifting lever is raised upper side). As same as dozer operating lever, when the operating lever is pushed forward, pressurized oil is supplied to H side [R side] of adjusting cylinder (12) to expand [retract] the crawler width. The reverse operation of the lever results to the retraction [expansion] of crawler width. For the crawler width adjusting operation, the machine must be lifted up with the attachment and dozer to make the crawler shoes at free conditions.

(RIGHT)

401

4, 5

3.9.1 Dozer Lowering Operating Circuit

(2) Main Circuit 1) Supply Circuit for Cylinder (11) The oil discharged from P1 port on variable pump in pump assy (2) enters into P1 port on control valve (1), and is led to A5 port through dozer valve. The pressurized oil passed through swivel joint (6) is supplied to H side of dozer cylinder (11) to activate dozer lowering motion. 2) Prevention of Dozer Lowering due to its own Weight A check valve opening at 14 kg/cm2 (200 psi) is provided in the return circuit of dozer valve on control valve (1). Therefore, if the dozer operating lever is operated while the engine is at a standstill, the dozer does not lower due to its own weight, because the oil pressure corresponding to the dozer weight is less than 14 kg/cm2 (200 psi).

(LEFT)

• The operation is conducted by the operating lever, which drives the cable. • Dozer / Crawler width operations are selected with shifting selector valve.

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

M O S1

22.6

1/4 F22414

Fig.13 Dozer lowering operation circuit 22-15

HYDRAULIC SYSTEM

3.10 TRAVEL / DOZER COMBINED OPERATING CIRCUIT At the combined operation of travel and dozer at the same time, the straight travel is secured with this function.

(LEFT)

4, 5

(RIGHT)

401

4, 5

RED

OPT

301

OPT

402

403

T 302

3.10.1 Travel (1st speed forwarding)/Dozer Lowering Operating Circuit

7 BOOM

1) Travel and Dozer Operations The travelling is of the link mechanism system with the lever operation, and the dozer is of the cable driving system with the operating lever. The operation of each lever directly shifts the travel valve spool and dozer valve spool in the control valve (1) respectively.

CRAWLER WIDTH

SWING

404

R 405

302

303 95kgf/cm2 303 95kgf/cm2

404

DOZER

405

ARM

H A

1/4

1/4 1/4

1/4

P DR

DR DR G E A B C D

Main Circuit The oil discharged from the variable pump (2) enters into P1 and P2 ports on control valve (1), and each flow is divided into 2 directions respectively. One of divided flows enters into the travel motor (4) through travel valve and swivel joint (6). The other divived flows of P1 and P2 join together after passing through the check valve, and enters into the dozer cylinder (11) through dozer valve and swivel joint (6) in which the selector valve is shifted to the dozer side.

A B C D F

F PP

A1 B1

BUCKET

3/16

Pb2

A3 B3

TRAVEL RIGHT

SERVICE

B7 A7

B8 A8

TRAVEL LEFT

Pb8

1/4

1/4 A6 B6

A5 B5

DOZER / CRAWLER

1/4

A4 B4

SWING

BOOM

1/4

A2 B2

Pb1

1/4

1/4 1/4

1/4

25 1/4

BUCKET

1/4

B9 A9

SLEW

Pb9

ARM 101 210kgf/cm2

3/16 A

21 (LEFT)T

P (RIGHT)

3/16 3/16

3/16

3/16 3/16

3/16

The dozer is operated by the joined pressurized oils of P1 and P2. Then there is no variation on the supply volume of pressurrized oil for both travel motors of left and right without one-sided variation on the supply volume for either of travel motor. Accordingly, the same volume of pressurrized oil is supplied for both travel motors to keep the straight traveling.

280kgf/cm 2

210kgf/cm 2

102 280kgf/cm 2

103 250kgf/cm 2 102

101

T Pa2

Pa1

Pa9

3/16

Pa8

TRAVEL 2-SPEED

LEVER LOCK

P3 P2

20 T1

ENGINE YANMAR 2TNE68 7.8 ps/2000 rpm

T 13A 35kgf/cm2

ISD 1

K 3

P P2

2 17

14903 60413247

OPT

3/8

(LEFT) T

3/8 3/8

1/4

M O S1

22.6

1/4 F22415

Fig.14 Travel (forward) 1st/dozer lowering operation during straight travel-circuit 22-16

HYDRAULIC SYSTEM

4. SCHEMATIC PIPING FOR HYDRAULIC SYSTEM (STANDARD & NIBBLER / BREAKER) (BLUE)

Each marking color of hoses is shown in ( ). No indication means black.

(WHITE) (PINK)

PILOT VALVE

PILOT VALVE (RIGHT)

(LEFT) (RED) (YELLOW)

FILTER

Each marking color of hoses is shown in ( ). No indication means black.

DUMPER

(BROWN) FILTER (ORANGE)

(GREEN) CONTROL VALVE

ORIFICE BUCKET CYLINDER

BUCKET

SOLENOID VALVE BOOM

ORIFICE SWING

TRAVEL 2-SPEED

TRAVEL RIGHT

LEVER LOCK TRAVEL LOCK CYLINDER

BOOM CYLINDER

DOZER OR CRAWLER

RELIEF VALVE

SERVICE

FILTER

TRAVEL LEFT

SLEW RIGHT

SWING CYLINDER

SLEW

SLEW LEFT

ARM

ARM CYLINDER SELECTOR VALVE (DOZER / CRAWLER WIDTH)

CHECK VALVE

SLEWING MOTOR

SWIVEL JOINT

SUCTION STRAINER

RETURN FILTER (WITH RELIEF VALVE) HYDRAULIC OIL TANK

ADJUSTABLE CRAWLER FRAME WIDTH CYLINDER

ENGINE

14903 60413247

HYDRAULIC PUMP

FORWARD BACKWARD

TRAVEL MOTOR (LEFT)

FORWARD

DOZER CYLINDER

BACKWARD

PILOT CIRCUIT MAIN PUMP DRIVE PRESSURE CIRCUIT SUPPLY / RETURN (DRAIN) CIRCUIT

TRAVEL MOTOR (RIGHT)

Fig. 15 Schematic piping for hydraulic system 22-17

HYDRAULIC SYSTEM

SCHEMATIC PIPING FOR HYDRAULIC SYSTEM (STANDARD & NIBBLER / BREAKER) (BLUE)

Each marking color of hoses is shown in ( ). No indication means black.

(WHITE) (PINK)

PILOT VALVE

Each marking color of hoses is shown in ( ). No indication means black.

PILOT (LEFT) (RED) (YELLOW)

FILTER

(BROWN) FILTER (ORANGE)

(GREEN) CONTROL VALVE

ORIFICE BUCKET CYLINDER

BUCKET

SOLENOID VALVE

BOOM

ORIFICE SWING

TRAVEL 2-SPEED

TRAVEL RIGHT

LEVER LOCK TRAVEL LOCK CYLINDER

BOOM CYLINDER

DOZER OR CRAWLER

RELIEF VALVE

SERVICE

FILTER

TRAVEL LEFT

SLEW RIGHT

SWING CYLINDER

SLEW

SLEW LEFT

ARM

ARM CYLINDER SELECTOR VALVE (DOZER / CRAWLER WIDTH)

CHECK VALVE

SLEWING MOTOR

SWIVEL JOINT

SUCTION STRAINER

RETURN FILTER (WITH RELIEF VALVE) HYDRAULIC OIL TANK

ADJUSTABLE CRAWLER FRAME WIDTH CYLINDER

ENGINE

FORWARD BACKWARD

Fig. 16 Schematic piping for hydraulic system 22-18

TRAVEL MOTOR (LEFT)

FORWARD

DOZER CYLINDER

BACKWARD

TRAVEL MOTOR (RIGHT)

PILOT CIRCUIT MAIN PUMP DRIVE PRESSURE CIRCUIT SUPPLY / RETURN (DRAIN) CIRCUIT

14903 60413247

HYDRAULIC PUMP

SECTION 23

ELECTRICAL SYSTEM

TABLE OF CONTENTS 1. How to read circuit diagram and harness connection .......................................... 23-1 1.1 Electric circuit diagram ................................................................................................................... 23-1 1.2 Earness connection ....................................................................................................................... 23-1

2. Electric circuit diagram ......................................................................................... 23-3 3. Electrical equipment and harness ........................................................................ 23-4

14903 60413247

3.1 Electrical equipment list ................................................................................................................. 23-4 3.2 Harness and cable list .................................................................................................................... 23-4 3.3 Electrical equipment and harness connection drawing .................................................................. 23-5 3.4 Arrangement drawing for components and harness ...................................................................... 23-6 3.5 Detail of harness and cable .......................................................................................................... 23-13

ELECTRICAL SYSTEM

1. HOW TO READ CIRCUIT DIAGRAM AND HARNESS CONNECTION 1.1 ELECTRIC CIRCUIT DIAGRAM (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. Example: 6 2 R

▼ ▼ ▼

WIRING COLOR TABLE COLOR

SYMBOL

COLOR

BLACK

ORANGE

GREEN

BROWN

BLUE

LIGHT GREEN

RED

GRAY

WHITE

SKY BLUE

YELLOW

VIOLET

PINK

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

▼

(3)

Wire color: red Wire size: 2 sq (mm2) Wire No: 6

SYMBOL

(2) The connector is to be connected with engaging the male (M) and fermale (F) connectors of the same number: Example: CN-101M and CN-10F Where: M means for Male and F for Fermale.

(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.

1.2 HARNESS CONNECTION

(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 piles. 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.

(1) Indication for connector LOCK

WIRE No.

CONNECTOR No.

CONNECTOR NAME WIRE COLOR

14903 60413247

2) 3)

The figure for the connector pin arrangement is shown by putting the lock (nail) to upper portion, and looking from the fitting face. The numbers in the connector show the wire No., and alphabetical letters show the wire color. On the side face of connector, the connector name and serial number of the connector No. are indicated. At the place indicated as “DOUBLE SPLICE”, two wires are connected to one place. 23-1

ELECTRICAL SYSTEM

14903 60413247

NOTES

23-2

ELECTRICAL SYSTEM

2. ELECTRIC CIRCUIT DIAGRAM

06902 60413249

F22418

23-3

ELECTRICAL SYSTEM

3. ELECTRICAL EQUIPMENT & HARNESS

3.2 HARNESS AND CABLE LIST

3.1 ELECTRICAL EQUIPMENT LIST CODE

ELECTRICAL FITTIGS LIGHT

L-1

CLUSTER GAUGE GLOW PLUG CURRENT LIMITER BATTERY SOCKET

BOOM WORKING LIGHT(RH)

LEVER LOCK SOL. 2 SPEED SELECT SOL. E/G STOP SOL.

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6

KEY SWITCH 2 SPEED SELECT SW. LEVER LOCK SW.(RH) LEVER LOCK SW.(LH) HORN SWITCH E/G WATER TEMP. SWITCH

SW-7

E/G OIL PRESSURE SWITCH

F22419

Main harness

H-2

Relay harness

H-3

Battery cable

H-4

Battery earth cable

H-5

Engine earth cable

H-6

Cluster gauge harness

H-7A

Key switch harness

H-7B

Harness (for key switch)

H-8

Horn switch harness

H-9

Power socket harness

H-10

Travel alarm harness

H-11

Travel alarm select sw. harness F22420

R-1 R-2 R-3 R-5 R-6

SAFETY RELAY 2-SPEED SELECT RELAY E/G STOP RELAY CHARGE INDICATOR RELAY TIMER UNIT

06902 60413249

RELAY

SV-1 SV-2 SV-3

H-1

REMARKS

STARTER MOTOR

MOTOR

M-1

FUSE BOX DYNAMO HORN FUSIBLE LINK

SOLENOID SENSOR

E-1 E-2 E-3 E-4 E-6 E-7 E-8 E-9 E-10

PART NAME GROUP CODE SE-1 FUEL SENSOR SE-2 ENGINE THERMO SENSOR

SWITCH

PART NAME

DIODE

GROUP CODE D-1 DIODE D-2 DIODE D-3 DIODE

NAME

23-4

ELECTRICAL SYSTEM

3.3 ELECTRICAL EQUIPMENT AND HARNESS CONNECTION DRAWING CN-305F

CN-307F R-3 : ENGINE STOP RELAY

R-2 : 2-SPEED SELECT RELAY CN-308F

R-1 : SAFETY RELAY

H-2 : RELAY HARNESS CN-304F POWER SOCKET

M-2

R-5 : CHARGE INDICATOR RELAY

F-2 H-7A : KEY SWITCH HARNESS E-6 : CLUSTER GAUGE H-6 : CLUSTER GAUGE HARNESS

E-1 : FUSE BOX

CN-317F CN-317M SW-1 : KEY SWITCH

CN-351F CN-318F CN-318M CN-314M M-22 CN-316M

CN-314F

SW-3 : LIMIT SWITCH (LEVER LOCK) RH

H-1 : MAIN HARNESS

L-1 : BOOM WORKING LIGHT

F-22

CN-301M

CN-315F

CN-311F

CN-301F

CN-315M

CN-312F

F-12

R-6 : TIMER UNIT E-8 : CURRENT LIMITER

CN-316F

F-18

M-1

E-2 : DYNAMO

F-11 F-13 SW-2 : 2-SPEED SELECT SWITCH F-14

CN-407F

E-4 : FUSIBLE LINK

F-17 F-16 SE-2 : SW-6 : THERMO THERMO SENSOR SWITCH

EARTH

P-1

P-2

CN-408F

F-15

EARTH

SV-3 : ENGINE STOP SOLENOID

SW-7 : OIL PRESSURE SWITCH

T-3 S

HORN

CN-409F SE-1 : FUEL SENSOR

M-1 : STARTER MOTOR EARTH

E-3 : HORN T-1 T-2

BOOM WORKING LIGHT

SW-5 HORN SWITCH

LEVER LOCK SOLENOID 2-SPEED SELECT RELAY

F-1 F-2

SAFETY RELAY CHARGE INDICATOR RELAY

H-5 : ENGINE EARTH CABLE

ENG. STOP SOLENOID RELAY

M-21

SW-4 : LIMIT SWITCH (LEVER LOCK) LH

14903 60413247

ENGINE STOP SOLENOID CLUSTER GAUGE 2-SPEED SELECT SWITCH TIMER UNIT

F-21

SV-1 : SV-2 : SOLENOID VALVE

CN-404F

H-4 : BATTERY EARTH CABLE

H-3 : BATTERY CABLE

CN-403F

CURRENT LIMITER LEVEL GAUGE

23-5

ELECTRICAL SYSTEM

3.4 ARRANGEMENT DRAWING FOR COMPONENTS AND HARNESS 3.4.1 Upper frame portion

TO FIX BOOM WORKING LIGHT E-3

SV-1, SV-2

H-1 MAIN HARNESS

E-9

PART OF "X"

SECTION BB

T=0.9 kgf·m (6.5 ftl·bs)

DETAIL OF “X” VIEW C

VIEW D

23-6

NOTE: T: TIGHTENING TORQUE

14903 60413247

SECTION AA

T=0.9 kgf·m (6.5 ftl·bs)

ELECTRICAL SYSTEM 3.4.2 Engine portion

TO INSTALL ENG THERMO SENSOR WITH PACKING TIGHTENING TORQUE: 4±0.5 kgf·m (29±4 ft·lbs) E-4 SE-2 ENG. THERMO SENSOR

SW-6

EARTH CABLE E-7

M-1 TYING HARNESS AT ENGINE SV-3 PASS HARNESS OVER HIGH PRESSURE TUBE FOR FUEL OF ENGINE, AND TIE IT AT UPPER SIDE OF BLOW-BY HOSE WITH CLIP

FIX CLAMP TOGETHER WITH BRACKET FOR WATER SEPARATOR BY CAPSCREW

SW-7 ENGINE OIL PRESS SW

INSTALL PROTECTIVE TUBE OF ENGINE STOP SOLENOID VALVE BESIDE COUPLER FOR AVOIDING DIRECT INTERFACE BETWEEN FLY WHEEL AND HARNESS

FRONT OF MACHINE

REAR OF MACHINE

14903 60413247

VIEW E

23-7

ELECTRICAL SYSTEM

14903 60413247

3.4.3 Console box & relay unit portions

23-8

ELECTRICAL SYSTEM

14903 60413247

3.4.4 Upper frame portion

23-9

ELECTRICAL SYSTEM

14903 60413247

3.4.5 Engine portion

23-10

ELECTRICAL SYSTEM 3.4.6 Console box & relay unit portions

R-2 TWO SPEED RELAY

H-2 RELAY HARNESS

14903 60413247

TO FRONT SIDE

CONNECTOR (JOINT WITH MAIN HARNESS)

23-11

ELECTRICAL SYSTEM 3.4.7 Battery portion

3.4.8 Fuel Tank Portion

T=0.37 kgf•m (27 lbf•ft)

SE-1 FUEL SENSOR

FUEL TANK

SECTION AA

3.4.9 Attachment Portion

H-3 BATTERY CABLE (+)

H-4 BATTERY EARTH CABLE (-)

EARTH POINT

23-12

E-9 BATTERY

14903 60413247

M-1 STARTER MOTOR

ELECTRICAL SYSTEM

3.5 DETAIL OF HARNESS AND CABLE 3.5.1 Main harness (code H-1)

BOOM WORKING LIGHT (RIGHT)

LEVER LOCK SW. (LEFT)

HORN SWITCH

HORN BODY EARTH

ENG. THERMO SENSOR ENG. THERMO SW

DOUBLE DOUBLE DOUBLE DOUBLE SPLICE SPLICE SPLICE SPLICE

↓

TAPING DOUBLE SPLICE

FUEL SENSOR

ENG. OIL PRESS. SW.

WHITE TAPING JOINT SPLICE HERE

DOUBLE SPLICE

↓

WHITE TAPING

↓

WHITE TAPING

SUPPLIED WITH DIODE DIODE : 7321-9332-60

↓ WHITE TAPING

GLOW PLUG

STARTER MOTOR

DOUBLE SPLICE

SUPPLIED WITH DIODE DIODE : 7321-9332-60

2-SPEED SELECT SW

14903 60413247

LEVER LOCK SOL.

2-SPEED SELECT SOL. SUPPLIED WITH FUSIBLE LINK FUSIBLE LINK : 7323-3525-50

23-13

ELECTRICAL SYSTEM CONNECTORS SELECTION TABLE

14903 60413247

MAIN HARNESS CONNECTION TABLE

23-14

ELECTRICAL SYSTEM

14903 60413247

3.5.2 Main harness (code H-1)

23-15

ELECTRICAL SYSTEM CONNECTORS SELECTION TABLE

14903 60413247

MAIN HARNESS CONNECTION TABLE

23-16

ELECTRICAL SYSTEM 3.5.3 Relay harness (code H-2)

POWER SOCKET

TO KEY SW HARNESS

SAFETY RELAY

SUPPLY WITH SUMITOMO 5440-0128 CHARGE INDICATOR RELAY

OUT

FUSE BOX

DOUBLE SPLICE

ENG. STOP RELAY

TO CLUSTER HARNESS

DOUBLE SPLICE

TAPING

↑

JOINT SPLICE HERE

TIMER UNIT

DOUBLE SPLICE

↑

DOUBLE SPLICE

5B, 5C JOINT SPLICE HERE

TAPING

↑ 7A, 7B JOINT SPLICE HERE

↑

↑ WHITE TAPING

7A, 7C JOINT SPLICE HERE

CURRENT LIMITER TWO-SPEED SELECT RELAY

TO MAIN HARNESS

14903 60413247

SUPPLIED WITH DIODE DIODE : 7321-9332-60

GENERATOR (DYNAMO)

23-17

ELECTRICAL SYSTEM RELAY HARNESS CONNECTION TABLE (1/2)

RELAY HARNESS CONNECTION TABLE (2/2)

CONNECTORS SELECTION TABLE

14903 60413247

SEALING PLUG

23-18

ELECTRICAL SYSTEM

14903 60413247

3.5.4 Relay harness (Code H-2)

23-19

ELECTRICAL SYSTEM RELAY HARNESS CONNECTION TABLE (1/2)

RELAY HARNESS CONNECTION TABLE (2/2)

14903 60413247

CONNECTORS SELECTION TABLE

23-20

ELECTRICAL SYSTEM 3.5.8 Cluster gauge harness (cable H-6)

3.5.5 Battery cable + (code H-3) TERMINAL (CAP TO BE INSTALLED)

INSULATION COVER TERMINAL CORRUGATED TUBE (INSIDE DIA. Ø10)

3.5.9 Key switch harness (cable H-7) 3.5.6 Battery earth cable -

(cable H-4) TERMINAL

TERMINAL CORRUGATED TUBE (INSIDE DIA. Ø10)

3.5.7 Engine earth cable (cable H-5)

14903 60413247

TERMINAL

FIG. 1

CORRUGATED TUBE (INSIDE DIA. Ø10) TERMINAL (CAP TO BE INSTALLED) AV30SQ

TERMINAL

FIG. 2

23-21

ELECTRICAL SYSTEM 3.5.10 Horn switch harness (H-8)

TO HORN SWITCH

TO MAIN HARNESS

↑ TAPING SUMITOMO HOUSING : 6090-1001 TERMINAL : 8240-4422 TOKYO DIP TOYO HOUSING ; MCA-30 TERMINAL ; 300401-2

3.5.11 Power socket harness (H-9)

YAZAKI HOUSING : 7120-1010 TERMINAL : 7115-1050

TO POWER SOCKET

↑

TO RELAY HARNESS

CORRUGATED TUBE

14903 60413247

YAZAKI HOUSING : 7120-8012 TERMINAL : 7113-1020

23-22

SECTION 24

COMPONENTS SYSTEM

TABLE OF CONTENTS Part I: Hydraulic components .................................................................................... 24-1 1. Hydraulic pump .................................................................................................... 24-1 1.1 Summary ......................................................................................................................................... 24-1 1.2 Construction .................................................................................................................................... 24-2 1.3 Operation ........................................................................................................................................ 24-3

2. Pilot valve ............................................................................................................. 24-5 2.1 Summary ......................................................................................................................................... 24-5 2.2 Construction .................................................................................................................................... 24-6 2.3 Operation ........................................................................................................................................ 24-7

3. Control valve ......................................................................................................... 24-8 3.1 Specifications .................................................................................................................................. 24-8 3.2 Construction .................................................................................................................................... 24-9 3.3 Hydraulic circuit diagram ............................................................................................................... 24-13 3.4 Explanation of operation ............................................................................................................... 24-14

4. Slewing motor ..................................................................................................... 24-18 4.1 Specifications ................................................................................................................................ 24-18 4.2 Construction .................................................................................................................................. 24-19 4.3 Operation ...................................................................................................................................... 24-21

5. Travel motor ........................................................................................................ 24-24 5.1 Specifications ................................................................................................................................ 24-24 5.2 Construction .................................................................................................................................. 24-25 5.3 Operation description .................................................................................................................... 24-29

14903 60413247

6. Swivel joint.......................................................................................................... 24-32 6.1 General view ................................................................................................................................. 6.2 Specifications ................................................................................................................................ 6.3 Construction .................................................................................................................................. 6.4 Operation ......................................................................................................................................

24-32 24-32 24-33 24-35

7. Cylinder .............................................................................................................. 24-36 7.1 Specifications ............................................................................................................................... 24-36 7.2 Construction and function ............................................................................................................ 24-37

INDEX

Part II: Electrical equipment .................................................................................... 24-44 1. Electrical equipment list ....................................................................................... 24-44 2. Electrical equipment arrangement ....................................................................... 24-45

14903 60413247

2.3 Specifications electrical equipment .............................................................................................. 24-53

COMPONENTS SYSTEM

Part I: HYDRAULIC COMPONENTS 1. HYDRAULIC PUMP 1.1 SUMMARY (1) GENERAL VIEW

SUCTION PORT S1 OIL FEEDING PORT

DISCHARGEPOR T P1

DISCHARGE PORT P3

DISCHARGE PORT P2

Fig. 1-1 General view of hydraulic pump

(2) SPECIFICATIONS

14903 60413247

PVD-00B-11-3-4732A

24-1

COMPONENTS SYSTEM

1.2 CONSTRUCTION

14903 60413247

Fig. 1-2 Hydraulic pump-Selectional view

24-2

COMPONENTS SYSTEM

1.3 OPERATION (1) Hydraulic Piston Pump Since the cylinder barrel of this piston pump is connected to the shaft with spline, it is rotated along with the shaft. The piston shoes which are incorporated in the cylinder barrel, follow to the rotation of the swash plate (slanted plate) resulting reciprocating movement that produces pumping action of suction and discharge depending upon the variation of the chamber volume. This pump has even number of pistons so that the pump acts as two pumps with the same capacity in the one pump casing. The valve plate, as shown in the Fig. 1-3, has two discharge grooves of outside (P1) and inside (P2). The every other piston chamber in the cylinder barrel is alternatively opened to either of discharge groove of outside (P1) or inside (P2), namely the same volume of discharge is independently exerted from P1 and P2 port. But suction groove is commonly used for both discharge grooves. In this system, because of the even number of pistons, the same number of pistons is to be opened to the outside and inside of the valve plate. And all the pistons are identical with each other for the diameter, located on the same pitch circle, and sliding on the same swash plate. Therefore, the discharge volume to outside (P1) and inside (P2) becomes equal. Furthermore, because of only one swash plate, no difference is produced on the discharge volume to P1 and P2 even though the slant angle of swash plate is varied due to variable control.

SUCTION GROOVE

DISCHARGE GROOVE P1

DISCHARGE GROOVE P2

(A) VALVE PLATE OPENING ON DISCHARGE GROOVE P1 OPENING ON DISCHARGE GROOVE P2

(B) CYLINDER BARREL

Fig. 1-3 Valve plate and Cylinder barrel

PISTON SHOE TDC CYLINDER BARREL VALVE PLATE DISCHARGE PORT

SWASH PLATE BDC DISCHARGE STROKE

SUCTION PORT

SUCTION STROKE

14903 60413247

Fig. 1-4 Operating principle

24-3

COMPONENTS SYSTEM

SPRING

SPRING FORCE F2

LOAD F1 BALL

Fig. 1-5

PUMP DISCHARGE

(2) Constant Power Control The constant power/variable discharge mechanism is achieved by changing the slant angle of swash plate. The variable mechanism to change the slant angle is of a simple direct acting type using a spring. The rotating center of the swash plate is located on the ball of back side.The direction of load F1 due to piston side is shown in the right sketch, which generates clock-wise turning moment against the swash plate. Opposing to this force, a spring with proper spring force (F2) is provided for the opposite direction. Along with increasing pressure, the clock-wise turning moment is also increased. When it overcomes the spring force, the slant angle becomes less decreasing the discharge volume. Thus the power is kept at constant.

(cuÂˇin) cc/rev (0.34)

(0.11)

Q1, Q2 (Q1=Q2) kgf / cm2 (psi) DISCHARGE PRESSURE (LOAD)

P1+P2 kgf / cm2 (psi) 2 (P1=P2)

14903 60413247

Fig. 1-6

24-4

COMPONENTS SYSTEM

2. PILOT VALVE 2.1 SUMMARY (1) General view

SINGLE OPERATION ANGLE (PORT 2,4)

SINGLE OPERATION ANGLE (PORT 1,3)

The adjust nut (opposing flats: 22): Fix adjust nut by means of spanner or the like (opposing flats: 22) when the lever is installed. Then tighten the mating lock nut to 4.2 ± 0.3 kgf·m (30 ± 2.2 lbf·ft)

6-PF1/4 T=3.0 ± 0.2kgf·m (21.7 ± 1.4 lbf·ft)

VIEW A

T=Tightening torque

(2) Specifications SPECIFICATIONS PV48M 2 70 kgf / cm (1,000 psi) 15 L/min (4.0 gal / min) 1.6 kg (3.5 lb)

ITEM Model(Type) Max. primary pressure Rated flow Weight

Fig. 2-1

F22467

(3) Performance characteristics

(299±21) 21±1.5 (290) 20.4 (145) 10.2 (78±11) 5.5±0.75

3.43

Secondary pressure 3.0

3.0 2.06±0.15

2.0

1.74 1.29

1.0 0.54

1.0

±0.07

0 0

40.8 (2.95)

4.0

0.54

1.1

2 4 6 6.5 7 Push rod stroke mm

Operation torque (N•m)

(498) 35 (435) 30.6

Secondary pressure (MPa)

Secondary pressure kgf/cm2(psi)

4.0

(580) 40.8

30.6 (2.21) 20.4 (1.48) 18.9 (1.29) 10.4 (0.95)

10.2 (0.74) 5.5 (0.40)

Operation torque kgf•cm (lbf•ft)

Single operation torque

PORT 1,3

5 10 15 19 Operation angle (deg.)

4.0

(435) 30.6 (299±21) 21±1.5

(290) 20.4 (145) 10.2 (78±11) 5.5±0.75 0

4.0

40.8 (2.95)

3.0

30.6 (2.21)

2.06±0.15

2.16

22.1 (1.60)

2.0

20.4 (1.48)

1.69

17.3 (1.25)

1.0

10.2 (0.74)

Single operation torque 3.43

1.0 0.54

0 0

Fig. 2-2

0.78

±0.07

1.1

Secondary pressure

4 6 8 8.5 9.4 Push rod stroke mm

5 10 15 20 Operation angle (deg.)

8.0 (0.58)

Operation torque kgf•cm (lbf•ft)

(498) 35

Secondary pressure (MPa)

Secondary pressure kgf/cm2(psi)

14903 60413247

PORT 2,4 (580) 40.8

25 F22466

24-5

COMPONENTS SYSTEM

2.2 CONSTRUCTION

APPLY LOCTITE #277 (PART OF SLANT LINE) APPLY GREASE ON TOP APPLY GREASE ON TOP

RIGHT PILOT VALVE

SECONDARY PRESSURE ADJUSTING SHIMS

NOT TO BE REUSED PORT 2,4

OPERATION

1 2 3 4

BUCKET DIGGING BOOM LOWERING BUCKET DUMP BOOM RAISING

LEFT PILOT VALVE PORT NO.

OPERATION

1 2 3 4

SLEWING LEFT ARM OUT SLEWING RIGHT ARM IN F14917

14903 60413247

Fig. 2-3 Pilot valve-sectional view

PORT 1,3

PORT NO.

24-6

COMPONENTS SYSTEM

2.3 OPERATION (1) Lever in neutral position (See Fig. 2-4) In this case, the force of the secondary pressure setting spring (241-2) that determines the output pressure of the pilot valve is not transmitted to the spool (201-2). Accordingly, the spool (201-2) is pushed up by the return spring (221-2) and spring seat (216-2) permitting the output port 2, 4 to connect with the tank port T. This makes the output pressure equal to the tank pressure.

PORT 2,4

PORT 1,3

Fig. 2-4 Lever in neutral position

(2) When the Lever is tilted (See Fig. 2-5) When the lever is tilted, the push rod (212-2) strokes. The spool (201-2) and spring seat (2162) 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.

PORT 2,4

PORT 1,3

14903 60413247

Fig. 2-5 When lever is tilted

(3) The Lever being held (See Fig. 2-6) 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 (241-2) 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.

PORT 2,4

PORT 1,3

Fig. 2-6 Lever being held

24-7

24-8

14903 60413247

(BUCKET)

(BOOM)

(SWING)

(TRAVEL RIGHT)

(DOZER BLADE) (CRAWLER WIDTH)

(SERVICE PORT)

(TRAVEL LEFT)

(1)

(SLEWING)

(ARM)

COMPONENTS SYSTEM

3. CONTROL VALVE

3.1 SPECIFICATIONS General view and hydraulic ports No.

Fig. 3-1

Table 3-1

COMPONENTS SYSTEM

3.2 CONSTRUCTION

(BUCKET)

(BOOM)

(SWING)

(TRAVEL RIGHT)

(DOZER BLADE) (CRAWLER WIDTH)

(SERVICE PORT)

(TRAVEL LEFT)

(SLEWING)

(ARM)

(1) Control valve: overall composition

Fig. 3-2 Control valve

OVERALL COMPONENT PARTS

14903 60413247

Table 3-2

24-9

COMPONENTS SYSTEM (2) Constituent Parts The control valve consists of the following three major groups. • Manual Operating Block: Travel, swing, dozer and service • Pilot Operating Block: Boom, arm, bucket and slew • Accessory Valve: Main relief, port (overload) relief and anti-void * For the operating block, some typical examples are described in the below. Refer to the Section for Control Valve in the Chart of Disassembling for the others. 1) Manual Operating Block : Swing (No.6)

Fig. 3-3

14903 60413247

2) Pilot operating block : Boom (No. 5)

Fig. 3-4 24-10

COMPONENTS SYSTEM 3) Port Relief Valve (Over Load) (No. 14) (No. 26) No. 14

No. 26

4) Port Relief Valve (Over Load)(No. 15)

Fig. 3-6

14903 60413247

5) Anti-Void Valve (No. 16)

Fig. 3-7

24-11

COMPONENTS SYSTEM 6) Main relief valve (No. 25)

Fig. 3-8

7) Main relief valve (No. 13)

14903 60413247

Fig. 3-9

24-12

COMPONENTS SYSTEM

3.3 HYDRAULIC CIRCUIT DIAGRAM

(DOTTED LINE)

ARM SLEWING TRAVEL LEFT SERVICE

DOZER TRAVEL RIGHT

SWING

BOOM BUCKET

(DOTTED LINE)

14903 60413247

Fig. 3-10

24-13

COMPONENTS SYSTEM

3.4 EXPLANATION FOR OPERATION (1) When the Spool is in the Neutral Position When the control valve spool is not actuated, hydraulic oil flows through the center bypass passage (1) and then through the tank passage (T) in the arrow direction, returning to the tank.

Fig. 3-11

(2) When the Spool is Actuated Explanation is given for the case where the spool is moved to the right. When the spool (2) is moved to the right, the center bypass passage (3) is closed and hydraulic oil entering from the pump passes through the load check valve (5) from the parallel passage (4), flowing from the A port to the actuator. On the other hand, oil returning from the B port flows through the tank passage (T) and returns to the tank.

Fig. 3-12

(3) Load Check Valve A load check valve (5) is included in each section except the travel (right, left) sections. This valve prevents oil from flowing backward due to the load pressure (C) from the actuator port during shifting of the spool.

14903 60413247

Fig. 3-13

24-14

COMPONENTS SYSTEM

14903 60413247

(4) Main Relief Valve A main relief valve is mounted between the pump circuit and tank circuit of each inlet housing and serves to maintain the circuit pressure at the set value. 1) When the Relief Valve is not Operating When the pressure in the circuit is low with respect to the set value, the relief valve maintains equilibrium. Hydraulic oil from the pump passes through the orifice from chamber (C)and arrives at the spring chamber (D) and the needle valve (poppet) (1). On the other hand, forces F and F1 are acting in the respective arrow direction on both sides of the main poppet (2). F = P X A F1 = P X A1 P : Pressure A, A1 : Cross Section Area Since the cross sectional area of A is less than that of A1, the main poppet (2) is pushed by the force "F1 - F" to the seat surface on the left side. 2) When the Relief Valve is Operating If the circuit's pressure becomes greater than the set valve of the spring (3), the needle valve (poppet) (1) is pushed to the right by hydraulic pressure and oil flows to the tank passage (T). When this happens, a pressure differential is generated between the both sides of orifice of the main poppet (2), and this hydraulic pressure pushes the main poppet toward the right. As a result, the pressurized oil in the circuit flows to the tank passage. This operation maintains the pressure in the circuit at the set value. (5) Port Relief Valve (Over Load Relief Valve) A port relief valve is located between the actuator port and the tank circuit (T). And when abnormal pressure due to shock pressure or external pressure is generated , in case that the actuator port is suddenly blocked by the spool or an overload occurs, these valves act to protect the actuator, absorbing abnormal pressure. 1) Arm (Head Side) Valve The Figure at right shows that hydraulic pressure reaches at chamber A from the actuator port. If this pressure becomes stronger than the set value of the spring (1), it pushes the poppet (2) to the right side and pressurized fluid from the actuator port flows to the tank passage [T].

Fig. 3-14

Fig. 3-15

Fig. 3-16

24-15

COMPONENTS SYSTEM 2) Boom (Rod Side) / Dozer (Head Side) Valve (A) Relieving Operation (a) When the pressure in the circuit is low with respect to the set value, the relief valve is maintained at equilibrium. Pressure from the pump passes from chamber (B) to the orifice in piston(4), then reaches chamber (C) and needle valve (poppet) (5). On the other hand, forces F and F1 are acting in the arrow direction on both sides of the main poppet (6). F = P X A F1 = P X A1 P : Pressure A, A1 : Sectional Area Since the sectional area of A is less than that of A1, the main poppet (6) is pushed by the force "F1 - F" to the seat surface on the left side.

(b) If the pressure in the circuit become higher than the force of the spring (7), the needle valve (poppet) (5) is pushed to the right by hydraulic pressure, opening passage. Oil then flows around the circumference of the needle valve (poppet) (5) and passes through the drill hole, flowing into the tank passage (T).

Fig. 3-17

Fig. 3-18

(c) When the needle valve (poppet) (5) opens, the pressure drops on the back side of the piston (4), and the piston (4) is pushed to the right, seating with the needle valve (poppet) (5). This shuts off the flow of hydraulic oil to the rear of the main poppet (6). As a result, the pressure in chamber C on the inside drops.

Fig. 3-19

14903 60413247

(d) Compared to the chamber (B) side, the pressure in chamber (C) is low and there is no equilibrium in pressure. For this reason, the main poppet (6) opens and pressurized oil flows to the tank passage (T).

Fig. 3-20

24-16

COMPONENTS SYSTEM (B) Suction Operation of valve When the cylinder is operated at high speed, and the supply of oil cannot follow up with it, creating a vacuum in chamber (B), oil is supplied from the tank side, preventing the occurrence of cavitation. When the pressure in chamber (B) is lower than the pressure in the tank passage (T), the differences in the sectional areas A and A1 cause the main poppet (6) to open. Thus, sufficient oil from the tank passage (T) enters chamber B, filling the empty space. Fig. 3-21

Fig. 3-22

14903 60413247

(6) Anti-Void Valve The anti-void valves are incorporated between the cylinder ports of the swing and bucket blocks (valves) and the tank circuit. When a cylinder is operated at high speed and when the supply of hydraulic oil can't follow up with it, causing a vacuum at the cylinder port, this valve supplies oil from the tank side, preventing cavitation. If the pressure of cylinder port (P) is less than the pressure in tank passage (T), the poppet (I) opens due to difference of sectional area A and A1. Accordingly oil flows to cylinder port (P) from tank passage (T) filling the chamber.

24-17

COMPONENTS SYSTEM

4. SLEWING MOTOR 4.1 SPECIFICATIONS (1) General view HYDRAULIC MOTOR CHECK VALVE RELIEF VALVE RELIEF VALVE BV PORT

HYDRAULIC CIRCUIT DIAGRAM

AV PORT

RELIEF VALVE

VIEW X

T (TANK) PORT VIEW X

14903 60413247

Fig. 4-1 General view of slewing motor

24-18

COMPONENTS SYSTEM

4.2 CONSTRUCTION

14903 60413247

VIEW X

Fig. 4-2 Slewing motor SECTION A-A

24-19

COMPONENTS SYSTEM

14903 60413247

Table 4-2

24-20

COMPONENTS SYSTEM

4.3 OPERATION (1) Operating of Hydraulic Motor

14903 60413247

Fig. 4-3 Operational principle

High pressure hydraulic oil flowing in the main port (1) enters the Geroller (4) via the valve (2) and valve plate (3).

Thus, since the 7 oil holes in the valve plate (3) connect with some of the 12 oil holes, a circuit is formed for oil to flow to the Geroller (4).

The Geroller (4) consists of a stator (5) and rotor (6), and the stator (5) contains 7 rollers inside it, and is fixed to the housing. The inner rotor has 6 external gears. For this reason, 7 chambers are formed inside the Geroller. The rotor (6) is so constructed that it rotated around inside the stator (5) with a planetary motion.

In this way, the rotor (6) of the Geroller (4) starts its planetary motion with hydraulic pressure, and only the self-rotation of the planetary motion is taken out by the drive shaft (7) and transmitted to the shaft (8).

On the other hand, there are 12 holes in the valve (2) for hydraulic oil, with high pressure hydraulic oil or returning oil flowing through half of these holes at a time.

The rotations of the valve (2) cause the oil holes in the valve which connect with the oil holes in the valve plate (3) to shift in sequence. For this reason, high pressure oil flowing in the Geroller (4) also flows into sequentially differing chambers. This causes the motor to rotate continuously.

In the same way, there are oil holes made in the valve plate (3) in 7 places. These oil holes connect with the 7 chambers in the Geroller (4).

Also, the rotations of the rotor (6) are transmitted via the valve drive shaft (9) to the valve (2).

24-21

COMPONENTS SYSTEM

POINT X : STATOR CENTER

POINT Y : ROTOR CENTER

Fig. B

1/14 REVOLUTION

Fig. C

1/7 REVOLUTION

Fig. D

1/6 REVOLUTION

In Fig. A, when high pressure oil is introduced into chambers B, C and D, the rotor (6) rotates in the arrow direction while making contact with the inside of the stator (5). The valve (2) rotates along with this, so the chambers in which high pressure oil is introduced also shift sequentially, but in the direction opposite the arrow direction, In Fig. B the rotor (6) has turned 1/14 revolution. This causes the chambers where high pressure oil is introduced to shift to A, G and F. At this time, the center of the rotor Y shifts in a circle around point X to pointed Y'. In Fig C, Y' shifts to Y".

24-22

That is, the center of the rotor (6) rotates in a circle around point X, 6/7 revolution, from Y to Y' to Y". In Fig. D point Y" has returned to point Y, making 1 cycle of shifting the chambers where high pressure oil is introduced. At this time, the â&#x20AC;˘ mark on the rotor (6) rotates 1/6 revolution in the reverse direction. From this, we can see that 1 revolution of the output shaft is achieved by introduction of high pressure oil into 42 chambers, that is, 7 chambers X 6 cycles = 42 chambers.

14903 60413247

Fig. 4-4 Operational principle

COMPONENTS SYSTEM (2) Operating of Relief Valve : Part-1 1) When the motor is started When the motor is started, since the inertia load is great, the pressure of the oil required to accelerate it rises. If this pressure reached the relief valve set pressure, the relief valve operates and oil returns to port M2. In this way, the motor begins to turn relieving oil from the relief valve, and as the speed increases, the amount of relief decreases until it stops. In this way, the shock during starting is absorbed.

MOTOR

RELIEF VALVE

CHECK VALVE

MOTOR

2) When the motor is stopped When the motor is stopped, the return circuit is closed off. However, since the motor tends to continue rotating due to inertia energy, the pressure in port M2 rises. When this pressure reaches relief valve's pressure, the relief valve operates and oil flows to port M1. On the other hand, a vacuum is generated at port M1. For this reason, oil flows into port M1 from the tank (T). In this way, the flow of oil to port M1 prevents cavitation from occurring as it absorbs the shock during stopping.

(3) Operating of Relief Valve : Part-2 Pressure in the circuit is introduced into chamber (A). This pressure is transmitted to chamber E via the orifice (1) and acts as a force to push the needle valve (2) to the right. When the pressure acting on the needle valve (2) is higher than the force of the spring (3), the needle valve (2) moves to the right and port M1 and port M2 are connected.

RELIEF VALVE

CHECK VALVE

Fig. 4-5

CHAMBER B

CHAMBER A

14903 60413247

Fig. 4-6

24-23

COMPONENTS SYSTEM

5. TRAVEL MOTOR 5.1 SPECIFICATIONS (1) General view

PRESSURE DETECTING PORT

PLUG FOR COUNTER SPOOL

2-SPEED SPOOL PLUG FOR 2-SPEED SPOOL PLUG FOR SHUTTLE SPOOL

COUNTER SPOOL

DR PORT

VIEW X PILOT PORT A, B PORT

VIEW Y

Fig. 5-1 General view of travel motor

(2) Specifications Table 5-1 Applicable model

E9SR EVOLUTION

Model

PHV-80-25-1-8832A Rated output revolution (1 st / 2 nd)rpm

38.5/76.4

Output torque

95.4 (690)

kgf·m (lbf•ft)

1/25.26

Reduction ratio Displacement (1 st / 2 nd)

cc/rev (cu·in/rev) 2

11.3/5.7 (0.69/0.35) 210 (2990)

Hydraulic

Rated operating pressure

kg/cm (psi)

motor

Rated output revolution

(1 st / 2 nd) rpm

Rated discharge

l/min (gal/min)

2-Speed shifting pressure

kg/cm2 (psi)

15 (210)

kg (lb)

17 (37)

Weight

14903 60413247

Reduction unit

973/1930 11.0/(2.91)

F22526

24-24

COMPONENTS SYSTEM

5.2 CONSTRUCTION (1) Basic Construction

14903 60413247

HYDRAULIC CIRCUIT DIAGRAM

Fig. 5-2 Basic construction of travel motor

24-25

COMPONENTS SYSTEM (2) Reduction unit

14903 60413247

Fig. 5-3 Travel motor reduction unit

24-26

COMPONENTS SYSTEM (3) Hydraulic motor

14903 60413247

Fig. 5-4 Hydraulic Motor

24-27

COMPONENTS SYSTEM (4) Hydraulic Valve (Body 1 assy)

14903 60413247

Fig. 5-5 Body 1 assy

24-28

COMPONENTS SYSTEM

5.3 OPERATION DESCRIPTION The travel motor is constructed with ; a stationary body consisting of a hydraulic motor and hydraulic valve ; and a rotating body that is made up of a simple planetary gear reducer. 5.3.1 REDUCTION UNIT (1) Function The reduction unit for the travel motor comprises two simple planetary gear sets. It converts highspeed rotary motion from the travel motor into lowspeed / high-torque motion, and rotates the body case. (2) Operation description Look at the Fig. 5-7. Shaft S2 gear is splined on the output shaft of the travel motor and the reduction unit, and the rotation of gear S2 undergoes primary reduction through gears S2, b2 and a2. After primary reduction, rotation undergoes secondary reduction through gears S1 (splined to carrier 2), b1 and a1. After secondary reduction, rotation is transmitted via the internal gears a1 and a2 to the reduction unit body, the sprocket installed with the body creats travel force.

STATIONARY PART

ROTATING PART

CARRIER 2

The reduction ratio for a two-stage simple planetary gear set can generally be expressed by R=

Zs1 x Zs1+Za1

Zs2 Zs2+Za2

Where Zs1 & Zs2 = number of teeth on gears S1 and S2 Za1 & Za2 = number of teeth on gears a1 and a2 In the case of travel motor of PHV series, because the body case rotates, the gear ratio R' is

Fig. 5-6 Reduction unit operation

1 1-1/R

14903 60413247

R' =

SIMPLE PLANETARY REDUCTION GEAR (2-STAGE)

24-29

COMPONENTS SYSTEM 5.3.2 HYDRAULIC MOTOR (1) Function of Motor This hydraulic motor of an axial piston (swash plate) type converts the hydraulic energy furnished by the pump into rotary motion.

PISTON (6) CYLINDER BARREL (4) VALVE PLATE (5)

(3) Operation Principle of two-Speed Motor The swash plate has two faces, I and II, on the opposite face on which the piston shoes are sliding, and is supported by two balls which are fixed to the body. Since the balls are eccentrically provided above the center line of the shaft, at the case of 1st speed, the combined force of the pressure oil exerted to the piston and the spring in the cylinder barrel pushes "I" face to the body, making the slant angle of the swash plate to

SHAFT (3)

PORT A

SWASH PLATE (7)

PORT B Fig. 5-7 Structure of Hydraulic Motor

SWASH PLATE PISTON BODY 2

FACE II

SHOE

BALL

SPRING FACE I

causing a large displacement. When the switch for 2nd speed is set on, the pressurized oil is led into the control room through the solenoid valve and the 2nd speed spool. Then the control piston pushes the swash plate to move it up to getting contact of "II" face with the body, and fix the swash plate with the slant angle of Ă&#x; causing a small displacement. While the engine is at a standstill, the control room is connected to the drain port through the 2nd speed spool. Then the swash plate is returned the 1st speed position by the spring force. Therefore, the travel motor is always set at 1st speed at every start-up of the engine.

