Hitachi Ex1200-5d Excavator Service Manual Set PDF Download by www.heydownloads.com

INTRODUCTION TO THE READER • This manual is written for an experienced technician

to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-29-832-7173 FAX: 81-29-831-1162

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.

• The Operator’s Manual • The Parts Catalog

• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/disassemble procedures.

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

IN-01

INTRODUCTION PAGE NUMBER • Each page has a number, located on the center

lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT:

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

IN-02

NOTE: Indicates supplementary technical information or know-how.

INTRODUCTION UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

• SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-03

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

INTRODUCTION (Blank)

IN-04

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL Group 1 Specifications Group 2 Component Layout

SECTION 2 SYSTEM

TECHNICAL MANUAL (Operational Principle)

Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System

SECTION 3 COMPONENT OPERATION Group Group Group Group Group Group Group Group

1 Pump Device 2 Swing Device 3 Control Valve 4 Pilot Valve 5 Travel Device 6 Signal Control Valve 7 Others(Upperstructure) 8 Others(Undercarriage)

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

SECTION 5 TROUBLESHOOTING Group 1 General Group 2 Cross Reference Table Group 3 Component Layout Group 4 Troubleshooting A Group 5 Troubleshooting B Group 6 Troubleshooting C Group 7 Troubleshooting D Group 8 Electrical System Inspection

WORKSHOP MANUAL SECTION 1 GENERAL INFORMATION Group 1 Precautions for Disassembling and Assembling Group 2 Tightening Torque SECTION 2 UPPERSTRUCTURE Group 1 Cab Group 2 Counterweight Group 3 Pump Device Group 4 Control Valve Group 5 Swing Device Group 6 Pilot Valve Group 7 Pilot Shut-Off Valve Group 8 Shockless Valve Group 9 Solenoid Valve

Group 10 Signal Control Valve Group 11 Oil Cooler Fan Motor SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing and Point

SECTION 1

GENERAL CONTENTS Group 1 Specifications Specifications............................................ T1-1-1 Working Range (Backhoe) ........................ T1-1-3 Working Range (BE Backhoe) .................. T1-1-4 Working Range (Loading Shovel) ............. T1-1-5 Engine ...................................................... T1-1-6 Engine Accessories .................................. T1-1-9 Hydraulic Devices ..................................... T1-1-9 Electrical Equipment ............................... T1-1-12

Group 2 Component Layout Main Components ..................................... T1-2-1 Electrical System Components (1) ............ T1-2-2 Electrical System Components (2) ............ T1-2-3 Electrical System Components (3) ............ T1-2-8 Electrical System Components (4) ............ T1-2-9 On and Around Pumps............................ T1-2-10 Others..................................................... T1-2-11

18ET-1-1

(Blank)

18ET-1-2

GENERAL / Specifications SPECIFICATIONS A C

E D H

M183-11-001

Model Type of Front-End Attachment Bucket Capacity (Heaped) Operating Weight Basic Machine Weight Engine A: Overall Width B: Cab Height C: Rear End Swing Radius D: Minimum Ground Clearance E: Counterweight Clearance F: Undercarriage Length G: Undercarriage Width H: Sprocket Center to Idler Center I: Track Shoe Width Ground Pressure Swing Speed Travel Speed (Fast/Slow) Gradeability

EX1200-5C Hydraulic Excavator BE Backhoe Backhoe [7.55 m (24’9”) BE boom, [9.1 m (29’10”) boom, 3.4 m (11’2”) arm] 3.4 m (11’2”) BE arm] PCSA 5.0 m3 (6.5 yd3), CECE 4.4 m3

PCSA 6.5 m3 (8.5 yd3)

108000 kg (238000 lb) 109000 kg (243000 lb) 80500 kg (177500 lb) CUMMINS QSK23 567 kW/1650 min-1 (771 PS/1650 rpm) 5430 mm (17 ft 10 in) 4320 mm (14 ft 2 in) 4850 mm (15 ft 11 in) 990 mm (3 ft 3 in) (Excluding shoe lug) 1790 mm (5 ft 10 in) 6410 mm (21 ft 0 in) 4610 mm (15 ft 2 in) 5000 mm (16 ft 5 in) 710 mm (28 in) (Grouser shoe) 136 kPa (1.39 kgf/cm2, 19.7 psi) 137 kPa (1.40 kgf/cm2, 19.9 psi) 5.8 min-1 (rpm) 3.5/2.4 km/h (2.2/1.6 mph) 35° (tanθ = 0.70)

T1-1-1

GENERAL / Specifications

E D I

H F

T183-01-01-002

EX1200-5C Hydraulic Excavator Loading Shovel PCSA 6.5 m3 (8.5 yd3)

111000 kg (245000 lb) 80900 kg (178400 lb) CUMMINS QSK23 567 kW/1650 min-1 (771 PS/1650 rpm) 5430 mm (17 ft 10 in) ∗5410 mm (17 ft 9 in) 4850 mm (15 ft 11 in) 990 mm (3 ft 3 in) (Excluding shoe lug) 1790 mm (5 ft 10 in) 6410 mm (21 ft 0 in) 4610 mm (15 ft 2 in) 5000 mm (16 ft 5 in) 710 mm (28 in) (Grouser shoe) 139 kPa (1.42 kgf/cm2, 20.2 psi) 5.8 min-1 (rpm) 3.5/2.4 km/h (2.2/1.6 mph) 35° (tanθ = 0.70)

NOTE: ∗The standard specification of loading shovel is equipped with an elevated cab.

T1-1-2

GENERAL / Specifications WORKING RANGE (BACKHOE)

C B

A´ A

M183-11-002

Boom Length Arm Length A : Maximum Digging Reach A’ : Maximum Digging Reach (on ground) B : Maximum Digging Depth C : Maximum Vertical Wall D : Maximum Cutting Height E : Maximum Dumping Height NOTE:

9.10 3.40 15340 15000 *9340 *7620 *13490 *8920

m (29′ 10″) m (11′ 2″) mm (50′ 4″) mm (49′ 3″) mm (30′ 8″) mm (25′ 0″) mm (44′ 3″) mm (29′ 3″)

∗ The dimensions do not include the height of the shoe lug.

T1-1-3

GENERAL / Specifications WORKING RANGE (BE BACKHOE)

D E

C B

A´ A

M183-11-003

7.55 3.40 13760 13380 *7940 *5080 *12300 *8020

m (24′ 9″) BE boom m (11′ 2″) BE arm mm (45′ 2″) mm (43′ 11″) mm (26′ 1″) mm (16′ 8″) mm (40′ 4″) mm (26′ 4″)

∗ The dimensions do not include the height of the shoe lug.

T1-1-4

GENERAL / Specifications WORKING RANGE (LOADING SHOVEL)

G E´

A B

C D

A B C D E E’ F G H

: : : : : : : : :

T183-01-01-003

Minimum Digging Distance Minimum Level Crowding Distance Level Crowding Distance Maximum Digging Reach Maximum Cutting Height Maximum Dumping Height Maximum Digging Depth Working Radius at Maximum Dumping Height Maximum Bucket Opening Width

NOTE:

4460 mm (14′ 8″) 6520 mm (21′ 5″) 4340 mm (13′ 10″) 11440 mm (37′ 6″) *12350 mm (40′ 6″) *8740 mm (28′ 8″) *5240 mm (17′ 2″) *6090 mm (20′ 0″) 1880 mm (6′ 2″)

∗ The dimensions do not include the height of the shoe lug.

T1-1-5

GENERAL / Specifications ENGINE MAIN SPECIFICATIONS Manufacturer .............................................CUMMINS Model.........................................................QSK23 Type...........................................................Diesel, 4 cycle, vertical, 6-cylinder inline, water-cooled, turbo charged, inter-cooled, direct injection type Cyl. No.-bore×stroke .................................6-170 mm×170 mm (6.7 in×6.7 in) Piston displacement ..................................23150 cm3 (1412 in3) Rated output (SAE J1995) (GROSS) ....567 kW/1650 min-1 (771 PS/1650 rpm) (NET) ..........538 kW/1650 min-1 (731 PS/1650 rpm) Dry weight .................................................2565 kg (5655 lb) Firing order ................................................1-5-3-6-2-4 Rotation direction ......................................Clockwise (view from fan side) COOLING SYSTEM Cooling fan ................................................Dia. 1219 mm (48 in), draw-in type Fan pulley ratio..........................................0.7 : 1 Thermostat ................................................Cracking temp. : 77 °C (170 °F) (under atmospheric pressure) .................Full open temp. : 90 °C (194 °F) Water pump ...............................................Centrifugal swirl type LUBRICATION SYSTEM Lubrication pump type ...............................Gear pump Oil filter ......................................................Full-flow paper element type with bypass function Oil pan capacity.........................................70 L (18.5 US gal) STARTING SYSTEM Voltage⋅Output...........................................24 V⋅7.5 kW×2 PRE-HEAT SYSTEM Type...........................................................Air heater ENGINE STOP SYSTEM Stop method ..............................................Fuel cut system with solenoid valve ALTERNATOR Type...........................................................AC generator with diode rectifier Voltage⋅Output...........................................24 V⋅75 A FUEL SYSTEM Injection pump ...........................................CUMMINS HPI electronic contrl Governor ...................................................Electronic all speed control

T1-1-6

GENERAL / Specifications PERFORMANCE Lubrication oil consumption.......................0.27 g kW⋅h (New engine, at rated horsepower) Fuel consumption ratio (GROSS)..............200 g/kW⋅h (147 g/PS⋅h) Max. output torque (GROSS)..............3580 N⋅m (365 kgf⋅m, 2641 lbf⋅ft) @ 1350±100 min-1 Max. no load speed .............................1850±50 min-1

T1-1-7

GENERAL / Specifications ENGINE PERFORMANCE CURVE Test Conditions: 1. THIS PERFORMANCE IS APPLIED UNDER CONDITIONS OF 25Â°C (AMBIENT TEMPERATURE). 100 kPa (750mmHg) (ATMOSPHERIC PRESSURE) AND 1kPa (7.5mmHg) VAPOR PRESSURE. 2. WITH MUFFLER, AIR CLEANER, WITHOUT FAN

Max. Torque (Gross) 3472Nm/1350rpm

Rated power (Gross) 567kw/1650rpm

Min. BSFC (Gross) 204g/kwh

T18E-01-01-002

T1-1-8

GENERAL / Specifications ENGINE ACCESSORIES RADIATOR ASSEMBLY Type...........................................................Radiator/Inter-cooler tandem type assembly Weight .......................................................350 kg (772 lb) Radiator Core type...................................................Corrugated fin Capacity.....................................................63 L (17 US gal) Air-tight testing pressure ...........................196 kPa (2.0 kgf/cm2, 28 psi) Cap opening pressure...............................88.2 kPa (0.9 kgf/cm2, 12.8 psi)

Inter-cooler Corrugated fin 980 kPa (10 kgf/cm2, 142 psi) -

BATTERY Capacity.....................................................176 Ah (5 hours) Voltage.......................................................12 V×2 Weight .......................................................66 kg (146 lb)×2 Fuel Cooler Weight .......................................................6.81 kg (15 lb) Core type...................................................Corrugated Capacity.....................................................3.3 L (0.87 US gal) Air-tight testing pressure ...........................1.5 MPa (15 kgf/cm2, 218 psi)

HYDRAULIC DEVICES PUMP DEVICE Type...........................................................Spur gear Gear speed ratio (Engine: Main pump) ....1 : 1.083 (Engine: Triple pump) ...1 : 1.106 MAIN PUMP Model.........................................................K3V280SH11RL Type...........................................................Variable displacement swash plate type plunger pump: regulator attached type Max. flow (Theoretical value) ....................500 L/min (132 US gpm)×3 3-UNIT PUMP (OIL COOLER FAN MOTOR DRIVE PUMP) Model.........................................................K3V63S Type...........................................................Variable displacement swash plate type plunger pump: Regulator attached type Max. flow (Theoretical value) ....................115 L/min (30.3 US gpm) (PILOT PUMP) Model.........................................................KFP3228 Type...........................................................Gear pump Max. flow (Theoretical value) ....................51.1 L/min (13.5 US gpm) (TRANSMISSION LUBRICATION OIL PUMP) Model.........................................................KP1015 Type...........................................................Gear pump Max. flow (Theoretical value) ....................27.1 L/min (7.2 US gpm)

T1-1-9

GENERAL / Specifications MAIN CONTROL VALVE Model.........................................................UH36-403 Type...........................................................Pilot pressure operated type (4-spool+5-spool) Main relief pressure...................................Normal: 31.4 MPa (310 kgf/cm2, 4410 psi) @340 L/min (89.7 US gpm) High Lift: 33.3 MPa (340 kgf/cm2, 4830 psi) @90 L/min (23.7 US gpm) Overload relief pressure ..........................33.3 MPa (340 kgf/cm2, 4830 psi) @110 L/min (29.0 US gpm) (Boom, Arm roll-in (BH) / Arm extend (LD), Bucket, Bucket open (LD)) 34.3 MPa (350 kgf/cm2, 4980 psi) @110 L/min (29.0 US gpm) (Arm roll-out (BH)/ Arm retract (LD)) 17.7 MPa (180 kgf/cm2, 2560 psi) @500 L/min (132 US gpm) (Bucket close (LD)) When jack-up prevention switch is ON: 9.8 MPa (100 kgf/cm2, 1420 psi) @110 L/min (29.0 US gpm) (Boom Lower) SWING CONTROL VALVE Model.........................................................UH36B2T1C2A2-3 Type...........................................................Pilot pressure operated type (4-spool) Main relief valve ........................................31.4 MPa (320 kgf/cm2, 4550 psi) @170 L/min (44.9 US gpm) Overload relief valve..................................31.4 MPa (320 kgf/cm2, 4550 psi) @110 L/min (29.0 US gpm) SWING DEVICE Type...........................................................Two-stage planetary reduction type SWING MOTOR Model.........................................................M2X210 CAB-10A Type...........................................................Swash-plate type, fixed displacement plunger motor SWING BRAKE VALVE Type...........................................................Non counter balance valve type Relief pressure ..........................................29.4 MPa (300 kgf/cm2, 4270 psi) SWING PARKING BRAKE Type...........................................................Multiple-wet-plate negative type Cracking pressure for release ...................2260+590-0 kPa (23+6-0 kgf/cm2, 327+85-0 psi) TRAVEL DEVICE Type...........................................................Three-stage planetary reduction gear TRAVEL MOTOR Model.........................................................MSF-340VP-EH Type...........................................................Swash-plate type, variable displacement plunger motor TRAVEL BRAKE VALVE Type...........................................................Counter balance valve type Relief pressure ..........................................29.4±1 MPa (300±10 kgf/cm2, 4266±142 psi)

T1-1-10

GENERAL / Specifications TRAVEL PARKING BRAKE Type...........................................................Multiple-wet-plate negative type Cracking pressure for release ...................1.8 MPa (18 kgf/cm2, 256 psi) CYLINDER (BACKHOE) Boom Rod Dia. ....................................................160 mm (6.30”) Cylinder Bore.............................................230 mm (9.06”) Stroke ........................................................2075 mm (6’ 10”) Fully retracted length.................................3170 mm (10’ 5”) Plating thickness .......................................30 µm (1.18 µin) or more

Arm 180 mm (7.09”) 260 mm (10.24”) 2205 mm (7’ 3”) 3385 mm (11’ 1”) 30 µm (1.18 µin) or more

Bucket (3.4 m Arm) 160 mm (6.30”) 230 mm (9.06”) 1790 mm (5’ 10”) 2895 mm (9’ 6”) 30 µm (1.18 µin) or more

Bucket (BE) Rod Dia. ....................................................170 mm (6.70”) Cylinder Bore.............................................240 mm (9.45”) Stroke ........................................................1790 mm (5’ 10”) Fully retracted length.................................2895 mm (9’ 6”) Plating thickness .......................................30 µm (1.18 µin) or more

Bucket (For 4.5 m Arm) 160 mm (6.30”) 230 mm (9.06”) 1790 mm (5’ 10”) 2895 mm (9’ 6”) 30 µm (1.18 µin) or more

Bucket (For 5.8 m Arm) 130 mm (5.12”) 190 mm (7.48”) 1555 mm (5’ 1”) 2385 mm (7’ 10”) 30 µm (1.18 µin) or more

Boom Rod Dia. ....................................................160 mm (6.30”) Cylinder Bore.............................................230 mm (9.06”) Stroke ........................................................2075 mm (6’ 10”) Fully retracted length.................................3170 mm (10’ 5”) Plating thickness .......................................30 µm (1.18 µin) or more

Arm 150 mm (5.91”) 215 mm (8.46”) 1835 mm (6’ 0”) 2785 mm (9’ 2”) 30 µm (1.18 µin) or more

Level 160 mm (6.30”) 230 mm (9.06”) 790 mm (2’ 7”) 1815 mm (5’ 11”) 30 µm (1.18 µin) or more

Bucket Rod Dia. ....................................................150 mm (5.91”) Cylinder Bore.............................................200 mm (7.87”) Stroke ........................................................1 600 mm (5’ 3”) Fully retracted length.................................3 405 mm (11’ 2”) Plating thickness .......................................30 µm (1.18 µin) or more

Bucket open/close 140 mm (5.51”) 85 mm (3.34”) 475 mm (1’ 7”) 1 090 mm (3’ 7”) 30 µm (1.18 µin) or more

(LOADING SHOVEL)

FRONT ATTACHMENT PILOT VALVE Model.........................................................HVP06A-040-101 TRAVEL PILOT VALVE Model.........................................................HVP05F-040-101 BUCKET OPEN / CLOSE PILOT VALVE (LOADING SHOVEL) Model.........................................................HVP05H-040-101 SOLENOID VALVE UNIT Solenoid valve (Function) ........................⋅ SA : Pump power decreasing (For pump 3) ⋅ SB : Pump power decreasing (For pump 1, 2) ⋅ SC : Boom mode selection (Max. input flow) ..............50 L/min (13 US grm) Pilot relief valve .........................................3.9 MPa (40 kgf/cm2, 570 psi)

T1-1-11

GENERAL / Specifications FLOW REDUCING SOLENOID VALVE Function.....................................................Flow reducing Max. input flow ..........................................60 L/min (15.8 US gal) TRAVEL MODE SHIFT SOLENOID VALVE Function.....................................................Travel mode shifting Max. input flow ..........................................30 L/min (7.9 US gal) 2-SPOOL EHC VALVE Function.....................................................Power increase solenoid valve ST: Speed sensing control Max. input pressure...................................3.9 MPa (40 kgf/cm2, 570 psi) Control pressure........................................Solenoid Valve ST: 0 to 2.7 MPa (0 to 27.5 kgf/cm2, 0 to 391 psi) Function.....................................................Oil cooler fan control solenoid valve SF Max. input pressure...................................3.9 MPa (40 kgf/cm2, 570 psi) Control pressure........................................Solenoid Valve SF: 0 to 1.4 MPa (0 to 13.9 kgf/cm2, 0 to 198 psi) OIL COOLER Weight .......................................................725 kg (1600 lbf) Core type...................................................Plate fin Capacity .................................................... Air-tight testing pressure ...........................980 kPa (10 kgf/cm2, 142 psi) OIL COOLER FAN MOTOR Function.....................................................A2FM63 Displacement.............................................63 cm3/rev Max Motor speed.......................................1400 min-1 (rpm) @ Engine 1650 min-1 (rpm) Relief valve................................................21.6 MPa (220 kgf/cm2, 3130 psi) OIL COOLER BYPASS CHECK VALVE Cracking pressure .....................................245 kPa (2.5 kgf/cm2, 36 psi) at 40 L/min (11 US gpm)

ELECTRICAL EQUIPMENT BATTERY RELAY Voltage⋅Current .........................................24 V⋅100 A STARTER RELAY 1 Voltage⋅Current .........................................24 V⋅180 A STARTER RELAY 2 Voltage⋅Current .........................................24 V LOAD DUMP RELAY Voltage⋅Current .........................................24 V⋅10 A HORN Specifications ............................................24 V⋅2.3 A, 330 Hz LIGHT Specifications ............................................Work lights : halogen 24 V⋅70 W

T1-1-12

GENERAL / Specifications AIR CONDITIONER Refrigerant.................................................134 a Cooler capacity..........................................19.73 MJ/h (4600 kcal/h) Cooler air flow ...........................................550 m3/h (720 yd3/h) or more Heater capacity .........................................21.0 MJ/h (5000 kcal/h) or more Temperature control ..................................Electronic control Refrigerant quantity ...................................Std. cab : 1250±50 g (2.76±0.1 lb) Elevated cab : 1300±50 g (2.87±0.1 lb) Compressor oil quantity ............................220 cm3 (0.23 US qt) (After replacement of the compressor, high pressure hose, condenser, receiver tank, liquid hose, or air conditioner unit, the compressor oil quantity is added.)

T1-1-13

GENERAL / Specifications (Blank)

T1-1-14

GENERAL / Component Layout MAIN COMPONENTS Backhoe

2 1

5 6 7 8

36 37

9 10

11 12

30 29

28 27 Loading Shovel

5 32

3 2 35

17 23

18 22 6 21

19 20 30 33

34 T183-01-02-016

1234-

Bucket Cylinder Arm Arm Cylinder Boom

11 12 13 14 -

Swing Device Main Control Valve Oil Cooler Oil Cooler Fan Motor

20 21 22 23 -

Swing Bearing Travel Device Upper Roller Lower Roller

29 30 31 32 -

5 - Boom Cylinder

15 - Intercooler

24 - Swing Control Valve

33 -

6 - Front / Swing Pilot Valve

16 - Radiator

25 - Center Joint

34 -

7 - Hydraulic Oil Tank

17 - Engine

26 - Track Adjuster

35 -

8 - Battery

18 - Pump Device

27 - Pilot Shut-Off Valve

36 -

9 - Fuel Tank 10 - Auto-Lubrication Device

19 - Signal Control Valve

28 - Front Idler

37 -

T1-2-1

Accumulator Travel Pilot Valve Bucket Level Cylinder (Loading Shovel Only) Pilot Valve (Bucket Open) (Loading Shovel Only) Pilot Valve (Bucket Close) (Loading Shovel Only) Bucket Open/Close Cylinder (Loading Shovel Only) Condenser (Air Conditioner) Fuel Cooler

GENERAL / Component Layout ELECTRICAL SYSTEM COMPONENTS (1) 2

Overall Layout

5 6

7 8

9 10

12 Refer to T1-2-12 13

(Refer to T1-2-4)

14 33 32 14

31 30 29

15 16 (Refer to T1-2-10)

(Refer to T1-2-3)

17 (Refer to T1-2-10) 18 (Refer to T1-2-10)

(Refer to T1-2-11) 27

26 25

19 (Refer to T1-2-8) 24

(Refer to T1-2-11) 23 1 - Work Light (on Cab Roof)

20 22

2 - Monitor

10 - Fresh Air Sensor (Air Conditioner) 11 - Fuel Temperature

3 - Quick Idle Switch

12 - Coolant Level Switch

4 - Work Light (at the right side of Frame) 5 - Starter Relay 1

13 - Coolant Temperature Sensor

6 - Battery

15 - Starter

7 - Battery Relay

16 - Solenoid Valve Unit

8 - Horn

17 - Flow Rate Decrease Solenoid Valve 18 - 2-Spool EHC Valve

9 - Fuel Sensor

14 - Air Cleaner Restriction Switch

19 - Engine Speed Sensor 1 (Pump) 20 - Engine Speed Sensor 2 (ECM) 21 - Pump Transmission Oil Pressure Switch 22 - Oil Pressure Sensor 23 - Pilot Pressure Sensor (All) 24 - Travel Mode Control Solenoid Valve 25 - Heavy Lift Solenoid Valve 26 - Hydraulic Oil Temperature Sensor 27 - Pilot Pressure Sensor (Travel)

T1-2-2

T18E-01-02-009

28 - Hydraulic Oil Level Switch 1, 2 29 - DC/DC Converter 30 - Horn Switch 31 - Work Light (Under Cab Floor) 32 - Sunlight Sensor 33 - Step Light 34 - Electrical Equipment Box

GENERAL / Component Layout ELECTRICAL SYSTEM COMPONENTS (2) In the Cab

1 6

T18E-01-02-010

2 4

M18E-01-009

T18E-01-02-013

1 - 12 V Power Source Terminal 2 - DC-DC Converter

4 - Buzzer Cancel Switch 5 - Travel Alarm Stop Switch (Optional)

Engine Fault Code Display Panel 7 - Fault Diagnosing Switch A

3 - MC Display Selection Switch

T1-2-3

Fault Diagnosing Switch B

DLU Check Switch

GENERAL / Component Layout Electrical Equipment Box

28 27 26 25 11

24 23 22

12 T18E-01-02-003

1 - Flow Rate Decrease Solenoid Valve Relay 2 - *Quick Idle Relay 3 - Auto-Lubrication Relay 4 - Preheat Indicator Relay 5 - *Coolant Lever Switch Relay 6 - *Auto-Idle Relay 7 - *Engine Protection Relay

8 - *Engine Stop Indicator Relay 9 - *Engine Warning Indicator Relay 10 - DLU 11 - *ECM Relay 12 - Power Transistor 3

15 - Main Controller A (Lower) 16 - Main Controller B (Upper) 17 - Fuse Box 1 18 - Fuse Box 2 19 - Step Light Relay

22 - Work Light Relay 2

24 - Upper Wiper Relay 2 25 - Upper Wiper Relay 1 26 - Lower Wiper Relay

13 - Power Transistor 2 14 - Power Transistor 1

20 - Load Dump Relay 21 - *Engine Stop Relay

27 - Horn Relay 28 - Work Light Relay 1

23 - Washer Relay

NOTE: The items with mark ”*” are not used for the machine equipped with CUMMINS engine.

T1-2-4

GENERAL / Component Layout (Blank)

T1-2-5

GENERAL / Component Layout Around Batteries

12 13 10 11

3 4 5 6

1234-

Air Heater Signal Relay Starter Relay 1 Battery Relay 1 Fusible Link 5 (250A)

567-

Battery Relay 2 1 Pole Junction Fusible Link 7 (125A)

T183-01-02-015

8 - Fusible Link 8 (125A) 9 - Fusible Link 6 (100A) 10 - Fusible Link 4 (45A)

T1-2-6

11 - Fusible Link 3 (75A) 12 - Fusible Link 2 (75A) 13 - Fusible Link 1 (45A)

GENERAL / Component Layout Used Circuit Fusible Link Part Name Fusible Link 1

Fusible Link 2

Fusible Link 3

Fusible Link 4 Fusible Link 5 Fusible Link 6 Fusible Link 7 Fusible Link 8

Circuit Monitor, Back up Power Circuit Main Controller B, DLU Main Power Circuit ECM Power Circuit Work Light Relays 1, 2 Power Circuit Washer Relay, Wiper Relay (L, H1, H2), Wiper Motor Power Circuit Air Conditioner Power Circuit Auto-Lubrication Solenoid Valve Relay, Flow Rate Decrease Solenoid Valve Relay, Power Transistors 1, 2 and 3 DC-DC Converter Power Circuit Main Controller A, B Solenoid Power Circuit Travel Alarm Power Circuit Monitor, Main Controller A Main Power circuit Step Light Relay Power Circuit Air Conditioner Air Heater Signal Relay Power Circuit Starter Relay Power Circuit Alternator Preheat Relay 1 Power Circuit Preheat Relay 2 Power Circuit

T1-2-7

Connected Fuse Box 1 (#1, #2) Fuse Box 2 (#1) Fuse Box 2 (#11～14)

Fuse Box 2 (#4～9)

Air Heater Signal Relay Starter Relay 1 Alternator Preheat Relay 1 Preheat Relay 2

GENERAL / Component Layout ELECTRICAL SYSTEM COMPONENTS (3) On and Around Engine

5 9

T18E-01-02-011

1 - ECM 2 - Alternator 3 - Engine Speed Sensor 1 (ECM)

Engine Speed Sensor 2 (Pump) 5 - Coolant Temperature Sensor (Monitor) 6 - Engine Oil Level Sensor

Preheat Relay

Starter

Coolant Temperature Sensor (ECM)

T1-2-8

10 - Engine Oil Pressure Sensor 11 - Suction Manifold Temperature Sensor 12 - Fuel Temperature Sensor

GENERAL / Component Layout ELECTRICAL SYSTEM COMPONENTS (4) Monitor Panel

Monitor and Switch Panels

35 34

33 32 31

3 4

30 29

5 6

7 8

27 26

17 18 19 20

25 9 T183-01-02-013

24 23 13

22 21

12 11

T183-01-02-010

36 M183-01-035

1 - Monitor Panel

19 - *Exhaust Gas Temperature Indicator 20 - hydraulic Oil Level Indicator 21 - Engine Warning Indicator 22 - Coolant Level Indicator

6 - Travel Mode Switch

10 - Air Conditioner Control Panel 11 - Auto-Lubrication (ALU) Timer Switch 12 - Heavy Lift Switch 13 - Boom Mode Selection Switch 14 - Coolant Temperature Gauge 15 - Fuel Gauge Switch

7 - Work Light Switch 8 - Wiper/Washer Switch

16 - Switch Panel 1 17 - Fuel Level Indicator

9 - Key Switch

18 - Alternator Indicator

25 - Engine Oil Level Indicator 26 - Pump Transmission Oil Pressure Indicator 27 - Engine Oil Pressure Indicator

2 - Quick Idle Switch 3 - Engine Control Dial 4 - Auto-Idle Switch 5 - Power Mode Switch

23 - Engine Stop Indicator 24 - Auto-Lubrication Indicator

28 - Preheat Indicator 29 - Download Indicator 30 - Overheat Indicator 31 - Air Filter Restriction Indicator 32 - Lubrication Mode Indicator 33 - Liquid Crystal Display (LCD) 34 - Auto-Idle Indicator 35 - Quick-Idle Indicator 36 - Step Light Switch

NOTE: The Item with mark “*” is not used for the machine equipped with CUMMINS engine.

T1-2-9

GENERAL / Component Layout ON AND AROUND PUMPS

1 Front

Pump Device

9 8 7 4

Solenoid Valves and Related Components

18 Solenoid Valve Unit

T183-01-02-006

11 17

2-Spool EHC Valve

12 15 Front

T183-01-02-007

1 - Main Pump 3 Regulator 2 - Main Pump 1 Regulator

6 - Transmission Lubrication Oil Pump 7 - Pilot Pump

3 - Main Pump 1

8 - Main Pump 2

4 - Oil Cooler Fan Motor Drive Pump 5 - Pump Transmission Oil Pressure Switch

9 - Main Pump 2 regulator

11 - Power Increase Solenoid Valve (ST) 12 - Oil Cooler Fan Control Solenoid Valve (SF) 13 - Pilot Filter 14 - Flow Rate Decrease Solenoid Valve

10 - Main Pump 3

T1-2-10

15 - Pilot Relief Valve 16 - Power Decrease Solenoid Valve (SA) 17 - Power Decrease Solenoid Valve (SB) 18 - Boom Mode Selection Solenoid Valve (SC)

GENERAL / Component Layout OTHERS Valves (1)

Swing Device

9 4 Front Side

8 5

T142-01-02-011

T183-01-02-008

Travel Device

Valves (2) 10

18 22

17 16 13 Valves (1)

14 T18E-01-02-002 T183-01-02-012

1 - Pilot Pressure Sensor (Travel) 2 - Shuttle Valve (Auxiliary Circuit) 3 - Reducing Valve 4 - Heavy Lift Solenoid Valve

5 - Travel Mode Control Solenoid Valve 6 - Brake Release Pressure Switch Valve

7 - Shuttle Valve (Swing Brake Release) 8 - Pilot Pressure Sensor (All) (Front Operation) 9 - Shuttle Valve (Boom Raise Priority) 10 - Shuttle Valve (For Switching Pump 3 Control Pressure) 11 - Arm Preference Valve

13 - Pump 3 Control Valve 14 - Shockless Valve 15 - Shuttle Valve (Swing Make-Up) 16 - Shock Reducing Valve

17 - Shuttle Valve (Pilot Pressure Control)

12 - Signal Control Valve

T1-2-11

18 - Shuttle Valve (Bucket Roll-In) 19 - Swing Parking Brake Release Valve 20 - Swing Relief Valve 21 - Counterbalance Valve

22 - Travel Relief Valve

GENERAL / Component Layout Coolant Level Switch

T18E-01-02-012

T1-2-12

MEMO ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... ....................................................................................................................................................................... .......................................................................................................................................................................

SECTION 2

SYSTEM CONTENTS SECTION 1 Control System Outline ...................................................... T2-1-1 Engine Control .......................................... T2-1-2 Pump Control .......................................... T2-1-12 Valve Control .......................................... T2-1-16 Oil Cooler And Fuel Cooler Fan Motor Control ................................... T2-1-24 Auto-Lubrication Control ......................... T2-1-26

SECTION 2 Hydraulic System Outline ...................................................... T2-2-1 Pilot Circuit ............................................... T2-2-2 Main Circuit............................................. T2-2-20 Pump Transmission Oil Cooling Circuit ...................................... T2-2-48 Oil Cooler Fan Motor Circuit ................... T2-2-48

SECTION 3 Electrical System Outline ...................................................... T2-3-1 Power Source Circuit ................................ T2-3-2 Bulb Check Circuit .................................... T2-3-3 Engine Start Circuit ................................... T2-3-4 Charging Circuit ........................................ T2-3-6 Accessory Circuit ...................................... T2-3-8 Surge Voltage Prevention Circuit ............ T2-3-10

18ET-2-1

(Blank)

18ET-2-2

SYSTEM / Control System OUTLINE Main controllers (A and B) with built-in microcomputers and ECM (Engine Control Module) are used for machine control. The main controllers (A and B) and ECM process signals from the engine control dial, engine speed sensors (1 and 2) and various switches, actuating the solenoid valves and electronic governor, and controlling the engine and pumps. Engine Control • Engine Speed Control • Quick-Idle Control • Auto-Idle Control • Low Temperature Start Control • Engine Diagnosing Control Pump Control • SP Mode Control • E Mode Control • Pump Flow Rate Control at Slow Engine Speed • Pump Flow Rate Control at Middle Engine Speed • Power Decrease Control to Prevent Engine Overheating • Power Decrease Control Abnormal Engine Oil Pressure • Power Decrease Control Low Coolant Level Valve Control • Travel Mode Control • Heavy Lift Control • Boom Mode Selection Control • Oil Cooler Fan Motor Control • Auto-Lubrication Control

T2-1-1

SYSTEM / Control System ENGINE CONTROL Engine Speed Control Purpose: Controls engine speed in response to engine control dial rotation. Operation: The electrical signal in response to the angle of engine control dial is sent to the ECM. The ECM drives the electronic governor due to the electrical signal and controls the engine speed.

Electronic Governor

Key Switch

ECM

Engine Control Dial

T142-04-03-001

T2-1-2

SYSTEM / Control System (Blank)

T2-1-3

SYSTEM / Control System Quick-Idle Control Purpose: Reduces fuel consumption by quickly decreasing engine speed. This function will be effective when the machine waits for a period of time as when waiting for a dump truck to be set in a loading position. Operation: When the quick idle switch on top of the right control lever is turned on, the main controller sends an electrical signal to the ECM. Consequently, the ECM actuates the electronic governor to lower the engine speed.

Quick-Idle Switch Monitor Controller

ECM

Electronic Governor

T142-04-03-003

T2-1-4

SYSTEM / Control System Auto-Idle Control Purpose: Reduces engine speed, fuels consumption and noise when all control levers are neutral and the engine is running at a speed faster than the auto-idle set speed with the auto-idle switch ON. NOTE: All pilot system pressure is routed to the swing brake release shuttle valve.

Swing Brake Release Shuttle Valve

Operation: When all control levers are in the neutral position, the pressure sensor in the swing brake release shuttle valve detects the pilot pressure. Then, approx. 3 second after main controller A is notified with the auto-idle switch ON that pilot pressure at the pressure sensor is 0.4 MPa (4 kgf/cm2, 57 psi) or lower, main controller sends out a signal to the ECM, by which the ECM reduces engine speed down to 1400 min-1. At the same time, main controller sends out signals to power decrease solenoid valves (SA and SB). Then, power decrease solenoid valves (SA and SB) are shifted by the delivered signals so that pilot pressure oil is routed to regulator ports PG of main pumps (1, 2, and 3). Consequently, the pump swash angle is reduced, causing the pump to reduce the flow rate. When a control lever is operated and the pressure sensor detects 0.7 MPa (7kgf/cm2, 100psi) pressure, main controller stops sending out signals the ECM. Thereby, engine speed is increased up to the speed set by the engine control dial. Therefore, when engine speed increases more than 1500 min-1, main controller A stops sending out signals to power decrease solenoid valves (SA and SB) so that the pump swash angle is increased, causing the pump flow rate to increase. (Refer to the Regulator in the COMPONENT OPERATION / Pump Device group for regulator operation.)

T2-1-5

Auto-Idle Switch

Pressure Sensor Main Controller A

Pilot Pump

Power Decrease Solenoid Valve

Electronic Governor

T18E-02-01-016

Main Pump 3 Main Pump 1 Main Pump 2

SYSTEM / Control System Low Temperature Start Control Purpose: Heats the intake air when the atmospheric temperature is low (0°C (32°F) or lower) in order to make the engine start more easily. Operation: 1. When the key switch is turned ON, current from the battery magnetizes relay 1 via fusible link 1, key switch and fuse box 1. 2. When temperature at suction manifold is 0°C (32°F) or lower with the condition at step 1, battery the ECM relay magnetizes the preheat signal relay. 3. When the preheat signal relay is magnetized, current from the battery magnetizes preheat relays 1, 2 via battery relay1, fusible link 4, the preheat signal relay. 4. When preheat relays 1, 2 are magnetized, current from the battery activates air heaters 1 and 2 respectively via fusible links 7, 8 and preheat relays 1, 2. 5. At the same time at step 4, current from the battery magnetizes the preheat lamp relay via fusible link 8, preheat relay 2 and the fuse. 6. When the preheat lamp relay is magnetized, current flows through the preheat indicator in the monitor controller and the preheat indicator is turned ON. 7. Air heaters 1, 2 are activated for 30 seconds.

T2-1-6

NOTE:

• When the key switch is turned except ON before the preheat is finished (30 seconds before), the preheat is finished automatically and the preheat lamp is also turned OFF. • When the key switch is kept ON (for 30 seconds or longer) after the preheat is finished, the preheat is finished automatically and the preheat lamp is also turned OFF. • If the preheat is required once more, return the key switch to the OFF position. After 5 minutes or longer turn the key switch ON again in order to perform the preheat. (The preheat cannot be performed in 5 minute or longer after the key switch is turned OFF in order to protect the engine.)

SYSTEM / Control System

Air Heater 1 Key Switch

Fusible Link 7

Fusible Link 1

Preheat Relay 1

From Battery

Fuse Box 2 Fuse #1 20A

Battery

Fusible Link 8

Fuse Box 2 Fuse #3 5A

Preheat Signal Relay

Preheat Relay 2 Air Heater 2 Fuse 5A

Preheat Indicator

Preheat Indicator Relay Monitor Controller

Electronic Governor

T18E-02-01-017

T2-1-7

SYSTEM / Control System Engine Diagnosing Control Purpose: Performs when the engine or the related parts are abnormal, and the engine protection indicator, engine warning indicator or engine stop indicator is turned ON. Operation: When the key switch is turned ON with fault diagnosing switch A ON, the electrical signal from ECM is sent to the monitor and the fault code is displayed on the engine fault code display panel. When pushing fault diagnosing switch B forward or backward while the fault code is displayed on the engine fault code display panel, the signal from ECM is selected and the previous or following fault code is displayed on the monitor. (Refer to the Troubleshooting A section, TROUBLESHOOTING.)

T18E-01-02-006

Fuse Box B Fuse #3 5A Engine Protection Indicator Engine Warning Indicator ECM

Engine Diagnostic Switch A

Engine Stop Indicator

Engine Diagnostic Switch B

Protection Lamp Relay Monitor

Engine Stop Indicator

Engine Stop Lamp Relay CPU

DLU 24V

Engine Warning Indicator

T18E-02-01-018

T2-1-8

SYSTEM / Control System (Blank)

T2-1-9

SYSTEM / Control System Engine Protection Control Purpose: Monitors engine operating condition according to input signals delivered from the coolant temperature sensor, coolant level switch, engine oil pressure sensor, suction manifold temperature sensor and engine speed sensor and reduces engine loads by decreasing pump drive power or stops the engine in case any engine trouble is detected.

• Overheating 1. When coolant temperature keeps over 100 °C (212 °F) for 5 seconds or longer, the engine speed decreases. 2. At the same time at step 1, ECM turns the protection lamp on engine fault code display monitor ON and sends the signal to DLU. 3. After DLU receives the signal, DLU sends the signal the monitor and main controller A respectively. 4. After monitor receives the signal, the stop lamp blinks once. After 5 seconds, the overheat indicator is turned ON and the buzzer rings. 5. After receiving the signal from DLU, main controller A instructs power increase solenoid valve ST so that power increase control is deactivated and only power decrease control by power decrease solenoid valves (SA and SB) are activated. (Refer to the Pump Control description pages.) 6. When coolant temperature increases 115°C (239 °F), ECM blinks the stop lamp on engine fault code display monitor. After 30 seconds, the engine stops automatically. When the engine stops, only the overheat indicator on monitor is turned ON.

• Reduction in Engine Oil Pressure 1. When reduction in engine oil pressure keeps for 5 seconds or longer, the engine speed decreases. 2. At the same time at step 1, ECM turns the protection lamp on engine fault code display monitor ON and sends the signal to DLU. 3. After DLU receives the signal, DLU sends the signal the monitor and main controller A respectively. 4. After monitor receives the signal, the stop lamp blinks once. After 5 seconds the engine oil pressure indicator is turned ON and the buzzer rings. 5. After receiving the signal from DLU, main controller A instructs power increase solenoid valve ST so that power increase control is deactivated and only power decrease control by power decrease solenoid valves (SA and SB) are activated. (Refer to the Pump Control description pages.) 6. In response to engine oil pressure, the control for auto-stop performs as following (2 types): 1 ) After 90 seconds, ECM blinks the stop lamp on engine fault code display monitor. After 30 seconds, the engine stops automatically. 2 ) The engine stops automatically at once.