Condition of 1st speed

CONTROL CHAMBER CONTROL PISTON Condition of 2nd speed Fig. 5-8 Hydraulic motor operation

24-30

CYLINDER BARREL

OPERATING PRESSURE

14903 60413247

(2) Construction and Operation Principle of Motor The pressurized oil supplied through the counterbalance valve is supplied to the valve plate (5). When pressurized oil is supplied to port A, it flows into the cylinder port on the cylinder barrel (4) of aligning with port A, and pushes the piston (6). The force on the piston is converted through the swash plate (7) into rotary motion, which is transmitted to the shaft (3) through the spline provided on the cylinder barrel (4). The return oil from the cylinder port flows out through port B on the valve plate (5). In case of the reverse rotation, the oil flows into port B, and the return oil flows out port A.

COMPONENTS SYSTEM 5.3.3 HYDRAULIC VALVE (COUNTER BALANCE VALVE) When pressure oil is supplied from port (A), the oil opens the check valve (3) and flows into port (A') on the inlet side of the travel motor. The oil also flows through the choke passage (C) into the chamber (D) where the oil overcome the force of spring (4), and moves the spool valve (2) to the right. Consequently, the return oil from the travel motor enters port (B'), flows through the passage (E) between the body (1) and the spool valve (2), and returns to port (B), rotating the travel motor. When the oil is supplied through port (B), each of these parts operates in the opposite direction, reversing the travel motor.

When the oil pressure at port (A) is isolated, the spool valve (2) that had been moved to the right tends to move back to the left due to the force of spring (4). At that time, the oil in the chamber (D) tries to flow to port (A) through choke passage (C), but the throttle effect of the choke passage (C) controls the speed of the spool valve (2) to return to the left. And even though the oil pressure at port (A) is isolated, the hydraulic motor tends to rotate due to its inertia force. However, because of returning speed of the spool valve (2) and the notch shape, the returning oil volume is controlled resulting smooth stop of the hydraulic motor.

14903 60413247

2nd Speed Spool (305)

Fig. 5-9 Hydraulic valve operation

24-31

COMPONENTS SYSTEM

6. SWIVEL JOINT 6.1 GENERAL VIEW

Fig.6-1 General view of swivel joint

6.2 SPECIFICATIONS Table. 6-1 Model (Type) Port

A.B.C.D.

E.F.G.P.

Max working pressure

kgf/cm (psi)

210 (2990)

40 (570)

3 (43)

Pressure test

kgf/cm2 (psi)

315 (4480)

60 (850)

5 (71)

20 (5.3)

10 (2.6)

1 (0.26)

Flow rate Revolution Weight

L/min (gal/min) -1

min {rpm}or less kg

14903 60413247

YV-7185 (YV-3630 including selector valve assy)

20 12 (26) F22580

24-32

COMPONENTS SYSTEM

6.3 CONSTRUCTION

Fig. 6-2 Construction

14903 60413247

Table. 6-2 Swivel joint parts

24-33

COMPONENTS SYSTEM

Fig. 6-3 Construction (2/2)

14903 60413247

Table 6-3 Parts for Selector Valve Assy

24-34

COMPONENTS SYSTEM

6.4 OPERATION (1) Swivel Joint The swivel joint is mounted on the machine's slew axis. It serves the role of maintaining continuous connection of hydraulic line independent of the upper frame's slew angle. On the body (2) and shaft (1), which are capable of rotating in each other, ports (3) are provided for oil pass as required number of hydraulic lines. On the inner circumference surface of the body (2) and the outer circumference surface of the shaft (1), grooves are machined for passage of hydraulic oil. Seals (4) are installed on the both sides of grooves. Oil from port (3) flow continuously through this passage (5) between the body (2) and shaft (1). The hydraulic line is to be connected without brake though the upper slewing body slews. The attached selector valve is able to shift twoindependent port (E, G)

14903 60413247

(2) Selector Valve The swivel joint provide a selector valve which make it possible to shift independent lines. By operation of the selector valve, shifting for operation of dozer blade cylinder and crawler frame width cylinder is done. 1) When spool (2) of the selector valve (1) is on the right side, port P of the selector valve (1) is connected to port E of the swivel joint (3). Owing to the above, oil from the control valve flow to the dozer blade cylinder. 2) When the spool (2) of the selector valve (1) shifts to left side, port P of the selector valve (1) is connected to port G of the swivel joint (3). Owing to the above oil from the control valve flow to the crawler frame width cylinder.

24-35

COMPONENTS SYSTEM

7. CYLINDER 7.1 SPECIFICATIONS (1) General view

B TH A G H N LE NGT D E DE D L EN CTE T EX RA LLY RET U F LLY FU

STAMP POSITION

Fig. 7-1 General view of cylinder

(2) Specifications Unit: mm (ftÂ·in)

14903 60413247

Table. 7-1

24-36

COMPONENTS SYSTEM

7.2 CONSTRUCTION AND FUNCTION 7.2.1 Construction (1) Boom cylinder

14903 60413247

Fig. 7-2 Construction of boom cylinder

24-37

COMPONENTS SYSTEM (2) Arm cylinder

14903 60413247

Fig. 7-3 Construction of arm cylinder

24-38

COMPONENTS SYSTEM (3) Bucket cylinder

14903 60413247

Fig. 7-4 Construction of bucket cylinder

24-39

COMPONENTS SYSTEM (4) Swing cylinder

14903 60413247

Fig. 7-5 Construction of swing cylinder

24-40

COMPONENTS SYSTEM (5) Dozer cylinder

14903 60413247

Fig. 7-6 Construction of dozer cylinder

24-41

COMPONENTS SYSTEM (6) Crawler width cylinder

14903 60413247

Fig. 7-7 Construction of crawler width cylinder

24-42

COMPONENTS SYSTEM 7.2.2 OPERATION Hydraulic oil flowing alternately in and out of the oil outlet and inlet on both sides (head and rod sides) of the piston acts on the piston and its force causes the piston to move back and forth. In cylinder equipped with a cushion mechanism, the shock resulting from the piston colliding with the cylinder head at the stroke end is dampened by it.

Cushion Mechanism

Fig. 7-8 Cushion Mechanism in cylinder

14903 60413247

Before the piston (1) nears the stroke end and collides with the cylinder head (2), the cushion bearing (3) which precedes it enters the cushion seal (4), shutting off the return passage for hydraulic oil on the rear end of the piston and making it possible for oil to be expelled only through the throttle hole provided in the cushion bearing (3) or along the groove. This causes the piston (1) back pressure to become high slowing the speed of the piston. The cushion mechanism is respectively provided at the rod side for boom cylinders, and at the head side for swing cylinder.

24-43

COMPONENTS SYSTEM

Part II: ELECTRICAL EQUIPMENT 1. ELECTRICAL EQUIPMENT LIST

ELECTRICAL FITTINGS

E-3 E-4 E-6

HORN FUSIBLE LINK

E-7

GLOW PLAG

E-8

CURRENT LIMITER

E-9 E-10

BATTERY SOCKET

L-1

BOOM WORKING LIGHT(RIGHT)

M-1

STARTER MOTOR

R-1 R-2 R-3 R-5 R-6

SAFETY RELAY 2-SPEED SELECTION RELAY E/G STOP RELAY

SV-1 SV-2 SV-3

LEVER LOCK SOL. 2SPEED SELECT SOL. E/G STOP SOLENOID

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6

KEY SWITCH 2 SPEED SELECT SW. LEVER LOCK SW.(RH) LEVER LOCK SW.(LH) HORN SWITCH E/G WATER TEMP. SWITCH

SW-7

ENGINE OIL PRESSURE SWITCH

F22563

CHARGE INDICATOR RELAY TIMER UNIT 14903 60413247

RELAY

MOTOR

GAUGE CLUSTER

SOLENOID SENSOR

FUSE BOX DYNAMO

LIGHT

E-1 E-2

PART NAME GROUP CODE SE-1 FUEL SENSOR SE-2 ENGINE THERMO SENSOR

SWITCH

PART NAME

DIODE

GROUP CODE D-1 DIODE D-2 DIODE D-3 DIODE

24-44

COMPONENTS SYSTEM

2. ELECTRICAL EQUIPMENT ARRANGEMENT 2.1.1 Upper frame portion

E-3 HORN

SV-1, SV-2 SOLENOID VALVE

H-1 MAIN HARNESS

RELAY UNIT E-9 BATTERY

VIEW A

14903 60413247

SW-2 TWO-SPEED SELECT SW.

24-45

COMPONENTS SYSTEM

14903 60413247

NOTES:

24-46

ELECTRICAL SYSTEM 2.1.2 Engine portion

SE-2 ENG. WATER TEMP. SENSOR

E-4 FUSIBLE LINK SW-6 ENG. THERMO SW

E-2 DYNAMO

H-5 EARTH CABLE E-7 GLOW PLUG

M-1 STARTER MOTOR

GUARD SUPPORT UPPER FRAME

SV-3 ENG. STOP SOL.

SW-7 ENGINE OIL PRESS SW

ENG. EARTH POINT REAR OF MACHINE

14903 60413247

FRONT OF MACHINE

23-47

ELECTRICAL SYSTEM 2.1.3 Control box & relay unit portions

R-1 SAFETY RELAY

R-3 ENGINE STOP RELAY

E-1 FUSE BOX

R-5 CHARGE INDICATOR RELAY R-2 TWO SPEED SELECT RELAY H-2 RELAY HARNESS

R-2 TWO SPEED RELAY

TO FRONT SIDE

DETAIL OF RELAY UNIT (FRONT) DETAIL OF RELAY UNIT (UPPER ENGINE) CONNECTOR (JOINT WITH MAIN HARNESS)

2.1.4 Fuel tank portion

2.1.5 Attachment portion

FUEL TANK

14903 60413247

SE-1 FUEL SENSOR

SECTION AA

23-48

ELECTRICAL SYSTEM

14903 60413247

2.1.4 Upper frame portion

23-49

ELECTRICAL SYSTEM

14903 60413247

2.1.5 Engine portion

23-50

ELECTRICAL SYSTEM

14903 60413247

2.1.6 Console box & relay unit portions

23-51

ELECTRICAL SYSTEM 2.1.7 Battery portion

2.1.8 Fuel tank portion

14903 60413247

2.1.9 Attachment portion

23-52

COMPONENTS SYSTEM

2.3 SPECIFICATIONS ELECTRICAL EQUIPMENT

Maker Part No. Rated current

7321-9332-60 2.5 A

7124-8252 DC12V

Yanmar Part No. Voltage Rated revolution Current

129150-77202 12V 4800 rpm 20A

14903 60413247

Maker Part No. Rated current

24-53

COMPONENTS SYSTEM

BG62-66-790A DC12V Max 3.5A 390 ± 20 Hz 110 ± 5 dB

Insulation resistance

1M Ωor more/500V Megger

14903 60413247

Maker Part No. Rated Voltage Rated current Basic frequency Sound level

24-54

COMPONENTS SYSTEM

Yanmar Part No. Rated Voltage Resistance

129795-77800 DC10.5 V 1.3Ω - 1.7Ω

Yanmar Part No. Current Regulated voltage Lamp

119653-77710 Nominal 20A 14.5 ± 0.5V 12V,3.4W or below

44B20R DC12V 34 Ah / 5 Hr Amount of electrolyte 2.5 l (0.66 gal) Weight 10.7 kgf (23.6 lbs)

14903 60413247

Type Voltage Capacity

24-55

14903 60413247

COMPONENTS SYSTEM

24-56

14903 60413247

COMPONENTS SYSTEM

24-57

14903 60413247

COMPONENTS SYSTEM

24-58

14903 60413247

COMPONENTS SYSTEM

24-59

14903 60413247

COMPONENTS SYSTEM

24-60

14903 60413247

COMPONENTS SYSTEM

24-61

COMPONENTS SYSTEM

14903 60413247

NOTE:

24-62

SECTION 31

WHOLE DISASSEMBLY AND ASSEMBLY

TABLE OF CONTENTS 1. Explaining chapter of whole disassembly and assembly...................................... 31-1

14903 60413247

1.1 Form for chapter of disassembly and assembly ............................................................................ 31-1 1.2 Indication of tightening torque ....................................................................................................... 31-1

WHOLE DISASSEMBLY AND ASSEMBLY

1. EXPLAINING CHAPTER OF WHOLE DISASSEMBLY AND ASSEMBLY 1.1 FORM FOR CHAPTER OF DISASSEMBLY AND ASSEMBLY This chapter is consist of 3-section as follows. (1) ATTACHMENT ............................................................................................................................ SEC. 32 Part I; Removing and installing assy Part II; Disassembling and assembling components 1) Hydraulic cylinder (including crawler width cylinder) (2) UPPER SLEWING STRUCTURE ................................................................................................ SEC. 33 Part I; Removing and installing assy Part II; Disassembling and assembling components 1) Hydraulic pump 2) Control valve 3) Pilot valve (ATT) 4) Pilot valve (Travel) 5) Slewing motor 6) Swivel joint (3) TRAVEL SYSTEM ...................................................................................................................... .SEC. 34 Part I; Removing and installing assy Part II; Disassembling and assembling components 1) Travel motor

1.2 INDICATION OF TIGHTENING TORQUE

14903 60413247

Tightening torque is indicated as follows, for example; T = 10 kgf·m (72 lbf·ft) Tolerance is ± 10% unless specified. • Refer SEC. 11 TOOLS for standard tightening torque.

31-1

WHOLE DISASSEMBLY AND ASSEMBLY

14903 60413247

NOTE

31-2

SECTION 32

ATTACHMENTS

TABLE OF CONTENTS Part I: Removing and installing assy 1. Attachment assy and name .................................................................................. 32-1 2. Bucket.................................................................................................................... 32-2 2.1 Removal of bucket .......................................................................................................................... 32-2 2.2 Installation of bucket ...................................................................................................................... 32-2 2.3 Adjusting procedure for adjustment of clearance between bucket and arm ................................... 32-3

3. Arm ....................................................................................................................... 32-4 3.1 Removal of arm .............................................................................................................................. 32-4 3.2 Installation of arm .......................................................................................................................... 32-5

4. Boom .................................................................................................................... 32-6 4.1 Removal of boom ........................................................................................................................... 32-6 4.2 Installation of boom ........................................................................................................................ 32-7

5. Swing .................................................................................................................... 32-8 5.1 Removal of swing bracket and cylinder .......................................................................................... 32-8 5.2 Installation of swing bracket and cylinder ....................................................................................... 32-9

6. Dozer .................................................................................................................. 32-10 6.1 Removal ....................................................................................................................................... 32-10 6.2 Installation .................................................................................................................................... 32-10

14903 60413247

Part II: Disassembling and assembling components 1. Cylinder .............................................................................................................. 32-11 1.1 Necessary tools ........................................................................................................................... 32-11 1.2 General precautions ..................................................................................................................... 32-11 1.3 Cylinder construction (example of swing cylinder) ....................................................................... 32-12 1.4 Disassembly ................................................................................................................................. 32-12 1.5 Assembly ...................................................................................................................................... 32-17 1.6 Maintenance standards ................................................................................................................ 32-22 1.7 Jig list ........................................................................................................................................... 32-25 1.8 Possible causes for trouble and remedy ...................................................................................... 32-28

ATTACHMENTS

Part I: REMOVING AND INSTALLING ASSY 1. ATTACHMENT ASSY AND NAME (L) SWING CENTER PIN

(M) SWING CYLINDER ROD PIN (J) BUCKET DRIVE PIN (N) SWING CYLINDER HEAD PIN

(K) BUCKET INSTALLING PIN

(H) BUCKET CYLINDER ROD PIN

(I) IDLER LINK PIN (G) BUCKET CYLINDER HEAD PIN

(E) ARM CYLINDER ROD PIN

(D) ARM CYLINDER HEAD PIN

(F) BOOM TOP PIN

(A) BOOM FOOT PIN

(B) BOOM CYLINDER HEAD PIN

(Q) DOZER CYLINDER ROD PIN

14903 60413247

(R) DOZER CYLINDER HEAD PIN

(P) DOZER PIN Fig. 1-1 Attachment name and position

32-1

ATTACHMENTS

2. BUCKET 2.1 REMOVAL OF BUCKET (1) Operate the operating lever and place the bucket on the ground, so the bucket and arm connecting pins are not loaded. (2) Move the O-rings (3) toward the bucket bosses using a spatula. (3) In order to remove pin (K) which links arm and bucket, remove the ring (2) and the pin (3) by means of straight driver, and draw out pin (K). • If the pin does not come off easily, the pin is loaded. Take off the load by manipulating the operating lever. • Take care so the dust seal between the arm and the bucket bosses is not damaged. (4) Adjust the bucket by manipulating the operating lever so the pin (J) between the bucket link and the bucket is not loaded. (5) Remove the ring (2) and pin (1) then pull out the pin (J). (6) Remove bucket assy. Weight: 17 kg (37 lb)

Fig. 2-2 To place bucket on ground

3 J

2 B

PIN FOR BUCKET LINK DUST SEAL

DAST SEAL

1 SECTION BB B

2.2 INSTALLATION OF BUCKET Installation is performed in the reverse order of removal, including the following workings: WARNING When aligning the pin borees, do not put your finger in the pin holes in any circumstances, but align them visually.

F15037

Fig. 2-3 Assembly of pin (SECTION A-A)

14903 60413247

(1) Clean the welded part of the structures and check that there is no crack on the part. (2) Check that the dust seal is not damaged, and replace a faulty one if necessary. (3) Adjust the clearance between the bucket and the arm according to Item 2.3. (4) Replace the weared pins and bushings according to the section "ATTACHMENT DIMENSIONS" of "SPECIFICATIONS". (5) When inserting the pin, coat the shaft with grease. • The bucket can be mounted easily if the bucket link is installed in the beginning.

Fig. 2-4 Installation of bucket

32-2

PIN FOR ARM

ATTACHMENTS

2.3 ADJUSTING PROCEDURE FOR ADJUSTMENT OF CLEARANCE BETWEEN BUCKET AND ARM • Clearance shall be checked at every 120-hour operation in case of normal working. • Shorten the checking interval according to work conditions. • Prior to adjusting work, wash the bucket hinge portion to remove adhered mud and grease, etc. (1) Move O-ring (3) toward the bucket boss, using a spatula, to see gap (B). (2) When adjusting clearance (B), bring the nonadjusting side of the bucket in contact with the arm. (3) Measure clearance (B) and check that it is within 0.6mm (0.024in). (4) Recondition clearance (B) less than 0.6mm (0.02in), where it is more than 0.6mm (0.024in). (5) Several shims (10) of 0.6mm (0.024in) thickness are set in each of the three capscrews (8). The clearance can be decreased by removing 0.6mm (0.024in) if one each shim is removed. (6) After reconditioning by required shims, tighten 3socket bolts (8) evenly. By the above procedure, bushing (A) is pushed toward inside, and then clearance is reconditioned within 0.6mm (0.024in).

(TEMPORARY POSITION)

Push pin (9) level with surface Fig. 2-5 Recondition of clearance between bucket and arm

: 6 mm

14903 60413247

T=3.4 kgf • m (25 lbf•ft) • Specified clearance is required between bushing (A) and arm. (7) Operate the bucket and check again that the total of both clearances are within 0.6mm (0.024in). (8) Refit O-ring (14) to its original position. Apply grease on the O-Ring.

32-3

ATTACHMENTS

3. ARM 3.1 REMOVAL OF ARM

Fig. 2-5 Arm removing posture

PIN (F) PORTION

PIN (E) PORTION

Fig. 2-6 Sectional view of installing pin

BUCKET CYLINDER

Fig. 2-7 Removal of arm assy SHIM

SHIM

14903 60413247

(1) Making the arm cylinder and bucket cylinder to the most contracting conditions, get touch the arm tip with the ground. (2) Loosing the air plug on the hydraulic oil tank, release the pressure in the tank. : 22 mm (3) Disconnect the 2 hoses connected to the bucket cylinder. Then apply a blinding plug to the openings. : 19mm, 22 mm (4) Lift up the arm cylinder body with a nylon sling in order not to exert any load to the pin (E). (5) Remove the capscrew and nuts that are preventing the pin (E) from coming out. Then remove the pin (E) and shims. : 17mm (6) Placing a square timber under the arm cylinder, get down the cylinder. (7) Install the pin (E) to the original position, and install the capscrew and nuts that prevents the pin (E) from coming out. Applying a rope to the pin (E) and the arm tip, slightly lift it up in order not exert any load to the pin (F). (8) Remove the capscrew that is preventing the pin (F) connecting the arm and boom, from coming out. Then pull off the pin (F). : 17mm (9) Remove the arm assy paying attention to the stability of arm. Weight of arm assy: approx. 40 kgf (88 lbs) (10) Removal of Bucket Cylinder 1) Remove the capscrew that is preventing the rod pin (H) from coming out, then pull off the pin (H). : 19mm 2) Remove the capscrew and nuts that are preventing the head pin (G) from coming out, then pull off the pin (G). : 17mm 3) Apply a nylon sling to the tube of bucket cylinder, and remove the cylinder. Weight ; 7 kgf (15 lbs)

PIN (H) PORTION PIN (G) PORTION Fig. 2-8 Sectional view of installing pin

32-4

ATTACHMENTS

3.2 INSTALLATION OF ARM Installation is performed in the reverse order of removal, including the following workings. WARNING At the alignment of pin bores, never insert your finger into the bores. Make sure to align them with visual confirmation.

0.5 ~ 1.0 mm (0.020 ~ 0.039 in)

STOPPER CAPSCREW Fig. 2-9 Tightening Procedure of Nuts

14903 60413247

(1) Make the welded area clean to inspect any cracks there. (2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 2-9 for the installing procedures). (3) Referring to the section "ATTACHMENT DIMENSIONS" of specifications, replace the wornout pin and bushing to new ones. (4) Before installing the pin, apply grease to the shaft area. (5) Referring to Fig. 2-10, install the capscrew and nuts to prevent the pin from coming out. : 17 mm (6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2-10. (7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

NUT

Fig. 2-10 Sectional view of installing pin

32-5

ATTACHMENTS

4. BOOM 4.1 REMOVAL OF BOOM (1) Get down the boom from which the arm was removed, and support the boom end with a stable stand. (2) Disconnect all hoses from the bucket cylinder, arm cylinder and boom cylinder, and apply a blinding plug to all the openings. : 19 mm, 22 mm (3) Disconnect the wiring for working light at the connector. Fig. 2-11 Removal of boom cylinder

(4) Removal of Boom Cylinder 1) Temporarily lift up the boom cylinder with a nylon sling to prevent the boom cylinder from falling down. 2) Removing the capscrew and nuts that are preventing the rod pin (C) from coming out, remove the pin (C). : 17 mm 3) Contract the rod, then put the cylinder on a stable stand. 4) Removing the capscrew that is preventing the head pin (B) from coming out, remove the pin (B). 5) Remove the boom cylinder. Weight : 7 kgf (15 lbs) (5) Removal of Boom Assy 1) Temporarily lift up the boom assy in order not to exert any load to the boom foot pin (A). Weight of boom assy : approx. 50 kgf (110 lbs) 2) Removing the capscrew that is preventing the boom foot pin (A) from coming out, pull off the pin (A). 3) Applying a sling to the boom assy, remove the boom assy.

SHIM

PIN (C) PORTION

PIN (B) PORTION

Fig. 2-12 Sectional view of installing pin

Fig. 2-13 Removal of Boom Assy

14903 60413247

SHIM

(6) Removal of Arm Cylinder 1) Removing the capscrew and nuts that are preventing the head pin (D) from coming out, remove the pin (D). : 17 mm 2) Applying a nylon sling to the tube of arm cylinder, remove the arm cylinder. Weight : 9 kgf (20 lbs)

PIN (D) PORTION

PIN (A) PORTION

Fig. 2-14 Sectional view of installing pin

32-6

ATTACHMENTS

4.2

INSTALLATION OF BOOM

Installation is performed in the reverse order of removal, including the following. â&#x20AC;˘ At the alignment of pin bores, never insert your finger into the bores. â&#x20AC;˘ Make sure to align them with visual check. (1) Make clean the welded area on each of structure to inspect any cracks there. (2) Check the dust seal for damages, and replace the faulty dust seal to new one (referring to Fig. 2-15 for the installing procedures). (3) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the wornout pin and bush to new ones. (4) Before inserting the pin, apply grease to the shaft area. (5) Referring to Fig. 2-16, install the capscrew and nuts to prevent the pin from coming out. : 17 mm

0.5 ~ 1.0 mm (0.020 ~ 0.039 in)

NUT

STOPPER CAPSCREW Fig. 2-15 Tightening Procedure of Nuts

(6) Make sure to provide an appropriate clearance for thrust direction at the installation of pin referring to Fig. 2-16. (7) For the adjustment for clearance, insert resin (plastic) shim first, then adjust the clearance with steel shims.

BOSS

Apply Loctite #242 equivalent

DUST SEAL

BUSHING

PIN (A) PORTION The sum of both clearances: less than 0.5 mm (0.020 in) after shim adjustment

14903 60413247

DUST SEAL INSTALLATION

The sum of both clearances: less than 0.5mm(0.020in) after shim adjustment

PIN (B) PORTION

PIN (C) PORTION

PIN (D) PORTION

Fig. 2-16 Sectional view of installing pin

32-7

ATTACHMENTS

5. SWING 5.1 REMOVAL OF SWING BRACKET AND CYLINDER (1) Preparation for removal 1) To make the removing work easy, swing by around 30Â° for leftward. 2) Remove the floor plate and left side cover.

5.1.1 Removal of Swing Bracket (A1) (1) Removing the capscrew (B4) that is preventing the rod side pin (M) of swing cylinder (B1) from coming out, remove the pin (M). : 17 mm (2) Install the boom foot pin (A) to the original position on swing bracket (A1), then temporarily lift it up. (3) Removing the capscrew (A4) that is preventing the pin (L) from coming out, remove the pin (L). : 17 mm (4) Remove the swing bracket. Weight of Swing Bracket: 16 kgf (35 lbs)

Fig. 2-17 Swing portion

5.1.2 Removal of Swing Cylinder (B1) (1) Disconnect 2 connecting hoses for the swing cylinder. : 19 mm, 22 mm (2) Removing the capscrew (B4) that is preventing the head side pin (N) of swing cylinder from coming out, remove the pin (N). : 17 mm (3) Take out the swing cylinder (B1) from the front side. Weight of Swing Cylinder : 15 kgf (33 lbs)

14903 60413247

Fig. 2-18 Removal of swing bracket

32-8

ATTACHMENTS

5.2 INSTALLATION OF SWING BRACKET AND CYLINDER Installation is performed in the reverse order of removal, including the following workings. (1) Check the dust seal for damages, and replace the faulty dust seal to new one. (2) Referring to the section "ATTACHMENT DIMENSIONS" of specifications, replace the wornout pin and bush to new ones. (3) Before inserting the pin, apply grease to the shaft area. (4) Refer to Fig. 2-19 for the shim adjustment at pin installing portion.

Insert a steel shim of 1 mm (0.039 in) into down side, and adjust the upper clearance making it less than 2 mm (0.079 in). Do not use more than 2 shims at the same portion.

Make sure to insert a steel shim of 1 mm (0.039 in) into upper side, and adjust the upper clearance making it between 0.5 ~ 1.0 mm (0.020 ~ 0.039 in).

SHIM B7

DUST SEAL DUST SEAL

14903 60413247

SHIM B7 B4 B4

Insert steel shim into cylinder side.

SECTION AA

SECTION BB

Fig. 2-19 Sectional view of pin installing

32-9

ATTACHMENTS

6. DOZER 6.1 REMOVAL (1) Put a support of appropriate height under the mounting side of dozer body, and make the dozer at a stable condition not to exert any load to the pin (B1). (2) Disconnect the hydraulic hoses and apply a plug to the connecting portions. : 19 mm, 22 mm (3) Apply a nylon sling to the dozer cylinder (C1), and lift it up slightly not to exert any load to the Pin (Q) of rod side. (4) Remove the capscrew (C3) and nuts (C4) that are preventing the pin (Q) from coming out, of rod side. Remove the pin (Q), and support the cylinder (C1) with a timber, etc. : 17 mm (5) Remove the capscrew (B2) and nuts (B3) that are preventing the dozer body fixing pin (P) from coming out, and remove the two pins (P). (6) Gradually move the machine to backward to remove the dozer. Weight of dozer assy with: Approx. 50 kgf (110 lbs) (7) If necessary, remove the dozer cylinder by means of removing the pin (R) of head side. Weight of dozer cylinder: 17 kg (37 lb)

(C3, C4)

(B2, B3)

Support of Timber, etc.

Fig. 2-20 Removing/installing dozer blade

6.2 INSTALLATION The installation is carried out with the reverse order of the removal paying attention for the following. (1) Referring to the Section "ATTACHMENT DIMENSIONS" of Specifications, replace the wornout bushings and dust seals to new ones. (2) Before installing pin (P), (Q) and (R), apply grease to their shaft area. (3) Refferring to Fig. 2-21, install the nuts for capscrew to prevent the pin from coming out. : 17 mm

NUT 0.5 ~ 1.0 mm (0.020 ~ 0.39 in) STOPPER CAPSCREW

14903 60413247

Fig. 2-21 Tightening procedures for nuts

32-10

ATTACHMENTS

Part II: DISASSEMBLING AND ASSEMBLING COMPONENTS 1. CYLINDER 1.1 NECESSARY TOOLS Though the required tools and jigs differ in types of cylinder, as a guide line, tools and jigs to be prepared are shown in Table 1-1.

Table 1-1 List of tools and jigs TOOL/JIG Hammer Screwdriver Chisel Vise Wrench

REMARKS 1. Steel hammer 2. Wooden or plastic hammer 2 ~ 3 kinds of minus driver of small and large sizes Flat chisel Capable to hold outer dia. of cylinder head and tube installing pin portion 1. Special wrench 2. Extension pipe for wrench

TOOL/JIG Gimlet

Jig

Measuring Device

REMARKS A sharp-point tool may be used in place of gimlet 1. For installing seal ring 2. For pushing seal ring into groove 3. For reforming seal ring 4. For pressing bushing 1. Slide calipers 2. Micrometer 3. Cylinder gauge 4. V-block

• For the details of special jigs, refer to item 1.7 of this section.

1.2 GENERAL PRECAUTIONS • After the installation of O-ring, confirm there is no twist on it. • Apply clean hydraulic oil to each sliding portion before the installation. • Confirm each sliding portion for no burr and defect, and its smooth sliding operation. • This manual describes mainly for the swing cylinder as an typical example.

14903 60413247

• Carry out the disassembly and assembly works in a clean work shop, and always keep disassembled parts at clean conditions. • Prior to disassembly, thoroughly clean the cylinder externally. • Use caution not to give any damages to the parts while carrying out the disassembly / assembly works. • Thinly apply grease or hydraulic oil to seals prior to installation.

32-11

ATTACHMENTS

1.3 CYLINDER CONSTRUCTION (EXAMPLE OF BOOM CYLINDER) • See CYLINDER for the others.

Fig. 1-1 Construction of swing cylinder

1.4 DISASSEMBLY • The numbers in ( ) following to each part name are the numbers corresponding to those in Fig. 1-1 "Boom cylinder" except for notes. (1) Disassembly of cylinder assy 1) Fix the clevis portion of tube with a vice, and hold the other end with a wooden stand to hold the cylinder in level. 2) Drain hydraulic oil remained in the cylinder. • Slowly move the piston rod so that the hydraulic oil does not spout out. Fig. 1-2 Disassembling cylinder assy

14903 60413247

3) Make straight the locking fin for the cylinder head. • Use cautions bending / straightening of locking fin, because locking fin and cylinder tube are made with one-piece.

Fig. 1-3 Unlocking cylinder head

32-12

ATTACHMENTS 4) Loosen the cylinder head (3). • Prior to loosening the cylinder head, pull out the piston rod (2) by 100 ~ 200 mm (4 ~ 8 in). • Cover the rod with an appropriate material to prevent it from unexpected bruises. 5) Pull off the piston rod assy from the tube. • Pull the piston rod in straight not to give any damages on the sliding surface.

Fig. 1-4 Disassembling cylinder head

(2) Disassembly of piston rod assy 1) Fix the piston rod assy in level.

Fig. 1-5 Disassembling piston rod

14903 60413247

Disassembly of the piston “For all the cylinders except the swing cylinder” a. Remove the setscrew (23), then remove the steel ball (22). • Since the setscrew is caulked at 2 positions with a punch, take off the caulked portion with a hand drill. b. Remove the piston (19) assy. c. Remove the cushion bearing (24) (for boom cylinder only).

24 19

23 22 F19763

Fig. 1-6 Removing piston assy

“For Swing cylinder” a. Remove the bolt (19) and washer (18), then remove the cushion bearing (17). b. Remove the set screw (16), then remove the steel ball (15). c. Remove the piston assy (12).

Fig. 1-7 Removing piston assy

32-13

ATTACHMENTS 3) Remove the cylinder head assy.

Fig. 1-8 Removing piston assy

(3) Disassembly of piston assy: 1) Remove the slide ring (20) from the piston (19). • Expand the split on the slide ring (20) as minimum as required to pull it off for axial direction (2 places). 2) Remove the seal ring assy (21). • Cut off the seal ring (21) or remove it using a minus screw driver.

21 F19795

Fig. 1-9 Disassembling piston assy

(4) Disassembly of cylinder head assy: 1) Remove the O-rings (8) (10) and back-up ring (9) from the outer periphery of cylinder head (3). Then remove the O-ring (14) and back-up ring (15) [for Boom cylinder only].

8,10

3 15 14 F19796

Fig. 1-10 Disassembling cylinder head assy

14903 60413247

2) Removal of U-ring “For boom cylinder” a. Remove the stopper (14). b. Remove the spacer (13). c. Remove the cushion ring (12). d. Remove the U-ring (5). e. Remove the back-up ring (6). SECTION A-A Fig. 1-11 Disassembling cylinder head assy

32-14

ATTACHMENTS “For arm, bucket, dozer, crawler width cylinder” a. Remove the O-ring (5). b. Remove the back-up ring (6).

SECTION A-A Fig. 1-12 Disassembling cylinder head assy

“For dozer cylinder” a. Remove the snap ring (18). b. Remove the packing header (17). c. Remove the O-ring (5).

5 17 18 F19799

SECTION A-A Fig. 1-13 Disassembling cylinder head assy

3) Remove the wiper ring (7). • Alternately tap inside of the metal ring of wiper ring at several positions, as shown in the figure, to push it out step by step from the groove.

Fig. 1-14 Removing wiper ring

14903 60413247

4) Remove the bushing (4) using a removal jig.

Fig. 1-15 Removing bushing

32-15

ATTACHMENTS (5) Disassembly of clevis portion: 1) Remove the wiper ring (27) from the clevis portion of tube (1) and piston rod (2).

F19802

27 Fig. 1-16 Removing dust seal

2) Remove the pin bushing (25) or (26). â&#x20AC;˘ Using a metal block, push it out with a press machine.

METAL BLOCK

14903 60413247

Fig. 1-17 Removing pin bushing

32-16

ATTACHMENTS

1.5 ASSEMBLY (1) Assembling clevis portion 1) With the installing jig (B) shown Item 1.7, press the bushings (25) or (26) into the piston rod assy (2) and tube assy (1).

B 25 or 26

• Prior to the work, apply hydraulic oil on the surface of parts. F19803

2) With the setting tool, install the wiper ring (27).

Fig. 1-18 Installing pin bushing

SETTING TOOL

Fig. 1-19 Installing dust seal

(2) Assembling cylinder head 1) With installing jig (A) shown Item 1.7, press-fit the bushing (4). • Prior to the work, apply hydraulic oil on inner periphery of the cylinder head (3). • At press-fitting the bushing (4) into the cylinder head (3), make the top surfaces of them in level without step.

14903 60413247

Fig. 1-20 Assembling cylinder head

2) Installing O-Ring “For boom cylinder” a. Install the back-up ring (6). b. Install the U-ring (5) paying attention for its installing direction. c. Install the cushion ring (12). d. Install the spacer (13). e. Install the stopper (14).

SECTION A-A Fig. 1-21 Installing O-ring

32-17

ATTACHMENTS “For arm, Bucket, dozer, Crawler width cylinder” a. Install the back-up ring (6). b. Install the U-ring (5).

Fig. 1-22 Installing O-ring

“For Swing cylinder” a. Install the O-ring (5). b. Install the packing (17). c. Install the snap ring (18).

5 17 18 F19805

SECTION A-A

Fig. 1-23 Installing O-ring

3) Using the setting tool, install the wiper ring (7).

SETTING TOOL

14903 60413247

Fig. 1-24 Installing wiper ring

32-18

ATTACHMENTS 7)

Install the back-up ring (9) and O-rings (8) (10).Then install the back-up ring (15) and O-ring (14) (for Boom cylinder only).

8,10

15 14 F19808

Fig. 1-25 Installing back-up ring and O-ring

O-RING

(3) Assembly of piston portion: 1) Install the O-ring for the seal ring assy (21).

Fig. 1-26 Installing O-ring

2) Set the sliding jig (C) shown Item 1-7 on the piston (19), then quickly push the seal ring (21) onto the piston (19) with the pushing jig (D) shown Item 17.

F19809

Fig. 1-27 Assembling seal ring

(O-RING)

3) Since the seal ring (21) is extremely stretched at the installation, reforma it with the reforming jig (E) shown Item 1-7.

14903 60413247

F19810

Fig. 1-28 Reforming seal ring

32-19

ATTACHMENTS 4)

Install the slide ring (20). • Expand the split on the slide ring (20) as minimum as required to install it toward the axial direction.

21 F19811

Fig. 1-29 Installing slide ring

(4) Installation of piston rod assy: 1) Fix the piston rod (2) in level, and install the cylinder head assy and holder onto it.

2) Install the piston assy. “All cylinders except Swing cylinder” a. Install the cushion bearing (24) (for boom cylinder only) and piston (19) on the piston rod (2), and tighten them up. • Tightening torque for piston: Refer to Table 1-4

Fig. 1-30 Installing head assy

b. Put the steel ball (22) into the threaded bore, and securely tighten it with the setscrew (23). And caulk the setscrew (23) with a punch at two points. • Tightening torque for setscrew: Refer to Table 1-4

“Swing cylinder” a. Install the piston (12) onto the piston rod, and tighten it up. • Tightening torque for piston : Refer to Table 1-4

23 22 F19813

Fig. 1-31 Installing piston assy

c. Install the cushion bearing (17), and tighten it up with the bolt (19). • Insert the no slit side of cushion bearing first. • Apply Locktite #271 to the bolt (19). • Tightening torque for bolt : Refer to Table 1-4 32-20

14903 60413247

b. Put the steel ball (15) into the threaded bore, and securely tighten it with the setscrew (16). And caulk the setscrew (16) with a punch at two points. • Tightening torque for setscrew : Refer to Table 1-4

Fig. 1-32 Installing piston assy

ATTACHMENTS (5) Assembly of cylinder: 1) Fix the tube in level, and install the piston rod assy into it. • At the installation, align the center of piston rod to the center of tube and install the piston rod in straight, paying attention not to damage seals.

Fig. 1-33

2) Install the cylinder head (3). • Apply hydraulic oil on the packings (seals)prior to install. • Tightening torque for cylinder head: Refer to Table 1-4

Fig. 1-34

3) Bend the locking fin on the tube to lock the cylinder head.

14903 60413247

Fig. 1-35

32-21

ATTACHMENTS

1.6 MAINTENANCE STANDARDS (1) Inspection after disassembly 1) Inspection item Table 1-2 PARTS NAME

INSPECTING PORTION

INSPECTION ITEM

REMEDY

Piston 1. Neck of rod

Presence of crack

Replace

rod

Presence of crack

Replace

3. Threads

Presence of seizure, etc.

Recondition or replace

4. Bend

Measure amount of bend

Refer to Rod Bend

5. Plated surface

1) Wearing off of plating

1. Replace

2) Rust on plating

2. Replace

3) Presence of defect

3. Recondition or replace

6. Rod

Wear of outside

Recondition or replace

7. Bushing at mounting part

Wear of inside

Replace

Cylinder

1. Welded part of bottom

Presence of crack

Replace

tube

2. Tube at mounting part

Presence of crack

Replace

3. Tube inside

Presence of defect

Replace if oil leak is seen

4. Bushing at mounting part

Wear of inside

Replace

1. Bushing

1) Wear of inside

Replace

2. Stepped part to which piston is attached

Rod cover

2) Defect of inside

14903 60413247

(2) Repair procedure Replace sliding parts and seal parts according to the followings. ( i ) Bushing .............................................................. where 1/4 of circumference is worn in copper color. ( ii ) Seals and slide rings ................................................... replace them when cylinder is disassembled. (iii) Pin bushing .................................................................................. where severe scuffing is appeared. (iv) Piston rod .................................................................. where the bent 0.5 mm/m or more is appeared.

32-22

ATTACHMENTS (3) Service limits Service limits represent the limits of wear on the sliding surfaces of the cylinder tube and the piston rod that have no such faults as may degrade the sealing effect. 0

1) Clearance between piston rod and rod bushing: Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25 mm (0.01 in). 2) Bend of piston rod : The allowable bend of the rod is maximum 0.5 mm / 1 m (0.02 in / 39.4 in). For measurement, support both ends of the parallel section of the piston rod with V-blocks, set a dial indicator in the center between the two V-blocks turn the piston rod, and read the difference between the maximum and minimum oscillations on the dial indicator.

1/2

F15085

Fig. 1-36 Measuring method

Table 1-3 shows an example of measurement Table 1-3 Example of measurement

• Even if the bend is within the tolerable limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after installation. Replace the rod if the cylinder makes a squeeking noise or dose not operate smoothly.

(4) Tightening torque B: Piston A: Cylinder head

C: Setscrew

D: Bolt (only for swing cylinder)

Unit: kgf•m (ft•lbs)

14903 60413247

Table 1-4

32-23

ATTACHMENTS (5) Inspection after installation PUMP

Unloaded performance test 1) Put the cylinder horizontally at unloaded condition. 2) Apply pressure slowly and alternately through the ports at both ends to operate the piston rod 5 or 6 times. 3) Check that the cylinder operates normally. Leakage test • External leakage 1) Apply test pressure for 3 minutes each to the rod retraction side and to the rod extension side of the cylinder. 2) Confirm that rod seals, cylinder head tightening part, and each weld are free from abnormalities, such as external leakage and permanent deformation. • Internal leakage 1) Disconnect the hose from the rod extension side of the cylinder. 2) Apply test pressure to the rod retraction side of the cylinder for 3 minutes. 3) Measure the leakage from the rod extension side. • Leakage should be below 1 cc (0.06 cu•in) / 3 min.

CONTROL VALVE

HYDRAULIC CYLINDER

TANK

Fig. 1-37 Unloaded test

PUMP CONTROL VALVE

HYDRAULIC CYLINDER Fig. 1-38 Leakage test

14903 60413247

(6) Bleeding air from hydraulic cylinder Bleed air from the cylinder after removing or installing it, or after disconnecting a hydraulic pipe. 1) Start the engine, and let it idling for about 5 minutes. 2) Repoat the step of extending and retracting the cylinder 4 or 5 times at slow speed of engine. • Move the piston rod 50 ~ 100 mm (2.0 ~ 3.9 in) short of its stroke end. Take care never to operate the relief valve. 3) Perform the above 2) procedures at high idling speed, then move the piston rod to its stroke end at low idling speed to operate the relief valve.

32-24

ATTACHMENTS

1.7 JIG LIST (1) Installing jig (A) for press fitting of head bushing (4).

(2) Installing jig (B) for press fitting of pin bushing (25) (26). 0 0 -0.25 (-0.010 )

øB

øF

øA

F ±0.2 (± 0.008)

0 ( øB-0.1 -0.004)

øA ± 0.2 (± 0.008)

F19814

Unit: mm (in)

14903 60413247

Unit: mm (in)

32-25

ATTACHMENTS (3) Sliding jig (C) for seal ring

50 (1.97)

15° 2 (0.08)

øC F19816

5 (0.20)

øA

øB

+0.008 A +0.2 +0.1 ( +0.004 )

E )

R (0.2 5 0

2 (0.08)

( +0.02 0 )

8°

A+0.5 0

øB ± 0.05 (± 0.002)

(1.18)

(4) Pushing jig (D) for seal ring

45 (1.77)

83 (3.27)

80 (3.15)

Material: nylon or acrylic

Unit: mm (in)

14903 60413247

Unit: mm (in)

32-26

ATTACHMENTS (5) Reforming jig (E) for seal ring

(

+0.1 +0.004 0 0

(R 0.12)

0. 12 )

)

20 (0.79)

50 (1.97)

14903 60413247

Unit: mm (in)

32-27

ATTACHMENTS

1.8 POSSIBLE CAUSES FOR TROUBLE AND REMEDY

TROUBLE CONDITIONS

MAJOR POSSIBLE CAUSES

REMEDY

Oil leakage from sliding • Foreign material is caught by O-ring or wiper • Remove foreign material. face of piston rod.

ring at its inside periphery.

(A ring shape oil is formed • Scuffing or fault on O-ring or wiper ring at • Replace each part with new one. on piston rod and en-

its inside periphery.

larged resulting dripping • Scores on sliding face of piston rod.

• Grind sliding face with a fine oil stone. (less than 1.6S)

down of oil)

• If leakage is not stopped by grinding, replace seals such as O-ring, etc. with new ones. • If leakage is not stopped by replacing seals, replace piston rod. • Re-plating of hard chrome on pis• Peeling off of hard chrome plating. Oil leakage from outer periphery of cylinder head. Oil leakage from welded portion.

ton rod.

• Damages on O-ring.

• Replace the part.

• Damages on back-up ring.

• Replace the part.

• Damages on welded portion on tube.

• Replace the part.

Piston movement due to • Foreign material is caught by sliding face • Remove foreign material. leakage.

of slide ring.

(For the case when static load that is equivalent to product of multiplication of • Scuffing or faulty condition on sliding face • Replace the part. max. working pressure

of slide ring.

and cylinder area, is applied to rod, max. movement of piston is larger • Scuffing on sliding face of seal ring assy.

• Replace the part.

than 0.5mm (0.02 in)) per • Damages on O-ring.

• Replace the part.

14903 60413247

10 minutes.

32-28

SECTION 33

UPPER SLEWING STRUCTURE

TABLE OF CONTENTS

Part I: Removing and installing assembly.........................................................33-1 1. Floor plate assy ..................................................................................................... 33-1 1.1 Removal ......................................................................................................................................... 33-1 1.2 Installation ...................................................................................................................................... 33-1

2. Guard (cover and support) .................................................................................... 33-1 2.1 Cover .............................................................................................................................................. 33-1 2.2 Supports ......................................................................................................................................... 33-2

3. Battery ................................................................................................................... 33-4 3.1 Removal preparation ...................................................................................................................... 33-4 3.2 Removal ......................................................................................................................................... 33-4 3.3 Installation ...................................................................................................................................... 33-4

4. Counterweight ....................................................................................................... 33-5 4.1 Removal preparation ...................................................................................................................... 33-5 4.2 Removal ......................................................................................................................................... 33-5 4.3 Installation ...................................................................................................................................... 33-5

5. Control box ............................................................................................................ 33-6 5.1 Removal preparation ...................................................................................................................... 33-6 5.2 Removal ......................................................................................................................................... 33-6 5.3 Installation ...................................................................................................................................... 33-6

6. Air cleaner ............................................................................................................. 33-7

14903 60413247

6.1 Disassembly preparation ................................................................................................................ 33-7 6.2 Disassembly ................................................................................................................................... 33-7 6.3 Assembly ........................................................................................................................................ 33-7

7. Dynamo ................................................................................................................. 33-7 7.1 Disassembly preparation ................................................................................................................ 33-7 7.2 Disassembly ................................................................................................................................... 33-7 7.3 Assembly ........................................................................................................................................ 33-7

INDEX

8. Starter ................................................................................................................... 33-8 8.1 Removal preparation ...................................................................................................................... 33-8 8.2 Removal ......................................................................................................................................... 33-8 8.3 Installation ...................................................................................................................................... 33-8

9. Muffler ................................................................................................................... 33-8 9.1 Disassembly preparation ................................................................................................................ 33-8 9.2 Removal ......................................................................................................................................... 33-8 9.3 assembly ........................................................................................................................................ 33-8

10. Fuel line ............................................................................................................... 33-9 10.1 Disassembly preparation .............................................................................................................. 33-9 10.2 Disassembly ................................................................................................................................. 33-9 10.3 Assembly ...................................................................................................................................... 33-9

11. Fuel tank ............................................................................................................ 33-10 11.1 Disassembly preparation ............................................................................................................ 33-10 11.2 Disassembly ............................................................................................................................... 33-10 11.3 Assembly .................................................................................................................................... 33-10

12. Hydraulic oil tank ............................................................................................... 33-11 12.1 Disassembly preparation ............................................................................................................ 33-11 12.2 Disassembly ............................................................................................................................... 33-11 12.3 Assembly .................................................................................................................................... 33-12

13. Pump ................................................................................................................. 33-14 13.1 Removal preparation .................................................................................................................. 33-14 13.2 Removal ..................................................................................................................................... 33-14 13.3 Installation .................................................................................................................................. 33-15

14. Radiator ............................................................................................................. 33-16 14.1 Disassembly preparation ............................................................................................................ 33-16 14.2 Disassembly ............................................................................................................................... 33-16 14.3 Assembly .................................................................................................................................... 33-16

15. Engine ............................................................................................................... 33-17 15.1 Removal preparation .................................................................................................................. 33-17 15.2 Removal ..................................................................................................................................... 33-17 15.3 Installation .................................................................................................................................. 33-18

16. Control valve ...................................................................................................... 33-19 16.1 Removal preparation .................................................................................................................. 33-19 16.2 Removal ..................................................................................................................................... 33-19 16.3 Installation .................................................................................................................................. 33-21

17. Pilot valve .......................................................................................................... 33-22

18. Slewing motor .................................................................................................... 33-23 18.1 Removal preparation .................................................................................................................. 33-23 18.2 Removal ..................................................................................................................................... 33-23 18.3 Installation .................................................................................................................................. 33-24

14903 60413247

17.1 Removal preparation .................................................................................................................. 33-22 17.2 Removal ..................................................................................................................................... 33-22 17.3 Installation .................................................................................................................................. 33-22

INDEX

19. Swivel joint......................................................................................................... 33-25 19.1 Removal preparation .................................................................................................................. 33-25 19.2 Removal ..................................................................................................................................... 33-25 19.3 Installation .................................................................................................................................. 33-27 19.4 Other removal method ............................................................................................................... 33-27

20. Upper frame ...................................................................................................... 33-28 20.1 Removal preparation .................................................................................................................. 33-28 20.2 Removal ..................................................................................................................................... 33-28 20.3 Installation .................................................................................................................................. 33-29

Part II : Disassembling and assembling components .............................................. 33-30 1. Hydraulic pump ................................................................................................... 33-30 1.1 Assembly drawing ........................................................................................................................ 33-30 1.2 Disassembly and assembly .......................................................................................................... 33-31 1.3 Maintenance standards ................................................................................................................ 33-38 1.4 Troubleshooting ............................................................................................................................ 33-39

2. Control valve ........................................................................................................ 33-40 1.1 Assembly drawing ........................................................................................................................ 33-40 1.2 Disassembling .............................................................................................................................. 33-48 1.3 Cleaning ....................................................................................................................................... 33-51 1.4 Inspection ..................................................................................................................................... 33-51 1.5 Assembling ................................................................................................................................... 33-52 1.6 Maintenance procedures for accessory valve .............................................................................. 33-56 1.7 Troubleshooting ............................................................................................................................ 33-60

3. Pilot valve ............................................................................................................ 33-62 3.1 Standards ..................................................................................................................................... 33-62

4. Slewing motor ...................................................................................................... 33-67 4.1 Assembly drawing ........................................................................................................................ 33-67 4.2 Dis/re-assembling ........................................................................................................................ 33-69 4.3 Maintenance standards ................................................................................................................ 33-78 4.4 Troubleshooting ............................................................................................................................ 33-79

5. Swivel joint........................................................................................................... 33-80

14903 60413247

5.1 Assembly drawing ........................................................................................................................ 33-80 5.2 Dis/re-assembling ........................................................................................................................ 33-83 5.3 Maintenance standards ................................................................................................................ 33-91 5.4 Troubleshooting ............................................................................................................................ 33-94

UPPER SLEWING STRUCTURE

Part I: REMOVING AND INSTALLING ASSEMBLY 1.

FLOOR PLATE ASSY

1.1 REMOVAL (1) Remove the floor mat (6). (2) Remove six SEMS bolts (4), the floor plate (1) and (2). : 13mm (3) Remove two SEMS bolts (5) and the cover (3). : 10mm

1.2 INSTALLATION Install in the reverse order of the removal and tighten according to the Tightening Torque table shown below.

GUARD (COVER AND SUPPORT) Fig. 1-1 Floor plate disassembly

2.1 COVER 2.1.1 Disassembly (1) Disassembling upper side covers 1) Remove the rubber caps (28) and the cap screws (26). : 13mm 2) Open the bonnet to remove the SEMS bolts (16). : 13mm 3) Remove the side covers (3) and (4).

14903 60413247

(2) Disassembling lower side covers 1) Remove the floor plate in advance (See item 1). 2) Remove each three SEMS bolts (16) (Front side two and rear lower one). : 13mm 3) Remove the side covers (1) and (2).

Fig. 2-1 Upper and lower cover disassembly

33-1

UPPER SLEWING STRUCTURE (3) Disassembling front side cover 1) Loosen the knobs (25). â&#x20AC;˘ Since the cover is attached by hinges, it falls down to near side when the knobs loosened. 2) Remove two SEMS bolts (16). : 13mm 3) Remove the cover assy (9).

(4) Disassembling bonnet 1) Remove two SEMS bolts (5-10). : 13mm

Fig. 2-2 Front cover disassembly

2) Remove the brackets (5-8) and (5-9), and the bonnet assy (5).

Fig. 2-3 Bonnet disassembly

2.2 SUPPORTS 2.2.1 Disassembly preparation (1) Removing control box 1) Remove the cap screws (16) for fixing the right and left control boxes, and move or remove the control boxes with the hoses attached (See item 5). FRONT

14903 60413247

2) In order to facilitate the movement of the right control box, disconnect cables for dozer and acceleration, if necessary.

Fig. 2-4 Control box removal

33-2

UPPER SLEWING STRUCTURE 2.2.2 Disassembly (1) Disassembling front support 1) Remove four capscrews (16). : 13mm

Selector valve lever for swivel joint

2) Put cables close to the support (6) in order, and remove the support (6) carefully without damaging the peripheral equipment.

(2) Disassembling lower support 1) Remove three capscrews (13). :19mm 2) Pull out the pin (C6) and disconnect the selector valve lever for swivel joint. 3) Remove the support (7). 4) Remove three tubes (11).

(3) Removing rear support 1) Remove the SEMS bolts (A3) and the fuel filter (A1) with the bracket. : 13mm

Fig. 2-5 Support disassembly

2) Remove the SEMS bolts (A6) and the coolant reserve tank (A4) with the bracket. :13mm 3) Remove the SEMS bolts (A5) and the relay assy (A2) with the bracket. :13mm 4) Remove four capscrews (16) and the support (8). (See Fig. 2-5)

14903 60413247

2.2.3 Assembly Assemble in the reverse order of the removal and tighten according to the Tightening Torque table shown below:

Fig. 2-6 Support accessory removal

33-3

UPPER SLEWING STRUCTURE

BATTERY

3.1 REMOVAL PREPARATION (1) Remove the left side guard (cover). (2) Open the cover under the seat.

Fig. 3-1 Battery

3.2 REMOVAL (1) Remove the band (12). (2) Removing battery cable 1) Pull out the battery to near side.

PLUS SIDE

2) Remove the minus (negative)side cable terminal. 3) Then remove the plus (positive) side cable terminal. : 13mm

WARNING Follow the battery cable removal procedure. Firstly disconnect the earth side battery cable. Connect the earth side finally. Failure to do so may result in dangerous situation due to spark.

MINUS SIDE Fig. 3-2 Battery removal

(3) Take out the battery holding the handles.

3.3 INSTALLATION

14903 60413247

Install in the reverse order of the removal.

33-4

UPPER SLEWING STRUCTURE

COUNTERWEIGHT

4.1 REMOVAL PREPARATION (1) Remove the side cover. (2) Prepare lifting tools. • Two lifting bolts M10 • Wire rope (Nylon sling)

4.2 REMOVAL (1) Remove two SEMS bolts (15) for fixing the bonnet fitting (striker) (10). : 17 mm (2) Install the lifting bolt to the thread hole from which the above bolts have removed, and temporarily lift up with a wire rope so that the rope is not sagging.

Fig. 4-1 Lifting counterweight

(3) Remove two capscrews (B1). : 19 mm (4) Operate a crane to remove the counterweight (A1). • Counterweight weight : 46 kg (101 lbs)

4.3 INSTALLATION (1) Install in the reverse order of the removal. (2) Lifting counterweight Ensure that two fixing bolts (B1) can be manually screwed in. (3) Apply Loctite #262 on the capscrew (B1) and install it with the washer (B2) and (B3). : 19 mm T = 11.7 kgf·m (85 lbf•ft)

14903 60413247

(4) Remove the lifting tool and install the striker (10) with two SEMS bolts (15). : 17 mm

Fig. 4-2 Counterweight removal

33-5

UPPER SLEWING STRUCTURE

CONTROL BOX

Rear

5.1 REMOVAL PREPARATION 1) Remove the minus terminal of the battery. 2) Depressurize the hydraulic oil tank (See item 12).

5.2 REMOVAL (1) Removing left control box 1) Remove two front and one rear capscrews (16). : : 13 mm

Front

2) Disconnect six pilot hoses (See item 17). (2) Removing right control box 1) Disconnect four connectors. 2) Remove two front and two rear capscrews (16). : : 13 mm 3) Disconnect six pilot hoses (See item 17). (3) Removing monitor panel 1) Remove the SEMS bolts (9) and (10). : Plus screw driver 2) Remove the SEMS bolts (4A) and (3B). : Plus screw driver 3) Remove the monitor panel [gauge cluster] (2B) while pulling out the harness.

Fig. 5-1 Control box removal

5.3 INSTALLATION

14903 60413247

Install in the reverse order of the removal and tighten according to the Tightening Torque table shown below:

Fig. 5-2 Monitor panel disassembly

33-6

UPPER SLEWING STRUCTURE

AIR CLEANER

6.1 DISASSEMBLY PREPARATION (1) Remove the floor plate (See item 1). (2) Remove the covers (See item 2.1).

6.2 DISASSEMBLY (1) Open the bonnet and remove the wing nut (15). (2) Remove the clips (8). (3) Disconnect the air hoses (1) and (2). : Minus screw driver (4) Remove the air cleaner assy (4) with the bracket (5).

Fig. 6-1 Air cleaner disassembly

6.3 ASSEMBLY Install in the reverse order of the removal.

DYNAMO

7.1 DISASSEMBLY PREPARATION (1) Remove the covers and the bonnet (See item 2). (2) Remove the minus terminal side of the battery.

Connector

7.2 DISASSEMBLY (1) Disconnect the connectors.

Fig. 6-2 Dynamo Assembly

(2) Remove the capscrews (16) and (18) and the nut (17). : 12 mm (18) : 14 mm (16) and (17)

Dynamo

(3) Remove the V-belt and the dynamo (1).

7.3 ASSEMBLY 14903 60413247

(1) Install in the reverse order of the removal. (2) V-belt tension Press the middle of V-belt with a thumb and adjust the deflection within the following range: Pressing force: 10 kgf (22 lbs) Deflection: 8 ~ 10 mm (0.31 ~ 0.39 inch)

Crank pulley

Fig. 6-3 V-belt tension

33-7

UPPER SLEWING STRUCTURE

STARTER

8.1 REMOVAL PREPARATION (1) Remove the covers and the bonnet. (2) Remove the minus side terminal of the battery. (3) Remove the slewing lock assy (to secure the space for taking out the starter). : 13 mm Fig. 8-1 Slewing lock assy

8.2 REMOVAL

STARTER

(1) Remove the terminal B of the starter. : 12 mm (2) Disconnect the connector of the terminal S of the starter. (3) Remove two fixing bolts and the starter. : 14 mm

8.3 INSTALLATION Install in the reverse order of the removal. • Fixing bolt (A) for slewing lock assembly Tightening torque: 2.4 kgf·m (17 lbf•ft) : 13 mm

Fig. 8-2 Starter removal

MUFFLER

9.1 DISASSEMBLY PREPARATION (1) Swing approximately 30 degrees to the right. (2) Remove the right side cover. (3) Remove the counterweight.

9.2 REMOVAL (1) Remove three capscrews (11). : 13 mm (2) Remove the nuts (9) (9A). : 13 mm (3) Remove the bands (5) and the muffler(1).

9.3 ASSEMBLY Shell matching position

Mount band referring to muffler welding position Approx. 5 mm

14903 60413247

Install in the reverse order of the removal and tighten according to the Tightening Torque table shown below:

Shell matching position Fig. 9-1 Muffler disassembly

33-8

UPPER SLEWING STRUCTURE

10. FUEL LINE 10.1 DISASSEMBLY PREPARATION (1) Drain fuel from the tank (See item (1) of 11.1 and (1) of 11.2). (2) Remove the counterweight (See item 4).

10.2 DISASSEMBLY (1) Removing water separator 1) Remove the capscrews (13). : 13 mm 2) Remove the clips (17). 3) Pull out the hoses (3) and (4). • Receive the remaining oil with an oil container without spilling. 4) Remove the water separator (2). (2) Removing filter 1) Remove the capscrews (13). : 13 mm 2) Remove the clips (17). 3) Disconnect the hoses (5) and (6). 4) Remove the clips (18). 5) Disconnect the hoses (7) and (8). • Receive the remaining oil with an oil container without spilling. 6) Remove the filter (1).

Fig. 10-1 Fuel line

10.3 ASSEMBLY

14903 60413247

Assemble in the reverse order of the removal and tighten according to the Tightening Torque Table 10-1.

Fuel tank portion

Water separator portion

Filter portion

Injection pump portion

Fig. 10-2 Fuel line

33-9

UPPER SLEWING STRUCTURE

11. FUEL TANK 11.1 DISASSEMBLY PREPARATION (1) Swing approximately 30 degrees to the right to facilitate to drain fuel. (2) Remove the counterweight (See item 4). (3) Remove the right and left control boxes and temporarily place them (See item 5). (4) Remove the rear support (See item 2.2).

11.2 DISASSEMBLY (1) Open the cap (A2) and loosen the drain plug (A7) to drain fuel. : 22 mm Tank capacity: 9 l (2.4 gal) (2) Disconnect the hoses connected to the fuel outlet flange (A4) and the return port flange (A5). (3) Disconnect the connector for the level sensor (A11). (4) Remove two capscrews (B5) for the tank retaining plate (B1) , and two SEMS bolts (B3) for the plate (B2). : 13 mm (5) Remove the tank (A1). Fig. 11-1 Fuel tank disassembly

11.3 ASSEMBLY

14903 60413247

Assemble in the reverse order of the removal and tighten according to the Tightening Torque table shown below.

33-10

UPPER SLEWING STRUCTURE

12. HYDRAULIC OIL TANK 12.1 Disassembly preparation (1) Prepare removal of the hydraulic oil tank in the method similar to the fore-mentioned fuel tank.

Air plug (A1-13)

(2) Remove the front support and the lower support (See item 2.2). (3) Remove the battery (See item 3).

Fig. 12-1 Depressurizing tank

12.2 Disassembly (1) Depressurizing tank The hydraulic tank is pressurized. Loosen the plug (A1-13) slowly to release air and depressurize. : 22 mm (2) Remove the plug (A1-10) to drain hydraulic oil. : 22 mm Tank capacity: Approx. 10 l (2.6 gal) (3) Disconnecting suction hose 1) Remove the clip (18). : Minus screw driver 2) Remove the hose (19). : Minus screw driver

Fig. 12-2 Suction hose removal

(4) Suction tube Remove the capscrew (A1-5) and the suction tube (A1-11) with the strainer (A1-2), if necessary. : 13 mm

O-RING

14903 60413247

O-RING

Fig. 12-3 Hydraulic oil tank disassembly

33-11

UPPER SLEWING STRUCTURE (5) Remove the pilot return oil hose (A3) and (A15). : 17 mm and 19 mm (6) Disconnect the drain oil hose fitting (A12) connected to the swivel. : 17 mm and 19 mm

Fig. 12-4 Hose removal

(7) Disconnect the return oil hose (15) from the solenoid valve. : 22 mm (8) Disconnect the return oil hose (5) from the slewing motor and the control valve. : 22 mm and 27 mm (9) Remove the SEMS bolts (B2) for retaining the tank (A1), and the SEMS bolts (B1) and (A22) for retaining the bracket. : 13 mm and 17 mm (10) Remove the tank (A1), and the shims (B3) and (B4). Weight : Approx. 16 kgf (35 lbs) Fig. 12-5 Hose removal

12.3 ASSEMBLY

14903 60413247

(1) Clean the hydraulic tank, hose and fitting. (2) Assemble in the reverse order of the removal and tighten according to the Tightening Torque table shown below:

Fig. 12-6 Hydraulic oil tank assembly

33-12

UPPER SLEWING STRUCTURE (3) After completing the installation, feed the specified hydraulic oil and check the oil level with the level gauge (A12). Amount of oil: Approx. 10 l (2.6 gal) (4) Releasing air 1) Start the engine with the plug (A1-13) open. 2) Run the engine in low idle condition for two to three minutes. Then extend and retract each cylinder a few times to release air from the circuit. (5) Pressurizing hydraulic tank 1) Extend each cylinder till the stroke end as shown in Fig. 12-7.

Bucket cylinder

Boom cylinder

Arm cylinder

Swing cylinder

Dozer cylinder

Fig. 12-7 Hydraulic oil tank pressurizing posture

2) Tighten the plug (A1-13) in this condition. : 22 mm T = 3.0 kgfÂˇm (22 lbfâ&#x20AC;˘ft) 3) Move the attachment to retract the cylinder rod to pressurize the tank. F15133

Fig. 12-8 Engine stop posture

14903 60413247

(6) Checking oil level again Stop the engine in the posture shown in Fig. 12-8 and check the hydraulic oil level. And ensure no oil leakage is found on each part.

33-13

UPPER SLEWING STRUCTURE

13. PUMP 13.1 REMOVAL PREPARATION (1) Remove the fuel tank (See item 11). (2) Depressurize the tank and drain the hydraulic oil (See item 12).

13.2 REMOVAL (1) Disconnecting the hoses and fittings connected to the pump â&#x20AC;˘ Attach a tag to hoses to identify. 1) Disconnect the pilot discharge oil hose (13A). : 22 mm

Fig. 13-1 Pilot hydraulic hose assembly

2) Remove the clip (18) and the suction hose (19). : Minus screw driver 3) Remove the capscrew (12) and the suction tube (16). : 17 mm 4) Disconnect the main pump discharge oil hoses (8) and (11). : 22 mm

Fig. 13-2 Main pump hose removal

(2) Remove the socket bolt (3B). 30 mm

: 10 mm

14903 60413247

â&#x20AC;˘ Special tool approx. 30 mm (1.2 inch) long with face to face 10 mm (3) Remove the pump (6B). Weight : Approx. 10 kgf (22 lbs)

Fig. 13-3 Pump Removal

33-14

UPPER SLEWING STRUCTURE

13.3 INSTALLATION Install in the reverse order of the removal according to the tightening torque and sealant instructions.

APPLY GREASE

(1) Apply grease on the spline part of the pump input shaft. Grease : Shell Retinux AM Grease or equivalent (= Molybdenum sulfide extreme pressure multi-purpose grease) Fig. 13-4 Pump Installation

(2) Insert the pump spline part to the coupling. T=6.6 kgf·m (48 lbf•ft) Apply loctite #262

(3) Apply sealant on the socket bolts (3B) and install the pump. Sealant: Loctite #262 30 mm

T=5.4 kgf·m (39 lbf•ft) DO NOT Apply loctite

: 10 mm T = 10.6 kgf·m (77 lbf•ft)

(4) Connect the main pump discharge oil hoses (8) and (11), and the pilot discharge oil hose (13A) (See Fig. 13-1 and 13-2). T=8.7 kgf·m (63 lbf•ft) Apply loctite #262 Coupling Fig. 13-5 Pump Installation

(5) Tighten the capscrew (12) and install the suction tube (16). : 17 mm (6) Apply sealant on the tube of insert portion of the suction hose (19) and fix with the clip (18). Sealant : Permatex : Minus screw driver T=0.5 ~ 0.6 kgf·m (3.6 ~ 4.3 lbf•ft)

NOTE: Tightening torque for connector to solenoid valves are specified as following table.

14903 60413247

(7) Restore each equipment removed in the preparation work to the original state. (8) After feeding hydraulic oil (approx. 10 l (2.6 gal), release air and pressurize the tank (See item 12.3).

33-15

UPPER SLEWING STRUCTURE

14. RADIATOR 14.1 DISASSEMBLY PREPARATION

Radiator cap

Cap (A11)

(1) Remove the counterweight (See item 4). (2) Remove the guards (covers and supports) (See item 2). • In order to facilitate the work, remove the related components if necessary.

Clip

14.2 DISASSEMBLY (1) Draining water from radiator 1) Remove the radiator cap. 2) Remove the cap (A11) fixed by a clip and drain water through the drain hose (A14). Volume: Approx. 1.1 l (0.29 gal)

Drain hose (A14) Fig. 14-1 Water Drain

(2) Remove the clip (A9) and then the connecting hose (A15) for the reserve tank (A4). (3) Remove the radiator hoses (A2) and (A3) fixed by the clip (A6). Tool: Cutting plier and Minus screw driver (4) Remove three capscrews (B1) fixing the radiator (A1). : 13 mm (5) Lift up the radiator assy (A1) by two persons or by a crane. Weght : Approx. 2.8 kgf (6.2 lbs)

14.3 ASSEMBLY

(4) Feed cooling water (LLC). See Section 5 of the OPERATION & MAINTENANCE manual for the mixing ratio of LLC. 33-16

Fig. 14-2 Radiator disassembly

Tightening torque for related parts

14903 60413247

(1) Assemble in the reverse order of disassembly. (2) Apply the sealant on the capscrew (B1) and install. Sealant: Loctite #262 : 13 mm T=2.9 kgf·m (21 lbf•ft) (3) Install the clip (A6) for the radiator hose. : Minus screw driver T=0.04 ~ 0.05 kgf·m (0.29 ~ 0.36 lbf•ft)

UPPER SLEWING STRUCTURE

15. ENGINE 15.1 REMOVAL PREPARATION (1) (2) (3) (4) (5)

Remove guards (cover and support) (See item 2). Remove the counterweight (See item 4). Remove the fuel tank (See item 11). Remove the hydraulic oil tank (See item 12). Remove the pump or the pump connecting hose (See item 13). (6) Remove the radiator (See Item 14).

15.2 REMOVAL (1) Disconnecting fuel hose 1) Disconnect the hose (6) and (8) connecting the fuel injection pump. 2) Disconnect the hose (3) and (5) connecting the feed pump.

Fig. 15-1 Fuel hose disconnection

(2) Disconnecting harness connector 1) Disconnect the connectors of the terminals B and S for the starter motor (M-1). : 12mm 2) Disconnect the connector for the dynamo (E-2). 3) Disconnect the terminals for the water thermo sensor (SE-2), water temperature switch (SW-6) and oil pressure switch (SW-7). 4) Disconnect the terminal for the glow plug (E-7). :7 mm 5) Disconnect the terminal for the engine earth cable (H-5) at the engine side. : 17 mm

SV-3 Engine stop solenoid valve SW-7 Engine oil pressure switch Engine earth point VIEW A

E-4 SE-2 ENGINE THERMO SENSOR FUSIBLE LINK SW-6 ENGINE WATER TEMPERATURE SWITCH E-2 DYNAMO

14903 60413247

E-7 GLOW PLUG

M-1 STARTER MOTOR UPPER FRAME

FRONT OF MACHINE

REAR OF MACHINE

Fig. 15-2 Harness connector disconnection

33-17

UPPER SLEWING STRUCTURE

WARNING Prepare a worktable capable of enduring the weight of the engine assembly and stably receiving the removed engine.

(3) Removing engine 1) Removing nuts for mounting engine Loosen the double nuts (8) fixing the engine on the rubber mount (6) and remove them with the washer (10). , : 13 mm 2) Lifting engine Pass a wire rope through the two lifting lugs at the top of the engine, and lift the engine. Weight : Approx. 65 kgf (143 lbs) 3)

Place the engine stably on the worktable for engine.

15.3 INSTALLATION (1) Perform installation in the reverse order of the removal. See the Figure below for the tightening torque and the sealant.

8 Nut (M8) T=2.2 kgf•m (16 lbf•ft) Apply Loctite #262 Washer

8 Nut (M8) T=2.0 kgf•m (14 lbf•ft) Apply Loctite #262 6 Rubber mount

Washer

8 Nut (M8) T=2.2 kgf•m (16 lbf•ft) Apply Loctite #262

Capscrew (M10) : 14 screws for 4 places T=5.4 kgf•m (39 lbf•ft) Apply Loctite #262

Fig. 15-3 Engine removal

33-18

14903 60413247

Rubber mount installation (4 places)

UPPER SLEWING STRUCTURE

16. CONTROL VALVE 16.1 REMOVAL PREPARATION (1) (2) (3) (4)

Remove the floor plate (See item 1). Remove guards (cover and support) (See item 2). Remove the counterweight (See item 4). Depressurize the hydraulic oil tank (See item 12.2).

16.2 REMOVAL

S/J S/M SW/CYL T

: : : :

Swivel joint Slewing motor Swing cylinder Tank

(1) Disconnecting hose Disconnect all the hoses connecting to the control valve, and attach blind plugs and tags recording installation place.

Bucket (H) Boom (R) Damper

Bucket (R) S/J SW/CYL

Boom (H) SW/CYL

Travel (Right rear)

Dozer (Lower)

Travel (Right front) Travel (Left rear) Dozer (Upper) Slewing (Right)

Travel (Left front)

S/M Slewing (Left) Arm (H)

14903 60413247

Arm (R)

To hydraulic tank

Fig. 16-1 Main hydraulic hose disconnection

33-19

UPPER SLEWING STRUCTURE P/V C/V LH RH

: : : :

Pilot valve Control valve Left-hand Right-hand

Fig. 16-2 Pilot hydraulic hose disconnection

(2) Removing yoke 1) Remove the pin (A64) and pull off the pin (A42). 2) Remove all the yokes connected to the control valve.

Dozer cable (Swing)

(Right travel) (Dozer)

(OPT)(nibbler & Breaker)

14903 60413247

(Left travel)

Fig. 16-3 Yoke disassembly

33-20

UPPER SLEWING STRUCTURE (3) Removing control valve 1) Remove three cap screws (7) with the washers (5). : 13 mm 2) Remove the control valve (1) with the brackets (2) and (3). Weight : Approx. 18 kgf (40 lbs) 3) Remove each two capscrews (4) and (7) for fixing the bracket. : 13 mm

16.3 INSTALLATION

Fig. 16-4 Control Valve Removal

(1) Perform installation in the reverse order of the removal. (2) Install the capscrews (4) and (7). : 13 mm T=3.4 kgfâ&#x20AC;˘m (25 lbfâ&#x20AC;˘ft)

WARNING Clean the mounting surface and take care to prevent deformation of the valve.

(3) Tighten hoses and so on with the following torque:

14903 60413247

(4) Pressurize the hydraulic oil tank (See item 12.3). (5) Operate the attachment and check the performance. (6) Check oil leakage and hydraulic oil level.

33-21

UPPER SLEWING STRUCTURE

17. PILOT VALVE 17.1 REMOVAL PREPARATION

(1) (2) (3) (4)

Since the same method applies to the right-hand and the left-hand, only the right-hand is described. Disconnect the minus terminal of the battery. Depressurize the hydraulic oil tank (See Fig. 121). Remove the right and left control boxes and the monitor panel (See item 5). Remove the SEMS bolts (9) and (10), and the cover assy (3) and (4) (See Fig. 17-1). : Plus screw driver

Boot

Fig. 17-1 Cover removal (Right control box)

17.2 REMOVAL (1) Disconnect each hose at the position with the mark * and attach plugs and tags to facilitate installation. (2) Shift the boots and remove four capscrews (B5). : 10 mm (3) Remove the pilot valve (B1). A

17.3 INSTALLATION (1) Perform installation in the reverse order of the removal with the following tightening torque. 1) Install the SEMS bolts (9) and (10). : Plus screw driver T=0.27 kgf·m (2.0 lbf•ft) 2) Connect the hoses and so on.

A A A A A

Fig. 17-2 Hose removal

ARM (R)

TANK

NOTE: Take care that tightening torque for connectors (Mark "A") connected to pilot valve is shown in the following table.

SLEW (R)

SLEW (L)

SOLENOID ARM (H) Left side (LH) BOOM (R)

(2) Pressurize the hydraulic oil tank (See item 12-3). (3) Operate the attachment and check the performance. (4) Check oil leakage and hydraulic oil level.

BUCKET (R)

BUCKET (H)

SOLENOID

BOOM (H) Right side (RH) Fig. 17-3 Pilot valve port location

33-22

14903 60413247

TANK

UPPER SLEWING STRUCTURE

18. SLEWING MOTOR 18.1 REMOVAL PREPARATION (1) Remove the floor plate assembly (See item 1). (2) Remove the guard (cover and support) (See item 2). (3) Drain oil from the hydraulic tank (See item 12-2). (4) Disconnect the cable for the dozer connected to the control valve at the position of the yoke (A16). (5) Removing travel lock cylinder (A37) 1) Remove the link (A31). 2) Remove the nut (A38). : 30 mm (Note) Provide matching marks or record the number of threads of the mounting portion to restore the original mounting position. 3) Disconnect the hose if necessary. : 19 mm

Cable for dozer

Hose connecting port

Fig. 18-1 Cable and lock cylinder removal

Slewing motor

18.2 REMOVAL (1) Disconnect three hoses (T), (AV) and (BV) connected to the slewing motor. : 19 mm

Fig. 18-2 Hose disconnection

14903 60413247

(2) Disconnect the grease piping hose (G). : 12 mm (3) Remove six socket bolts (2). : 8 mm (Long tool approx. 200 mm (8 inch) in length required) : Universal joint required (4) Remove the slewing motor. Weight : Approx. 15 kgf (33 lbs)

Fig. 18-3 Slewing motor removal

33-23

UPPER SLEWING STRUCTURE

18.3 INSTALLATION (1) Install in the reverse order of the removal according to the tightening torque shown below. 1) When the cover (5) was removed, install it to the position. : 10 mm T= 0.8 kgf·m (5.8 lbf•ft) APPLY THREE-BOND 1215 WQUIVALENT

2) Apply loctite #515 to whole the fitting surface of slew motor. 3) Install the socket bolt (2) for mounting the motor. : 8 mm T=6.7 kgf·m (48 lbf•ft) Apply Loctite #262

Fig. 18-4 Installation of cover

4) Install the nut (A38) for the lock cylinder. : 30 mm T=15.3 kgf·m (111 lbf•ft) 5) Connect hoses.

To slewing motor

To swing cylinder

(2) Feed grease to the pinion and gear part of the slewing motor. (3) Pressurize the hydraulic oil tank (See Fig. 12-3). (4) Check the slewing operation. (5) Check oil leakage and hydraulic oil level.

14903 60413247

Fig. 18-5 Pinion and gear lubrication

33-24

UPPER SLEWING STRUCTURE

19. SWIVEL JOINT 19.1 REMOVAL PREPARATION (1) Lift the machine by approx. 30 cm (12 inch) and insert support blocks at four places of the crawler shoes, namely front, rear, right and left, to sequre working space under the machine.

Fig. 19-1 Lifting machine

(2) Engage the slewing lock. (3) Remove the slewing motor (See item 18). (4) Remove the under cover (A11). Capscrew (A5): M8 : 13 mm (5) Take out the crawler frame width cylinder (See the item for cylinder in section of TRAVEL SYSTEM).

19.2 REMOVAL (1) Disconnect all the hoses connected to the swivel joints. Install plug to the connecting ports and attach tags. Fig. 19-2 Under cover removal

[C/V: Control valve] To tank

14903 60413247

Swivel joint

Fig. 19-3 Upper side hose disconnection

33-25

UPPER SLEWING STRUCTURE

Travel motor

A (Upper) Forward B (Lower) Backward

B (Upper) Forward A (Lower) Backward

(Left-hand)

(Right-hand)

Fig. 19-5 Lower side hose disconnection

33-26

14903 60413247

Fig. 19-4 Connecting port relation

UPPER SLEWING STRUCTURE (2) Removing stopper Remove two capscrews (8) and the stopper (3). : 19 mm (Long tool approx. 350 mm (14 inch) in length required) : Universal joint required

(3) Removing swivel joint 1) Remove four capscrews (C2). : 13 mm (Long tool approx. 350 mm (14 inch) in length required) : Universal joint required

Fig. 19-6 Stopper removal

2) Remove the swivel joint (C1) from the lower side. Weight : Approx. 12 kgf (26 lbs)

19.3 INSTALLATION (1) Install in the reverse order of the removal with the tightening torque shown below. 1) Install the capscrew (C2). : 13 mm T= 3.4 kgf·m (25 lbf•ft) Apply Loctite #262 2) Install the capscrew (8). : 19 mm T=11.73 kgf·m (85 lbf•ft) 3) Connect hoses.

Lower frame

Fig. 19-7 Swivel joint removal

14903 60413247

(2) Pressurize the hydraulic oil tank. (3) Check the performance.

19.4 OTHER REMOVAL METHOD Remove the upper frame referring to item 20 "Upper frame" and remove the swivel joint from the lower frame. 33-27

UPPER SLEWING STRUCTURE

20. UPPER FRAME 20.1 REMOVAL PREPARATION (1) Remove the floor plate assembly (See item 1). (2) Remove the guards (cover and support) (See item 2). (3) Remove the counterweight (See item 4). (4) Drain oil from the hydraulic oil tank (See item 122). (5) Disconnect the upper side hose for the swivel joint (See item 19-2). (6) Remove the stopper for the swivel joint (See item 19-6). (7) Remove the attachment (See the "Boom" item of the section of attachment). (8) Remove the swing bracket (See the "Swing" item of the section of attachment).

20.2 REMOVAL (1) Providing match marks to slewing bearing Provide match marks between the upper frame and the outer race of the slewing bearing.

Upper frame

Outer race for slewing bearing

(2) Lifting upper frame temporarily Temporarily lift the upper frame at three points applying wire ropes on a position of the swing bracket mounting hole for the front side and on two positions of the rear end of the upper frame. Fig. 20-1 Slewing bearing and upper frame

(3) Removing bolt for mounting Remove the slewing bearing, 14 capscrews for fixing the outer race and a reamer bolt (10). : 19 mm

14903 60413247

(4) Removing upper frame Lift the upper frame a little to ensure safety, remove it and place on a worktable capable of enduring the weight. Weight : Approx. 340 kgf (750 lbs) Fig. 20-2 Lifting rear side

33-28

UPPER SLEWING STRUCTURE

20.3 INSTALLATION (1) Perform installation in the reverse order of the removal. (2) Cleaning contact surface Clean the bottom surface of the upper frame and the top surface of the slewing bearing. (3) Lifting method 1) Apply wire ropes to the upper frame and lift up horizontally. 2) Check the match marks provided at the disassembly.

Fig. 20-3 Slewing bearing installation POSITION OF INNER ZONE S (ENGRAVED AS S)

3) Slowly lower while aligning the match marks and watching the engaging condition between the slewing pinion gear and the internal gear of the inner race of slewing bearing. (4) Installing slewing bearing and upper frame 1) Apply Loctite #262 on a reamer bolt (10) and 14 capscrews (7) and temporarily tighten. 2) Tighten the reamer bolts and capscrews with the specified torque at the front, rear, right and left positions apart from each other by 180° alternately. : 19 mm T = 11.7 kgf·m (85 lbf•ft) Apply loctite #262

REAMER BOLT POSITION

GREASE FEEDING PORT

Fig. 20-4 Upper frame installation

14903 60413247

(5) Install each equipment removed in the above removal preparation to the original position and check the performance.

SLEWING MOTOR CENTER

33-29

UPPER SLEWING STRUCTURE

Part II: DISASSEMBLING AND ASSEMBLING COMPONENTS HYDRAULIC PUMP

1.1 ASSEMBLY DRAWING

Fig. 1-1 Hydraulic pump-Sectional view

14903 60413247

Table 1-1

33-30

UPPER SLEWING STRUCTURE

1.2 DISASSEMBLY AND ASSEMBLY

Table 1-2

(1) Tool Required tools are listed in Table 1-2 (2) General precautions 1) The disassembling and assembling works are to be carried out in a clean place, providing clean containers to place the disassembled parts in. 2) Before disassembling, make around the ports clean and remove the paint around each joint with a wire brush. 3) Clean each of the disassembled parts with a washing oil. 4) Put a matching mark on each of the mating parts so that they shall be installed to the original positions. 5) Replace all the seals to new one at every disassembly. 6) Check each part for abnormal wear and seizure, remove sharp edges and burrs with a sand paper, etc., if any. 7) Avoid to adjust each adjusting screw, except the necessity. (3) Disassembling 1) Removling the gear pump Remove 4-socket bolt (68) M8 X 30 : 6mm 2) Removing the pressure adjusting setscrew (60). Loosen the lock nut (61), and remove the pressure adjusting setscrew (60). : 4mm : 13mm

14903 60413247

â&#x20AC;˘ Before removal of the adjusting setscrew, record the projected length of the setscrew.

Fig. 1-2 Removing the gear pump

3) Separating the body S(1) and the body H(2) : 4mm a. Remove two (upper side) of four socket bolts (44), and screw two preliminary assembling bolts (M10 X 65) into the bores by about 10mm (0.4in). b. Slowly loosen the remaining two socket bolts (44). c. Loosen the preliminary assembling bolts (M10 X 65), and separate the body S and the body H. â&#x20AC;˘ Lightly tap the inserting portion of spring (15) on the body H with a plastic hammer for easy separation. Fig. 1-3 Separating body (S) and (H)

33-31

UPPER SLEWING STRUCTURE 4)

Remove the spring (15) and spring holder (18) from the body S.

Fig. 1-5

5) Remove the cylinder barrel (4) assy from the body S(1).

Fig. 1-6

6) Remove the swash plate (10) and oscillating pin (12) from the body S(1). 7) Remove the stopper pin A(25) and coned disk spring (33) in order.

Fig. 1-7

8) Remove the snap ring (34) from the shaft side of body S(1). 9) Remove the shaft (3) with bearing (30) from the body S(1). 14903 60413247

â&#x20AC;˘ Use a plastic hammer to remove the shaft assy for tapping shaft end.

Fig. 1-8

33-32

UPPER SLEWING STRUCTURE 10) Remove the spring guide (19) and valve plate (5) from the body H(2). â&#x20AC;˘ Screw up the pressure adjusting setscrew into the bore for to remove the spring guide (19).

Fig. 1-9

11) Disassembling cylinder barrel (4) assy a. Remove the shoe holder (8) with piston shoe assy (6) (7) and barrel holder (9) from the cylinder barrel (4) assy. b. Remove the piston shoe assy (6) (7) and barrel holder (9) from shoe holder (8).

Fig. 1-10

c. Remove the needle pins (11) from the cylinder barrel (4).

Fig. 1-11

14903 60413247

d. Remove the snap ring (35), and remove the outer retainer (24), spring (14) and inner retainer (24) from cylinder barrel (4).

Fig. 1-12

33-33

UPPER SLEWING STRUCTURE (4) Assembling Basically, assembling work is carried out with the reverse order of disassembling. 1) Installing shaft (3) Install the oil seal (32), shaft (3) with bearing (30) and snap ring (34) to the body S(1). â&#x20AC;˘ Apply grease slightly on the lip and outer portion of oil seal prior to assembling. â&#x20AC;˘ Use the insertion jig to install the oil seal (32), and push it into the place lightly tapping the jig with a hammer.

Unit, mm (in) Fig. 1-13 Oil seal insertion Jig

2) Install four coned disk springs (33) to the stopper pin A(25), and install it to the body S(1).

Fig. 1-14

3) Install the oscillating pin (12) to the swash plate (10), and install it in the spherical bore on the body S(1).

4) Assembling cylinder barrel (4). a. Install the retainer (24), spring (14), retainer (24) and snap ring (35) to the cylinder barrel (4).

14903 60413247

Fig. 1-15

Fig. 1-16

33-34

UPPER SLEWING STRUCTURE b. Install the needle pins (11) to the cylinder barrel (4).

Fig. 1-17

c. Install the barrel holder (9) to the cylinder barrel (4). d. Install the piston shoe assy (6) (7) to the shoe holder (8), and install it to the cylinder barrel (4).

Fig. 1-18

5) Install the cylinder barrel assy to the body S.

Fig. 1-19

14903 60413247

6) Install the spring (15) to the spring holder (18). And install the spherical part of spring holder (18) in the bore of swash plate (10).

Fig. 1-20

33-35

UPPER SLEWING STRUCTURE 7) Install the spring guide (19) to the body H(2). 8) Positioning the valve plate (5) to the spring pin (56) on the body H(2), install with care, • The grooved face on the valve plate (5) is siding face with the cylinder barrel (4). Pay attention to its direction.

Fig. 1-21

9) Install the joint (66) to the shaft (3).

Fig. 1-22

10) Install the packing (13) to the mating face of the body S(1). • Set the packing conforming to the positioning pins (20) on the body S. 11) Install two preliminary installing socket bolts (M10 X 65) to the upper part, and tighten them up with care. And when the gap between the mating faces becomes 5 to 10mm (0.20 to 0.39in), change them to four socket bolts (44) and tighten them up. : 8mm T=6 ± 0.5 kgf·m (43 ± 4 lbf•ft)

Fig. 1-23

12) Install the pressure adjusting setscrew (60).

14903 60413247

• Using the lock nut (61), lock the pressure adjusting setscrew (60) at the same length as before the removal. : 4mm : 13mm

Fig. 1-24

33-36

UPPER SLEWING STRUCTURE 13) Installing gear pump a. Install the steel ball (67) and O-ring (71) to the connecting portion of gear pump for piston pump assy. Then temporarily tighten the socket bolts (68) with washer (4), fixing the gear pump kit (65). b. Install the another two socket bolts (68) with washers (4). Tighten equally the four bolts. : 6mm T = 2.65 ± 0.15 kgf·m (19.2 ± 1.1 lbf•ft) 14) Assembling confirmation To check if the assembly has been done perfectly, fasten the shaft on a vice lightly, and turn the pump. It should be turned comparatively lightly. If its rotation is heavy, do the assembling works over again.

Fig. 1-25 Installing gear pump

14903 60413247

• Shaft idle turning torque approx. 0.6 ~ 1.2 kgf·m (4.3 ~ 8.7 lbf•ft)

33-37

UPPER SLEWING STRUCTURE

1.3 MAINTENANCE STANDARDS (1) Parts replacing standards

(cuÂ·in) cc/rev (0.34)

(0.11)

Q1, Q2 (Q1=Q2)

DISCHARGE PRESSURE (LOAD)

33-38

(1620) P1+P2 2 (P1+P2)

(2990) kgf / cm2 (psi)

kgf / cm2 (psi) 14903 60413247

PUMP DISCHARGE

(2) Pump control characteristic

UPPER SLEWING STRUCTURE

1.4 TROUBLESHOOTING

Remedy

Trouble

Possible Causes

1. Engine overload

1) Over rated engine speed 2) Over rated pressure 3) Seizure or damage on pump inside parts

1) Adjust to rated speed. 2) Adjust to rated pressure. 3) Repair or replace pump.

2. Pump discharge volume drops abnormally or pressure does not rise

1) Insufficient engine speed 2) Failure on pump coupling 3) Seizure or damage on inside parts of pump

1) Adjust engine speed. 2) Repair/replace coupling. 3) Repair/replace pump.

3. Abnormal noise and vibration (cavitation phenomenon)

1) Air/water in hydraulic oil

1) Retighten piping, especially for suction pipe. Change oil if water contained. 2) Wash/replace suction strainer. 3) Recondition suction pipe. 4) Repair/replace additional pump.

2) Clogging suction strainer 3) Clogging/choking suction pipe 4) Trouble on additional pump (if any) 5) Damage on caulked portion of piston shoe 6) Loosening on installing portion of pump 7) Coupling failure 4. Oil leakage

1) Failure on O-ring/seat packing

6) Recondition installation of pump. 7) Replace coupling. 1) Replace O-ring/seat packing. (Install it correctly with care.) 2) Retighten with specified torque. 3) Replace/repair oil seal/shaft.

14903 60413247

2) Loosening/poor tightening of gear coupling 3) Oil leakage at oil seal edge

5) Replace piston assy.

33-39

UPPER SLEWING STRUCTURE

CONTROL VALVE

1.1 ASSEMBLY DRAWING

(BUCKET)

(BOOM)

(SWING)

(TRAVEL RIGHT)

(DOZER BLADE / ) CRAWLER WIDTH

(SERVICE PORT)

(TRAVEL LEFT)

Fig. 2-1 Control Valve

(SLEWING)

(ARM)

(1) Control Valve : Assembly drawing

14903 60413247

OVERALL COMPONENT PARTS

33-40

UPPER SLEWING STRUCTURE (2) Inlet Block (No.3)

Fig. 2-2

(3) Bucket Block (No.4)

14903 60413247

Fig. 2-3

33-41

UPPER SLEWING STRUCTURE (4) Boom Block (No.5)

Fig. 2-4

(5) Swing Block (No.6)

14903 60413247

Fig. 2-5

33-42

UPPER SLEWING STRUCTURE (6) Travel (Right) Block (No.7)

Fig. 2-6

14903 60413247

(7) Dozer / Adjustable Crawler Frame Width Block (No.8)

Fig. 2-7

33-43

UPPER SLEWING STRUCTURE (8) Service Port Block (No.9)

Fig. 2-8

(9) Travel (Left) Block (No.10)

14903 60413247

Fig. 2-9

33-44

UPPER SLEWING STRUCTURE (10) Slewing Block (No.11)

Fig. 2-10

(11) Arm Block (No.12)

14903 60413247

Fig. 2-11

33-45

UPPER SLEWING STRUCTURE (12) Main Relief Valve (No.25)

Fig. 2-12

(13) Main Relief Valve (No.13)

14903 60413247

Fig. 2-13

33-46

UPPER SLEWING STRUCTURE (14) Port Relief Valve (Over Load) (No.14)

Fig. 2-14

(15) Port Relief Valve (Over Load) (No.15)

Fig. 2-15

14903 60413247

(16) Anti-Void Valve (No.16)

Fig. 2-16

33-47

UPPER SLEWING STRUCTURE

1.2 DISASSEMBLING (1) Precautions for Disassembling 1) Make the actuator being not pressurized condition, then stop the engine. Otherwise, it causes for danger of spouting out of high pressure oil and jumping out of inside parts at the disassembling. 2) Release the air inside of the tank. 3) Thoroughly make around the disassembled area clean in order not to allow invasion of any foreign materials into the valves. 4) Put a tag to every disassembled part to identify the positioning of them at the reassembling. 5) Replace the disassembled seals to new ones. (Oring, Backup ring and Wiper ring)

Fig. 2-17

(2) Removal of Accessory Valves 1) Remove the relief valve assy's (13), (14), (15), (25) and (26), and anti-void assy (16). : 24 mm • Do not disassemble the relief valves and antivoid valve except it is necessary. (3) Removal of Block Assy 1) Loosen and remove the nuts (1) from the bolts (2) to disassemble each block in turn. : 12 mm • Pay attention to the washer (22) which is provided at one place. 2)

Manual Operating Blocks. (Travel, Swing, Dozer and Service) a) Remove the O-ring (13), spring (10) and load check valve (9) from the valve housing.