T2-1-10

When the engine stops, only the engine oil pressure indicator on monitor is turned ON.

SYSTEM / Control System (Blank)

T2-1-11

SYSTEM / Control System PUMP CONTROL SP Mode Control Purpose: Changes the pump flow rate in response to the engine speed change to utilize engine output effectively when the engine runs faster than the rated speed. Operation: When engine speed increases over 1550 min-1 with the SP mode ON, main controller sends out signals to power increase solenoid valve ST in response to the signals from engine speed sensor 1. Therefore the signals from main controller A to power increase solenoid valve ST changes as engine speed changes. Power increase solenoid valve ST delivers the pilot oil pressure corresponding to the received signals to main pump regulator ports PZ, increasing the pump swash angle in proportion to the delivered pilot oil pressure. Then, the pump flow rate increases, accelerating actuator speeds and increasing the engine loads. This operation continues until engine speed is reduced to 1550 min-1. (Refer to the Regulator in the COMPONENT OPERATION / Pump Device group for regulator operation.) E Mode Control Purpose: Reduces pump 3 flow rate when the machine is engaged in less production work. Operation: When the E mode switch is ON, main controller A sends out signals to power decrease solenoid valve SA, shifting power decrease solenoid valve SA. Then, the pilot oil pressure is delivered to main pump 3 regulator port PG, reducing the main pump 3 swash angle so that the pump 3 flow rate is reduced. Therefore, actuator operating speeds are reduced. NOTE: Since no signals are delivered to power decrease solenoid valve SB from main controller A, main pumps 1 and 2 are not controlled. (Refer to the Regulator in the COMPONENT OPERATION / Pump Device group for regulator operation.)

Main Controller A SP Mode Switch

Engine Speed Sensor 1

Power Increase Solenoid Valve ST Pilot Pump

Main Pump T183-02-01-009

Main Controller A E Mode Switch

Power Decrease Solenoid Valve SA

Pilot Pump PG

Main Pump 3 T142-04-03-006

T2-1-12

SYSTEM / Control System Pump Flow Rate Control at Slow Engine Speed Purpose: Prevents the engine from stalling even if engine speed is reduced to less than 850 min-1 due to engine load increase while the engine is running at slow speed. Operation: When main controller A is instructed by signals from engine speed sensor 1 that engine speed is reduced to less than 850 min-1, main controller A sends out signals to the flow rate decrease solenoid valve. When the flow rate decrease solenoid valve is activated, it closes the pilot pressure oil circuit from the pump flow rate control valve in the signal control valve to main pump 1 and 2 regulator ports Pi. Consequently, the pump swash angle is reduced so that the engine load is reduced. This operation continues until engine speed increases to more than 1400 min-1. (Refer to the COMPONENT OPERATION / Signal Control Valve group for signal pilot control valve operation.) (Refer to the Regulator in the COMPONENT OPERATION / Pump Device group for regulator operation.)

T2-1-13

Main Controller A

Flow Rate Decrease Solenoid Valve

Signal Control Valve

Engine Speed Sensor 1

Main Pump 2

Main Pump 1 T18E-02-01-006

SYSTEM / Control System Pump Flow Rate Control at Middle Engine Speed Purpose: Prevents engine speed from being reduced to less than 1400 min-1 due to engine load while the engine is running at middle speed. Operation: When main controller A is instructed by signals from engine speed sensor 1 that engine speed is reduced to less than 1400 min-1, main controller A sends out signals to power decrease solenoid valves SA and SB. When power decrease solenoid valves SA and SB are shifted, the pilot pressure oil routed to main pump 1, 2, and 3 regulator ports PG. Consequently, the pump swash angle is reduced so that the pump flow rate is reduced, reducing the engine loads. This operation continues until engine speed increases to more than 1500 min-1. (Refer to the Regulator in the COMPONENT OPERATION / Pump Device group for regulator operation.)

Main Controller A

Pilot Pump Power Decrease Solenoid Valve SA

Engine Speed Sensor 1

PG PG

Main Pump T18E-02-01-007

T2-1-14

SYSTEM / Control System Power Decrease Control to Prevent Engine Overheat Power Decrease Control at Abnormal Engine Oil Pressure Power Decrease Control at Lower Coolant Level Purpose: Reduces main pump 1, 2, and 3 output to reduce the engine loads when the coolant temperature increases over 100 °C (212 °F), when the engine oil pressure is abnormal, when the coolant level is reduced, or when temperature of suction manifold reaches over 85 °C (185 °F). Operation: When the coolant temperature increases to 100 °C (212 °F), when engine oil pressure is reduced or when temperature of suction manifold reaches over 85 °C (185 °F) and if the coolant level is reduced to lower than the specified level, main controller A sends out signals to power decrease solenoid valves SA and SB, shifting power decrease solenoid valves SA and SB. Then, the pilot pressure oil is routed to main pump 1, 2, and 3 regulator ports PG. Consequently, swash angle in main pumps 1, 2, and 3 is reduced so that the pump flow rate is reduced. Thereby, the engine loads are reduced, preventing the engine from being overloaded.

Suction Manifold Temperature Sensor

ECM

Engine Oil Pressure Sensor DLM

Coolant Level Switch Coolant Temperature Sensor Main Controller A

Power Decrease Solenoid Valve SB Power Decrease Solenoid Valve SB

Pilot Pump

Engine

Main Pump 3

Main Pump 2

Main Pump 1 T18E-02-01-014

T2-1-15

SYSTEM / Control System VALVE CONTROL Travel Mode Control Purpose: Controls the travel mode. Operation: Slow Mode: When the travel mode switch is turned to position, main controller B doesnâ&#x20AC;&#x2122;t send signals to the travel mode control solenoid valve so that the solenoid valve is deactivated. Therefore, reducing valve port D is connected to the hydraulic oil tank. Then, pilot oil pressure delivered from the pilot pump to the travel motors via the brake release pressure control valve and the reducing valve is maintained at 1.8 MPa (18 kgf/cm2, 256 psi) by the reducing valve. Accordingly, the travel mode control valves in the travel motors are not shifted. Then, pressure oil from the main pump is not supplied to the tilt pistons so that the travel motors rotate at slow speed. (Refer to the Travel Motor in the COMPONENT OPERATION / Travel Device group for travel motor swash angle control operation.)

T2-1-16

SYSTEM / Control System

From Main Pump

Pilot Pump

Reducing Valve

1.8 MPa Port D

Brake Release Pressure Control Valve

Travel Motor

Shuttle Valve

Parking Brake

From Main Pump

Tilt Piston OFF Travel Mode Control Solenoid Valve

Travel Mode Control Valve Shuttle Valve

Main Controller B

From Signal Control Valve

Travel Mode Switch

T183-02-02-013

T2-1-17

SYSTEM / Control System Fast Mode: When the travel mode switch is turned to position, main controller B sends out signals to the travel mode control solenoid valve so that the solenoid valve is activated. Therefore, pilot oil pressure from the pilot pump via the brake release pressure control valve and the travel mode control solenoid valve is routed to reducing valve port D, fully opening the reducing valve. Then, pilot oil pressure delivered from the pilot pump to the travel motors is maintained at 3.9 MPa (40 2 kgf/cm , 569 psi). Accordingly, the travel mode control valves in the travel motors are shifted. Then, pressure oil from the main pump is supplied to the tilt pistons so that the travel motors rotate at fast speed. (Refer to the Travel Motor in the COMPONENT OPERATION / Travel Device group for travel motor swash angle control operation.)

T2-1-18

SYSTEM / Control System

From Main Pump

Pilot Pump

Reducing Valve Brake Release Pressure Control Valve

3.9 MPa Port D

Shuttle Valve

Travel Motor

Parking Brake

From Main Pump

Tilt Piston ON Travel Mode Control Solenoid Valve

Travel Mode Control Valve Shuttle Valve

Main Controller B

From Signal Pilot Control Valve

Travel Mode Switch

T183-02-02-014

T2-1-19

SYSTEM / Control System Heavy Lift Control Purpose: Increases the main relief set-pressure. Operation: When the heavy lift switch is turned ON, main controller A receives signals from the switch and activates the heavy lift solenoid valve and activates the flow rate decrease solenoid valve. Then, the pilot oil pressure from the pilot pump is routed to the main relief valve via the heavy lift solenoid valve, increasing the relief set-pressure. (refer to the main relief pressure control on the COMPONENT OPERATION /Control Valve group.) Other than the above, the pilot pressure oil from the pump flow rate control valve in signal control valve to main pump 1 and 2 regulator ports Pi is blocked by the flow rate decrease solenoid valve so that main pump 1 and 2 flow rates are reduced to minimum.

T2-1-20

SYSTEM / Control System

Heavy Lift Switch

Main Control Valve

Main Relief Valve Main Controller A

Signal Control Valve

Heavy Lift Solenoid Valve

Pilot Pump

Flow Rate Decrease Solenoid Valve

Pi REG

REG

Main Main Pump 3 Pump 2

T2-1-21

Pi REG

Main Pump 1

T18E-02-01-012

SYSTEM / Control System Boom Mode Selection Control Purpose: Reduces machine vibration while performing digging or leveling work. Operation: When the boom mode selection switch is turned ON, main controller B activates boom mode selection solenoid valve SC so that pressure oil from the pilot pump is routed to the boom overload relief pressure switch valve via boom mode selection solenoid valve SC. Then, the boom overload relief pressure switch valve is shifted, blocking the pressure oil flow from the boom cylinder rod side to the overload relief valve pilot port. Therefore, the overload relief valve set-pressure is reduced to 9.8 MPa (100 kgf/cm2, 1420 psi). This reduces machine vibration while performing digging or leveling, but disenables to lower the bucket to raise the machine front off ground. NOTE: Refer to the COMPONENT OPERATION / Control valve group for the boom overload relief pressure switch valve.

T2-1-22

SYSTEM / Control System

Boom Cylinder

Boom Mode Selection Solenoid Valve SC

Pilot Pump Boom Overload Relief Pressure Switch Valve

Overload Relief Valve Main Controller B Boom Mode Selection Switch

Travel

Front All

Pilot Pressure Sensors

T18E-02-01-009

T2-1-23

SYSTEM / Control System OIL COOLER AND FUEL COOLER FAN MOTOR CONTROL Purpose:

Fuel Temperature Sensor

Changes the fan motor speed in three stages (Low, Middle and High speeds) as the hydraulic oil and fuel temperatures change to properly maintain the hydraulic oil and fuel temperatures.

Operation: Main controller A receives signals in response to each temperature from the hydraulic oil temperature sensor and fuel temperature sensor. Based on the received signals, controller A activates fan control solenoid valve SF so that pressure oil from the pilot pump is routed to the fan motor drive pump, controlling the fan motor drive pump speed. Then, the oil cooler fan motor speed is controlled by pressure oil from the fan motor drive pump.

Hydraulic Oil Temperature Sensor Main Controller A

Oil Cooler Fan Motor

Oil Cooler Fan Motor Drive Pump

Oil Cooler Fan Control Solenoid Valve SF

Pilot Pump Hydraulic Oil Temperature

T183-02-01-015

If the fan motor speed mode of fuel temperature is different from that of hydraulic oil temperature, the fan runs in response to the faster fan motor.

1400±50 min 800 min

-1

800 min 1100 min

-1

1100 min

-1

Fan Motor Speed T18E-02-01-011

Oil Temperature VS Fan Motor Speed

Fuel Temperature 66 °C (151 °F) 69 °C (156 °F) 66 °C (151 °F) 63 °C (145 °F)

Oil Cooler Fan Motor Speed 800→ 1100 min-1 1100→ 1400±50 min-1 1400±50→ 1100 min-1 1100→ 800 min-1

Hydraulic Oil Temperature 70 °C (157 °F) 80 °C (176 °F) 75 °C (167 °F) 65 °C (149 °F)

Pilot Pressure from Fan Control Solenoid Valve [Current from MC] 0.99 Mpa (10 kgf/cm2, 142 psi) [285 mA] 0 MPa (0 kgf/cm2, 0 psi) [200 mA] 0.99 Mpa (10 kgf/cm2, 142 psi) [285 mA] 1.36 Mpa (14 kgf/cm2, 199 psi) [309 mA]

NOTE: The fan motor speeds shown in the above table are those driven at engine rated speed (1650 min-1).

T2-1-24

Fan Motor Speed Mode Low→Middle Middle→High High→Middle Middle→ Low

SYSTEM / Control System (Blank)

T2-1-25

SYSTEM / Control System AUTO-LUBRICATION CONTROL Purpose: Automatically lubricates the front attachment joint pins with grease. (Refer to the COMPONENT OPERATION / Others (Upperstructure) group.) Operation: â&#x20AC;˘ Auto-Lubrication 1. When the auto-lubrication switch on the monitor panel is turned to the AUTO position, the monitor controller sends a signal to the main controller B. 2. Then, based on signals from the auto-lubrication interval switch, main controller B connects the ground circuit of the power transistor 3. 3. As long as a signal from main controller B is input, power transistor 3 activates the auto-lubrication relay. 4. As long as the auto-lubrication relay is activated. Then, the grease pump is driven, discharging grease. 5. In addition, main controller B monitors the auto-lubrication system with the proximity switch to check if it operates normally. 6. When the proximity switch is turned ON, main controller B deactivates the auto-lubrication relay. Therefore, the grease pump is stopped.

â&#x20AC;˘ Manual Lubrication

1. When the auto-lubrication switch on the monitor panel is turned to the MANUAL position, the monitor controller sends a signal to the main controller B. 2. Then, main controller B connects the ground circuit of the power transistor 3. Power transistor 3 activates the auto-lubrication relay and holds it activated. 3. Turn the lubricator grease pump switch ON. 4. Since the grease pump discharges grease, lubrication can be performed using the lubricator or a grease gun. 5. When the proximity switch is turned ON, main controller B receives a signal, deactivating the auto-lubrication relay. Therefore, the grease pump is stopped.

NOTE: In auto-lubrication mode, if the proximity switch is not shifted to either ON or OFF position within 5 minutes after the auto-lubrication relay is activated, main controller B judges that a system failure has occurred or the grease volume has been reduced, lighting the auto-lubrication indicator.

T2-1-26

NOTE: In manual lubrication mode, the auto-lubrication indicator is always kept ON.

SYSTEM / Control System

Auto-Lubrication Interval Switch Power Transistor 3 Fuse #14 To Lubrication Circuit

Auto-Lubrication Relay Grease Pump Switch

Lubricator Monitor Controller Grease Pump

Auto-Lubrication Indicator

Main Controller B

Proximity Switch T183-02-01-011

T2-1-27

SYSTEM / Control System (Blank)

T2-1-28

SYSTEM / Hydraulic System OUTLINE The hydraulic system consists of the main circuit, pilot circuit, pump transmission oil cooling circuit, and oil cooler fan motor circuit. Pilot Circuit: A hydraulic circuit that shifts the control valve spools, that controls the pumps, valves, and motors, and releases the parking brakes. Main Circuit: A hydraulic circuit that actuates cylinders, and motors by pressure oil delivered from the main pumps. Pump Transmission Oil Cooling Circuit: An oil circuit that cools the pump transmission oil by routing it through the oil cooler. Oil Cooler Fan Motor Circuit: A hydraulic circuit that drives the oil cooler fan motor with pressure oil from the oil cooler fan motor drive pump. (Refer to the oil cooler fan motor control in Control System group.)

T2-2-1

SYSTEM / Hydraulic System PILOT CIRCUIT Pressure oil from the pilot pump is used as working pressure for the following pilot circuits. • Control Circuit • Brake Release Circuit • Travel Motor Overrunning Prevention Circuit • Main Pump 3 Flow Rate Control Circuit • Combined Operation Circuit of Arm Roll-Out (Backhoe) / Arm Retract (Loading Shovel), Bucket Roll-In (Backhoe) / Tilt-Out (Loading Shovel), Boom Raise and Swing • Flow Rate Control Circuit for Boom Raise and Swing Combined Operation • Mode Selection Circuit • Auto-Idle Circuit • Pump Flow Rate Control Circuit • Main Relief Set-Pressure Control Circuit • Boom Raise Priority Circuit • Travel Mode Control Circuit • Heavy Lift Circuit • Boom Mode Selection Circuit

T2-2-2

SYSTEM / Hydraulic System Backhoe Pilot Valve (Travel)

Pilot Valve (Arm / Swing)

Pilot Valve (Boom / Bucket)

Pilot Shut-Off Valve

Accumulator

Shuttle Valve (Pilot Control)

Pilot Check Valve

Shuttle Valve (Bucket Roll-In)

Shockless Valve

Shuttle Valve (For Swing Pump 3 Control Pressure) Pump 1 Regulator

Pump 2 Regulator

Shockless Valve Pump 3 Regulator

Shuttle Valve (Swing Parking Brake Release)

Arm Preference Valve

Solenoid Valves

SC SB SA

Pump 3 Control Valve

Pilot Relief Valve 2-Unit EHC Valve Pilot Filter Oil Cooler Fan Motor Drive Pump

Swing Control Valve

Signal Pressure Control Valve

Shuttle Valve (For Swing Make-Up) Flow Rate Decrease Solenoid Valve

Pilot Pump

Main Control Valve

Heavy Lift Solenoid Valve

Hydraulic Oil Tank

Reducing Valve Brake Release Pressure Control Valve

Travel Mode Solenoid Valve

Travel Motor Travel Motor

Swing Motor Swing Motor

T18E-02-02-001

T2-2-3

SYSTEM / Hydraulic System Loading Shovel Pilot Valve (Travel)

Pilot Valve (Bucket Close)

Pilot Valve (Bucket Open)

Pilot Valve (Boom / Bucket)

Pilot Valve (Arm / Swing)

Pilot Shut-Off Valve Shuttle Valve (Pilot Control)

Accumulator

Shuttle Valve (Bucket Tilt-In)

Shockless Valve

Pilot Check Valve

Shuttle Valve (For Swing Pump 3 Control Pressure) Pump 1 Regulator Arm Preference Valve

Pump 2 Regulator

Pump 3 Regulator

SC SB SA

Shockless Valve Shuttle Valve (Swing Parking Brake Release)

Pump 3 Control Valve

Solenoid Valves

Pilot Relief Valve

Pilot Filter

Pilot Pump

Swing Control Valve

Signal Pressure Control Valve 2-Unit EHC Valve

Shuttle Valve (For Swing Make-Up)

Oil Cooler Fan Motor Drive Pump Flow Rate Decrease Solenoid Valve

Main Control Valve

Heavy Lift Solenoid Valve

Hydraulic Oil Tank

Reducing Valve Brake Release Pressure Control Valve

Travel Mode Solenoid Valve

Travel Motor Travel Motor

Swing Motor Swing Motor T18E-02-02-002

T2-2-4

SYSTEM / Hydraulic System (Blank)

T2-2-5

SYSTEM / Hydraulic System Control Circuit Pressure oil from the pilot pump flows to the main control valve and to the swing control valve to shift control valve spools via the pilot check valve, pilot shut-off valve, pilot valve, shuttle valve, and shockless valve. When the pilot shut-off valve is closed, pressure oil is not routed to the pilot valve so that the machine does not operate even if the control levers are operated. A couple of accumulators are provided in the control circuit, allowing pressure oil to be delivered for a while after the engine is stopped. Therefore, even after the engine stops due to any trouble with the front attachment raised, pilot oil pressure is delivered to the control valve spools so that the front attachment can be lowered.

T2-2-6

SYSTEM / Hydraulic System Backhoe

Boom / Bucket

Swing /Arm

Travel

Accumulator

Pilot Shut-Off Valve

5 6

Pilot Check Valve

Pilot Pump

Signal Control Valve

Hydraulic Oil Tank

14 13 3 1

10 9 12 11

12 1 8

8 7

1 2

2 3

8 7

10 9

4 3

3 4

Swing Control Valve 14 13

Main Control Valve T18E-02-02-003

1- Boom Raise 2- Boom Lower 3- Arm Roll-Out 4- Arm Roll-In

5- Left Swing 6- Right Swing 7- Bucket Roll-In 8- Bucket Roll-Out

9- Left Travel Forward 10- Left Travel Reverse 11- Right Travel Forward

T2-2-7

12- Right Travel Reverse 13- Auxiliary 14- Auxiliary

SYSTEM / Hydraulic System Loading Shovel

Bucket Close To Pilot Valve Bucket Open, Close

Travel

Bucket Open

Boom / Bucket

Swing /Arm

Accumulator

Pilot Shut-Off Valve

5 6

Pilot Check Valve

Pilot Pump

Signal Control Valve

Hydraulic Oil Tank

14 13 3 1

10 9 12 11

12 1 8

8 7

1 2

2 3

8 7

10 9

4 3

3 4

Swing Control Valve 14 13

Main Control Valve T18E-02-02-004

1- Boom Raise 2- Boom Lower 3- Arm Retract 4- Arm Extend

5- Left Swing 6- Right Swing 7- Bucket Tilt-In 8- Bucket Tilt-Out

9- Left Travel Forward 10- Left Travel Reverse 11- Right Travel Forward

T2-2-8

12- Right Travel Reverse 13- Bucket Close 14- Bucket Open

SYSTEM / Hydraulic System Brake Release Circuit

Travel Motor

â&#x20AC;˘ When traveling or operating front attachment:

When either the travel or the front attachment control levers are operated, pressure oil from the signal control valve is routed to the brake release pressure control valve. Then, pressure oil from the pilot pump is routed to the travel motor via the brake release pressure control valve and the reducing valve, releasing the travel parking brake. Also, pressure oil that has passed through the brake release pressure control valve is routed to the swing parking brake release valve. Then, pressure oil from the pilot pump flows through the swing parking brake release valve and release the swing parking brake. Therefore, dragging of the swing brake will be prevented when digging work is performed.

Pilot Pump

Reducing Valve

Shuttle Valve

Brake Release Pressure Control Valve

Shuttle Valve

Swing Motor

From Signal Pilot Pressure Control Valve Swing Parking Brake Release Valve

T18E-02-02-005

Pilot Pump

â&#x20AC;˘ When rotating upperstructure:

When the swing lever is operated, swing pilot pressure oil is routed to the brake release pressure control valve via the shuttle valves. Then, pressure oil from the pilot pump flows through the brake release pressure control valve to the swing parking brake release valve pilot port, allowing pressure oil from the pilot pump to flow through the swing parking brake release valve to release the swing parking brake.

Swing Motor

Swing Parking Brake Release Valve

Brake Release Pressure Control Valve

Shuttle Valve

Shuttle Valve Swing Pilot Pressure T18E-02-02-006

T2-2-9

SYSTEM / Hydraulic System Travel Motor Overrunning Prevention Circuit When the front attachment control levers are operated, pilot pressure from the front attachment circuit is routed to the priority valve pilot port in the signal control valve, shifting the priority valve. Then, when the right travel lever is operated under this condition, the pilot pressure oil from the right travel spool is routed to the flow combiner valve control spool pilot port in the signal control valve. Thereby, pressure oil from the pilot pump flows to the flow combiner valve pilot port in the main control valve via the priority valve and the flow combiner valve control spool, shifting the flow combiner valve. Then, pressure oil from main pump 2 is also routed into the left travel motor via the flow combiner valve. Therefore, the flow combiner valve cannot be shifted unless the right travel lever is operated. For example, when the left travel/boom combined operation is operated with the left track jacked-up using the boom function, only main pump 1 oil flow is supplied to the left travel motor since the flow combiner valve is closed. (Without this travel motor overrunning prevention circuit, two main pump flows could be supplied to the left travel motor, possibly causing overrunning of the left travel motor in the above mentioned operation.) (Refer to the COMPONENT OPERATION /Control Valve group.)

T2-2-10

SYSTEM / Hydraulic System

Signal Control Valve Priority Valve

Pilot Pump

Flow Combiner Valve

Right Travel (Forward) Pilot Pressure

Right Travel (Reverse) Pilot Pressure

Flow Combiner Valve Control Spool

Front Attachment Pilot Pressure T18E-02-02-007

T2-2-11

SYSTEM / Hydraulic System Main Pump 3 Flow Rate Control Circuit When either function of the arm roll-in (backhoe) / arm extend (loading shovel), bucket roll-in (backhoe) / tilt-in (loading shovel), boom raise or swing is operated, the pump 3 control valve is shifted. Then, pressure oil from the pilot pump is routed to the main pump 3 regulator as flow rate control pressure Pi, increasing the main pump 3 flow rate. Therefore, actuator operating speeds when a combine operation of arm roll-in (backhoe) / arm extend (loading shovel), bucket roll-in / tilt-in (loading shovel), boom raise or swing is made are ensured. (Refer to the COMPONENT OPERATION / Pump Control Valve group.)

Bucket Roll-In (Backhoe) Tilt-In (Loading Shovel) Pilot Pressure

Arm Roll-In (Backhoe) Arm Extend (Loading Shovel) Pilot Pressure

Boom Raise Pilot Pressure

Shuttle Valve

Right Swing Pilot Pressure Left Swing Pilot Pressure Shuttle Valve

REG

Pump 3 Control Valve

Main Pump 3

Pilot Pump

T2-2-12

REG

Main Pump 2

REG

Main Pump 1

T18E-02-02-008

SYSTEM / Hydraulic System (Blank)

T2-2-13

SYSTEM / Hydraulic System Combined Operation Circuit of Arm Roll-Out (Backhoe) / Arm Retract (Loading Shovel), Bucket Roll-In (Backhoe) / Tilt-Out (Loading Shovel), Boom Raise, and Swing When the arm roll-out (backhoe) / arm retract (loading shovel) and swing functions are operated at the same time for example, the swing pilot pressure oil shifts the arm preference valve via the shuttle valves. Therefore, no pilot pressure oil is routed to the arm 3 spool pilot port in the swing control valve so that arm 3 spool is not moved. Then, the return oil from the arm cylinder cannot pass through arm 3 spool, restricting the return oil flow. Thereby, arm hesitation while rolling out (backhoe)/retracting the arm (loading shovel) is prevented. (Refer to the combined operation circuit in this group and the COMPONENT OPERATION /Pump Control Valve group.)

T2-2-14

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Backhoe. Right Swing Boom Raise Bucket Roll-In Left Swing Pilot Pressure Pilot Pressure Pilot Pressure Pilot Pressure

Arm Roll-Out Pilot Pressure

Arm Cylinder

Shuttle Valve (Pilot Pressure Control)

Arm Preference Valve

Main Control Valve

Swing Control Valve Boom 3

Swing

Arm 1

Arm 2

Arm 3 Bucket 3

Main Pump 1 Main Pump 2 Main Pump 3

T18E-02-02-009

T2-2-15

SYSTEM / Hydraulic System Mode Selection Circuit

• Refer to the SP Mode and E Mode Control in the Control System group.

Auto-Idle Circuit

• Refer to the Auto-Idle Control in the Control System group.

Pump Flow Rate Control Circuit

• Refer to the Pump Flow Rate Control at Slow Engine Speed and the Pump Flow Rate Control at Middle Engine Speed in the Control System group.

Main Relief Set-Pressure Control Circuit

• Refer to the COMPONENT OPERATION / Main Relief Pressure Setting Change in the Control Valve group, and Heavy Lift Control in the Control System group.

Boom Raise Priority Circuit

• Refer to the Main Circuit, Combined Control Circuit,

Boom and Arm Combined Operation (Boom Raise and Arm Roll-Out) in this group. Travel Mode Control Circuit

• Refer to the Travel Mode Control in the Control System group.

Heavy Lift Circuit

• Refer to the Heavy Lift Control in the Control System group.

Jack-Up Prevention Circuit

• Refer to the Jack-up Prevention Control in the Control System group.

T2-2-16

SYSTEM / Hydraulic System (Blank)

T2-2-17

SYSTEM / Hydraulic System Swing Motor Make-Up Circuit Pressure oil from the pilot valve flows into port Pi of the regulator in the main pump 2 via the shuttle valve (for swing makeup) and shockless valve when the swing operation is operated. Therefore, the delivery volume from the main pump 2 increases. When the swing control lever is returned to the neutral position, pressure oil routed to port Pi of the regulator in the main pump 2 decreases, so that the delivery volume from the main pump 2 tries to decrease. However, the shockless valve prevents the pressure oil from returning suddenly to the hydraulic oil tank from port Pi of the regulator in the main pump 2. As a result, the delivery volume from the main pump 2 is maintained for a time being. As delivery volume from the main pump 2 is maintained, back pressure of the return oil from the main control valve 4-spool side increases, so that the make-up volume to the swing motor increases. As a result, the cavitation of the swing motor can be prevented.

T2-2-18

SYSTEM / Hydraulic System

Swing (Right) Pilot Pressure

to Swing Control Valve Right Swing

Swing (Left) Pilot Pressure

to Swing Control Valve Left Swing

Shuttle Valve (for Swing Make-Up)

Shockless Valve

Pi Main Pump 2

REG

Main Control Valve

4-Spool Side Oil Cooler Swing Motor 5-Spool Side

T18E-02-02-010

T2-2-19

SYSTEM / Hydraulic System MAIN CIRCUIT Main pumps 1, 2, and 3 draw hydraulic oil from the hydraulic oil tank. Main pump 1, main pump 2, and main pump 3 deliver hydraulic oil to the 5-spool section of the main control valve, to the 4-spool section of the main control valve, and the swing control valve, respectively. The delivered oil is further routed to the motors and/or cylinders in response to control valve operation. The return oil from the main control valve flows back to the hydraulic oil tank through the two return circuits. When the return oil temperature is low (high oil viscosity), or when a large amount oil is returned, oil flow resistance in the oil cooler increases. In this case, the bypass relief valve opens so that the return oil flows directly back to the hydraulic oil tank. When the return oil temperature increases (low oil viscosity), oil flow resistance in the oil cooler decreases. Therefore, the bypass relief valve doesnâ&#x20AC;&#x2122;t open so that the return oil flows back to the hydraulic oil tank after passing through the oil cooler.

T2-2-20

SYSTEM / Hydraulic System Backhoe Arm Cylinder

Boom Cylinder

Bucket Cylinder

Swing Motor Center Joint

Hydraulic Oil Tank

Swing Control Valve Main Control Valve (4-Spool Section)

Boom 3 Swing

Right Travel

Bucket 3

Bucket 1

Arm 3

Boom 1 Arm 2 Oil Cooler

Main Control Valve (5-Spool Section) Left Travel Bucket 2 Boom 2

Bypass Relief Valve

Arm 1 Auxiliary

Radiator Center Joint Main Pump 3 Main Pump 2 Main Pump 1 Right Travel Motor

Left Travel Motor High Pressure Oil Low Pressure Oil (Suction) Low Pressure Oil (Return) Circuit Oil Pilot Oil Drain Oil

T18E-02-02-024

T2-2-21

SYSTEM / Hydraulic System Bucket Boom Level Arm open/close Cylinder Cylinder Cylinder Cylinder

Loading Shovel

Bucket Cylinder

Swing Motor Center Joint Hydraulic Oil Tank

Swing Control Valve Main Control Valve (4-Spool Section)

Boom 3 Swing

Right Travel

Bucket 3

Bucket 1

Arm 3

Boom 1 Arm 2 Oil Cooler

Main Control Valve (5-Spool Section) Left Travel Bucket 2 Boom 2

Bypass Relief Valve

Arm 1 Bucket open/close Radiator Center Joint Main Pump 3 Main Pump 2 Main Pump 1 Right Travel Motor

Left Travel Motor High Pressure Oil Low Pressure Oil (Suction) Low Pressure Oil (Return) Circuit Oil Pilot Oil Drain Oil

T18E-02-02-025

T2-2-22

SYSTEM / Hydraulic System (Blank)

T2-2-23

SYSTEM / Hydraulic System Single Operation Circuit

â&#x20AC;˘ Boom Operation

Backhoe Boom Raise: Pressure oil from main pump 1 flows through the boom 2 spool in the 5-spool section of the main control valve. Pressure oil from main pump 2 flows through the boom 1 spool in the 4-spool section of the main control valve. Pressure oil from main pump 1 and 2 merges, and flows to the boom cylinder bottoms after passing through holding valve check valve. Pressure oil from main pump 3 flows through the boom 3 spool in the swing control valve and the holding valve check valve. Boom Lower: Pressure oil from the main pump 2 flows is fed to the boom cylinder rod side through the boom 1 spool in the 4-spool section of the main control valve. Pressure oil from the main pump 3 flows back into the hydraulic oil tank through the boom 3 spool in the swing control valve, so that it does not flow to the boom cylinder rod side even when the spool is shifted. The lowering side of the boom 2 spool in the 5-spool section of the main control valve is exclusively used for boom regeneration. Only the return oil from the boom cylinder bottom side flows there. NOTE: Refer to the COMPONENT OPERATION / Control Valve group for the holding valve functions.

T2-2-24

SYSTEM / Hydraulic System

Boom Cylinder

Swing Control Valve 4-Spool Section

Main Control Valve

Holding Valve Check Valve Holding Valve Switch Valve

Boom 3

Boom1 Boom 2

Holding Valve Check Valve

5-Spool Section Main Pump 1 Main Pump 2

Holding Valve Switch Valve

Main Pump 3

T18E-02-02-012

T2-2-25

SYSTEM / Hydraulic System Loading Shovel Boom Raise: Pressure oil from main pump 1 flows through the boom 2 spool in the 5-spool section of the main control valve. Pressure oil from main pump 2 flows through the boom 1 spool in the 4-spool section of the main control valve. Pressure oil from main pump 1 and 2 merges, and flows to the boom cylinder bottom side and the level cylinder rod side after passing through holding valve check valve. Pressure oil from main pump 3 flows through the boom 3 spool in the swing control valve and the holding valve check valve. Boom Lower: Pressure oil from the main pump 2 flows is fed to the boom cylinder rod side and the level cylinder bottom side through the boom 1 spool in the 4-spool section of the main control valve. Pressure oil from the main pump 3 flows back into the hydraulic oil tank through the boom 3 spool in the swing control valve, so that it does not flow to the boom cylinder rod side even when the spool is shifted. The lowering side of the boom 2 spool in the 5-spool section of the main control valve is exclusively used for boom regeneration. Only the return oil from the boom cylinder bottom side flows there. NOTE: Refer to the COMPONENT OPERATION / Control Valve group for the holding valve functions.

T2-2-26

SYSTEM / Hydraulic System Boom Cylinder

Boom Cylinder

Level Cylinder

Swing Control Valve

4-Spool Section

Main Control Valve

Holding Valve Check Valve Holding Valve Switch Valve

Boom 3

Boom1 Boom 2

Holding Valve Check Valve

5-Spool Section Main Pump 1 Main Pump 2

Holding Valve Switch Valve

Main Pump 3

T18E-02-02-013

T2-2-27

SYSTEM / Hydraulic System â&#x20AC;˘ Arm Operation

Backhoe Arm Roll-In: The return oil from the arm cylinder rod side flows into the arm 1 spool in the 5-spool side of the main control valve. The return oil is twice reduced by the orifices at the arm 1 spool and the arm regenerative valve in order to increase the pressure on the arm cylinder rod side. When this pressure exceeds that on the arm cylinder bottom side, the check valve in the arm 1 spool opens. The return oil from the arm cylinder rod side combines with that from the main pump 1, and then flows again to the arm cylinder bottom side. Pressure oils from the main pump 2 and main pump 3 flow to the arm cylinder bottom side through the arm 2 spool in the 4-spool section of the main control valve and the arm 3 spool of the swing control valve, respectively. The return oil does not flow through the swing control valve, because it is blocked by a check valve in the return route to the swing control valve.

Arm Roll-Out: Pressure oil from main pumps 1 and 2 flows to the arm cylinder rod side while taking the same oil passages as those of arm roll-in operation and opening the holding valve check valve. Pressure oil from main pump 3 passes through arm 3 spool in the swing control valve, opens the check valve, and flows to the arm cylinder rod side. NOTE: Refer to the COMPONENT OPERATION / Control Valve group for the holding valve functions.

T2-2-28

Check Valve

Arm 1 Spool

Orifice

Arm Regenerative Valve Orifice

T111-02-05-035

SYSTEM / Hydraulic System

Arm Cylinder

Main Control Valve

4-Spool Section

Swing Control Valve

Holding Valve Check Valve Arm 3

Arm1 Arm 2

Check Valve 5-Spool Section

Holding Valve Switch Valve

Main Pump 1 Main Pump 2

Arm Regenerative Valve

Main Pump 3

T18E-02-02-014

T2-2-29

SYSTEM / Hydraulic System Loading Shovel Arm Extend: The return oil from the arm cylinder rod side flows into the arm 1 spool in the 5-spool side of the main control valve. The return oil is twice reduced by the orifices at the arm 1 spool and the arm regenerative valve in order to increase the pressure on the arm cylinder rod side. When this pressure exceeds that on the arm cylinder bottom side, the check valve in the arm 1 spool opens. The return oil from the arm cylinder rod side combines with that from the main pump 1, and then flows again to the arm cylinder bottom side. Pressure oils from the main pump 2 and main pump 3 flow to the arm cylinder bottom side through the arm 2 spool in the 4-spool section of the main control valve and the arm 3 spool of the swing control valve, respectively. The return oil does not flow through the swing control valve, because it is blocked by a check valve in the return route to the swing control valve. Arm Retract: Pressure oil from main pumps 1 and 2 flows to the arm cylinder rod side while taking the same oil passages as those of arm extend operation and opening the holding valve check valve. Pressure oil from main pump 3 passes through arm 3 spool in the swing control valve, opens the check valve, and flows to the arm cylinder rod side. NOTE: Refer to the COMPONENT OPERATION / Control Valve group for the holding valve functions.

T2-2-30

Check Valve

Arm 1 Spool

Orifice

Arm Regenerative Valve Orifice

T111-02-05-035

SYSTEM / Hydraulic System

Arm Cylinder

Main Control Valve

4-Spool Section

Swing Control Valve

Holding Valve Check Valve Arm1

Arm 3

Arm 2

Check Valve

5-Spool Section Holding Valve Switch Valve

Main Pump 1 Main Pump 2

Arm Regenerative Valve

Main Pump 3

T18E-02-02-015

T2-2-31

SYSTEM / Hydraulic System â&#x20AC;˘ Bucket Operation

Bucket Roll-In (Backhoe) / Tilt-In (Loading Shovel) Pressure oil from main pump 1, main pump 2, and main pump 3 flows to the bucket cylinder bottoms after passing through the bucket 2 spool in the 5-spool section of the main control valve, the bucket 1 spool in the 4-spool section of the main control valve, and the bucket 3 spool in the swing control. Bucket Roll-Out (Backhoe) / Tilt-Out (Loading Shovel) Pressure oil from main pump1 and 2 is routed to the bucket cylinder rod side after passing through the bucket 2 spool in the 5-spool section and the bucket 1 spool in the 4-spool section of the main control valve, respectively. Pressure oil from main pump 3 doesnâ&#x20AC;&#x2122;t flow to the bucket cylinder rod side because the oil circuit from the bucket 3 spool to the bucket cylinder is blocked.

T2-2-32

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Backhoe. Bucket Cylinder

Main Control Valve

4-Spool Section

Swing Control Valve

Bucket 1

Bucket 2

Bucket 3

5-Spool Section

Main Pump 1 Main Pump 2 Main Pump 3

T18E-02-02-016

T2-2-33

SYSTEM / Hydraulic System â&#x20AC;˘ Bucket Open/Close Operation (Loading Shovel

only) Bucket Open: Pressure oil from main pump 1 flows to the bucket open/close cylinder rod side after passing through the bucket open/close spool in the 5-spool section of the main control valve. Bucket Close: Pressure oil from main pump1 flows to the bucket open/close cylinder bottom side after passing through the bucket open/close spool in the 5-spool section.

T2-2-34

SYSTEM / Hydraulic System Bucket Open/close Cylinder

Main Control Valve

4-Spool Section

5-Spool Section

Backet Open/Close Main Pump 1

T18E-02-02-017

T2-2-35

SYSTEM / Hydraulic System â&#x20AC;˘ Travel Operation

Left Travel: Pressure oil from main pump 1 is routed into the left travel motor via the left travel spool in the 5-spool section of the main control valve. Right Travel: Pressure oil from main pump 2 is routed into the right travel motor via the right travel spool in the 4-spool section of the main control valve.

â&#x20AC;˘ Swing Operation

Pressure oil from main pump 3 is routed into the swing motor via the swing spool in the swing control valve.

T2-2-36

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Backhoe.

Left Travel Motor

Right Travel Motor

Main Control Valve

4-Spool Section

Swing Control Valve

Swing

Swing Motor

5-Spool Section

Main Pump 1 Main Pump 2 Main Pump 3

T18E-02-02-018

T2-2-37

SYSTEM / Hydraulic System Combined Operations

â&#x20AC;˘ Swing and Boom Combined Operation

When swing and boom raise combine operation is performed, the swing and boom 1, 2, and 3 spools are shifted. Pressure oil from main pump 1 is routed to the boom 2 spool after passing through the auxiliary and boom 2 spools in the 5-spool section of the main control valve. Pressure oil from main pump 2 is routed to the boom 1 spool via the parallel circuit after passing through the right travel spool in the 4-spool section of the main control valve. Then, both pressure oils are jointly routed to the bottom of boom cylinders via the holding valve check valve. Pressure oil from main pump 3 enters the swing control valve. Then, it is separately routed to the boom 3 spool and the swing spool. Pressure oil from the boom 3 spool is routed to the boom cylinder bottoms via the holding valve check valve. Pressure oil from the swing spool is routed to the swing motor via the parallel circuit. For simultaneous operation of swing and boom lowering, the pressure oil from the main pump 2 flows to the boom cylinder rod side through the travel (right) spool in the main control valve and the parallel circuit. The pressure oil from the boom 3 spool in the swing control valve does not flow into the hydraulic oil tank, because it is blocked by the swing spool. The pressure oil from the main pump 3 flows into the swing spool through the parallel circuit. The return oil from the boom cylinder flows back into the hydraulic oil tank through the boom 1 spool and boom 2 spool.