• The O-ring is not incorporated in the service block. Do not remove the spacer (13) because it is press-fitted. • Remove the poppet (16) which is incorporated on the service block at its mating face with the dozer block. 33-48

Fig. 2-18 Swing Block

14903 60413247

• The load check valve (9) and spring (10) are not incorporated in the travel block.

Fig. 2-19 Service Block

UPPER SLEWING STRUCTURE b) Remove the poppet (16) which is incorporated on the dozer block at its mating face with the service block. c) Remove the poppet (16) which is incorporated on the travel (left) block at its mating face with the service block. 3)

Pilot Operating Blocks (Boom, Arm, Bucket and Slew) Remove the O-rings (10), springs (9) and load check valves (8) from each valve housing. 4) Inlet Block Remove the O-ring (2) from the inlet housing (1). (Note) Classifying the disassembled parts into each group of blocks, put a tag to every disassembled part to identify the positioning of them at the reassembling.

Fig. 2-20 Dozer Block

Fig. 2-21 Travel (left) Block

Fig. 2-22 Boom Block

(4) Disassembling Block Assy [A] Manual Operating Block (Travel, Swing, Dozer and Service) 1) Loosening the socket bolt (15), remove the cap (7), and pull the spool (2) out of the valve housing (1) at the sub-assembled conditions with the seal plate (8), wiper (11) and O-ring (12) of cap (7) side. : 4 mm

14903 60413247

Then loosen and remove the screw (14) of the opposite side to remove the seal plate (8), wiper (11) and O-ring (12).

WARNING â&#x20AC;˘ Pull out the spool in straight not to give any scores on it. Otherwise, it causes for difficulty to insert the spool or malfunction even though the spool is able to be inserted. â&#x20AC;˘ Put a tag to each spool disassembled to identify the positioning of them at the reassembling. Erroneous assembling causes for dangerous malfunction of the actuator. Fig. 2-23 Swing Block

33-49

UPPER SLEWING STRUCTURE 30 ~ 40 (1.2 ~ 1.6)

ø 12 (ø 0.47)

2 ~ 4 (0.08 ~ 0.16)

70 ~ 100 (2.8 ~ 3.9)

3) Disassembling Spool End Put the spool (2) between hard wooden blocks (see Fig. 2-24), and hold the wooden blocks (putting the spool into) with a vice. Loosen the socket capscrew (4), disassemble the spring seat (5) and spring (6), and then remove the wiper (11) and O-ring (12). : 5 mm • Pay attention for jumping out of capscrew, etc. due to spring force at the disassembling.

Fig. 2-24 Wooden Blocks

4) Disassembling Dozer Block a) Loosen and remove the spool head (3), and then remove the spacer (19), spring (18) and poppet (17) from the spool (2). b) Remove the O-ring (20) and backup ring (21) from the spacer (19).

Fig. 2-25 Dozer Block

[B] Pilot Operating Block (Boom, Arm, Bucket and Slew) 1) Loosening the socket bolt (12), remove the cap (3). Pull the spool (2) out of the valve housing at the sub-assembled conditions. And remove the O-ring (11) of the cap side. : 4 mm 2)

Then loosening the socket capscrew (12) of the opposite side, remove the cap (7) and O-ring (11). : 4 mm

14903 60413247

WARNING • Pull out the spool in straight not to give any scores on it. Otherwise, it causes for difficulty to insert the spool or malfunction even though the spool is able to be inserted. • Put a tag to each spool disassembled to identify the positioning of them at the reassembling. Erroneous assembling causes for dangerous malfunction of the actuator.

Fig. 2-26 Boom Block

33-50

UPPER SLEWING STRUCTURE 3) Disassembling Spool End Put the spool (2) between hard wooden blocks (see Fig. 2-24), and hold the wooden block (putting the spool into) with a vice. Loosen the capscrew (4), and disassemble the spring seat (5) and spring (6). : 5 mm • An adhesive was applied to the capscrew (4) of the spool end. It is recommendable to heat the outer periphery of spool at threaded portion up to 200 to 250°C (392 to 482°F) to make the removal easy. 4) Disassembling Arm Block a) Remove the capscrew (4), then remove the spacer (17), spring (14) and poppet (13) from the spool. b) Remove the O-ring (15) and backup ring (16) from the spacer (17).

1.3 CLEANING

Fig. 2-27 Arm Block

Make all the disassembled parts clean with a clean mineral oil. Dry them up with compressed air, and put them on a clean paper or cloth to inspect them.

1.4 INSPECTION

14903 60413247

Inspect all the parts for scores, sharp edges and burs, notches and other abnormalities on their outer periphery. 1) Confirm the smoothness on the surface of seal groove on the valve housing without any dust, dent, rust, etc. 2) Remove any dent or score on the seat face of check valve, if any, with rapping. Pay attention not to leave the rapping agent in the valve, by cleaning up the remained rapping agent. 3) Check the outer periphery of sliding portion with the seal of manual spool for any scratches or dents. Slight scratches or dents are possible to remove with an oil stone or cloth applying rapping agent to it. 4) Confirm smooth movement on every sliding and fitting parts. And make every groove and passage free from any foreign materials. 5) Replace any spring snapped off or deformed to new one.

6) If operating conditions of relief valve is bad, inspect it in accordance with the item 1-6, maintenance procedures. 7) All the seals, wiper and O-rings removed are to be replaced to new ones.

33-51

UPPER SLEWING STRUCTURE

1.5 ASSEMBLING (1) Precautions for Assembling 1) At the assembling, pay attention for O-rings (or seals) to handle them as follows: • The O-rings are to be free from any defects while molding and any scores while handling. • The O-rings and the installing portions of Oring are to be sufficiently lubricated with grease or hydraulic oil. • Do not stretch the O-rings not to give them permanent transformation. • Do not roll the O-rings to install them in place. (When the O-ring is twisted at the installation, such twisting is difficult to restore to normal condition after the installation, resulting oil leakage.) 2) The tightening torque specified in this manual is based on the wet (applying hydraulic oil) condition. (2) Assembling Block [A] Manual Operating Blocks (Travel, Swing, Dozer and Service) 1) Install the O-ring (12), wiper (11) and seal plate (8) in turn to the spool (2), put the spring (6) between the spring seats (5), and then install it on the spool with the capscrew (4). : 5mm T=0.53 ~ 0.75 kgf·m(3.8~ 5.4 lbf•ft)

Fig. 2-28 Travel (Right) Block

SEAL PLATE (8) SPRING SEAT (5)

CAPSCREW (4)

SPOOL (2)

WIPER (11) O-RING (12)

VALVE HOUSING (1) SEAL GROOVE

Fig. 2-29 Installing Direction of Wiper (11)

2) In case of Dozer Block a) Insert the poppet (17) and spring (18) into the spool. Then assemble the spacer (19) to which the O-ring (20) and backup ring (21) are installed in advance. b) Remove oil adhered on the threaded portion of spool head (3), then apply adhesive (Loctite # 271 + hardening agent to hasten going solid), and tighten up the spool head (3). T=0.3 ~ 0.5 kgf·m(2.2 ~ 3.6 lbf•ft) 33-52

Fig. 2-30 Dozer Block

14903 60413247

• To assemble the spool, put the spool (2) between hard wooden blocks (see Fig. 2-24), and hold the wooden blocks (putting the spool into) with a vice. • Apply grease to outer periphery of the spring (6). • Pay attention to installing direction of the wiper (11). Refer to the Fig. 2-29 for the installation.

UPPER SLEWING STRUCTURE c) Install the spool assy to the valve housing (1) at the same position and direction as before disassembling, and install the cap (7) with the socket capscrew (15). : 4 mm T=0.74 ~ 1.0 kgf·m (5.4 ~ 7.2 lbf•ft) d) Install the O-ring (12), wiper (11) and seal plate (8) in turn to the spool head side, and tighten them up with the screw (14) T=0.25 ~ 0.30 kgf·m (1.8 ~ 2.2 lbf•ft) Fig. 2-31 Swing Block

WARNING • Slowly insert the spool in straight against the bore. • After insertion, slide the spool with fingers. If some resistance is felt to the fingers for the sliding, it may cause for malfunction of the spool.

[B] Pilot Operating Blocks (Boom, Arm, Bucket and Slew) 1) Remove oil adhered on the threaded portions of spool (2) and socket capscrew (4), apply adhesive (loctite # 271 + hardening agent to hasten going solid), put the spring (6) between the spring seats (5), and then install them to the spool with the socket capscrew (4). : 5 mm T= 0.49 ~ 0.73 kgf·m(3.5 ~ 5.3 lbf•ft)

14903 60413247

• To assemble the spool, put the spool between wooden hard blocks (see Fig. 2-24) and hold the wooden blocks (putting the spool into) with a vice. 2) In case of Arm Block a) Install the poppet (13) and spring (14) to the spool (2), then assemble the spacer (17) with the O-ring (15) and backup ring (16) to the spool (2). b) Remove oil adhered on the threaded portion of socket capscrew (4), then apply adhesive (Loctite # 271 + hardening agent to hasten going solid). Put the spring (6) between the spring seats (5), and then tighten up them with the capscrew (4). T=0.3 ~ 0.5 kgf·m(2.2 ~ 3.6 lbf•ft)

Fig. 2-32 Arm Block

33-53

UPPER SLEWING STRUCTURE c) Tighten up the cap (3) with O-ring (11) with the socket capscrew (12). : 4 mm T= 0.74 ~ 1.02 kgf·m(5.4 ~ 7.4 lbf•ft) d) Likely to the above, tighten up the cap (7) (to provide O-ring (11)) with the socket capscrew (12) to the opposite side. : 4 mm T= 0.74 ~ 1.02 kgf·m(5.4 ~ 7.4 lbf•ft)

Fig. 2-33 Boom Block

(3) Installing Block Assy's 1) Manual Operating Block a) Install the O-ring (13), load check valve (9), spring (10) and poppet (16)(only for dozer block) to each valve housing (1) of swing block and dozer block. Fig. 2-34 Dozer Block

b) Install the O-ring (13) and poppet (16) to the travel (left) block.

Fig. 2-35 Travel (left) Block

14903 60413247

c) Install the poppet (16) to the service block. Confirm the press-fitted spacer (13).

Fig. 2-36 Service Block

33-54

UPPER SLEWING STRUCTURE d) Install the O-ring (13) to the travel (right) block.

Fig. 2-37 Travel (right ) Block

2) Pilot Operating Block Install the O-ring (10), load check valve (8) and spring (9) to each valve housing of boom, bucket, arm and slew. Fig. 2-38 Boom Block

3) Inlet Block Install the O-ring (2) to the inlet housing (1).

Fig. 2-39 Inlet Block

14903 60413247

4) Put each block on the bolts (2), and tighten up them with the nut (1). • Pay attention to the fact that the washer (22) is installed at one place. : 12 mm T = 2.7 ~ 3.0 kgf·m(20 ~ 22 lbf•ft)

(4) Installing Accessory Valve Install the relief valve assy's (13). (14), (15), (25) and (26) and anti-void valve assy (16) to their positions. : 24 mm T = 7 ~ 8 kgf·m (51 ~ 58 lbf•ft) Fig. 2-40 Control Valve

33-55

UPPER SLEWING STRUCTURE

1.6 MAINTENANCE PROCEDURES FOR ACCESSORY VALVE 1.6.1 Main Relief Valve (13)(P2 Relief) (1) Disassembling 1) Removing the plug (2), remove the sleeve (3), main poppet (4) and spring (9). 2) Loosening the adjuster kit (7), take out the pilot poppet (6), spring (8) and washer (16). • Do not disassemble the pilot seat (5) because it is caulked at its tip end of plug (2).

Fig. 2-41 Main Relief Valve (13)

(2) Cleaning and Inspection Make all the parts clean with clean mineral oil, dry them up with compressed air, and then conduct inspection for them. 1) The seat faces on the tip end of each poppet and sleeve are to be evenly contacted with each mating face without any defects. 2) The main poppet (4) and sleeve (3) are to slide smoothly and lightly. There should be no scratches and scores on the outer periphery of poppet and inner periphery of sleeve. 3) The spring should have no snapping off, deformation and abrasion. 4) The orifices on main poppet (4) and pilot seat (5) are to be free from clogging with foreign materials. • Through the inspection of the above, when some slight scratches or scores are found out, remove them with lapping. For the defective parts, replace them as assembly.

Insert the pilot poppet (6), spring (8) and washer (16) into the plug (2), and screw up the adjuster kit with O-ring (15) into it to preliminarily assemble the lock nut.

33-56

Attach the O-ring (13) to the cap, then install the cap to the valve housing, and conduct the pressure adjustment. • Do not reuse the O-rings and backup rings, but replace them to new ones.

14903 60413247

(3) Assembling 1) Insert the main poppet (4) and spring (9) into the sleeve (3), then put it over the pilot seat (10) in which the O-ring (10) and backup ring (11) are installed in advance. 2) Attaching the O-ring (12) to the plug (2), tighten up the above assembly to the cap (1). : 24 mm T = 7 ~ 8 kg·m(51 ~ 58 lbf•ft)

UPPER SLEWING STRUCTURE 1.6.2 Main Relief Valve (25)(P1 Relief) Combination Port Relief Valve (14) (1) Disassembling 1) Remove the plug (2), then disassemble the wave washer (16), poppet (3), poppet (4), piston (5) and spring (7). 2) Loosening the nut (9), remove the adjuster (9A), then take out the spring (8) and pilot poppet (6), (2) Cleaning and Inspection Carry out the work in accordance with the above item "1.6.1-(2)."

14903 60413247

(3) Assembling 1) Install the O-ring (10), backup ring (11) to the poppet (4), then insert its assembly into the poppet (3). 2) Insert the piston (5) and spring (7) into the poppet (4). • The assembled condition of the above 1) and 2) is called as Assembly A. 3) Insert the O-ring (12) and backup ring (13) into the plug (2). Then insert the pilot poppet (6) and pilot spring (8) into it. Attaching the O-ring (18) to it, tighten them up with the adjuster (9A). 4) Preliminarily install the nut (9). 5) Attach the O-ring (14) and wave washer (16) to the above plug (2). • The assembled condition of the above 3) through 5) is called as Assembly B. 6) Insert the Assembly A of the above into the cap (1), then install the Assembly B. : 24 mm T = 7 ~ 8 kgf·m(51 ~ 58 lbf•ft)

Fig. 2-41 Relief Valve

7) Attach the O-ring (15) to the cap (1), then adjust the pressure referring to the item 1.6.4 of the below. • Do not reuse the O-rings and backup rings, but replace them to new ones. (4) Confirmation for Operation after Assembling After assembling the relief valve, push the poppet (3) into inside, and confirm that if the piston (5) is possible to lightly turn with fingers. When it is impossible, replace the relief valve as assembly. NOTE: Note that the inside structure of the P1 main relief valve is different from that of the port relief valve.

33-57

UPPER SLEWING STRUCTURE 1.6.3 Direct Port Relief Valve (1) Disassembling 1) Loosening the lock nut (5), remove the adjuster (5A). 2) Take the spring (4) and poppet (3) out of housing (1).

(2) Cleaning and Inspection Carry out the work in accordance with the above item 1.6.1-(2).

Fig. 2-42 Port Relief Valve

(3) Assembling 1) Insert the poppet (3) and spring (4) into the housing. Then screw up the adjuster (5A) with O-ring (7) into it (with hand as deep as possible). 2) Install the above assembly to the housing. Then adjust pressure referring to the item 1.6.4 of the below. • Do not reuse the O-rings and backup rings, but replace them to new ones.

1.6.4 Pressure Adjusting Procedures 1) Attach a precise pressure gauge to the inlet circuit (port side circuit of the pump). 2) Operate the pump with the rated speed. 3) Set the spool for cylinder of control valve at full stroke, then read the pressure gauge. (at stroke end of cylinder) 4) Turn the adjuster to clock-wise up to obtaining the specified pressure. Fig. 2-43 Relief Valve

• Refer to the Table 2-1 for the pressure increase by one turn of adjuster.

• Tightening Torque : Main Combination Relief : 2.8 ~ 3.2 kgf·m (20 ~ 23 lbf•ft) Direct Relief : 5.0 ~ 5.9 kgf·m(36 ~ 43 lbf•ft)

33-58

14903 60413247

5) When the specified pressure is obtained, tighten up the nut holding the adjuster not to allow its turning.

UPPER SLEWING STRUCTURE 1.6.5 Anti-Void Valve (1) Disassembling 1) Take the valve assy consisting of the sleeve (1), poppet (2), spring seat (4), spring (3) and snap ring (6) out of the plug (5). 2) Remove the snap ring (6) pushing the spring seat (4). Fig. 2-44 Anti-Void Valve

(2) Cleaning and Inspection 1) The seat faces on the tip end of poppet (2) and sleeve (1) are to be evenly contacted with each mating face without any defects. 2) The poppet (2) and sleeve (1) are to slide smoothly and lightly. There should be no scratches and scores on the outer periphery of poppet and inner periphery of sleeve. 3) The spring should have no snapping off, deformation and abrasion. â&#x20AC;˘ Through the inspection of the above, when some slight scratches or scores are found out, remove them with lapping. For the defective parts, replace them as assembly.

14903 60413247

(3) Assembling 1) Insert the poppet (2), spring (3) and spring seat (4) into the sleeve (1) in turn. 2) Install the snap ring (6) pushing down the spring seat (4). 3) Install the above valve assy to the plug (5).

33-59

UPPER SLEWING STRUCTURE

1.7 TROUBLESHOOTING

14903 60413247

(1) General Matters for Control Valve

33-60

14903 60413247

UPPER SLEWING STRUCTURE

33-61

UPPER SLEWING STRUCTURE

PILOT VALVE

3.1 STANDARDS 3.1.1 Assembly Drawing APPLY LOCTITE #277 (PART OF SLANT LINE) APPLY GREASE ON TOP

APPLY GREASE ON TOP

SECONDARY PRESSURE ADJUSTING SHIMS

NOT TO BE REUSED PORT 2,4

Unit, kgf·m (ft·lbs)

14903 60413247

Fig. 3-1 Pilot valve (Standard)

PORT 1,3

33-62

UPPER SLEWING STRUCTURE 3.1.2 Disassembly & Assembly (1) Tools

HANDLE LEVER

BOOTS

LEAD WIRE

(2) Caution for disassembly & assembly 1) Exercise sufficient care to prevent invasion of dust when disassembling and assembling components. 2) Handle the parts with sufficient care, preventing defect. 3) The spools, spring seats and springs used in ports 1, 3 and ports 2, 4 of this pilot valve differ slightly in dimensions. Before removing those parts, record the locations so they are installed in correct positions.

14903 60413247

(3) Disassembly 1) Remove the handle lever assy, boots and lead wires from valve body (101). (See Fig. 3-2) 2) Fix the pilot valve with a vise, placing copper plates (or lead plates). 3) Place a wrench in the opposing flats of the disk (302) and turn counterclockwise till joint (301)gets loosened. : 22 mm 4) Remove the operating part of the handle (301, 302, 312) from the valve body (101). 5) Remove plate (151) 6) Remove plug (211)from valve body (101) so as not to exert uneven load upon it, utilizing the groove in the outer circumference of plug (211) and using a flat Minus driver (b).

WARNING â&#x20AC;˘ Take care that the plug (211) may jump out by spring force of the springs (221-1, 221-2, 241-1, 241-2) while the plug is pulling out.

Fig. 3-2 Disassembling handle lever

PORT 2, 4

PORT 1, 3

Fig. 3-3 Disassembling pilot valve

7) Remove push rods (212) and spring seats (216-1, 216-2). 8) Record the related location of the holes in the spool assy and valve body (101). Remove the spool assy from valve body (101). 9) Take off springs (241-1, 241-2). 10) Loosen socket capscrews (125), using an hexagonal wrench key and remove port plate (111) from valve body (101). : 6mm 33-63

UPPER SLEWING STRUCTURE 11) Disassemble the spool (201-1, 201-2), spring seat (216-1, 216-2), spring (241-1, 242-2) and washer 2 (217). These parts to be treated as assy until assembling. 12) Loosen disk (302), adjusting nut (312) and lock nut on the handle operating parts, using spanner, and disassemble joint (301). : 22 mm (4) Assembling 1) Before assembling, wash parts with washing oil and dry them with compressed air, Avoid using cloth if possible.

Fig. 3-4 Spool assy

• Before assembling correct all defects made during disassembling, clean parts, coat moving parts with oil and refit parts back in original place. 2) Replace O-rings with new ones. Replace seal washers (121) with new ones, also. 3) Fit O-rings (122) into valve body (101). 4) Install port plate (111) to valve body (101). In that case, beware of the mounting position so that spring pin (126) can be set in the hole of valve body (101) side. 5) Tighten slowly, with specified torque, two socket capscrews (125) with seal washers (121). : 6mm T= 3 ± 0.3 kgf·m (22 ± 2 lbf•ft)

PORT 2, 4

PORT 1, 3

14903 60413247

Fig. 3-5 Assembling

33-64

UPPER SLEWING STRUCTURE 6) Install washer (217), spring (241-1, 241-2) and spring seat (216-1, 216-2) into spool (201-1, 2012)in that order. (See Fig. 3-4) 7) Assemble spring (221-1, 221-2) into valve body (101) so it was located before removal. 8) Install the reducing valve assy into valve body (101). 9) Assemble seal (213) in plug (211) so its lip faces as Fig. 3-6. Then insert, push rod (212) with seat spring (216-1, 216-2) into plug (211).Coat the surface of push rod (212) with hydraulic oil. (See Fig. 3-6)

APPLY HYDRAULIC OIL

Fig. 3-6 Inserting push rod

10) Assemble O-ring (214) to plug (211). 11) Assemble the plug assy into valve body (101). (It stops because of the sliding resistance of the Oring.) 12) Attach plate (151) to valve body (101). 13) Fasten joint (301) to valve body (101) with specified torque. : 22 mm T=4.8 ± 0.3 kgf·m (35 ± 2 lbf•ft)

14903 60413247

14) Install disc (302) to joint (301), and fasten adjusing nut (312) in a position where the disc contacts the tip of four push rods (212), to specified torque. : 22 mm T=7 ± 0.5 kgf·m (51 ± 4 lbf•ft) • Fasten the adjusting nut so the gap between disc (302) and push rod (212) gets below 0.2 mm (0.008 in) 15) Pass a lead wire through the hole of the valve body, and through the side hole in the adjusting nut located between 60° and 120°, and pull it out. 16) Assemble bushing (457) into plate (151) and pass lead wire through it. Slacken the lead wire to an extent that is required for moving when operation is performed. 17) Apply heat resistant grease over the contact surface of the joint rotating part, the plate and the push rod.

18) Install the handle lever assy and the boots to valve body (101).

33-65

3.1.3 Maintenance standards (1) Parts replacement standards 1) Replace O-ring and other seals at each disassembly and assembly. 2) Replace worn parts if leaks affects the operating system. 3) Replace spools having excessive wear on their sliding portion. 4) Replace a push rod that is worn to 1mm (0.04in) or over on its top end. (See Fig. 3-7) 5) Replace operating lever and handle pins that have a play of 2mm (0.08in) or over. 6) Replace such parts that arise abnormal sounds, hunting and drops in the primary pressure.

(0.28 in)

UPPER SLEWING STRUCTURE

(0.04 in)

Fig. 3-7 Wear of push rod

14903 60413247

3.1.4 Troubleshooting

33-66

UPPER SLEWING STRUCTURE

SLEWING MOTOR

4.1 ASSEMBLY DRAWING

14903 60413247

VIEW X

SECTION A-A

33-67

UPPER SLEWING STRUCTURE

14903 60413247

Table 4-1

33-68

UPPER SLEWING STRUCTURE

4.2 DIS/RE-ASSEMBLING (1) General Precautions • The work for dis/re-assembling shall be carried out at a clean shop providing some clean containers to put in the disassembled parts. • Before the disassembling, make around each port clean, and remove paint at connecting portions to be disconnected, with a wire brush. • Make each disassembled part clean with a cleaning oil. • Put matching marks / tags to each disassembled part to ensure the same positioning at the reassembling. • All the seals must be replaced to new ones at every disassembling, and thinly apply grease to them at the installation. • Check each part for abnormal abrasion or seizure, and remove any sharp edges and burs with sandpaper. (2) Tools The tools required for the dis/re-assembling are shown in the below table. Provide them prior to the work.

14903 60413247

(3) Disassembling • The external view is shown in Fig. 4-2

Fig. 4-2

33-69

UPPER SLEWING STRUCTURE 1) Remove the capscrew (44). : 14 mm

2) Remove the valve housing (25) assy, then remove the spring (17), pin (19) and balancing plate (16). â&#x20AC;˘ Pay attention not to lose the spring (17) and pin (19) for the balancing plate (16).

3) Remove the valve (15).

14903 60413247

4) Remove the valve plate (13) and valve drive (23).

33-70

UPPER SLEWING STRUCTURE Remove the Geroller (22) and main drive (21).

Remove the wear plate (11).

Remove the retaining ring (7) with a snap ring plier.

Pull out the pinion gear (2) with a press machine or plastic hammer.

14903 60413247

33-71

UPPER SLEWING STRUCTURE 9) Remove the X-ring (6).

10) Remove the ball bearing (4) of the rear side, tapping the inner race of bearing with a minus screw driver, etc. and plastic hammer. NOTE: Do not remove the bearing, except for the necessity.

11) Remove the ball bearing (3) of the front side, tapping the inner race of bearing with a minus screw driver, etc. and plastic hammer.

14903 60413247

NOTE: Do not remove the bearing, except for the necessity.

33-72

UPPER SLEWING STRUCTURE (4) Assembling 1) Install the ball bearing (4) of the rear side to the bearing housing (1), with a plastic hammer or press machine.

2) Install the ball bearing (3) of the front side to the bearing housing (1), with a plastic hammer or press machine.

3) Install the X-ring (6) to the bearing housing (1).

14903 60413247

4) Press the pinion gear (2) into the bearing housing (1), with a press machine.

33-73

UPPER SLEWING STRUCTURE 5) Install the retaining ring (7) to the pinion gear (2).

6) Install the shaft face seal (10) to the wear plate (11).

7) Insert the main drive (21) into the inner spline on pinion gear (2). Then attaching the O-ring (8) to the bearing housing (1), install the wear plate (11).

DRAIN PORT

â&#x20AC;˘ Align the grease port (for lubrication of slewing gear) on the flange of bearing housing (1) with the drain port on the wear plate (11) as shown in the sketch. 8) Attaching the O-ring (12) to the wear plate (11), install the Geroller (22).

GREASE PORT

DRAIN PORT

33-74

14903 60413247

â&#x20AC;˘ Align the drain port on wear plate (11) with the drain port on the Geroller (22).

UPPER SLEWING STRUCTURE 9) Install the valve drive (23) to the Geroller (22).

10) Attaching the O-ring (12) to the valve plate (13), install it to the Geroller (22). • Align the drain port on valve plate (13) with the drain port on Geroller (22).

DRAIN PORT

11) Install the valve (15). • The installation of valve (15) is of an important work to determine the rotating direction of the motor. Pay special attention to it referring to the below figure.

WARNING • The erroneous installation for the timing is very dangerous, because it causes for the reverse rotation of the motor.

VALVE VALVE DRIVE

14903 60413247

• Shift by 15 deg. between the outer tooth on Geroller and the side hole on valve.

GEROLLER ROTOR

OUTER TOOTH

SIDE HOLE

33-75

UPPER SLEWING STRUCTURE 12) Insert the steel ball (26), spring (29) and O-ring (28) into the valve housing (25), and tighten up them with the plug (27). : 5 mm T = 6 kgfÂˇm (43 lbfâ&#x20AC;˘ft)

13) Install the spring (17) and pin (19) to the valve housing (25).

14) Install the inner face seal (18) and outer face seal (20) to the balancing plate (16).

14903 60413247

15) Aligning the cut on balancing plate (16) with the pin (19), install it to the valve housing (25).

33-76

UPPER SLEWING STRUCTURE 16) Installing valve housing (25): a) Attach the O-rings (14) and (24) to the valve housing (25). b) Insert a slender bar such as a screw driver from the B port side on valve housing to hold the balancing plate (16) not to come off, then install the valve housing (25) to the valve (15). • Align the drain port on valve plate (13) with the drain port on valve housing (25).

SLENDER BAR

DRAIN PORT DRAIN PORT

14903 60413247

17) Tighten up the capscrew (44). : 14 mm T = 5.4 kgf·m (39.0 lbf•ft)

33-77

UPPER SLEWING STRUCTURE

14903 60413247

4.3 MAINTENANCE STANDARDS

33-78

UPPER SLEWING STRUCTURE

14903 60413247

4.4 TROUBLESHOOTING

33-79

UPPER SLEWING STRUCTURE

SWIVEL JOINT

5.1 ASSEMBLY DRAWING

FILL WITH GREASE

14903 60413247

Table 5-1

Fig. 5-1 Swivel joint-Sectional view

33-80

UPPER SLEWING STRUCTURE

RIVET SCREW

Fig. 5-2 Swivel Joint-Developed elevation

14903 60413247

Table 5-2 Swivel Joint Parts

33-81

UPPER SLEWING STRUCTURE

Fig. 5-3 Selector valve-Developed elevation

14903 60413247

Table 5-3 Parts for Selector Valve Assy

33-82

UPPER SLEWING STRUCTURE

5.2 DIS/RE-ASSEMBLING 5.2.1 General Precautions (1) The work for dis/re-assembling shall be carried out at a clean shop providing some clean containers to put in the disassembled parts.

(4) All the seals must be replaced to new ones at every disassembling, and thinly apply grease to them at the installation.

(2) Before the disassembling, make around each port clean, and remove paint at connecting portions to be disconnected, with a wire brush.

(5) Check each part for abnormal abrasion or seizure, and remove any sharp edges and burs with sandpaper.

(3) Make each disassembled part clean with a cleaning oil.

(6) Check seal grooves for adhesion of foreign materials or dust.

5.2.2 Tools The tools required for the dis/re-assembling are shown in the below table. Provide them prior to the work.

14903 60413247

5.2.3 Disassembling [A] Disassembling Swivel Joint (1) Removing Selector Valve Assy (21) Remove the socket bolt (111), then remove the selector valve assy (21) from the swivel joint. Also remove the O-rings (8) and (9). : 4 mm

NOTE: Do not remove the pin (5) except for the replacement.

33-83

UPPER SLEWING STRUCTURE (2) Remove the bolt (17) and washer (18), then remove the flange (3). : 13 mm

17-18

(3) Remove the O-ring (10).

(4) Remove the snap ring (13) from the shaft (1) with the snap ring plier. (5) Remove the thrust ring (4) from the shaft (1).

10 13

(6) Pull out the shaft (1) from the body (2) applying a pad to the shaft (1) end and tapping the pad with a plastic hammer. â&#x20AC;˘ There is some resistance to pull out the shaft due to interference of seal.

PAD 2 1

(7) Remove the dust seal (10) from the shaft (1).

14903 60413247

F15345

33-84

UPPER SLEWING STRUCTURE (8) Remove the O-ring (7), backup ring (11) and slipper seal (6) with a spatula or pin.

F15346

[B] Disassembling Selector Valve (1) Remove the socket bolt (111), then remove the selector valve assy (21) from the swivel joint. Also remove the O-rings (8) and (9). : 4 mm

(2) Remove the plug (114), and pull out the spring (106) and steel ball (110). : 4 mm

14903 60413247

(3) Remove the socket bolt (112), and remove the detent cover (104) from the body (101).

33-85

UPPER SLEWING STRUCTURE (4) Pull out the spool (102) from the body (101).

(5) Remove the socket bolt (113), then remove the cover (103) from the body (101). : 4 mm

(6) Removal of seals. 1) Remove the O-ring (107) from the body (101). 2) Remove the O-ring (108) and backup ring (109) from the cover (103).

14903 60413247

(7) If required, remove the socket bolt (113), and remove the bracket (105) from the body (101).

33-86

UPPER SLEWING STRUCTURE 5.2.4 Assembling [A] Assembling Swivel Joint (1) Installing pin (5): When the pin (5) has been removed, tap it into the shaft (1) with a plastic hammer paying attention to the installing length. (2) Installing plugs: When plugs (14), (15) and (16) have been removed, install them with each specified tightening torque. = 6 mm, Plug (14): T = 3.0 kgf·m(22 lbf•ft) Plug (15): = 5 mm, T = 1.9 kgf·m(14 lbf•ft) Plug (16): = 4 mm, T = 1.0 kg·m( 7.2 lbf•ft)

(3) Install the dust seal (12) to the shaft (1). • Apply grease in plenty to the lip portion of dust seal (12).

(4) Installing seals: Install the O-ring (7), backup ring (11) and slipper seal (6) into each groove on the body (2).

14903 60413247

• Confirm each positioning of the seals referring to the structural drawing. • Pay attention not to give any damages, scores and twisting to the seals.

33-87

UPPER SLEWING STRUCTURE (5) Installing shaft (1): Insert the shaft (1) into the body (2) paying attention to the relative positioning of the shaft (1) and body (2). • Thinly apply grease to outer periphery of the shaft (1). • For the insertion of the shaft (1), evenly tap the shaft with a plastic hammer, paying attention not to give any damages to the seals

(6) Install the thrust ring (4) and snap ring (13). • Confirm the fact that the snap ring (13) is securely positioned into the groove on the shaft (1).

(7) Installing O-ring (10) and flange (3): 1) Attach the O-ring (10) to the face of gasket on the body (2). 2) Install the flange (3) to the body (2) with the spring washer (18) and bolt (17). : 13 mm T = 2.8 kg·m (20 lbf•ft)

14903 60413247

(8) Installing hose adapters (20): When the hose adapters has been removed, install them to the shaft (1) and body (2) respectively with the specified tightening torque. : 17 mm T = 3.0 kgf·m (22 lbf•ft)

33-88

UPPER SLEWING STRUCTURE [B] Assembling Selector Valve (1) Attach the O-ring (107) to the body (101).

(2) Install the detent cover (104) to the body (101) with the socket bolt (112). : 4 mm T = 0.7 kgf·m (5.1 lbf•ft)

(3) Insert the spool (102) into the body (101).

(4) Attach the O-ring (108) and backup ring (109) to the cover (103).

(5) Attach the O-ring (107) to the body (101).

14903 60413247

(6) Install the cover (103) to the body (101) with the socket bolt (113). : 4 mm T = 0.7 kgf·m (5.1 lbf•ft)

33-89

UPPER SLEWING STRUCTURE (7) Insert the steel ball (110) and spring (106) into the detent cover (104), and install it with the plug (114). : 4 mm T = 1.0 kgf·m (7.2 lbf•ft) • Confirm the effectiveness of the detent by means of moving the spool.

(8) Install the bracket (105) to the body (101) with the socket bolt (113). : 4 mm T = 0.7 kgf·m (5.1 lbf•ft)

(9) Attach the O-rings (8) and (9) to the side sealing face on the side of shaft (1).

14903 60413247

(10) Install the selector valve assy (21) to the swivel joint with the socket bolt (111). : 4 mm T = 0.7 kg·m (5.1 lbf•ft)

33-90

UPPER SLEWING STRUCTURE

5.3 MAINTENANCE STANDARDS 5.3.1 Check Procedures and Remedy

5.3.2 Parts Use Limit (1) Body, Shaft

14903 60413247

(2) Flange and (3) Thrust Ring

33-91

UPPER SLEWING STRUCTURE (4) Slipper Seal

BULGING

1.5 mm or more

0.5 mm or more

(5) O-ring

BULGING

1.5 mm or more

(6) Backup Ring

Width 4mm or less Thickness

14903 60413247

1.5 mm or more

33-92

UPPER SLEWING STRUCTURE 5.3.3 Inspection After Assembly After assembly is completed, check for leakage of oil in each circuit using the equipment shown below.

(1) Connect a pipe (3) between the hydraulic pump (2) and the shaft (1) side port. (2) Connect a pressure gauge to the body (4) side. (3) Increase the pressure gradually to 210 kg/cm2 (2990 psi) adjusting the relief valve (6), then perform 1 minute leak test. â&#x20AC;˘ Open the neighboring ports on both sides and check visually for leakage from the ports.

14903 60413247

â&#x20AC;˘ Check for external leakage, etc. by a color check.

33-93

UPPER SLEWING STRUCTURE

5.4 TROUBLESHOOTING (1) Swivel Joint

14903 60413247

(2) Selector Valve

33-94

SECTION 34

TRAVEL SYSTEM

TABLE OF CONTENTS

Part I: Removing and installing assy ................................................................34-1 1. Name of travel system parts ................................................................................. 34-1 2. Crawler ................................................................................................................. 34-1 2.1 Removal and installation procedures ............................................................................................. 34-1 2.2 Construction ................................................................................................................................... 34-3 2.3 Maintenance standards .................................................................................................................. 34-3

3. Slide plate (shoe slide) ......................................................................................... 34-4 3.1 Removal and installation procedures ............................................................................................. 34-4 3.2 Maintenance standards .................................................................................................................. 34-4

4. Lower roller ........................................................................................................... 34-5 4.1 Removal and installation procedures ............................................................................................. 34-5 4.2 Construction ................................................................................................................................... 34-6 4.3 Disassembly and assembly ............................................................................................................ 34-6 4.4 Maintenance standards .................................................................................................................. 34-8

5. Front idler .............................................................................................................. 34-9 5.1 Removal and installation procedures ............................................................................................. 34-9 5.2 Construction ................................................................................................................................. 34-10 5.3 Disassembly and assembly .......................................................................................................... 34-10 5.4 Maintenance standards ................................................................................................................ 34-12

6. Idler adjuster ........................................................................................................ 34-13

14903 60413247

6.1 Removal and installation procedures ........................................................................................... 34-13 6.2 Construction ................................................................................................................................. 34-13 6.3 Disassembly and assembly .......................................................................................................... 34-14 6.4 Maintenance standards ................................................................................................................ 34-14

7. Sprocket .............................................................................................................. 34-15 7.1 Removal and installation procedures ........................................................................................... 34-15 7.2 Maintenance standards ................................................................................................................ 34-15

INDEX

8. Travel motor ......................................................................................................... 34-16 8.1 Removal and installation procedures ........................................................................................... 34-16 8.2 Maintenance standards ................................................................................................................ 34-17

9. Slewing bearing ................................................................................................... 34-18 9.1 Removal and installation procedures ........................................................................................... 34-18 9.2 Construction ................................................................................................................................. 34-19 9.3 Disassembly and assembly .......................................................................................................... 34-19 9.4 Maintenance standards ................................................................................................................ 34-20

10. Adjustable crawler frame width 10.1 Removal and installation procedures ......................................................................................... 34-21 10.2 Maintenance standards .............................................................................................................. 34-23

Part II: Disassembling and assembling components ......................................34-24 1. Travel motor ......................................................................................................... 34-24

14903 60413247

1.1 Assembly drawing ........................................................................................................................ 34-24 1.2 Disassembly and assembly ......................................................................................................... 34-28

TRAVEL SYSTEM

Part I: REMOVING AND INSTALLING ASSY NAME OF TRAVEL SYSTEM PARTS

Fig. 1-1 Name and location of parts

2. 3. 4. 5. 6.

Crawler Slide plate Lower roller Front idler Idler adjuster

7. 8. 9. 10.

Sprocket Travel motor Slewing bearing Adj. crawler frame width

CRAWLER

2.1 REMOVAL AND INSTALLATION PROCEDURES

90°~110°

2.1.1 Removing rubber crawler (1) Lift the one side of machine with attachment, as shown in Fig. 2-1, and place support under lower frame to support machine.

14903 60413247

(2) Loosen grease nipple for crawler adjuster, discharging grease in cylinder, and release tension of crawler. : 19 mm

WARNING • When loosening the grease nipple of the adjuster, do not loosen it more than one turn. • Where grease does not come out well, drive the crawler of removal side forward / reverse. The over loosening of grease nipple will cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple. Never stand toward the grease nipple for safety.

SUPPORT

F15356

Fig. 2-1 Crawler removing posture

F15357

GREASE NIPPLE

Fig. 2-2 Loosening crawler tension

34-1

TRAVEL SYSTEM (3) Put steel pipes on the rubber crawler to be caught in, and slowly rotate the sprocket backward. Stop the rotating when steel pipes reached horizontal line of idler.

ROTATING DIRECTION

(4) Slide the rubber crawler sideways, and remove it.

2.1.2 Installing rubber crawler Installation work is performed in the reverse order of removal. (1) Engage the rubber crawler with the sprocket and mount it on the idler. (2) Put steel pipes on the rubber crawler to be caught in, and rotate the sprocket backward.

F15358

STEEL PIPE

Fig. 2-3 Removing rubber crawler

ROTATING DIRECTION

(3) Stop rotation when steel pipes reached horizontal line of idler. (4) Slide the rubber crawler to the position to be set on idler exactly. (5) Confirm that the rubber crawler is engaged securely with the sprocket, idler and lower roller.

F15359

STEEL PIPE

Fig. 2-4 Installing rubber crawler

(6) Tighten the grease nipple for the crawler adjuster, and adjust tension by feeding grease. : 19mm T = 6 ± 1 kgf·m (43 ± 7 lbf•ft)

Appropriate tension A = 45 ~ 55 mm (1.8 ~ 2.2 in)

GREASE FUN F15360

Fig. 2-5 Feeding grease

LOWER ROLLER

F15361

Fig. 2-6 Rubber crawler tension

34-2

14903 60413247

CRAWLER FRAME

TRAVEL SYSTEM

2.2 CONSTRUCTION (1) Construction of rubber crawler No.

NAME

Q’TY for machine

RUBBER CRAWLER ASSY

• This standard machine provides rubber crawler.

Fig. 2-7 Rubber crawler assy

2.3 MAINTENANCE STANDARDS (1) Rubber crawler CORE

RUBBER COVER

CENTER LINE OF STEEL CORD SECTION A-A

Place mark M or ∞ mark at machine center

L: Distance between the bottom of frame and top of rubber crawler Fig. 2-8 Rubber crawler shoe

Unit: mm (in)

14903 60413247

Table 2-1

34-3

TRAVEL SYSTEM

3. SLIDE PLATE (SHOE SLIDE) 3.1 REMOVAL AND INSTALLATION PROCEDURES Two each of slide plates are provided at both sides of left and right to support and guide the crawler at upper side of the lower frame. 3.1.1 Removal (1) Loosen the grease nipple for crawler adjusting within one turn to discharge grease and release tension on the crawler. : 19mm

GREASE NIPPLE

Fig. 3-1 Releasing crawler tension

WARNING Turn the grease nipple slowly paying attention not to turn more than one turn, and be careful for the spouting out grease. (2) Push up the crawler with a hydraulic jack, and place suitable wood block to keep a clearance between the crawler and lower frame. (3) Remove the fixing socket bolts, and remove the slide plates from the lower frame. : 8 mm 3.1.2 Installation 1) Applying Loctite #262 to the fixing socket bolts, tighten them up. : 8 mm T= 5.6±0.28 kgf·m (41±2 lbf·ft) • At the installation, as same as the case for the removal, support the crawler with wood block so that the works are able to carry out without hindrance. 2) After installation of the slide plates, tighten grease nipple to adjust the crawler, and feed grease to adjust the tension on the crawler. : 19mm T = 6±1 kgf·m (43±7 lbf·ft)

SQUARE LUMBER

Fig. 3-2 Square lumber support

SLIDE PLATE SOCKET BOLT

Fig. 3-3 Removing / Installing slide plate

Fig. 3-4 Slide plate

Unit : mm (in)

34-4

14903 60413247

3.2 MAINTENANCE STANDARDS

TRAVEL SYSTEM

LOWER ROLLER

4.1 REMOVAL AND INSTALLATION PROCEDURES

LOWER ROLLER ASSY

4.1.1 Removing (1) Slightly loosen capscrews (2) fastening lower roller assy to the lower frame. : 19mm (2) As same as the case for removal of the crawler, loosen the grease nipple for crawler adjusting within one turn to discharge the grease, and release the tension on the crawler. : 19mm

CAPSCREW

CAPSCREW Fig. 4-1 Lower roller assy

(3) Lift the lower frame good enough to remove the lower roller, using the attachment. (4) After lifting the lower frame to a proper height, place square lumber under the lower frame to stabilize the machine. (5) Remove the capscrews (2) fastening the lower roller, and remove the lower roller assy. : 19mm Weight of lower roller assy : 3.8 kgf (8.4 lbs) 4.1.2 Installing (1) Coast the mounting capscrews (2) with Locktite #262 in advance.

SUPPORT Fig. 4-2 Crawler removing posture

(2) Place the roller assy between the crawler and lower frame. Fasten the capscrews (2) temporarily. : 19mm

14903 60413247

(3) Lower the machine in full contact with the ground and tighten the capscrews (2) as specified. : 19mm T = 11.7 kgf·m (85 lbf•ft) (4) Tighten the grease nipple of the crawler adjuster. Lift the machine, and adjust the crawler tension by feeding grease. : 19mm T = 6 ±1 kgf·m (43 ± 7 ft·lbs)

GREASE GUN

Fig. 4-3 Feeding grease

34-5

TRAVEL SYSTEM

4.2 CONSTRUCTION No.

NAME

Q’TY

Roller

Shaft

Bearing

No.

NAME

Q’TY

Seal

Snap ring

Plug

Fig. 4-4 Lower roller construction

4.3 DISASSEMBLY AND ASSEMBLY 4.3.1 Disassembling 1) Loosen the plug (7) to drain oil. 2) Remove the seals (5). 3) Remove the snap ring (6).

Put the lower roller on the supporting stand, and push out the shaft (2) together with the bearings (3).

Fig. 4-5 Removing seal (5)

• Except the case that replacement of the bearing (3) is necessary, do not remove the bearings from the shaft (2).

METAL BLOCK

STAND

Fig. 4-6 Removing shaft / bearing

34-6

14903 60413247

TRAVEL SYSTEM 4.3.2 Assembling (1) Apply molybdenum grease to the shaft (2), and install the bearings (3).

METAL BLOCK

• In case of re-use of the bearing, confirm its smooth rotation, and no defect and rust on them. (2) Apply molybdenum grease to the lower roller (1), and press the shaft (2) together with the bearings into the place. STAND

(3) Install the snap ring (6).

Fig. 4-7 Installing shaft / bearing

(4) For the seal (5), first apply grease into groove on the lip portion of the seal body (5a). Then push the seal body (5a) and sleeve (5b) into the place evenly with the specialized pushing jig paying attention not to give any distortion on the lip.

SEAL PUSHING JIG

• Replace the seal to new one at reassembly. • When the seal is not installed properly due to one-sided pressing etc, replace it to new one. (5) With the same procedure of the above, install the seal (5) of the opposite side. (6) Fill in 75 cc (4.6 cu·in) of the gear oil SAE #90 through the bore of plug on the roller (1).

Fig. 4-8 Installing seal

(7) Tighten up the plug (7). : 5 mm

14903 60413247

• After assembling the lower roller, confirm its smooth rotation with hands and no leakages on it.

Fig. 4-9 Assembling lower roller

34-7

TRAVEL SYSTEM

4.4 MAINTENANCE STANDARDS

Fig. 4-10 Lower Roller

14903 60413247

Unit mm (in)

34-8

TRAVEL SYSTEM

5. FRONT IDLER 5.1 REMOVAL AND INSTALLATION PROCEDURES 5.1.1 Removing (1) Remove the crawler assy. (2) Remove idler together with idler adjuster assy, rolling it, using a crowbar or equivalent. (3) Loosen capscrews (c), and separate idler assy (a) from idler adjuster assy (b). : 17 mm Weight of idler assy: Approx. 9 kgf (20 lb) Weight of idler adjuster assy: 2.8 kgf (6.2 lb)

Fig. 5-1 Removing idler

WARNING The separated idler assy (a) is easy to fall down. Lay it down so it does not fall down on your feet, utilizing wood block.

5.1.2 Installing (1) Install idler assy (a) to the idler adjuster assy (b) by means of capscrews (c) in the reverse order of removing the idler assy. Coat the threaded part of capscrews (c) with Loctite #262 beforehand. : 17 mm T : 4.7 kgf·m (34 lbf·ft) (2) The assembly of the idler and idler adjuster is to be installed to the lower frame so that the grease feeding plug (1) of idler is positioned to outside, and the grease feeding port of the grease nipple (2) of idler adjuster assy is facing to outside.

Fig. 5-2 Disassembling idler assy

Fig. 5-3 Installing idler

(3) Following procedures of Item 2, install the crawler assy, and adjust the crawler tension.

14903 60413247

• On that occasion, confirm the lubrication through the grease nipple is proper and that grease is not leaking from the grease cylinder.

34-9

TRAVEL SYSTEM

5.2 CONSTRUCTION

LOCATE PIN'S GAP OUTSIDE

VIEW A

Fig. 5-4 Idler assy construction

5.3 DISASSEMBLY AND ASSEMBLY

Fig. 5-5 Extruding pin

PRESSING SHAFT EXTRUDING JIG

• Except the case that replacement of the bearing (11) is necessary, do not remove the bearing from the shaft (5).

STAND

Fig. 5-6 Extruding shaft

34-10

14903 60413247

5.3.1 Disassembly (1) Remove the plug (8) and drain the oil [ Approx. 30 cc (1.8 cu·in) ] : 5 mm 2) Push out the spring pin (6) applying the pin extruding jig to it and lightly tapping the jig with a hammer, then remove the collar (12) (13). 3) Remove the seals (4) and retaining rings (7). 4) Supporting the idler (1) with the supporting stand, apply the shaft extruding jig to the shaft (5), and push out it together with the bearing (11) using a pressing machine.

PIN EXTRUDING JIG

TRAVEL SYSTEM 5.3.2 Assembly (1) Apply molybdenum grease to the shaft (5), and install the bearings (11).

SHAFT PRESSING JIG

• In case of re-use of the bearing, confirm its smooth rotation, and no defect and rust on them. (2) Applying molybdenum grease to the idler (1), press the shaft (5) together with the bearings into the idler.

STAND

(3) Install the retaining ring (7). (4) For the seal (4), first enclose grease into the lip portion of the seal body (4a). Then push the seal body (4a) and sleeve (4b) into the place evenly with the specialized pushing jig paying attention not to give any distortion on the lip.

Fig. 5-7 Shaft / Bearing installation SEAL PUSHING JIG

• Replace the seal to new one at reassembly. • When the seal is not installed properly due to one-sided pressing etc, replace it to new one. (5) Install the opposite seal (5)with the same procedure. (6) Install the collar (12) to the shaft (5), and fix it with tapping the spring pin (6) in. Install the collar (13) of the opposite side with the same procedure.

Fig. 5-8 Installing seal

• Install the spring pin (6) so that the gap on it faces to outside. [See Fig. 5-10]

PIN EXTRUDING JIG

(7) Fill in 30 cc (1.8 cu·in) of the gear oil SAE #90 through the bore for plug on the idler (1). (8) Tighten up the plug (8). : 5 mm Fig. 5-9 Tapping pin

14903 60413247

IDLER SLIDE

LOCAL PIN’S GAP OUTSIDE Fig. 5-10 Pin's gap direction

34-11

TRAVEL SYSTEM

5.4 MAINTENANCE STANDARDS

Fig. 5-11 Idler assy

14903 60413247

Unit mm (in)

34-12

TRAVEL SYSTEM

6. IDLER ADJUSTER 6.1 REMOVAL AND INSTALLATION PROCEDURES 6.1.1 Removing (1) Idler adjuster assy assembled with idler assy (a) is removed from the lower frame. Do this work by referring to "5.1.1" Removing front idler. (2) Loosen capscrews (c) and remove idler assy (a) from idler adjuster assy (b). : 17 mm Weight of idler assy: 9 kg (20 lbs) Weight of idler adjuster assy: 2.8 kg (6.2 lbs) Fig. 6-1 Disassembling idler assy

WARNING The separated idler assy is easy to fall down. Lay it down so it does not fall down on your feet, utilizing square lumber. 6.1.2 Installing (1) Installation is done in the reverse order of removal: First of all, assemble idler assy (a) to idler adjuster assy (b), and tighten them together with capscrews (c). In that case, coat the threaded part of capscrews (c) with Loctite #262 beforehand. : 17 mm T : 4.7 kgf·m (34 ft·lbs) (2) Before installing the idler adjuster to the crawler frame, assemble it with the idler assy. For the procedure, refer to "5.1.2" Installing front idler.

14903 60413247

6.2 CONSTRUCTION

Fig. 6-2 Idler adjuster assy

34-13

TRAVEL SYSTEM

6.3 DISASSEMBLY AND ASSEMBLY LH

6.3.1 Disassembly (1) Pull the piston (1) out of grease cylinder (2) (2) Remove the oil seal (10), O-ring (8) and back-up ring (9) from the grease cylinder (2).

6.3.2 Assembly (1) Install the back-up ring (9), O-ring (8) and oil seal (10) to the grease cylinder (2). • Apply thin layer of grease to these parts before installation.

Fig. 6-3 Assembling idler adjuster

(2) Fill up the grease cylinder (2) with grease. Remove the grease nipple from the grease cylinder (2). Then release air in the cylinder through the bore of grease nipple pushing the piston (1) with hand. • Pay attention to the fact that the adjustment for crawler shoe tension cannot carry our properly if the releasing air is insufficient. (3) Attach the grease nipple (7) to the grease cylinder (2). : 19mm T = 6 ± 1 kgf·m (43 ± 7 lbf•ft)

6.4 MAINTENANCE STANDARDS

14903 60413247

Fig. 6-4 Idler adjuster assy

34-14

TRAVEL SYSTEM LOWER FRAME

7. SPROCKET 7.1 REMOVAL AND INSTALLATION PROCEDURES 7.1.1 Removing (1) Remove the crawler assy. (2) Place wood block under the lower frame so the sprocket is off the ground. (3) Loosen socket bolts (M10) for the attaching of the sprocket by means of an allen wrench key and remove the sprocket. : 8 mm Single weight of sprocket: 5 kg (11 lb)

SQUARE LUMBER

SPROCKET

Fig. 7-1 Free sprocket from load

SOCKET BOLT

7.1.2 Installing (1) Check the fixing parts of the travel motor and the sprocket, eliminate burrs and dirt thoroughly, and install the sprocket. (2) Apply Loctite #262 to the sprocket attaching socket bolts and fasten the sprocket temporarily. (3) Remove the wood block under the lower frame and tighten socket bolts with specified torque to fix sprocket and travel motor. : 8 mm T= 6 kgf·m (43 lbf·ft) (4) Install crawler.

SPROCKET Fig. 7-2 Removing sprocket

TRAVEL MOTOR

7.2 MAINTENANCE STANDARDS Fig. 7-3 Tightening socket bolts

(0.63)

P. C. D. 278 (10.9)

8 (2. 72

14903 60413247

NUMBER OF TEETH Z = 12

Fig. 7-4 Sprocket

(1.18)

1) .3 (0

(0.59)

(0 .2 0)

DETAIL OF "X" Unit: mm (in)

34-15

TRAVEL SYSTEM

8. TRAVEL MOTOR LOWER FRAME

8.1 REMOVAL AND INSTALLATION PROCEDURES 8.1.1 Removing (1) Remove the crawler assy. (2) Place square lumber under the lower frame so the sprocket is off the ground. (3) Remove the capscrews (A5) located inside the lower frame and remove the cover (A8). : 13mm

SQUARE LUMBER

SPROCKET

Fig. 8-1 Free sprocket free from load

(4) Loozen the air plug of hydraulic oil tank and release air in the tank. : 22mm (5) Disconnect the joint of hydraulic piping connected with the travel motor, and plug the joints in order to prevent outflow of oil and entering of dust. : 19mm, 22mm (6) Remove socket bolts (B4) that fasten the travel motor to the lower frame. On that occasion, put a matching mark between the lower frame and the travel motor. : 8mm

Fig. 8-2 Removing cover / travel motor

(7) Place a wire sling in a part near the sprocket of the travel motor for balancing, and remove the unit out of the lower frame. Weight of travel motor (with sprocket) : 23 kgf (51 lbs)

(2) Coat the threaded part of the mounting socket bolts (B4) with Loctite #262 and tighten them. : 8mm T : 5.6 kgfÂˇm (41 lbfâ&#x20AC;˘ft)

34-16

WOOD BLOCK

F15425

Fig. 8-3 Removing / Installing travel motor

14903 60413247

8.1.2 Installing (1) If there are burrs and dirt on fitting part with which the travel motor are fastened, eliminate it beforehand. Place a wire sling in the travel unit with the same way as in the removing, and install it to the lower frame.

TRAVEL SYSTEM (3) Reconnect the hydraulic pipings as before, and tighten the joints with specified torque. Unit: kgf•m (lbf•ft)

(4) Install the covers (A8) located inside the lower frame, and tighten capscrews (A4). (See Fig. 8-2) : 13 mm

Fig. 8-4 Installing hydraulic pipings (RH-travel motor) LEVEL PLUG

(5) Remove the square lumber supported the lower frame and install the crawler. (6) Check the oil level in the reduction gear of travel motor [See Item (7) mentioned below] and replace or replenish oil as required. Spec. of oil: GEAR OIL SAE #90 Volume of oil: 330cc (20 cu·in) : 8 mm (7) Checking oil level in reduction gear a) Stop the machine so the drain plug comes right under the machine. b) Remove the level plug and check the oil level and contamination. The oil level is proper if it is close to the plug bore. Replenish oil when deficient.

DRAIN PLUG Fig. 8-5 Checking oil level

Socket bolt for sprocket Loctite #262 5.6 kgf·m (41 lbf•ft) TRAVEL MOTOR

8.2 MAINTENANCE STANDARDS

Socket bolt for travel motor Loctite #262 5.6 kgf·m (41 lbf•ft)

14903 60413247

Fig. 8-6 Installing travel motor

34-17

TRAVEL SYSTEM

9. SLEWING BEARING 9.1 REMOVAL AND INSTALLATION PROCEDURES 9.1.1 Removing (1) Remove the upper slewing structure (See detail of "Upper Slewing Structure"). (2) Remove capscrews (B) that fix the inner race of slewing bearing (A) : 19mm Fig. 9-1 Slewing bearing

(3) Remove the grease in the inner race of slewing bearing. (4) Fix lifting-bolts to slewing bearing (A), and lift it by crane. Weight of slewing bearing assy: 36 kgf (79 lbs) 9.1.2 Installing (1) Before installing the slewing bearing, clean thoroughly the bearing and the mating surface of the lower frame to be free from dirt, oil and other foreign materials. Fig. 9-2 Lifting slewing bearing

(2) Lift up the bearing and place it on the lower frame, aligning the "S" mark stamped on the inner race as shown in Fig. 9-3.

Loctite #262 11.7 kgf·m (85 lbf·ft)

(3) Coat the threads of the capscrews (B) with Loctite #262 and tighten all capscrews temporarily. (4) Tighten the capscrews at 180˚ intervals alternately, and tighten them up to a specified torque. : 19 mm T : 11.7 kgf·m (85 lbf·ft)

LOWER FRAME

INNER "S" ZONE (S-MARK)

(5) After installing the slewing bearing on the lower frame, install upper slewing structure.

REAMER BOLT

14903 60413247

CENTER OF SLEWING MOTOR

GREASING port

Fig. 9-3 Location of "S" mark to install slewing bearing

34-18

TRAVEL SYSTEM

9.2 CONSTRUCTION

Fig. 9-4 Cross-section of slewing bearing

9.3 DISASSEMBLY AND ASSEMBLY 9.3.1 Disassembling (1) Remove seal (6) fitted in the groove in the inner circumference on top of outer race (1) and seal (5) fitted in the groove in the outer circumference under inner race (2), from the bearing, and place the bearing level on a square lumber. (2) Remove taper pin (8), using a hammer and an extrusion rod. (3) Remove plug (9), using an puller bolt made use of the threaded bore in the center of the plug. (4) After removing plug (9), take out balls (3) and spacers (4) (4A) from the bore in order, while rotating outer race (1) slightly.

14903 60413247

9.3.2 Assembling (1) Degrease thoroughly the groove for seal (6) located in the inner circumference of outer race (1) and the groove for seal (5) located in the outer circumference of inner race (2). Coat the grooves with adhesive Cyano Bond PO-1, fit seal (5), and place inner race (2) on a surface table. (2) Lift and lower outer race (1) slowly till the top surface of inner race (2) matches the bottom of the sealing groove of outer race (1). Place an adjusting washer under outer race (1) in order to support the outer race so the track surface of ball (3) is aligned. (3) Forward, balls (3) and spacers (4) (4A) coated with the specified grease (NLGI No.2 Lithium bace with MOS2) alternately through the bole for plug (9) in outer race (1).

WARNING When forwarding balls (3) and spacers (4) (5), the raceways must be aligned completely. To achieve it, outer race (1) should be adjusted. It is very dangerous to put your finger into the plug bore directly ; always use a push rod or a hooked rod.

SQUARE LUMBER

Fig. 9-5 Disassembling slewing bearing

Fig. 9-6 Removing balls / spacers

PUSH ROD

SQUARE LUMBER Fig. 9-7 Installing balls

34-19

TRAVEL SYSTEM (4) Install plug (9) to outer race (1), confirming the direction and the position of the bore for taper pin (8).

LIFTING BOLT

HOOK ROD

(5) Push taper pin (8) into bore, and caulk the head of the taper pin with a punch. (6) Coat seal (6) with adhesive Cyano Bond PO-1 and place it into groove of outer race (1). (7) Confirm that grease nipple (7) is useful. Apply grease (NLGI-2 EP type) and confirm that the outer race rotates smoothly and that the lip of the seal is not scored.

SQUARE WOOD Fig. 9-8 Installing spacer

9.4 MAINTENANCE STANDARDS

14903 60413247

Regarding the maintenance standards for the wear of the slewing bearing, refer to the section Maintenance Standards and Test Procedures, item Measuring Slewing Performances.

34-20

TRAVEL SYSTEM

10. ADJUSTABLE CRAWLER FRAME WIDTH 10.1 REMOVAL AND INSTALLATION PROCEDURES 10.1.1Removal (1) Preparation for Removal 1) Lift up the machine by around 30 cm (1 ft) to secure the working space under the machine, and set a stable supporting stand at four positions, left and right of front and rear of crawler shoes. 2) Release air in the hydraulic oil tank. : 22 mm 3) Remove the under cover (11). Capscrew (5) : M8 : 13 mm

Fig. 10-1 Lift up the machine

(2) Remove the capscrew (A8) that is fixing the cover (A7). : 10 mm (3) Disconnect the hydraulic hose connected to the adjusting cylinder (A1), and apply a plug to openings. : 19mm, 22 mm (4) Remove the capscrews (A4) that are fixing the brackets (A3). : 19 mm

Fig. 10-2 Removing under cover

(5) Remove the pins (A2). (6) Remove the nuts (10) and (14) for the stopper bolt (9). : 24 mm

14903 60413247

â&#x20AC;˘ In order not to change the stopper position, do not loosen the double nuts (10) and (15) of the opposite side.

Fig. 10-4 Stopper bolt (9)

Fig. 10-3 Removing adjusting cylinder

34-21

TRAVEL SYSTEM (7) Preparation to remove Crawler Frame Assy 1 ) Lifting up the machine with the attachment and dozer, support the lower frame (machine body) applying stable supporting stands under the lower frame to make the crawler frame free. 2) Disconnect the hydraulic piping connected to the travel motor at the joint portion, and plug the joint portion to prevent oil outflow and dust invasion. : 19, 22 mm (8) Lift up the crawler assy with a crane, remove the crawler assy with pulling it with a lever block or alike one to sideward.

Fig. 10-5 Removing Crawler Assy

(9) Remove the adjusting cylinder (A1) together with the cover (A7), bracket (A3), etc. Weight of adjusting cylinder: 7.5 kgf (17 lbs)

Fig. 10-6 Removing/Installing Adjusting Cylinder

10.1.2 Installation Paying attention to the following items, the installation shall be carried out with the reverse order of the removal. (1) Apply grease on the surface of square pillars before insertion.

APPLY GREASE

Fig. 10-7 Crawler Frame

(2) Insert the crawler frame assy utilizing a lever block, etc., paying attention not to grate the square pillars. 14903 60413247

â&#x20AC;˘ Adjust the inserting direction so that the tips of square pillars fit into the opponent of square pillars. Fig. 10-8 Installing Crawler Assy

34-22

TRAVEL SYSTEM T=16 kgf·m (116 lbf•ft)

(3) Confirm the installing length of stopper bolts for both left and right. (Refer to Fig. 10-9) Nuts (10) & (15) : M16 : 24 mm T=16 kgf·m(116 lbf•ft) (4) Apply grease to the pin (A2). Grease : Shell Lenatecs AM Grease or equivalent

(4.65+0.080 in) (0.020~ 0.039 in) (7.48 in)

(5) Installation of Capscrew (A4) •Apply loctite #262. : 19 mm T=11.7 kgf·m(85 lbf•ft)

Fig. 10-9 Installing Stopper Bolts (9)

(6) Re-connect the hydraulic pipings for the adjusting cylinder and hydraulic pump as they had been, and tighten them with the specified torque. Tightening Torque of Joint

Unit:kgf·m(lbf•ft)

(7) Pressurize the hydraulic oil tank, then confrim the smooth operation of adjusting cylinder and travel motor without any leakages.

10.2 MAINTENANCE STANDARDS

Fig. 10-10 Installing Adjustable Crawler Frame Width

Refer to Fig. 10-9

14903 60413247

}

34-23

TRAVEL SYSTEM

Part II: DISASSEMBLING AND ASSEMBLING COMPONENTS TRAVEL MOTOR

1.1 ASSEMBLY DRAWING 1.1.1 Sectional view

14903 60413247

Fig. 1-1

VIEW A Fig. 1-2 Travel motor assembly-Sectional View

34-24

TRAVEL SYSTEM 1.1.2 Developed elevation of reduction unit

14903 60413247

Fig. 1-3 Travel motor reduction unit

34-25

TRAVEL SYSTEM 1.1.3 Developed elevation of hydraulic motor

14903 60413247

Fig. 1-4 Hydraulic Motor

34-26

TRAVEL SYSTEM 1.1.4 Developed elevation of hydraulic valve (body 1 assy)

14903 60413247

Fig. 1-5 Body 1 assy

34-27

TRAVEL SYSTEM

1.2 DISASSEMBLY AND ASSEMBLY 1.2.1 General precautions • Carry out disassembly and assembly on a clean site. Disassembled parts should be kept in a clean tray. • Before proceeding to disassembly, clean surfaces around the ports. Remove remained painting materials from every connecting parts with wire brush. • Wash disassembled parts with washing oil.

• Leave match-marks on the surface of parts so as to reassemble correctly. • Do not reuse sealing parts or snap rings. Replace them with new ones at every disassembly. • Make sure there is no abnormal abrasion or seizure. Remove sharp edges and burrs by sandpaper.

1.2.2 Disassembly (1) Disassembling reduction unit 1-1) Remove the plug (131) from the cover (102) and drain out the lubricating oil. : 8 mm Oil quantity: approx. 330 cc (20 cu·in)

Fig. 1-6 Plug removal

1-2) Put a minus screw driver or the like into the gap on the body (101) to remove the O-snap ring (113). 1-3) Remove the cover (102).

Fig. 1-7 O-snap ring removal

14903 60413247

1-4) Remove the O-ring (130).

Fig. 1-8 O-ring removal

34-28

TRAVEL SYSTEM 1-5) Remove the snap ring (125) from the top of the shaft (203), and then the S2 gear (109).

Fig. 1-9 Snap ring (125) removal

1-6) Remove the carrier II (104) assy.

Fig. 1-10 Removing carrier II (104) assy

1-7) Disassembling carrier II a) Remove the snap ring (137) from the B2 pin (111). b) Remove the thrust washer (121), the B2-gear (107), the needle (117) and the thrust washer (121) one after another. â&#x20AC;˘ Quantity Needle (117) : 13 / B2-gear : 1

c) Remove the snap ring (123), and then the S1 gear (108).

Fig. 1-11 Snap ring (137) removal

14903 60413247

â&#x20AC;˘ The B2 pin is pressed in. Unnecessary disassembly should be avoided.

Fig. 1-12 Snap ring (123) removal

34-29

TRAVEL SYSTEM 1-8) Remove the snap ring (137) from the B1 pin of the body 2 (202), and then the thrust plate (114). â&#x20AC;˘ Quantity of snap ring: 3

Fig. 1-13 Snap ring (137) removal

1-9) Remove the B1 gear (106), the needle (116), the ring (138) and the thrust washer (134) from the B1 pin in sequence. â&#x20AC;˘ Quantity: Ring (138): 3 Thrust washer (134): 3 B1 gear (106): 3 Needle (116): 15/place

Fig. 1-14 B1 gear (106) removal

1-10) Fasten the reduction unit flange and the hydraulic motor flange by a C-clamp or a hydraulic press and then remove the snap ring (122) (See the sketch below).

Fig. 1-15 Snap ring (122) removal

14903 60413247

1-11) Pull out the reduction unit body from the hydraulic motor together with the steel balls with retainer and the inner ring (1 set) of the bearing (120). Remove the bearing (120) from the body (101).

Fig. 1-16 Bearing (120) removal

34-30

TRAVEL SYSTEM 1-12) Remove the seal ring (112) together with the Oring (129) from the body (101).

Fig. 1-17 Seal ring (112) removal

1-13) Remove the steel balls with retainer and the inner ring (1 set) of the bearing (120) from the body 2 (202) of hydraulic motor. 1-14) Remove the floating seal (118) and the O-ring (119).

Fig. 1-18 Bearing (120) removal

(2) Disassembling hydraulic motor and hydraulic valve 2-1) Fix the hydraulic motor by a vice and remove the cap screws (222). • Apply an aluminum sheet or the like between the hydraulic motor and the vice so as to avoid damaging the body 2. : 5 mm

14903 60413247

2-2) Remove the body 1 (301) from the body 2 (202). • Be careful not to allow the valve plate (205) to drop. • Be careful that the drain oil may flow out from the case.

Fig. 1-19 Cap screw (222) removal

2-3) Remove the valve plate (205) and the O-rings (217) and (218) from the body 1 (301). • The spring pin (223) and the bearing (216) are pressed in. Unnecessary disassembly should be avoided.

Fig. 1-20 Body (1) and (2) disassembly

34-31

TRAVEL SYSTEM 2-4) Pull out the cylinder barrel (204) assy from the body 2 (202).

Fig. 1-21 Removing cylinder barrel (204) assy

2-5) Disassembling cylinder barrel assy a) Remove the piston shoe assy (206) and (207). â&#x20AC;˘ The piston (206) and the shoe (207) cannot be disassembled because they are caulked together. b) Remove the shoe holder (208), the barrel holder (209) and the pin (212).

Barrel holder (209)

Cylinder barrel (204)

Shoe holder (208) Pin (212) Shoe (207)

Piston (207) Fig. 1-22 Disassembling cylinder barrel (204) assy

2-6) Remove the snap ring (221) from the cylinder barrel (204), and the retainer (214) and the spring (213) are removed.

Fig. 1-23 Snap ring (221) removal

Snap ring (221) Retainer (214)

Retainer (214)

Cylinder barrel (204)

Fig. 1-24 Cylinder barrel (204) disassembly

34-32

14903 60413247

Spring (213)

TRAVEL SYSTEM 2-7) Remove the swash plate (210) from the body 2 (202).

Fig. 1-25 Swash plate (210) removal

2-8) Remove two balls (220) from the body 2 (202).

Fig. 1-26 Ball (220) removal

2-9) Remove the shaft (203) from the body 2 (202). • Hit the other side lightly with a plastic hammer when the shaft (203) does not come out easily. • Be careful not to damage the oil seal (219) with the shaft. • The bearing (215) is pressed in to the shaft (203). Unnecessary disassembly should be avoided.

Fig. 1-27 Shaft (203) removal

14903 60413247

2-10) Remove the control piston (211) from the body 2 (202). 2-11) Remove the cylindrical pin (224) from the body 2 (202).

Fig. 1-28 Control piston (211) removal

34-33

TRAVEL SYSTEM 2-12) Remove the plugs (312) [both sides], the pins (321) [both sides] and the shuttle spool (306) [one side] from the body 1 (301). : 5 mm 2-13) Remove the plugs (311) with the O-rings (318) [both sides], the spring (309) [one side], and the 2speed spool (305) [one side] from the body 1 (301). : 8 mm

Fig. 1-29 Removing spool (305 and 306)

2-14) Remove the plugs (310) with the O-rings (319) [both sides], the springs (308) [both sides], the rings (314) [both sides] and the spool (302) assy [one side] from the body 1 (301). : 27 mm â&#x20AC;˘ The spool (302) assy cannot be disassembled because screw lock agent is applied on the thread.

14903 60413247

Fig. 1-30 Removing spool (302)

34-34

TRAVEL SYSTEM 1.2.3 Assembly (1) Assembling hydraulic motor and hydraulic valve 1-1) Insert the spool (302) assy [one side], the rings (314) [both sides] and the springs (308) [both sides] into the body 1 (301) in this order, and tighten the plugs (310) [both sides] provided with the O-rings (319). : 27 mm T = 17 ~ 20 kgf·m (123 ~ 145 lbf•ft)

Fig. 1-31 Installing spool (302)

1-2) Insert the 2-speed spool (305) [one side] and the spring (309) [one side] into the body (301), and tighten the plugs (311) [both sides] provided with the O-rings (318). : 8 mm T = 4.7 ~ 5.3 kgf·m (34 ~ 38 lbf•ft) • Do not mistake the position and direction of the spool (305) and the spring (309) (See sectional drawing). 1-3) Insert the shuttle spool (306) [one side] and the pins (321) [both sides] into the body (301), and tighten the plugs (312) [both sides]. : 5 mm T = 0.6 kgf·m (4.3 lbf•ft)

14903 60413247

Fig. 1-32 Installing spool (305) and (306)

34-35

TRAVEL SYSTEM 1-4) Press in the bearing (216) and the spring pin (223) if they are removed from the body (301). 1-5) Install the O-rings (217) and (218).

Fig. 1-33 Installing bearing, O-ring etc.

1-6) Press in the oil seal (219) to the body (202). â&#x20AC;˘ Fill grease between the lips of the oil seals. â&#x20AC;˘ Press in the oil seal in the following direction.

Pressing in direction

Fig. 1-34 Oil seal (219) installation

1-7) Install the cylindrical pin (224) to the body (202).

Fig. 1-35 cylindrical pin (224) installation

14903 60413247

1-8) Press in the bearing (215) to the shaft (203) if it is removed.

Fig. 1-36 Bearing (215) installation

34-36

TRAVEL SYSTEM 1-9) Install the control piston (211) to the body 2 (202).

Fig. 1-37 Control piston (211) installation

1-10) Install the shaft (203) to the body 2 (202).

Fig. 1-38 Shaft (203) installation

1-11) Install two balls (220) to the body 2 (202).

Fig. 1-39 Ball (220) installation

14903 60413247

1-12) Install the swash plate (210) to the body 2 (202).

Fig. 1-40 Swash plate (210) installation

34-37

TRAVEL SYSTEM 1-13) Install the retainer (214), the spring (213) and the retainer (214) to the cylinder barrel (204)in this order, and fix by the snap ring (221).

Snap ring (221) Retainer (214) Spring (213) Retainer (214)

Cylinder barrel (204)

Fig. 1-41 Installing parts to cylinder barrel (204)

Fig. 1-42 Snap ring (221) installation

1-14) Assembling shoe holder (208) Install the piston (206) and the shoe (207) assy to the shoe holder (208) to complete the shoe holder assy.

Fig. 1-43 Shoe holder (208) assembly

14903 60413247

1-15) Assembling cylinder barrel (204) a) Insert three pins (212) to the cylinder barrel (204).

Fig. 1-44 Pin (212) installation

34-38

TRAVEL SYSTEM b)

Install the barrel holder (209).

Shoe holder (208) assy

c) Further install the shoe holder assy (208) to complete the cylinder barrel assy (204).

Fig. 1-45 Cylinder barrel (204) assy

1-16) Insert the cylinder barrel (204) assy into the body 2 (202) till the shoe contacts with the swash plate (210).

Fig. 1-46 Installing cylinder barrel (204) assy

1-17) Install the valve plate (205) to the body 1 (301). • Install so that the copper surface of the valve plate (205) is directed upward [cylinder barrel (204) side]. • Apply hydraulic oil on the slide surface (copper surface) of the valve plate (205). • Apply grease on the reverse side of the valve plate (steel surface) to prevent it from dropping.

Fig. 1-47 Valve plate (205) installation

14903 60413247

1-18) Feed approximately 100 cc (6 cu in) of hydraulic oil to the body 2 (202). 1-19) Combine the bodies 1 (301) and 2 (202).

Fig. 1-48 Combining bodies (202) and (301)

34-39

TRAVEL SYSTEM 1-20) Fasten the bodies 1 (301) and 2 (202) with the capscrews (222). • When clamping the hydraulic motor with a vice, protect the body with an aluminum sheet etc. : 5 mm T = 2.8 ~ 3.1 kgf·m (20 ~ 22 lbf•ft)

Fig. 1-49 Tighten capscrews (222)

(2) Assembling reduction unit 2-1) Install the floating seat (118) and the O-ring (119) to the hydraulic motor body 2 (202). • Apply grease on the O-ring (119) to facilitate the installation.

Fig. 1-50 Floating seat (118) installation

2-2) Install the inner race of the bearing (120) and the steel balls with the retainer to the body 2 (202) in this order. • Do not mistake the direction of the inner race and the retainer when installing (See sectional drawing). • Be careful not to loss steel balls because they may come off from the retainer.

Inner race

Fig. 1-51 Bearing (120) inner race installation

14903 60413247

Retainer

Fig. 1-52 Bearing (120) retainer installation

34-40

TRAVEL SYSTEM 2-3) Insert the seal ring (112) provided with the O-ring (129) to the body (101).

Fig. 1-53 Seal ring (112) installation

2-4) Assemble the hydraulic motor and the body (101). • Fasten with C-clamps or a hydraulic press (See the sketch below).

Fig. 1-54 Body (101) assembly

2-5) Installing bearing (120) a) Install the steel balls with the retainer to the body (101). b) Install the retainer to the body 2 (202). • Do not mistake the direction of the inner race and the retainer when installing (See crosssectional drawing).

Fig. 1-55 Bearing (120) installation

14903 60413247

2-6) Fix the bearing (120) with the snap ring (122). • Adjust preload to the bearing by the thickness of the snap ring (122).

Fig. 1-56 Snap ring (122) installation

34-41

TRAVEL SYSTEM 2-7) Install the thrust washers (134), the ring (138), the needle (116) and the B1 gear (106) to the B1 pin portion of the hydraulic motor in sequence. • Quantity Ring (138): 3 Thrust washer (134): 3 B1 gear (106): 3 Needle (116): 15/place

Fig. 1-57 B1 gear (106) installation

2-8) Install the thrust plate (114) and fix it with the snap ring (137). • Install the thrust plate (114) directing the convex side upward. • Quantity of snap rings: 3 • The snap ring has the right and wrong sides. Install the ring directing the edge side upward (cover side).

Fig. 1-58 Thrust plate (114) fixing

2-9) Assembling carrier II (104) a) Press in the B2 pins (111) if they are removed. b) Insert the S1 gear (108) and fix it with the snap ring (123). • The snap ring has the right and wrong sides. Install the ring directing the edge side upward (cover side). c) Install the thrust washer (121), B2 gear (107), the needle (117) and the thrust washer (121) in sequence. • Quantity Needle (117): 13 / B2 gear: 1 Fix them with the snap ring (137). • The snap ring has the right and wrong sides. Install the ring directing the edge side upward (cover side).

14903 60413247

Fig. 1-59 S1 (108) gear fixing

Fig. 1-60 Snap ring (137) installation

34-42

TRAVEL SYSTEM 2-10) Install the carrier II (104) assy.

Fig. 1-61 Installing carrier II (104)assy

2-11) Install the S2 gear (109) to the shaft (203) and fix with the snap ring (125). â&#x20AC;˘ The snap ring has the right and wrong sides. Install the ring directing the edge side upward (cover side).

Fig. 1-62 S2 gear (109) fixing

2-12) Install the O-ring (130) to the body (101).

14903 60413247

Fig. 1-63 O-ring (101) installation

34-43

TRAVEL SYSTEM 2-14) Feed 330 cc (20 cu·in) of lubricating oil and install the cover (102). • Match the characters "DRAIN" of the cover (102) to the recess of the body (101) to assemble. • Lubricating oil: API Grade CD SAE 30

Recess Fig. 1-64 Cover (102) installation

2-15) Install the O-snap ring (113) and fix the cover (102). • Apply a minus screw driver or the like on the end surface of the snap ring (113) and strike in circumference direction.

Fig. 1-65 O-snap ring (113) installation

2-16) Tighten the two plugs (131). • Firstly tighten the plug at the "DRAIN" characters side, and prevent the cover (102) from rotating by the brim. : 8 mm T = 4.7 ~ 5.2 kgf·m (34 ~ 38 lbf•ft)

14903 60413247

Fig. 1-66 Plug (131) installation

34-44

TRAVEL SYSTEM 1.3 Cautions for HandLing (1) Installation method 1) Mating part of sprocket A Mating part of body B 2) When installing the motor to the machine body and when mounting the sprocket to it, push it in gently utilizing the mounting bolts without striking it with a hammer. 3) Use specified types of the motor mounting and sprocket mounting bolts and tighten them with the specified torque (equivalent to or higher than 10.9 T).

14903 60413247

(2) Piping 1) Two piping ports (PF1/4) are provided. A drain pipe is connected to only one of them, another being plugged. When piping it, use the port at which the casing is filled up with hydraulic oil. Fill in 100 cc (6 cuÂˇin) of hydraulic oil and perform piping. 2) The back pressure of drain (allowable pressure in the hydraulic motor casing) is restricted by the oil seal. Therefore, the allowable working pressure of the drain pipe casing is restricted to 3 kgf/cm2 (43 psi) or less and the surge 10 kgf/cm2 (142 psi) or less. (3) Lubricating oil for gears 1) Use API, Grade CD, SAE30 for lubricating oil (The machine was shipped from the factory with Idemitsu Apolloil Diesel Motive S-330 filled). 2) The gear oil may be any of the recommended brands. Avoid mixing different brands. Use the same brand as much as possible. 3) Oil is filled up at shipping. Replenish oil according to the following steps: (All plugs are sealed with O-rings.) a) Remove the plug at the oil feeding. Note: Be careful that the plug or oil may pop out, due to internal pressure. b) Fill in lubricating oil to LEVEL. c) Tighten the plug. 4) Volume of lubricating oil : 330 cc (20 cuÂˇin) 5) Schedule of changing lubricating oil Initial after 200 hr or two months of operation 2nd and thereafter every 1000hr or one year of operation

Fig. 1-67

OIL FEEDING (DRAIN) PORT PF 3/8

OIL DRAIN (FEEDING) PORT PF 3 / 8

Fig. 1-68

(4) General precautions We recommend the user to prepare a check sheet for lubricating oil. Check oil leakage and loose bolts periodically to prevent trouble.

34-45

TRAVEL SYSTEM

14903 60413247

NOTE:

34-46

SECTION 42

TROUBLESHOOTING (HYDRAULIC SYSTEM)

TABLE OF CONTENTS 1. General precautions ............................................................................................. 42-1 1.1 Confirm actual troubled conditions at site ...................................................................................... 42-1

2. Trouble diagnosis: hydraulic ................................................................................... 42-2

14903 60413247

3. Troubleshooting ..................................................................................................... 42-3

TROUBLESHOOTING (HYDRAULIC SYSTEM)

1. GENERAL PRECAUTIONS Troubleshooting provides the process to investigate the cause of trouble in order when a trouble occurred. This manual describes the way how to solve the specific phenomenon systematically as quick as possible. For the troubleshooting concerning the inside of equipment, refer to the troubleshooting for each manual of the equipment.

Make field investigation.

1.1 CONFIRM ACTUAL TROUBLED CONDITIONS AT SITE (1) Get to the site as quickly as possible. Verify the machine model, serial number, situation of trouble and field, and notify possible arrival time to the user. (2) Verify background of trouble occurred. 1) Model name and serial number. 2) Kind of attachment. Check that the combination of attachments was proper and that the operating manner was not unreasonable. 3) Operating time on the hour-meter. 4) Record of troubles. First trouble or repeated trouble. 5) History of the trouble and additional modifications. Reoccurrence of the same trouble in the past or trouble due to additional modification. (3) 1) 2) 3)

14903 60413247

How to diagnose trouble Verify defective part. Reproduce the troubled conditions. Where the defective part can not be verified, surmise the possible causes systematically. 4) Verify the surmised cause. 5) Report estimated repairing method, procedures and term to the user.

Verifying background of trouble occurred.

(4) Explanation of the cause of trouble 1) Explain the cause of trouble to the user. For example, explain the oil leakage through the piston is caused by defect on the piston rod. And the proper operating manner of the machine should be explained to the user to prevent reoccurrence of the same kind of trouble.

Diagnosing trouble by means troubleshooting.

Handling of damaged parts The damaged parts to be claimed and returned are the evidence, so they should be handled with care. For example, protect them from invasion of water, soil, etc., into ports on a hydraulic equipment, etc., at the returning them. And also use care not to give any damages and breakage for transport.

42-1

TROUBLESHOOTING (HYDRAULIC SYSTEM)

TROUBLE DIAGNOSIS: HYDRAULIC

14903 60413247

42-2

TROUBLESHOOTING (HYDRAULIC SYSTEM)

TROUBLESHOOTING

14903 60413247

42-3

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-4

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-5

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-6

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-7

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-8

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-9

14903 60413247

TROUBLESHOOTING (HYDRAULIC SYSTEM)

42-10

SECTION 43

TROUBLESHOOTING (ELECTRICAL SYSTEM)

TABLE OF CONTENTS 1. Trouble diagnosis: electrical system ...................................................................... 43-1

14903 60413247

2. Troubleshooting ..................................................................................................... 43-2

TROUBLESHOOTING (ELECTRICAL SYSTEM)

14903 60413247

TROUBLE DIAGNOSIS: ELECTRICAL SYSTEM

NOTE: Indication of wire color in the following pages to be. XXX / YYY ; XXX shows base color of wire. YYY shows narrow line color of wire.

43-1

TROUBLESHOOTING (ELECTRICAL SYSTEM)

TROUBLESHOOTING

14903 60413247

1-(1)

43-2

TROUBLESHOOTING (ELECTRICAL SYSTEM)

14903 60413247

1-(2)

43-3

TROUBLESHOOTING (ELECTRICAL SYSTEM)

14903 60413247

1-(4)

43-4

TROUBLESHOOTING (ELECTRICAL SYSTEM)

14903 60413247

2-(1) 3-(1)

43-5

TROUBLESHOOTING (ELECTRICAL SYSTEM)

14903 60413247

3-(2)

43-6

SECTION 44

TROUBLESHOOTING (ENGINE)

TABLE OF CONTENTS 1. Trouble diagnosis: engine ...................................................................................... 44-1

14903 60413247

2. Troubleshooting ..................................................................................................... 44-2

TROUBLESHOOTING (ENGINE)

TROUBLE DIAGNOSIS: ENGINE

14903 60413247

44-1

TROUBLESHOOTING (ENGINE)

TROUBLESHOOTING

14903 60413247

44-2

TROUBLESHOOTING (ENGINE) 1-(2)

14903 60413247

NOTE: Check with the engine start key held in ON position.

44-3

TROUBLESHOOTING (ENGINE)

14903 60413247

NOTE: Check the above items in the condition of coolant temperature at 50 ± 5°C (122 ± 9°F).

44-4

TROUBLESHOOTING (ENGINE)

14903 60413247

3-(1)

NOTE: Check the above items in the condition of coolant temperature at 50 ± 5°C (122 ± 9°F). 44-5

TROUBLESHOOTING (ENGINE)

NOTE: Check the above items in the condition of coolant temperature at 50 ± 5°C (122 ± 9°F).

14903 60413247

NOTE: Check in the condition of no engine oil leankage.

NOTE: Check in the condition to proper fuel is used. 44-6

TROUBLESHOOTING (ENGINE)

14903 60413247

NOTE: Check with the engine start key held in OFF position.