T2-2-38

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Backhoe.

Boom Cylinder

Right Travel

Swing Control Valve Main Control Valve Holding Valve Parallel Check Valve Circuit Holding Valve Switch Valve

4-Spool Section

Parallel Circuit

Boom 3

Swing

Boom 1 Boom 2 Arm 1

Holding Valve Check Valve

Auxiliary

Swing Motor

5-Spool Section Main Pump 1 Main Pump 2

Holding Valve Switch Valve

Main Pump 3

T18E-02-02-019

T2-2-39

SYSTEM / Hydraulic System â&#x20AC;˘ Swing and Arm Combined Operation

When swing and arm combined operation is performed, the swing spool and arm spools 1, 2, and 3 are shifted. Pressure oil from main pump 1 is routed to arm 1 spool via the auxiliary spool in the 5-spool section of the main control valve. Pressure oil from main pump 2 is routed to arm 2 spool via the parallel circuit in the 4-spool section of the main control valve. Then, both pressure oil flows are jointly routed to the arm cylinder.

Pressure oil from main pump 3 enters the swing control valve and pressure oil flows to the swing spool and arm spool 3. When swing and arm roll-out (backhoe) / arm retract (loading shovel) combined operation is performed, the arm 3 spool in the swing control valve is not shifted as pilot pressure oil to the arm 3 spool is blocked by the arm preference valve. Then, the return oil from the arm cylinder cannot pass through arm 3 spool, restricting the return oil flow. Thereby, arm hesitation while rolling out (backhoe) / retracting the arm (loading shovel) is prevented. When swing, boom raise, and/or bucket function is operated, the arm preference valve is shifted, blocking the pilot pressure oil flow to the arm roll-out (backhoe) / arm retract (loading shovel) spool. (Refer to T2-2-15.)

T2-2-40

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Swing and Arm Roll-In (Backhoe) Combined.

Arm Cylinder

Parallel Circuit

Main Control Valve

Swing Control Valve

4-Spool Section

Parallel Circuit

Swing

Arm 2 Arm 1

Arm 3

Auxiliary Swing Motor Arm Preference Valve

5-Spool Section Main Pump 1 Main Pump 2 Main Pump 3

T18E-02-02-020

T2-2-41

SYSTEM / Hydraulic System â&#x20AC;˘ Boom and Arm Combined Operation

Boom Lower and Arm Roll-In (Backhoe) / Arm Extend (Loading Shovel): When boom lower and arm roll-in (backhoe) / arm extend (loading shovel) combine operation is made, both boom 1, 2, 3 spools and arm 1, 2, 3 spools are operated. Pressure oil from main pump 1 is routed to the arm spool 1 via the auxiliary spool in the 5-spool section of the main control valve. Pressure oil from main pump 2 is routed to the boom 1 spool and the arm 2 spool via the parallel circuit in the 4-spool section of the main control valve. When pressure in the bottom of the boom cylinder is higher than pressure in the boom cylinder rod side, pressure oil in the bottom of the boom cylinder flows into the boom cylinder rod sides via the boom 2 spool, accelerating the boom lower speed. Pressure oil from main pump 3 is routed to the arm 3 spool in the swing control valve. Both pressure oil from the boom 1 spool and the boom 2 spool are jointly routed into the boom cylinder rod side. Pressure oil from the arm 1, 2, and 3 spools are jointly routed into the arm cylinder bottom side. The holding valve switch valves in the boom 1 and boom 3 raise circuits are shifted by the boom lower pilot pressure so that the holding valve check valve is opened. The return oil from the boom cylinders flows back to the hydraulic oil tank through the holding check valve and the boom 1 and 3 spools. The holding valve switch valves in the arm 1 roll-out (backhoe) / retract (loading shovel) circuit are shifted by the arm roll-out (backhoe) / retract (loading shovel) pilot pressure so that the holding valve check valve is opened. The return oil from the arm cylinder is routed to the arm 1 spool via the holding check valve. The return oil flow from the arm cylinder is restricted by the orifice in the spool and the arm oil flow regenerative control valve. When the return oil pressure increases more than the bottom side pressure the return oil doesnâ&#x20AC;&#x2122;t flow back to the hydraulic oil tank but is routed to the arm cylinder bottom through the arm 1 spool check valve. (Refer to the COMPONENT OPERATION/Control Valve group for the boom and arm holding valve and the arm regenerative valve.)

T2-2-42

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Boom Lower and Arm Roll-In (Backhoe) Combined.

Boom Cylinder

Arm Cylinder

Parallel Circuit

Swing Control Valve Holding Valve Check Valve

Main Control Valve

4-Spool Section

Holding Valve Check Valve

Boom 3

Boom 1 Boom 2

Arm 1

Arm 3

Holding Valve Check Valve

Arm 2

Holding Valve Check Valve

Auxiliary

5-Spool Section

Main Pump 1

Holding Valve Switch Valve

Main Pump 2

Holding Valve Switch Valve Arm Regenerative Valve

Main Pump 3

T18E-02-02-021

T2-2-43

SYSTEM / Hydraulic System â&#x20AC;˘ Boom Raise and Arm Roll-Out (Backhoe) / Arm Re-

tract (Loading Shovel): When boom raise and arm roll-out (backhoe) / arm retract (loading shovel) combined operation is made, both boom 1, 2, 3 spools and arm 1 spool are operated. Arm 2 spool is not shifted as pilot pressure oil from the arm flow rate control valve in the signal control valve acts on the arm roll-in (Backhoe)/arm extend (Loading shovel) side of arm 2 spool. Pressure oil from main pump 1 is routed to the boom 2 spool via the parallel circuit and the arm 1 spool via the auxiliary spool in the 5-spool section of the main control valve. Pressure oil from main pump 2 is routed to the boom 1 spool via the parallel circuit in the 4-spool section of the main control valve. Pressure oil from main pump 3 is routed to the boom 3 spool in the swing control valve. Pressure oil is not routed to the arm 3 spool since the parallel circuit is not provided. Therefore, the boom raise speed is ensured. When boom raise and arm roll-out (backhoe) / arm retract (loading shovel) combined operation is performed, the arm 3 spool is not shifted as pilot pressure oil to arm 3 spool is blocked by the arm preference valve. Then, the return oil from the arm cylinder cannot pass through arm 3 spool, restricting the return oil flow. Thereby, arm hesitation while rolling out (backhoe) / retracting the arm (loading shovel) is prevented. When swing, boom raise, and/or bucket function is operated, the arm preference valve is shifted, blocking the pilot pressure oil flow to the arm roll-out (backhoe) / arm retract (loading shovel) spool. (Refer to the arm roll-out (backhoe) / arm retract (loading shovel) and bucket roll-in (tilt-in), boom raise, swing combined operation circuit.) Pressure oil from the boom 1 spool, the boom 2 spool, and the boom 3 spool is routed jointly to the boom cylinder bottoms after passing through the holding valve check valves. Pressure oil from the arm 1 spool and the arm 2 spool are jointly routed to the arm cylinder rod side after passing through the holding valve check valve.

T2-2-44

SYSTEM / Hydraulic System Arm Cylinder

Boom Cylinder

Swing Control Valve Main Control Valve

Holding Valve Check Valve

4-Spool Section

Boom 3

Boom 1 Boom 2

Arm 3

Arm 2 Arm 1

Holding Valve Check Valve

Auxiliary Arm Preference Valve

5-Spool Section Main Pump 1

Boom Raise Pilot Pressure

Main Pump 2

Parallel Circuit

Main Pump 3

Parallel Circuit

Arm Roll-Out Pilot Pressure

Arm Flow Rate Control Valve

Signal Control Valve

NOTE: The drawing shown in the above is Boom Raise and Arm Roll-Out (Backhoe) Combined.

Boom Raise Pilot Pressure

Arm Roll-out (Backhoe) Arm retract (Loading shovel) Pilot Pressure

T2-2-45

T18E-02-02-022

SYSTEM / Hydraulic System â&#x20AC;˘ Travel and Front Attachment Combined Operation

When travel and front attachment such as boom raise combined operation is made, the travel spools (right and left) and boom 1,2,3 spools are operated. As the boom spools are moved, the signal pilot pressure increases so that the flow combiner valve in the main control valve is shifted. Pressure oil from main pump 1 is routed to the boom 2 spool via the auxiliary and arm 1 spools in the 5-spool section of the main control valve. Pressure oil from main pump 2 is routed into the right travel motor via the right travel spool in the 4-spool section of the main control valve. On the other hand, pressure oil is routed into the left travel motor via the flow combiner valve, the left travel spool so that the machine can travel straight. Pressure oil from main pump 3 is routed to the boom 3 spool in the swing control valve. Pressure oil from boom 2 and 3 spools are jointly routed to the boom cylinder bottoms.

T2-2-46

SYSTEM / Hydraulic System NOTE: The drawing shown in the below is Backhoe.

Boom Cylinder

Left Travel Motor

Right Travel Motor

Flow Combiner Valve Right Travel

Main Control Valve

4-Spool Section

Swing Control Valve

Left Travel

Boom 3

Boom 2 Boom1

Arm 1

Auxiliary

5-Spool Section

Main Pump 1 Main Pump 2 Main Pump 3

T18E-02-02-023

T2-2-47

SYSTEM / Hydraulic System PUMP TRANSMISSION CIRCUIT

OIL

COOLING

The pump transmission oil pump draws transmission oil and delivers it to the oil cooler. After being cooled in the oil cooler, the transmission oil is returned into the pump transmission via each lubricating section. Thereby, oil temperature increase is prevented, foreign matter is filtered and removed, and each part in the pump transmission is lubricated.

OIL COOLER FAN MOTOR CIRCUIT Refer to the CONTROL SYSTEM Section. Manifold Oil Cooler

Engine

Pump Transmission

Suction Filter

Filter

Transmission Oil Pump T183-02-02-022

T2-2-48

SYSTEM / Electrical System OUTLINE The electrical system roughly falls into three sections such as the main circuit, the control circuit, and the monitor circuits.

• Main Circuit

Engine and accessory circuit

• Control Circuit

Engine and pump control circuits consisting of actuators such as solenoid valves, main controller A and B, ECM (Engine Control Module), sensors, pressure switches, etc.

• Monitor Circuit

Machine operation status indication circuit consisting of sensors, switches, etc.

Outline of the major functions and construction of the main circuit are explained hereafter.

• Power Source Circuit

Supplies electric power to all electrical systems on the machine.

• Bulb Check Circuit

Checks for burned monitor warning lights and indicator bulbs.

• Engine Start Circuit

Rotates the starter to start the engine.

• Charging Circuit

Recharges the batteries and supplies current to all the electrical components from the alternator.

• Accessory Circuit

Operates when the key switch is in the ACC position.

• Surge Voltage Prevention Circuit

Protects the electrical equipment such as the controller from surge voltage developed when stopping the engine.

T2-3-1

SYSTEM / Electrical System POWER SOURCE CIRCUIT Negative terminal of the battery is connected to the vehicle frame. When the key switch is OFF, battery current is supplied to the monitor, main controller B, DLU and ECM as backup power.

Fuse Box 1

Key Switch

DLU

Fusible Link

Battery Relay 2 Fuse Box 2

Load Damp Relay

Battery Relay 1 Battery

Monitor Controller ECM Main Controller B

T18E-02-03-007

T2-3-2

SYSTEM / Electrical System BULB CHECK CIRCUIT When the key switch is turned ON, terminal B is connected to terminals ACC and M in the key switch. The current from terminal M magnetizes battery relay 2 so that battery current is routed to the monitor controller via battery relay 2, the 1 pole junction, and the fuse box 1, turning all warning lights and indicators on the monitor panel ON. Any warning light and/or indicator which doesnâ&#x20AC;&#x2122;t come ON at this time may have burned out. Fuse Box 1

Key Switch

Fusible Link

1 Pole Junction Battery Relay 2

Engine Stop Solenoid Relay

Battery Relay 1 Battery

Monitor Controller

T18E-02-03-008

T2-3-3

SYSTEM / Electrical System ENGINE START CIRCUIT 1. When the key switch is turned ON, current from key switch terminal M magnetizes battery relays 1 and 2 via fuse #10 in fuse box 1. 2. When battery relays 1 and 2 are magnetized, battery current is routed to starter motors (2 used) terminals B via battery relays 1 and 2. 3. When the key switch is set to the START position, current from key switch terminal G2 is applied through fuse #19 in fuse box 1 in order to magnetize starter relay 1. 4. When starter relay 1 is magnetized, battery current is routed to terminal S in starter relay 2 via battery relay 2, fusible link 5 and starter relay 1. 5. When current is routed to terminal S in starter relay 2, the coil in starter relay 2 is magnetized and terminal B is connected to terminal C. 6. When terminal B is terminal C in the starter motor, the coil in the starter motor is magnetized, drawing main contactor so that the contact point is closed. At the same time, the pinion gear is extended to engage with the engine ring gear. 7. When the main contactor contact point is closed, battery current is routed to the motor from starter motor terminal B, rotating the motor. 8. Once the engine starts, the alternator begins to generate electricity and supplies current from alternator terminals B and R.

9. Current from the alternator terminal R is applied to starter relay 2 terminal R to demagnetize starter relay 2. 10. Consequently, starter relay 2 is turned OFF so that starter relay 1 magnetizing current is cut off, turning starter relay 1 OFF. 11. When magnetizing current routed to starter motor terminal C from the starter relay 1 is cut off, the main contactor is turned OFF, causing the pinion gear in the starter to retract. 12. At the same time, battery current is cut off so that starter motor stops rotating. 13. While the engine is rotating (when the alternator is generating), no current is routed to starter terminal C. Therefore, even if the key switch is turned to the START position, the starter will not rotate.

T2-3-4

SYSTEM / Electrical System

Key Switch

Fusible Link 1 Fuse Box 1

1 Pole Junction

Battery Relay 2

Fusible Link 5 Fusible Link 6 Fusible Link 7

Battery Relay 1

Fusible Link 8

Battery

Fuse Box 2

Alternator

Starter Relay

Starter Motor 2

ECM

Starter Motor 1

Safety Relay 2

Safety Relay 1

T18E-02-03-010

T2-3-5

SYSTEM / Electrical System CHARGING CIRCUIT (KEY SWITCH: ON) When the key switch is released after the engine starts, the key switch returns to the ON position. In the ON position, key switch terminal B is connected to terminals ACC and M in the key switch. After the engine starts, the alternator is rotated, starting generation.

Connection in Fusible Link Fusible Link Connecting Fuse Box #1 (45 A)

#2 (75 A)

Remarks Backup Power, Main Power Main Controller B Main Power ECM Main Power Work Light Relays 1 and 2 Power Washer Relay, Wiper Relay (L, H1, H2), Power Wiper Motor Air Conditioner Power Auto-Lubrication Solenoid Valve Relay, Power Flow Rate Decrease Solenoid Valve Relay, Power Transistors 1, 2 and 3 DC-DC Converter Power Main Controllers A and B Solenoid Power Travel Alarm Power

Monitor (Input Power), Main Controller A

Step Light Relay

#9 −

Air Conditioner Preheat Signal Relay

Power Power

−

Starter Relay 1

Power

−

Alternator

Power

−

Preheat Relay 1

Power

−

Preheat Relay 2

Power

Fuse Box 1

Fuse Box 2 Fuse Box 1

#2 #1 #11 #12 #13 #14

#3 (75 A)

#4 (45 A) #5 (250 A) #6 (100 A) #7 (125 A) #8 (125 A)

Current from alternator terminal B is routed to the batteries via fusible link #6 (100 A) and the battery relay, recharging the batteries. At the same time, current from alternator terminal B flows to all electrical circuits via the junction box, fusible link, fuse box 1, and fuse box 2. Current from alternator terminal R is routed to the monitor controller turning the alternator indicator OFF.

Fuse Box 1

#4 #5

Connected to: Monitor (Backup), DLU

T2-3-6

Main Power

SYSTEM / Electrical System

Key Switch

Fusible Link 1 Fuse Box 1

1 pole Junction

Fusible Link 2

Battery Relay 2

Fusible Link 3

Fusible Link 4 Battery Relay 1 Fusible Link 5 Battery

Fusible Link 6

Fuse Box 2

Fusible Link 7

Alternator

Fusible Link 8 Starter Relay

Air Heater 2 Air Heater 1

Monitor Controller

T18E-02-03-011

T2-3-7

SYSTEM / Electrical System ACCESSORY CIRCUIT When the key switch is turned to the ACC position, terminal B is connected to terminal ACC in the key switch. Current from terminal ACC is routed to the radio, cigar lighter, cab light, and horn via fuses #15, #16, #17 and #18.

Fuse Box 1 Radio

Key Switch

Fusible Link #1

Cigar Lighter Cab Light Horn

Battery Relay 2

Battery Relay 1

Battery T18E-02-03-009

T2-3-8

SYSTEM / Electrical System (Blank)

T2-3-9

SYSTEM / Electrical System SURGE VOLTAGE PREVENTION CIRCUIT The surge voltage prevention circuit prevents the occurrence of surge voltage developed when the engine is stopped to protect electronic components such as the main controller from being damaged by this surge voltage. When the key switch is turned OFF while the engine is running, current from key switch terminal M to the battery relay is interrupted, deactivating the battery relay. The engine, however, will continue running for a while due to its inertia soon after the key switch is turned OFF. Consequently, if the battery relay is turned OFF at this time, current from alternator terminal B cannot flow to the batteries, casing surge voltage to develop in the circuit. Battery current is constantly routed to main controller B. To keep the battery relay ON while the engine is running, the main controller B built in timer allows the ground circuit of power transistor 3 to close for 15 seconds after the key switch is turned OFF. Therefore, the load damp relay is kept ON for 15 seconds so that current to magnetize the battery relay is kept supplied. Consequently, current from alternator terminal B is routed to the batteries via the battery relay, preventing the occurrence of surge voltage.

T2-3-10

SYSTEM / Electrical System

Key Switch

Fuse Box 1 Fusible link 1 1 Pole Junction

Battery Relay 2

Fusible link 3

Battery Relay 1 Load Damp Relay Power Transistor 3

Fusible link 5 Battery

Fusible link 6 Fusible link 7

Alternator

Fusible link 8 Main Controller B Monitor Controller

Safety Relay 2

Safety Relay 1

T18E-02-03-012

T2-3-11

SYSTEM / Electrical System (Blank)

T2-3-12

SECTION 3

COMPONENT OPERATION CONTENTS Group 1 Pump Device

Group 5 Travel Device

Outline ...................................................... T3-1-1

Outline ......................................................T3-5-1

Main Pump, Oil Cooler Fan Motor

Travel Reduction Gear ..............................T3-5-2

Drive Pump ............................................. T3-1-2

Travel Motor ..............................................T3-5-3

Regulators ................................................ T3-1-5

Travel Brake Valve ....................................T3-5-5

3-Unit Pump............................................ T3-1-26

Travel Motor Displacement Angle Change........................................T3-5-10

Group 2 Swing Device

Parking Brake .........................................T3-5-12

Outline ...................................................... T3-2-1 Swing Motor.............................................. T3-2-2

Group 6 Signal Control Valve

Valve Unit ................................................. T3-2-4

Outline ......................................................T3-6-1

Swing Parking Brake................................. T3-2-6

Pilot Port ...................................................T3-6-2

Swing Reduction Gear .............................. T3-2-7

Shuttle Valve .............................................T3-6-6 Shockless Valve ......................................T3-6-10

Group 3 Control Valve

Pump 1 and 2 Flow Rate Control Valve ...T3-6-14

Outline ...................................................... T3-3-1

Arm Flow Rate Control Valve,

Hydraulic Circuit ..................................... T3-3-10

Flow Combiner Valve Control Spool,

Flow Combiner Valve .............................. T3-3-12

Priority Valve .........................................T3-6-16

Main Relief Valve .................................... T3-3-14 Overload Relief Valve ............................. T3-3-15

Group 7 Other (Upperstructure)

Make-Up Valve........................................ T3-3-15

Pilot Shut-Off Valve ...................................T3-7-1

Holding Valve .......................................... T3-3-16

Shockless Valve ........................................T3-7-2

Arm Regenerative Valve ......................... T3-3-18

Solenoid Valve ..........................................T3-7-6

Boom Overload Relief Pressure

Oil Cooler Fan Motor .................................T3-7-8

Switch Valve.......................................... T3-3-20

Accumulator ..............................................T3-7-9 Auto-Lubrication System .........................T3-7-10

Group 4 Pilot Valve Outline ...................................................... T3-4-1 Operation .................................................. T3-4-2

Group 8 Other (Undercarriage) Swing Bearing ...........................................T3-8-1 Center Joint...............................................T3-8-2 Track Adjuster ...........................................T3-8-3

18ET-3-1

(Blank)

18ET-3-2

COMPONENTS OPERATION / Pump Device OUTLINE The pump device consists of the pump transmission, main pumps and 3-unit pump. Power from the engine is transmitted to each pump through the pump transmission. The gear reduction ratio for the main pumps is 1.083 and for the 3-unit pump is 1.106. The main hydraulic pump is a variable displacement swash plate tandem plunger type pump, supplying high pressure hydraulic oil to the main circuit. The 3-unit pump consists of three pumps of various types. From the pump transmission side, the 1st pump is the oil cooler fan motor drive pump.

The 2nd pump is a pilot pump supplying pressure oil to the pilot circuit. The 3rd (farthest away from the pump transmission) is a transmission oil circulation pump. The oil cooler fan motor drive pump is a variable displacement swash plate plunger type pump. The pilot pump and the transmission oil circulation pump are gear pumps.

Main Pump 3

Pump Transmission

Main Pump 2

Main Pump 1

3-Unit Pump

T183-01-02-006

T3-1-1

COMPONENTS OPERATION / Pump Device MAIN PUMP, OIL COOLER FAN MOTOR DRIVE PUMP The shaft is connected to the cylinder block via a spline coupling. The plungers are inserted into the cylinder block bores. Engine driving force is transmitted to the shaft via the pump transmission. As the shaft rotates, the plunger rotates align with cylinder block, sliding along the surface of the shoe plate. Because the swash plate is positioned at an angle against the plungers, the plungers reciprocate in the cylinder block bores, drawing and discharging hydraulic oil.

Shaft

Shoe Plate

Swash Plate

Servo Piston

Plunger

Cylinder Block W142-02-03-010

T3-1-2

COMPONENTS OPERATION / Pump Device Flow Rate Increasing/Decreasing Operation The flow rate of the pump is varied by changing the angle of the swash plate which changes the stroke of the plunger. When pressure oil from the regulator moves the servo piston, the swash angle changes accordingly as the swash plate is connected to the servo piston.

Servo Piston

Shaft

Valve Plate Cylinder Block Plunger Swash Plate T142-02-01-001

T3-1-3

COMPONENTS OPERATION / Pump Device (Blank)

T3-1-4

COMPONENTS OPERATION / Pump Device REGULATORS • Horsepower Reducing Control (only for Main Pump) When the E mode switch is turned ON, the horsepower reducing control pressure PG, from the horsepower reducing solenoid valve SA, acts on the main pump 3, and reduces the pump swash angle. When the engine speed slows to 1400 min -1 or less, the horsepower reducing control pressure PG, from the horsepower reducing solenoid valves SA/SB, acts on all main pumps, and reduce the pump horsepower by reducing the pump swash angle. • Horsepower Increasing Control (only for Main Pump) When the engine speed increases to 1550 min-1 or more, the horsepower increasing control pressure PZ, from the horsepower increasing solenoid valve ST, increases the pump horsepower by increasing the pump swash angle. • Smaller Swash Angle (Less Flow Rate) Priority Control It two or more orders to increase/decrease the pump flow rate are given simultaneously to the regulator, the one to indicate the smallest pump flow rate will have the higher priority.

The regulators are located on the main pump and oil cooler fan motor drive pump to control the flow rate. Regulator Controls • Constant Torque Control Control the pump flow rate depending on the pump delivery pressure in order to maximize utilization of the engine horsepower. The control includes the following two operations: (1) Overload Prevention Operation: When the delivery pressure increases, reduce the flow rate by reducing the pump swash angle. (2) Flow Rate Recovery Operation: When the delivery pressure decreases, increase the flow rate by increasing the pump swash angle. • Flow Rate Control On the regulator for the main pump, flow rate controls pressure Pi from the signal control valve controls the pump swash angle. Consequently, the pump delivers the flow rate according to the lever operation, reducing the fuel consumption. On the regulator for the oil cooler fan motor drive pump, flow rate control pressure Pi from the fan pump solenoid valve SF controls the flow rate by changing the pump swash angle.

Position of Ports

Main Pump

Oil Cooler Fan Motor Drive Pump Pi Pi

Psv PG

T183-03-01-101

P-

Pump Delivery Pressure

PG-

Horsepower Reducing Control Pressure (Horsepower Reducing Solenoid Valve SA, SB) Horsepower Increasing Control Pressure (Horsepower Increasing Solenoid Valve)

PZ-

Pi-

Flow Rate Control Pressure (Flow Rate Reducing Solenoid Valve, Signal Control Valve) Psv- Pump Servo Assisting Pressure (Pilot Pump)

T3-1-5

COMPONENTS OPERATION / Pump Device Cross Section (Regulator for Main Pump)

A B

T183-03-01-002

Cross Section A-A 1

12 T117-02-01-006

1234-

Inner Spring Sleeve Spool Pin

5678-

Pin Pin Lever 1 Hole

9 - Pin 10 - Pilot Piston 11 - Spring

T3-1-6

12 - Feedback Lever 13 - Pin 14 - Servo Piston

COMPONENTS OPERATION / Pump Device Cross Section B-B

19 20

T117-02-01-007

15 - Piston 16 - Compensating Piston 17 - Lever 2

18 - Pin 19 - Hole 20 - Compensating Piston

21 - Outer Spring 22 - Inner Spring

T3-1-7

23 - Piston 24 - Pin

COMPONENTS OPERATION / Pump Device Cross Section (Regulator for Fan Motor Drive Pump) A B

T183-03-01-102

Cross Section A-A 1

12 T146-03-01-008

1235-

Inner Spring Sleeve Spool Pin

6789-

Pin Lever 1 Hole Pin

10 - Pilot Piston 11 - Spring 12 - Feedback Lever

T3-1-8

13 - Pin 14 - Servo Piston 25 - Pin

COMPONENTS OPERATION / Pump Device Cross Section B-B

21 22

T146-03-01-005

15- Piston 16- Compensating Piston 17- Lever 2

18- Pin 19- Hole

20- Compensating Piston 21- Outer Spring

T3-1-9

22- Inner Spring 24- Pin

COMPONENTS OPERATION / Pump Device Link Mechanism Movement of pilot piston (10) is transmitted to lever 1 (7) via pin (9). Lever 1 (7) rotates around pin (4), which is fixed to the support plug. Movement of compensating rod (20) is transmitted to lever 2 (17) via pin (24). Lever 2 (17) rotates around pin (18), which is fixed to the housing. Pin (5) is threaded through a hole on feedback lever (12), and the ends of pin (5) are inserted in a hole on levers 1(7) and 2 (17) respectively. (The hole is larger than the pin (5) diameter.)

18 Housing

For this reason, when lever 1 (7) or lever 2 (17) rotates, pin (5) comes into contact with the hole edge on the lever, and is moved further. As a result, feedback lever (12) rotates around pin (13) located on servo piston (14). On the other hand, when compensating rod (20) and pilot piston (10) are not moved, i.e. levers 1 and 2 do not move, and when servo piston (14) is moved, feedback lever (12) rotates around pin (5), so that spool (3) moves.

NOTE: 17

To decrease swash angle To increase swash angle

19 12

20 6 5 7 8 4

Support Plug

13 10 14

3- Spool 4- Pin 5- Pin 6- Pin

T117-02-01-009

7- Lever 1

12- Feedback Lever

18- Pin

8- Hole 9- Pin 10- Pilot Piston

13- Pin 14- Servo Piston 17- Lever 2

19- Hole 20- Compensating Rod 24- Pin

T3-1-10

COMPONENTS OPERATION / Pump Device (Blank)

T3-1-11

COMPONENTS OPERATION / Pump Device Constant Torque Control â&#x20AC;˘ Overload Preventing Operation 1. If pump delivery pressure P rises from P1 to P2, compensating piston (16) moves compensating rod (20) to the right until it balances with outer spring (21) and inner spring (22). 2. Movement of compensating rod (20) is transmitted to lever 2 (17) via pin (24), rotating lever 2 (17) counterclockwise around pin (18). 3. Since pin (5), which is connected to feedback lever (12), is inserted into hole (19) on lever 2 (17), feedback lever (12) rotates around pin (13) clockwise as lever 2 (17) rotates, moving spool (3) to the right.

7. As servo piston (14) moves, feedback lever (12) moves via pin (13). Since compensating rod (20) and lever 2 (17) do not move, feedback lever (12) rotates counterclockwise around pin (5), shifting spool (3) to the left until the notches on spool (3) and sleeve (2) close completely. As these notches close, the pump pressure stops acting on the servo piston large chamber. Consequently, the movement of servo piston (14) stops. 8. With the above operation, the pump delivery flow rate decreases from Q1 to Q2, relieving excessive load otherwise applied to the pump.

4. As spool (3) is moved, pump pressure P is routed to the servo piston large chamber via spool (3). Although pump pressure P is also routed to the servo piston small chamber, servo piston (14) is moved to the right due to the difference in pressure receiving area between the servo piston ends. 5. As servo piston (14) is moved to the right, the pump displacement angle decreases corresponding to the distance that servo piston (14) has moved, decreasing the pump delivery flow rate. 6. As the pump pressure P acts on the compensating piston (16), compensating rod (20) and lever 2 (17) do not move even if servo piston (14) moves.

T3-1-12

Q (Flow Rate) Q1 Q2

P (Pump Delivery Pressure)

COMPONENTS OPERATION / Pump Device 1

21 22

Pressure (P1 â&#x2020;&#x2019; P2)

Small Chamber

Large Chamber

13 18

12 24

Housing

24 T117-02-01-010

19 12

2 5

T117-02-01-009

1- Spring 2- Sleeve 3- Spool 5- Pin

12- Feedback Lever 13- Pin 14- Servo Piston 16- Compensating Piston

17- Lever 2 18- Pin 19- Hole 20- Compensating Rod

T3-1-13

21- Outer Spring 22- Inner Spring 24- Pin

COMPONENTS OPERATION / Pump Device â&#x20AC;˘ Flow Rate Recovery Operation 1. If pump pressure P drops from P2 to P1, compensating piston (16) (along with compensating rod (20)) is returned to the left until it balances against outer spring (21) and inner spring (22). 2. Movement of compensating rod (20) is transmitted to lever 2 (17) via pin (24), rotating lever 2 (17) clockwise around pin (18) which is fixed to the housing. 3. Since pin (5), which is connected to feedback lever (12), is inserted into hole (19) on lever 2 (17), feedback lever (12) rotates around pin (13) counterclockwise as lever 2 (17) rotates, moving spool (3) to the left

6. As servo piston (14) is moved and because compensating rod (20) and lever 2 (17) do not move, feedback lever (12), which is connected to servo piston (14) via pin (13), also rotates clockwise around pin (5), moving spool (3) to the right until the notches on sleeve (2) are completely closed, thus closing the line from the servo piston large chamber to the hydraulic oil tank. As a result, movement of servo piston (14) stops 7. With the above operation, the pump delivery flow rate increases from Q2 to Q1.

4. Since pin (5), which is connected to feedback lever (12), is inserted into hole (19) on lever 2 (17), feedback lever (12) rotates around pin (13) counterclockwise as lever 2 (17) rotates, moving spool (3) to the left 5. As servo piston (14) is moved to the left, the pump displacement angle increases corresponding to the distance that servo piston (14) has moved, increasing the pump delivery flow rate.

T3-1-14

(Flow Rate) Q1 Q2

P1 P2

(Pump Delivery Pressure)

COMPONENTS OPERATION / Pump Device 2

18 19 5

20 21

Pressure (P2 â&#x2020;&#x2019; P1)

Small Chamber

Large Chamber

14 Housing

13 18

24 T117-02-01-011

12 5

T117-02-01-009

2- Sleeve 3- Spool 5- Pin 12- Feedback Lever

13- Pin 14- Servo Piston 16- Compensating Piston 17- Lever 2

18- Pin 19- Hole 20- Compensating Rod

T3-1-15

21- Outer Spring 22- Inner Spring 24- Pin

COMPONENTS OPERATION / Pump Device Flow Rate Control â&#x20AC;˘ Flow Rate Increasing Operation 1. On the main pump, flow rate control pressure Pi acts on pilot piston (10) by operating the control lever. On the oil cooler fan motor drive pump, flow rate control pressure Pi from fan pump solenoid valve SF acts on pilot piston (10). As pressure Pi increase, pilot piston (10) is moved to the right until pilot piston (10) balances against spring (11). 2. As lever 1 (7) is connected to pilot piston (10) via pin (9), movement of pilot piston (10) rotates lever 1 (7) counterclockwise around pin (4) which is fixed to the support plug.

6. As servo piton (14) is moved and because pilot piston (10) and lever 1 (7) do not move, feedback lever (12), which is connected to servo piston (14) via pin (13), rotates clockwise around pin (5), moving spool (3) to the right until the notches on sleeve (2) are completely closed, thus closing the line from the servo piston large chamber to the hydraulic oil tank. As a result, movement of servo piston (14) stops. 7. With the above operation, the pump delivery flow rate is increased in proportion to the increment of pressure Pi.

3. Because pin (5) on feedback lever (12) is inserted into hole (8) on lever 1 (7), feedback lever (12) rotates counterclockwise around pin (13) as lever 1 (7) rotates, moving spool (3) to the left. 4. As spool (3) is moved, pressure oil in the servo piston large chamber is routed to the hydraulic oil tank via spool (3). Since pump pressure P is routed to the servo piston small chamber all the time, servo piston (14) is moved to the left.

NOTE: Refer to the SYSTEM / Hydraulic System / Pilot Circuit description. Q (Flow Rate)

5. As servo piston (14) is moved to the left, the pump displacement angle increases corresponding to the distance that servo piston (14) has moved, increasing the pump delivery flow rate.

T3-1-16

Pi (Flow Rate Control Pressure)

COMPONENTS OPERATION / Pump Device 2

Housing

T117-02-01-012

5 7

Support Plug

14 9 13 10

T117-02-01-009

2- Sleeve 3- Spool 4- Pin

5- Pin 7- Lever 1 8- Hole

9- Pin 10- Pilot Piston 11- Spring

T3-1-17

12- Feedback Lever 13- Pin 14- Servo Piston

COMPONENTS OPERATION / Pump Device â&#x20AC;˘ Flow Rate Decreasing Operation 1. On the main pump, the pressure Pi decreases by returning the control lever, so that pilot piston (10) is returned to the left until it, or pressure Pi in other words, balances against spring (11). On the oil cooler fan motor drive pump, the pressure Pi from fan pump solenoid valve SF decreases, so that pilot piston (10) is returned to the left until it, or pressure Pi in other words, balances against spring (11).

6. As servo piston (14) moves, feedback lever (12) moves via pin (13). Since pilot piston (10) and lever 1 (7) do not move, feedback lever (12) rotates counterclockwise around pin (5), shifting spool (3) to the left until the notches on spool (3) and sleeve (2) closes completely. As these notches close, the pump pressure stops acting on the servo piston large chamber. Consequently, the movement of servo piston (14) stops.

2. As lever 1 (7) is connected to pilot piston (10) via pin (9), movement of pilot piston (10) rotates lever 1 (7) clockwise around pin (4) which is fixed to the support plug.

7. With the above operation, the pump delivery flow rate is decreased in proportion to the degree of the decrement of pressure Pi. NOTE: Refer to the SYSTEM / Hydraulic System / Pilot Circuit description.

3. Because pin (5) on feedback lever (12) is inserted into hole (8) on lever 1 (7), feedback lever (12) rotates clockwise around pin (13) as lever 1 (7) rotates, moving spool (3) to the right.

Q (Flow Rate)

T3-1-18

Pi (Flow Rate Control Pressure)

COMPONENTS OPERATION / Pump Device 2

9 T117-02-01-013

5 7

Support Plug

14 9 13 10

T117-02-01-009

2- Sleeve 3- Spool 4- Pin

5- Pin 7- Lever 1 8- Hole

9- Pin

12- Feedback Lever

10- Pilot Piston 11- Spring

13- Pin 14- Servo Piston

T3-1-19

COMPONENTS OPERATION / Pump Device Horsepower Reducing Control (only for Main Pump) 1. Horsepower reducing control pressure PG acts on piston (15). When pressure PG acts on piston (15), compensating piston (16) and compensating rod (20) move until they balance against outer spring (21) and inner spring (22). 2. Movement of compensating rod (20) is transmitted to lever 2 (17) via pin (24), rotating lever 2 (17) counterclockwise around pin (18). 3. Since pin (5), which is connected to feedback lever (12), is inserted into hole (19) on lever 2 (17), feedback lever (12) rotates around pin (13) clockwise as lever 2 (17) rotates, moving spool (3) to the right. 4. As spool (3) is moved, pump pressure P is routed to the servo piston large chamber via spool (3). Although pump pressure P is also routed to the servo piston small chamber, servo piston (14) is moved to the right due to the difference in pressure receiving area between the servo piston ends.

6. As servo piston (14) moves, feedback lever (12) moves via pin (13). Since compensating rod (20) and lever 2 (17) do not move, feedback lever (12) rotates counterclockwise around pin (5), shifting spool (3) to the left until the notches on spool (3) and sleeve (2) close completely. As these notches close, the pump pressure stops acting on the servo piston large chamber. Consequently, the movement of servo piston (14) stops. 7. With the above operation, the P-Q curve is reset as illustrated (when horsepower reducing control pressure PG acts on piston (15)). Consequently, the torque constant control (overall preventing operation and delivery flow rate decreasing operation) is performed on this reset P-Q curve. NOTE: Refer to the SYSTEM / Hydraulic System / Pilot Circuit description.

Q (Flow Rate)

5. As servo piston (14) is moved to the right, the pump displacement angle decreases corresponding to the distance that servo piton (14) has moved, decreasing the pump delivery flow rate.

P(Pressure)

T3-1-20

COMPONENTS OPERATION / Pump Device 15

14 Housing

13 18

T117-02-01-014

12 5

T117-02-01-014

2- Sleeve 3- Spool 5- Pin 12- Feedback Lever

13- Pin 14- Servo Piston 15- Piston 16- Compensating Piston

17- Lever 2 18- Pin 19- Hole 20- Compensating Rod

T3-1-21

21- Outer Spring 22- Inner Spring 24- Pin

COMPONENTS OPERATION / Pump Device Horsepower Increasing Control (only for Main Pump) 1. When horsepower increasing control pressure Pz rises, piston (23) moves compensating rod (20) to the left until it balances against pump pressure P which is acting on compensating piston (16). 2. Movement of compensating rod (20) is transmitted to lever 2 (17) via pin (24), rotating lever 2 (17) clockwise around pin (18) which is fixed to the housing. 3. Since pin (5), which is connected to feedback lever (12), is inserted into hole (19) on lever 2 (17), feedback lever (12) rotates around pin (13) counterclockwise as lever 2 (17) rotates, moving spool (3) to the left.

6. As servo piston (14) is moved and because compensating rod (20) and lever 2 (17) do not move, feedback lever (12), which is connected to servo piston (14) via pin (13), rotates clockwise around pin (5), moving spool (3) to the right until the notches on sleeve (2) are completely closed, thus closing the line from the servo piston large chamber to the hydraulic oil tank. As a result, movement of servo piston (14) stops. 7. With the above operation, the P-Q curve is reset as illustrated (when horsepower increasing control pressure Pz rises). Consequently, the constant torque control (overload preventing operation and delivery flow rate increasing operation) is performed on this reset P-Q curve.

4. As spool (3) is moved, pressure oil in the servo piston large chamber is routed to the hydraulic oil tank via spool (3). Since pump pressure P is routed to the servo piston small chamber all the time, servo piston (14) is moved to the left. 5. As servo piston (14) is moved to the left, the pump displacement angle increases corresponding to the distance that servo piston (14) has moved, increasing the pump delivery flow rate.

NOTE: Refer to the SYSTEM / Hydraulic System / Pilot Circuit description. Q (Flow Rate)

P(Pressure)

T3-1-22

COMPONENTS OPERATION / Pump Device 2

21 22 23 Pz

14 Housing

13 18

T117-02-01-015

12 5

T117-02-01-014

2- Sleeve 3- Spool 5- Pin 12- Feedback Lever

13- Pin 14- Servo Piston 16- Compensating Piston 17- Lever 2

18- Pin 19- Hole 20- Compensating Rod 21- Outer Spring

T3-1-23

22- Inner Spring 23- Piston 24- Pin

COMPONENTS OPERATION / Pump Device Smaller Swash Angle (Less Flow Rate) Priority Control The swash plate angle control by flow rate control or increasing/reducing horsepower control is transmitted to feedback lever (12) and spool (3) through hole (8) on lever 1 (7) and hole (19) on lever 2 (17) via pin (5). (Refer to Flow Rate Control, Horsepower Increasing Control and Horsepower Reducing Control). Pin (5) comes into contact against the sides which decreases swash plate angle, placed in holes (8) and (19) on lever 1 (7) and lever 2 (17). Therefore, the flow rate reducing and horsepower reducing controls are selected with preferentially.