44-7

TROUBLESHOOTING (ENGINE)

14903 60413247

NOTES

44-8

SECTION 51

ENGINE

TABLE OF CONTENTS 1. SPECIFICATIONS AND PERFORMANCE ....................................................... 51-1 1.1 2TNE68 ......................................................................................................................................... 51-1 1.2 3TNE68 ........................................................................................................................................ 51-2 1.3 3TNE74 ........................................................................................................................................ 51-3 1.4 3TNE78A ...................................................................................................................................... 51-4 1.5 3TNE82A ...................................................................................................................................... 51-5 1.6 3TNE82 ........................................................................................................................................ 51-6 1.7 3TNE84 ........................................................................................................................................ 51-7 1.8 3TNE88 ........................................................................................................................................ 51-8 1.9 4TNE82 ........................................................................................................................................ 51-9 1.10 4TNE84 ...................................................................................................................................... 51-10 1.11 4TNE88 ...................................................................................................................................... 51-11 1.12 3TNE84T .................................................................................................................................... 51-12 1.13 4TNE84T .................................................................................................................................... 51-13

2. CROSS SECTIONAL VIEWS ............................................................................. 51-15 2.1 SPECIAL SWIRL PRECOMBUSTION CHAMBER SYSTEM ...................................................... 51-15 2.2 DIRECT INJECTION SYSTEM .................................................................................................... 51-16

3. COOLING WATER, LUBRICATING OIL AND FUEL OIL .................................. 51-17 3.1 COOLING WATER ....................................................................................................................... 51-17 3.2 LUBRICATING OIL ....................................................................................................................... 51-17 3.3 FUEL OIL ..................................................................................................................................... 51-19

4. TROUBLESHOOTING ........................................................................................ 51-21 4.1 TROUBLE CAUSES AND REMEDIES ........................................................................................ 51-21 4.2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE ......... 51-23

14903 60413247

5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS .................... 51-25 5.1 SPECIAL SERVICE TOOLS ........................................................................................................ 51-25 5.2 MEASURING INSTRUMENTS..................................................................................................... 51-27

6. MEASUREMENT, INSPECTION AND ADJUSTMENT ...................................... 51-31 6.1 MEASURING THE COMPRESSION PRESSURE ....................................................................... 51-31 6.2 ADJUSTMENT THE VALVE HEAD CLEARANCE ....................................................................... 51-33 6.3 CHECKING THE V-BELT TENSION ............................................................................................. 51-34

INDEX 6.4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE ............................................................................................................. 51-34 6.5 CHECKING AND ADJUSTAMENT THE FUEL INJECTION TIMING ........................................... 51-38 6.6 ADJUSTAMENT THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS ........................... 51-40 6.7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR WATER LEAKAGE ........ 51-40 6.8 CHECKING THE BATTERY ......................................................................................................... 51-41 6.9 CHECKING THE SENSORS........................................................................................................ 51-43 6.10 CHECKING THE OIL COOLER ................................................................................................. 51-44 6.11 CHECKING THE PISTON COOLING NOZZLE ......................................................................... 51-45

7. MEASURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION ... 51-47 7.1 CYLINDER HEAD ........................................................................................................................ 51-47 7.2 CYLINDER BLOCK ...................................................................................................................... 51-53 7.3 VALVE ROCKER ARM ................................................................................................................. 51-56 7.4 PISTON AND PISTON RING ....................................................................................................... 51-58 7.5 CONNECTING ROD .................................................................................................................... 51-63 7.6 CAMSHAFT ................................................................................................................................. 51-66 7.7 CRANKSHAFT ............................................................................................................................. 51-68 7.8 GEARS ......................................................................................................................................... 51-71 7.9 TROCHOID PUMP ....................................................................................................................... 51-73

8. DISASSEMBLY AND REASSEMBLY ................................................................. 51-75 8.1 DISASSEMBLY ............................................................................................................................ 51-75 8.2 PRECAUTIONS BEFORE AND DURING REASSEMBLY ........................................................... 51-80

9. SERVICE DATA ................................................................................................. 51-85 9.1 CYLINDER HEAD ...................................................................................................................... 51-85 9.2 CYLINDER BLOCK .................................................................................................................... 51-86 9.3 VALVE ROCKER ARM ............................................................................................................... 51-86 9.4 PISTON ...................................................................................................................................... 51-87 9.5 PISTON RING ............................................................................................................................ 51-88 9.6 CONNECTING ROD .................................................................................................................. 51-89 9.7 CAMSHAFT ............................................................................................................................... 51-89 9.8 CRANKSHAFT ........................................................................................................................... 51-89 9.9 SIDE GAP AND BACKLASH ..................................................................................................... 51-90 9.10 OTHERS ................................................................................................................................... 51-90

10. TIGHTENING TORQUE ................................................................................... 51-91 10.1 MAIN BOLT/NUT ........................................................................................................................ 51-91 10.2 STANDARD BOLT AND NUT ..................................................................................................... 51-91

11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM .................. 51-93 11.1 EXPLODED VIEW (YPFR TYPE) .............................................................................................. 51-93 11.2 DISASSEMBLY .......................................................................................................................... 51-94 11.3 INSPECTION ............................................................................................................................. 51-95 11.4 REASSEMBLY ........................................................................................................................... 51-97

12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM ...................... 51-99 12.1 EXPLODED VIEW (YPES TYPE) .............................................................................................. 51-99 12.2 SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY ................................ 51-100 12.3 DISASSEMBLY ........................................................................................................................ 51-101 12.4 INSPECTION ........................................................................................................................... 51-105 12.5 REASSEMBLY ......................................................................................................................... 51-107 13.1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM ....................... 51-113 13.2 EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM ........................... 51-114 13.3 DISASSEMBLY ........................................................................................................................ 51-115 13.4 INSPECTION ........................................................................................................................... 51-119 13.5 REASSEMBLY ......................................................................................................................... 51-121

14. TURBOCHARGER .......................................................................................... 51-125 14.1 SPECIFICATIONS .................................................................................................................... 51-125 14.2 CONSTRUCTION .................................................................................................................... 51-125

06902 60413249

13. GOVERNOR ................................................................................................... 51-113

INDEX 14.3 WASTE GATE VALVE ADJUSTING METHOD ........................................................................ 51-127 14.4 EXPLODED VIEW OF TURBOCHARGER (W/WASTE GATE) ............................................... 51-129

15. SERVICE INFORMATION FOR CARB ULG REGULATION ........................... 51-131

06902 60413249

15.1 EMISSION CONTROL LABEL ................................................................................................. 51-131 15.2 LIMITING THE HIGH IDLE AND LOW IDLE ADJUSTMENT SCREW .................................... 51-136 15.3 LIMITING THE FUEL VOLUME LIMITER SCREW .................................................................. 51-137

14903 60413247

INDEX

SPECIFICATIONS AND PERFORMANCE

SPECIFICATIONS AND PERFORMANCE *

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

1.1 2TNE68

SPECIFICATIONS

Model 2TNE68 Item Unit VM CH VH Application — Vertical, 4-cycle water-cooled diesel engine Type — Special swirl pre-combustion chamber Combustion system — 2 – 68 X 72 No. of cylinders – Bore X Stroke mm 0.523 Displacement C° 1–2 Firing order — 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 Revolution speed rpm Continuous — — — — — — 7.72 9.12 — — — kW(HP) (10.5) (12.4) rating Output* 5.74 6.25 6.84 7.43 7.94 8.46 8.46 10.0 8.68 9.19 9.64 Max. rating kW(HP) (7.8) (8.5) (9.3) (10.1) (10.8) (11.5) (11.5) (13.6) (11.8) (12.5) (13.1) Max. revolution speed at +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 2180 0 2375 0 2570 0 2780 0 2970 0 3180 0 3180 0 3780 0 3425 0 3640 0 3850 0 no load rpm Min. revolution speed at ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 23.0 Fuel injection timing 14±1 16±1 deg (FID, b.T.D.C.) Compression pressure MPa 3.24±0.1 (33±1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 11.8 0 (120 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C° 1.6/0.6 2.3/1.0 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity 0.6 (for engine only) Cooling fan mm Discharge type, 5 X Ø290 No. of blade X dia. Crank V-pulley dia./ mm Ø95/Ø85 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 373.5 X 417 X 540 / 373.5 X 417 X 498 / 383.5 X 417 X 498 383.5 X 409 X 540 mm *1 Dimensions L X W X H 383.5 X 417 X 540

PERFORMANCE

14903 60413247

*1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

55 / 65

≤12

≤10

≤12

≤5

≤7

≤20

≤30

Recovery time

sec

Fluctuation of revolution

rpm

Rated operation

MPa (kgf/cm2)

≤9

≤8

≤7

≤6 ≤6

≤30 0.25±0.05 (2.5±0.5)

0.29±0.05 (3.0±0.5)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

51-1

SPECIFICATIONS AND PERFORMANCE

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

1.2 3TNE68

SPECIFICATIONS

Model 3TNE68 Item Unit VM CH VH Application — Vertical, 4-cycle water-cooled diesel engine Type — Special swirl pre-combustion chamber Combustion system — 3 – 68 X 72 No. of cylinders – Bore X Stroke mm 0.784 Displacement C˚ 1–3–2–1 Firing order — 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 Revolution speed rpm Continuous — — — — — — 11.7 13.7 — — — kW(HP) (15.7) (18.4) rating * Output 8.6 9.4 10.3 11.2 12.0 12.9 12.9 15.1 13.1 13.8 14.5 Max. rating kW(HP) (11.5) (12.6) (13.8) (15.0) (16.1) (17.3) (17.3) (20.2) (17.6) (18.5) (19.4) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 2180 0 2375 0 2570 0 2780 0 2970 0 3180 0 3180 0 3780 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 23.0 Fuel injection timing 14±1 16±1 deg (FID, b.T.D.C.) Compression pressure MPa 3.24±0.1 (33±1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 11.8 0 (120 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 2.4/1.0 3.0/1.0 Max/Effective — Recommended lubricating oil API grade CC class or higher — Cooling system Liquid cooling/Radiator C˚ Cooling water capacity 0.9 (for engine only) Cooling fan mm Pusher type, 5 X Ø310 No. of blade X dia. Crank V-pulley dia./ mm Ø105/Ø85 Fan V-pulley dia. — Governor Mechanical centrifugal governor (All speed type) — Starting system Electrical 463.5 X 401 X496/ mm 463.5 X 401 X 496 / 473.5 X 401 X 496 473.5 X 401 X 496 *1 Dimensions L X W X H 473.5 X 401 X 496

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

70 / 81

≤12

≤10

≤12

≤5

≤8

≤20

≤30

Recovery time

sec

Fluctuation of revolution

rpm

Rated operation

MPa (kgf/cm2)

≤9

≤8

≤7

≤6 ≤30 0.25±0.05 (2.5±0.5)

0.29±0.05 (3.0±0.5)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -2

≤6

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

14903 60413247

PERFORMANCE

*1 Dry weight

SPECIFICATIONS AND PERFORMANCE

1.3 3TNE74

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 3TNE74 Item Unit VM CH VH Application — Vertical, 4-cycle water-cooled diesel engine Type — Special swirl pre-combustion chamber Combustion system — 3 – 74 X 78 No. of cylinders – Bore X Stroke mm 1.006 C˚ Displacement 1–3–2–1 — Firing order 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Revolution speed Continuous — — — — — — 15.1 17.4 — — — kW(HP) (20.2) (23.3) rating * Output 11.0 12.1 13.2 14.3 15.5 16.6 16.6 19.1 16.6 17.1 17.7 kW(HP) Max. rating (14.8) (16.2) (17.7) (19.2) (20.8) (22.3) (22.3) (25.6) (22.3) (22.9) (23.7) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 2180 0 2375 0 2570 0 2780 0 2970 0 3180 0 3180 0 3780 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 23.0 Fuel injection timing deg 14±1 16±1 (FID, b.T.D.C.) Compression pressure MPa 3.43±0.1 (35±1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 11.8 0 (120 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.: 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 2.4/1.0 3.3/1.4 Max/Effective — Recommended lubricating oil API grade CC class or higher Cooling system Liquid cooling/Radiator — Cooling water capacity 0.9 (for engine only) C˚ Cooling fan Pusher type, 5 X Ø310 Pusher type, 6 X Ø335 mm No. of blade X dia. Crank V-pulley dia./ mm Ø110/Ø85 Ø110/Ø97 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 469.1 X 440 X 502/ 469.1 X 440 X 502 / 476.6 X 440 X 502 476.6 X 440 X 502 mm *1 Dimensions L X W X H 476.6 X 440 X 502

PERFORMANCE

14903 60413247

*1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

85 /102

100

85 / 100

≤12

≤10

≤12

≤5

≤8

≤20

≤30

Recovery time

sec

Fluctuation of revolution

rpm

Rated operation

MPa (kgf/cm2)

≤9

≤8

≤7

≤6 ≤6

≤30 0.25±0.05 (2.5±0.5)

0.29±0.05 (3.0±0.5)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

51-3

SPECIFICATIONS AND PERFORMANCE

1.4 3TNE78A

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 3TNE78A Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 3 – 78 X 84 No. of cylinders – Bore X Stroke mm 1.204 Displacement C˚ 1–3–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm 9.1 10.8 — Continuous — — — — — 18.0 21.0 — — — kW(HP) (12.2) (14.5) (24.1) (28.2) rating * Output 9.9 11.9 13.2 14.6 15.9 17.2 18.5 19.9 19.9 23.2 20.5 21.6 23.2 Max. rating kW(HP) (13.3) (16.0) (17.7) (19.6) (21.3) (23.1) (24.8) (26.7) (26.7) (31.1) (27.5) (29.0) (31.1) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1575 0 1870 0 2180 0 2375 0 2570 0 2780 0 2970 0 3180 0 3150 0 3745 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤1200 ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1 deg (FID, b.T.D.C.) Compression pressure MPa 3.14±0.1 (32±1), at 250 rpm (kgf/cm2) Fuel injection pressure +1.0 +10 MPa 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No.: 45 min.) — Lubrication system Forced lubrication with trochoid pump Lubricating oil capacity 3.6/1.3 5.0/1.7 C˚ Max/Effective — Recommended lubricating oil API grade CC class or higher — Cooling system Liquid cooling/Radiator C˚ Cooling water capacity 1.8 (for engine only) Cooling fan mm Pusher type, 6 X Ø335 No. of blade X dia. Crank V-pulley dia./ mm Ø120/Ø90 Ø110/Ø110 Fan V-pulley dia. — Governor Mechanical centrifugal governor (All speed type) — Starting system Electrical 520.5 X 489 X 565/ mm *1 Dimensions L X W X H 553X489X565 520.5 X 489 X 565 / 528 X 489 X 565 528 X 489 X 565 528 X 489 X 565

Governing performance (full speed range)

L.O. press.

kg Transient speed difference Steady state speed band

138

112/128

≤10

≤8

≤5

≤4

≤12 ≤9

≤8

≤7

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

MPa (kgf/cm2)

51 -4

≤6

≤10

≤8

≤12

≤5

≤4

≤8

≤5

≤6 ≤30

0.29±0.05 (3.0±0.5)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

112 / 124

124

≥0.06 (≥0.6)

0.34±0.05 (3.5±0.5)

14903 60413247

PERFORMANCE

*1 Dry weight

SPECIFICATIONS AND PERFORMANCE

1.5 3TNE82A

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model Item Unit Application — Type — Combustion system — mm No. of cylinders – Bore X Stroke C˚ Displacement — Firing order rpm Revolution speed Continuous kW(HP) rating * Output kW(HP) Max. rating Max. revolution speed at no load Min. revolution speed at no load Direction of rotation Power take off Compression ratio Fuel injection timing (FID, b.T.D.C.) Compression pressure Fuel injection pressure Recommended diesel gas oil Lubrication system Lubricating oil capacity Max/Effective Recommended lubricating oil Cooling system Cooling water capacity Cooling fan No. of blade X dia. Crank V-pulley dia./ Fan V-pulley dia. Governor Starting system ]1 Dimensions L X W X H

PERFORMANCE

14903 60413247

]1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

3TNE82A CL

1500 9.9 (13.3) 11.0 (14.8) +50 0

1575

VM Vertical, 4-cycle water-cooled diesel engine Direct injection system 3 – 82 X 84 1.330 1–3–2–1 1800 2000 2200 2400 2600 2800 12.0 — — — — — (16.1) 13.2 14.6 16.0 17.5 19.0 20.5 (17.7) (19.6) (21.5) (23.5) (25.5) (27.5)

1870

+50 0

2180

+50 0

2375

+50 0

2570

+50 0

2780

2970

— 21.9 (29.4)

+50 0

3180

+50 0

rpm ≤1200

≤800

— — —

Counterclockwise (viewed from flywheel) Flywheel 18.0

deg

10±1

MPa (kgf/cm2) MPa (kgf/cm2) — — C˚

12±1

14±1

19.6

+1.0 0

(200

+10 0

)

ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Forced lubrication with trochoid pump 3.6/1.3

5.0/1.7

— — C˚

API grade CC class or higher Liquid cooling/Radiator 1.8 (for engine only)

Pusher type, 6 X Ø335

16±1

3.04±0.1 (31±1), at 250 rpm

Ø120/f90

— —

Ø110/Ø110

Mechanical centrifugal governor (All speed type) Electrical

553 X 489 X 565

520.5 X 489 X 565 / 528 X 489 X 565

138

112/128

≤10

≤8

≤5

≤4

≤12 ≤9

≤8

≤7

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

+50 0

3000

0.25 ± 0.05

MPa (2.5 ± 0.5) (kgf/cm2)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

≤6

0.29±0.05 (3.0±0.5) ≥0.06 (≥0.6)

51-5

SPECIFICATIONS AND PERFORMANCE

1.6 3TNE82

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 3TNE82 Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 3 – 82 X 90 No. of cylinders – Bore X Stroke mm 1.425 Displacement C˚ 1–3–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Continuous 10.5 12.7 — — — — — — 21.0 24.4 — — — kW(HP) rating (14.1) (17.0) (28.2) (32.7) * Output 11.6 14.0 15.5 16.9 18.4 19.9 21.3 23.2 23.2 26.9 24.4 25.6 26.9 Max. rating kW(HP) (15.6) (18.8) (20.8) (22.7) (24.7) (26.7) (28.6) (31.1) (31.1) (36.1) (32.7) (34.3) (36.1) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1570 0 1870 0 2160 0 2375 0 2570 0 2780 0 2970 0 3180 0 3150 0 3745 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤1200 ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1 deg (FID, b.T.D.C.) Compression pressure MPa 3.04 ± 0.1 (31 ± 1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 4.7/1.8 6.9/2.1 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.0 (for engine only) Cooling fan mm Pusher type, 6 X Ø335 No. of blade X dia. Crank V-pulley dia./ mm Ø120/Ø90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 556 X 486 X 623 / mm *1 Dimensions L X W X H 589X486X623 556 X 486 X 623 / 564 X 486 X 623 564 X 486 X 623 564 X 486 X 623

PERFORMANCE

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

161

138/155

≤10

≤8

≤5

≤4

≤12 ≤8

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -6

≤7

Recovery time

Rated operation

149

≤6

138/149

≤10

≤8

≤12

≤5

≤4

≤8

≤5

≤6 ≤30

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

14903 60413247

*1 Dry weight

SPECIFICATIONS AND PERFORMANCE

1.7 3TNE84

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 3TNE84 Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 3 – 84 X 90 No. of cylinders – Bore X Stroke mm 1.496 Displacement C˚ 1–3–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Continuous 11.3 13.5 — — — — — — 22.4 26.1 — — — kW(HP) rating (15.2) (18.1) (30.0) (35.0) * Output 12.4 14.8 16.4 18.1 19.7 21.3 23.0 24.6 24.6 28.7 25.6 27.0 28.3 Max. rating kW(HP) (16.6) (19.8) (22.0) (24.3) (26.4) (28.6) (30.8) (33.0) (33.0) (38.5) (34.3) (36.2) (38.0) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1600 0 1900 0 2175 0 2375 0 2600 0 2800 0 3000 0 3225 0 3200 0 3800 0 3455 0 3670 0 3870 0 no load rpm Min. revolution speed at ≤1200 ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1 deg (FID, b.T.D.C.) Compression pressure MPa 3.24 ± 0.1 (33 ± 1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 4.7/1.8 6.9/2.1 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.0 (for engine only) Cooling fan mm Pusher type, 6 X Ø335 No. of blade ¥ dia. Crank V-pulley dia./ mm Ø120/Ø90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 556 X 486 X 623/ 564 X 486 X 623 564 X 486 X 623 mm ]1 Dimensions L X W X H 589X486X623 556 ¥X 486 X 623 / 564 X 486 X 623 kg

PERFORMANCE

14903 60413247

]1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

161

138/155

≤10

≤8

≤5

≤4

≤12 ≤9

≤8

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

149

≤7

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

138 / 149

≤10

≤8

≤12

≤5

≤4

≤8

≤5

≤6 ≤30 0.39±0.05 (4.0±0.5)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51-7

SPECIFICATIONS AND PERFORMANCE

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

PERFORMANCE

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

1500 12.3 (16.5) 13.5 (18.1) 1600

+50 0

VM Vertical, 4-cycle water-cooled diesel engine Direct injection system 3 – 88 X 90 1.642 1–3–2–1 1800 2000 2200 2400 2600 2800 14.8 — — — — — (19.8) 16.3 18.0 19.9 21.6 23.5 25.2 (21.9) (24.1) (26.7) (29.0) (31.5) (33.8)

1900

+50 0

2175

+50 0

2600

≤1200

+50 0

2800

— — —

3000

27.1 (36.3)

+50 0

3225

+50 0

Counterclockwise (viewed from flywheel) Flywheel 18.0

deg

10±1

MPa (kgf/cm2) MPa (kgf/cm2) — —

12±1

14±1

19.6

+1.0 0

(200

+10 0

)

ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Forced lubrication with trochoid pump

C˚

4.7/1.8

6.9/2.1

— — C˚

API grade CC class or higher Liquid cooling/Radiator 2.0 (for engine only)

Pusher type, 6 X Ø335

Ø120/Ø90

— — mm

16±1

3.43 ± 0.1 (35 ± 1), at 250 rpm

Ø110/Ø110

Mechanical centrifugal governor (All speed type) Electrical 589 X 486 X 623

556 X 486 X 623 / 564 X 486 X 623

161

138/155

≤10

≤8

≤5

≤4

≤12 ≤9

≤8

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

+50 0

—

≤800

0.29 ± 0.05

MPa (3.0 ± 0.5) (kgf/cm2)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -8

2375

3000

rpm

*1 Dry weight

3TNE88

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

≤7

14903 60413247

1.8 3TNE88

SPECIFICATIONS AND PERFORMANCE

1.9 4TNE82

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 4TNE82 Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 4 – 82 X 90 No. of cylinders – Bore X Stroke mm 1.901 Displacement C˚ 1–3–4–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Continuous 14.3 17.1 — — — — — — 27.7 32.7 — — — kW(HP) rating (19.2) (22.9) (37.1) (43.9) * Output 15.7 18.8 20.6 22.6 24.5 26.5 28.5 30.5 30.5 36.0 32.4 34.2 36.0 Max. rating kW(HP) (21.1) (25.2) (27.6) (30.3) (32.9) (35.5) (38.2) (40.9) (40.9) (48.3) (43.4) (45.9) (48.3) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1575 0 1870 0 2160 0 2375 0 2570 0 2780 0 2970 0 3180 0 3150 0 3745 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤1200 ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1 (FID, b.T.D.C.) Compression pressure MPa 3.04±0.1 (31±1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 5.8/2.3 7.9/2.5 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.7 (for engine only) Cooling fan mm Pusher type, 6 X Ø370 No. of blade X dia. Crank V-pulley dia./ mm Ø120/Ø90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 658 X 498.5 650 X 498.5 X 618 / 683 X 498.5 mm *1 Dimensions L X W X H 632 X 448.5 X 618 / 658 X 498.5 X 618 X 618 658 S 498 X 618 X 618 kg

PERFORMANCE

14903 60413247

*1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

184

160/170

≤10

≤8

≤5

≤4

≤12 ≤8

≤7

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

170

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

≤6

160/170

≤10

≤8

≤12

≤5

≤4

≤8

≤5

≤6 ≤30

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

51-9

SPECIFICATIONS AND PERFORMANCE

1.10 4TNE84

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model 4TNE84 Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 4 – 84 X 90 No. of cylinders – Bore X Stroke mm 1.995 Displacement C˚ 1–3–4–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Continuous 14.9 17.7 — — — — — — 29.9 34.7 — — — kW(HP) rating (20.0) (23.7) (40.1) (46.5) * Output 16.4 19.5 21.9 24.1 26.3 28.5 30.7 32.9 32.9 38.2 33.9 35.8 38.2 Max. rating kW(HP) (22.0) (26.1) (29.4) (32.3) (35.3) (38.2) (41.2) (44.1) (44.1) (51.2) (45.5) (48.0) (51.2) +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1575 0 1870 0 2180 0 2400 0 2590 0 2810 0 2995 0 3210 0 3150 0 3745 0 3455 0 3670 0 3890 0 no load rpm Min. revolution speed at ≤1200 ≤800 ≤1500 ≤800 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing deg 10±1 12±1 14±1 16±1 24±1 18±1 20±1 24±1 (FID, b.T.D.C.) Compression pressure MPa 3.24±0.1 (33±1), at 250 rpm (kgf/cm2) Fuel injection pressure +1.0 +10 +1.0 +10 MPa 19.6 0 (200 0 ) 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 5.8/2.3 7.9/2.5 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.7 (for engine only) Cooling fan mm Pusher type, 6 X Ø370 No. of blade X dia. Crank V-pulley dia./ mm Ø120/Ø90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 658 X 498.5 650 X 498.5 X618/ 683 X 498.5 mm *1 Dimensions L X W X H 632 X 498.5 X 618/658 X 498.5 X 618 658 X 498.5 X 618 X 618 X 618

Governing performance (full speed range)

L.O. press.

kg Transient speed difference Steady state speed band

184

≤10

≤8

≤5

≤4

160/170 ≤12 ≤9

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -10

≤8

160 / 170

170

≤7

≤10

≤8

≤12

≤5

≤4

≤8

≤5

≤6 ≤30

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

14903 60413247

PERFORMANCE

*1 Dry weight

SPECIFICATIONS AND PERFORMANCE

1.11 4TNE88

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in.

SPECIFICATIONS

Model Item Unit — Application — Type Combustion system — mm No. of cylinders – Bore X Stroke C˚ Displacement — Firing order Revolution speed rpm Continuous kW(HP) rating Output* kW(HP) Max. rating Max. revolution speed at no load Min. revolution speed at no load Direction of rotation Power take off Compression ratio Fuel injection timing (FID, b.T.D.C.) Compression pressure Fuel injection pressure Recommended diesel gas oil Lubrication system Lubricating oil capacity Max/Effective Recommended lubricating oil Cooling system Cooling water capacity Cooling fan No. of blade ¥ dia. Crank V-pulley dia./ Fan V-pulley dia. Governor Starting system *1 Dimensions L X W X H

PERFORMANCE

14903 60413247

*1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

4TNE88 CL

1500 16.4 (22.0) 18.0 (24.1) 1575

+50 0

VM Vertical, 4-cycle water-cooled diesel engine Direct injection system 4 – 88 X 90 2.189 1–3–4–2–1 1800 2000 2200 2400 2600 2800 19.6 — — — — — (26.3) 21.6 24.1 26.5 28.8 31.3 33.7 (29.0) (32.3) (35.5) (38.6) (42.0) (45.2)

1870

+50 0

2180

+50 0

2400

+50 0

2590

+50 0

2810

2995

— 36.0 (48.3)

+50 0

3210

+50 0

rpm ≤1200

≤800

— — —

Counterclockwise (viewed from flywheel) Flywheel 18.0

deg

10±1

MPa (kgf/cm2) MPa (kgf/cm2) — —

12±1

14±1

19.6

+1.0 0

(200

+10 0

)

19.6

+1.0 0

(200

+10 0)

ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Forced lubrication with trochoid pump

C˚

5.8/2.3

7.9/2.5

— — C˚

API grade CC class or higher Liquid cooling/Radiator 2.7 (for engine only)

Pusher type, 6 X Ø370

16±1

3.43±0.1 (35±1), at 250 rpm

Ø120/Ø90

— —

Ø110/Ø110

Mechanical centrifugal governor (All speed type) Electrical

683 X 498.5 X 618

632 X 498.5 X 618 / 658 X 498.5 X 618

184

160 /170

≤10

≤8

≤5

≤4

≤12 ≤9

≤8

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤25

Rated operation

+50 0

3000

0.29 ± 0.05

MPa (3.0 ± 0.5) (kgf/cm2)

Idling *1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

≤7

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

51-11

SPECIFICATIONS AND PERFORMANCE

1.12 3TNE84T

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in. Model Unit — — — mm C˚ — rpm

3600 — 34.2 (45.9)

SPECIFICATIONS

3TNE84T Item Application CL VM CH VH Type Vertical, 4-cycle water-cooled diesel engine Combustion system Direct injection system 3 – 84 X 90 No. of cylinders – Bore X Stroke 1.496 Displacement Firing order 1–3–2–1 Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 Continuous 14.0 16.6 — — — — — — 28.0 30.5 — — kW(HP) rating (18.8) (22.3) (37.5) (40.9) * Output 15.8 18.8 21.0 22.8 25.0 26.9 29.1 30.9 30.9 34.2 32.0 33.1 Max. rating kW(HP) (21.2) (25.2) (28.2) (30.6) (33.5) (36.1) (39.0) (41.4) (41.4) (45.9) (42.9) (44.4) Max. revolution speed at +50 +50 +50 +50 +50 +50 +50 +50 1600 0 1900 0 2175 0 2375 0 2600 0 2800 0 3020 0 3240 0 no load rpm +50 +50 Min. revolution speed at 1200 0 ≤800 0 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing deg 10±1 12±1 14±1 16±1 (FID, b.T.D.C.) Compression pressure MPa 2.94 ± 0.1 (30 ± 1), at 250 rpm (kgf/cm2) +1.0 +10 Fuel injection pressure MPa 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 4.8 / 1.9 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.0 (for engine only) Cooling fan mm Pusher type, 6 X Ø335 No. of blade X dia. Crank V-pulley dia./ mm Ø110/Ø90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical

PERFORMANCE

*1 Dry weight

Governing performance (full speed range)

L.O. press.

Transient speed difference Steady state speed band

589X54.0X629

632 X 540 X 629 / 632 X 540 X 629

166

147/160

≤10

≤8

≤5

≤4

≤12 ≤9

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤22

Rated operation Idling

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

*1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -12

≤8

0.34±0.05(3.5±0.5) ≥0.06 (≥0.6)

14903 60413247

*1 Dimensions L X W X H

SPECIFICATIONS AND PERFORMANCE

Output conditions : Intake back pressure ≤ 250 mmAq, Exhaust back pressure ≤ 550 mmAq, other conditions complying with JIS D 1005–1986. After minimum 30 hour’s run-in. Model 4TNE84T Item Unit Application CL VM CH VH — Type Vertical, 4-cycle water-cooled diesel engine — Combustion system Direct injection system — 4 – 84 X 90 No. of cylinders – Bore X Stroke mm 1.995 Displacement C˚ 1–3–4–2–1 Firing order — Revolution speed 1500 1800 2000 2200 2400 2600 2800 3000 3000 3600 3200 3400 3600 rpm Continuous 19.1 24.3 — — — — — — 37.1 40.8 — — — kW(HP) rating (25.6) (32.6) (49.8) (54.7) * Output 21.3 26.9 28.0 30.5 33.5 35.7 38.6 41.2 41..2 45.6 42.7 44.1 45.6 Max. rating kW(HP) (28.6) (36.1) (37.5) (40.9) (44.9) (47.9) (51.8) (55.3) (55.3) (61.2) (57.3) (59.1) (61.2) +50 +50 +50 +50 +50 +50 +50 +50 Max. revolution speed at 1600 0 1900 0 2175 0 2375 0 2600 0 2800 0 3000 0 3225 0 no load rpm +50 +50 Min. revolution speed at 1200 0 800 0 no load Direction of rotation — Counterclockwise (viewed from flywheel) Power take off — Flywheel Compression ratio — 18.0 Fuel injection timing deg 10±1 12±1 14±1 16±1 (FID, b.T.D.C.) Compression pressure MPa 2.94±0.1 (30±1), at 250 rpm (kgf/cm2) Fuel injection pressure +1.0 +10 +1.0 +10 MPa 19.6 0 (200 0 ) 19.6 0 (200 0 ) (kgf/cm2) Recommended diesel gas oil — ISO 8217 DMA, BS 2869 A1 or A2 (Cetane No. 45 min.) Lubrication system — Forced lubrication with trochoid pump Lubricating oil capacity C˚ 5.8/2.3 Max/Effective Recommended lubricating oil — API grade CC class or higher Cooling system — Liquid cooling/Radiator Cooling water capacity C˚ 2.7 (for engine only) Cooling fan mm Discharge type, 6 X Ø370 No. of blade X dia. Crank V-pulley dia./ mm Ø110/f90 Ø110/Ø110 Fan V-pulley dia. Governor — Mechanical centrifugal governor (All speed type) Starting system — Electrical 674 X 498.5 mm *1 Dimensions L X W X H 641 X 498.5 X 713 / 649 X 498.5 X 713 X 713

SPECIFICATIONS

1.13 4TNE84T

PERFORMANCE

14903 60413247

*1 Dry weight

Governing performance (full speed range)

L.O. press.

kg Transient speed difference Steady state speed band

184

≤10

≤8

≤5

≤4

165 / 175 ≤12 ≤9

≤8

Recovery time

sec

≤5

≤6

Fluctuation of revolution

rpm

≤15

≤22

Rated operation Idling

0.29±0.05 MPa (3.0±0.5) 2 (kgf/cm )

≤7

0.34±0.05 (3.5±0.5) ≥0.06 (≥0.6)

*1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51-13

SPECIFICATIONS AND PERFORMANCE

14903 60413247

NOTE

*1. Designation of engine dimension and dry weight in numerals. CL/CH application: engine with flywheel housing VM/VH application: engine with back plate/with flywheel hausing

51 -14

CROSS SECTIONAL VIEW

2. CROSS SECTIONAL VIEWS

14903 60413247

2.1 SPECIAL SWIRL PRECOMBUSTION CHAMBER SYSTEM (INDIRECT INJECTION SYSTEM)

51-15

CROSS SECTIONAL VIEW

14903 60413247

2.2 DIRECT INJECTION SYSTEM

51-16

COOLING WATER, LUBRICATING OIL AND FUEL OIL

3. COOLING WATER, LUBRICATING OIL AND FUEL OIL 3.1 COOLING WATER

3.2 LUBRICATING OIL

1. Proper use of cooling water Impurities in cooling water are deposited in the engine and radiator in the form of scale and cause rusting. For this reason, heat conduction of the cooling system and cooling water flow are impaired, and cause cooling functions to reduce and the engine to overheat. Therefore, drain the cooling water at intervals of 400 hours or one year. Never use hard water as the cooling water. In order to prevent the cooling water from freezing in cold weather, be sure to use an antifreeze agent. For further information on and proper usage and type of rust-preventive agents, antifreezes, and cleaning agents, contact your nearest dealer.

1. Proper use of lubricating oil Use of proper lubricating oil brings about the following effects.

2. Cooling water system diagram Indirect injection system and direct injection system

(1) The friction part of the engine is protected from friction and wear. (2) The engine parts is protected from rusting and corrosion. (3) The high temperature part of the engine is effectively cooled. (4) The engine is protected from leakage of combustion gas. (5) The engine parts are protected from sludge deposits. For the above reasons, use lubricating oil API Service Classification Class CC or better. Instruct your customers to replace lubricating oil initially at 20-30 hours in a dusty place, 50 hours in a less dusty place, and at intervals of 250 hours (100 hours in a dusty place) thereafter.

14903 60413247

Reference : Lubricating oil to be used at ambient temperature Select the viscosity of lubricating oil depending on ambient temperature at which the engine is used, according to SAE Service Grade shown below.

Ambient temperature at which the engine is used, Ë&#x161;C

123456789 123456789 123456789 123456789: Recommended SAE Service Grade

51-17

COOLING WATER, LUBRICATING OIL AND FUEL OIL

2. Lubrication system diagram (1) Indirect injection system

14903 60413247

(2) Direct injection system

51 -18

COOLING WATER, LUBRICATING OIL AND FUEL OIL

3.3 FUEL OIL 1. Proper use of diesel gas oil Use a diesel gas oil equivalent to or better than ISO 8217 DMA, BS 2869 Part 1 class A1 or Part 2 class A2. (Cetane Number: 45 min.) Give your customers instructions on proper use of fuel oil, or the customers may suffer from troubles stated below.

(2) Deposits in the piston ring groove Deposits in the piston ring groove cause blow-by gas, poor lubrication, imperfect combustion, excessive fuel consumption, contamination of lubricating oil, premature wear, etc. of the cylinder liner and piston ring.

(1) Deposits on the exhaust valve Deposits on the exhaust valve cause unburnt oil mixture in exhaust gas and erosion of the exhaust valve seat, to occur in addition to poor compression, imperfect combustion, excessive fuel consumption, etc.

(3) Clogging or corrosion of nozzle hole in fuel injection valve Imperfect combustion causes the fuel injection mechanism to wear and corrode and the nozzle to be clogged.

2. Fuel system diagram (1) Indirect injection system

14903 60413247

(2) Direct injection system

51-19

COOLING WATER, LUBRICATING OIL AND FUEL OIL

14903 60413247

NOTE

51 -20

TROUBLESHOOTING

4. TROUBLESHOOTING TROUBLE CAUSES AND REMEDIES

Carefully read Chapter 6, Measurement, Inspection and Adjustments, and Chapter 7, Measuring Procedures, Service Data and Countermeasures. Familiarize yourself with Chapter 6 and Chapter 7, which practice is extremely important for extending the service life of the engine.

Engine System

Exhaust temperature rise

Pressure rise

Pressure drop

Low water temperature

Much blow-by gas

Low L.O. pressure

Mixture with water

Diluted by fuel oil

Excessive consumption

Poor return to low speed

Overheat

Cooling Air water intake

Lubricating oil

Large engine vibration

During work

Black

White

Black

White

Regular

Less

Exhaust smoke

During idling

Engine Exhaust During starts but color work stops soon.

Nil

Cause

Engine will not start.

Symptom of trouble

Hunting

Uneven combustion sound

Insufficient Poor engine exhaust output color

Abnormal engine noise

Fails to start

High knocking sound during combustion

The following table summarizes the symptoms and causes of general troubles. If any symptom of trouble is found, a corrective action shall be taken before the said symptom develops into a serious accident.

Excessive fuel consumption

4.1

Corrective action

Improper clearance of intake/exhaust valve

Adjust valve clearance (Refer to Chapter 6, 6.2.)

Compression leakage from the valve seat

Rap valve seat (Refer to Chapter 7, 7.1.2. )

Seized intake/exhaust valve

Correct or replace.

Blowout of cylinder head gasket

Replace the gasket. (Refer to Chapter 8, 8.2-(10) )

Seized or broken piston ring

Replace the piston ring. (Refer to Chapter 7, 7.4.3, 4, (5) )

Worn piston ring, piston and cylinder

Make honing and use oversize parts. (Refer to Chapter 7, 7.2.3. and 7.4-(8) )

Seized crank pin metal and bearing

Repair or replace.

Improper arrangement of piston ring joints

Correct the ring joint positions. (Refer to Chapter 7, 7.4-(5) )

Reverse assembly of the piston ring

Properly reassemble. (Refer to Chapter 7, 7.4-(5) )

Worn crank pin and journal metal

Measure and replace . Refer to Chapter 7, 7.5.3. and 7.7-(5) )

Loosened connecting rod bolt

Tighten bolt to the specified torque. (Refer to Chapter 10, 10.1.)

Foreign matter trapped in combustion chamber

Disassemble and repair the combustion chamber. Eliminate

Excessive gear backlash

foreign matter.

Worn valve guide of intake/exhaust valves

Adjust meshing of gears. (Refer to Chapter 7, 7.8-(2) )

Poor governor

Measure and replace. (Refer to Chapter 7, 7.1-(3) )

Improper open/close timing of intake/exhaust valves

Repair and adjust. (Refer to Chapter 13.)

Cooling Water System

14903 60413247

Turbocharger

Adjust valve clearance (refer to Chapter 6, 6.2) and check intake/exhaust valve timing (Refer to Chapter 9, 9.1)

Dirty blower Waste gate malfunction

Clean the blower.

Worn journal bearing

Disassemble and inspect the waste gate. Disassemble and inspect the journal bearing.

Cooling effect of radiator, excessive Cooling effect of radiator, insufficient

Malfunction of thermostat (kept closed). (Refer to Chapter 6, 6.9)

Insufficient cooling water level Cracked water jacket

Malfunction of thermostat (kept opened). (Refer to Chapter 6, 6.9) Slipping fan belt (Refer to Chapter 6, 6.3) Check water leakage from Cooling water system (Refer to Chapter 6, 6.7) and clean cooling water system (Refer to chapter 3, 3.1)

Slackened fan belt tension

Repair and replace.

Poor thermostat

Adjust fan belt tension. (Refer to Chapter 6, 6.3) Check or replace. (Refer to Chapter 6, 6.9) 51-21

51-22

Exhaust temperature rise

Pressure rise

Pressure drop

Low water temperature

Overheat

Much blow-by gas

Low L.O. pressure

Mixture with water

Diluted by fuel oil

Excessive consumption

Excessive fuel consumption

Poor return to low speed

Large engine vibration

During work

Black

White

Black

White

Regular

Less

Nil

Exhaust smoke

During idling

Engine Exhaust During starts but color work stops soon.

Cooling Air water intake

Lubricating oil

Corrective action

Improper properties of lubricating oil

Use proper lubricating oil (Refer to Chapter 3, 3.2)

Leakage from lubricating oil system

Repair

Insufficient delivery capacity of trochoid pump

Check and repair. (Refer to Chapter 7, 7.9)

Clogged lubricating oil filter

Clean or replace.

Poor pressure control valve

Clean, adjust or replace.

Insufficient lubricating oil level

Proper lubricating oil supply (Refer to Chapter 3.2)

Excessively early timing of fuel injection pump

Check and adjust. (Refer to Chapter 6, 6.5)

Excessively late timing of fuel injection pump

Check and adjust. (Refer to Chapter 6, 6.5)

Improper properties of diesel gas oil

Use proper diesel gas oil. (Refer to Chapter 3, 3.3)

Water intrusion to fuel system

Inspect and repair. (Refer to Chapter 6, 6.7)

Clogged fuel filter

Clean or replace.

Air entrance in fuel system

Perform air bleeding.

Clogged or cracked fuel pipe

Clean or replace.

Insufficientl fuel supply to fuel injection pump

Inspect the fuel tank valve cock, fuel filter, fuel piping and fuel feed pump.

Uneven injection by fuel injection pump

Inspect and adjust. (Refer to Chapter 11 and 12)

Excessive fuel injection

Inspect and adjust. (Refer to Chapter 11 and 12)

Poor spray pattern from fuel injection nozzle

Inspect and adjust. (Refer to Chapter 6, 6.4.2 )

Clogged air filter

Clean

Engine used at high temperature or at high altitude

Use higher-output engine.

Clogged exhaust pipe

Clean.

Malfunction of starting motor

Repair or replace.

Malfunction of alternator

Repair or replace.

Breaking of wires

Repair.

Low battery voltage

Recharge the battery. (Refer to Chapter 6, 6.8)

14903 60413247

Electric Wiring System

Air/exhaustgas System

Fuel System

Lubricating Oil System

Cause

Engine will not start.

Symptom of trouble

Hunting

Uneven combustion sound

Insufficient Poor engine exhaust output color

Abnormal engine noise

Fails to start

High knocking sound during combustion

TROUBLESHOOTING

4.2 TROUBLE DIAGNOSIS THROUGH MEASUREMENT OF COMPRESSION PRESSURE

* : For the compression pressure measuring procedure, refer to chapter 6, 6-1. Measurement of compression pressure.

3. Gas leak through the nozzle gasket or cylinder head gasket. In addition, the compression pressure decreases as the engine parts are worn and lose durability through use of the engine for a long period. Scratches on the cylinder or piston caused by dust or foreign matter through the soiled air cleaner element, and wear or breakage of piston rings also decrease the compression pressure. For this reason, diagnose the engine status by measuring the compression pressure.

Reduction in compression pressure of the cylinder is one of major causes of an increase in blow-by gas (which causes contamination and increased consumption of lubricating oil, and other trouble) as well as the engine starting failure. The compression pressure is influenced by the following factors: 1. Degree of clearance between the piston and cylinder. 2. Degree of clearance around intake/exhaust valve seats. (1) Causes and countermeasures to be taken when the compression pressure is less than the limit value.

* For the compression pressure limit values, refer to Chapter 6, 6-1 Measurement of compression pressure.

14903 60413247

No.

Item

Cause

Countermeasures

· Filter element of air cleaner

· Clogged filter element · Broken filter element · Defective filter element seal

· Clean the filter element. · Replace the filter element with a new one.

· Valve clearance

· Excessive valve clearance or no clearance

· Adjust the valve clearance (Refer to Chapter 6, 6.2.)

· Valve timing

· Improper valve timing · Improper valve clearance

· Adjust the valve clearance (Refer to Chapter 6, 6.2.) · Inspect and adjust of the valve rocker arm. (Refer to Chapter 7, 7.3, 7.6 and 7.8.)

· Cylinder head gasket · Nozzle gasket

· Gas leak through the gasket

· Replace the gasket. · Re-tighten the cylinder head and nozzle to the specified torque. (Refer to Chapter 10, 10.1.)

· Intake/exhaust valve · Valve seat

· Gas leak caused by worn valve seats or trapped foreign matter · Seizure of valves

· Rap valve seats. (Refer to Chapter 7, 7.1(2)) · Replace the intake/exhaust valves.

· Piston · Piston ring · Cylinder

· Gas leak caused by scratches and wear of piston, piston ring and cylinder

· Perform honing and use oversize parts. (Refer to Chapter 7, 7.2(3) and 7.4(8))

51-23

TROUBLESHOOTING

14903 60413247

NOTE

51 -24

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

5. SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENTS Although main engine parts can be disassembled and reassembled only with standard service tools, it is recommended to provide the following special service tools and measuring instruments for more efficient and accurate work, correct measurement, diagnosis, and troubleshooting. 5.1 SPECIAL SERVICE TOOLS

No. 1

Tool name Valve guide extraction tool

Illustration

Applicable model and tool dimension (mm) Dimension Model

2/3TNE68

3TNE74

6.5

3TNE78A/82A

6.5

3/4TNE82 3/4TNE84(T) 3/4TNE88

7.5

* Locally manufactured

Valve guide insertion tool

(mm) Dimension Model

3TNE74

3TNE78A/82A

3/4TNE82 3/4TNE84(T) 3/4TNE88

2/3TNE68

* Locally manufactured

Connecting rod bushing replacer

(mm) Dimension Model

d1 -0.3

2/3TNE68

20 -0.6

3TNE74

21 -0.6

-0.3

23 26

3TNE78A/82A

-0.3 23 -0.6

3/4TNE82 3/4TNE84(T) 3/4TNE88

100

26 -0.6

-0.3

-0.3 -0.6 -0.3 -0.6 -0.3 -0.6 -0.3

29 -0.6

14903 60413247

* Locally manufactured

Valve spring compressor (Replacement of valve spring)

Model

Yanmar Code No.

All model

129100â&#x20AC;&#x201C;92630

51-25

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

No.

Tool name

Filter wrench (Removal and installation of L.O. filter)

Camshaft bushing tool (Extraction of camshaft bushing)

Illustration

Applicable model and tool dimension Sold on market

(mm) Dimension Model 2/3TNE68

d1 -0.3

-0.3 -0.6 -0.3 -0.6 -0.3 -0.6

-0.3 -0.6

36 -0.6

-0.3 -0.6 -0.3 -0.6

3TNE74

3TNE78A/82A

3/4TNE82 3/4TNE84(T) 3/4TNE88

45 -0.6

-0.3

* Locally manufactured

Flex-Hone (for honing cylinder liner) ] : For the usage procedure of the Flex-Hone, refer to Chapter 7, 7-2, 3.

Piston insertion tool (Insertion of piston)

Model

Yanmar Code No.

2/3TNE68

129400–92400

3TNE74

129400–92410

3TNE78A/82A 3/4TNE82 3/4TNE84(T) 3/4TNE88

129400–92420 129400–92430

Model

Yanmar Code No.

All model

95550–002476

Note: The above piston insertion tool is applicable to pistons 60~125 mm in diameter.

Sold on market Piston ring replacer 14903 60413247

51 -26

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

5.2 MEASURING INSTRUMENTS

14903 60413247

No.

Instrument name

Purpose of use

Dial gauge

Measures bent shafts, distorted flat surface, gaps, etc.

Test indicator

Measures the limited small portions and deep portions unmeasurable with dial gauge.

Magnetic stand

Used together with the dial gauge: holds the dial gauge at different angles.

Micrometer

Measures the outside diameter of the crankshaft, piston, and piston pin, etc.

Cylinder gauge

Measures the inside diameter of the cylinder liner, connecting rod metal, etc.

Vernier callipers

Measures the outside diameter, depth, thickness, width, etc. of various items.

Depth Micrometer

Measures the sinkage of the valve.

Square

Measures inclination of valve spring, squareness of engine parts, etc.

V-block

Measures bent shaft.

Illustration

51-27

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

No.

Instrument name

Purpose of use

Torque wrench

Used for tightening bolts and nuts to the specified torques.

Thickness gauge

Measures gaps between the rings and mating ring grooves and around shaft couplings during installation

Cap tester

Checks the fresh water system for leakage.

Battery coolant tester

Checks the antifreeze for concentration and the battery electrolyte for specific gravity, and charging state.

Nozzle tester

Checks the fuel injection valve for spray patterns and injection pressure.

Digital thermometer

Measures temperature of each part.

Contact type

Measures RPM of the rotary shaft by bringing the gage head into contact with the mortise.

Photoelectric type

Applies a reflecting tape on the circumference of the rotating parts to measure RPM. 14903 60413247

Tachometer

Illustration

51 -28

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

No.

Instrument name

Tachometer

High pressure fuel pipe clamping type

Purpose of use

Illustration

Measures engine RPMâ&#x20AC;&#x2122;s using pulse system, irrelevantly to the center of the rotary shaft and the circumference of the rotary object.

Circuit tester

Measures the resistance, voltage, and continuity of electric circuits.

Compression gauge kit

Measures compression pressure. Yanmar Code No.

14903 60413247

TOL-97190080

51-29

SPECIAL SERVICE TOOLS AND MEASURING INSTRUMENT

14903 60413247

NOTE

51 -30

MEASUREMENT, INSPECTION AND ADJUSTMENT

6. MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.1 MEASURING THE COMPRESSION PRESSURE

51-31

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51 -32

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.2 ADJUSTMENT THE VALVE HEAD CLEARANCE

51-33

MEASUREMENT, INSPECTION AND ADJUSTMENT

6.3 CHECKING THE V-BELT TENSION

14903 60413247

6.4 MEASURING AND CHECKING THE INJECTION PRESSURE AND SPRAY PATTERNS OF THE FUEL INJECTION VALVE

51 -34

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51-35

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51 -36

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51-37

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.5 CHECKING AND ADJUSTAMENT THE FUEL INJECTION TIMING

51 -38

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51-39

MEASUREMENT, INSPECTION AND ADJUSTMENT

6.6 ADJUSTAMENT THE NO-LOAD MAXIMUM (OR MINIMUM) REVOLUTIONS

14903 60413247

6.7 CHECKING THE COOLING WATER SYSTEM AND RADIATOR FOR WATER LEAKAGE

51 -40

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.8 CHECKING THE BATTERY

51-41

14903 60413247

MEASUREMENT, INSPECTION AND ADJUSTMENT

51 -42

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.9 CHECKING THE SENSORS

51-43

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.10 CHECKING THE OIL COOLER

51 -44

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

6.11 CHECKING THE PISTON COOLING NOZZLE

51-45

MEASUREMENT, INSPECTION AND ADJUSTMENT

14903 60413247

NOTE

51 -46

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

7. MEASURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION In maintaining various parts, make measurement according to the following measurement procedure. If any trouble is found and if any part deviates from the standard size, replace it with a new one. However, if any part within the limit is expected to deviate from the standard presumably because of the record of its use, be sure to replace such a part beforehand.

2. Intake/exhaust valve seats (1) Valve sinking Over long periods of use and repeated lappings, combustion efficiency may drop. Measure the sinking depth and replace the valve and valve seat if the valve sinking depth exceeds the standard value. (mm)

7.1 CYLINDER HEAD 2/3TNE68

1. Distortion and inspection of the combustion surface

Standard

(1) Remove intake/exhaust valves and fuel injection valve from the engine. Clean the surface of the cylinder head.

Valve sinking depth

Intake 0.3~0.5 valve Exhaust 0.75~0.95 valve

(2) Place a straight-edge along each of the four sides and each diagonal of the cylinder head. Measure the clearance between the straight-edge and combustion surface with a thickness gauge.

14903 60413247

Cylinder head combustion surface distortion

Standard

Wear limit

All models

0.05 or less

0.15

Wear Wear Standard limit limit 1.0

0.4~0.6

1.0

VM:0.75~0.95 CH:0.40~0.60 VH:0.40~0.60

1.0

3TNE78A 3TNE82A

(mm) Valve sinking depth

3TNE74

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Standard

Wear Wear Standard limit limit

Intake valve

0.296 ~0.496

1.0

0.306 ~0.506

1.0

Exhaust valve

0.3~0.5

1.0

0.3~0.5

1.0

(3) Visually check to see if the combustion surface is free from discoloration, cracks, and crazing. In addition, use the color check kit for cracks and crazing.

51-47

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

(2) Width and angle of the valve seat Remove carbon deposits from the seat surface. Measure width and angle of the seat using vernier calipers and an angle gauge. (mm)

Standard

3TNE74

Wear Wear Standard limit limit

Valve seat width

Intake

1.15

1.65

1.44

1.98

Exhaust

1.41

1.91

1.77

2.27

Valve seat angle

Intake

120˚

—

120˚

—

Exhaust

90˚

—

90˚

—

3TNE78A 3TME82A

Standard

Valve seat width Valve seat angle

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

Intake

1.36 ~1.53 1.98

1.07 ~1.24 1.74

Exhaust

1.66 ~1.87 2.27

1.24 ~1.45 1.94

Intake Exhaust

(2) When the seat surface is worn or roughened heavily, correct seat surface using a seat grinder or seat cutter, and finish it according to step (1).

120˚

—

120˚

—

90˚

—

90˚

—

[Procedure for Using The Seat Grinder and Seat Cutter] (1) Correct the roughened seat surface with a seat grinder or seat cutter. Seat grinder

Angle ( )

Intake valve

30˚

Exhaust valve

45˚

(2) When the seat width is enlarged from the initial value, correct it by grinding the seat surface with a 70˚ seat grinder or seat cutter. Then, grind the seat to the standard width with a 15˚ grinder. *

51 -48

When using a seat cutter, evenly apply pressure taking care of avoiding uneven cutting.

14903 60413247

2/3TNE68

[Valve Seat Correction Procedure] (1) When the seat surface is worn or roughened slightly, lap the seat surface with a valve compound mixed with oil to a smooth state.

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

(3) Knead valve compound with oil and finish the valve seat by lapping. *

If any valve requires correction, be sure to measure the oil clearance between the valve stem outside dia. and valve guide inside dia. If the oil clearance exceeds the limit, replace the valve or valve guide before correcting the valve seat surface. (For oil clearance between the valve and valve guide, refer to section 3 in this chapter.)

(4) Finally, lap the valve using only oil. *

1. After the valve seat is corrected, thoroughly clean the valve and cylinder head using diesel oil or the like. Thoroughly remove the valve compound or grindstone powder. 2. For slightly poor contact, take steps (3) and (4).

14903 60413247

[Extraction of Valve seat] Without valve seat

2/3TNE68: 3 TNE74: Direct injection system:

All VM CL and VM

With valve seat

3TNE74 (IDI): Direct injection system: Turbocharged engine:

CH and VH CH and VH All

[Insertion of valve seat] (1) Put the valve seat in a container which contains liquefied nitrogen, or ether or alcohol with dry ice to cool it sufficiently. (2) Heat the cylinder head around the portion for valve seat insertion to 80~100Ë&#x161;C with a dryer. (3) With the new intake/exhaust valve, securely insert the sufficiently cooled valve seat into the cylinder head by tapping the head of the intake/exhaust valve. (4) Stand the cylinder head until the entire cylinder head is cooled to normal temperature.

(1) Grind the circumference of the intake/ exhaust valve head being or having been used to the dimension smaller than the valve seat outer diameter. (2) Grind the circumference of the stem end of the valve to the same dimension as the fitting diameter of the cotter. (3) Weld the intake/exhaust valve head with the valve seat at three positions. (4) Hit the stem end of the intake/exhaust valve to extract the valve seat.

51-49

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

3. Intake/exhaust valve 3TNE78A 3TNE82A

(1) Wear and bend of the valve stem Replace a valve stem if bent or worn badly. In this case, replace the valve guide at the same time. (2) Valve stem and valve guide Oil clearance is a difference between the valve guide inside diameter measured with a three-point micrometer (capable of measuring inside diameter between 4 mm and 8 mm) or a cylinder gauge (capable of measuring 6 mm or greater inside diameter) and the stem outside diameter measured with a micrometer. When oil clearance is near the limit, replace both the intake/exhaust valve and valve guide with new ones.

Standard Stem O.D. Intake valve

Guide I.D. Oil clearance

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

6.945 ~6.960 6.9 7.000 ~7.015 7.08 0.040 ~0.070 0.18

Stem O.D. 6.940 ~6.955 6.9 Exhaust Guide I.D. 7.015 valve ~0.045 7.08 Oil 0.045 clearance ~0.075 0.18

7.955 ~7.975 7.9 8.010 ~8.025 8.1 0.035 ~0.070 0.2 7.955 ~7.970 8.015 ~8.030 0.045 ~0.075

7.9 8.1 0.2

(3) Thickness of valve head Measure the thickness of the valve head with a micrometer. When the measured value is near the wear limit, replace the valve with a new one.

(Measuring the valve stem outside diameter) (mm)

Standard

3TNE74

Wear Wear Standard limit limit

0.025 ~0.055 0.18

6.960 ~6.975 6.9 7.005 ~7.020 7.08 0.030 ~0.060 0.18

Stem O.D. 5.445 ~5.460 5.4 Exhaust Guide I.D. 5.500 valve ~5.515 5.58 0.040 Oil ~0.070 0.18 clearance

6.945 ~6.960 6.9 7.005 ~7.020 7.08 0.045 ~0.075 0.18

Intake valve

Stem O.D. 5.460 ~5.475 5.4 5.500 Guide I.D. ~5.515 5.58 Oil clearance

2/3TNE68

Thickness of valve head

Standard

Wear Wear Standard limit limit

0.85 ~1.15

0.99 ~1.29 0.50

Exhaust 0.95 Valve ~1.25

Intake valve

0.50 0.95 ~1.25

3TNE78A 3TNE82A

Thickness of valve head

51 -50

Intake valve

3TNE74

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Standard

Wear Wear Standard limit limit

1.244 ~1.444

1.244 ~1.444 0.50

Exhaust 1.35 Valve ~1.55

0.50 1.35 ~1.55

14903 60413247

2/3TNE68

(mm)

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

[Replacing the Valve Guide] (1) Extract the valve guide from the cylinder head using the valve guide extraction tool. *

For the valve guide extraction tool, refer to Chapter 5, 5-1.

(2) In a container containing liquefied nitrogen, ether or alcohol together with dry ice, put the valve guide to cool it. Then hit the sufficiently cooled valve guide to fit into the cylinder head using the valve guide insertion tool. *

For the valve guide insertion tool, refer to Chapter 5, 5-1.

(3) After inserting the valve guide, finish the inside of the valve guide with a reamer.

4. Valve stem seal [Time of Replacement]

(4) Check the projection of the valve guide. (mm) 2/3TNE68

3TNE74

Wear Wear Standard Standard limit limit Valve guide projection

—

Wear Wear Standard limit limit —

—

14903 60413247

Valve guide projection

[Precautions on Installation] Make sure that the entire surface of valve stem is smooth, and sufficiently apply lubricating oil to the valve stem before reassembling intake/exhaust valves.

3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE78A 3TNE82A Standard

(1) When oil loss is found excessive (2) When the valve stem seal is removed (3) When intake/exhaust valves are removed

51-51

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

5. Checking the valve spring (1) Visually check to see if the valve spring is free from flaws and corrosion. (2) Measure the free length (length of the spring) and inclination (squareness of the side of the coil). (mm) 2/3TNE68 Standard Free length Valve Inclination spring Tension (kg) (when compressed

to by 1 mm)

3TNE74

Wear Wear Standard limit limit

—

37.4

—

0.8

—

1.0

1.14 ~1.40

—

*2.37/

1.87

—

* Tension at variable pitch. 3TNE78A 3TNE82A Standard Free length Valve Inclination spring Tension (kg) (when compressed to by 1 mm)

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

44.4

—

1.1

—

1.1

*3.61

—

*2.36

/3.101

—

14903 60413247

* Tension at variable pitch.

/2.71

6. Checking valve spring holder and cotter Check contact of the inner surface of the valve spring holder with the circumference of the cotter as well as contact of the inner circumference of the cotter with the notch on the head of the valve stem. If such contact is uneven or if the cotter sinks, replace the cotter with a new one.

51 -52

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

7.2 CYLINDER BLOCK 1. Checking the cylinder block (1) Visually check to see if the cylinder block is free from water leak, oil leak and cracks. If any cylinder block is suspected to be cracked, check it by color check. (2) Replace the cylinder block if badly damaged and incorrectable. (3) Thoroughly clean each oil hole. Make sure that it is not clogged. 2. Measuring the bore and distortion of the cylinder Measure the bore of each cylinder with a cylinder gauge. Measure the cylinder at point a, approx. 20 mm below the crest of the liner, and at points b and c at equal pitch (a–b = b–c). Obtain distortion (roundness and cylindricity of each cylinder) from the measured values as follows: • Roundness: Difference between max. and min. bore values on the same cross section of each liner. • Cylindricity: Difference between max. and min. bore values in the same direction of each liner. Honing (honing and boring) is required when the measured value exceeds the limit. For oversized piston and piston ring, refer to this chapter, 7.4, 8.

14903 60413247

51-53

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION (mm) 2/3TNE68 Standard

Cylinder roundness Cylindricity

Wear Wear Standard limit limit

68.000 74.000 ~68.030 68.20 ~74.030 74.20 0.00 0.00 ~0.01 0.03 ~0.01 0.03 0.00 0.00 ~0.01 0.03 ~0.01 0.03

3TNE78A

Standard Cylinder bore Cylinder roundness Cylindricity

3TNE82A 3/4TNE82

Wear Wear Standard limit limit

78.000 82.000 ~78.030 78.20 ~82.030 82.20 0.00 0.00 ~0.01 0.03 ~0.01 0.03 0.00 0.00 ~0.01 0.03 ~0.01 0.03

3/4TNE84 (T)

3/4TNE88

Wear Wear Standard Standard limit limit Cylinder bore Cylinder roundness Cylinder cylindricity

84.000 88.000 ~84.030 84.20 ~88.030 88.20 0.00 0.00 ~0.01 0.03 ~0.01 0.03 0.00 0.00 ~0.01 0.03 ~0.01 0.03

3. Honing (1) Practice of honing Honing or boring the cylinder if unevenly worn, flawed, or otherwise damaged. Slight uneven worn, flaws, etc. may well be only honing with a Flex-Hone. However, significant uneven wear should be first bored and then honed. It is important to take into careful consideration as to whether the cylinder can attain perfect roundness after honing, boring, or both, considering maximum wear. In addition, carefully study as to whether prepared oversized pistons and piston rings are applicable. (For the oversized piston and piston ring, refer to this chapter 7.4, 8.)

51 -54

(2) Procedure for using the Flex-Hone It is common practice to use the FlexHone for honing. The procedure for using it appears in the following table. Any material must allow for approx. 1/1000 mm when honed with the Flex-Hone. 1. Necessary items Flex-Hone, power drill, and honing fluid

Model

Flex-Hone Yanmar code No.

Applicable bore (mm)

2/3TNE68

129400–92400

63~70

3TNE74

129400–92410

70~76

3TNE78A/82A 3/4TNE82 3/4TNE84(T)

129400–92420

76~89

3/4TNE88

129400—92430

83~95

14903 60413247

Cylinder bore

3TNE74

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

2. Handling procedure Apply the honing fluid to the Flex-Hone. Insert the Flex-Hone into the cylinder while turning it, move it up and down for about 30 sec for a cross hatch angle of 30-40˚. Extract the Flex-Hone while turning it. *

Use the Flex-Hone at a speed of 300–1200 rpm. Use of the Flex-Hone at a higher speed may be hazardous. Never insert into or extract from the cylinder the Flex-Hone, with the power drill left stopped.

14903 60413247

4. Overhaul of cylinder (Reference)

51-55

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

7.3 VALVE ROCKER ARM 1. Measuring the outside diameter of rocker arm shaft and inside diameter of rocker arm Oil clearance is the difference between the rocker arm inside diameter measured with a cylinder gauge and the rocker arm shaft outside diameter measured with a micrometer. When the oil clearance is near the limit, replace the rocker arm shaft and rocker arm with new ones. (mm)

2/3TNE68

Intake/exhaust rocker arm

3TNE78A/82A 3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE74

Standard

Wear limit

Standard

Wear limit

Standard

Wear limit

Rocker arm shaft outside diameter

9.972 ~9.987

9.95

11.966 ~11.984

11.95

15.966 ~15.984

15.95

Rocker arm bushing inside diameter

10.000 ~10.020

10.09

12.000 ~12.020

12.09

16.000 ~16.020

16.09

Oil clearance

0.013 ~0.048

0.14

0.016 ~0.054

0.14

0.016 ~0.054

0.14

2. Checking push rod bend, measuring tappet outside diameter and checking contact surface

14903 60413247

Put the push rod on the stool, and measure the gap between the push rod and stool to make sure the push rod is in close contact with the stool. Also, measure the outside diameter of the tappet with a micrometer.

51 -56

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION (mm)

2/3TNE68

3TNE74

Standard

Wear limit

Standard

Wear limit

Standard

Wear limit

0.03 or less

—

0.03 or less

—

0.03 or less

—

Tappet stem outside diameter

17.950 ~17.968

17.93

20.927 ~20.960

20.90

11.975 ~11.990

11.93

Tappet guide hole inside diameter

18.000 ~18.018

18.05

21.000 ~21.021

21.05

12.000 ~12.018

12.05

Oil clearance

0.032 ~0.068

0.12

0.040 ~0.094

0.15

0.010 ~0.043

0.12

Push rod bending

Tappet

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

3. Other checks (1) Valve rocker arm shaft spring Check to see if the rocker arm shaft spring is free from corrosion and wear. If not, replace it with a new one. (2) Wear of intake/exhaust valve rocker arm and valve cap Check the intake/exhaust valve rocker arm for their contact surfaces with valve cap. If any of them is abnormally worn or partially flaked, replace it.

14903 60413247

(3) Check the portion where the valve clearance adjusting screw is in contact with the push rod. If the portion is worn and flaked, replace the pushrod or adjusting screw.

51-57

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

7.4 PISTON AND PISTON RING 1. Checking the piston (1) Remove carbon deposits from the head and combustion surface of the piston so as not to impair the piston. Check to see if there is any crack or damage. (2) Check the circumference and ring groove of the piston, and replace if worn or damaged. 2. Measuring the piston outside diameter To measure the piston outside diameter, measure the long diameter of the oval hole in vertical direction to the pin hole and at a position 22–25 mm from the lower end of the piston.

(mm) 2/3TNE68 VM, VH

3TNE74

Wear Standard

limit

3TNE78A

3TNE82A

3/4TNE82

3/4TNE84(T)

3/4TNE88

CH Wear Standard

limit

Wear Standard

limit

Wear Standard

limit

Wear Standard

limit

Wear Standard

limit

Wear Standard

limit

wear Standard

limit

Piston outside diameter

67.960 67.940 73.940 77.950 81.950 81.945 83.945 87.945 ~67.990 67.90 ~67.970 67.90 ~73.970 73.90 ~77.980 77.90 ~81.980 81.90 ~81.975 81.90 ~83.975 83.90 ~87.975 87.90

Minimum clearance between piston and cylinder

0.025 ~0.055

—

0.045 ~0.075

3. Shapes of piston rings

— 0.045 ~0.075

— 0.035 ~0.065

—

0.035 ~0.065

Model

—

0.040 ~0.070

—

0.040 ~0.070

—

0.040 ~0.070

—

2/3TNE68, 3TNE74

Application

VM, CH, VH

Model Application Top ring

51 -58

3TNE78A/82A, 3/4TNE82, CL, VM

3/4TNE84(T) 3/4TNE88

CH, VH, w/turbocharged

14903 60413247

Top ring

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

4. Measuring the ring groove width, ring width, and end clearance To measure the piston ring groove width, first measure the width of the piston ring. Then, insert the piston ring into the ring groove that has been carefully cleaned. Insert a thickness gauge in between the piston ring and groove to measure the gap between them. Obtain the ring groove width by adding ring width to the measured side clearance.

14903 60413247

To measure the end clearance, push the piston ring into the sleeve using the piston head, insert a thickness gauge in end clearance to measure. If the sleeve is worn, measure the end clearance after pushing the piston ring to the portion of the sleeve which is less worn (approx. 30 mm from the lower end of the sleeve).

51-59

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION (mm) 2/3TNE68

Standard Ring groove width Ring width Top ring

Min. side clearance End clearance

2nd ring

Oil ring

1.550 ~1.570 1.470 ~1.490 0.060 ~0.100 0.100 ~0.250

3TNE74

3TNE82A, 3/4TNE82, 3/4TNE84(T)

3TNE78A

3/4TNE88

Wear Wear Wear Wear Wear Standard Standard Standard Standard limit limit limit limit limit — — — 1.5

1.550 ~1.570 1.470 ~1.490 0.060 ~0.100 0.200 ~0.400

— — — 1.5

2.035 ~2.050 1.940 ~1.960 0.075 ~0110 0.200 ~0.400

— — — 1.5

2.065 ~2.080 1.970 ~1.990 0.075 ~0.110 0.200 ~0.400

— — — 1.5

2.060 ~2.075 1.970 ~1.990 0.070 ~1.105 0.200 ~0.400

— — — 1.5

Ring groove width

1.540 ~1.555

—

1.520 ~1.535

—

2.025 ~2.040

—

2.035 ~2.050

—

2.025 ~2.040

—

Ring width

1.430 ~1.450

—

1.410 ~1.430

—

1.975 ~1.990

—

1.970 ~1.990

—

1.970 ~1.990

—

Min. side clearance

0.090 ~0.125

—

0.090 ~0.125

—

0.035 ~0.065

—

0.045 ~0.080

—

0.035 ~0.070

—

End clearance

0.150 ~0.350

1.5

0.200 ~0.400

1.5

0.250 ~0.400

1.5

0.200 ~0.400

1.5

0.200 ~0.400

1.5

Ring groove width

3.010 ~3.025

—

3.010 ~3.025

—

3.015 ~3.030

—

4.015 ~4.030

—

4.015 ~4.030

—

Ring width

2.970 ~2.990

—

2.970 ~2.990

—

2.970 ~2.990

—

3.970 ~3.990

—

3.970 ~3.990

—

Min. side clearance

0.020 ~0.055

—

0.020 ~0.055

—

0.025 ~0.060

—

0.025 ~0.060

—

0.025 ~0.060

—

End clearance

0.150 ~0.350

1.5

0.150 ~0.350

1.5

0.200 ~0.400

1.5

0.200 ~0.400

1.5

0.200 ~0.400

1.5

5. Reassembly of piston ring

(2) Stagger the piston rings joints at 120˚ intervals, making sure that they are not aligned along the piston. Apply lube oil to the circumference of the piston.

51 -60

14903 60413247

(1) Using the piston ring replacer, insert the piston ring into the ring groove, with the manufacturer’s mark near the joint of the piston ring facing up to the combustion chamber side. After fitting the piston ring, make sure that the piston ring moves freely.

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

6. Measuring the outside diameter of the piston pin and the pin hole diameter Measure outside diameter of the piston pin and pin hole diameter. Replace the piston pin if the wear limit is exceeded. Apply lubricating oil to the piston pin before inserting it into the piston.

(mm) 2/3TNE68 Standard

3TNE74

Wear Wear Standard limit limit

Piston pin outside 19.991 20.991 diameter ~20.000 19.90 ~21.000 20.90 Piston 21.000 and Piston pin hole 20.000 ~20.008 20.02 ~21.008 21.02 piston dia. pin 0.000 0.000 Oil clearance ~0.017 0.12 ~0.017 0.12

3TNE78A 3TNE82A Standard

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

Piston pin outside 22.991 25.987 ~23.000 22.90 ~26.000 25.90 Piston diameter and Piston pin hole 23.000 26.000 piston dia. ~23.008 23.02 ~26.009 26.02 pin 0.000 0.000 Oil clearance ~0.017 0.12 ~0.022 0.12

7. [Reference] Top clearance (mm) 2/3TNE68 Standard Top clearance

Wear Wear Standard limit limit

0.610 ~0.730 —

14903 60413247

3TNE78A 3TNE82A Standard

Top clearance

3TNE74

0.658 ~0.778 —

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

0.650 ~0.770 —

0.660 ~0.780 —

51-61

MESAURING PROCEDURE, SERVICE DATA AND CORRECTIVE ACTION

8. List of the oversized piston and piston ring (0.250S: Oversized by 0.25 mm) Size classification

Model

Piston assy code (including piston ring assy)

Piston ring assy code

VM VH

0.250S

119265—22900

3TNE74

VM CH VH

0.250S

119623—22900

119623—22950

3TNE78A

CL VM CH VH

0.250S

119818—22910

119818—22950

3TNE82A

CL VM

0.250S

119813—22900

129003—22950

CL VM

0.250S

129003—22900

129003—22950

CH VH

0.250S

129003—22910

129003—22950

CL VM

0.250S

129002—22900

129002—22950

CH VH

0.250S

129002—22910

129002—22950

CL VM

0.250S

129001—22900

129001—22950

2/3TNE68

119265—22930 119265—22950

3/4TNE82

3/4TNE84(T)

14903 60413247

3/4TNE88

51 -62

COOLING WATER, LUBRICATING OIL AND FUEL OIL

3. Measuring the crankpin and bushing clearance

7.5 CONNECTING ROD 1. Visual inspection Inspect the portion near the boundary of the chamfered portion and I-beam section of the big and small ends of the connecting rod as well as the portion near the oil hole of the bushing at the small end for cracks, deformation, and discoloration. 2. Measuring the twist and parallelism Measure the twist and parallelism by use of the connecting rod aligner. (mm) All models Standard Twist and parallelism

0.03 or less per 100 mm

To measure the oil clearance of the crankpin and bushing, measure the inside diameter of the crankpin metal and outside diameter of the crankpin, and obtain the difference between them. If the measured oil clearance exceeds or near the wear limit, replace the crankpin metal. If the crankpin is excessively or unevenly worn, grind the crankpin, and use an oversized crankpin metal. *

To measure the inside diameter of the crankpin metal, reassemble the crankpin metal to the connecting rod and tighten the rod bolt to the specified torque, making sure each metal is fitted on the correct position.

Wear limit 0.08

(kgf-m)

2/3TNE68 3TNE78A 3TNE74 3TNE82A

3/4TNE82, 3/4TNE84(T), 3/4TNE88

14903 60413247

Specified torque Rod bolt tightening torque (Apply lube oil to the rod bolt)

2.3~2.8

3.8~4.2

4.5~5.5

51-63

COOLING WATER, LUBRICATING OIL AND FUEL OIL (mm) 2/3TNE68

3TNE74

3TNE78A 4TNE82A

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Standard Wear limit Standard Wear limit Standard Wear limit Standard Wear limit

Crankpin side

Crankpin bushing inside dia.

39.000 ~39.016

—

43.000 ~43.016

—

46.000 ~46.016

—

51.000 ~51.010

—

Crankpin metal thickness

1.487 ~1.500

—

1.487 ~1.500

—

1.487 ~1.500

—

1.492 ~1.500

—

35.970 ~35.980

35.91

39.970 ~39.980

39.91

42.952 ~42.962

42.91

47.952 ~47.962

47.91

0.033 ~0.059

0.15

0.033 ~0.059

0.15

0.038 ~0.0900

0.16

0.038 ~0.074

0.16

Crankpin outside diameter Oil clearance

4. Measuring the oil clearance between the piston pin bushing and piston pin To measure of oil clearance between the piston pin bushing and piston pin, measure the inside diameter of the piston pin bushing and outside diameter of the piston pin, and obtain the difference between them.

(mm) 2/3TNE68

3TNE74

Wear Wear Standard limit limit 21.025 Piston pin bushing 20.025 ~20.038 20.10 ~21.038 21.10 Piston inside diameter 20.991 Piston pin out- 19.991 pin ~20.000 19.90 ~21.000 20.90 side side diameter 0.025 0.025 Oil clearance ~0.047 0.2 ~0.047 0.2 Standard

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard Standard limit limit Piston pin bushing 23.025 23.10 26.025 26.10 inside diameter ~23.038 ~26.038 Piston Piston pin out- 22.991 25.987 pin ~23.000 22.90 ~26.000 25.90 side side diameter Oil clearance

51 -64

0.025 ~0.047

0.2

0.025 ~0.051

0.2

5. Checking the crankpin metal for contact Apply a blue ink or a minium to the crankpin metal upper surface. Attach the crankpin metal to the connecting rod, and tighten the rod bolt to the crankshaft to the specified torque (Refer to this section 3) to check the metal for contact. If the contact surface occupies 75% or more of the total surface, the crankpin metal is acceptable in terms of contact.

14903 60413247

3TNE78A 3TNE82A

COOLING WATER, LUBRICATING OIL AND FUEL OIL

7. Side gap of the connecting rod After attaching the connecting rod to the crankshaft, tighten the rod bolt to the specified torque (see this section 3). Measure the side gap by inserting a thickness gauge into the side gap. If the standard is exceeded, replace the crankpin metal or connecting rod. (mm) All models Side gap

0.2~0.4

14903 60413247

6. Assembling the piston and connecting rod Assemble the piston with the connecting rod, with the mark at the big end of the connecting rod facing the fuel injection pump. Reassemble the piston so that the recess of the combustion chamber is on the side of the fuel injection pump as seen from the top.

51-65

COOLING WATER, LUBRICATING OIL AND FUEL OIL

8. Oversized crankpin metal

3. Measuring the bend of the camshaft

(0.25mm, oversized) Crankpin metal Part code No.

Metal thickness (mm) Standard

2/3TNE68

119260—23350

1.625

3TNE74

119620—23350

1.625

3TNE78A/82A

119810—23350

1.625

3/4TNE82 3/4TNE84(T) 3/4TNE88

129150—23350

1.625

Support the camshaft with V blocks. Using a dial gauge, measure the runout of the journal at the center of the camshaft, while rotating the camshaft. Take 50% of the measured runout as bend. (mm) All models

Camshaft bend

Standard

Wear limit

0.02 or less

0.05

7.6 CAMSHAFT 1. Camshaft side gap Before extracting the camshaft, bring a dial gauge into contact with the camshaft gear and measure the side gap around the camshaft. If the measured value exceeds the limit, replace the thrust metal with a new one.

4. Measuring the intake/exhaust cam height

(mm) All models 0.05~0.25

2. Checking the camshaft for appearance Check the camshaft for the contact surface of the tappet to the cam, seizure and wear of the bearing, and damage of the cam gear.

51 -66

14903 60413247

Side gap

COOLING WATER, LUBRICATING OIL AND FUEL OIL (mm)

2/3TNE68

Standard

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE74

Wear limit

Standard

Wear limit

Standard

Wear limit

Intake cam

29.970 33.950 38.635 29.75 33.75 38.40 ~30.030 ~34.050 ~38.765

Exhaust cam

29.970 33.950 38.635 29.75 33.75 38.40 ~30.030 ~34.050 ~38.765

Cam height

5. Measuring the outside diameter of the camshaft bearing Measure the outside diameter of the camshaft with a micrometer. Calculate the oil clearance from measured camshaft outside diameter and the camshaft bushing inside diameter measured with a cylinder gauge after inserting the camshaft bushing into the cylinder block. (mm)

2/3TNE68

Standard

3TNE74

Wear limit

Standard

Wear limit

Standard

Wear limit

Camshaft journal outside diameter

35.940 39.940 44.925 35.85 39.85 44.85 ~35.960 ~39.960 ~44.950

Oil clearance

0.040 ~0.085

Camshaft journal outside diameter

35.910 39.910 44.910 35.85 39.85 44.85 ~35.935 ~39.935 ~44.935

Oil clearance

0.065 ~0.115

Camshaft journal outside diameter

35.940 39.940 44.925 35.85 39.85 44.85 ~35.960 ~39.960 ~44.950

Oil clearance

0.040 ~0.125

Gear side

Intermediate

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

Flywheel side

—

0.040 ~0.085

0.065 ~0.115

0.040 ~0.125

—

0.040 ~0.130

0.065 ~0.115

0.040 ~0.100

—

6. Extracting the camshaft bushing Extract the bushing with camshaft bushing

14903 60413247

tool (refer to Chapter 5, 5.1.)

51-67

COOLING WATER, LUBRICATING OIL AND FUEL OIL

7.7 CRANKSHAFT 1. Side gap around the crankshaft Before extracting the crankshaft and when reassembling it, bring a dial gauge into contact to the end of the crankshaft. Force the crankshaft to both sides in the axial direction to measure the thrust gap. Alternatively, insert a thickness gauge directly into a thrust gap between the thrust metal in the standard part and crankshaft to measure the side gap. If the limit is exceeded, replace the thrust metal with a new one. (mm) All models Thrust gap

0.090~0.271

3. Checking the metal Check the metal for flaking, melting, seizure, and the state of the contact face. Replace the metal if found defective. 4. Bend of the crankshaft Support the crankshaft with V-blocks at both ends of the journals; measure the runout at the center journal with a dial gauge while rotating the crankshaft to check the extent of crankshaft bend. (mm)

All models Standard Bend

0.02 or less

14903 60413247

2. Color check of crankshaft Clean the crankshaft and check it using a color check kit or a magnaflux inspector. Replace the crankshaft if cracked or badly damaged. If the crankshaft is slightly damaged, correct it by re-grinding.

51 -68

COOLING WATER, LUBRICATING OIL AND FUEL OIL

5. Measurement of crankpin and journal Measure the outside diameter, roundness, taper angle of the crankpin and the journal. If uneven wear or roundness exceeds the wear limit but measured outside diameter is within the limit, use the crankpin and journal after correcting them by regrinding. Replace them with new ones, if any of the limit is exceeded. An oversized crankpin metal by 0.25 mm is available. (See this Chapter 7.5, 8.)

(mm) 2/3TNE68

3TNE74

3TNE78A 4TNE82A

3/4TNE82, 3/4TNE84(T),

3/4TNE88 Standard Wear limit Standard Wear limit Standard Wear limit Standard Wear limit 35.970 ~35.980

35.91

39.970 ~39.980

39.91

42.952 ~42.962

42.91

47.952 ~47.962

47.91

Crankshaft journal outside diameter Bearing metal thickness

39.970 ~39.980

39.90

43.970 ~43.980

43.90

46.952 ~46.962

46.91

53.952 ~53.962

53.91

1.487 ~1.500

—

1.987 ~2.000

—

1.987 ~2.000

—

1.995 ~2.010

—

Crank journal and bushing oil clearance

0.033 ~0.059

0.15

0.033 ~0.059

0.15

0.038 ~0.093

0.25

0.038 ~0.068

0.15

Crankpin outside Crankpin diameter

14903 60413247

Crank journal

51-69

COOLING WATER, LUBRICATING OIL AND FUEL OIL

6. Precautions in mounting the metal cap (1) The lower metal (cap side) has no oil groove. (2) The upper metal (cylinder block side) has an oil groove. (3) Check the cylinder block alignment No. (4) Place the relief mark “FW” of the cap on the flywheel side. (5) Place the main bearing metal on the flywheel side.

7. Undersized main metal by 0.25 mm and the oversized thrust metal by 0.25 mm Main metal

Thrust metal Metal thickness (mm) Standard

Part code

Metal thickness (mm) Standard

2/3TNE68

719260—02870

1.625

119260—02940

2.125

3TNE74

719620—02870

2.125

119620—02940

2.125

3TNE78A/82A

119810—02870

2.125

119810—02940

2.125

3/4TNE82 3/4TNE84(T) 3/4TNE88

129150—02870

2.125

129150—02940

2.125 14903 60413247

Part code

51 -70

COOLING WATER, LUBRICATING OIL AND FUEL OIL

7.8 GEARS 1. Checking gears Inspect the gears and replace if the teeth are damaged, worn, or chipped. 2. Measuring the backlash Apply a dial gauge onto the pitch circle of the gear, and measure the backlash. (mm)

Crankshaft gear, Camshaft gear, Back- Idle gear and lash Fuel injection pump drive gear

2/3TNE68, 3TNE74

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

0.04~0.12

0.07~0.15

L.O. pump gear

0.11~0.19

3. Checking and measuring the idling gear shaft and idling gear (1) Measure the bushing inside diameter and the idle gear shaft outside diameter, and replace the bushing or idling gear shaft if the oil clearance exceeds the wear limit. (mm) 2/3TNE68 3TNE74 Standard

Idle gear

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

Wear Wear Standard limit limit

Shaft outside 19.959 19.93 45.950 45.93 dia. ~19.980 ~45.975 Bushing 20.000 46.000 inside dia. ~20.021 â&#x20AC;&#x201D; ~46.025 46.08 Oil clearance 0.020 ~0.062

0.15

0.025 0.15 ~0.075

14903 60413247

(2) Make sure that the oil hole of the idle gear shaft and bushing is a through hole.

51-71

COOLING WATER, LUBRICATING OIL AND FUEL OIL

4. Gear train

14903 60413247

After installing each gear, make sure that aligning marks A , B and C of the idle gear are aligned with those of the fuel injection pump gear, cam gear and crank gear.

51 -72

COOLING WATER, LUBRICATING OIL AND FUEL OIL

7.9 TROCHOID PUMP 1. Clearance between outer rotor and pump body Insert a thickness gauge between the outer rotor and pump body to measure the clearance.

3. Side clearance between pump body and inner rotor, outer rotor Place a straight-edge against the end of the pump and insert a thickness gauge between the straight-edge and the rotors to measure the side clearance. 2/3TNE68 3TNE74

All models Wear limit

Standard Clearance between outer rotor and pump body

0.10~0.16

0.25

2. Clearance between outer rotor and inner rotor Insert a thickness gauge between the top of the inner rotor tooth and the top of the outer rotor tooth to measure the clearance. (mm)

Pump body and inner-, outer-rotor side clearance

3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE78A 3TNE82A

Standard

Wear Wear Wear limit Standard limit Standard limit

0.03 ~0.09

0.13

0.05 ~0.10 0.15

0.03 ~0.09

4. Clearance between rotor shaft and side cover hole Measure the rotor shaft outside diameter and the side cover hole diameter, and calculate the difference between the hole diameter and the outside diameter. (mm)

All models Standard

14903 60413247

Clearance between outer rotor and inner rotor

â&#x20AC;&#x201D;

0.15

All models

Wear limit

Standard

Wear limit

0.013 ~0.043

0.2

0.15 Clearance between rotor shaft and side cover hole

5. Others (1) Check for looseness of drive gear/rotor shaft fitting, and replace the entire assembly if loose or wobbly. (2) Push the oil pressure regulating valve piston from the oil hole side, and replace the entire assembly if the piston does not return due to spring breakage, etc. (Engine with oil cooler only) (3) Make sure that the rotor shaft rotates smoothly and easily when the drive gear is rotated. 51-73

COOLING WATER, LUBRICATING OIL AND FUEL OIL

14903 60413247

NOTE

51 -74

DISASSEMBLY AND ASSEMBLY

8. DISASSEMBLY AND REASSEMBLY Peripheral parts such as air cleaner, muffler and radiator differ in installation and types for each application. Therefore, description in this Chapter is started with the steps to be taken just after the peripheral parts have been removed.

Perform the procedure, with reference to the attached drawings, “Engine component Exploded View.”

8.1 DISASSEMBLY *

For the number following the part name, refer to attached drawing 1 and 2, “Exploded Views of Engine Components”

Step

Removal Parts

1. Thoroughly remove sand, dust, dirt and soil from the surface of the engine.

Remarks

2. Drain cooling water and lubricating oil from the engine. 2

1. Remove turbocharger 74 and exhaust manifold 1 . 2. Remove intake manifold 2 and surge tank 75 .

1. Close the fuel cock valve of the fuel tank.

1. If nozzle seat (7) is left on the cylinder head, remove the cylinder head before extracting nozzle seat (7).

2. Remove high-pressure fuel pipe (3).

2. To prevent dust from entering fuel injection nozzle (6), fuel injection pump (8) and high-pressure fuel pipe (3), seal their respective threads with a tape or the like.

3. Remove fuel return pipe (4). 4. Loosen the tightening nut on fuel injection nozzle retainer (5) and extract the retainer and fuel injection nozzle (6).

14903 60413247

3. Whenever extracting fuel injection nozzle (6), replace nozzle protector (9) with a new one.

Fuel injection nozzle for Indirect injection system is screwed type.

1. Remove bonnet assembly (10).

1. Remove valve rocker arm shaft assembly (11).

1. Attach a tag to push rod (12) for each cylinder No. to put the push rod in order.

2. Remove push rod (12).

2. Remove valve cap (13) from the intake/exhaust valve head. 3. Note that tappet (59) of the indirect injection system can be removed at the same time when push rod (12) is extracted. 4. Attach a tag to tappet (59) for each cylinder No. to put the tappet in order. 51-75

DISASSEMBLY AND ASSEMBLY

Step

Removal Parts

1. Remove fan mounting bolt (14), and then remove fan (15). 2. Loosen adjusting bolt (16) for the Vbelt adjuster, and then remove Vbelt (17).

Remarks 1. Never turn down alternator (18) vigorously toward the cylinder block. Otherwise, your finger may be nipped and alternator (18) broken.

3. Remove alternator (18). 4. Remove the spacer for cooling fan (19) and V-pulley (20). 7

1. Remove lubricating oil filter assembly (21). 2. Extract dipstick (22) from the oil dipstick hole.

1. Disconnect fuel return pipes (23) to (26). 2. Remove fuel filter (27).

1. Disconnect cooling water pipe (28) from the cooling water pump. 2. Remove thermostat assembly (29). 3. Remove cooling water pump (30).

1. Remove cylinder head tightening bolt (31). 2. Remove cylinder head assembly (32).

1. Lay a cardboard or the like on the floor and place cylinder head assembly (32) on it so as not to damage the combustion surface. 2. Order of loosening the cylinder head tightening bolts

14903 60413247

3. Remove cylinder head gasket (33).

51 -76

DISASSEMBLY AND ASSEMBLY

Step

Removal Parts

Remarks 3. To remove the intake/exhaust valves from cylinder head assembly(32), take the following steps: (1) Using a valve spring compressor (see Chapter 5, 5-1), compress valve spring (34) and remove valve cotter (35).

(2) Remove valve retainer (36) and valve spring (34). (3) Remove intake valve (37) and exhaust valve (38). 11

1. Remove crankshaft V-pulley clamping bolt (39).

1. Extract crankshaft V-pulley (40) by hitting the bolt of the puller using a plastic hammer or the like.

2. Using a puller, extract crankshaft Vpulley (40). 12

1. Remove oil pan mounting bolt (42) under gear case (41).

1. Never fail to remove stiffner bolt (44) at the center of the gear case.

2. Remove gear case mounting bolt (43).

2. When removing the gear case, carefully protect oil seal (45) from damage.

3. Remove gear case (41). 13

1. Remove the nut from fuel injection pump drive gear (46). Extract fuel injection pump drive gear (46) using a puller.

1. Remove lubricating oil pump (47).

1. Remove starting motor (55) from flywheel housing (54).

1. Remove flywheel mounting bolt (56).

1. Before removing fuel injection pump (8), make sure of the position of the arrow of the pump body for adjusting fuel injection timing as well as the position of the scribed line of the gear case flange. (Applies only to direct injection system.)

1. Carefully protect the ring gear from damage.

2. Remove flywheel (57).

14903 60413247

1. Remove flywheel housing (54).

1. Carefully protect the oil seal from damage.

2. Remove oil seal case (58) with a screwdriver or the like by utilizing grooves on both sides of oil seal case (58).

51-77

DISASSEMBLY AND ASSEMBLY

Step

Removal Parts

Remarks

1. Remove oil pan (60) and spacer (61).

1. Put the cylinder block with the attaching surface of the cylinder head facing down. 2. Carefully protect the combustion surface of the cylinder block from damage. 3. For indirect injection system, be careful to the possibility of the tappet to drop off when the cylinder block is turned upside down, because the tappet is cylindrical in shape.

1. Remove idle gear shaft (48), and then remove idle gear (49).

1. Turn the cylinder block aside and carefully prevent tappet (59) from jamming on the cam.

2. Remove mounting bolt (52) of thrust bearing (51) through the hole of the camshaft gear (50). Remove camshaft assembly (53).

2. Preheat camshaft gear (50) and camshaft assembly (53) to 180Ë&#x161;C ~ 200Ë&#x161;C which are shrink fitted, before removing them.

1. Remove gear case flange (62).

1. Remove lubricating oil strainer (63).

1. Remove crankpin side cap (64) of the connecting rod. l While turning crankshaft (65), place piston (66) in the bottom dead center (BDC).

1. Before extracting piston (66), remove carbon deposits from the upper wall of the cylinder using fine sandpaper, while taking care not to damage the inner surface of the cylinder. 2. Make sure that cap No. of connecting rod (67) agrees with cylinder No. 3. Take care not to let crankpin metal (68) fall when removing connecting rod crankpin side cap (64).

1. Remove main bearing cap bolt (69). While shaking main bearing cap (70), remove main bearing cap (70) together with lower main bearing metal (71).

1. Before extracting crankshaft (65), measure the side gap around it.

2. Extract crankshaft (65), taking care not to damage it.

14903 60413247

3. Remove upper main bearing metal (72).

51 -78

DISASSEMBLY AND ASSEMBLY

Step

Removal Parts

Remarks

Apply a dial gauge to the end of crankshaft (65). Force the crankshaft on both sides in the axial direction to measure the thrust gap. Alternatively, insert a thickness gauge directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap. If the limit size is exceeded, replace the thrust metal with a new one. (mm) All models Thrust gap

0.090 ~ 0.271

2. Notice on the removal of thrust metal 73 (1) When removing thrust metal (73), ascertain the position and direction where thrust metal is installed in relation to the cap. (2) Make sure that the thrust metal groove is outward in relation to the cap. 24

1. Remove piston (66) and connecting rod (67) assembly.

1. To selectively remove a desired piston and connecting rod assembly without extracting crankshaft (65), take the steps itemized below: (1) Remove carbon deposits from the upper wall of the cylinder using fine sandpaper, taking care not to damage the inner surface of the cylinder. (2) While turning the crankshaft, with the crankpin side cap 64 removed, raise the piston up to the top dead center (TDC). (3) Extract the piston/connecting rod assembly while tapping the connecting rod (67) at the large end with the handle of a plastic hammer or the like.

1. Remove tappet (59).

14903 60413247

51-79

DISASSEMBLY AND ASSEMBLY

8.2 PRECAUTIONS BEFORE AND DURING REASSEMBLY To reassemble engine components, reverse the procedure of diassembly. However, follow the precautions below particularly before and during reassembly. (1) Cleaning the component Use particular care to clean the cylinder block, cylinder head, crankshaft, and camshaft. Ensure that they are free from chips, dust, sand, and other foreign matter.

directly between the base thrust metal and the thrust surface of the crankshaft to measure the gap. If the limit size is exceeded, replace the thrust metal with a new one. (mm) All models Thrust gap

0.090 ~ 0.271

(2) Parts to be replaced during reassembly Be sure to replace the following parts with new ones during assembly. (1) Valve stem seal (2) Head gasket packing (3) Nozzle protector of the fuel injection valve (4) Various copper packings, O-rings and gasket packings. (3)

Measuring the side gap around crankshaft Apply a dial gauge to the end of the crankshaft. Force the crankshaft on both sides in the axial direction to measure the thrust gap. Alternatively, insert a thickness gauge

14903 60413247

(4) Gear train After having installed each gear, make sure that marks (A), (B) and (C) of the idle gear align with marks of the fuel injection pump drive gear, camshaft gear and crankshaft gear as shown below.

51 -80

DISASSEMBLY AND ASSEMBLY

(5) Where to use liquid packings 1. Between the cylinder block and gear case flange 2. Between the gear case flange and gear case cover 3. Between the cylinder block and oil seal case (indirect injection system only) 4. Oil pan installation surface

2. Assemble the piston rings to the cylinder, staggering the piston rings joints at 120Ë&#x161; intervals, making sure that they are not aligned along the piston. Apply lube oil to the circumference of the piston.

* Use Three Bond No. 005 (Yanmar part code: 97777-001212) as the liquid packing. * Apply the liquid packing so as not to form any break on the midway. Otherwise, oil leakage, etc., may result.

(6) Coating the lubricating oil on intake/ exhaust valve stem

Apply lubricating oil down to the lower surface (hatched portion in the figure) of the valve guide before reassembling the valve stem.

14903 60413247

(7) Reassembly of the piston ring 1. Insert the piston ring into the ring groove, where the side with the manufacturerâ&#x20AC;&#x2122;s mark on the matching ends facing up (to the combustion chamber side), using a piston ring replacer. After fitting the piston ring, make sure it moves easily and smoothly.

51-81

DISASSEMBLY AND ASSEMBLY

(8)

Coating the lubricating oil to pushrod adjusting screw contact Apply lubricating oil to the hatched portion of the push rod as shown in the figure, before reassembly.

(9)

Assembly direction of piston and connecting rod

3TNE78A, 3TNE82A, 3/4TNE82 3/4TNE84(T), 3/4TNE88

14903 60413247

Connecting rod

Piston

2/3TNE68, 3TNE74

51 -82

DISASSEMBLY AND ASSEMBLY

(10) Order of tightening cylinder heads and tightening torque

Tighten cylinder heads in numerical order shown below to the specified torque.

(kgf-m)

Tightening torque

2/3TNE68

3TNE74

3TNE78A 3TNE82A

3/4TNE82 3/4TNE84(T) 3/4TNE88

3.8 ~4.2

6.0~6.5

6.8~7.2

8.7~9.3

14903 60413247

(11) After having reassembled the cylinder heads, carry out confirmation running to see if they are free from leakage of water and oil.

51-83

DISASSEMBLY AND ASSEMBLY

14903 60413247

NOTE

51 -84

SERVICE DATA

9. SERVICE DATA 9.1 CYLINDER HEAD (Unit: mm) Model 2/3TNE68 Standard

Wear limit

Standard

Wear limit

Standard

Wear limit

Standard

Wear limit

0.05 or less

0.15

0.05 or less

0.15

0.05 or less

0.15

0.05 or less

0.15

Intake

120°

—

120°

—

120°

—

120°

—

Exhaust

90°

—

90°

—

90°

—

90°

—

Intake

1.15

1.65

1.44

1.98

1.36~1.53

1.98

1.07~1.24

1.74

Exhaust

1.41

1.91

1.77

2.27

1.66~1.87

2.27

1.24~1.45

1.94

Item Cylinder head combustion surface distortion Valve seat angle

Valve seat width

Valve stem outside dia. Intake valve

Valve guide inside dia. Oil clearance Valve stem outside dia.

Exhaust valve

Valve guide inside dia. Oil clearance

5.460 ~5.475 5.500 ~5.515 0.025 ~0.055 5.445 ~5.460 5.500 ~5.515 0.040 ~0.070 7

Valve guide projection

Valve sinking

Thickness of valve head

Intake valve timing

5.4 5.58 0.18 5.4 5.58 0.18

6.960 ~6.975 7.005 ~7.020 0.030 ~0.060 6.945 ~6.960 7.005 ~7.020 0.045 ~0.075

—

0.3~0.5

Intake valve depth

14903 60413247

Valve spring

6.9 7.08 0.18 6.9 7.08 0.18 —

1.0

6.945 ~6.960 7.000 ~7.015 0.040 ~0.070 6.940 ~6.955 7.000 ~7.015 0.045 ~0.075 12

6.9 7.08 0.18 6.9 7.08 0.18 —

0.296 ~0.496

0.4~0.6 1.0

7.955 ~8.025 8.010 ~7.975 0.035 ~0.070 7.955 ~8.030 8.015 ~7.970 0.045 ~0.075 15

1.0

VM: 0.75~0.95 CH: 0.40~0.60 VH: 0.40~0.60

Intake valve

0.85~1.15

0.99~1.29

Exhaust valve

0.95~1.25

1.35~1.55

7°~17°

10°~20°

Open

b.TDC

5°~15°

a.BDC

37°~47°

0.5

35°~45°

0.3~0.5

1.244 ~1.444

0.5

40°~50° —

8.1 0.2 7.9 8.1 0.2 —

1.0

0.75~0.95

0.5

7.9

0.306 ~0.506

Exhaust valve

— Exhaust valve timing

3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE78A 3TNE82A

3TNE74

0.5

40°~50° —

—

Open

b.BDC

37°~47°

40°~50°

51°~60°

51°~61°

a.TDC

5°~15°

8°~18°

13°~23°

Free length

—

37.4

—

44.4

—

Inclination

—

0.8

—

1.0

—

1.1

—

1.1

1.14 ~1.40

—

(variable pitch)

—

(variable pitch)

—

(variable pitch)

Tension (kg) (when compressed to 1mm length) Intake & exhaust valve clearance

2.37

3.61 /1.87

0.15~0.25

—

0.15~0.25

2.36 /2.71

—

0.15~0.25

—

/3.101 —

0.15~0.25

—

51-85

SERVICE DATA

9.2 CYLINDER BLOCK (Unit: mm) Model 2/3TNE68 Standard

Item

68.000 ~68.030 68.020 ~68.030 68.010 ~68.020 68.000 ~68.010 0.00 ~0.01 0.00 ~0.01

Cylinder bore L mark Cylinder bore

M mark S mark

Cylinder roundness Cylindricity

Model

82.000 ~82.030 82.020 ~82.030 82.010 ~82.020 82.000 ~82.010 0.00 ~0.01 0.00 ~0.01

Cylinder bore L mark Cylinder bore

M mark S mark

Cylinder roundness Cylindricity

Wear limit

68.20

0.03 0.03

3TNE82A 3/4TNE82A Standard

Item

3TNE74 Standard 74.000 ~74.030 74.020 ~74.030 74.010 ~74.020 74.000 ~74.010 0.00 ~0.01 0.00 ~0.01

3TNE78A Wear limit

74.20

0.03 0.03

3/4TNE84(T)

Wear limit

82.20

0.03 0.03

Standard 84.000 ~84.030 84.020 ~84.030 84.010 ~84.020 84.000 ~84.010 0.00 ~0.01 0.00 ~0.01

Wear limit

Standard 78.000 ~78.030 78.020 ~78.030 78.010 ~78.020 78.000 ~78.010 0.00 ~0.01 0.00 ~0.01

78.20

0.03 0.03

3/4TNE88

Wear limit

84.20

0.03 0.03

Standard 88.000 ~88.030 88.020 ~88.030 88.010 ~88.020 88.000 ~88.010 0.00 ~0.01 0.00 ~0.01

Wear limit

88.20

0.03 0.03

9.3 VALVE ROCKER ARM (Unit: mm)

2/3TNE68

Item

Intake & Exhaust rocker arm

Rocker arm shaft outside dia. Rocker arm bushing inside dia. Oil clearance

Pushrod bending

Tappet

Tappet stem outside dia. Tappet guide hole inside dia. Oil clearance

51 -86

3TNE74

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88 Wear Standard limit

Standard

Wear limit

Standard

Wear limit

9.972~9.987

9.95

11.966~11.984

11.95

15.966~15.984

15.95

10.000~10.020

10.09

12.000~12.020

12.09

16.000~16.020

16.09

0.013~0.048

0.14

0.016~0.054

0.14

0.016~0.054

0.14

0.03 or less

—

0.03 or less

—

0.03 or less

—

17.950~17.968

17.93

20.927~20.960

20.90

11.975~11.990

11.93

18.000~18.018

18.05

21.000~21.021

21.05

12.000~12.018

12.05

0.032~0.068

0.12

0.040~0.094

0.15

0.010~0.043

0.12

14903 60413247

Model

SERVICE DATA

9.4 PISTON (Unit: mm) Model

2/3TNE68 VM, VH

Piston outside dia. L mark ML mark MS mark S mark Min. clearance between piston and cylinder

67.960 ~67.990 67.980 ~67.990 67.975 ~67.980 67.970 ~67.975 67.960 ~67.970 0.025 ~0.055

67.940 ~67.970 67.960 ~67.970 67.90

3TNE82A

—

Piston pin outside dia. Piston pin hole dia.