T3-1-24

COMPONENTS OPERATION / Pump Device Cross Section

T117-02-01-013

T117-02-01-014

3- Spool 5- Pin

7- Lever 1 8- Hole

12- Feedback Lever 17- Lever 2

T3-1-25

19- Hole

COMPONENTS OPERATION / Pump Device 3-UNIT PUMP The engine power is transmitted through the pump transmission to the shaft. As the shaft turns, the three pumps are operated simultaneously. The oil cooler fan motor drive pump (A) is a variable displacement swash plate plunger type pump. It has the cylinder block splined to the shaft. As the shaft and cylinder block rotate, the plungers move in and out of their bores, drawing and pushing hydraulic oil. Pilot pump (B) and transmission oil circulation pump (C) are gear type pumps. The shaft drives the drive gear, and the driven gear are driven by the drive gear. Hydraulic oil drawn into the pump housings are delivered to the outlets along the housing inner surfaces. C

T183-03-01-003

AB-

Oil Cooler Fan Motor Drive Pump (Variable Displacement Swash Plate Plunger Type Pump) Pilot Pump (Tandem Gear Pump)

Suction Side Driven Gear

Drive Gear

Housing Delivery Side (Outlet) T137-02-03-005

T3-1-26

C-

Transmission Oil Circulation Pump (Tandem Gear Pump)

COMPONENT OPERATION / Swing Device OUTLINE The swing device consists of the valve unit, motor , and reduction gear. The motor is driven by pressure oil from the pump and transmits rotational force to the reduction gear.

The reduction gear functions to reduce the rotation speed of swing motor and to increase its torque before transmitting the rotational force from swing moter to the pinion shaft. The valve unit functions to protect the swing circuit.

Motor

Valve Unit

Reduction Gear

T142-02-02-001

T3-2-1

COMPONENT OPERATION / Swing Device SWING MOTOR The swing motor is a swash-plate-type axial plunger motor. The swing motor consists of shaft (4), swash plate (3), shoes (2), plungers (5), rotor (6), valve plate (9), housing (1), and parking brake.

The spherical end of plunger (5) is installed in shoe (2) by a ball-and-socket joint. The shaft part of plunger (5) is inserted into rotor (6). Rotor (6) is installed onto shaft (4) with a spline coupling. The parking brake is a wet-type multiple disc brake, consisting of friction plates (7) and plates (8).

1 6

4 T142-02-02-002

1 - Housing 2 - Shoe 3 - Swash Plate

4 - Shaft 5 - Plunger

6 - Rotor 7 - Friction Plate

T3-2-2

8 - Plate 9 - Valve Plate

COMPONENT OPERATION / Swing Device Operational Principle Swing speed varies depending on the amount of oil delivered from the pump. When pressure oil is fed into the rotor bores via port (A), the plungers are pushed from the top dead center to the bottom dead center causing the shoes to slide along the swash plate, developing rotational force.

The rotational force is then transmitted to the swing reduction gear via the shaft. As the rotor is rotated, the plungers are moved to port (B) side one by one, returning oil to the hydraulic oil tank. When pressure oil is fed via port (B), the motor rotates in the opposite direction

Plunger

Shoe

Shaft

T142-02-02-004

T3-2-3

COMPONENT OPERATION / Swing Device VALVE UNIT The valve unit consists of the make-up valve and the relief valve. Make-Up Valve When swing is stopped, the upperstructure tends to keep rotating due to swing inertia force, causing the swing motor to continue rotating further, and to begin drawing oil from the pump, developing cavitation the motor. The make-up valve draws hydraulic oil through the Port M (Return Circuit) to compensate for the lack of oil, and prevent cavitation.

Drain Port Make-Up Valve Port M Make-Up Port

Relief Valve

Control Valve T142-02-02-005

Relief Valve

Make-Up Valve

Control Valve

T140-02-04-002

T3-2-4

COMPONENT OPERATION / Swing Device Relief Valve When starting or stopping swing operation, oil pressure in the swing circuit becomes high. The relief valve prevents the circuit pressure from rising higher than the specified pressure. Plunger is pushed to the left by pressure Pp at port (P) and pressure-receiving area A2. However, plunger is also pushed back to the right by spring force and pressure Pg at chamber (g) and pressure-receiving area A1. Chamber (g) is connected to port (P) through orifice (m). When force acting on the right is higher than that on the left, the relief valve operates.

Relief Valve

Control Valve T142-02-02-005

Spring

Plunger

Port P

Chamber (g)

m T142-02-02-006

T3-2-5

COMPONENT OPERATION / Swing Device SWING PARKING BRAKE When the brake is released (OFF):

The swing parking brake is a wet-type multiple disc brake. Also, the swing parking brake is a negative type, i.e. the brake is released when brake release pressure is routed into brake-piston chamber (b). The brake release pressure is supplied from the pilot pump when a control lever is operated. When the control levers are in neutral (or while the engine is stopped), the brake release pressure is returned to the hydraulic oil tank and the swing parking brake is automatically applied by spring (1). (Refer to the pilot circuit diagram in the Hydraulic System Group of the System Section.)

Brake Release Chamber (b) Pressure from Pilot Pump

â&#x20AC;˘ When Parking Brake is Released (OFF) (When Control Lever is Operated) When a control lever is operated, the pressure in the pilot signal circuit rises because the corresponding control valve spool is shifted. The pressure in the pilot signal circuit acts on the switch valve of the parking brake release valve, shifting it. As the switch valve is shifted, the brake release pressure from the pilot pump is routed into chamber (b) via the swing parking release valve, acting on and pushing brake piston (2). As a result, plates (3) and friction plates (4) become contact free with each other, thus releasing the parking brake.

Pressure Oil from Pilot Swing Parking Signal Circuit Brake Release via Shuttle Valve Valve

2 5

T142-02-02-007

When the brake is applied (ON): Drain Port

â&#x20AC;˘ When Parking Brake is Applied (ON) (When Control Levers are in Neutral.) When the control levers are in neutral, the pressure in the pilot signal circuit does not rise. For this reason, the switch valve is not shifted and the parking brake release pressure is not routed to chamber (b). The pressure oil in chamber (b) is released to the motor drain port. Thus, plates (3), which are secured to the outer circumference of rotor (6), and friction plates (4), which are secured to the inner wall of motor housing (5), are pushed by spring (1) via brake piston (2), coming into tight contact with each other. As a result, rotor (6) is secured immovable, thus applying the swing parking brake.

1234-

Spring Brake Piston Plate Friction Plate

5 - Motor Housing 6 - Rotor 7 - Orifice

T3-2-6

5 Chamber (b)

T142-02-02-007

COMPONENT OPERATION / Swing Device SWING REDUCTION GEAR The swing reduction gear is a planetary-gear-type two stage reduction gear. Both first and second stage ring gears are immovable because they are fixed to the housing.

The motor shaft rotates first stage sun gear (9). As the first stage reduction takes place between first stage planetary gears (1) and first stage carrier (7), second stage sun gear (5) is rotated. Then, the second stage reduction takes place between second stage planetary gears (2) and second stage carrier (4) before the rotational force is transmitted to shaft (3).

8 2

7 6 5 4

W142-02-06-003

1 - First Stage Planetary Gear 2 - Second Stage Planetary Gear 3 - Shaft

4 - Second Stage Carrier 5 - Second Stage Sun Gear

6 - Second Stage Ring Gear 7 - First Stage Carrier

T3-2-7

8 - First Stage Ring Gear 9 - First Stage Sun Gear

COMPONENT OPERATION / Swing Device (Blank)

T3-2-8

COMPONENT OPERATION / Control Valve OUTLINE 4-Spool Section: Right travel, Bucket 1, Boom 1, and arm 2 in that order viewed from the front side. 5-Spool Section: Left Travel, Bucket 2, Boom 2, Arm 1, and Auxiliary in that order viewed from the front side. Swing Control Valve: Boom 3, Swing, Bucket 3, and arm 3 in that order viewed from the front side. Pressure oil from the pilot pump is routed to the signal pilot pressure circuit to control each operation. NOTE: BH: Backhoe LD: Loading Shovel

Two kinds of control valves, main control valve and swing control valve, are used on this machine. The control valve regulates oil pressure, flow rate and flow direction in the hydraulic circuit. The main control valve consists of two blocks, the 5-spool and 4-spool blocks. The swing control valve is a one block (4-spool) type. Major components of the control valve are a main relief valve, oil flow combiner valve, and spools. Both the main and swing control valves are pilot-pressure operated type. The spool arrangements in the control valve are as follows:

Left Travel

Main Control Valve

Bucket 2

Front Side

Arm Regenerative Valve

Right Travel Bucket 1 Boom 1

Make-Up Valve (Arm 2)

Boom 2

Arm 2

Overload Relief Valve (Boom Mode Selection)

Slow Return Valve

Overload Relief Valve (Bucket 2)

4-Spool Block

Arm 1

Overload Relief Valve (Boom)

5-Spool Block

Overload Relief Valve (Bucket)

Holding Valve Switch Valve (Boom)

4-Spool Block Main Relief Valve

Overload Relief Valve (Aux.:BH, Bucket Open/Close: LD)

Boom Overload Relief Pressure Switch Valve Auxiliary (Backhoe) Bucket Open/Close (Loading Shovel)

Front Side T183-03-03-029

Shuttle Valve

Holding Valve Switch Valve (Arm)

5-Spool Block

Overload Relief Valve (Arm) T183-03-03-028

Swing Control Valve Holding Valve Switch Valve (Boom)

Front Side Main Relief Valve

Mack-Up Valve (Arm 3)

Overload Relief Valve (Swing) Boom 3 Swing Bucket 3 Arm 3 T183-03-03-030

T3-3-1

Front Side

T183-03-03-031

COMPONENT OPERATION / Control Valve Main Control Valve

Auxiliary: BH Bucket Open/Close: LD

10 34 Arm 1 Arm 2

Boom 2 Boom 1

13 14

Bucket 2

Bucket 1

17 18

Left Travel

29 28 19

Right Travel

27 26

22 21

T18E-03-03-001

NOTE: BH: Backhoe LD: Loading Shovel 1 - Holding Valve Switch Valve (Boom) 2 - Load Check Valve (Arm 2 Tandem Circuit) 3 - Load Check Valve (Arm 2 Parallel Circuit) 4 - Arm Regenerative Valve 5 - Load Check Valve (Arm 1 Parallel Circuit1) 6 - Load Check Valve (Arm 1 Parallel Circuit2) 7 - Load Check Valve (Auxiliary Tandem Circuit) 8 - Load Check Valve (Arm 1 Tandem Circuit) 9 - Holding Valve Switch Valve (Arm)

10 - Overload Relief Valve (Aux.: BH, Bucket Open/Close: LD) 11 - Overload Relief Valve (Arm) 12 - Holding Valve Check Valve (Arm) 13 - Load Check Valve (Boom 2 Tandem Circuit) 14 - Load Check Valve (Boom 2 Parallel Circuit) 15 - Overload Relief Valve (Boom Mode Selection) 16 - Boom Overload Relief Pressure Switch Valve 17 - Load Check Valve (Bucket 2 Tandem Circuit) 18 - Overload Relief Valve (Bucket 2)

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

28 - Load Check Valve (Bucket 1 Tandem Circuit) 29 - Overload Relief Valve (Bucket 1) 30 - Load Check Valve (Boom1 Parallel Circuit) 31 - Overload Relief Valve (Boom) 32 - Holding Valve Check Valve (Boom) 33 - Slow Return Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T3-3-2

34 - Make-Up Valve (Arm 2)

COMPONENT OPERATION / Control Valve 11

15, 16 18 E

Section A

25 10 Front

29 24

33 Section B

T183-03-03-003

T183-03-03-002

Section C

Right Travel

Bucket 1

Left Travel

40 Bucket 2

17 19

21 20 18

29 T183-03-03-004

T183-03-03-005

NOTE: BH: Backhoe LD: Loading Shovel 35 - Right Travel (Forward) Port

37 - Left Travel (Reverse) Port

36 - Left Travel (Forward) Port

38 - Right Travel (Reverse) Port

39 - Bucket 1 (Roll-Out : BH, Tilt-Out : LD) Port 40 - Bucket 2 (Roll-Out : BH, Tilt-Out : LD) Port

T3-3-3

41 - Bucket 1 (Roll-In : BH, Tilt-In : LD) Port 42 - Bucket 2 (Roll-In : BH, Tilt-In : LD) Port

COMPONENT OPERATION / Control Valve 2

Auxiliary: BH Bucket Open/Close: LD

10 34 Arm 1 Arm 2

Boom 2 Boom 1

13 14

Bucket 2

Bucket 1

17 18

Left Travel

29 28 19

Right Travel

27 26

22 21

T18E-03-03-001

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T3-3-4

34 - Make-Up Valve (Arm 2)

COMPONENT OPERATION / Control Valve 43

Section D

Boom 1

Section E

Boom 2 Arm 2

16 31

Arm 1

6 3 14

2 11

T183-03-03-007

T183-03-03-006

51 Auxiliary (BH) Bucket Open/Close (LD)

Section F

10 Section G

T183-03-03-009

9 34

52 T183-03-03-008

43 - Boom 1 (Lower) Port

46 - Boom 2 (Raise) Port

44 - Boom 2 (Lower) Port

47 - BH: Arm 2 (Roll-Out) Port LD: Arm 2 (Retract) Port 48 - BH: Arm 1 (Roll-Out) Port LD: Arm 1 (Roll-In) Port

45 - Boom 1 (Raise) Port

49 - BH: Arm 2 (Roll-In) Port LD: Arm 2 (Extend) Port 50 - BH: Arm 1 (Retract) Port LD: Arm 1 (Extend) Port

T3-3-5

51 - BH: Auxiliary Port LD: Bucket (Open) Port 52 - BH: Auxiliary Port LD: Bucket (Open) Port

COMPONENT OPERATION / Control Valve Swing Control Valve 1

Boom 3

Swing

Bucket 3

Arm 3

1 - Main Relief Valve 2 - Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

T18E-03-03-002

4 - Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3)

7 - Check Valve (Arm 3)

10 - Holding Valve Switch Valve

8 - Make-Up Valve (Arm 3)

11 - Holding Valve Check Valve (Boom 3)

6 - Load Check Valve (Arm 3 Parallel Circuit)

9 - Overload Relief Valve (Swing)

T3-3-6

COMPONENT OPERATION / Control Valve 12

Section A

1 B

T183-03-03-011

Section B

T183-03-03-012

Section C

Swing

Boom 3

3 2 10

11 15

T183-03-03-013

12 - Boom 3 (Lower) Port

13 - Boom 3 (Raise) Port

14 - Swing (Left) Port

T3-3-7

15 - Swing (Right) Port

T183-03-03-014

COMPONENT OPERATION / Control Valve

Boom 3

Swing

Bucket 3

Arm 3

4 - Main Relief Valve 5 - Load Check Valve (Boom 3) 6 - Load Check Valve (Swing)

T18E-03-03-002

7 - Load Check Valve (Bucket 3) 8 - Load Check Valve (Arm 3)

10 - Check Valve (Arm 3)

12 - Holding Valve Switch Valve

11 - Make-Up Valve (Arm 3)

13 - Holding Valve Check Valve (Boom 3)

9 - Load Check Valve (Arm 3 Parallel Circuit)

12 - Overload Relief Valve (Swing)

T3-3-8

COMPONENT OPERATION / Control Valve 16

Section D

Section E

Bucket 3

Arm 3

5 4

T183-03-03-015

T183-03-03-016

Section F

NOTE: BH: Backhoe LD: Loading Shovel 16 - Bucket 3 (Roll-Out) Port

T183-03-03-017

17 - Bucket 3 (Roll-In) Port

18 - BH: Arm 3 (Roll-Out) Port LD: Arm 3 (Retract) Port

T3-3-9

19 - BH: Arm 3 (Roll-In) Port LD: Arm 3 (Extend) Port

COMPONENT OPERATION / Control Valve HYDRAULIC CIRCUIT Main Circuit Pressure oil from main pump 1, main pump 2, and main pump 3 are routed to the 5-spool section of the main control valve, the 4-spool section of the main control valve, and the swing control valve respectively. Each main circuit is provided with a parallel circuit, making combined operations possible. The main relief valve regulates the maximum oil pressure in the main circuit. Overload relief valves are provided in the boom, arm, bucket, swing, and auxiliary circuits. Pilot Control Circuit Pressure oil (indicated by figure No.) from the pilot valve acts on the spool ends in the control valve to operate the spools. External Pilot Pressure Circuit

â&#x20AC;˘ Pilot Pressure from boom mode selection solenoid valve (SC) shifts the boom overload relief pressure switch valve. (Refer to the SYSTEM / Control System group.) â&#x20AC;˘ Pilot pressure from the flow combiner valve control spool in the signal control valve shifts the flow combiner valve. (Refer to the SYSTEM / Hydraulic System group.)

T3-3-10

COMPONENT OPERATION / Control Valve

From Flow Combiner Valve Control Spool in Signal Control Valve

Main Relief Valve

Overload Relief Valve

Flow Combiner Valve

Overload Relief Valve

Boom Overload Relief Pressure Switch Valve

Overload Relief Valve

Main Pump 1

From Boom Mode Selection Solenoid Valve

Main Pump 2 Main Pump 3

T18E-03-03-003

1 - Boom Raise 2 - Boom Lower

5 - Left Swing 6 - Right Swing

9 - Left Travel Forward 10 - Left Travel Reverse

3 - Arm Roll-Out (Backhoe) Arm Retract (Loading Shovel) 4 - Arm Roll-In (Backhoe) Arm Roll-Out (Loading Shovel)

7 - Bucket Roll-In (Backhoe) Bucket Tilt-In (Loading Shovel)

11 - Right Travel Forward

8 - Bucket Roll-Out (Backhoe) Bucket Tilt-Out (Loading Shovel)

T3-3-11

12 - Right Travel Reverse 13 - Bucket Close (Loading Shovel) 14 - Bucket Open (Loading Shovel)

COMPONENT OPERATION / Control Valve FLOW COMBINER VALVE 1. Normally, the spring pushes the spool, blocking the valve ports. 2. When the front attachment and travel control levers are operated at the same time, the right travel pilot oil pressure shifts the flow combiner valve control spool in the signal control valve so that the pilot pressure shifts the flow combiner valve spool. 3. When the flow combiner valve spool is shifted, pressure oil from main pump 2 is routed to the left travel spool. 4. Therefore, pressure oil from main pump 2 is routed to the left travel spool in parallel with the right travel spool and pressure oil from main pump 1 is routed to the front attachment. Consequently, the machine can travel straight when a combine operation of travel and front attachment is performed.

Travel Motor (Right)

Travel Motor Flow Combiner Valve

Pilot Pressure from Flow Combiner Valve Control Spool in Signal Pilot Pressure Control Valve

Spring Main Pump 2

T3-3-12

T183-03-03-022

COMPONENT OPERATION / Control Valve In Neutral:

In Operation: Spring

Spring

Spool

To Left Travel Spool

Pressure Oil from Main Pump 2

T183-03-03-023

T3-3-13

Pilot Pressure from Flow Combiner Valve Control Spool

T183-03-03-024

COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE Main relief valve set pressure is shifted in two stages by the pilot pressure from the heavy lift solenoid valve. When the heavy lift system is activated, the main relief pressure is set in the high stage. When the heavy lift system is deactivated, the main relief pressure is set in the low stage. Low Relief Pressure Setting When the heavy lift switch is turned OFF, the heavy lift solenoid valve is demagnetized so that the signal pilot pressure is not routed to shuttle valve PF1. Since shuttle valve PF2 is connected to the hydraulic oil tank, the piston doesnâ&#x20AC;&#x2122;t move to the left, reducing pilot poppet pushing force. When pressure at port HP increases over the spring set-force, the pilot poppet is unseated, allowing pressure oil to flow to port LP through passage A. When the pilot poppet is unseated, pressure in the spring chamber A is reduced so that the main poppet is unseated, allowing pressure oil to flow from port HP to port LP.

Main Poppet

Pilot Poppet

High Relief Pressure Setting When the heavy lift switch is turned ON, the heavy lift solenoid valve is magnetized by main controller A so that the pilot pressure is routed to shuttle valve PF1. Then, the pilot pressure pushes the piston to the left, compressing the spring. Then, the pilot poppet is pushed by increased force, increasing the main relief valve set-pressure. The relief valve operation is the same as that in the low relief set-pressure.

Spring

Piston

PF2 Spring Chamber A

PF1

Shuttle Valve Heavy Lift Solenoid Valve

Passage A

T111-02-05-014

T3-3-14

COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE (With Make-Up Function) 1

Overload relief valves are provided at the output ports to the swing motors, and the boom, arm, and bucket cylinders. The overload relief valve prevent the actuator circuit pressure from increasing excessively when the actuator(s) is (are) moved by external loads. When pressure in port HP increases up to set-force of spring (4), pilot poppet (3) is unseated, allowing pressure oil to flow to port LP from chamber (a) via the clearance around main poppet (2). Then, pressure difference arises between port HP and chamber (a) due to the orifice located between them. When this pressure difference increases over set-force of spring (5), piston (1) and main poppet (2) are unseated so that pressure oil flows directly to port LP from port HP. In addition, this relief valve draws oil from the hydraulic oil tank if pressure in the actuator becomes negative to prevent cavitation in the circuit (make-up function). 1 - Piston 2 - Main Poppet 3 - Pilot Poppet

Orifice

T111-02-05-019

4 - Spring 5 - Spring LP

T111-02-05-021

MAKE-UP VALVE

Make-up valves are provided at the output ports of the arm 2 and 3 spool sections, assisting the makeup function of the overload relief valve. When pressure in port HP is higher than port LP, poppet (7) is kept seated due to difference (d1-d2) in pressure receiving areas on poppet (7). Therefore, when pressure in port HP is reduced lower than port LP, poppet (7) is pushed to the right to unseat due to difference (d1-d2) in pressure receiving areas on poppet (7). 6 - Spring

d2 HP

7 - Poppet

T111-02-05-023

T111-02-05-024

T3-3-15

COMPONENT OPERATION / Control Valve HOLDING VALVE â&#x20AC;˘ In Neutral The cylinder holding pressure at cylinder port C is routed to camber (a) through orifice (b) in check valve (2). Then, Check valve (2) is kept seated due to difference (d1-d2) in pressure receiving areas, completely blocking cylinder port (c).

The holding valves are provided at the output ports of the main control valve to the boom raise and the arm roll-out circuit and at the output port of the swing control valve to the boom raise circuit, preventing cylinder drift.

External Force

1 g a

Holding Pressure

3 d

Pi f

T111-02-05-025

â&#x20AC;˘ When lowering the boom or rolling the arm in: Pilot pressure Pi is routed to switch valve (1), causing chamber (a) to connect to the hydraulic oil tank. Then, pressure in chamber (a) is reduced so that check valve (2) is unseated.

At the same time, spool (3) is shifted, pressure oil from (c) to (f) via (d) to allow the cylinder to move.

1 a

2 3 d

Pi f

T111-02-05-026

1 - Switch Valve

2 - Check Valve

3 - Spool

T3-3-16

COMPONENT OPERATION / Control Valve (Blank)

T3-3-17

COMPONENT OPERATION / Control Valve ARM REGENERATIVE VALVE

The arm regenerative valve is provided to prevent arm cylinder hesitation while rolling in the arm so that arm controllability is greatly improved.

PB PR i

The return oil flow from the cylinder rod side is restricted in two stages at orifice (A) in spool (2) and orifice (B) in arm regenerative valve so that pressure PR at the cylinder rod side increases. When pressure PR at the cylinder rod side increases more than pressure PB at the cylinder bottom side, check valve (3) is opened. Then, the return oil from the cylinder rod side is combined with pressure oil from the pump and supplied again to the cylinder bottom side.

3 2 h A

7 b

9 B

1 T111-02-05-035

9 2

A h

B d

6 1 - Arm Cylinder 2 - Spool 3 - Check Valve

5 4 - Piston 5 - Spool

T111-02-05-028

6 - Spring 7 - Arm Regenerative Valve

T3-3-18

8 - Holding Valve 9 - Load Check Valve

COMPONENT OPERATION / Control Valve When pressure PB at the bottom side is higher than the rod side, check valve (3) is closed, blocking the return oil circuit. In addition, oil pressure from the pump is routed to piston (4) end in arm regenerative flow control valve (7) via passage (b), moving spool (5) to the left so that orifice (B) is widened. Therefore, the return oil from the rod side can flow out via passage (d) to the hydraulic oil tank.

1 PB PR i

3 2 h A

7 b

9 B

1 T111-02-05-035

9 2

A h

B d

6 1 - Arm Cylinder 2 - Spool 3 - Check Valve

5 4 - Piston 5 - Spool

T111-02-05-029

6 - Spring 7 - Arm Regenerative Valve

T3-3-19

8 - Holding Valve 9 - Load Check Valve

COMPONENT OPERATION / Control Valve BOOM OVERLOAD RELIEF PRESSURE SWITCH VALVE The boom overload relief pressure switch valve is provided at the output port to the boom cylinders. The boom overload relief pressure switch valve is operated by the pilot oil pressure from boom mode selection solenoid valve (SC) so that the overload relief valve set pressure in the boom cylinder rod side is reduced. Normally, pressure oil in port HP is routed to chamber (c) via piston (6), closing main poppet (5). Therefore, the overload relief valve set-pressure is maintained. When the pilot oil pressure from boom mode selection solenoid valve (SC) is routed to piston (1), piston (1) unseats poppet (2). When poppet (2) is unseated, chamber (a) and (b) are connected to port LP via passage (d). When pressure at chamber (c) increases up to set-force of spring (3), pilot poppet (4) is unseated, reducing pressure in chamber (c) so that piston (6) and main poppet (5) are moved to the left. Thereby, main poppet (5) is unseated, allowing pressure oil to directly flow to port LP from port HP. Consequently, the overload relief valve set-pressure is reduced. (Refer to the SYSTEM/Control System group)

T3-3-20

COMPONENT OPERATION / Control Valve 1

Pilot Pressure

c T183-03-03-018

Pilot Pressure

c T183-03-03-019

Pilot Pressure

b 1 - Piston 2 - Poppet

3 - Spring 4 - Pilot Poppet

5 - Main Poppet

T3-3-21

LP 6 - Piston

T183-03-03-020

COMPONENT OPERATION / Control Valve (Blank)

T3-3-22

COMPONENT OPERATION / Pilot Valve OUTLINE The pilot valve functions to control pilot pressure oil, causing the control valve spools to move. The two types of 4-port pilot valves are used for the front swing operations and travel operations as a standard. The 2-port pilot valve is used for the bucket opens/closes operations (loading shovel only). Front / Swing Pilot Valve

The pilot valves have the same mechanism to the reducing valve, except the mechanism of the cam part which press the pusher between the pilot valves for front swing/travel operations and bucket operations.

Bucket Open / Close Pilot Valve (Only for Loading Shovel)

Travel Pilot Valve

T P

1 T 4

2 T183-03-04-001

2 2

T178-03-04-001

T178-03-04-002

• Front/Swing Pilot Valve Right Port #

ISO Lever Type

• Travel Pilot Valve 1

Travel Left Forward

Pattern

Travel Left Reverse

H (Hitachi)

Common to

Bucket Roll-Out

←

Travel Right Reverse

Backhoe and

Boom Lower

←

Travel Right Forward

Bucket Roll-In

←

Shovel

Boom Raise

←

• Bucket Open/Close Pilot Valve (Only for Loading Shovel)

Left

Backhoe

H (Hitachi)

Port #

ISO Lever Type

Arm Roll-In

Swing Left

Swing Right

Arm Roll-In

Arm Roll-Out

Swing Right

Pattern

Swing Left

Arm Roll-Out

Arm Roll-In

Swing Left

Swing Right

Arm Roll-Out

Shovel

Arm Roll-Out

Swing Right

Swing Left

Arm Roll-In

T3-4-1

Left

Bucket Close

Right

Bucket Open

COMPONENT OPERATION / Pilot Valve OPERATION Spool (6) head comes in contact with the upper face of spring guide (3) which is kept raised by return spring (5). NOTE: The pilot valve for bucket open/close has the same internal structure as the pilot valve for travel. Refer to the movement of the pilot valve for travel. Neutral (Output Diagram: A to B): 1. When neutral, spool (6) totally blocks pressure oil port P (from the pilot pump).The output port is opened to port T (hydraulic oil tank) through the passage in spool (6). Therefore, oil pressure in the output port (to the control valve) is equal to that in port T. 2. When the control lever is slightly tilted, cam (1) is tilted, moving pusher (2) downward. Then, pusher (2) compress return spring (5) along with spring guide (3). At this time, as oil pressure in the output port is equal to that in port T, spool (6) moves downward while keeping the under face of the spool head in contact with spring guide (3). 3. This status continues until hole (7) on spool (6) is opened to port P.

T3-4-2

D Pilot Pressure C

Lever Stroke T522-02-05-001

COMPONENT OPERATION / Pilot Valve Front Attachment / Swing Pilot Valve

7 Port P

Output Port

Port T

Port P

Output Port

Port T

Port P

Output Port

T183-03-04-002

T183-03-04-004

Travel Pilot Valve 1

Port T

7 3

Output Port

Port P

Port T

6 Port P

Output Port 1 - Cam 2 - Pusher

3 - Spring Guide 4 - Balance Spring

Port P

Output Port

T183-03-04-003

5 - Return Spring 6 - Spool

T3-4-3

7 - Hole

T183-03-04-005

COMPONENT OPERATION / Pilot Valve During Metering or Decompressing (Output Diagram: C to D) 1. When the control lever is further tilted to move pusher (2) downward more, hole (7) on spool (6) is opened to port P, allowing pressure oil in port P to flow into the output port. 2. Oil pressure in the output port acts on the bottom face of spool (6) so that spool (6) is pushed upward. 3. However, until upward force acting on the bottom face of spool (6) overcomes balance spring (4) force, balance spring (4) is not compressed. Then, spool (6) is not raised, allowing oil pressure in the output port to increase. 4. As oil pressure in the output port increases, force to push spool (6) upward increases. When, this force overcomes balance spring (4) force, balance spring (4) is compressed so that spool (6) is moved upward. 5. As spool (6) is moved upward, hole (7) is closed so that pressure oil from port P stops flowing into the output port, stopping pressure oil in the output port to increase. 6. As spool (6) is moved downward, balance spring (4) is compressed, increasing the spring force. Therefore, oil pressure in the output port becomes equal to the oil pressure acting on the bottom face of spool (6) being balanced in position with the spring force.

T3-4-4

D Pilot Pressure C

Lever Stroke T522-02-05-001

COMPONENT OPERATION / Pilot Valve Front Attachment / Swing Pilot Valve

6 Port T

Port T

Port P

Output Port

Port P

Output Port

T183-03-04-006

T183-03-04-008

Travel Pilot Valve 1

5 6

Port T

Port P

Output Port 1 - Cam 2 - Pusher

3 - Spring Guide 4 - Balance Spring

Port P

Output Port

T183-03-04-007

5 - Return Spring 6 - Spool

T3-4-5

7 - Hole

T183-03-04-009

COMPONENT OPERATION / Pilot Valve Full Stroke (Output Diagram: E to F) 1. When the control lever is fully stroked, pusher (2) is moved downward until pusher (2) in the front attachment / swing pilot valve comes in contact with the casing shoulder, or cam (1) on the travel pilot valve comes in contact with the casing. 2. At this moment, the bottom of pusher (2) directly pushes spool (6). Therefore, even if oil pressure in the output port increases further, hole (7) on spool (6) is kept open. 3. Consequently, oil pressure in the output port is equal to oil pressure in port P. NOTE: Total lever strokes for the front attachment and swing controls are determined by stroke dimension (E) of pusher (2). Total lever stroke for the travel control is determined by stroke dimension (E) of cam (1).

T3-4-6

D Pilot Pressure

Lever Stroke T522-02-05-001

COMPONENT OPERATION / Pilot Valve Front Attachment / Swing Pilot Valve

3 4 5 E

6 Port T

Port P

Output Port

T183-03-04-010 T183-03-04-002

Travel Pilot Valve

1 E

3 4 5 6

Port T

Port P

Output Port 1 - Cam 2 - Pusher

3 - Spring Guide 4 - Balance Spring

T183-03-04-003 T183-03-04-011

5 - Return Spring 6 - Spool

T3-4-7

7 - Hole

COMPONENT OPERATION / Pilot Valve (Blank)

T3-4-8

COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of a travel motor (12), planetary reduction gear (1) to (11), (13) and sprocket (14).

3 2 1

6 7 8 9

11 12 14

T183-03-01-001

1234-

Third Stage Carrier Third Stage Sun Gear Second Stage Planetary Gear First Stage Planetary Gear

5678-

Ring Gear Shaft First Stage Carrier Second Stage Sun Gear

T3-5-1

9 - Second Stage Carrier 10 - Third Stage Planetary Gear 11 - Housing

12 - Travel Motor 13 - Drum 14 - Sprocket

COMPONENT OPERATION / Travel Device TRAVEL REDUCTION GEAR The travel reduction gear is a three stage planetary gear. When the travel motor rotates clockwise, shaft (6) rotates clockwise, transmitting this motor driving power to ring gear (1) via first stage planetary gears (8), first stage carrier (5), second stage sun gear (7), second stage planetary gears (9), second stage carrier (4), third stage sun gear (3), third stage planetary gears (10) and third stage carrier (2). 11

As third stage carrier (2) is held stationary with housing (11), ring gear (1) rotates. Ring gear (1) is bolted to drum (13) so that sprocket (12) is rotated.

1 2 3 4 5

6 7 Third Stage

Second Stage

First Stage

8 10

T183-03-05-002

1234-

Ring Gear Third Stage Carrier Third Stage Sun Gear Second Stage Carrier

5 - First Stage Carrier 6 - Shaft 7 - Second Stage Sun Gear

8 - First Stage Planetary Gear 9 - Second Stage Planetary Gear 10 - Third Stage Planetary Gear

T3-5-2

11 - Housing (Travel Motor) 12 - Sprocket 13 - Drum

COMPONENT OPERATION / Travel Device TRAVEL MOTOR The travel motor is a variable displacement swash plate axial plunger type, consisting of swash plate (7), rotor (16), plungers (4) with shoes, valve plate (1), output shaft (11), tilt pistons (9), casing (8), and so forth.

Four of tilt piston (9) are located in casing (8). The pressure to change travel speed acts on these tilt pistons (9) to change swash plate (7) angle. Rotor (16) is preloaded against valve plate (1) by spring (14) to prevent oil from leaking at the clearance between them. Hydraulically released type disc parking brake (3) is installed in the travel motor.

T183-03-05-003

15 12345-

Valve Plate Spring Parking Brake Plunger Holder

6789-

Retainer Plate Swash Plate Casing Tilt Piston

14 10 11 12 13 -

T3-5-3

Spring Output Shaft Roller Bearing Ball

14 15 16 17 -

Spring Brake Piston Rotor Valve Cover

COMPONENT OPERATION / Travel Device Pressure oil from the pump flows to port A of valve plate (1), and enters into one-sided bores in rotor (2) located just behind the right-side crescent-shaped oil port (port A side) of valve plate (1). Then, plungers in the right half side of rotor (2) are pushed out toward swash plate (5), and slide on the swash plate to rotate rotor (2) and output shaft (6).

As output shaft (6) rotates, rotor (2) also rotates. Then, when plungers (3) reach port B, oil is routed to the hydraulic oil tank. Whether pressure oil from the pump is supplied to port A or port B determines the travel direction.

Port B

Port B Port A

Port A

1 2 3 4

Valve Plate T183-03-05-009

1 - Valve Plate 2 - Rotor

3 - Plunger 4 - Shoe

5 - Swash Plate

T3-5-4

6 - Output Shaft

COMPONENT OPERATION / Travel Device TRAVEL BRAKE VALVE The travel brake valve is located on the travel motor head and consists of the following valves: Counterbalance Valve: ensures smooth starts and stops and prevents overrunning when traveling down slopes. Overload Relief Valve: prevents overloads and surge pressure in the motor circuit.

Check Valve: ensures smooth starts and stops, and prevents cavitation from occurring in the motor circuit by functioning together with counterbalance valve. Travel Speed Shift Valve: controls the tilt pistons when travel mode switch is operated.

Cross Section A-A-A Overload Relief Valve

Counterbalance Valve

Travel Speed Shift Valve

Check Valve

A Overload Relief Valve

Counterbalance Valve T183-03-05-004

T3-5-5

COMPONENT OPERATION / Travel Device Travel Operation When supply oil from the main control valve is routed to port P1, supply oil flows around spool CB, opens check valve BC and is led to motor port BM. However, return oil from motor port AM is blocked by spool CB in the counterbalance valve. As supply oil pressure at port P1 increases, supply oil is routed to chamber G through orifice F in spool CB, moving spool CB down against spring force. Consequently, return oil from motor port AM starts to flow into port P2 through notch H in spool CB, allowing the travel motor to rotate. When the travel levers are returned to the neutral position, the oil in both ports P1 and P2 are routed to the hydraulic oil tank through the control valve. Thus, oil pressure in chamber G decrease, and spool CB is moved back to the original position by spring force. Then, the oil flow circuits is blocked, causing the travel motors to stop rotating. Descending Operation When the machine travels down a slope, the travel motors are forcibly driven by the machine weight so that the motor draws oil like a pump. When the motor draws oil, oil pressure at port P1 and chamber G decrease, causing spool CB to move upwards to restrict return circuit from the motor. Then, the return oil flow from the motor is restricted by the spool, increasing pressure at port AM. The increased pressure at port AM brakes the motor. Thus, the restricted return oil flow from the travel motor increases the pressure at port P1 again, moving spool CB back down. This repeated movement of the spool (hydraulic brake action) prevents the machine from overrunning.

T3-5-6

COMPONENT OPERATION / Travel Device (Travel Operation) BM

Check Valve BC

Spool CB G

Spool CB F P1 To BM

H P2 P2

From AM

Counterbalance Valve

T183-03-05-005

(Descending Operation) BM

Spool CB G

Spool CB

P1 P1 To BM

P2 P2 From AM

T183-03-05-006

T3-5-7

COMPONENT OPERATION / Travel Device Circuit Protection If pressure in the circuit increases over the setting pressure of the overload relief valve, this valve opens to relieve peak pressure to the lower pressure side to protect the motor from overloading. This valve also functions to release shock pressure caused by inertia force developed when the motor stops.

Overload Relief Valve

Poppet

Low Pressure

High Pressure

T3-5-8

T183-03-05-011

COMPONENT OPERATION / Travel Device (Blank)

T3-5-9

COMPONENT OPERATION / Travel Device TRAVEL MOTOR DISPLACEMENT ANGLE CHANGE The travel speed mode changes as the displacement angle of swash plate (3) is changed by tilt piston (5).

â&#x20AC;˘ Slow Speed Travel

(Maximum Displacement Angle) While pilot pressure (7) that pressure is reduced by the signal pressure from the travel 2nd speed shift solenoid valve is supplied to travel speed shift valve (1), spool A (8) is held in neutral by spring (2), blocking pressure oil from the control valve. Pilot pressure (7) is routed to the parking brake through the passage of spool A (8) via the circumference clearance of spool B (9) to release the parking brake. At the same time, the line to tilt pistons (5) is opened to the hydraulic oil tank line

With the above, the swash plate (3) displacement angle is fixed to the large side, and thus the plunger (6) stroke becomes maximum. Accordingly, the amount of oil required to rotate the travel motor (per turn) becomes maximum, resulting in slow speed travel motor operation. (Refer to the Control System Group in the SYSTEM Section for the control circuit.)

Travel Speed Shift Valve

To Hydraulic Oil Tank

Parking Brake

3 5 4

From Control Valve 1 - Travel Speed Shift Valve 2 - Spring 3 - Swash Plate

4 - Ball 5 - Tilt Piston

6 - Plunger 7 - Pilot Pressure (from Reducing Valve)

T3-5-10

T183-03-05-007

8 - Spool A 9 - Spool B

COMPONENT OPERATION / Travel Device â&#x20AC;˘ Fast Speed Travel

(Minimum Displacement Angle) While non-pressure-reduced pilot pressure (7) is supplied to travel speed shift valve (1), pilot pressure (7) is supplied to chamber (a) via the circumference clearance of spool B (9), shifting spool A (8) to the right. Also, the pilot pressure (7) is supplied to the parking brake via chamber (b) in spool A (8) to release the parking brake. By the movement of spool A (8), pressure oil from the control valve exerts on tilt pistons (5).

Tilt pistons (5) push swash plate (3), changing the displacement angle to the minimum, resulting in the fast speed travel motor operation. (Refer to the Control System Group in the SYSTEM Section for the control circuit.)

Travel Speed Shift Valve

From Travel Speed Shift Valve

Parking Brake

3 5

From Control Valve T183-03-05-008

1 - Travel Speed Shift Valve 2 - Spring 3 - Swash Plate

4 - Ball 5 - Tilt Piston

6 - Plunger 7 - Pilot Pressure (from Reducing Valve)

T3-5-11

8 - Spool A 9 - Spool B

COMPONENT OPERATION / Travel Device PARKING BRAKE The parking brake is a negative-type brake released when pilot oil pressure is applied to parking brake chamber M. Whenever the travel control valve spools are in neutral, the parking brake is automatically applied.

The friction plates are connected to the rotor, and the plates to the casing via spline couplings respectively. When the spring pushes the piston to the right, the friction plates come into contact with the plates, applying the parking brake. (Refer to the pilot circuit diagram in the Hydraulic Circuit Group, the SYSTEM Section, for pilot oil flow.)

Spring

Piston M

Plate Friction Plate Casing

Rotor

T3-5-12

T183-03-05-003

COMPONENT OPERATION / Travel Device Brake ON When the control lever is in the neutral position, the friction plates and plates are pressed down by spring force, braking the motor. Pressure oil in brake chamber M is released to the hydraulic oil tank.

Spring

Spring Plate Friction Plate

Casing

Rotor

T111-03-04-007

Brake OFF When the control lever is operated, pilot oil is led to brake chamber M and pushes the brake piston against spring force. Consequently, the friction plates are separated from the plates, releasing the parking brake.