20.000 ~20.008 0.000 ~0.017

Oil clearance

73.940 ~73.970 73.960 ~73.970

77.950 ~77.980 77.970 ~77.980

81.950 ~81.980 81.970 ~81.980

67.955 73.955 77.965 81.965 67.90 73.90 77.90 81.90 ~67.960 ~73.960 ~77.970 ~81.970 67.950 73.950 77.960 81.960 ~67.955 ~73.955 ~77.965 ~81.965 67.940 73.940 77.950 81.950 ~67.950 ~73.950 ~77.960 ~81.960 0.045 0.045 0.035 0.035 — — — — ~0.075 ~0.075 ~0.065 ~0.065

0.610 ~0.730 19.991 ~20.000

Top clearance

Piston and piston pin

3TNE78A

Standard Wear Standard Wear Standard Wear Standard Wear Standard Wear limit limit limit limit limit

Item

Piston outside dia.

3TNE74

— 19.90 20.02 0.12

0.658 0.650 0.650 — — — ~0.778 ~0.770 ~0.770 20.991 22.991 22.991 20.90 22.90 22.90 ~21.000 ~23.000 ~23.000 21.000 23.000 23.000 21.02 23.02 23.02 ~21.008 ~23.008 ~23.008 0.000 0.000 0.000 0.12 0.12 0.12 ~0.017 ~0.017 ~0.017

Model 3/4TNE82 Standard

Item Piston outside dia. L mark Piston outside dia.

ML mark MS mark S mark

Min. clearance between piston and cylinder Top clearance Piston pin outside dia. Piston and piston pin

Piston pin hole dia.

Wear limit

81.90

— — 25.90 26.02 0.12

Standard 83.945 ~83.975 83.965 ~83.975 83.960 ~83.965 83.955 ~83.960 83.945 ~83.955 0.040 ~0.070 0.660 ~0.780 25.987 ~26.000 26.000 ~26.009 0.000 ~0.022

3/4TNE88

Wear limit

83.90

— — 25.90 26.02 0.12

Standard 87.945 ~87.975 87.965 ~87.975 87.960 ~87.965 87.955 ~87.960 87.945 ~87.955 0.040 ~0.070 0.660 ~0.780 25.987 ~26.000 26.000 ~26.009 0.000 ~0.022

Wear limit

87.90

— — 25.90 26.02 0.12

14903 60413247

Oil clearance

81.945 ~81.975 81.965 ~81.975 81.960 ~81.965 81.955 ~81.960 81.945 ~81.955 0.040 ~0.070 0.660 ~0.780 25.987 ~26.000 26.000 ~26.009 0.000 ~0.022

3/4TNE84(T)

51-87

SERVICE DATA

9.5 PISTON RING (Unit: mm) Model

Standard

Item Ring groove width Ring width Top ring Min. side clearance End clearance Ring groove width

2nd ring

Ring width Min. side clearance End clearance Ring groove width

Oil ring

Ring width Min. side clearance End clearance

Model

Ring groove width Ring width Top ring Min. side clearance End clearance Ring groove width Ring width Min. side clearance End clearance Ring groove width

Oil ring

Ring width Min. side clearance End clearance

51 -88

Wear limit — — — 1.5 — — — 1.5 — — — 1.5

3TNE82A 3/4TNE82 Standard

Item

2nd ring

1.550 ~1.570 1.470 ~1.490 0.060 ~0.100 0.100 ~0.250 1.540 ~1.555 1.430 ~1.450 0.090 ~0.125 0.150 ~0.350 3.010 ~3.025 2.970 ~2.990 0.020 ~0.055 0.150 ~0.350

3TNE74

2.065 ~2.080 1.970 ~1.990 0.075 ~0.110 0.200 ~0.400 2.035 ~2.050 1.970 ~1.990 0.045 ~0.080 0.200 ~0.400 4.015 ~4.030 3.970 ~3.990 0.025 ~0.060 0.200 ~0.400

Standard

3TNE78A Wear limit

1.550 ~1.570 1.470 ~1.490 0.060 ~0.100 0.200 ~0.400 1.520 ~1.535 1.410 ~1.430 0.090 ~0.125 0.200 ~0.400 3.010 ~3.025 2.970 ~2.990 0.020 ~0.055 0.150 ~0.350

— — — 1.5 — — — 1.5 — — — 1.5

3/4TNE84(T) Wear limit — — — 1.5 — — — 1.5 — — — 1.5

Standard 2.065 ~2.080 1.970 ~1.990 0.075 ~0.1100 0.200 ~0.400 2.035 ~2.050 1.970 ~1.990 0.045 ~0.080 0.200 ~0.400 4.015 ~4.030 3.970 ~3.990 0.025 ~0.060 0.200 ~0.450

Standard 2.035 ~2.050 1.940 ~1.960 0.075 ~0.110 0.200 ~0.400 2.025 ~2.040 1.975 ~1.990 0.035 ~0.065 0.250 ~0.400 3.015 ~3.030 2.970 ~2.990 0.025 ~0.060 0.200 ~0.400

Wear limit — — — 1.5 — — — 1.5 — — — 1.5

3/4TNE88

Wear limit — — — 1.5 — — — 1.5 — — — 1.5

Standard 2.060 ~2.075 1.970 ~1.990 0.070 ~0.105 0.200 ~0.400 2.025 ~2.040 1.970 ~1.990 0.035 ~0.070 0.200 ~0.400 4.015 ~4.030 3.970 ~3.990 0.025 ~0.060 0.200 ~0.400

Wear limit — — — 1.5 — — — 1.5 — — — 1.5

14903 60413247

2/3TNE68

SERVICE DATA

9.6 CONNECTING ROD (Unit: mm) Model 2/3TNE68 Standard

Item

Crankpin side

Crankpin bushing inside dia. Crankpin metal thickness Crankpin outside dia. Oil clearance Piston pin bushing inside dia.

Piston pin side Piston pin outside dia. Oil clearance Twist and parallelism

39.000 ~39.016 1.487 ~1.500 35.970 ~35.980 0.033 ~0.059 20.025 ~20.038 19.991 ~20.000 0.025 ~0.047 Less than 0.03 per 100 mm

Wear limit

Standard

43.000 ~43.016 1.487 — ~1.500 39.970 35.91 ~39.980 0.033 0.15 ~0.059 21.025 20.10 ~21.038 20.991 19.90 ~21.000 0.025 0.2 ~0.047 Less than 0.08 0.03 per 100 mm —

3/4TNE82, 3/4TNE84(T), 3/4TNE88

3TNE78A 3TNE82A

3TNE74 Wear limit

Standard

46.000 ~46.016 1.487 — ~1.500 42.952 39.91 ~42.962 0.038 0.15 ~0.090 23.025 21.10 ~23.038 22.991 20.90 ~23.000 0.025 0.2 ~0.047 Less than 0.08 0.03 per 100 mm —

Wear limit

Standard

51.000 ~51.010 1.492 — ~1.500 47.952 42.91 ~47.962 0.038 0.16 ~0.074 26.025 23.10 ~26.038 25.987 22.90 ~26.000 0.025 0.2 ~0.051 Less than 0.08 0.03 per 100 mm —

Wear limit — — 47.91 0.16 26.10 25.90 0.2 0.08

9.7 CAMSHAFT (Unit: mm) 3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88 Wear Standard limit 44.925 44.85 ~44.950 0.040 — ~0.130 44.910 44.85 ~44.935 0.065 — ~0.115 44.925 44.85 ~44.950 0.050 — ~0.100

Model 2/3TNE68

Gear side

Camshaft journal outside dia. Oil clearance

Intermediate

Camshaft journal outside dia. Oil clearance

Flywheel side

Wear limit

Standard

Item

Camshaft journal outside dia. Oil clearance

3TNE74

35.940 ~35.960 0.040 ~0.085 35.910 ~35.935 0.065 ~0.115 35.940 ~35.960 0.040 ~0.125

35.85 — 35.85 — 35.85 —

Standard 39.940 ~39.960 0.040 ~0.085 39.910 ~39.935 0.065 ~0.115 39.940 ~39.960 0.040 ~0.125

Wear limit 39.85 — 39.85 — 39.85 —

9.8 CRANKSHAFT (Unit: mm) Model 2/3TNE68 Standard

14903 60413247

Item

Crank journal

Bend

Crankshaft journal outside dia. Bearing metal thickness Crank journal and bushing oil clearance

Wear limit

3TNE74 Standard

Wear limit

3TNE78A 3TNE82A Standard

Wear limit

3/4TNE82, 3/4TNE84(T), 3/4TNE88 Standard

Wear limit

39.970 43.970 46.952 53.952 39.90 43.90 46.91 53.91 ~39.980 ~43.980 ~46.962 ~53.962 1.487 1.987 1.987 1.995 — — — — ~1.500 ~2.000 ~2.000 ~2.000 0.033 0.033 0.038 0.038 0.15 0.15 0.25 0.15 ~0.059 ~0.059 ~0.093 ~0.068 0.02 0.02 0.02 0.02 — — — — or less or less or less or less

51-89

SERVICE DATA

9.9 SIDE GAP AND BACKLASH (Unit: mm) Model

All models Standard

Item Crankshaft

0.090~0.271

Camshaft

0.05~0.25

Side gap Connecting rod

0.2~0.4

Idle gear

0.1~0.3

(Unit: mm) Model 2/3TNE68, 3TNE74 Item

Backlash

Crankshaft gear, Camshaft gear, Idle gear and Fuel injection pump drive gear

0.04 ~ 0.12

L.O. pump gear

3TNE78A/82A, 3/4TNE82, 3/4TNE84(T), 3/4TNE88

0.07 ~ 0.15

0.11 ~ 0.19

9.10 OTHERS (Unit: mm) Model 2/3TNE68

3TNE74

Item

Cooling water pump discharge volume

Thermostat valve opening temperature Thermoswitch operating temperature

51 -90

L/min

3/4TNE82, 3/4TNE84(T), 3/4TNE88

11.9 (at 3600rpm) 15.8 (at 3600rpm) 19.6 (at 3600rpm) 25.0 (at 3000rpm) 2.5 (at 750rpm) 4.4 (at 800rpm) 8.0 (at 800rpm)

kgf/cm2

3.0~4.0

kgf/cm2

0.4~0.6

35 (at 3220~ 3280 rpm)

70 (at 3220~ 3280 rpm)

69.5~72.5

L/min

Opening temperature

°C

Lift height

45 (at 4320~ 55 (at 4320~ 4380 rpm) 4380 rpm) 32 (at 3320~ 40 (at 3320~ 3380 rpm) 3380 rpm) 69.5~72.5

69.5~72.5

Min. 4.5 Min. 8.0 Min. 8.0 Min. 8.0 (at 85°C and above) (at 85°C and above) (at 85°C and above) (at 85°C and above) 107~113

107~113

100 and above

°C OFF

14903 60413247

High speed operation Low speed operation Pressure control valve opening pressure L.O. pressure switch operating pressure Lubricating oil pump discharge volume

3TNE78A 3TNE82A

TIGHTENING TORQUE

10. TIGHTENING TORQUE 10.1 MAIN BOLT/NUT (Unit: kgf-m) Model No.

Item

2/3TNE68

3TNE74

3TNE78A 3TNE82A

3/4TNE82, 3/4TNE84(T), 3/4TNE88

Torque 1

Cylinder head bolt

Lubricating oil applied (Thread dia. X pitch)

3.8~4.2 (M8 X 1.25)

6.0~6.5 (M9 X 1.25)

6.8~7.2 (M9 X 1.25)

8.7~9.3 (M10 X 1.25)

Connecting rod bolt

Lubricating oil applied (Thread dia. X pitch)

2.3~2.8 (M7 X 1.0)

2.3~2.8 (M7 ¥ 1.0)

3.8~4.2 (M8 X 1.0)

4.5~5.5 (M9 X 1.0)

Flywheel clamping bolt

Lubricating oil applied (Thread dia. X pitch)

8.2~8.8 (M10 X 1.25)

8.0~9.0 (M10 ¥ 1.25)

8.5~9.0 (M10 X 1.25)

Metal cap clamping bolt

Lubricating oil applied (Thread dia. X pitch)

5.3~5.7 (M9 X 1.25)

8.0~8.5 (M10 ¥ 1.25)

7.8~8.2 (M10 X 1.5)

9.8~10.2 (M12 X 1.5)

Crankshaft V-pulley clamping bolt

Fuel injection nozzle nut

S48C:11.5~12.5 S48C:11.5~12.5 FC25: 8.5~9.5 FC25: 8.5~9.5 (M12 X 1.5) (M12 X 1.5) 5.0~5.45.0~5.4 0.7~0.9 Lubricating oil not applied (M20 X 1.5) (M20 X 1.5) (Thread dia. X pitch)

Timer clamping nut

Lubricating oil not applied (Thread dia. X pitch)

Glow plug

Lubricating oil not applied (Thread dia. X pitch)

1.5~2.0 (M10 X 1.25)

—

Stub shaft bolt

Lubricating oil not applied (Thread dia. X pitch)

5.5~6.5 (M10 X 1.5)

—

10 Governor weight support nut

Lubricating oil not applied (Thread dia. X pitch)

7.0~7.5 (M12 X 1.25)

4.5~5.0 (M12 X 1.25)

11 High pressure pipe sleeve clamping nut

Lubricating oil not applied (Thread dia. X pitch)

3.0~3.5 (M12 X 1.5)

Lubricating oil applied (Thread dia. X pitch)

—

8.5~9.5 FC25C (M14 X 1.5) 0.7~0.9 (M6 X 1.0) 6.0~7.0 (M12 X 1.75)

•Material S48C(taper) • FC25 (taper) 8.5~9.5 11.5~12.5 (M14 X 1.5)

(M6 X 1.0) 6.0~7.0 (M12 X 1.75)

10.2 STANDARD BOLT AND NUT * : Lubricating oil not applied (Unit: kgf-m) Item Hexagon headed bolt (7T) and nut

PT plug

14903 60413247

Pipe joint bolt

Thread dia. ¥ pitch

Tightening torque

Remarks

M6 x 1

1.0~1.2

M8 x 1.25

2.3~2.9

1) When bolting the aluminum parts, tighten the bolts with 80% of the tightening torque specified in the Table. 2) 4T bolt and lock nut should be tightened with 60% of the torque shown in the table.

M10 x 1.5

4.5~5.5

M12 x 1.75

8.0~10.0

1/8

1.0

1/4

2.0

3/8

3.0

1/2

6.0

1.3~1.7

M12

2.5~3.5

M14

4.0~5.0

M16

5.0~5.5

51-91

TIGHTENING TORQUE

14903 60413247

NOTE

51 -92

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

11. FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

06902 60413249

11.1 EXPLODED VIEW (YPFR TYPE)

51-93

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

11.2 DISASSEMBLY

(4) Remove the plunger spring and plunger spring lower retainer.

To disassemble the fuel injection pump, classify disassembled parts for each cylinder and carefully avoid allowing them to be mixed with one another. Identifiably classify paired parts supplied as assemblies, such as “plunger and plunger barrel” and “delivery valve and delivery valve holder” for each cylinder. Use particular care to prevent the assembly from going to pieces and being scattered. (1) Remove the fuel injection pump. (2) Extract the plunger guide stopper pin and remove the plunger guide stopper and plunger barrel stopper.

(6) Remove the delivery valve spring holder and then remove fuel control rack, delivery valve holder, delivery valve spring and delivery valve.

06902 60413249

(3) Remove the right plunger roller guide assembly.

(5) Remove the plunger spring upper retainer and the fuel control pinion.

51-94

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

(7) Remove the plunger barrel assembly.

11.3 INSPECTION Before inspection, thoroughly clean the parts, using new diesel oil. Be careful to avoid damage to the sliding surface of the plunger and delivery valve, etc.

(8) Remove the other plungers by repeating the above steps. *

(1) Plunger guide outer roller, inner roller and plunger roller guide. Inspect for wear and scratches with the plunger guide outer roller, inner roller and plunger roller guide. If a gap between the fuel injection pump camshaft and plunger guide outer roller exceeds 0.3 mm, replace the plunger roller guide assembly with a new one.

Never loosen the eccentric screw for adjusting and set screw for the fuel injection volume adjusting plate.

06902 60413249

(2) Fuel control rack and fuel control pinion 1. Inspect for bending of fuel control rack and wear or deformation of engaged surface of fuel control pinion and fuel control rack.

2. Check to see if the fuel control rack moves smoothly. If not, replace the fuel control rack with a new one.

51-95

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

(3) Plunger 1. Thoroughly clean the plunger. If any plunger lead is scratched or discolored, replace the plunger assembly with a new one.

2. To test the plunger, hold the plunger barrel tilted approx. 60Ë&#x161; and check to see if it slides down smoothly. If so, the plunger is acceptable. While turning the plunger, repeat the test several times. If any plunger slides down too quickly (slowly) or jams in the midway, correct it or replace the whole plunger assembly.

2. Stop up the hole in the bottom of the delivery valve holder and keep the seat as it is. Insert the delivery valve to the holder. While releasing your upper finger, check to see if the delivery valve springs back. If so, it is acceptable.

3. Likewise as described in item 2, stop up the hole in the bottom of the delivery valve holder and check to see if the delivery valve perfectly falls by gravity, when the finger is released from the bottom hole. If so, the delivery valve is acceptable. If not, replace it.

06902 60413249

(4) Delivery valve 1. If the suck-back collar or seat of the delivery valve is found scratched, dented, worn, or otherwise damaged, replace the whole delivery valve assembly.

51-96

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

11.4 REASSEMBLY (1) Insert the plunger barrel packing into the fuel injection pump body. (2) Insert the plunger barrel assembly.

(5) Fit the plunger mounted with the plunger spring upper retainer, plunger spring and plunger spring lower retainer. * Ensure that the match mark of the plunger aligns with that of the fuel control pinion.

(3) Fit the delivery valve assembly, delivery valve spring and delivery valve spring holder. (kgf-m) Delivery valve spring holder tightening torque.

4.0 ~4.5

(6) Insert the plunger adjusting shim. Press the plunger guide assembly by hand. While aligning the plunger guide stopper pin with the mating hole of the stopper pin of the fuel injection pump body, attach the plunger guide stopper pin.

06902 60413249

(4) Reassemble the fuel control rack and fuel control pinion. * 1. Ensure that the match mark of the fuel control rack aligns with that of the fuel control pinion. * 2. Make sure that the fuel control rack moves smoothly over alla the strokes.

51-97

FUEL INJECTION PUMP FOR INDIRECT INJECTION SYSTEM

06902 60413249

NOTE

51-98

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

12. FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

14903 60413247

12.1 EXPLODED VIEW (YPES TYPE)

51-99

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

12.2 SPECIAL SERVICE TOOLS FOR DISASSEMBLY AND REASSEMBLY No. 1

Name of tool Side clearance measuring gauge Yanmar code No.

158090-51050

158090-51100

158090-51200

Rack lock screw Yanmar code No.

Measurement of camshaft side clearance

Tappet holder tool Yanmar code No.

Application

Plunger insertion tool Yanmar code No.

Shape and size

158090-51510

Governor weight extractor tool Yanmar code No. Governor weight for 3 pcs. 158090-51400

14903 60413247

Governor weight for 4 pcs. 158090-51450

51-100

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

12.3 DISASSEMBLY (1) Remove the bottom cover from the fuel injection pump to drain lubricating oil from the fuel injection pump.

(4) Remove the fuel feed pump. * Do not disassemble the fuel feed pump.

(2) Turn the fuel injection pump upside down to drain fuel oil.

(5) Remove the fuel injection pump side cover.

(3) Take out the governor weight assembly using the governor weight extractor (special service tool) For separating the governor assembly from the fuel injection pump, refer to Chapter 13, 13-3.

14903 60413247

51-101

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(6) While turning the fuel injection pump camshaft, raise the plunger guide up to the max. stroke. Insert the tappet holders (special service tool) between the plunger spring lower retainer and fuel injection pump body.

(9) Turn the fuel injection pump upside down. Move all plunger guides toward the plunger. Then, turn aside the fuel injection pump. While turning the fuel injection pump camshaft, find a position where the cams of each cylinder does not interfere with the plunger guide outer roller and place the camshaft in the position. (10) Apply a plate against the governor end side of the camshaft. While tapping the plate, extract a set of the camshaft and drive bearing.

(Special service tool: Tappet Holder) (7) Extract the woodruff key from the fuel injection pump camshaft. (8) Extract the fuel injection pump camshaft bearing horizontally by inserting two screwdrivers into the two grooves on the face where the bearing holder of the fuel injection pump camshaft is installed.

(11) Remove the plunger guide stopper.

14903 60413247

*1. Carefully avoid allowing the thread of the fuel injection pump camshaft to damage the oil seal. *2. Carefully avoid allowing the adjusting packings and oil seal between the pump body and bearing holder to be lost.

51-102

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(12) By using the handle of a hammer, etc., push up the plunger guide from the bottom of the pump and take out the tappet holders (special service tool). *

* Separate these parts for each cylinder.

Use particular care to remove the tappet holder. Carefully prevent the plunger guide, plunger, etc., from jumping out. This is because the plunger spring is powerful enough to force them out.

(13) Take out the plunger guide assembly.

(15) Remove the stop screw from the fuel control pinion.

Do not erect the fuel injection pump body, wherever possible. Otherwise, the plunger guide assembly falls off. Therfore, hold the fuel injection pump body tilted and remove the plunger guide assembly.

14903 60413247

(14) Take out the plunger, plunger spring and plunger spring lower reteiner from the lower part of the fuel injection pump.

51-103

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

*1. When the stop screw of the fuel control pinion is loosened, the fuel control pinion is separated from the control sleeve. Before loosening, therefore, make sure that the match mark of the fuel control pinion aligns with that of the control sleeve. If the match mark is difficult to identify or the match mark offsets, put new match marks. This practice helps adjusting injection volume later on.

Carefully prevent the control rack spring and spacer on the control rack from being missing.

(18) Loosen the bolt for the holder stopper. Remove the delivery valve sping holder. *2. Separate all these parts for each cylinder.

(16) Remove the fuel control pinion, control sleeve and plunger spring upper retainer. *: Separate all these parts for each cylinder.

14903 60413247

(17) Remove the control rack stopper. Extract the control rack.

51-104

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(19) Take out the delivery valve assembly. *

1. Carefully prevent small parts such as the delivery valve packing, delivery valve spring and delivery valve stopper from being missing. 2. Clearly separate the delivery valve assembly for each cylinder.

12.4 INSPECTION Before inspection, thoroughly clean the parts, using new diesel oil. Be careful to avoid damage to the sliding surface of the plunger and delivery valve, etc. (1) Plunger 1. Thoroughly clean the plunger. If any plunger lead is scratched or discolored, replace the plunger assembly with a new one. 2. To test the plunger, hold the plunger barrel tilted approx. 60Ë&#x161; and check to see if it slides down smoothly. If so, the plunger is acceptable. While turning the plunger, repeat the test several times. If any plunger slides down too quickly (slowly) or jams in the midway, correct it or replace the whole plunger assembly.

(20) Take out the plunger barrel toward the upper part of the fuel injection pump. * Keep the plunger barrel just picked up together with the plunger which has been taken out.

14903 60413247

(2) Delivery valve 1. If the suck-back collar or seat of the delivery valve is found scratched, dented, worn,or otherwise damaged, replace the whole delivery valve assembly.

51-105

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

2. Stop up the hole in the bottom of the delivery valve holder and keep the seat as it is. Insert the delivery valve into the holder. While releasing your upper finger, check to see if the delivery valve springs back. If so, it is acceptable. If not, replace it. 3. Likewise as described in item 2, stop up the hole in the bottom of the delivery valve holder and check to see if the delivery valve falls by gravity perfectly, when the bottom holeâ&#x20AC;&#x2122;s finger is released. If so, the delivery valve is acceptable. If not, replace it.

(4) Fuel injection pump camshaft and bearing 1. Fuel injection pump camshaft Check for damage and wear of the camshaft surface, deformation of keyway and deformation of threads on both ends. If the camshaft proves to be defective, replace it. 2. Bearing If the taper roller and outer race has flaking, wear, or any other damage on the surface, replace the bearing.

(3) Plunger guide, plunger barrel, etc. 1. Check to see if the sliding surface of the plunger guide is free form excessive wear.

* When replacing the fuel injection pump camshaft, replace the bearing at the same time.

2. Check to see if the seat of the plunger barrel has uneven contact, burrs, the mark of blow-by gas or other defects etc. If so, correct or replace the plunger barrel. Otherwise, lubricating oil in use will be thinned. 3. If the surface of the plunger guide outer roller indicates wear, flaking, etc., replace the outer roller.

5. If the plunger guide assembly has a combination of the pin and roller that indicates chatters, replace the plunger guide assembly.

51-106

14903 60413247

4. If the plunger guide has the circumference and roller pin hole worn or scratched, etc., replace it with a new one.

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(5) Control rack and fuel control pinion 1. Check the controll rack for bends and the wear and deformation of the portion where it is engaged with the fuel control pinion.

12.5 REASSEMBLY (1) Put the plunger barrel into the fuel injection pump from its top. *

2. Check to see if the portion where the control rack is engaged with the fuel control pinion is free from wear and deformation. *

Make sure that the plunger barrel stopper is snugly fitted with the key way.

If the control rack is in trouble with the teeth face and sliding part, it encounters increased resistance, causing the engine to be out of order (such as uneven revolutions and abrupt revolution changes).

(2) Insert the delivery valve assembly, delivery valve spring and delivery valve stopper from the top of the fuel injection pump in that order. *

Replace the delivery valve packing and O-ring with new ones before reassembling the fuel injection pump.

14903 60413247

(3) Fit the control rack and tighten the control rack stopper. *1. Never fail to install the control rack spring. *2. Make sure that the control rack moves smoothly over the full stroke.

51-107

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(4) Insert a rack lock screw (special service tool) into the thread hole of the control rack stopper and fix the control rack.

(5) Peep through the bottom of the fuel injection pump and align the match mark of the control rack with that of the fuel control pinion.

(7) Mount the plunger spring upper retainer *1. Mount the plunger spring upper retainer so that its recess faces downward. *2. Once again, ascertain that the control rack moves smoothly.

(6) While holding the fuel control pinion by one hand so that its match mark may not be out of position, reassemble the control sleeve and lightly tighten the stop screw of the fuel control pinion. *

Reassemble the control sleeve in the direction in which the holes around the control sleeve face the stop screw. At the same time, align the match mark with that of fuel control pinion.

14903 60413247

(8) Mount the plunger spring.

51-108

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(9) Mount the plunger spring lower retainer on the top of the plunger. While aligning the match mark of the plunger flange with that of the control sleeve, reassemble the plunger from the bottom of the fuel injection pump using a plunger insertion tool (special service tool).

*2. Check to see if the control rack moves freely. If not, the plunger spring interferes with something else. In this case, hold the plunger spring in position using a screwdriver. *3. When replacing the plunger guide assembly with a new one, insert the standard shim, and temporarily tighten it.

(11) Make sure that the plunger guide detent groove is in position. Tighten the plunger guide stopper. *

Never reassemble the plunger in reverse. Otherwise, fuel injection volume increases excessively to the point where fuel injection volume becomes uncontrollable.

(10) Insert the plunger guide assembly into the fuel injection pump from its bottom. Push up the plunger guide using the handle of a hammer, etc., and put a tappet holder (special service tool) in between the lower spring retainer and fuel injection pump body.

14903 60413247

*1. While keeping the plunger guide detent groove facing upward, align with the mating screw hole of the plunger guide stopper on the fuel injection pump body.

51-109

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(12) Place the bearings on both ends of the fuel injection pump camshaft. Insert the bearings while tapping them from driving side. *

Turn the fuel injection pump upside down. Move the plunger guide toward the plunger spring and drive in the fuel injection pump camshaft.

(16) Fix the fuel injection pump. Using a mallet, tap the end of the fuel injection pump camshaft to adjust the side clearance of the fuel injection pump camshaft using an adjusting packing and a side clearance gauge (special service tool). (mm)

(13) Fit the oil seal to the inner side of the bearing holder. Mount the bearing holder. *

Apply lubricating oil to the fuel injection pump camshaft and oil seal of the fuel injection pump camshaft in advance so as not to damage the oil seal.

All models Camshaft side clearance

0.02 ~ 0.05

[Adjustment Procedure] If a clearance is found small, remove the adjusting packing. If a clearance is found large, add one or more adjusting packing. Thickness of adjusting packing : 0.5, 0.4, 0.3, and 0.15 mm.

(15) Turn the fuel injection pump camshaft, and extract the tappet holder (special service tool).

51-110

14903 60413247

(14) Drive the woodruff key into the fuel injection pump camshaft.

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

(17) Mount the fuel injection pump side cover.

(20) Tighten the holder stopper to the specified torque.

(kgf-m)

All models Tightening torque *

(18) Mount the fuel injection pump bottom cover.

0.3

Never tighten the delivery holder excessively. Otherwise, it upsets, causing oil to leak through it.

(19) Tighten the delivery valve spring holder to the specified torque.

(kgf-m)

All models Tightening torque

3.5 ~ 4.0

(21) Mount the fuel feed pump.

14903 60413247

*1. Tighten the delivery valve spring holder by handas far as possible. If the bolt get hard to turn part way, the packing or delivery valve may be out of position. Remove, correct, and start tighten again. *2. Never tighten the delivery valve holder excessively. Excessive tightening causes the control rack to malfunction.

51-111

FUEL INJECTION PUMP FOR DIRECT INJECTION SYSTEM

14903 60413247

NOTE

51-112

GOVERNOR

13. GOVERNOR

14903 60413247

13.1 EXPLODED VIEWS OF GOVERNOR FOR INDIRECT INJECTION SYSTEM

51-113

GOVERNOR

14903 60413247

13.2 EXPLODED VIEWS OF GOVERNOR FOR DIRECT INJECTION SYSTEM

51-114

GOVERNOR

13.3 DISASSEMBLY Disassembly and reassembly can be carried out similarly for Indirect injection system and Direct injection system. (1) Remove the governor case.

(3) Remove the governor case mounting bolt. Remove the governor case from the fuel injection pump while gently tapping the governor case with a wooden hammer. Create a gap between the governor case and fuel injection pump by moving only the moving parts of the governor lever.

Loosen the stop nut on models with angleich assembly.

(4) Pull out the governor link snap pin by inserting long nosed pliers between the fuel injection pump and governor case.

14903 60413247

(2) Remove the control lever hex. nut and pull out the control lever from the control lever shaft.

51-115

GOVERNOR

(5) Separate the governor and fuel injection pump by sliding the governor case and fuel injection pump apart and pulling out the snap pin of the governor link from the control rack.

(7) Use long nosed pliers to unhook the governor spring from the tension lever and control lever shaft.

(8) Remove the shaft retainer on the governor lever shaft. (for IDI) Remove the circlips on both ends of the governor lever shaft. (for DI)

14903 60413247

(6) Remove the stop lever return spring from the governor lever shaft. (DI only)

51-116

GOVERNOR

(9) Put a rod 8 mm in dia. or less in one end of the governor lever shaft and tap the governor lever shaft until the O-ring comes out the other side of the governor case.

(11) Remove the governor link from the governor lever.

14903 60413247

(10) After removing the O-ring, lightly tap the end of the shaft where the O-ring was removed from, and extract the governor lever shaft.

The governor assembly consists of the governor lever, tension lever and angleich assembly, and is normally not disassembled.

51-117

GOVERNOR

(12) When you need to pull out the stop lever, remove the stop lever shaft stop pin, and lightly tap the inside of the governor case. (DI only)

(15) Fix the bearing holder with a vise to hold the fuel injection pump camshaft. Loosen the governor support nut with a box spanner a few turns. *

When the taper fit comes apart after you have removed the nut, the governor weight may fly out - Be careful.

(13) When you need to pull out the control lever shaft, lightly tap the end of the shaft with a wooden hammer, and extract the control lever. *1. Do not loosen the FO limiter assembly unless necessary. *2. On models with torque springs, first remove the box nut, stop nut, and then the torque spring assembly.

(16) Remove the governor weight assembly from the fuel injection pump camshaft using the governor weight extractor (special service tool).

14903 60413247

(14) Pull out the governor sleeve on the end of the fuel injection pump camshaft by hand.

51-118

GOVERNOR

13.4 INSPECTION 1. Inspection of governor weight assembly (1) Replace the governor weight if it does not open and close smoothly.

(2) Replace the governor weight assembly if the contact surface with governor sleeve is extremely worn. (3) Replace if there is governor weight support and pin wear or the the caulking is loose. (4) Replace if the governor weight support stopper is excessively worn. 2. Inspection of governor sleeve (1) Replace the governor sleeve if the contact surface with governor weight is worn or there is pitching. (2) Replace the governor sleeve if the contact surface with shifter is excessively worn or there is pitching.

14903 60413247

(3) If the governor sleeve does not move smoothly on the fuel injection pump camshaft due to governor sleeve inner dia. wear or other reasons, replace.

51-119

GOVERNOR

Inspection of governor lever shaft assembly

(1) Measure the clearance between the governor lever shaft and bushing, and replace if it is near the wear limit. (mm) Standard dimension Governor lever shaft outer dia

8 â&#x20AC;&#x201C;0.005 â&#x20AC;&#x201C;0.014

Bushing inner dia.

8 +0.11 +0.06

Standard clearance

0.065 ~0.124

Limit

0.5

(2) Inspect the shifter contact surface, and if it is worn or scorched, remove the spring pin to disassemble and replace the shifter only.

Inspection of torque spring assembly

(1) Inspect the tip of the piston and contact surface for wear and replace if it is faulty. (2) Replace the assembly if the torque spring is broken.

(3) Check link parts for bends or kinks that will cause malfunctioning, and replace if it is faulty. *1. Side gap on top of governor lever shaft. (mm) Standard side gap

0.4

2. Replace the governor lever, tension lever, bushing, shifter and angleich spring as an assembly.

Inspection of springs

(1) Check the governor spring and other springs and replace if they are broken, settled or corroded.

Inspection of angleich spring assembly

(1) Inspect the sliding surface of shifter and replace if it is faulty. (2) Replace the angleich spring assembly if the angleich spring is broken.

51-120

14903 60413247

GOVERNOR

13.5 REASSEMBLY Inspect all parts after disassembly and replace any parts as necessary. Before starting reassembly, clean all parts and put them in order. Make sure to readjust the unit after reassembly to obtain the specified performance. (1) Fix the bearing holder with a vise to hold the fuel injection pump camshaft. Insert the governor weight assembly in the taper portion at the end of the fuel injection pump camshaft. Mount the washer, and tighten the governor weight support nut with the specified torque.

(3) After the stop lever is disassembled, mount the stop lever return spring on the stop lever, tap the stop lever lightly with a wooden hammer to insert it, and tighten the stop lever stop pin. (DI only)

(kgf-m) Governor weight support nut tightening torque Indirect injection system

7.0 ~ 7.5

Direct injection system

4.5 ~ 5.0

(2) Open the governor weight to the outside, and insert the sleeve in the end of the fuel injection pump camshaft. Make sure that the sleeve moves smoothly after inserting it.

(5) If the governor lever has been disassembled, tap in the spring pin.

14903 60413247

(4) After the control lever shaft is removed, lightly tap and insert the control lever shaft and washer from inside the governor case, using an appropriate plate.

51-121

GOVERNOR

(6) Mount the governor link to the governor lever assembly .

*2. Make sure to insert the governor lever shaft in the correct direction.

*1. Make sure that the correct governor link mounting holes are used and that it is mounted in the correct direction. *2. Make sure that the governor link moves smoothly.

*3. Donâ&#x20AC;&#x2122;t forget to mount the washers on both sides of the governor lever.

(7) Put the governor lever shaft assembly in the governor case, insert the governor lever shaft and tap it in until the O-ring groove comes out the opposite side of the governor case. (for DI)

(8) After you have mounted the O-ring, tap the governor lever in the opposite direction, and mount the circlip on the grooves at both ends. (for DI)

14903 60413247

*1. Fit the O-ring beforehand to the side you tap in.

51-122

GOVERNOR

(11) Pull the governor link as far as possible towards the governor case mounting surface, insert the governor link pin in the fuel control rack pin hole and fit the snap pin on it.

After mounting the governor lever assembly, make sure the governor lever assembly moves smoothly.

(9) Fit the stop lever return spring to the end of the governor lever shaft. (DI only) (12) Mount the governor case to the fuel injection pump while lightly tapping it with a wooden hammer, and tighten the tightening bolt. (13) Mount the governor case cover. On models with idle subspring, insert the adjusting spring and adjusting rod on the governor case cover adjusting bolt. *

If the angleich spring assembly has been removed, tighten the nut temporarily. The nut should be securely tightened after adjustment.

14903 60413247

(10) Hook the governor spring on the control lever shaft and tension lever hook with long nosed pliers.

51-123

GOVERNOR

(14) Insert the control lever in the control lever shaft and tighten the nut. Move the control lever back and forth to make sure that the entire link moves smoothly.

14903 60413247

51-124

GOVERNOR

14. TURBOCHARGER 14.1 SPECIFICATIONS

3TNE84T (CL, VM)

3TNE84T (CH, VH)

4TNE84T (CL)

4TNE84T (VM, CH, VH)

Applicable engine model (application)

Turbocharger model Turbocharger specification

RHB31

RHB51

Standard (w/waste gate)

Turbine type

Radial flow

Blower (compressor) type

Centrifugal

Lubrication method Max. continuous allowable rpm

External lubrication 250,000

Max. continuous allowable gas inlet temperature Dry weight

180,000 750Ë&#x161;C

2.4 kg

4.2 kg

Note) VM and VH applications are provided with the waste gate.

14903 60413247

14.2 CONSTRUCTION

No.

Part name

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

Turbine shaft Oil thrower Turbine side seal ring Seal plate Journal bearing Thrust bearing Compressor housing M5 hexagon bolt M5 spring washer Compressor side clamp Turbine housing M6 hexagon bolt Turbine side clamp Lock washer Bearing housing Retaining ring M3 countersunk flat head screw Compressor wheel Shaft end nut Heat protector

51-125

GOVERNOR

[Note] A waste gate valve is adopted in the turbocharger for VM or VH (variable speed) application. * The waste gate valve is a turbocharger speed control system to maintain the intake air pressure at a constant level by bypassing a part of the exhaust gas for driving the turbocharger by using the intake air pressure on the compressor side. It consists of a control assâ&#x20AC;&#x2122;y separated from the turbocharger and a valve assâ&#x20AC;&#x2122;y built in the turbine housing.

(2) Compressor The compressor wheel installed on the turbine shaft is rotated with the shaft to suck and compress air for feeding into the intake manifold. This is called the blower or compressor. (3) Bearing 1. Thrust bearing As the turbine shaft is constantly applied with a thrust force, this bearing prevents the shaft from being moved by the thrust force.

51-126

2. Radial (journal bearing) A floating journal bearing is adopted. Because the bearing moves with the turbine shaft as oil films are formed both inside and outside of the bearing, the bearing sliding speed is slower than the turbine shaft speed as compared with the ordinary fixed type bearing. The dynamic stability is improved as a result. 3. Compressor side sealing mechanism To prevent the intake air and oil from leaking, a seal ring and a seal plate is provided to form a double wall structure on the rear side of the compressor wheel.

14903 60413247

(1) Turbine The exhaust gas from the engine is accelerated at the nozzle portion in the turbine housing and blown onto the turbine impeller to rotate the turbine shaft. This is called the turbine. A seal ring and heat insulating plate are installed to prevent the bearing from being adversely influenced by the gas.

GOVERNOR

14.3 WASTE GATE VALVE ADJUSTING METHOD Since turbochargers for VM and VH applications are provided the waste gate valve each, adjustment of the waste gate valve opening pressure and lift is indispensable at the time of overhaul or inner parts replacement. Omission of this adjustment will adversely affect the engine performance. [Note]

If the adjustment is impossible, leave off inner parts replacement but replace the whole turbocharger assâ&#x20AC;&#x2122;y.

(1) Checking the waste gate valve pressure and lift characteristics 1. Equipment Prepare the equipment shown in the figure below. 2. Measuring instruments and devices Capable of measuring 0 to10 mm (A flat head type is desirable.)

Manometer

Either mercury column or electric type (capable of measuring 0 to 1500 mmHg)

Pressure regulating valve

Capable of gradually adjusting in a range between 0 and 2 kg/cm2 (for controlling the pressure applied to the waste gate actuator)

Pressure reducing valve

Used for suppressing the air supply pressure at 5 kg/cm2 or less

Pressure gage

Bourdon tube pressure gage (0 to 10 kg/cm2)

14903 60413247

Dial gage

51-127

GOVERNOR

3. Check method (1) Set the manometer control pressure (Pc) applied to the waste gate actuator to 0 and set the dial gage to the zero point.

(2) Waste gate actuator leak test Apply 1.2 kg/cm2 to the actuator and hold the state for 1 minute. The actuator is good if the pressure then is 1.1 kg/cm2 or more.

(2) Gradually open the pressure regulating valve and measure the Pc value when the actuator rod is operated by 2 mm. (3) For the hysteresis, let the rod move to 3 mm first. Then gradually close the pressure regulating valve, measure the pressure when the rod is moved to 2 mm and obtain the difference from the pressure measured in (2) above. 4. Precautions (1) Set the dial gage on the extension line of the actuator rod. (2) The piping and joints shall completely be free from leak. (3) Fix the turbocharger and dial gage securely. (4) An electric manometer, if used, shall have sufficient precision. (5) Even when an electric manometer is used, preparation of a mercury column type manometer is recommended for calibration and daily check.

(7) Do not apply over 5 kg/cm2 to the actuator.

51-128

14903 60413247

(6) The speed for increasing/decreasing Pc by means of the pressure regulating valve shall be very slow near the measuring point. If the 2 mm position is exceeded, restart from the beginning.

GOVERNOR

14.4 EXPLODED VIEW OF TURBOCHARGER (W/WASTE GATE)

14903 60413247

No.

Part name

No.

Part name

Turbine shaft

Bolt

Thrust bushing

Lock plate

Oil thrower

Bearing housing

Seal ring

Retaining ring

Seal ring

Screw

Seal ring (turbine side)

Screw

Lock nut

Lock washer

Impeller

Heat protector

Seal plate

Liquid gasket

Journal bearing

Waste gate actuator

Thrust bearing

Hose

Compressor housing

Adapter

Flanged bolt

Clip

Spring washer

Retaining ring

Clamp

Waste gate valve

Turbine housing

Link plate

51-129

GOVERNOR

14.5 TIGHTENING TORQUE

Part No.

Tightening torque (kg-cm) Part name

Size RHB31

RHB51

Lock nut

—

9 ~ 11

18 ~ 22

Flanged bolt

40 ~ 50

←

Bolt

120 ~ 130

120 ~130 275 ~ 295

Screw

12 ~ 14

←

Screw

12 ~ 14

←

14.6 SERVICE STANDARDS

Unit: mm RHB31

RHB51

RHB31

RHB51

Turbine shaft journal outside diameter (A)

6.257 ~ 6.263

7.99 ~ 8.00

6.25

7.98

Turbine shaft seal ring groove width (E)

1.038 ~ 1.062

1.25 ~ 1.28

1.07

1.29

Compressor side seal ring groove width (G1)

1.02 ~ 1.03

1.22 ~ 1.23

1.04

1.31

Compressor side seal ring groove width (G2)

0.82 ~ 0.83

1.02 ~ 1.03

0.84

1.11

0.002

0.005

0.011

Journal bearing inside diameter (C)

6.275 ~ 6.285

8.01 ~ 8.03

6.29

8.04

Journal bearing outside diameter (D)

9.940 ~ 9.946 12.32 ~ 12.33

9.93

12.31

Bearing housing inside diameter (B)

9.995 ~ 10.005 12.40 ~ 12.41

10.01

12.42

Bearing

Turbine shaft runout

Seal ring Thrust fixing area bearing

Wear limit

Thrust bearing width (J) Thrust bushing groove dimension (K)

3.59 ~ 3.61

3.99 ~ 4.01

3.58

3.98

3.632 ~3.642

4.04 ~ 4.05

3.65

4.07

Turbine side (bearing housing) (F)

11.00 ~ 11.018 15.00 ~ 15.02

11.03

15.05

Compressor side (seal ring) (H1)

9.987 ~ 10.025 12.40 ~ 12.42

10.04

12.45

Compressor side (seal ring) (H2)

7.968 ~ 8.00

10.00 ~ 10.02

8.01

10.05

Rotor play in axial direction

0.022 ~ 0.053

0.03 ~ 0.06

0.07

0.09

Rotor play in radial direction

0.061 ~ 0.093

0.08 ~0.13

0.12

0.17

51-130

14903 60413247

Turbine shaft

Standard dimension

14903 60413247

GOVERNOR

51-131

14903 60413247

GOVERNOR

51-132

14903 60413247

GOVERNOR

51-133

14903 60413247

GOVERNOR

51-134

14903 60413247

GOVERNOR

51-135

14903 60413247

GOVERNOR

51-136

14903 60413247

GOVERNOR

51-137

GOVERNOR

14903 60413247

NOTE

51-138

CROSS SECTIONAL VIEW Attached Drawing 1.

14903 60413247

Exploded views of engine components

51-139

CROSS SECTIONAL VIEW

14903 60413247

NOTE

51-140

CROSS SECTIONAL VIEW Attached Drawing 2.

14903 60413247

Exploded views of engine components

51-141

CROSS SECTIONAL VIEW

14903 60413247

NOTE

51-142