Spring

Spring Plate Friction Plate

Rotor

Casing T111-03-04-008

T3-5-13

COMPONENT OPERATION / Travel Device (Blank)

T3-5-14

COMPONENT OPERATION / Signal Control Valve OUTLINE The signal control valve is provided in the pilot circuit between the pilot valve and the control valve, and controls pilot signal pressure used to regulate the pumps and various kinds of valves. The signal control valve consists of shuttle valves, shockless valve, pump 1 and 2 flow rate control valve, flow combiner valve control spool, arm flow rate control valve and priority valve.

Pilot Valve Side

T178-03-06-016

Cross Section A-A

Shockless Valve

Arm Flow Rate Control

Auxiliary

Pump 1 and 2 Flow Rate Control Valve

Auxiliary

Flow Combiner Valve Control Spool

Priority Valve

T178-03-06-002

T3-6-1

COMPONENT OPERATION / Signal Control Valve PILOT PORT NOTE: BH: Backhoe LD: Loading Shovel Pilot Valve Side Port Name Connecting to Port A Right Pilot Valve Port B Right Pilot Valve Port C

Left Pilot Valve

Port D Port E Port F

Right Pilot Valve Hydraulic Oil Tank Left Pilot Valve

Port G

Left Pilot Valve

Port H Port I Port J Port K Port L Port M

Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD)

Port N Port SA Port SB Port PI Port PH Port SH Port DF

Pump 1 and 2 Regulator − Pilot Shut-Off Valve Pilot Shut-Off Valve − Hydraulic Oil Tank

T3-6-2

Note Boom Raise Pilot Pressure Boom Lower, Bucket Roll-Out Pilot Pressure Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Boom Raise Pilot Pressure Returning to Hydraulic Oil Tank Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Pump 1 and 2 Control Pressure Plug Primary Pilot Pressure Primary Pilot Pressure (Heat Circuit) Plug Returning to Hydraulic Oil Tank

COMPONENT OPERATION / Signal Control Valve

Pilot Valve Connecting Side C

PH A

E M D H B

SB G

Pilot Valve Side

I SH

J DF SA

L T178-03-06-016

T3-6-3

COMPONENT OPERATION / Signal Control Valve NOTE: BH: Backhoe LD: Loading Shovel Control Valve Side Port Name Connecting to Port 1 Control Valve Port 2 − Port 3 − Port 4 − Port 5 − Port 6 Control Valve Port 7

Control Valve

Port 8 Port 9 Port 10 Port 11 Port 12 Port 13

Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve

Port 14

Control Valve

Port SE Port SM Port SN Port SP Port SL Port SK

Shuttle Valve Shuttle Valve Shuttle Valve Shuttle Valve Control Valve −

Note Boom Raise Pilot Pressure Plug Plug Plug Plug Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Reverse Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Reverse Pilot Pressure Auxiliary Close Pilot Pressure (BH) Bucket Close Pilot Pressure (LD) Auxiliary Open Pilot Pressure (BH) Bucket Open Pilot Pressure (LD) Boom Raise Priority Pilot Pressure Auxiliary Swing Brake Release Swing Brake Release Combiner Valve Shifting Pressure Plug

T3-6-4

COMPONENT OPERATION / Signal Control Valve

Control Valve Connecting Side SM

3 5

1 13 2 SK

4 SE 8

14 Control Valve Side

7 9 6

Pressure Sensor (Travel)

T3-6-5

T178-03-06-015

COMPONENT OPERATION / Signal Control Valve SHUTTLE VALVE NOTE: BH: Backhoe LD: Loading Shovel The shuttle valve selects the pilot pressure oil used to perform each operation and routes it to the corresponding flow rate control valves and/or switch valve spools. The flow rate control valves and/or switch valve spools corresponding to each operation are as follows: Pump 1 and 2 Flow Control Valve Boom Raise Boom Lower Arm Roll-Out (BH) Arm Roll-In (LD) Arm Roll-In (BH) Arm Roll-Out (LD) Bucket Roll-In Bucket Roll-Out Right Travel Left Travel Auxiliary (Close) (BH) Bucket Close (LD) Auxiliary (Open) (BH) Bucket Open (LD)

Arm Flow Rate Control Valve

Flow Combiner Valve Control Spool

Priority Valve

{ {

{ −

− −

{ {

{

−

{

−

{

{ { { −

− − − −

− − { −

{ { − −

−

{

−

{

T3-6-6

COMPONENT OPERATION / Signal Control Valve Swing Arm

Boom

Bucket

Left Travel

Right Travel

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12 1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

11 10

7 14 - Boom, Arm, Bucket

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm Roll-Out (LD), Bucket Roll-In

16 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

NOTE: BH: Backhoe LD: Loading Shovel

T3-6-7

COMPONENT OPERATION / Signal Control Valve

Swing Arm

Boom

Left Travel

Bucket

Right Travel

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12

11 10 9

NOTE: BH: Backhoe LD: Loading Shovel

T3-6-8

COMPONENT OPERATION / Signal Control Valve

Pilot Valve Side

T178-03-06-016

Cross Section B-B 9 5

7 16 17 15

14 10

4 2

T178-03-06-009

1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

14 - Boom, Arm, Bucket

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm Roll-Out (LD), Bucket Roll-In

16 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

T3-6-9

COMPONENT OPERATION / Signal Control Valve SHOCKLESS VALVE

Detail of C

The shockless valve is provided in the boom raise circuit and functions during boom lowering operation. During Boom Raising Operation: 1. Boom raise pilot pressure oil is routed into port A and acts on the spool. 2. Immediately after operation is started, the low pilot pressure oil flows to port 1 via clearance C between the spool and the housing, and inner passage 2. 3. The set-force of spring A is weaker than that of spring B. Therefore, when the pilot pressure increases, the spool is moved to the left. 4. As the spool is moved to the left, port A is connected to port 1, increasing pressure in port 1 so that the spools of the boom 1 and 2 in the main control valve is moved.

Inner Passage 1

Spring A

Port A

Spool Spring B

Inner PasPort 1 sage 2

Control Valve Side

T3-6-10

T183-03-06-002

Pilot Valve Side

Oil Chamber T178-03-06-013

COMPONENT OPERATION / Signal Control Valve During Boom Raising Operation:

Boom Raise Pilot Pressure Port A

Spool

Inner Passage 2 Spring B Spring A

Port 1

T183-03-06-003

Boom Raise Pilot Pressure Port A

Spool

Port 1

T183-03-06-004

to Spools of Boom 1 and 2 in Main Control Valve

T3-6-11

COMPONENT OPERATION / Signal Control Valve During Boom Lowering Operation (Shock Reducing Operation) 1. When the boom is lowered, the return oil from the boom raise spools of the boom 1 and 2 in the main control valve is routed to port 1. 2. Since the spool blocks the oil passage between port 1 and port A, the return oil cannot flow directly to port A. 3. Port 1 is connected to spring A side via inner passage 1 and to the oil chamber via inner passage 2. 4. Pressure oil in the oil chamber flows out from clearance C between the spool and the housing, reducing pressure in the oil chamber. Then, the spool is moved to the right by pressure in the spring A side. Thereby, clearance C between the spool and the housing is closed, blocking pressure oil flow. 5. When clearance C is closed, pressure in the oil chamber increases, moving the spool to the left. Therefore, clearance C is opened again allowing pressure oil to flow to port A. 6. As operation in steps (4 and 5) are repeated, pressure oil is gradually returned to port A so that the spools of the boom 1 and 2 in the main control valve returns slowly.

Detail of C

Inner Passage 1 Port A

Spring A

Spool Spring B

Inner Passage Port 1 2

Control Valve Side

T3-6-12

T183-03-06-002

Pilot Valve Side

Oil Chamber

T178-03-06-013

COMPONENT OPERATION / Signal Control Valve During Boom Lowering Operation (Shock Reducing Operation) Inner Passage 1 Spring A

Spool

to Pilot Valve Port A

Inner Passage 2 Port 1 from Spools of Boom 1 and 2 in Main Control Valve Inner Passage 1 Spool Port A

Oil Chamber

Inner Passage 2 Port 1 from Spools of Boom 1 and 2 in Main Control Valve to Pilot Valve Spool Port A

Oil Chamber

Inner Passage 2 Port 1 from Spools of Boom 1 and 2 in Main Control Valve

Oil Chamber

Spring A

T3-6-13

T183-03-06-003

T183-03-06-005

T183-03-06-004

COMPONENT OPERATION / Signal Control Valve PUMP 1 AND 2 FLOW RATE CONTROL VALVE The pump flow rate control valve delivers pump control pressure Pi to the pump regulator in response to the pilot oil pressure from the pilot valve, and controls the swash angle of the pump 1 and 2 to deliver the flow rate required by the control lever. 1. Pilot oil pressure from the pilot valve in the travel and front operation system is routed into the spring chamber side of the pump 1 and 2 flow rate control valve after being selected by the shuttle valves in the signal pilot pressure control valve. 2. Then, the spool is moved to the right, causing the primary pilot pressure to flow in port SA. 3. Therefore, pressure in port SA increases. 4. Oil pressure in port SA acts on the right end of the spool. Thus, the spool is moved back to the left until pressure force in port SA is balanced with pilot pressure force in the spring chamber so that pressure in port SA stops increasing. In other words, the primary pilot pressure is reduced to the pressure which is corresponding to the pilot pressure from the pilot valve, and deliver the pressure as Pi pressure to the regulators in pump 1 and 2 from port SA.

T3-6-14

COMPONENT OPERATION / Signal Control Valve

Spring

Spool

Port SA

Primary Pilot Pressure Pilot Pressure

Shuttle Valve

T178-03-06-017

T3-6-15

COMPONENT OPERATION / Signal Control Valve ARM FLOW RATE CONTROL VALVE, FLOW COMBINER VALVE CONTROL SPOOL, PRIORITY VALVE NOTE: The three captioned spools are indicated in operational principle. BH: Backhoe LD: Loading Shovel The arm flow rate control valve delivers the arm roll-out (BH)/arm roll-in (LD) pilot pressure to the roll-in (BH)/roll-out (LD) side of the arm 2 spool in the main control valve by shifting the spool using boom raise pilot pressure.

Arm Flow Rate Control Valve:

To Hydraulic Oil Tank Spool

Arm Roll-Out (BH) / Arm Roll-In (LD) Pilot Pressure Spring

T178-03-06-014

Boom Raise Pilot Pressure

The flow combiner valve control spool delivers the pilot pressure to the flow combiner valve in the main control valve from the priority valve by shifting the spool using right travel pilot pressure.

To Arm 2 Spool Roll-In Side (BH) / Roll-Out Side (LD)

Flow Combiner Valve Control Spool: To Hydraulic Oil Tank

Pilot Pressure from Priority Valve

Spool

Spring

T178-03-06-014

Right Travel Pilot Pressure

The priority valve delivers the primary pilot pressure to flow combiner valve control spool by shifting the spool using boom, arm, bucket and auxiliary (BH)/bucket open/close (LD) pilot pressure.

To Flow Combiner Valve

Priority Valve: To Hydraulic Primary Pilot Oil Tank Pressure Spool

Spring

Boom, Arm, To Flow Combiner Bucket, Auxiliary Valve Control Spool (BH) / Bucket Open/Close (LD) Pilot Pressure

T3-6-16

T178-03-06-014

COMPONENT OPERATION / Others (Upperstructure) PILOT SHUT-OFF VALVE The pilot shut-off valve is a manually operated switch valve. The valve spool is rotated when the pilot control shut-off lever is operated, switching ON and OFF the pilot pressure oil to the pilot valve.

Cross Section Z-Z

Operation with Pilot Control Shut-Off Lever in LOCK Position When the pilot control shut-off lever is in the LOCK position, the pilot shut-off valve is set in neutral (OFF), blocking pilot pressure oil from the pilot pump to enter the pilot valves. Pressure oil is routed to the signal control valve via port A5. Pilot pressure oil on the pilot valve side is routed to the hydraulic tank via port T4. As a result, the pilot valve becomes inoperable with the control levers. P Port from Pilot Pump

A5 Port to Signal Control Valve

Operation with Pilot Control Shut-Off Lever in UNLOCK Position

T178-03-07-002

When the pilot control shut-off lever is moved to the UNLOCK position, the pilot shut-off valve is turned to the ON position, blocking the line to the tank from the pilot valve and, at the same time, routing the pilot pressure oil from the pilot pump to the pilot valves via ports A1, A2 and A3. Thus, the pilot valves become operable with the control levers. A2

A5 A1 - Travel Pilot Valve A2 - Left Pilot Valve A3 - Right Pilot Valve

T178-03-07-003

A4 - Signal Control Valve (Port PI) A5 - Signal Control Valve (Port PH) P - Primary Pilot Pressure

T3-7-1

T1 - Travel Pilot Valve T2 - Left Pilot Valve T3 - Right Pilot Valve

T4 - Hydraulic Oil Tank

COMPONENT OPERATION / Others (Upperstructure) SHOCKLESS VALVE The shockless valve is located in the boom lower pilot operation circuit and pump 2 regulator Pi pressure circuit. The shockless valve in the boom lower pilot operation circuit controls boom lower pilot pressure and the flow of the holding valve control valve for boom lowering to cushion abrupt movement at the boom lower spool and holding valve control valve. The shockless valve of the pump 2 regulator Pi pressure circuit controls the flow between port Pi of the regulator in the pump 2 and the pilot valve at the swing stopping operation to prevent rapidly decrease of the delivery amount from pump 2. (Refer to the Hydraulic Pressure System Group in the SYSTEM Section for the swing motor make-up circuit.)

To Boom Lower Spool and Holding Valve Control Valve A

Plunger

Orifice T183-03-07-008

From Pilot Valve

Shockless Valve in Boom Lower Pilot Operation Circuit â&#x20AC;˘ When a control lever is operated, the pilot valve routes the pilot pressure to port B of the shockless valve. Just after the control lever operation, the pilot pressure oil flows to Port A through the shockless valve only via orifice of the plunger. When pressure from the pilot valve increases further, the plunger move to the left, so that hydraulic oil volume increases.

To Boom Lower Spool and Holding Valve Control Valve A

Plunger

B From Pilot Valve

T3-7-2

T183-03-07-009

COMPONENT OPERATION / Others (Upperstructure) â&#x20AC;˘ Return oil from the boom lower spool in the control

valve and holding valve control valve is returned to the hydraulic oil tank via orifice. When the quantity of return oil increases, increasing the pressure in the A side of the shockless valve, the plunger is moved to the right in proportion to the pressure to restrict the return oil.

From Boom Lower Spool and Holding Valve Control Valve A

Plunger

Orifice

To Hydraulic Oil Tank via Pilot Valve From Boom Lower Spool and Holding Valve Control Valve A

T183-03-07-008

Plunger

B To Hydraulic Oil Tank via Pilot Valve

T3-7-3

T183-03-07-010

COMPONENT OPERATION / Others (Upperstructure) Shockless Valve Pressure Circuit

Pump

Regulator

To Port Pi of Regulator in Pump 2 A

Plunger

â&#x20AC;˘ When a control lever is operated, the pilot valve

routes the pilot pressure to port B of the shockless valve. Just after the control lever operation, the pilot pressure oil flows through the shockless valve only via orifice. Then, it enters into Port A and act on the port Pi of the regulator in the pump 2. When the pressure increases further, the plunger move to the left, so that hydraulic oil volume increases.

Orifice T183-03-07-008

From Pilot Valve To Port Pi of Regulator in Pump 2 A

Plunger

B From Pilot Valve

T3-7-4

T183-03-07-009

COMPONENT OPERATION / Others (Upperstructure) â&#x20AC;˘ Return oil from port Pi of the regulator in the pump

2 is returned to the hydraulic oil tank via orifice. When the quantity of return oil increases, increasing the pressure in the A side of the shockless valve, the plunger is moved to the right in proportion to the pressure to restrict the return oil.

From Port Pi of Regulator in Pump 2 A

Plunger

Orifice

To Hydraulic Oil Tank via Pilot Valve From Port Pi of Regulator in Pump 2 A

T183-03-07-008

Plunger

B To Hydraulic Oil Tank via Pilot Valve

T3-7-5

T183-03-07-010

COMPONENT OPERATION / Others (Upperstructure) SOLENOID VALVE

Solenoid Valve Unit

Solenoid Valve Unit Upon receiving signals from the main controller, the solenoid valve unit controls the main pump flow. The solenoid vale unit consists of two horsepower reducing solenoid valves (SA, SB), boom mode selection solenoid valve (SC) and pilot relief valve. Solenoid Valve SA: Horsepower Reducing Solenoid Valve: used for the main pump 3 oil flow control. Solenoid Valve SB: Horsepower Reducing Solenoid Valve: used for the main pump 1 and 2 oil flow control. Solenoid Valve SC: Boom Mode Selection Solenoid Valve: used for the pilot pressure control of the overload relief pressure switch valve. (Refer to the Control System Group in the SYSTEM Section for the pump control.)

Boom Mode Selection Solenoid Valve

Horsepower Reducing Solenoid Valve

Pilot Relief Valve

T183-03-07-003

Spring

Spool

Solenoid

â&#x20AC;˘ Solenoid Valve Operation In Neutral:

The spool is pushed to the right by the spring. Pilot pressure P is blocked. When Magnetized: The spool is pushed to the left by the energized solenoid. Pilot pressure P is connected to the output port.

Output Port

T2 Tank Port

T111-02-07-003

Spool

Spring

â&#x20AC;˘ Pilot Relief Valve Operation

The pilot relief valve sets the pilot pressure delivered to the port P at a certain level. The relief port T1 is connected to the heat circuit in the shockless valve.

T111-02-07-004

T3-7-6

COMPONENT OPERATION / Others (Upperstructure) Flow Rate Reducing Solenoid Valve Upon receiving signals from the main controller A, the flow reducing solenoid valve controls the main pump 1 and 2 flow. (Refer to the Control System Group in the SYSTEM Section for the pump control.) Travel Mode Solenoid Valve Upon receiving signals from the main controller A, the travel 2nd speed shift solenoid valve controls the swash angle of the travel motor. (Refer to the Control System Group in the SYSTEM Section for the valve control.)

Reducing Flow Rate Solenoid Valve T183-03-07-004

Heavy Lift Solenoid Valve Upon receiving signals from the main controller A, the heavy lift solenoid valve changes the main relief pressure from the main control valve. (Refer to the Control System Group in the SYSTEM Section for the valve control.) 2-Spool EHC Valve This valve consists of the horsepower increasing solenoid valve ST and oil cooler fan control solenoid valve SF. The pressure corresponding to the electric signal from the main controller A is output to the main pump and regulator of the oil cooler fan motor drive pump from this valve. (Refer to the Control System Group in the SYSTEM Section.) Horsepower Increasing Solenoid Valve ST: Control of the increasing delivery volume from the main pump. Oil Cooler Fan Control Solenoid Valve SF: Control of the oil cooler fan motor rotation speed.

T3-7-7

Heavy Lift Solenoid Valve

Travel Mode Solenoid Valve

T183-03-07-005

2-Spool EHC Valve Horsepower Increasing Solenoid Valve ST Oil Cooler Fan Control Solenoid Valve SF T183-03-07-006

COMPONENT OPERATION / Others (Upperstructure) OIL COOLER FAN MOTOR The oil cooler fan motor is a inclined-shaft type, fixed displacement axial plunger motor. The operating principle of this motor is the same as the travel motor. (Refer to the Travel Device section in this manual.)

Drive Disk

Rotor T142-06-04-021

T3-7-8

COMPONENT OPERATION / Others (Upperstructure) ACCUMULATOR The accumulator is provided in the pilot circuit to buffer fluctuations in oil pressure, and to maintain the pilot pressure for a short time period after the engine is stopped. The accumulator mainly consists of body (5), holder (4), bladder (2), which encloses nitrogen gas (N2), and poppet (1). â&#x20AC;˘ Pressure oil from the pilot pump enters into the accumulator via port A. Pilot pressure compresses the nitrogen gas in bladder (2) until they balance against each other.

Nitrogen Gas (N2)

â&#x20AC;˘ When pressure supply is stopped due to engine stall or any other reasons, bladder (2) starts expanding, supplying accumulated oil into the pilot circuit via port A.

Pilot Pressure Oil

A T105-02-10-003

1 - Poppet 2 - Bladder 3 - Oil Port

T3-7-9

4 - Holder 5 - Body 6 - Gas Plug

COMPONENT OPERATION / Others (Upperstructure) AUTO-LUBRICATION SYSTEM The auto-lubrication system lubricates the front joint pin automatically. The main components are grease pump, auto-lubrication interval switch, auto-lubrication shift switch and grease pump switch. This system can be switched AUTO/OFF/MANUAL by the auto-lubrication shift switch. If the switch is turned AUTO, the lubrication is performed at the interval set by the auto-lubrication interval switch. If the switch is turned OFF, the lubrication is not performed. If the switch is turned MANUAL, the lubrication must be performed by using a grease gun (lubrication is not performed automatically).

Grease Pump Switch

Grease Pump

T183-03-07-007

T3-7-10

COMPONENT OPERATION / Others (Undercarriage) SWING BEARING This bearing is a single-row shear ball-type bearing, comprising outer race (1), inner race (3), balls (6), supports (5), rod and turn buckle (7) and seals (2), (4). Outer race (1) is bolted to the upperstructure and inner race (3) is bolted to the undercarriage.

The internal gear of inner race (3) engages with the output shaft of the swing reduction gear.

W142-03-01-002

1 - Outer Race 2 - Seal

3 - Inner Race 4 - Seal

5 - Support 6 - Ball

T3-8-1

7 - Rod and Turn Buckle

COMPONENT OPERATION / Others (Undercarriage) CENTER JOINT The center joint is a 360Â° rotating joint. When the upperstructure is rotated, the center joint avoids twisting of hoses and allows hydraulic oil to flow smoothly to or from the travel motors. The spindle is attached to the main frame, and the body is bolted to the swing center of the undercarriage.

Hydraulic oil flows to the right and left travel motors via the spindle and the oil ports of the body. Seals prevent oil leaks between the spindle and body into adjacent passages.

Spindle

Body

Seal

W183-03-08-001

T3-8-2

COMPONENT OPERATION / Others (Undercarriage) TRACK ADJUSTER The track adjuster located on the side frame is composed of spring (5) and adjuster cylinder (6). Spring (5) absorbs loads applied to the front idler. Adjuster cylinder (6) adjusts track sag. â&#x20AC;˘ Grease is applied through grease fitting into chamber A of adjuster cylinder (6) as illustrated below. The pressure of the grease pushes piston rod (8) out and decreases track sag. â&#x20AC;˘ To increases track sag, loosen valve (1) 1 to 1.5 turns counterclockwise to release grease from the track adjuster cylinder through the grease discharge hole.

1 Grease Fitting

CAUTION: The adjusting cylinder is highly pressurized. Loosening valve (1) quickly and/or excessively may cause valve (1) to fly off and the highly pressurized grease to spout out, possibly resulting in personal injury. Be sure to loosen valve (1) slowly and gradually, keeping face and body parts away from valve (1). In addition, never attempt to loosen grease fitting (2).

Grease Discharge Hole

M104-07-119

W142-03-04-016

1 - Valve 2 - Nut

3 - Washer 4 - Spacer

5 - Spring 6 - Adjuster Cylinder

T3-8-3

7 - Flange 8 - Piston Rod

COMPONENT OPERATION / Others (Undercarriage) (Blank)

T3-8-4

Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162

Hitachi Ref. No.

SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:

MODEL: PUBLICATION NO.:

YOUR NAME: DATE: FAX:

(Located at the right top corner in the cover page)

PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

INTRODUCTION TO THE READER • This manual is written for an experienced technician

to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.

• The Operator’s Manual • The Parts Catalog

• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

IN-01

INTRODUCTION PAGE NUMBER • Each page has a number, located on the center

lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual

W: Workshop Manual

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT:

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

IN-02

NOTE: Indicates supplementary technical information or know-how.

INTRODUCTION UNITS USED Example : 24.5 MPa (250 kgf/cm2, 3560 psi)

• SI Units (International System of Units) are used in this manual. MKSA system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length Volume

Weight Force Torque

To Convert From mm mm L L m3 kg N N N⋅m N⋅m

Into in ft US gal US qt yd3 lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-03

To Convert From MPa MPa kW kW °C km/h min-1 L/min mL/rev

Into kgf/cm2 psi PS HP °F mph rpm US gpm cc/rev

Multiply By 10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

INTRODUCTION (Blank)

IN-04

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury.

• Follow recommended precautions and safe operating practices.

SA-688 001-E01A-0001

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol.

• DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

• WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

• DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs.

• Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• CAUTION also calls attention to safety messages in this manual.

• To avoid confusing machine protection with personal

safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

NOTE indicates an additional explanation for an element of information. 002-E01A-1223

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary.

• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

SA-003

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• The safety messages in this SAFETY chapter are in-

tended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01B-0003

• To ensure that a fire-extinguisher can be always used when necessary, check and service the fire-extinguisher at the recommended intervals as specified in the fire-extinguisher manual.

• Establish emergency procedure guidelines to cope with fires and accidents.

• Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone.

004-E01A-0437

SA-2

SA-437

SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job.

You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine.

• Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating the machine.

005-E01A-0438

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing.

• Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434 006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by

walking around it before you start it to avoid personal injury.

• In the walk-around inspection, be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

SA-3

SA-435

SAFETY GENERAL PRECAUTIONS FOR CAB • Before entering the cab, thoroughly remove all dirt and/or oil from the soles of your work boots. If any controls such as a pedal is operated while with dirt and/or oil on the soles of the operator’s work boots the operator’s foot may slip off the pedal, possibly resulting in a personal accident.

• Don’t leave parts and/or tools lying around the operator’s seat. Store them in their specified locations.

• Avoid storing transparent bottles in the cab. Don’t attach any transparent type window decorations on the windowpanes as they may focus sunlight, possibly starting a fire.

• Refrain from listening to the radio, or using music headphones or mobile telephones in the cab while operating the machine.

• Keep all flammable objects and/or explosives away from the machine.

• After using the ashtray, always cover it to extinguish the match and/or tobacco.

• Don’t leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode.

524-E01A-0000

SA-4

• Do not use any controls as handholds. • Never jump on or off the machine. Never mount or dismount a moving machine.

• Be careful of slippery conditions on platforms, steps, SA-439

and handrails when leaving the machine.

008-E01A-0439

ADJUST THE OPERATOR’S SEAT • A poorly adjusted seat for either the operator or for the

work at hand may quickly fatigue the operator leading to misoperations.

• The seat should be adjusted whenever changing the operator for the machine.

• The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back.

• If not, move the seat forward or backward, and check again.

009-E01A-0378

SA-5

SA-378

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may be-

come injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death.

• Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine.

• Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

SA-237

• We recommend that the seat belt be replaced every three years regardless of its apparent condition. 010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

• Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move.

• Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. 011-E01A-0426

SA-6

SA-426

SAFETY OPERATE ONLY FROM OPERATOR’S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death.

• Start the engine only from the operator’s seat. • NEVER start the engine while standing on the track or on ground.

• Do not start engine by shorting across starter terminals.

• Before starting the engine, confirm that all control lev-

SA-444

ers are in neutral. 012-E01B-0444

• The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation.

• Never use a frozen battery.

SA-032

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

S013-E01A-0032

KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off the machine.

• Only allow the operator on the machine. Keep riders off.

• Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner.

SA-379 014-E01B-0379

SA-7

SAFETY INVESTIGATE JOB SITE BEFOREHAND • When working at the edge of an excavation or on a road shoulder, the machine could tip over, possibly resulting in serious injury or death.

• Investigate the configuration and ground conditions of the job site beforehand to prevent the machine from falling and to prevent the ground, stockpiles, or banks from collapsing.

• Make a work plan. Use machines appropriate to the work and job site.

• Reinforce ground, edges, and road shoulders as nec-

SA-380

essary. Keep the machine well back from the edges of excavations and road shoulders.

• When working on an incline or on a road shoulder, employ a signal person as required.

• Confirm that your machine is equipped a FOPS cab before working in areas where the possibility of falling stones or debris exist.

• When the footing is weak, reinforce the ground before starting work.

• When working on frozen ground, be extremely alert. As ambient temperatures rise, footing becomes loose and slippery.

• Beware the possibility of fire when operating the machine near flammable objects such as dry grass. 015-E01A-0380

PROTECT AGAINST FALLING STONES AND DEBRIS • Confirm that your machine is FOPS cab equipped before working in areas where the possibility of falling stones or debris exist.

SA-490 015-E01A-0380

SA-8

SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, pro-

vide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect travel pedal/lever operation may result in serious injury death.

• Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. SA-491 017-E01A-0491

SA-9

SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the

travel levers/pedals direction corresponds to the direction you wish to drive.

• Be sure to detour around any obstructions. • Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Don’t allow personnel to stay around the machine while traveling. SA-387

• Driving on a slope may cause the machine to slip or

overturn, possibly resulting in serious injury or death.

• When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.5 to 1.0 m (A) above the ground.

• If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop.

SA-388

SA-441

• Driving across the face of a slope or steering on a slope may cause the machine to skid or turnover. If the direction must be changed, move the machine to level ground, then, change the direction to ensure safe operation.

SA-589

019-E01C-0492

SA-10

SAFETY AVOID INJURY FROM ROLLAWAY ACCI-DENTS • Death or serious injury may result if you attempt to mount or stop a moving machine.

To avoid rollaways: • Select level ground when possible to park machine.

• Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground.

• Turn the auto-idle switch and the H/P mode switch off.

SA-391

• Run the engine at slow idle speed without load for 5 minutes to cool down the engine.

• Stop the engine and remove the key from the key switch.

• Pull the pilot control shut-off lever to LOCK position. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade.

• Position the machine to prevent rolling. • Park a reasonable distance from other machines. SA-392 020-E02A-0493

SA-11

To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR.

• Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

SA-383

• No machine motions shall be made unless signals are clearly understood by both signalman and operator.

• Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling.

• Keep windows, mirrors, and lights clean and in good condition.

• Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting.

• Read and understand all operating instructions in the operator’s manual. 021-E01A-0494

SA-12

SA-384

SAFETY KEEP PERSON CLEAR FROM WORKING AREA • A person may be hit severely by the swinging front attachment or counterweight and/or may be crushed against an other object, resulting in serious injury or death.

• Keep all persons clear from the area of operation and machine movement.

• Before operating the machine, set up barriers to the sides and rear area of the bucket swing radius to prevent anyone from entering the work area.

SA-386 022-E01A-0386

NEVER POSITION BUCKET OVER ANYONE • Never lift, move, or swing bucket above anyone or a

truck cab. Serious injury or machine damage may result due to bucket load spill or due to collision with the bucket.

023-E01A-0487

SA-487

AVOID UNDERCUTTING • In order to retreat from the edge of an excavation if the footing should collapse, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

• If the footing starts to collapse and if retreat is not possible, do not panic. Often, the machine can be secured by lowering the front attachment, in such cases.

SA-488 024-E01A-0488

SA-13

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE --- SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death.

To avoid tipping:

SA-012

• Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine.

• Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable.

• Reduce swing speed as necessary when swinging loads.

SA-440

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E01B-0495

NEVER UNDERCUT A HIGH BANK • The edges could collapse or a land slide could occur causing serious injury or death.

SA-489 026-E01A-0489

SA-14

SAFETY DIG WITH CAUTION • Accidental severing of underground cables or gas lines

may cause an explosion and/or fire, possibly resulting in serious injury or death.

• Before digging check the location of cables, gas lines, and water lines.

• Keep the minimum distance required, by law, from cables, gas lines, and water lines.

• If a fiber optic cable should be accidentally severed, do not look into the end. Doing so may result in serious eye injury.

SA-382

• Contact your local “diggers hot line” if available in your area , and/or the utility companies directly. Have them mark all underground utilities. 027-E01A-0382

OPERATE WITH CAUTION • If the front attachment or any other part of the machine hits against an overhead obstacle, such as a bridge, both the machine and the overhead obstacle will be damaged, and personal injury may result as well.

• Take care to avoid hitting overhead obstacles with the boom or arm.

028-E01A-0389

SA-389

AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines.

• When operating near an electric line, NEVER move any part of the machine or load closer than 3 m plus twice the line insulator length.

• Check and comply with any local regulations that may apply.

• Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381

029-E01A-0381

SA-15

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be

struck by the falling load or may be crushed underneath it, resulting in serious injury or death.

• When using the machine for craning operations, be sure to comply with all local regulations.

• Do not use damaged chains or frayed cables, sables, slings, or ropes.

• Before craning, position the upperstructure with the travel motors at the rear.

SA-014

• Move the load slowly and carefully. Never move it suddenly.

• Keep all persons will away from the load. • Never move a load over a person’s head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall.

030-E01A-0014

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result.

• Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

• Keep bystanders away from the working area before striking any object.

031-E01A-0432

SA-16

SA-432

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a level surface.

• Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch off. • Run engine at slow idle speed without load for 5 minutes.

• Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK posi-

SA-390

tion.

• Close windows, roof vent, and cab door. • Lock all access doors and compartments.

033-E08B-0390

HANDLE FLUIDS SAFELY－AVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ig-

nites, an explosion and/or a fire may occur, possibly resulting in serious injury or death.

• Do not refuel the machine while smoking or when near open flame or sparks.

• Always stop the engine before refueling the machine. • Fill the fuel tank outdoors. • All fuels, most lubricants, and some coolants are flammable.

SA-018

• Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously.

• Securely tighten the fuel and oil filler cap.

SA-019 034-E01A-0496

SA-17

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before doing work.

• Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving.

• Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. SA-028

2. Lower the bucket to the ground. 3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool.

• If a maintenance procedure must be performed with the engine running, do not leave machine unattended.

• If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work.

• Never work under a machine raised by the boom. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual.

• Keep all parts in good condition and properly installed.

• Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

• When cleaning parts, always use nonflammable detergent oil. Never use highly flammable oil such as fuel oil and gasoline to clean parts or surfaces.

• Disconnect battery ground cable(–) before making adjustments to electrical systems or before performing welding on the machine. 500-E02B-0497

SA-18

SA-527

SAFETY • Sufficiently illuminate the work site. Use a maintenance work light when working under or inside the machine.

• Always use a work light protected with a guard. In case the light bulb is broken, spilled fuel, oil, antifreeze fluid, or window washer fluid may catch fire.

SA-037

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injury.

• Before performing any work on the machine, attach a “Do Not Operate” tag on the control lever. This tag is available from your authorized dealer.

501-E01A-0287 SS2045102

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first.

• Always lower the attachment to the ground before you work on the machine.

• If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack.

SA-527

519-E01A-0527

STAY CLEAR OF MOVING PARTS • Entanglement in moving parts can cause serious injury. • To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026 SA-026

SA-19

SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure.

Failure to follow the precautions below may result in serious injury, blindness, or death.

• Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY.

• As pieces may fly off, be sure to keep body and face away from valve.

• Travel reduction gears are under pressure.

SA-344

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot.

• Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E01B-0344

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic ham-

mers, and blades can fall and cause serious injury or death.

• Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

SA-034 504-E01A-0034

SA-20

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pres-

sure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

• To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

SA-039

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot

during operation. The engine, hoses, lines and other parts become hot as well.

• Wait for the oil and components to cool before starting

SA-225

any maintenance or inspection work. 505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pres-

sure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

• Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual).

• Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

S506-E01A-0019

SA-21

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death.

• Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

• Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care

SA-031

to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-292

507-E03A-0499

SA-22

SA-044

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires.

• Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.

• Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.

• Do not bend or strike high-pressure lines.

SA-019

• Never install bent or damaged lines, pipes or hoses. Check for Shorts: • Short circuits can cause fires.

• Clean and tighten all electrical connections. • Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires.

• Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps.

• DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel, oil, antifreeze fluid and window washer fluid, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires.

• Prevent fires by inspecting and cleaning the machine daily, and by removing spilled or accumulated flammables immediately. Check Key Switch: • If fire breaks out, failure to stop the engine will escalate fire, hampering fire fighting. Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops.

• If any abnormalities are found, be sure to repair them before operating the machine.

508-E02B-0019

SA-23

SAFETY Check Emergency Engine Stop Switch: • If a fire breaks out, failure to release pressurized air inside the hydraulic tank will escalate fire, hampering fire fighting. • Check the emergency engine stop switch function every 250 hours: 1)

Start the engine and run it at slow Idle.

Turn the emergency engine stop switch to the EMERG. STOP position.

Confirm that both engines stop and that pressurized air inside the hydraulic oil tank is released (a hissing sound should be heard).

• If any abnormalities are found, be sure to repair them before operating the machine. Check Heat Shields: • Damaged or missing heat shield may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine. 508-E02A-0393

EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way:

• Stop the engine by turning the key switch to the OFF position if there is time.

• Use a fire extinguisher if there is time. • Exit the machine. • In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method.

SA-393

518-E02B-0393

SS-1510

SA-24

SAFETY PRECAUTIONS FOR WELDING AND GRINDING • Welding may generate gas and/or small fires. • Be sure to perform welding in a well ventilated and prepared area. Store flammable objects in a safe place before starting welding.

• Only qualified personnel should perform welding. Never allow an unqualified person to perform welding.

• Grinding on the machine may create fire hazards. Store flammable objects in a safe place before starting grinding. • After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

SA-818

523-E01A-0818

BEWARE OF EXHAUST FUMES •

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016

SA-25

SA-016

SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near

pressurized fluid lines, resulting in severe burns to yourself and bystanders.

• Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

• Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

SA-030

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids.

• Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030

REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is

heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness.

• Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. SA-029

• Remove paint before welding or heating: 1. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 511-E01A-0029

SA-26

SAFETY PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not charge a frozen battery; it may explode. Warm the battery to 16 °C (60 °F) first.

• Do not continue to use or charge the battery when electrolyte level is lower than specified. Explosion of the battery may result.

SA-032

• Loose terminals may produce sparks. Securely tighten all terminals.

• Battery electrolyte is poisonous. If the battery should

explode battery electrolyte may be splashed into eyes, possibly resulting in blindness.

• Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn.

• Refer to the freon container for proper use when servicing the air conditioning system.

• Use a recovery and recycling system to avoid venting freon into the atmosphere.

• Never let the freon stream make contact with the skin. SA-405 513-E01A-0405

SA-27

SAFETY HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause se-

rious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

• Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

SA-309

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309

DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the envi-

ronment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries.

• Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

• Do not pour waste onto the ground, down a drain, or into any water source.

• Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

• Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-28

SA-226

SECTION AND GROUP CONTENTS

TECHNICAL MANUAL (Troubleshooting)

SECTION 4 OPERATIONAL PERFORMANCE TEST Group Group Group Group Group

1 2 3 4 5

Introduction Standard Engine Test Excavator Test Component Test

SECTION 5 TROUBLESHOOTING Group Group Group Group Group Group Group Group

1 General 2 Cross Reference Table 3 Component Layout 4 Troubleshooting A 5 Troubleshooting B 6 Troubleshooting C 7 Troubleshooting D 8 Electrical System Inspection

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

SECTION 3 COMPONENT OPERATION Group 1 Pump Device Group 2 Swing Device Group 3 Control Valve Group 4 Pilot Valve Group 5 Travel Device Group 6 Signal Control Valve Group 7 Others (Upperstructure) Group 8 Others (Undercarriage)

SECTION 3 UNDERCARRIAGE Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing and Point

SECTION 4

OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction

Group 5 Component Test

Operational Performance Tests ................ T4-1-1

Primary Pilot Pressure .............................. T4-5-1

Preparation for Performance Tests ........... T4-1-2

Secondary Pilot Pressure ......................... T4-5-3 Solenoid Valve Set Pressure..................... T4-5-4

Group 2 Standard

Main Pump Delivery Pressure................... T4-5-7

Operational Performance Standard .......... T4-2-1

Main Relief Valve Set Pressure................. T4-5-8

Main Pump P-Q Diagram.......................... T4-2-4

Overload Relief Valve Set Pressure ........ T4-5-12

Oil Cooler Fan Motor Drive Pump

Main Pump Flow Rate Measurement ...... T4-5-16

P-Q Diagram........................................... T4-2-4

Oil Cooler Fan Motor Drive Pump Flow Rate Measurement ....................... T4-5-22

Group 3 Engine Test

Swing Motor Drainage ............................ T4-5-28

Engine Speed ........................................... T4-3-1

Travel Motor Drainage ............................ T4-5-30

Group 4 Excavator Test Travel Speed ............................................ T4-4-1 Track Revolution Speed............................ T4-4-2 Mistrack .................................................... T4-4-3 Travel Parking Function............................ T4-4-4 Swing Speed ............................................ T4-4-5 Swing Function Drift ................................. T4-4-6 Swing Motor Leakage ............................... T4-4-8 Maximum Swingable Slant Angle.............. T4-4-9 Swing Bearing Play ................................ T4-4-10 Hydraulic Cylinder Cycle Time................ T4-4-12 Cylinder Drift........................................... T4-4-14 Control Lever Operating Force ............... T4-4-15 Control Lever Stroke............................... T4-4-16 Boom Raise/Swing Combined Operation Check................................... T4-4-17

18ET-4-1

(Blank)

18ET-4-2

OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TESTS Use operational performance test procedure to quantitatively check all system and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values. 2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard. 3. To economically operate the machine under optimal conditions. Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders. 2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves. Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data. Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are. 2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions. The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours. Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

T4-1-1

OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS

FOR

PERFORMANCE

Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data. 2. Carry out tests under the exact test conditions prescribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

T105-06-01-003

T105-06-01-004

OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL DARD

PERFORMANCE

STAN-

The standard performance values are listen in the table below. Refer to the Groups 3 to 5 for performance test procedures. Values indicated in parentheses are reference values. The fuel lever shall be placed in the fast idle position and the hydraulic oil temperature is to be maintained at 50 ± 5 °C (122 ± 9 °F) unless otherwise specified. EX1200-5C (Standard Performance)

Performance Test ENGINE SPEED Fast Idle Speed Slow Idle Speed Auto-Idle Speed Quick Idle Speed TRAVEL SPEED Fast Speed Mode Slow Speed Mode TRACK REVOLUTION SPEED Fast Speed Mode Slow Speed mode MISTRACK (in both fast and slow mode) TRAVEL MOTOR DRIFT SWING SPEED SWING FUNCTION DRIFT (Backhoe) (Loading Shovel) SWING MOTOR DRIFT MAXIMUM SWINGABLE SLANT ANGLE

min

Refer to T4-3-1

-1

1850±50 850±50 1400±100 850±50 Refer to T4-4-1

sec /20 m

21.3±1.6 30.5±2.0 Refer to T4-4-2

sec /3 rev

42.0±4.0 61.0±4.0 mm /20 m mm /5 min sec /3 rev

200 or less 0 30.0±2.0

mm /180°

mm /5 min

1100 or less  0

deg

(Backhoe)

Refer to T4-4-3 Refer to T4-4-4 Refer to T4-4-5 Refer to T4-4-6

Refer to T4-4-8 Refer to T4-4-9

12 or possibly more 10 or possibly more

(Loading Shovel) SWING BEARING PLAY

Remarks

2.0 or less

Allowable Limit: 6.3, Refer to T4-4-10

NOTE: BH: Backhoe: With 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 Boom LD: Loading Shovel: With 6.5 m3 Bucket

T4-2-1

OPERATIONAL PERFORMANCE TEST / Standard EX1200-5C (Standard Performance)

Performance Test CYLINDER CYCLE TIME (Backhoe) Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out (Loading Shovel) Boom Raise Boom Lower Arm Extend Arm Retract Bucket Tilt-In Bucket Tilt-Out Bucket Open Bucket Close DIG FUNCTION DRIFT (Backhoe) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom (Loading Shovel) Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom CONTROL LEVER OPERATING FORCE (HITACHI Control Pattern) Boom Lever

Remarks Refer to T4-4-12

sec

4.3±0.5 3.1±0.5 4.5±0.5 3.5±0.5 3.0±0.5 2.3±0.5

BE: 4.5±0.5 BE: 3.3±0.5 BE: 4.5±0.5 BE: 4.0±0.5 BE: 3.3±0.5 BE: 2.7±0.5

5.5±0.5 4.0±0.5 2.9±0.5 2.5±0.5 3.3±0.5 2.2±0.5 1.1±0.5 1.6±0.5 Refer to T4-4-14

mm/5 min

20 or less 20 or less 30 or less 300 or less

BE: 30 or less BE: 30 or less BE: 30 or less BE: 400 or less

20 or less 20 or less 30 or less 300 or less Refer to T4-4-15 N (kgf)

Arm Lever (LD: Extend/Retract) Arm Lever (BH: Roll-in/Roll-out) Bucket Lever (*Roll-In/**Roll-Out) Swing Lever (Right/Left)

Travel Lever

19.7 (2.0) or less 16.7 (1.7) or less 16.7 (1.7) or less 16.7 (1.7) or less

ISO Control Pattern: Swing Lever (Right/Left) ISO Control Pattern: Swing Lever (Right/Left)

19.7 (2.0) or less

ISO Control Pattern: Arm Lever (LD: Extend/Retract, BH: Roll-out, Roll-in)

24.5 (2.5) or less

Bucket Open/Close Pedal NOTE: * In the case of loading shovel specification, the operation is bucket tilt-in **In the case of loading shovel specification, the operation is bucket tilt-out

BH: Backhoe: with 5.0 m3 (PCSA heaped) Bucket, 3.4 m Arm, 9.1 m Boom LD: Loading Shovel: with 6.5 m3 Bucket

T4-2-2

OPERATIONAL PERFORMANCE TEST / Standard EX1200-5C (Standard Performance)

Performance Test LEVER STROKE (HITACHI Control Pattern) Boom Lever Arm Lever

Refer to T4-4-16

105±10 83±10

Bucket Lever Swing Lever

ISO Control Pattern: Swing Lever

83±10 105±10

Travel Lever Bucket Open/Close Pedal BOOM RAISE/SWING COMBINED OPERATION (with Empty Bucket) Time sec/90° Bucket Tooth Tip Height (H) from Ground mm 2 HYDRAULIC COMPONENT MPa (kgf/cm ) PRIMARY PILOT PRESSURE: Fast Idle Slow Idle SECONDARY PILOT PRESSURE 2 SOLENOID VALVE SET PRESSURE MPa (kgf/cm ) Travel Mode Solenoid Valve Flow Rate Reducing Solenoid Valve Power Decrease Solenoid Valve Power Increase Solenoid Valve Oil Cooler Fan Control Solenoid Valve 2 MAIN PUMP DELIVERY PRESSURE MPa (kgf/cm ) 2 MAIN RELIEF PRESSURE MPa (kgf/cm ) Boom, Arm, Bucket, and Bucket Open (LD)

ISO Control Pattern: Arm Lever

115±10 5.5±0.6 7300 or more 4.9±0.5 (50±5) 3.9±0.5 (40±5) 3.6 (37) or less

BH (5.5±0.6: LD), Refer to T4-4-17 BH (7500 or more: LD) Refer to T4-5-1 Refer to T4-5-2 Refer to T4-5-3

3.6 (37) or less 3.6 (37) or less 3.6 (37) or less 0 to 2.7 (0 to 27) 0 to 1.36 (0 to 13.9)

Power Boost Travel Swing OVERLOAD RELIEF PRESSURE Arm Roll-out (BH), Arm Retract (LD)

Remarks

Refer to T4-5-8 31.5±1.0 (320±10) 33.3±1.0 (340±10) 29.4±1.0 (300±10) 29.4±1 (300±10)

MPa (kgf/cm )

Boom, Arm Roll-In (BH), Arm Extend (LD), Bucket, Bucket Open (LD) Bucket Close (LD) MAIN PUMP FLOW RATE L/min OIL COOLER FAN DRIVE PUMP FLOW RATE SWING MOTOR DRAINAGE L/min (at max. constant speed) TRAVEL MOTOR DRAINAGE L/min (at slow speed with track raised off the ground) NOTE: LD: Loading Shovel BH: Backhoe

T4-2-3

34.3＋1.0-0 (350＋10-0) 33.3＋1.0-0 (340＋10-0) 17.7＋1.0-0 (180＋10-0) − − 2 or less 5 or less

Refer to T4-5-12

Refer to T4-2-4, T4-5-16 Refer to T4-2-4, T4-5-22 Allowable Limit: 4, Refer to T4-5-28 Allowable Limit: 10, Refer to T4-5-30

OPERATIONAL PERFORMANCE TEST / Standard MAIN PUMP P-Q DIAGRAM

OIL COOLER FAN MOTOR DRIVE PUMP P-Q DIAGRAM

• Hydraulic P-Q Control • Rated Pump Speed: 1787 min-1 (rpm) • Pump Gear Reduction Ratio: 1.083 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

• Hydraulic P-Q Control • Rated Pump Speed: 1825 min-1 (rpm) • Pump Gear Reduction Ratio: 1.106 • Hydraulic Oil Temperature: 50±5 °C (122±9 °F)

NOTE: Refer to T4-5-17. NOTE: Refer to T4-5-23. Main Pump P-Q Diagram Q L/min (US gal/min) A 490 (129) B 312 (82) C 107 (28) D 485 (128) E 307 (81) F 151 (40) G 477 (126) H 299 (79) I 220 (58)

P MPa (kgf/cm2, psi) 8.4 (86, 1218) 15.7 (160, 2276) 33.3 (340, 4828) 12.6 (128, 1827) 19.9 (203,2885) 33.3 (340, 4828) 19.2 (196, 2784) 26.5 (270, 3842) 33.3 (340, 4828)

Q (Flow Rate) L/min

Oil Cooler Fan Motor Drive Pump P-Q Diagram Q P L/min (US gal/min) MPa (kgf/cm2, psi) A 100 (26) 4.9 (50, 710) B 97 (25) 18.8±0.5 (192±5, 2726±72.5) C 82 (21) 21.6 (220, 3132)

Q (Flow Rate) L/min

600 A

500

600

G SP Mode Control (Pz) = 3.30 MPa

500

400 400 300 200

H 300

E Mode Control (PG) = 2.08 MPa

I F C

100

200 100

P (Pressure) MPa T183-04-04-005

B C

P (Pressure) MPa T183-04-04-017

T4-2-4

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Summary: 1. Measure engine speed by using the on-board diagnostic system (Refer to the TROUBLESHOOTING / General group) or a pulse meter. 2. Measure the engine speeds in each mode. NOTE: Unless engine speed is correctly adjusted, all performance test results will be inaccurate. Therefore, check engine speed setting before performing any tests. Test Condition: Hydraulic Oil Temperature: 50±5 °C (122±9 °F) Ground Conditions: Solid and level surface Measurement: 1. Stop the engine. Turn the key switch OFF. 2. As for the pulse meter, remove the connector from the engine speed sensor. Install the pulse meter. 3. Start the engine. Measure the maximum and minimum engine speeds. As for the pulse meter, read the pulse of engine speed sensor and calculate the engine speed by using the following formula. Engine speed=Pulse value×60/138 (min-1) Evaluation: Refer to T4-2 Operational Performance Standard.

T4-3-1

OPERATIONAL PERFORMANCE TEST / Engine Test (Blank)

T4-3-2

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring time required for the machine to travel the specified distance. Preparation: 1. Equally adjust the track sag on both right and left undercarriages. 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Empty the bucket and roll in the arm. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Deceleration Zone 3 to 5 m

Finish

Track Sag 490 to 550 mm (19 to 22 in)

Travel Test Distance 20 m

Measurement: 1. Measure travel time at both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving the travel levers full stroke. 4. Measure the time required to travel the travel test distance 20 m (65.5 ft). 5. After measuring the forward travel time, rotate the machine upperstructure 180°. Then, measure the reverse travel time on the way back to the starting position in the same method. 6. Repeat steps (4) and (5) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-1

T145-05-03-001

Start

Acceleration Zone 3 to 5 m

T142-05-03-001

T145-05-03-005

OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: 1. Check the overall operational performance of the travel power system (between the hydraulic pumps and travel motors) by measuring the track revolution cycle time. Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in). 2. Mark one shoe with chalk or a piece of cloth on the track to be measured. 3. Rotate the upperstructure 90° to the track and lower the bucket to raise the track to be measured off the ground. Keep the boom and arm angle between 90 to 110° as illustrated. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

90 to 110°

T142-05-03-011

CAUTION: Never work under a machine raised and solely supported by the boom. Place blocks under the machine frame to support the machine. 90 to 110°

Measurement: 1. Measure the track rotation time at both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Operate the travel control lever of the raised track in full forward and reverse. 4. After the track revolution attains to constant speed, measure the time required for the marked shoe to rotate three times in both directions. 5. Raise the other side of the track and repeat the procedure. 6. Repeat steps (3) and (4) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

T142-05-03-012

Forward Reverse

T145-05-03-001

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-2

OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK Summary: 1. Check the equilibrium in operational performance between the right and left travel power systems (between the hydraulic pumps and travel motors) by measuring the amount of mistrack found while the machine travels for the specified distance. NOTE: When tested on a concrete surface road, the amount of mistrack may be reduced. Preparation: 1. Equally adjust the track sag on both right and left undercarriages to 490 to 550 mm (19 to 22 in). 2. Prepare a flat and firm travel test yard 20 m (65.5 ft) long with fringes 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Set the front attachment in the driving position. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure the amount of mistracking in both fast and slow travel speeds. 2. Engine Control Dial : Maximum Position 3. Start machine to travel from the rear end of the acceleration zone by moving both travel levers full stroke. 4. Draw a 20 m (65.5 ft) straight line along the rut from the travel start point to the travel end point as illustrated. Measure the maximum distance between the rut and the straight line. 5. Conduct the measurement in both forward and reverse travel operation in the same method. 6. Repeat steps (4) and (5) three times and calculate the average values.

T145-05-03-005

T145-05-03-006

Deceleration Zone 3 to 5 m

Maximum Distance (A) 20 m

Acceleration Zone 3 to 5 m

Evaluation: Refer to T4-2 Operational Performance Standard.

T115-07-03-005

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-3

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL PARKING FUNCTION Summary: To measure the parking brake function on a specified slope. 0.5 to 1.0 m

Preparation: 1. The surface of the test slope shall be even with a gradient of 20 % (11.31). 2. Hold the bucket 0.5 to 1.0 m (20 to 39 in) above the ground with the arm and bucket fully rolled in. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T142-05-03-002

Measurement: 1. Climb the slope and place the travel levers in neutral. 2. Stop the engine. 3. After the machine stops, put alignment marks on a track link or shoe, and the track side frame. 4. After 5 minutes, measure the distance between the marks on the track link or shoe and the track side frame. Evaluation: Refer to T4-2 Operational Performance Standard.

0.5 to 1.0 m

T118-04-03-001

Position where the machine comes to a stop.

Alignment marks on the track side frame and shoe when the machine comes to a stop. Displacement measured after 5 minutes. T105-06-03-006

T4-4-4

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Check the overall operational performance of the swing power system (between the hydraulic pumps and swing motors) by measuring time required for the machine upperstructure to make three complete turns. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shobel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. NOTE: In case it is difficult to secure the space wide enough, test the machine with the boom raised and the arm retracted. 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T145-05-03-007

T145-05-03-008

CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Dial : Maximum Position 2. Auto-Idle Switch : OFF 3. Operate the swing control lever at full stroke. 4. After the swing attains to constant speed, measure the time required for the upperstructure to rotate three times. 5. Measure in both directions (clockwise and counterclockwise). 6. Repeat steps (3) and (5) three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

3 Revolutions

T145-05-03-009

Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-5

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT Summary: 1. Measure the swing drift on the swing bearing outer race circumference when stopping after a 180° full-speed swing. NOTE: The swing motor is equipped with a swing parking brake mechanical brake. Preparation: 1. Confirm that the swing gears and bearing are sufficiently greased. 2. Secure a space wide enough for the machine upperstructure to swing on a flat and firm surface. Never attempt to perform this test on a slope. 3. Empty the bucket and position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 4. Put aligning marks on the outer circumference of the swing bearing and the track frame. 5. Swing the upperstructure 180°. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9° F).

T4-4-6

T145-05-03-007

T145-05-03-008

OPERATIONAL PERFORMANCE TEST / Excavator Test CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement. Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever full stroke. When the upperstructure rotates 180Â° back to the original position (when the marks on the swing bearing and track frame aligns with each other), return the swing lever to neutral. 3. After the upperstructure stops, measure the distance between the two marks along the outer circumference of the swing bearing. 4. Align the marks again. Then, measure in the opposite direction. 5. Repeat steps (2) to (4) three times and calculate the average values.

Return the swing control lever to the neutral position.

Drift Amount

Rotate 180Â°

Evaluation: Refer to T4-2 Operational Performance Standard. Start Rotation

Remedy: Refer to the T5-5 Troubleshooting B.

T142-05-03-003

T4-4-7

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: Check for upperstructure drift while suspending a load on a slope. Preparation: 1. Check the lubrication of the swing gear and swing bearing. 2. Park the machine on a smooth slope with a gradient of 26.8 % (15°). 3. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used. Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 4. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket. Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height. 5. Swing the upperstructure to position it 90° to the slope. Make aligning marks on the swing bearing periphery and track frame using tape, as illustrated. 6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Stop the engine. After five minutes, measure the difference between the marks along the swing bearing periphery and the track frame. 2. Perform the measurement in both right and left swing directions. 3. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-8

T142-05-03-004

Measure Difference Between Marks

Marking on the Track Frame Marking on the Swing Bearing T105-06-03-010

OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: With the upperstructure swung 90° to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side. Preparation: 1. Check that the swing gear and bearing are well lubricated. 2. Load bucket fully. In lieu of loading the bucket, weight (W: tons) of the following specification can be used. Backhoe: W=6000 kg (13200 lb) (Up to serial No. 2122) W=6600 kg (14500 lb) (Serial No. 2123 and later) Loading Shovel:W=9450 kg (20800 lb) 3. Backhoe: With the arm rolled out, and bucket rolled in, position the arm top pin height to be level with the boom foot pin. Apply a rated load to the bucket. Loading Shovel: With the arm cylinder and bucket cylinders fully extended, position the arm top pin flush with the boom foot pin height. 4. Climb a slope and swing the upperstructure 90° to the slope. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Engine Control Dial : Maximum Position Auto Idle Switch : OFF 2. Operate the swing lever to full stroke to swing the upperstructure to the uphill side. 3. If the machine can swing, measure the cab floor slant angle. 4. When the machine can swing, increase the slope angle and repeat steps (2 and 3). Check in both clockwise and counterclockwise directions. 5. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-9

T142-05-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: Wear on the swing bearing races and rollers is checked by measuring the play between the outer and inner races of the swing bearing. Preparation: 1. Confirm that the swing bearing mounting bolts are securely tightened. 2. Confirm that the swing bearing is well lubricated and rotates smoothly with no noise. 3. Attach a dial gauge on the track frame using a magnet base. 4. Position the upperstructure so that the bucket faces toward the front idlers. 5. Position the dial gauge so that its needle point comes in contact with the bottom face of the swing bearing outer race. 6. Empty the bucket NOTE The measured value will vary depending on the location where the magnet base is secured. Secure the magnet base onto the round trunk or a location as close to the round trunk as possible.

T4-4-10

Dial Gauge

Round Trunk

Magnet Base T105-06-03-015

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Take measurements of the play at positions A, B, C, and D. 2. Position the front attachment as described in the following. Backhoe: With the arm cylinders fully retracted and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder fully extended and the bucket cylinders fully extended, position the arm top pin height flush with the boom foot pin height. 3. Record the dial gauge reading (h1). Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h2). 4. Calculate bearing play (H) from this data (h1 and h2) as follows: H=h2 ďź? h1

A B

D C

Measure the plays at positions A, B, C and D.

T145-05-03-023

Evaluation: Refer to the Performance Standard Table in Group T4-2. Backhoe Measurement : (h1)

Measurement : (h2)

T142-05-03-006

Loading Shovel Measurement : (h1)

Measurement : (h2)

T142-05-03-005

T4-4-11

OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. Check the overall operational performance of the front attachment hydraulic system (between the hydraulic pumps and each cylinder) by measuring the cycle time of the boom, arm, bucket, and bucket dump (open/close) cylinders with the bucket emptied. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). 2. Position the front attachment as described in the following. • Backhoe Boom Cylinder: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket to the ground. Arm Cylinder: With the bucket cylinder fully extended while positioning the center line between the arm and bucket connection pin centers vertical with the arm cylinder extended half stroke. Bucket Cylinder: Adjust the boom and arm cylinder so that the center of full stroke movement of the bucket is positioned vertically. • Loading Shovel Boom Cylinder: With the bucket cylinder and the arm cylinder fully extended, lower the bucket to the ground. Arm Cylinder: With the arm fully retracted, position the bucket so that the rear bucket does not come in contact with the arm stopper. Then, adjust the boom cylinder stroke to position the bucket bottom 1 m (39 in) above the ground. Bucket Cylinder: With the bucket closed and held in a load dump position, adjust the boom cylinder stroke so that bucket bottom height is approx. 1 m (39 in) above the ground. Bucket Dump (Open-Close) Cylinder: With the bucket cylinder and arm cylinder fully extended, adjust the boom cylinder stroke so that the bucket bottom height approx. 1 m (39 in) above the ground.

Backhoe

Boom Cylinder

T145-05-03-012

Arm Cylinder T118-04-03-003

Bucket Cylinder T145-05-03-014

Loading Shovel

Boom Cylinder

T145-05-03-015

Arm Cylinder T145-05-03-016

Bucket Cylinder T145-05-03-017

Dump Cylinder

T145-05-03-018

T4-4-12

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Select the following lever and switch positions: Engine Control Lever: Maximum Position Auto-Idle Switch: OFF 2. To measure cylinder cycle times: (Cylinder full stroke includes cylinder cushioning zone.) 2-1. Boom cylinders: Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-2. Arm cylinder: Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the arm at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-3. Bucket cylinder: Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible. 2-4. Bucket dump (Open-Close) cylinder: Mesure the time it takes to open the bucket, and the time it takes to close the bucket. To do so, position the bucket dump at one stroke end, then move the bucket open-close pedal to the other stroke end as quickly as possible. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. NOTE: Backhoe front : 9.1 m (29 ft) Boom 3.4 m (11 ft) Arm 4.6 m3 (6.0 yd3) Bucket * 5.0 m3 (6.5 yd3) Bucket (PCSA heaped) Loading shovel front: 6.3 m3 (8.2 yd3) Bucket When the bucket weight is increased by welding wear-resist plates, cylinder cycle times may become slower. Remedy: Refer to the T5-5 Troubleshooting B.

T4-4-13

OPERATIONAL PERFORMANCE TEST / Excavator Test CYLINDER DRIFT Summary: 1. While holding the soil weight of or a specified weight in the bucket, the dig function drift is measured to check for internal oil leaks in the control valve, boom, arm, and bucket cylinders. 2. After replacing the hydraulic cylinders, slowly operate each cylinder for approx. 10 minutes to bleed air from the hydraulic circuit before starting the test. Preparation: 1. Load bucket fully. In lieu of loading the bucket, weight (W) of the following specification can be used. Backhoe: W=6000 kg (13200 lb)(Up to Serial No. 2122) W=6600 kg (14500 lb)(Serial No. 2123 and later) Loading Shovel: W=9450 kg (20800 lb) 2. Position the front attachment as described in the following. Backhoe: With the arm cylinder with rod approx.50 mm (2 in) extended from the fully retracted position, and bucket cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height. Loading shovel: With the arm cylinder with the rod approx. 50 mm (2 in) retracted from the fully extended position, and bucket cylinder with the approx. 50 mm (2 in) retracted from the fully extended, position the arm top pin height flush with the boom foot pin height. 3. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

T145-05-03-020

BH: Boom and Bucket Cylinders Retraction LD: Boom, Arm and Bucket Cylinders Retraction Mark

Mark

T110-06-03-002

BH: Arm Cylinder Extension

Mark

Measurement: 1. Stop the engine. 2. After five minutes have passed, measure the retractions of the boom, arm, and bucket cylinders as illustrated 3. Repeat step (2) three times and calculate the average values.

T110-06-03-001

NOTE: BH: Backhoe LD: Loading Shovel

Evaluation: Refer to T4-2 Operational Performance Standard. Solution: Refer to T5-5 Troubleshooting B.

T4-4-14

T145-05-03-021

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Use a spring scale to measure the maximum resistance of each control lever as illustrated. 2. Measure the maximum operating force of the front attachment control lever. 3. Measure the operating force at the grip center of each control lever. Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F). Measurement: 1. Measure all control levers. 2. Engine Control Dial : Maximum Position.

T107-06-03-003

CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. 3. Operate each boom, arm, bucket and swing lever to at full stroke and measure the maximum operating force for each. 4. Lower the bucket to the ground to raise one track off the ground. Operate the travel lever to full stroke and measure the maximum operating force required. When finished, lower the track and then jack-up the other track. 5. Repeat steps 3. to 4. three times and calculate the average values. Evalution: Refer to the Performance Standard Table in Group T4-2.

T4-4-15

T107-06-03-004

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each control lever stroke and stroke play, and check if it can be moved smoothly. 2. Measure each lever stroke at the lever grip center. 3. If a stroke play is present in the neutral position, add half the value of the play to the one side stroke. Preparation: 1. Maintain the hydraulic oil temperature at 50 ± 5 °C (122 ± 9 °F). Measurement: 1. Stop the engine. 2. Measure the boom, arm, bucket, swing, and travel levers full stroke from the neutral position at the lever grip top center. 3. Measure the stroke straight from the neutral position to the stroke end. 4. Repeat each measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard.

T4-4-16

T107-06-03-005

OPERATIONAL PERFORMANCE TEST / Excavator Test BOOM RAISE/SWING ERATION CHECK

COMBINED

OP-

Summary: 1. Check the combined operation performance while operating the boom raise and swing simultaneously. 2. Run the engine at full speed and check if the boom cylinders move without hesitating.

T142-05-03-007

Preparation: 1. Empty the bucket and position the machine with front attachment positioned as illustrated. 2. Maintain the hydraulic oil temperature at 50 ± 5 °C (122 ± 9 °F). CAUTION: Prevent personal injury. Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement.

T142-05-03-008

Measurement: 1. Run the engine at the maximum speed with the auto idle switch OFF. 2. Operate the boom raise and swing levers full stroke. Measure the time required for the machine to swing 90 ° and bucket tooth tip height H raised while swinging. 3. Repeat the measurement in both directions three times and calculate the average values. T142-05-03-009

Evaluation: Refer to T4-2 Operational Performance Standard. Solution: Refer to T5-5 Troubleshooting B.

T142-05-03-010

T4-4-17

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-4-18

OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine. Tee

Pressure Gauge

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Disconnect the line end from the pilot filter. Connect tee (ST 6477) and pressure gauge (ST 6942) between the pilot filer and the line end. 4. Start the engine. Check the connection for oil leaks. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement: 1. Engine Control Dial: Maximum Speed (Fast Idle Position) 2. Read the primary pilot pressure on the gauge. Turn the engine control dial to the slow idle, then back to the fast idle. Read the pressure gauge again. 3. Read the pressure gauge three times in total. Calculate the average value. Evaluation: Refer to the Operational Performance Standard group (T4-2).

T4-5-1

T142-05-04-001

OPERATIONAL PERFORMANCE TEST / Component Test Primary Pilot Pressure Adjustment Procedure Adjustment: Adjust the pilot relief valve setting if required.

Pilot Relief Valve

T183-04-04-001

1. Remove the plug. : 22 mm

Plug

Shim

2. Adjust the set pressure using the shims. Adding shim(s) increases the pressure setting, and vice versa. Add or subtract shims to adjust the setting. 3. Retighten the plug. : 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)

4. Recheck the relief pressure setting.

T111-06-04-004

NOTE: Standard Change in Relief Pressure Setting (Reference) Shim Thickness kPa (kgf/cm2) (psi) (mm) 0.25 78 (0.8) (11) 0.5 147 (1.5) (21) 1.0 294 (3.0) (43)

T4-5-2

OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE

Main Control Valve

The secondary pilot pressure can also be measured Left Travel with the built-in diagnosing system. (Forward) NOTE: BH: Backhoe Bucket 2 LD: Loading Shovel (BH: Roll-Out

Right Travel (Forward) Bucket 1 (BH: Roll-Out, LD: Tilt-Out) Boom 1 (Lower)

LD: Tilt-Out)

Preparation: 1. Stop the engine.

Boom 2 (Lower)

BH: Arm 1 (Roll-Out) LD: Arm 1 (Roll-In)

Bucket 1 (BH: Roll-In, LD: Tilt-In)

BH: Arm 2 (Roll-in) LD: Arm 2 (Extend) BH: Auxiliary LD: Bucket (Close)

Boom 2 (Raise)

Bucket 2 (BH: Roll-in, LD: Tilt-in) BH: Arm 1 (Roll-In) T183-03-03-027 LD: Arm 1 (Extend)

Swing Control Valve

Boom 3 (Lower) Swing (Left) BH: Bucket 3 (Roll-Out) LD: Bucket 3 (Tilt-Out) T183-03-03-030

2. Fully operate the control lever for the function to be measured. Read the secondary pilot pressure on the gauge.

Evaluation: Refer to the Operational Performance Standard group (T4-2).

T183-03-03-028

Left Travel (Reverse)

BH: Arm 3 (Roll-Out) LD: Arm 3 (Retract)

3. Repeat the measurement three times. Calculate the average value.

Right Travel (Reverse)

Boom 1 (Raise)

CAUTION: Before starting measurement, check that there are no bystanders and/or obstructions within the swing radius. When measuring the boom lower secondary pilot pressure operate the machine carefully as the base machine front will be raised off the ground. This will cause the base machine to become imbalanced and possibly allow the rear of the machine to come in contact with the ground. 1. Engine Control Dial :Maximum Speed

BH: Arm 2 (Roll-Out) LD: Arm 2 (Retract)

BH: Auxiliary LD: Bucket (Open)

Boom 3 (Raise) Swing (Right) BH: Bucket 3 (Roll-In) LD: Bucket 3 (Tilt-In) BH: Arm 3 (Roll-In) LD: Arm 3 (Extend)

T4-5-3

T183-03-03-031

OPERATIONAL PERFORMANCE TEST / Component Test SOLENOID VALVE SET PRESSURE (Travel mode control solenoid valve, flow rate decrease solenoid valve, power decrease solenoid valve, boom mode selection solenoid valve, heavy lift solenoid valve, power increase solenoid valve, oil cooler fan control solenoid valve)

Travel Mode Control Solenoid Valve

Preparation: 1. Stop the engine. Output Port

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it.

T183-05-04-019

Flow Rate Decrease Solenoid Valve

2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Connect tee (ST 6450. For the power decrease solenoid valve, power increase solenoid valve and oil cooler fan control solenoid valve, use ST 6451) and pressure gauge (ST 6942) on the solenoid valve output port. : 17 mm, 22 mm

Output Port

T183-05-04-018

Power Decrease Solenoid Valve

4. Start the engine. Check the pressure gauge connection for oil leaks.

Output Port

5. Maintain the hydraulic oil temperature at 50±5° C (122±41 °F). Measurement: 1. Measure the pressure setting for each solenoid valve as follows: • Travel Mode Control Solenoid Valve Measure the shifting pressure at fast and slow speeds by the travel mode switch. • Flow Rate Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure while applying a load to the front attachment. • Power Decrease Solenoid Valve Turn the engine control dial to the slow idle position. Read the pressure. • Boom Mode Selection Solenoid Valve Turn on the boom mode selection switch. Read the pressure.

T183-04-04-001

Boom Mode Selection Solenoid Valve

T4-5-4

Output Port

T183-04-04-001

OPERATIONAL PERFORMANCE TEST / Component Test • Heavy Lift Solenoid Valve Turn on the heavy lift switch. Read the pressure.

• Power Increase Solenoid Valve

Heavy Lift Solenoid Valve

Observe the pressure change while turning the engine control dial from the slow idle position to the fast idle position. • Oil Cooler Fan Control Solenoid Valve Heat the hydraulic oil temperature sensor, and read the pressure at 69 °C (156 °F), 70 to 79 °C (158 to 174 °F) and 80 °C (176 °F). 2. Repeat the measurements three times and calculate the average values.

Output Port

T183-05-04-017

Power Increase Solenoid Valve

Evaluation: Refer to the Operational Performance Standard group (T4-2).

Output Port

T183-05-04-016

Oil Cooler Fan Control Solenoid Valve

Output Port

T4-5-5

T183-05-04-016

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-6

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP DELIVERY PRESSURE The main pump delivery pressure can also be measured with the built-in diagnosing system. Preparation: 1. Stop the engine. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

Test Port

4. Start the engine. Check the pressure gauge connection for oil leaks. 5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F).

Test Port Pressure Gauge

T183-04-04-002

Measurement: 1. Engine Control Dial : Maximum Speed 2. Measure the pressure with the control levers in neutral. 3. Read the pressure gauge three times in total. Calculate the average value. Evaluation: Refer to the Operational Performance Standard group (T4-2). Remedy: Refer to the Troubleshooting B group (T5-5).

T4-5-7

T183-04-04-003

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE The main pump delivery pressure can also be measured with the built-in diagnosing system. Summary: Measure the main relief valve set pressure at the main pump delivery port. Preparation: 1. Stop the engine. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Slowly loosen the cap to release air from the hydraulic oil tank. 3. Remove the plug from the test port on the main pump delivery port. Connect adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) on the test port.

Test Port

Test Port Pressure Gauge

4. Start the engine. Check the pressure gauge connection for oil leaks.

T183-04-04-002

5. Maintain the hydraulic oil temperature at 50±5 °C (122±41 °F). Measurement: 1. Engine Control Dial : Maximum Speed 2. Operate the bucket, arm and boom control levers to the stroke ends (fully extended and retracted) to relieve the each function. (Operate the control lever one function at a time.) 3. For the swing function, place one side of the bucket against an immovable object and slowly operate the swing lever to the stroke end to relieve the swing function.

T183-04-04-003

Evaluation: Refer to the Operational Performance Standard group (T4-2).

4. For the travel function, place the track to be measured against a pile of soil to make it immovable. Slowly operate the travel lever to the stroke end to relieve the travel function. 5. Read the pressure gauge while relieving each function.

T4-5-8

NOTE: If all measured values are lower than the specified main relief pressure, the setting of the main relief valve is suspected to be the cause. If the relief pressure for a particular function is lower than the specified main relief pressure, something other than the main relief valve is the cause.

OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Procedure

Pressure

Setting

Adjustment Main Control Valve

Adjustment: Adjust the main relief valve pressure settings using plug (for the low-side main relief pressure) and sleeve (for high-side main relief pressure) after loosening lock nut (4).

• High-Side

Main Relief Adjustment Procedure

Pressure

Main Relief Valve

Setting

1. Loosen lock nut 2. Tighten plug until the bottom of piston comes into contact with sleeve. Retighten lock nut 2. : 22 mm, 30 mm : Lock nut 2 (4): 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)

T183-03-03-029

Swing Control Valve

Main Relief Valve

2. Loosen lock nut 1. Turn sleeve to adjust the relief pressure setting, referring to the table below. : 22 mm, 41 mm : Lock nut 1: 98 N⋅m (10 kgf⋅m, 22 lbf⋅ft)

• Low-Side

Main Relief Adjustment Procedure

Pressure

Setting

3. Loosen lock nut 2. Turn plug counterclockwise until the specified value is obtained. Retighten lock nut 2. : 22 mm, 30 mm : Lock nut 2: 59 N⋅m (6 kgf⋅m, 13 lbf⋅ft)

Plug

T183-03-03-030

Lock Nut 2 Sleeve Lock Nut 1 Piston

4. Recheck the set pressures. NOTE: : Standard Change in Pressure Setting Sleeve and 1/4 1/2 3/4 1 plug turns MPa 4.4 8.8 13.2 17.7 (kgf/cm2) (45) (90) (135) (180) (psi) (640) (1280) (1920) (2560)

T162-04-04-010

Sleeve, Plug

Pressure Increase

Pressure Decrease W107-02-05-127

T4-5-9

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve

Swing Relief Valve Set Pressure Adjustment Procedure

Adjustment: Loosen the lock nut. : 17 mm 1. Turn the adjusting screw to adjust the pressure setting. T142-01-02-011

Adjusting Screw

2. Retighten the lock nut. : 17 mm : 19.5 to 29.5 N⋅m (2 to 3 kgf⋅m, 15 to 22 lbf⋅ft)

Lock Nut

3. Recheck the relief pressure setting.

T142-02-02-006

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 2.75 5.49 8.24 11.0 (kgf/cm2) (28) (56) (84) (112) (psi) (340) (796) (1195) (1593)

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease

T105-06-05-002

T4-5-10

OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Valve Set Pressure Adjustment Procedure

Adjustment: 1. Loosen the lock nut. : 19 mm 2. Turn the adjusting screw to adjust the pressure setting. : 6 mm

Travel Relief Valve T183-01-02-012

3. Retighten the lock nut. : 19 mm : 34.3 to 44.1 N⋅m (3.5 to 4.5 kgf⋅m, 25.3 to 32.5 lbf⋅ft)

Lock Nut

4. Recheck the relief pressure setting.

Adjusting Screw

NOTE: Standard Change in Relief Pressure Setting Screw Turns 1/4 1/2 3/4 1 MPa 1.96 3.92 5.88 7.85 (kgf/cm2) (20) (40) (60) (80) (psi) (280) (570) (850) (1140)

T142-05-04-007

Lock Nut

Pressure Increase

Adjusting Screw

Pressure Decrease W107-02-05-129

T4-5-11

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD PRESSURE

RELIEF

VALVE

SET

Summary: 1. The circuit pressure must be increased by applying an external force while blocking the return circuit from the control valve. This measuring method is hazardous and the results obtained with this method are unreliable. 2. The oil flow rate used to set the overload relief pressure is far less than that used to set the main relief pressure. Therefore, measuring the overload pressure in the main circuit by increasing the main relief set-pressure more than the overload valve set-pressure is not a proper method. In addition, in case a main relief valve designed to leak a small quantity of oil before reliving is used, its pre-leaking start pressure must be increased more than the overload relief valve set-pressure. However, the pre-leaking start pressure is not always increased more than the overload relief valve set-pressure as the adjustable upper limit of the main relief valve set-pressure is provided. Accordingly, the overload relief valve assembly should be removed from the machine and checked on a specified test stand at a correct oil flow rate. Some overload relief valves come in contact with the control valve body to block the oil passage. When this type of overload relief valve is checked, the control valve body must be precisely finished as the test unit. Provide one control valve other than that on the machine as a test kit. 3. If the overload relief valve performance must be checked on the machine, however, measure the main relief pressure while releasing each front function respective to the measuring overload relief valve. And, assume that the overload relief valve is functioning correctly if the obtained main relief pressure is within the specified value range. Measure the main pressure of the front functions as follows:

T4-5-12

OPERATIONAL PERFORMANCE TEST / Component Test Overload Relief Valve Set Pressure Adjusting Procedure

â&#x20AC;˘ Boom, Arm, Bucket 1, Bucket 2,

Auxiliary: BH/Bucket Open, Close :LD, Swing NOTE: BH: Backhoe LD: Loading Shovel Adjusting Screw

NOTE: In principle, adjust the overload relief valve set pressure on a test stand.

Lock Nut

Adjustment: Adjust the pressure setting of the overload relief valve using adjusting screw after loosening lock nut. 1. Loosen lock nut. : 19 mm 2. Turn adjusting screw to adjust the pressure setting referring to the table below. : 6 mm

T162-04-04-004

Adjusting Screw

3. Retighten lock nut. : 19 mm : 98 Nxm (10 kgfxm, 72 lbfxft) 4. Recheck the set pressures. Pressure Increase

NOTE: Standard Change in Pressure Setting

W107-02-05-129

Screw Turns

1/4

1/2

3/4

MPa

3.9

7.8

11.7

15.6

(kgf/cm )

(40)

(78)

(120)

(160)

(psi)

(566)

(1131)

(1697)

(2262)

Pressure Decrease

T4-5-13

OPERATIONAL PERFORMANCE TEST / Component Test • Boom Mode Selection NOTE: In principle, adjust the overload relief valve set pressure on a test stand. Adjustment: Adjust the pressure setting of the overload relief valve using sleeve after loosening lock nut (1). 1. Loosen lock nut (1). : 36 mm 2. Turn sleeve to adjust the pressure setting referring to the table below. : 30 mm

Boom Mode Selection

3. Retighten lock nut. : 36 mm : 98 N⋅m (10 kgf⋅m, 72 lbf⋅ft)

T183-03-03-028

Sleeve

4. Recheck the set pressures.

Lock Nut

NOTE: Standard Change in Pressure Setting Screw Turns

1/4

1/2

3/4

MPa

8.9

17.8

26.7

35.6

(kgf/cm )

(90)

(180)

(270)

(360)

(psi)

(1290)

(2581)

(3872)

(5162)

T183-04-04-007

Sleeve

Pressure Increase

Pressure Decrease W107-02-05-127

T4-5-14

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-15

OPERATIONAL PERFORMANCE TEST / Component Test MAIN PUMP FLOW RATE MEASUREMENT NOTE: MC/V: Main Control Valve SC/V: Swing Control Valve

• P-Q Control (Torque Control) Summary: Main pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the main pump delivery line. Measure the flow rate by using the built-in diagnosing system and a pressure gauge. Preparation: IMPORTANT: The method described here is a simplified method, so that the flow rate is reduced by approx. 5% compared to the actual measurement (ex. bench test). If the actual measurement is required, connect the return circuit to the hydraulic oil tank instead of the control valve. CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port. NOTE: Keep operating the vacuum pump while connecting the measurement piping.

to Main Pump 1, 2 and MC/V → to Main Pump 3 and SC/V →

Delivery Hose Split Flange (ST 6133)

T183-04-04-013

Delivery Hose Flange (ST 6123)

Bolt (ST 6458)

Test Hose (ST 6145)

Adapter (ST 6146) Hydraulic Tester (ST 6299) Adapter (ST 6146)

Main Pump

Test Hose (ST 6145)

2. Remove the delivery hose from the main pump to be measured, then install flange (ST 6123) on the removed hose using split flange (ST 6133) and bolt (ST 6458).

Split Flange (ST 6133) Bolt (ST 6458)

3. Install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on flange (ST 6123).

Pipe (ST 6132) T183-04-04-014

Pressure Gauge (ST 6941)

4. Install pipe (ST 6132) on the delivery port of the main pump using split flange (ST 6133) and bolt (ST 6458), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe. Remove a plug from the pressure check port on the main pump, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941). Hose (ST 6943)

Adapter (ST 6069)

T4-5-16

T183-04-04-003

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect pipes from pump regulator ports Psv and Pi. Install tee (ST 6640) to port Psv. Connect tee (ST 6640) between port Psv and circuit Psv. Connect hose (ST 6961) and elbow (ST 6635, Code No. 0095) to tee (ST 6640). Connect the other end of hose (ST 6961) to port Pi using elbow (ST 6635, Code No. 0095). Install a plug to the pipe end disconnected from port Pi. (By connecting the pump servo assist pressure (Psv pressure) circuit to port Pi, the condition similar to the maximum pump flow rate (maximum Pi pressure at full stroke operation of the control lever) can be obtained. 6. Disconnect the power increase solenoid valve connector and power decrease solenoid valve connector. 7. Fully open the loading valve of the hydraulic tester. 8. Start the engine. Check the line connections for any oil leaks. Select the monitor function on the built-in diagnosing system. Measurement: 1. Hydraulic oil temperature: 50±5 °C (122±41 °F)

Port Psv Port Pi

T183-01-02-006

Psv Pressure Hose (ST 6961) Tee (ST 6640) Elbow (ST 6635) Elbow (ST 6635)

T183-04-04-004

2. Engine Control Dial: Maximum speed 3. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4) 4. Repeat the measurement three times and calculate the average values. Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NP×Q) / (i×Ne) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.083) NP: Specified Pump Speed (1787 min-1) Ne: Measured Engine Speed

T4-5-17

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Minimum and Maximum Flow Rate Pump flow rate can be adjusted by changing the maximum stroke of the servo piston. To adjust the maximum flow rate, loosen nut (1) and turn adjusting screw (2) on the large chamber side end of the servo piston. To adjust the minimum flow rate, loosen nut (3) and turn adjusting screw (4) on the small chamber side end of the servo piston. : 30 mm for nut (1), (3) : 13 mm for adjusting screw (2) : 10 mm for adjusting screw (4)

NOTE: Turn adjusting screw (2) clockwise to decrease the maximum flow rate and counterclockwise to increase. Turning adjusting screw (2) one forth turns changes approximately 9.2 L/min-1 of flow rate. Turn adjusting screw (4) clockwise to increase the minimum flow rate and counterclockwise to decrease. Turning adjusting screw (4) one forth turns changes approximately 9.2 L/min-1 of flow rate.

T183-04-04-006

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Minimum Flow Rate Adjustment

Pi (Flow Rate Control Pressure)

T4-5-18

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjust the screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjust screw (6). When resetting outer spring (1), loosen nut (3) and adjust screw (4).

NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.17 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Adjusting Screw (4) : 13 mm : Nut (5) : 4 mm : Adjusting Screw (6) 1

2 3

4 5

T117-05-04-005

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 40.9 L/min (10.8 US gal/min) Pressure Change 1.74 MPa (17.8 kgf/cm2) (252 psi) Engine Torque Change 67.6 N⋅m (6.9 kgf⋅m) (50 lbf⋅ft) (Pump Flow Rate) Q

Inner Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 18.9 L/min (5 US gal/min) Pressure Change 1.80 MPa (18.4 kgf/cm2) (261 psi) Engine Torque Change 45.1 N⋅m (4.6 kgf⋅m) (33 lbf⋅ft) (Pump Flow Rate) Q

(Pump Delivery Pressure)

T4-5-19

(Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1). Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

NOTE: When the flow rate control is adjusted, the relief oil minimizing control is also changed at the same time. : 13 mm : Nut (2) : 4 mm : Adjusting Screw (3)

1 2

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 Pressure Change (Pi) 0.15 MPa (1.5 kgf/cm2) (21.8 psi) Flow Rate Change 42.7 L/min (11.2 US gal/min) (Pump Flow Rate) Q

Flow Rate Control

(Pump Flow Rate) Q

Pi (Flow Rate Control Pressure)

T4-5-20

Relief Oil Minimizing Control

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-21

OPERATIONAL PERFORMANCE TEST / Component Test OIL COOLER FAN MOTOR DRIVE PUMP FLOW RATE MEASUREMENT

Delivery Hose

â&#x20AC;˘ P-Q Control (Torque Control) Summary: Oil cooler fan motor drive pump performance is checked by measuring the pump flow rate with a hydraulic tester installed at the oil cooler fan motor drive pump delivery line. Preparation: CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 1. Stop the engine. Slowly loosen the cap to release air from the hydraulic oil tank. Connect the vacuum pump to the oil filler port. NOTE: Keep operating the vacuum pump while connecting the measurement piping.

T183-04-04-015

Split Flange (4506459) Delivery Hose

Bolt (ST 6408) Adapter (ST 6146) Test Hose (ST 6145)

2. Remove the delivery hose, then install flange (ST 6574) on the removed hose using split flange (4506459) and bolt (ST 6408).

Test Hose (ST 6145) Flange(ST 6574) Adapter(ST 6146) Hydraulic Tester (ST 6299) Bolt (ST 6408) Split Flange Pipe (4506459) (ST 6575) Oil Cooler Fan Motor Drive Pump

3. Install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on flange (ST 6574). 4. Install pipe (ST 6575) on the delivery port of the main pump using split flange (4506459) and bolt (ST 6408), then install test hose (ST 6145), adapter (ST 6146) and hydraulic tester (ST 6299) on the pipe. Remove a plug from the pressure check port, then install adapter (ST 6069), hose (ST 6943) and pressure gauge (ST 6941).

T183-04-04-018

Hose (ST 6943)

Pressure Gauge (ST 6941)

Adapter (ST 6069)

T4-5-22

T183-04-04-019

OPERATIONAL PERFORMANCE TEST / Component Test 5. Disconnect the pipe from regulator ports Pi. Leave the port Pi open to the atmosphere. Plug the disconnected pipe end. 6. Disconnect the connector of the oil cooler fan control solenoid valve SF. 7. Fully open the loading valve of the hydraulic tester. 8. Start the engine. Check the line connections for any oil leaks. Pi

Measurement: 1. Engine Control Dial: Maximum speed

T183-04-04-016

2. Slowly close the loading valve of the hydraulic tester to obtain the specified pressure on P-Q curve, and measure the pump flow rate and engine speed at each pressure. (Refer to T4-2-4) 3. Repeat the measurement three times and calculate the average values. Evaluation: Convert the measured flow rates to the values at the specified pump speed using the following formulas: QC = (NPĂ&#x2014;Q) / (iĂ&#x2014;Ne) QC: Converted Flow Rate Q: Measured Flow Rate i: Pump Drive Gear Ratio (1.106) NP: Specified Pump Speed (1825 min-1) Ne: Measured Engine Speed

T4-5-23

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Maximum and Minimum Flow Rate The pump flow rate can be adjusted by changing the maximum servo piston stroke. When adjusting the maximum flow rate, loosen nut (1) and adjusting screw (2) on the servo piston large chamber side. When adjusting the minimum flow rate, loosen nut (3) and adjusting screw (4) on the servo piston small chamber side.

NOTE: Turning adjusting screw (2) clockwise decreases the maximum flow rate, and turning counterclockwise increases. 1/4 turn of adjusting screw (2) changes the flow rate approx. 3 L/min (0.8 US gal/min). Turning adjusting screw (4) clockwise increases the minimum flow rate, and turning counterclockwise decreases. 1/4 turn of adjusting screw (4) changes the flow rate approx. 3 L/min (0.8 US gal/min).

: 24 mm : Nut (1), Nut (3) : 8 mm : Adjusting Screw (2) : 8 mm : Adjusting Screw (4)

T183-03-01-003

(Pump Flow Rate) Q

Maximum Flow Rate Adjustment

(Pump Flow Rate) Q

Minimum Flow Rate Adjustment

Pi (Flow Rate Control Pressure)

T4-5-24

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Torque Control The torque control is performed by pump delivery pressure P. Therefore, the torque constant control is adjusted by changing the set-force of inner spring (2) and outer spring (1). (Before adjusting screws (4) and (6), mark the end of the adjusting screw with a white marker for the record of the original position.) When resetting inner spring (2), loosen nut (5) and adjusting screw (6). When resetting outer spring (1), loosen nut (3) and adjusting screw (4).

NOTE: When adjusting screw (4) is turned, inner spring (2) set-force varies. Therefore, when adjusting screw (4) is turned, turn adjusting screw (6) 2.24 times the turns of adjusting screw (4) in the opposite direction to keep inner spring (2) set-force unchanged. : 36 mm : Nut (3) : 24 mm : Adjusting Screw (4) : 13 mm : Nut (5) : 4 mm : Adjusting Screw (6) 1

W117-02-02-017

Outer Spring Adjustment Data Adjusting Screw Turn 1/4 Flow Rate Change 9.3 L/min (2.5 US gal/min) Pressure Change 1.88 MPa (19.2 kgf/cm2) (273 psi) Engine Torque Change 16.7 N⋅m (1.7 kgf⋅m) (12.3 lbf⋅ft) (Pump Flow Rate) Q

(Pump Delivery Pressure)

T4-5-25

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjustment of Flow Rate Control The flow rate control is performed by pump flow rate control pressure Pi. Therefore, the flow rate control is adjusted by resetting the set-force of spring (1). Loosen nut (2) and turn adjusting screw (3) to reset the set-force of spring (1).

NOTE: When the flow rate control is adjusted, the relief oil minimizing control is also changed at the same time. : 13 mm : Nut (2) : 4 mm : Adjusting Screw (3)

1 2

T117-05-04-006

Spring Adjustment Data Adjusting Screw Turn 1/4 Pressure Change (Pi) 0.13 MPa (1.3 kgf/cm2) (18.9 psi) Flow Rate Change 6.8 L/min (1.8 US gal/min)

(Pump Flow Rate) Q

Flow Rate Control

(Pump Flow Rate) Q

Pi (Flow Rate Control Pressure)

T4-5-26

Relief Oil Minimizing Control

P (Pump Delivery Pressure)

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-27

OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE

Cap

Summary: To check swing motor performance, measure the amount of oil draining from the swing motor while swinging the upperstructure. Swing motor while swinging the upperstructure. NOTE: The amount of drain oil from the swing motor will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature within 50±5 °C (122±41 °F). Preparation: 1. Maintain hydraulic oil temperature at 50±5 °C (122±41 °F). Rotate the swing motor to warm the inside of the motor.

Drain Hose M183-07-052

Front Side

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may fly off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank. 3. Disconnect the swing motor drain hose at the hydraulic oil tank end. Install plug (ST 6491) to the disconnected end on the hydraulic oil tank. : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

T183-04-04-008

Drain Hose

Preconditions for Measurement: 1. Engine Control Dial : Maximum Speed CAUTION: Prevent personal injury. Always make sure that the area is clear and that coworkers are out of the swing area before starting machine operation. Also, take care not fall off the machine during the measurement.

T183-04-04-009

ST 6491

T183-04-04-010

T4-5-28

OPERATIONAL PERFORMANCE TEST / Component Test Measurement: 1. Amount of Oil Drained While Swinging the Upperstructure 1-1. Fully retract the arm cylinder. Fully extend the bucket cylinder. Raise the boom so that the arm tip pin height is the same as the boom foot pin height. Be sure that the bucket is empty. 1-2. Start the engine. Operate and hold the swing lever full stroke. Start draining oil measurement after the swing speed reaches a constant maximum speed. The measuring time should be more than 20 seconds. 1-3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values. 2. Amount of Oil Drained While Relieving Swing Motor Circuit 2-1. Thrust the bucket teeth into the ground as illustrated so that the upperstructure does not rotate when the swing lever is operated full stroke. 2-2. Start the engine. Operate and hold the swing lever full stroke. Start drain oil measurement when drain oil starts coming out of the drain hose end. The measuring time should be more than 20 seconds. 2-3. Repeat the measurement at least three times in both clockwise and counterclockwise directions, and calculate the average values.

T145-05-03-007

T145-05-03-008

Evaluation: Refer to the Performance Standard Table in Group T4-2. ∗ Conversion of the amount of drain oil measured into the per-minute value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the per-minute value using the formula below: ∆Q = 60 × q / t

T183-04-04-009

Where : ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L)

T4-5-29

OPERATIONAL PERFORMANCE TEST / Component Test TRAVEL MOTOR DRAINAGE

Cap

Summary: To check travel motor performance, measure the amount of oil draining from the travel motor, while rotating the travel motor with the measuring side track jacked up.

NOTE: The amount of drain oil from the travel motor and the drain oil pressure will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature within 50±5 °C (122±41 °F). Preparation: 1. Main main hydraulic oil temperature at 50±5 °C (122±41 °F). Rotate the travel motor to warm the inside of the motor.

Drain Hose

M183-07-052

CAUTION: Do not quickly loosen the cap on the hydraulic oil tank. The cap may pop off due to internal pressure. Always turn the cap slowly to release any remaining pressure before removing it. 2. Properly shut down the engine. Slowly loosen cap to release air from the hydraulic oil tank. 3. Disconnect the travel motor drain hose at the travel motor end. Install plug (ST 6637) to the disconnected end. Connect the drain hose (3/4-16UN) to the travel motor. : 27 mm : 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)

M183-01-001

Drain Hose

Preconditions for Measurement: Engine Control Dial: Maximum Position

Drain Hose

T157-05-04-019

ST 6637

T183-04-04-011

T4-5-30

OPERATIONAL PERFORMANCE TEST / Component Test Preconditions for Measurement: Engine Control Dial : Maximum Speed Measurement: 1. Start the engine. Jack up the measuring side track using the front attachment, as illustrated. 90～110°

CAUTION: Securely support the raised track using wooden blocks. T142-05-03-011

2. Rotate the raised track with the travel lever operated full stroke. Start drain oil measurement after the track rotation speed reaches a constant maximum speed. The measuring time should be more than 20 seconds. 3. Repeat the measurement at least three times in both forward and reverse directions and calculate the average values. Evaluation: Refer to the Performance Standard Table in Group T4-2.

T142-05-03-012

∗ Conversion of the amount of drain oil measured into the paramount value First measure the amount of drain oil using a calibrated container. Then, convert the measured drain oil into the paramount value using the formula below: ∆Q = 60 × q / t Where : ∆Q : Amount of drain oil per minute (L/min) t : Time measured (seconds) q : Total amount of drain oil (L) T157-05-04-019

T4-5-31

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-5-32

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

SECTION 5

TROUBLESHOOTING CONTENTS Group 1 General

Group 4 Troubleshooting A

Introduction .............................................. T5-1-1 Diagnosing Procedure .............................. T5-1-2 Built-In Diagnosing System Operation ...... T5-1-4 Built-In Diagnosing Function Display List.. T5-1-6 Binary Number Bit List.............................T5-1-11 Main Controller Fault Code List .............. T5-1-14

Group 2 Cross Reference Table Electrical Circuit Diagram ......................... T5-2-1 Hydraulic Circuit Diagram (Backhoe)........ T5-2-6 Hydraulic Circuit Diagram (Loading Shovel)................................................... T5-2-8

Group 3 Component Layout Main Components .................................... T5-3-1 Electrical System Components (1)............ T5-3-2 Electrical System Components (2)............ T5-3-3 Electrical System Components (3)............ T5-3-8

Troubleshooting A Procedure .................... T5-4-1 Main Controller Fault Code List ................ T5-4-2 Main Controller A Fault Code 01, 02, 03 ............................. T5-4-4 Fault Code 04 ......................................... T5-4-4 Fault Code 05 ......................................... T5-4-5 Fault Code 06 ......................................... T5-4-6 Fault Code 07 ......................................... T5-4-7 Fault Code 08, 09 ................................... T5-4-8 Fault Code 10 ....................................... T5-4-10 Fault Code 11, 12, 13............................ T5-4-12 Fault Code 25 ....................................... T5-4-13 Main Controller B Fault Code 31, 32, 33 ........................... T5-4-14 Fault Code 34 ....................................... T5-4-14 Fault Code 37 ....................................... T5-4-15 Sensor Activating Range......................... T5-4-16

Group 5 Troubleshooting B

Electrical System Components (4)............ T5-3-9

Troubleshooting B Procedure ................... T5-5-1

On and Around Pumps ........................... T5-3-10

Correlation between Trouble

Main Control Valve ................................. T5-3-12

Symptoms and Part Failures ................... T5-5-2

Swing Control Valve ............................... T5-3-16

Engine System Troubleshooting ............. T5-5-14

Signal Control Valve ............................... T5-3-21

All Actuator System Troubleshooting ...... T5-5-36

Others .................................................... T5-3-30

Front Attachment System Troubleshooting .................................... T5-5-44 Swing System Troubleshooting ............... T5-5-58 Travel System Troubleshooting............... T5-5-61 Other System Troubleshooting................ T5-5-68 Work After Replacing Components ......... T5-5-92 Add Compressor oil ................................ T5-5-92 Charge Air Conditioner With Refrigerant ............................................ T5-5-93

18ET-5-1

Group 6 Troubleshooting C

Group 7 Troubleshooting D

Troubleshooting C (Troubleshooting for Monitor) Procedure .............................................T5-6-1

Troubleshooting D Procedures .................T5-7-1 Fault Code Indication by Indicator Blinking Pattern ......................................T5-7-3

Malfunction of Coolant Temperature Gauge................................T5-6-2

Fault Codes for Quantum Engines ............T5-7-5

Malfunction of Fuel Gauge .......................T5-6-4

Group 8 Electrical System Inspection

Malfunction of Indicator Light Check System ........................................T5-6-6

Precautions for Inspection and

Malfunction of Overheat Indicator .............T5-6-8 Malfunction of Air Cleaner Restriction

Maintenance ...........................................T5-8-1 Inspections for Disconnecting

Indicator ...............................................T5-6-10

Connectors .............................................T5-8-3

Malfunction of Fuel Level Indicator .........T5-6-12

Fuse Inspection ........................................T5-8-4

Malfunction of Preheat Indicator .............T5-6-14

Fusible Link Inspection .............................T5-8-7

Malfunction of Download Indicator ..........T5-6-15

Battery Voltage Check ..............................T5-8-8

Malfunction of Alternator Indicator ..........T5-6-16

Alternator Check ......................................T5-8-8

Malfunction of Engine Oil Pressure

Voltage Check ........................................T5-8-10

Indicator ...............................................T5-6-18

Continuity Check ....................................T5-8-17

Malfunction of Pump Transmission Oil Pressure Indicator ...........................T5-6-20 Malfunction of Engine Oil Level Indicator ...............................................T5-6-22 Malfunction of Coolant Level Indicator ....T5-6-24 Malfunction of Hydraulic Oil Level Indicator ...............................................T5-6-26 Malfunction of Auto-Lubrication Indicator ...............................................T5-6-30 Malfunction of Engine Stop Indicator ......T5-6-32 Malfunction of Engine Warning Indicator ...............................................T5-6-34 Malfunction of Quick-Idle Indicator .........T5-6-36 Malfunction of Auto-Idle Indicator ...........T5-6-38 Malfunction of Hourmeter .......................T5-6-40 Malfunction of Buzzer .............................T5-6-42 Malfunction of Liquid Crystal Display (LCD)...T5-6-44 Malfunction of Engine Troubleshooting Operation .............................................T5-6-46

18ET-5-2

TROUBLESHOOTING / General INTRODUCTION Refer to the inspection and troubleshooting procedures after any machine trouble has occurred. The inspection and troubleshooting procedures are presented in an orderly fashion in this section to help you quickly find the cause and solution of the machine trouble. The troubleshooting section in this manual consists of 8 groups; General, Cross Reference Table, Component Layout, Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes), Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status), Troubleshooting C (monitor diagnosis), Troubleshooting D (engine diagnosis indicated by the flashing pattern of indicator lights), and Electrical System Inspection. • General • Cross Reference Table • Component Layout • Troubleshooting A (base machine diagnosis using the built-in diagnosing system’s fault codes) • Troubleshooting B (base machine diagnosis starting with inspection of abnormal operational status) Refer to these procedures when troubleshooting by inspecting abnormal machine operational status. Example: Even if the fuel lever is operated, engine speed doesn’t change. • Troubleshooting C (monitor diagnosis) Refer to these procedures when gauges and/or indicators are malfunctioning. Example: The fuel gauge doesn’t operate. • Troubleshooting D (engine diagnosis relies on the flashing pattern of indicator lights) The engine is diagnosed by referring to the flashing pattern of the engine warning indicator. • Electrical System Inspection Refer to this group when required to obtain precautions and/or information for the electrical system inspection. Example: Fuse Inspection

T5-1-1

TROUBLESHOOTING / General DIAGNOSING PROCEDURE These six basic steps are essential for efficient troubleshooting: 1. Study the system • Study the machine’s technical manuals. Know the system and how it works, and what the construction, functions and specifications of the system components are. T107-07-01-001

2. Ask the operator Before inspecting, get the full story of malfunctions from your star witness --- the operator. • How is the machine being used? (Find out if the machine is being operated correctly) • When was the trouble noticed, and what types of work the machine doing at that time? • What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? • Did the machine have any other troubles previously? If so, which parts were repaired before?

T107-07-01-002

3. Inspect the machine Before starting the troubleshooting procedure, check the machine’s daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batteries, as troubles in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine. If troubleshooting is started without checking for blown fuses, a wrong diagnosis may result, wasting time. Be sure to check for blown fuses before troubleshooting. Even if a fuse looks normal by visual inspection, a fine crack is difficult to find. Always use a tester when checking the fuses.

T5-1-2

T107-07-01-003

TROUBLESHOOTING / General 4. Operate the machine yourself Try to identify the trouble by operating the machine yourself. If the trouble cannot be confirmed, stop the engine and obtain further details of the malfunction from the operator. Also, check for any incomplete connections of the wire harnesses.

5. Perform troubleshooting

T107-07-01-004

CAUTION: If a harness or pipe is disconnected with the engine running, the machine may operate incorrectly, or high pressure oil may spray, causing personal injury. Be sure to disconnect harnesses or pipes after stopping the engine. Perform self-diagnosis by operating the built-in self-diagnosing system. In case any fault code has been displayed by diagnosis using the built-in self-diagnosing system, check the cause of the trouble by referring to Troubleshooting A in this section. After the machine trouble has been corrected, the fault code will be deleted. If the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system, check the cause of the trouble by referring to Troubleshooting D in this section. Therefore, in case problems which are not easily repredicable are encountered, use the built-in self-diagnosing system and ECM diagnosis system to display the fault code. In case no fault codes are displayed, check all related parts/component operating condition using the monitor function of the built-in self-diagnosing system while referring to troubleshooting B in this section.

T107-07-01-006

6. Trace possible causes Before reaching a conclusion, check the most likely causes again. Try to identify the actual cause of the trouble. Based on your conclusion, make a plan for appropriate repairs to avoid consequent malfunctions. T107-07-01-007

T5-1-3

TROUBLESHOOTING / General BUILT-IN DIAGNOSING OPERATION

SYSTEM

IMPORTANT: This system is to be operated by the HITACHI Dealer Only. Don't explain this system function to the customer. In the service mode, the monitor LDC displays the diagnosing items, fault codes and monitored results (not all of them). Built-In Diagnosing System Activation 1. While pressing the monitor SET switch, turn the key switch ON.

Display Selection Switch

Built-In Diagnosing System Operation 1. Each time the display selection switch is pressed, the displayed item will be changed as shown in the table on T5-1-6 or T5-1-7.

SET Switch

NOTE: The fault code is indicated in the display order 8. Fifteen fault codes for the main controller A and five fault codes for the main controller B are indicated. In case more than one fault code is indicated, they will be displayed with an interval of 1 second in order. â&#x20AC;˘ The LCD in the service mode displays only the item No. on the left and the monitored result on the right. The item description is not displayed.

Liquid Crystal Display (LCD)

T183-01-02-013

Display Selection between Main Controller A and B 1. Remove the side cover on the left console. 2. Switch the MC display selection switch. ON: Displays the main controller A value OFF: Displays the main controller B value NOTE: The main controller A value is displayed when the MC display selection switch is in neutral position.

Side Cover M183-01-008

MC Display Selection Switch

Machine Front

Neutral OFF

T5-1-4

T183-05-01-001

TROUBLESHOOTING / General (Blank)

T5-1-5

TROUBLESHOOTING / General BUILT-IN DIAGNOSING DISPLAY LIST Main Controller A Display Description Order 1. Hour Meter 2. Trip1 3. Trip2 4. Engine Actual Speed 5. Hydraulic Oil Temperature 6. 7. 8. Fault Code * 9. Main Pump 1 Pressure 10. Main Pump 2 Pressure 11. Main Pump 3 Pressure 12. Front Operation Pressure 13. Travel Operation Pressure Engine Exhaust Gas 14. Temperature 15.

FUNCTION

Monitored Result

Unit

{{{{{ h {{{{{ h {{{{{ h n {{{{ {{{ L1 {{ L2 {{{ 0 {{ 1 {{{{ 2 {{{{ 3 {{{{ 4 {{{{ 5 {{{{ 6 0

min-1 °C － % － MPa MPa MPa MPa MPa °C

EC Angle Digital Input 0

7 8

{{{{ {{

Digital Input 1

{{

Digital Input 2

{{

Digital Input 3

{{

Digital Output

{{

Proportional Valve ON/OFF Output

{{

Hydraulic Oil Cooling Output Current Power Increase Output Current

{{{{

V 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** mA

{{{{

16.

17.

18.

19.

20.

21. 22. 23.

NOTE: * Refer to T5-1-14 for the Fault Codes. ** Refer to T5-1-8 and T5-1-11 for 2 Digits displayed in Hexadecimal Number.

T5-1-6

Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) Possible to display Possible to display Display Purpose Only Display Purpose Only Possible to display Possible to display Possible to display Possible to display Possible to display Possible to display Fixed by 0 °C (32 °F) (Not used for the CUMMINS engine) Possible to display Possible to display

Possible to display

Possible to display Possible to display

TROUBLESHOOTING / General

Main Controller B Display Description Order 1. Hour Meter 2. Trip1 3. Trip2 4. Engine Actual Speed 5. Hydraulic Oil Temperature 6. 7. 8. Fault Code * 9. Digital Input 0

Monitored Result {{{{{ h {{{{{ h {{{{{ h n {{{{ {{{ L1 {{ L2 {{{ 0 {{ 1 {{

10.

Digital Input 1

{{

11.

Digital Input 2

{{

12.

Digital Input 3

{{

13.

Digital Output 1

{{

14.

Proportional Valve ON/OFF Output

{{

15.

Auto-Lubrication Status 1

{{

16.

Auto-Lubrication Status 2 (upper 4 bits) Auto-Lubrication Status 2 (lower 4 bits) Auto-Lubrication Interval Selection

{{{{

{{

Digital Output 2 (upper 4 bits) Digital Output 2 (lower 4 bits) －－－

{{{{

17. 18.

19. 20. 21. 22. 23. NOTE:

Unit

min-1 °C － % － 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** 2 Digits displayed in Hexadecimal Number ** 4 Digits displayed in Binary Number *** 4 Digits displayed in Binary Number *** －－－

d E F

* Refer to T5-1-15 for the Fault Codes. ** Refer to T5-1-8 and T5-1-11 for 2 Digits displayed in Hexadecimal Number. *** Refer to T5-1-13 for 4 Digits displayed in Binary Number.

T5-1-7

Remarks Standard Mode Standard Mode (Subtraction) Standard Mode (Subtraction) Possible to display Possible to display Display Purpose Only Display Purpose Only Possible to display Possible to display

Possible to display

Possible to display Possible to display Possible to display

Possible to display Possible to display －－－

TROUBLESHOOTING / General Hexadecimal Number and 2 Digits Display Correspondence Chart between Number and Binary Number Hexadecimal Number Binary Number

Hexadecimal

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Digital Input of Main Controller A (Ex.) Monitor Display 60

8 Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number in the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 6 0110 Lower 0 0000 Therefore, binary number 01100000 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit bit bit bit bit bit bit bit

7 6 5 4 3 2 1 0

⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔

0 1 1 0 0 0 0 0

Main Controller Selection Switch = 0 Engine Oil Level Indicator Heavy Lift Switch Display Selection = 0 Checker Connection Blank = 0 Blank = 0 Blank = 0

Main Controller A bit Status of Main Controller

(0)

Contact Terminal is GND Opened Current

(1) Contact Terminal is Closed

Diagram 1. In Case of Digital Input

3. If the value is "1", the terminal point corresponding the bit is closed. The contact terminal is connected to ground, so that power flows. If the value is "0", the terminal point is opened, so that current does not flow. (Refer to Diagram 1) From the above information, it becomes apparent that the engine oil level indicator on the monitor is switched on, the heavy lift switch is turned on, and the checker is disconnected. 4. Convert the value for digital input 1, digital input 2, digital input 3 of the main controller A, and digital input 0, digital input 1, digital input 2 and digital input 3 of the main controller B. Then, calculate the corresponding bit values.

T5-1-8

GND

TROUBLESHOOTING / General In Case of Digital Output of Main Controller A (Ex.) Monitor Display 51

c Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 5 0101 lower 1 0001 Therefore, binary number 01010001 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7

⇔

bit bit bit bit bit bit bit

⇔ ⇔ ⇔ ⇔ ⇔ ⇔ ⇔

1 0 1 0 0 0 1

6 5 4 3 2 1 0

Engine Exhaust Gas Temperature Alarm Output Engine Oil Pressure Alarm Output Pump Cut-Off Output Travel Alarm Output Engine Protection Output Blank = 0 Engine Stop Request Auto-Idle Output

Main Controller A bit Status of Main Controller

Current Vcc Load

(1) GND

Vcc Load

(0) GND

Diagram 2. In Case of Digital Output

3. If the value is "1", the controller internal voltage at the terminal corresponding the bit is connected to ground, so that power flows. If the value is "0", the controller internal voltage at the terminal corresponding the bit does not connected to ground, so that power does not flow. (Refer to Diagram 2) From the above information, it becomes apparent that the engine oil pressure indicator is turned on, and motion alarm and auto-idle control are activated. 4. Convert the value for digital output 1 of the main controller B. Then, calculate the corresponding bit values.

T5-1-9

TROUBLESHOOTING / General Correspondence Chart between Hexadecimal Number and Binary Number Hexadecimal Number Binary Number

0000

0001

0010

0011

0100

0101

0110

0111

1000

1001

1010

1011

1100

1101

1110

1111

In Case of Proportional Valve ON/OFF Output of Main Controller A (Ex.) Monitor Display 60

d Upper

Hexadecimal Number 2 Digits Display Section Lower

1. Convert the upper and lower number on the hexadecimal number 2 digits display section. (Refer to Correspondence Chart between Hexadecimal Number and Binary Number). Upper 6 0110 lower 0 0000 Therefore, binary number 01100000 can be obtained. 2. This value corresponds the bit on the Binary Number Bit List (refer to T5-1-11), as follows: bit 7 bit 6

⇔ ⇔

0 1

bit 5

⇔

bit bit bit bit bit

⇔ ⇔ ⇔ ⇔ ⇔

0 0 0 0 0

4 3 2 1 0

Heavy Lift Solenoid Valve Output #1,#2 Pump Power Decrease Solenoid Valve Output #3 Pump Power Decrease Solenoid Valve Output Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0

3. If the value is "1", power flows at the terminal corresponding the bit. If the value is "0", current does not flow at the terminal. (Refer to Diagram 3) From the above information, it becomes apparent that power flows on the #1, #2 power decrease solenoid valve and #3 pump power decrease solenoid valve. 4. Convert the value for the proportional valve On/Off output of the main controller B. Then, calculate the corresponding bit values.

T5-1-10

Main Controller A bit Status of Main Controller

Current Solenoid Valve

(1) Energized

Solenoid Valve (0) De-energized

Diagram 3. Proportional Valve ON/OFF Output

TROUBLESHOOTING / General BINARY NUMBER BIT LIST Upper

Lower

Hexadecimal Number Binary Number

bit 7

Main Controller A Display Description Order 16

Digital Input 0

Digital Input 1

Digital Input 2

bit 6

bit

Digital Input 3

Digital Output

Proportional Valve ON/OFF Output

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

Main Controller Selection Switch Engine Oil Level Indicator Heavy Lift Switch Display Selection Switch Blank = 0 Auto-Idle Switch Overheat Switch S/P Mode Switch Blank = 0

3 2 1 0 3 2 1 0 3

Air Filter Restriction Indication Switch Coolant Level Switch Engine Oil Pressure Switch (Low Pressure) Blank = 1 Fuel Level Indicator Alternator Indicator Engine Oil Pressure Switch (High Pressure) Engine Exhaust Gas Temperature Alarm Output Engine Oil Pressure Alarm Output Pump Cut-Off Output Travel Alarm Output Heavy Lift Solenoid Valve Output #1, #2 Pump Power Decrease Solenoid Valve Output #3 Pump Power Decrease Solenoid Valve Output Blank = 0

Checker Connection Switch Blank = 0 Blank = 0 Blank = 0 E Mode Switch Blank = 0 Blank = 0 Blank = 0 Pump Contamination Sensor Input (Optional) Blank = 0

0 1

Blank = 0 Blank = 0

3 2 1 0

Blank = 0 Blank = 0 Blank = 0 Blank = 0

Engine Protection Output

2 1 0 3 2

Blank = 0 Engine Stop Output Auto-Idle Output Blank = 0 Blank = 0

Blank = 0

7 6 5 4 7

bit 4

7 6 5 4 7 6 5 4 7

5 4

bit 5

6 5 4 7 6 5 4

T5-1-11

TROUBLESHOOTING / General Upper

Lower

Hexadecimal Number Binary Number

bit 7

Main Controller B Display Description Order

bit 6

bit

bit 5

bit 4

bit 3

bit 2

bit 1

Upper

bit 0

bit

Lower

Digital Input 0

Digital Input 1

6 5 4 7

Hydraulic Oil Level Switch (2) Boom Mode Selection Switch Auto-Lubrication Interval Set (A) Blank = 0

2 1 0 3

Digital Input 2

6 5 4 7

Blank = 0 Travel Mode Switch Auto-Lubrication Timer Switch (B) Blank = 1

2 1 0 3

Digital Input 3

Digital 1

6 5 4 7 6 5 4 7

2 1 0 3 2 1 0 3

Proportional Valve ON/OFF Output

Blank = 0 Auto-Lubrication Interval Set (B) Auto-Lubrication Cycle Switch (B) Hydraulic Oil Level Alarm Output Load Dump Prevention Output Step Light Output Auto-Lubrication Relay Output Boom Mode Selection Solenoid Valve Output Travel Mode Control Solenoid Valve Output Blank = 0 Blank = 0 Auto-Lubrication Activating Auto-Lubrication Indication Auto-Lubrication Error Occurrence Blank = 0

Checker Connection Switch Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Main Switch (A) Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Main Switch (B) Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Timer Switch (A) Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0 Blank = 0 Auto-Lubrication Alarm Output Blank = 0

Blank = 0

1 0 3 2 1 0

Blank = 0 Blank = 0 Blank = 0 Blank = 0 Lubrication Selection Lubrication Selection

Output

Auto-Lubricatio n Status 1

7 6 5 4 7

Main Controller Selection Switch Hydraulic Oil Level Switch (1) Step Light Switch Display Selection Switch Blank = 0

3 2 1 0 3

6 5 4 7 6 5 4

NOTE: Lubrication status of Status 1 are as follows: Stopping: bit1=0 / bit0=0 Manual: bit1=0 / bit0=1 Auto: bit1=1 / bit0=0

Auto-Lubrication

T5-1-12

TROUBLESHOOTING / General NOTE: No need to convert to binary number. Display Description Upper Data Set Value Order (Long, Middle, Short) = 0 (80, 70, 60) min Selection of (Long, Middle, Short) = 18 Auto-Lubrication 1 (50, 40, 30) min Interval (Long, Middle, Short) = 2 (30, 20, 10) min

Lower

Interval Value

Long

Middle

Short

Selection Pattern of Auto-Lubrication Interval Auto-Lubrication Upper Lower Interval (min.) 0 0 80 0 1 70 0 2 60 1 0 50 1 1 40 1 2 30 2 0 30 2 1 20 2 2 10 4 Digits Displayed in Binary Number

bit 3

Main Controller B Display Description Order

Auto-Lubrication Status 2 (upper 4 bits)

Auto-Lubrication Status 2 (lower 4 bits)

Digital Output 2 (upper 4 bits)

Digital Output 2 (lower 4 bits)

bit 2

bit 1

bit 0

bit 3 2 1 0 3 2 1 0 3 2 1 0 3 2 1 0

Auto-Lubrication Activating Auto-Lubrication Indicator Auto-Lubrication Error Occurrence Blank = 0 Blank = 0 Blank = 0 Lubrication Selection Lubrication Selection Hydraulic Oil Level Indicator Load Dump Prevention Output Step Light Output Auto-Lubrication Relay Output Auto-Lubrication Indicator Output Blank = 0 Blank = 0 Blank = 0

NOTE: Lubrication status of Auto-Lubrication Status 2 (lower 4 bits) are as follows: Stopping: bit1=0 / bit0=0

T5-1-13

Manual: bit1=0 / bit0=1 Auto: bit1=1 / bit0=0

TROUBLESHOOTING / General MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 00 Normal 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

08 09 10

11 12 13 14

Cause • Faulty Main Controller A •

• • • • Abnormal Main Controller A Reception • (Between Main Controller A and Main • Controller B) Abnormal Main Controller A Reception • (Between Main Controller A and DLU, or • between Main Controller A and Built-In Diagnosing System) Abnormal Front Pilot Pressure • Abnormal Travel Pilot Pressure • • Abnormal Engine Governor Angle • • • • Abnormal Pump 1 Delivery Pressure • Abnormal Pump 2 Delivery Pressure • Abnormal Pump 3 Delivery Pressure • Abnormal Engine Exhaust Gas Tempera- • ture • • Abnormal Oil Temperature Sensor • • •

T5-1-14

Faulty Main Controller A Faulty Main Controller A Faulty Harness Faulty Engine Speed Sensor 1 Faulty Main Controller A Faulty Harness Faulty Main Controller A Faulty Harness

Faulty Main Controller A Faulty Harness Faulty Pilot Pressure Sensor Faulty Main Controller A Faulty ECM Faulty Harness Faulty Engine Governor Angle Faulty Main Controller A Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty Main Controller A Faulty Harness Faulty Exhaust Gas Temperature Sensor Faulty Main Controller A Faulty Harness Faulty Oil Temperature Sensor

TROUBLESHOOTING / General Main Controller B Fault code Trouble 30 Normal 31 Abnormal EEPROM 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage 37 Abnormal Main Controller B Reception (Between Main Controller B and Built-In Diagnosing System)

Cause • Faulty Main Controller B • Faulty Main Controller B • Faulty Main Controller B • Faulty Harness

T5-1-15

TROUBLESHOOTING / General (Blank)

T5-1-16

TROUBLESHOOTING / Cross Reference Table IMPORTANT: The No. indicates the component number in the circuit diagram. The position indicates the componentâ&#x20AC;&#x2122;s position in the circuit diagram. The number at left side is horizontal lines of drawing frame, the alphabet at right side is vertical lines of drawing frame. Refer to the page and item number in the following group.

ELECTRICAL CIRCUIT DIAGRAM No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018 019 020 021 022 023 024 025 026 027 028 029 030 031 032 033

1G 1G 2G 1H 2K 2B 4C 4I 5C 5F 6H 6H 6I 5J 8C 7C 7C 7D 7D 7D 7D 7E 7E 7E 8D 8D 8D 8D 8D 8D 8D 8D 8D

Component Name Work Light (on Cab Roof) Work Light (at the right side of Frame) Work Light (Under Cab Floor) Horn Fresh Air Sensor (Air Conditioner) DLU (Cummins) Data Link Connector RADIO DLU (Mitsubishi) Sunlight Sensor Wiper Relay (Low) Wiper Relay (High 1) Wiper Relay (High 2) Air Conditioner Unit Monitor Coolant Temperature Gauge Fuel Gauge Liquid Crystal Display (LCD) Switch Panel 1 Auto-Idle Indicator Quick-Idle Indicator Lubrication Mode Indicator (OFF) Lubrication Mode Indicator (Manual) Lubrication Mode Indicator (Auto) Overheat Indicator (L1) Air Filter Restriction Indicator (L2) Fuel Level Indicator (L3) Preheat Indicator (L4) Download Indicator (L5) Alternator Indicator (L6) Engine Oil Pressure Indicator (L7) Pump Transmission Oil Pressure Indicator (L8) Exhaust Gas Temperature Indicator (L9)

T5-2-1

Page T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-4 T5-3-3 T5-3-4 T5-3-2 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9

Item Number 1 4 31 8 10 10 10 32 26 25 24 2 14 15 33 16 34 35 32 32 32 30 31 17 28 29 18 27 26 19

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

034 035 036 037 038 039 040 041 044 045 046 047 048 049 050 051 052 053 054 055 056 057 058 059 060 061 062 063 064 065

8D 8D 8D 8E 8E 8E 8I 8G 10G 10G 9L 9L 9L 9L 10K 10K 11K 11K 11K 12K 14K 11D 11F 12F 11G 11H 14D 14D 14D 14D

Component Name Engine Oil Level Indicator (L10) Coolant Level Indicator (L11) Hydraulic Oil Level Indicator (L12) Auto-Lubrication Indicator (L13) Engine Stop Indicator (L14) Engine Warning Indicator (L15) Travel Alarm Stop Switch (Option) Washer Relay (R3) Work Light Relay 1 (R5) Quick Idle Relay (R9) Heavy Lift Solenoid Valve (SC) Travel Mode Control Solenoid Valve (ST) Oil Cooler Fan Control Solenoid Valve (SF) Power Increase Solenoid Valve (ST) Oil Pressure Sensor 3 Oil Pressure Sensor 2 Oil Pressure Sensor 1 Hydraulic Oil Temperature Sensor Pilot Pressure Sensor (Travel) Pilot Pressure Sensor (All) Solenoid Valve Unit Quick Idle Switch Horn Switch Horn Relay (R6) Power Transistor Unit 2 Power Transistor Unit 1 Auto-Idle Switch Work Light Switch Wiper/Washer Switch Engine Control Dial

T5-2-2

Page T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-9 T5-3-3 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-2 T5-3-10 T5-3-10 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-2 T5-3-4 T5-3-4 T5-3-4 T5-3-9 T5-3-9 T5-3-9 T5-3-9

Item Number 25 22 20 24 23 21 5 23 28 2 25 24 12 11 22 22 22 26 27 23 16 3 30 27 13 14 4 7 8 3

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

066 067 068 069 070 071 072 073 074 075 076 077 078 079 080 081 082 083 084 085 086 087 088 089 091 092 093 094 095 096 097

14D 14D 13F 14F 13H 16A 16C 16D 16H 15K 16K 17F 17F 17F 17F 18H 18I 17K 18K 18H 19H 20K 17C 18C 18G 19G 19B 20C 22B 21C 21F

Component Name Travel Mode Switch Power Mode Switch Auto-Idle Relay (R6) Engine Protection Relay (R27) Flow Rate Decrease Solenoid Valve Relay (R7) Fuse Box 1 Fuse Box 2 DC/DC Converter MC Display Selection Switch Flow Rate Decrease Solenoid Valve Pump Transmission Oil Pressure Switch Boom Mode Selection Switch Buzzer Cancel Switch Heavy Lift Switch Entrance Light Switch Power Transistor Unit 3 Main Controller B (MCX-B) Hydraulic Oil Level Switch1 Hydraulic Oil Level Switch2 Auto-Lubrication Relay (R11) Auto-Lubrication (ALU) Timer Switch Air Cleaner Restriction Switch Entrance Light Relay Load Dump Relay Preheat Indicator Relay (R13) Coolant Level Sensor Relay (R30) Key Switch Engine Stop Relay Engine Stop Solenoid Relay (R18) Entrance Light Engine Warning Indicator Relay (R15)

T5-2-3

Page T5-3-9 T5-3-9 T5-3-4 T5-3-4 T5-3-4 T5-3-4 T5-3-4 T5-3-2 T5-3-3 T5-3-10 T5-3-10 T5-3-9 T5-3-3 T5-3-9 T5-3-9 T5-3-4 T5-3-4 T5-3-2 T5-3-2 T5-3-4 T5-3-9 T5-3-2 T5-3-4 T5-3-4 T5-3-9 T5-3-4 T5-3-2 T5-3-4

Item Number 6 5 6 7 1 17 18 29 3 14 5 13 4 12 36 12 16 28 28 3 11 14 20 4 9 21 33 9

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

098 099 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119

21G 21I 21I 22I 22I 23B 22F 25B 25B 25B 25B 25C 25C 25C 25C 26E 25F 26B 28C 28C 29D 29F

Component Name Engine Stop Indicator Relay (R16) Cummins Indicator Panel Protction Indicator (L3) Stop Indicator (L2) Warning Indicator (L1) Starter Relay (R19) ECM Relay (R17) Fusible Link 1 (45A) Fusible Link 2 (75A) Fusible Link 3 (75A) Fusible Link 4 (45A) Fusible Link 5 (250A) Fusible Link 6 (100A) Fusible Link 7 (125A) Fusible Link 8 (125A) Auto-Lubrication Device Fuel Level Sensor 1 Pole Junction Battery Relay 2 Battery Relay 1 Battery (12Vx2) Alternator

T5-2-4

Page T5-3-4 T5-3-6 T5-3-4 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-6 T5-3-1 T5-3-2 T5-3-6 T5-3-6 T5-3-6 T5-3-1 T5-3-8

Item Number 8 2 11 13 12 11 10 4 9 7 8 10 9 6 5 3 8 2

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

120 121 122 123 124 125 126 127 128 129 130

29G 29G 29H 31F 30F 30G 31H 29J 9G 9I 27F

Component Name Engine Oil Level Switch Grid Heater Relay 1 Grid Heater Relay 2 Coolant Temperature Sensor Starter 2 Starter 1 Engine Speed Sensor (Pump) ECM (Cummins) Work Light Relay 2 (R4) Main Controller A (MCX-A) Coolant Level Sensor

Page T5-3-8 T5-3-8 T5-3-2 T5-3-2 T5-3-2 T5-3-8 T5-3-4 T5-3-4 T5-3-2

T5-2-5

Item Number 6 5 15 15 19 1 22 15 12

Note

TROUBLESHOOTING / Cross Reference Table HYDRAULIC CIRCUIT DIAGRAM (BACKHOE) No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018

1G, H 1I 1J 3C, E 3D 4H 5K 4I 2K 4B 4B 3D 4G 5J

019 020 021 022 023 024 025 026 027 028 029 030

7D 6D 9F 8G 9H 10B 10F 10F 11F 11F 11G 10K

Component Name Front / Swing Pilot Valve Travel Pilot Valve Accumulator Boom Cylinder Bucket Cylinder Shuttle Valve (Bucket Roll-In) Shock Reducing Valve Shuttle Valve (Pilot Pressure Control) Pilot Shut-Off Valve Oil Cooler Oil Cooler Fan Motor Arm Cylinder Hydraulic Oil Tank Shuttle Valve (For Switching Pump 3 Control Pressure) Swing Device Travel Device Brake Release Pressure Switch Valve Shuttle Valve (Boom Raise Priority) Signal Control Valve Main Control Valve Heavy Lift Solenoid Valve Reducing Valve Shuttle Valve (Swing Brake Release) Travel Mode Control Solenoid Valve Shuttle Valve (Auxiliary Circuit) Arm Preference Valve

T5-2-6

T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30

Item Number 6 30 29 5 1 18 16 17 27 13 14 3 7 10

T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30

11 21 6 9 19 12 4 3 7 5 2 11

Page

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048

12I 12K 15K 14K 16G 15I 16I 16I 17I 17I 18I 18H 20H 20H 20H 19I 19J 19J

Component Name Swing Control Valve Pump 3 Control Valve Shockless Valve Shuttle Valve (Swing Make-Up) Engine Main Pump 3 Main Pump 2 Oil Cooler Fan Motor Drive Pump Pilot Pump Transmission Lubrication Oil Pump Main Pump 1 Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve (SA) Power Decrease Solenoid Valve (SB) Boom Mode Selection Solenoid Valve (SC) Power Increase Solenoid Valve (ST) Oil Cooler Fan Control Solenoid Valve (SF) Pilot Filter

T5-2-7

Page T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10

Item Number 24 13 14 15 17 10 8 4 7 6 3 14 16 17 18 11 12 13

Note

TROUBLESHOOTING / Cross Reference Table HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL) No.

Position

001 002 003 004 005 006 007 008 009 010 011 012 013 014 015 016 017 018

1F, G 1H 1H 1I 1J 2C, E 2C, D 2D 3D 4H 5K 4I 2K 4B 4B 4D 4G 5J

019 020 021 022 023 024 025 026 027 028 029 030

7D 6D 9F 8G 9H 10B 10F 10F 11F 11F 11G 10K

Component Name Front / Swing Pilot Valve Pilot Valve (Bucket Open) Travel Pilot Valve Pilot Valve (Bucket Close) Accumulator Boom Cylinder Bucket Cylinder Dump Cylinder Level Cylinder Shuttle Valve (Bucket Roll-In) Shock Reducing Valve Shuttle Valve (Pilot Pressure Control) Pilot Shut-Off Valve Oil Cooler Oil Cooler Fan Motor Arm Cylinder Hydraulic Oil Tank Shuttle Valve (For Switching Pump 3 Control Pressure) Swing Device Travel Device Brake Release Pressure Switch Valve Shuttle Valve (Boom Raise Priority) Signal Control Valve Main Control Valve Heavy Lift Solenoid Valve Reducing Valve Shuttle Valve (Swing Brake Release) Travel Mode Control Solenoid Valve Shuttle Valve (Auxiliary Circuit) Arm Preference Valve

T5-2-8

T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-1 T5-3-30

Item Number 6 33 30 34 29 5 1 35 32 18 16 17 27 13 14 3 7 10

T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-1 T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30 T5-3-30

11 21 6 9 19 12 4 3 7 5 2 11

Page

Note

TROUBLESHOOTING / Cross Reference Table

No.

Position

031 032 033 034 035 036 037 038 039 040 041 042 043 044 045 046 047 048

12I 12K 15K 14K 16G 15I 16I 16I 17I 17I 18I 18H 20H 20H 20H 19I 19J 19J

T5-2-9

Page T5-3-1 T5-3-30 T5-3-30 T5-3-30 T5-3-1 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10 T5-3-10

Item Number 24 13 14 15 17 10 8 4 7 6 3 14 16 17 18 11 12 13

Note

TROUBLESHOOTING / Cross Reference Table (Blank)

T5-2-10

TROUBLESHOOTING / Component Layout MAIN COMPONENTS Backhoe

2 1

5 6 7 8 9 10

36 37

11 12

30 29

28 27 Loading Shovel

5 32

3 2 35

17 23

18 22 6 21

19 20 30 33

34 T183-01-02-016

1 - Bucket Cylinder 2 - Arm

11 - Swing Device 12 - Main Control Valve

21 - Travel Device 22 - Upper Roller

3 - Arm Cylinder

13 - Oil Cooler

23 - Lower Roller

4 - Boom

14 - Oil Cooler Fan Motor

24 - Swing Control Valve

5 - Boom Cylinder

15 - Intercooler

25 - Center Joint

678910 -

16 17 18 19 20 -

26 27 28 29 30 -

Front / Swing Pilot Valve Hydraulic Oil Tank Battery (12Vx2) Fuel Tank Auto-Lubrication Device

Radiator Engine Pump Device Signal Control Valve Swing Bearing

T5-3-1

Track Adjuster Pilot Shut-Off Valve Front Idler Accumulator Travel Pilot Valve

31 - Bucket 32 - Level Cylinder (Loading Shovel Only) 33 - Pilot Valve (Bucket Open) (Loading Shovel Only) 34 - Pilot Valve (Bucket Close) (Loading Shovel Only) 35 - Dump Cylinder (Loading Shovel Only) 36 - Condenser (Air Conditioner) 37 - Fuel Cooler

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (1) Overall Layout 3

7 8

9 10

(Refer to T5-3-4)

(Refer to T5-3-11)

13 33 32 14

31 30 29

15 16 (Refer to T5-3-10)

(Refer to T5-3-3)

17 (Refer to T5-3-10) 18 (Refer to T5-3-10)

(Refer to T5-3-30) 27

26 25

19 (Refer to T5-3-8) 24

(Refer to T5-3-30) 23 1 - Work Light (on Cab Roof)

20 22

2 - Monitor

10 - Fresh Air Sensor (Air Conditioner) 11 - Fuel Temperature

3 - Quick Idle Switch

12 - Coolant Level Sensor

4 - Work Light (at the right side of Frame) 5 - Starter Relay 1

13 - Coolant Temperature Sensor

6 - Battery

15 - Starter 1,2

7 - Battery Relay

16 - Solenoid Valve Unit

8 - Horn

17 - Flow Rate Decrease Solenoid Valve 18 - 2-Spool EHC Valve

9 - Fuel Level Sensor

14 - Air Cleaner Restriction Switch

19 - Engine Speed Sensor (Pump) 20 - Engine Speed Sensor 2 (ECM) 21 - Pump Transmission Oil Pressure Switch 22 - Oil Pressure Sensor 1, 2, 3 23 - Pilot Pressure Sensor (All) 24 - Travel Mode Control Solenoid Valve (ST) 25 - Heavy Lift Solenoid Valve (SC) 26 - Hydraulic Oil Temperature Sensor 27 - Pilot Pressure Sensor (Travel)

T5-3-2

T18E-01-02-009

28 - Hydraulic Oil Level Switch 1, 2 29 - DC/DC Converter 30 - Horn Switch 31 - Work Light (Under Cab Floor) 32 - Sunlight Sensor 33 - Entrance Light 34 - Electrical Equipment Box

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (2) In the Cab

1 6

T18E-01-02-010

2 4

M18E-01-009

T18E-01-02-013

1 - 12 V Power Source Terminal 2 - DC-DC Converter

4 - Buzzer Cancel Switch 5 - Travel Alarm Stop Switch (Optional)

Engine Fault Code Display Panel 7 - Fault Diagnosing Switch A

3 - MC Display Selection Switch

T5-3-3

Fault Diagnosing Switch B

DLU Check Switch

TROUBLESHOOTING / Component Layout Electrical Equipment Box

28 27 26 25 11

24 23 22

12 T18E-01-02-003

1 - Flow Rate Decrease Solenoid Valve Relay (R7) 2 - *Quick Idle Relay (R9) 3 - Auto-Lubrication Relay (R11) 4 - Preheat Indicator Relay (R13) 5 - *Coolant Lever Switch Relay 6 - *Auto-Idle Relay (R6) 7 - *Engine Protection Relay (R27)

8 - *Engine Stop Indicator Relay (R16) 9 - *Engine Warning Indicator Relay (R15) 10 - DLU (Cummins, Mitsubishi)

15 - Main Controller A (MCX-A) 16 - Main Controller B (MCX-B) 17 - Fuse Box 1

22 - Work Light Relay 2 (R4)

24 - Wiper Relay (High 2)

11 - *ECM Relay (R17)

18 - Fuse Box 2

25 - Wiper Relay (High 1)

12 - Power Transistor Unit 3

19 - Step Light Relay

26 - Wiper Relay (Low)

13 - Power Transistor Unit 2 14 - Power Transistor Unit 1

20 - Load Dump Relay 21 - *Engine Stop Relay

27 - Horn Relay (R6) 28 - Work Light Relay 1 (R5)

23 - Washer Relay (R3)

NOTE: The items with mark ”*” are not used for the machine equipped with CUMMINS engine.

T5-3-4

TROUBLESHOOTING / Component Layout (Blank)

T5-3-5

TROUBLESHOOTING / Component Layout Around Batteries

12 13 10 11

3 4 5 6

1234-

Air Heater Signal Relay Starter Relay (R19) Battery Relay 1 Fusible Link 5 (250A)

567-

Battery Relay 2 1 Pole Junction Fusible Link 7 (125A)

T183-01-02-015

8 - Fusible Link 8 (125A) 9 - Fusible Link 6 (100A) 10 - Fusible Link 4 (45A)

T5-3-6

11 - Fusible Link 3 (75A) 12 - Fusible Link 2 (75A) 13 - Fusible Link 1 (45A)

TROUBLESHOOTING / Component Layout Used Circuit Fusible Link Part Name Fusible Link 1

Fusible Link 2

Fusible Link 3

Fusible Link 4 Fusible Link 5 Fusible Link 6 Fusible Link 7 Fusible Link 8

T5-3-7

Connected Fuse Box 1 (#1, #2) Fuse Box 2 (#1) Fuse Box 2 (#11～14)

Fuse Box 2 (#4～9)

Air Heater Signal Relay Starter Relay 1 Alternator Preheat Relay 1 Preheat Relay 2

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (3) On and Around Engine

5 9

T18E-01-02-011

1 - ECM (Cummins) 2 - Alternator 3 - Engine Speed Sensor 1 (ECM)

Engine Speed Sensor 2 (Pump) 5 - Coolant Temperature Sensor 6 - Engine Oil Level Sensor

Preheat Relay

Starter

Coolant Temperature Sensor (ECM)

T5-3-8

10 - Engine Oil Pressure Sensor 11 - Suction Manifold Temperature Sensor 12 - Fuel Temperature Sensor

TROUBLESHOOTING / Component Layout ELECTRICAL SYSTEM COMPONENTS (4) Monitor Panel

Monitor and Switch Panels

1 35 34 16

32 31 3

30 29

5 6

27 26

7 8

17 18 19 20

T183-01-02-013

24 23

22 21

13 12 11

36 M183-01-035

T183-01-02-010

1 - Monitor Panel 2 - Quick Idle Switch 3 - Engine Control Dial 4 - Auto-Idle Switch

10 - Air Conditioner Control Panel 11 - Auto-Lubrication (ALU) Timer Switch 12 - Heavy Lift Switch

6 - Travel Mode Switch

13 - Boom Mode Selection Switch 14 - Coolant Temperature Gauge 15 - Fuel Gauge

7 - Work Light Switch

16 - Switch Panel 1

8 - Wiper/Washer Switch

17 - Fuel Level Indicator (L3)

9 - Key Switch

18 - Alternator Indicator (L6)

5 - Power Mode Switch

19 - *Exhaust Gas Temperature Indicator (L9) 20 - Hydraulic Oil Level Indicator (L12) 21 - Engine Warning Indicator (L15) 22 - Coolant Level Indicator (L11) 23 - Engine Stop Indicator (L14) 24 - Auto-Lubrication Indicator (L13) 25 - Engine Oil Level Indicator (L10) 26 - Pump Transmission Oil Pressure Indicator (L8) 27 - Engine Oil Pressure Indicator (L7)

28 - Preheat Indicator (L4) 29 - Download Indicator (L5) 30 - Overheat Indicator (L1) 31 - Air Filter Restriction Indicator (L2) 32 - Lubrication Mode Indicator (OFF) (Manual) (Auto) 33 - Liquid Crystal Display (LCD) 34 - Auto-Idle Indicator 35 - Quick-Idle Indicator 36 - Entrance Light Switch

NOTE: The Item with mark “*” is not used for the machine equipped with CUMMINS engine.

T5-3-9

TROUBLESHOOTING / Component Layout 1

ON AND AROUND PUMPS Front

Pump Device

9 8 7 4

Solenoid Valves and Related Components

18 Solenoid Valve Unit

T183-01-02-006

11 17

2-Spool EHC Valve

12 15 Front

T183-01-02-007

1 - Main Pump 3 Regulator 2 - Main Pump 1 Regulator

6 - Transmission Lubrication Oil Pump 7 - Pilot Pump

3 - Main Pump 1

8 - Main Pump 2

4 - Oil Cooler Fan Motor Drive Pump 5 - Pump Transmission Oil Pressure Switch

9 - Main Pump 2 regulator

11 - Power Increase Solenoid Valve (ST) 12 - Oil Cooler Fan Control Solenoid Valve (SF) 13 - Pilot Filter 14 - Flow Rate Decrease Solenoid Valve

10 - Main Pump 3

T5-3-10

15 - Pilot Relief Valve 16 - Power Decrease Solenoid Valve (SA) 17 - Power Decrease Solenoid Valve (SB) 18 - Boom Mode Selection Solenoid Valve (SC)

TROUBLESHOOTING / Component Layout Coolant Level Switch

T18E-01-02-012

T5-3-11

TROUBLESHOOTING / Component Layout MAIN CONTROL VALVE

Auxiliary: BH Bucket Open/Close: LD

10 34 Arm 1 Arm 2

Boom 2 Boom 1

13 14

Bucket 2

Bucket 1

17 18

Left Travel

29 28 19

Right Travel

27 26

22 21

T18E-03-03-001

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T5-3-12

34 - Make-Up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 11

15, 16 18 E

Section A

25 10 Front

29 24

33 Section B

T183-03-03-003

T183-03-03-002

Section C

Right Travel

Bucket 1

Left Travel

40 Bucket 2

17 19

21 20 18

29 T183-03-03-004

T183-03-03-005

NOTE: BH: Backhoe LD: Loading Shovel

35 - Right Travel (Forward) Port

37 - Left Travel (Reverse) Port

36 - Left Travel (Forward) Port

38 - Right Travel (Reverse) Port

39 - Bucket 1 (Roll-Out : BH, Tilt-Out : LD) Port 40 - Bucket 2 (Roll-Out : BH, Tilt-Out : LD) Port

T5-3-13

41 - Bucket 1 (Roll-In : BH, Tilt-In : LD) Port 42 - Bucket 2 (Roll-In : BH, Tilt-In : LD) Port

TROUBLESHOOTING / Component Layout 2

Auxiliary: BH Bucket Open/Close: LD

10 34 Arm 1 Arm 2

Boom 2 Boom 1

13 14

Bucket 2

Bucket 1

17 Left Travel

29 28 19

Right Travel

27 26

22 21

T18E-03-03-001

19 - Load Check Valve (Left Travel Tandem Circuit)

27 - Main Relief Valve

20 - Load Check Valve (Left Travel Parallel Circuit) 21 - Load Check Valve (Bucket 2 Parallel Circuit) 22 - Check Valve (Main Relief Pressure Combining Circuit) 23 - Flow Combiner Valve

24 - Check Valve (Travel Flow Combine Circuit) 25 - Check Valve (Main Relief Pressure Combining Circuit) 26 - Shuttle Valve

T5-3-14

34 - Make-Up Valve (Arm 2)

TROUBLESHOOTING / Component Layout 43

Section D

Boom 1

Section E

Boom 2 Arm 2

16 31

Arm 1

6 3 14

2 11

T183-03-03-007

T183-03-03-006

51 Auxiliary (BH) Bucket Open/Close (LD)

Section F

10 Section G

T183-03-03-009

9 34

52 T183-03-03-008

43 - Boom 1 (Lower) Port

46 - Boom 2 (Raise) Port

44 - Boom 2 (Lower) Port

47 - BH: Arm 2 (Roll-Out) Port LD: Arm 2 (Retract) Port 48 - BH: Arm 1 (Roll-Out) Port LD: Arm 1 (Roll-In) Port

45 - Boom 1 (Raise) Port

49 - BH: Arm 2 (Roll-In) Port LD: Arm 2 (Extend) Port 50 - BH: Arm 1 (Retract) Port LD: Arm 1 (Extend) Port

T5-3-15

51 - BH: Auxiliary Port LD: Bucket (Open) Port 52 - BH: Auxiliary Port LD: Bucket (Open) Port

TROUBLESHOOTING / Component Layout SWING CONTROL VALVE 1

Boom 3

Swing

Bucket 3

Arm 3

1 - Main Relief Valve 2 - Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

4 - Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3) 6 - Load Check Valve (Arm 3 Parallel Circuit)

7 - Check Valve (Arm 3) 8 - Make-Up Valve (Arm 3) 9 - Overload Relief Valve (Swing)

T5-3-16

T18E-03-03-002

10 - Holding Valve Switch Valve 11 - Holding Valve Check Valve (Boom 3)

TROUBLESHOOTING / Component Layout 12

Section A

1 B

T183-03-03-011

Section B

T183-03-03-012

Section C

Swing

Boom 3

3 2 10

11 15

T183-03-03-013

12 - Boom 3 (Lower) Port

13 - Boom 3 (Raise) Port

14 - Swing (Left) Port

T5-3-17

15 - Swing (Right) Port

T183-03-03-014

TROUBLESHOOTING / Component Layout

Boom 3

Swing

Bucket 3

Arm 3

12-

Main Relief Valve

Load Check Valve (Boom 3) 3 - Load Check Valve (Swing)

Load Check Valve (Bucket 3) 5 - Load Check Valve (Arm 3) 6 - Load Check Valve (Arm 3 Parallel Circuit)

Check Valve (Arm 3) 8 - Make-Up Valve (Arm 3) 9 - Overload Relief Valve (Swing)

T5-3-18

T18E-03-03-002

10 - Holding Valve Switch Valve 11 - Holding Valve Check Valve (Boom 3)

TROUBLESHOOTING / Component Layout 16

Section D

Section E

Bucket 3

Arm 3

5 4

T183-03-03-015

T183-03-03-016

Section F

NOTE: BH: Backhoe LD: Loading Shovel 16 - Bucket 3 (Roll-Out) Port

T183-03-03-017

17 - Bucket 3 (Roll-In) Port

18 - BH: Arm 3 (Roll-Out) Port LD: Arm 3 (Retract) Port

T5-3-19

19 - BH: Arm 3 (Roll-In) Port LD: Arm 3 (Extend) Port

TROUBLESHOOTING / Component Layout (Blank)

T5-3-20

TROUBLESHOOTING / Component Layout SIGNAL CONTROL VALVE

Pilot Valve Side

T178-03-06-016

Cross Section A-A

Shockless Valve

Arm Flow Rate Control

Auxiliary

Pump 1 and 2 Flow Rate Control Valve

Auxiliary

Flow Combiner Valve Control Spool

Priority Valve

T178-03-06-002

T5-3-21

TROUBLESHOOTING / Component Layout Pilot Port NOTE: BH: Backhoe LD: Loading Shovel Pilot Valve Side Port Name Port A Port B Port C

Connecting to Right Pilot Valve Right Pilot Valve Left Pilot Valve

Port D Port E Port F

Right Pilot Valve Hydraulic Oil Tank Left Pilot Valve

Port G

Left Pilot Valve

Port H Port I Port J Port K Port L Port M

Port N Port SA Port SB Port PI Port PH Port SH Port DF

Pump 1 and 2 Regulator − Pilot Shut-Off Valve Pilot Shut-Off Valve − Hydraulic Oil Tank

T5-3-22

TROUBLESHOOTING / Component Layout

Pilot Valve Connecting Side C

PH A

E M D H B

SB G

Pilot Valve Side

I SH

J DF SA

L T178-03-06-016

T5-3-23

TROUBLESHOOTING / Component Layout NOTE: BH: Backhoe LD: Loading Shovel Control Valve Side Port Name Port 1 Port 2 Port 3 Port 4 Port 5 Port 6

Connecting to Control Valve − − − − Control Valve

Port 7

Control Valve

Port 8 Port 9 Port 10 Port 11 Port 12 Port 13

Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve

Port 14

Control Valve

Port SE Port SM Port SN Port SP Port SL Port SK

Shuttle Valve Shuttle Valve Shuttle Valve Shuttle Valve Control Valve −

T5-3-24

TROUBLESHOOTING / Component Layout

Control Valve Connecting Side SM

3 5

1 13 2 SK

4 SE 8

14 Control Valve Side

7 9 6

Pressure Sensor (Travel)

T5-3-25

T178-03-06-015

TROUBLESHOOTING / Component Layout Shuttle Valve NOTE: BH: Backhoe LD: Loading Shovel

Pump 1 and 2 Flow Control Valve Boom Raise Boom Lower Arm Roll-Out (BH) Arm Roll-In (LD) Arm Roll-In (BH) Arm Roll-Out (LD) Bucket Roll-In Bucket Roll-Out Right Travel Left Travel Auxiliary (Close) (BH) Bucket Close (LD) Auxiliary (Open) (BH) Bucket Open (LD)

Arm Flow Rate Control Valve

Flow Combiner Valve Control Spool

Priority Valve

{ {

{ −

− −

{ {

{

−

{

−

{

{ { { −

− − − −

− − { −

{ { − −

−

{

−

{

T5-3-26

TROUBLESHOOTING / Component Layout Swing Arm

Boom

Bucket

Left Travel

Right Travel

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12 1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

11 10

7 14 - Boom, Arm, Bucket

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm Roll-Out (LD), Bucket Roll-In

16 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm. Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

NOTE: BH: Backhoe LD: Loading Shovel

T5-3-27

TROUBLESHOOTING / Component Layout

Swing Arm

Boom

Left Travel

Bucket

Right Travel

Shockless Valve

6 Arm Flow Rate Control Valve P1 and P2 Pump Flow Rate Control Valve Flow Combiner Valve Control Spool Priority Valve

T183-03-06-001

17 16 15 14 13 12

11 10

NOTE: BH: Backhoe LD: Loading Shovel

T5-3-28

TROUBLESHOOTING / Component Layout

Pilot Valve Side

T178-03-06-016

Cross Section B-B 9 5

7 16 17 15

14 10

4 2

T178-03-06-009

1 - Auxiliary (BH), Bucket Open/Close (LD)

6 - Right Travel

2 - Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD) 3 - Arm Roll-Out (BH), Arm Roll-In (LD)

7 - Left Travel, Right Travel

4 - Boom, Bucket Roll-Out 5 - Boom, Arm Roll-Out (BH), Arm Roll-In (LD), Bucket Roll-Out

8 - Boom, Arm, Bucket, Right Travel 9 - Left Travel

14 - Boom, Arm, Bucket

10 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD), Left Travel 11 - Boom, Arm, Bucket, Right Travel

15 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

12 - Arm Roll-In (BH), Arm Roll-Out (LD), Bucket Roll-In

16 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD)

13 - Room Raise, Arm, Bucket

17 - Boom Raise, Arm Roll-Out (BH), Arm Roll-In (LD), Auxiliary (BH), Bucket Open/Close (LD)

T5-3-29

TROUBLESHOOTING / Component Layout OTHERS Valves (1)

Swing Device

9 4 Front Side

8 5

T142-01-02-011

T183-01-02-008

Travel Device

Valves (2) 10

18 22

17 16 13 Valves (1)

14 T18E-01-02-002 T183-01-02-012

1 - Pilot Pressure Sensor (Travel) 2 - Shuttle Valve (Auxiliary Circuit) 3 - Reducing Valve 4 - Heavy Lift Solenoid Valve

5 - Travel Mode Control Solenoid Valve 6 - Brake Release Pressure Switch Valve

13 - Pump 3 Control Valve 14 - Shockless Valve 15 - Shuttle Valve (Swing Make-Up) 16 - Shock Reducing Valve

17 - Shuttle Valve (Pilot Pressure Control)

12 - Signal Control Valve

T5-3-30

18 - Shuttle Valve (Bucket Roll-In) 19 - Swing Parking Brake Release Valve 20 - Swing Relief Valve 21 - Counterbalance Valve

22 - Travel Relief Valve

TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE Refer to troubleshooting A procedure in case any fault codes are displayed after diagnosing the main controller A and/or B using the built-in diagnosing system.

• How to Read Troubleshooting Flow Charts

YES (OK)

・

(2)

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1) NO (NOT OK)

・ · Key switch: ON

(3)

Instructions, reference, and/or inspection methods and/or measurements are occasionally described under the box. If incorrectly checked or measured, not only will troubleshooting be unsuccessful but also damage to the components may result.

・

Refer to "Electrical System Inspection" group (Group 8) for descriptions in the dotted-line box.

・

Use the built-in diagnosing system for descriptions in the double-line box.

・

Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes allows you to estimate the possible causes before actually following the flow chart.

NOTE: All harness end connectors are seen from the open end side.

Harness Open End Side

Harness End Connector T158-05-03-001

T5-4-1

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER FAULT CODE LIST Main Controller A Fault Code Trouble 00 Normal 01 Abnormal EEPROM 02 Abnormal RAM 03 Abnormal A/D Conversion 04 Abnormal Sensor Voltage 05 Abnormal Engine Speed

Cause

• Faulty Main Controller A

08 09

Abnormal Main Controller A Reception (Between Main Controller A and Main Controller B) Abnormal Main Controller A Reception (Between Main Controller A and DLU, or between Main Controller A and Built-In Diagnosing System) Abnormal Front Pilot Pressure Abnormal Travel Pilot Pressure

Abnormal Engine Control Dial Angle

11 12 13 25

Abnormal Pump 1 Delivery Pressure Abnormal Pump 2 Delivery Pressure Abnormal Pump 3 Delivery Pressure Abnormal Oil Temperature Sensor

• • • • • •

Faulty Main Controller A Faulty Main Controller A Faulty Harness Faulty Engine Speed Sensor 1 Faulty Main Controller A Faulty Harness

• Faulty Main Controller A • Faulty Harness • • • • • • • • • • • • •

T5-4-2

Faulty Main Controller A Faulty Harness Faulty Pilot Pressure Sensor Faulty Main Controller A Faulty ECM Faulty Harness Faulty Engine Control Dial Faulty Main Controller A Faulty Harness Faulty Pump Delivery Pressure Sensor Faulty Main Controller A Faulty Harness Faulty Oil Temperature Sensor

TROUBLESHOOTING / Troubleshooting A Main Controller B Fault Code Trouble Cause 30 Normal 31 Abnormal EEPROM • Faulty Main Controller B 32 Abnormal RAM 33 Abnormal A/D Conversion 34 Abnormal Sensor Voltage • Faulty Main Controller B 37 Abnormal Main Controller B Reception • Faulty Main Controller B (Between Main Controller B and Built-In • Faulty Harness Diagnosing System)

T5-4-3

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER A FAULT CODE 01 ABNORMAL EEPROM FAULT CODE 02 ABNORMAL RAM FAULT CODE 03 ABNORMAL A/D CONVERSION YES

∗Faulty main controller A.

Check if engine and machine actuators operate normally.

Faulty main controller A.

YES

Look for the cause from other fault phenomenon.

Exchange main controller A and main controller B. Check if the fault code is displayed.

* Even if any fault codes are still displayed after retrying, the machine can be used unless there are malfunctioning on the engine or machine.

FAULT CODE 04 ABNORMAL SENSOR VOLTAGE YES

Faulty main controller A.

Check if voltage at alternator terminal B is normal. · 24V: With engine stopped · 28V: With engine running

Faulty alternator.

T5-4-4

TROUBLESHOOTING / Troubleshooting A FAULT CODE 05 ABNORMAL ENGINE SPEED

Disconnect connector from engine speed sensor 1. Check if resistance between sensor end connector terminals #1 and #2 matches specification. Âˇ Specification: 200 to 300 â&#x201E;Ś

Connect engine speed sensor 1 harness end connector terminals #1 and #2. YES Disconnect connector D from main controller A. Check for continuity between connector D harness end terminals #D13 and #D14.

Main Controller A Connector D

D14

Check for continuity between connector D harness end terminal #D13 and engine speed sensor 1 harness end connector terminal #2.

Broken harness between main YES controller A and engine speed sensor 1 (terminal #1).

Broken harness between main controller A and engine speed sensor 1 (terminal #2). Faulty engine speed sensor 1.

Connector (Harness End Connector Viewed from the Open End Side)

D13

Faulty main controller A.

YES

T183-05-04-009

Engine Speed Sensor 1

T18E-05-04-001

T5-4-5

TROUBLESHOOTING / Troubleshooting A FAULT CODE 06 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND MAIN CONTROLLER B)

Exchange main controller A and main controller B. Turn off MC display selection switch to change the monitor display to main controller B. Display the faulty code. Check if Code 37 is displayed.

YES

Faulty main controller A.

Broken harness between main controller A and main controller B.

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector D

T183-05-04-009

Main Controller B Connector D

D10

T183-05-04-009

T5-4-6

TROUBLESHOOTING / Troubleshooting A FAULT CODE 07 ABNORMAL MAIN CONTROLLER A RECEPTION (BETWEEN MAIN CONTROLLER A AND DLU, OR BETWEEN MAIN CONTROLLER A AND BUILT-IN DIAGNOSING SYSTEM) Between Main Controller A and DLU

YES

Disconnect connector 76B from DLU. Check if voltage between harness end connector terminals #41 and #33 is 5Âą0.5 V.

Disconnect joining connector between DLU and main controller A. Check for continuity between DLU harness end connector 76B terminal #32 and joining connector DLU end terminal #2.

YES

Faulty DLU.

Faulty ground wire on DLU.

YES

Âˇ Key Switch: ON NO

Reconnect connector D to main controller A. Connect DLU harness end connector 76B terminals #41 and #33 with a clip.

Check for continuity between connector D harness end terminals #D11 and #D12.

Between Main Controller Diagnosing System

and

Faulty main controller A.

Check harness between DLU harness end connector 76B terminal #41 and connector D harness end terminal #D11 for breakage or short circuit.

Broken harness between DLU harness YES end connector 76B terminal #41 and connector D terminal #D11.

Built-In

Broken harness between main controller A and monitor controller.

YES Check harness between main controller A connector harness end terminal #D10 and monitor controller connector B harness end terminal #B1 for breakage or short circuit.

Broken harness between DLU harness end connector 76B terminal #33 and connector D terminal #D12.

Faulty main controller A.

Connector DLU

Main Controller Connector D

Connector 76B

D10

D11

Monitor Controller Connector B D12

Joining Connector (Between DLU and Main Controller A)

T18E-05-04-003 T183-05-04-013 T18E-05-04-002 T183-05-04-009

T5-4-7

TROUBLESHOOTING / Troubleshooting A FAULT CODE 08 ABNORMAL FRONT PILOT PRESSURE FAULT CODE 09 ABNORMAL TRAVEL PILOT PRESSURE

Disconnect connectors from all operation pressure sensor and NO travel pressure sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V. · Key switch: ON Check if fault codes are switched after switching all operation pressure sensor with travel pressure sensor and retrying.

Check harness between connector C terminal #C1 (all operation YES pressure) (or #C2 (travel operation pressure)) and all operation pressure sensor (or travel pressure sensor) terminal #2 for breakage or short circuit.

Check if voltage between all operation pressure sensor (or travel pressure sensor) harness end connector NO terminal #1 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector C C2 C10

C23

C31

All Operation Pressure Sensor, Travel Pressure Sensor

Faulty main controller A.

Broken harness between main YES controller A and all operation pressure sensor or travel pressure sensor (terminal #3).

Broken harness between main controller A and all operation pressure sensor or travel pressure sensor (terminal #1). Faulty pressure sensor.

YES

Broken harness between main YES controller A and all operation pressure sensor or travel pressure sensor.

T5-4-8

TROUBLESHOOTING / Troubleshooting A (Blank)

T5-4-9

TROUBLESHOOTING / Troubleshooting A FAULT CODE 10 ABNORMAL ENGINE ANGLE

Disconnect switch box connector. Check if resistance between switch box end connector terminals #2 and #4 is 5±0.5 kΩ. Reconnect switch box connector. Insert tester probe into connector terminal #3 from the reverse side. Check if voltage varies as specified when engine control dial is turned.

CONTROL

DIAL

Disconnect switch box connector. YES Check if voltage between harness end connector terminals #2 and #4 is 5±0.5 V.

Disconnect ECM connector 31 poles. Check harness YES between connector 31 poles harness end terminal #5 and switch box terminal #3 for breakage or short circuit.

· Key switch: ON

· Specification: See table below.

Disconnect ECM connector 31 poles. Check for continuity between switch box harness end connector terminal #4 and ECM harness end connector terminal #6.

YES Broken harness between ECM and engine control dial.

Faulty harness between switch box and engine control dial.

Broken harness between ECM and engine control dial (terminal #4).

Check for continuity between switch box YES harness end connector terminal #2 and ECM harness end connector #4.

Faulty engine control dial.

Engine Control Dial Specification Maximum Speed 0.3 to 1.0 V Minimum Speed 4.0 to 4.7 V Connector (Harness End Connector Viewed from the Open End Side) ECM Connector 31 Poles

Switch Box

T18E-05-04-004

T5-4-10

TROUBLESHOOTING / Troubleshooting A

YES

Faulty ECM.

Broken harness between ECM and engine control dial (terminal #2).

T5-4-11

TROUBLESHOOTING / Troubleshooting A FAULT CODE 11 ABNORMAL PUMP 1 DELIVERY PRESSURE FAULT CODE 12 ABNORMAL PUMP 2 DELIVERY PRESSURE FAULT CODE 13 ABNORMAL PUMP 3 DELIVERY PRESSURE Disconnect pump delivery pressure NO sensor. Check if voltage between harness end connector terminals #1 and #3 is 5±0.5 V.

Check if fault codes are switched after switching pump delivery pressure sensor (pump 1) with pump delivery pressure sensor (pump 2) or (pump 3) and retrying.

· Key switch: ON

Check harness between main controller A connector C (connector 31P) harness end terminals YES #C4 (pump 1), #C5 (pump 2) or #C6 (pump 3) and pump delivery pressure sensor terminal #2 for breakage or short circuit.

Check if voltage between pump delivery pressure sensor harness end connector terminal #1 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector C C4

C23

Faulty main controller A.

Broken harness between main YES controller A and pump delivery pressure sensor (terminal #3).

Broken harness between main controller A and pump delivery pressure sensor (terminal #1). Faulty pump delivery pressure sensor.

YES

Broken harness YES between main controller A and pump delivery pressure sensor.

C6 C10

C31

Pump Delivery Pressure Sensor

T146-05-03-006

T5-4-12

TROUBLESHOOTING / Troubleshooting A FAULT CODE 25 ABNORMAL OIL TEMPERATURE SENSOR

Connect oil temperature sensor harness end connector terminals #1 and #2 YES with a clip. Remove connector B and connector C from main controller A. Check for continuity between connector B harness end terminal #B22 and connector C terminal #C24.

Disconnect oil temperature sensor. Check if sensor end connector resistance matches specification.

· Specification: See table below.

Oil Temperature Sensor Specification Oil Temperature Resistance(kΩ) (°C) (°F) -20 -4 16.2±1.6 0 32 (5.88) 20 68 2.45±0.24 40 104 (1.14) 60 140 (0.534) 80 176 0.322 Connector (Harness End Connector Viewed from the Open End Side) Main Controller A Connector B B8

B19

B25 B22

Connector C C10

C23

C31 C24

Oil Temperature Sensor 1

Connect main controller A connector B harness end terminal #B22 to vehicle frame. Check for continuity between oil temperature sensor harness end connector terminal #2 and vehicle frame.

Broken harness between main YES controller A and oil temperature sensor (terminal #1).

Broken harness between main controller A and oil temperature sensor (terminal #2). Faulty oil temperature sensor.

Faulty main controller A.

YES

T5-4-13

TROUBLESHOOTING / Troubleshooting A MAIN CONTROLLER B IMPORTANT: The fault code is displays on the monitor by the fault signal from main controller B which comes via main controller A. Check that main controller A operates normally before performing troubleshooting of main controller B.

FAULT CODE 31 ABNORMAL EEPROM FAULT CODE 32 ABNORMAL RAM FAULT CODE 33 ABNORMAL A/D CONVERSION YES

Check if machine operates normally.

* Faulty main controller B.

Switch main controller B with main controller A. Turn on MC display selection switch, then switch the monitor display NO to main controller A. Check if code 01, 02 or 03 is displayed when fault code is displayed.

YES

Look for the cause from other fault phenomenon.

Faulty main controller B. NO

* Even if any fault codes are still displayed after retrying, the machine can be used unless there are malfunctioning on the engine or machine.

FAULT CODE 34 ABNORMAL SENSOR VOLTAGE

Check if voltage at alternator terminal B is normal.

Switch main controller B with main controller A. Turn on MC display selection switch, then YES switch the monitor display to main controller A. Check if code 04 is displayed when fault code is displayed.

Âˇ 24 V: With engine stopped Âˇ 28 V: With engine running

YES

Faulty main controller B.

Broken harness between main controller A and main controller B. (Refer to fault code 06) Faulty alternator.

T5-4-14

TROUBLESHOOTING / Troubleshooting A FAULT CODE 37 ABNORMAL MAIN CONTROLLER B RECEPTION (BETWEEN MAIN CONTROLLER B AND BUILT-IN DIAGNOSING SYSTEM)

Switch main controller B with main controller A. Turn on MC display selection switch, then switch the monitor display to main controller A. Check if code 07 is displayed

YES

Faulty main controller B.

Broken harness between main controller A and main controller B. (Refer to fault code 06)

T5-4-15

TROUBLESHOOTING / Troubleshooting A SENSOR ACTIVATING RANGE 1. Checking Method

• Hydraulic Oil Temperature: 50±5 °C • Unless specified: Engine Control Dial

Power Mode Switch

Auto-Idle Switch

S/P

OFF

Maximum Speed

• Monitor each sensor using the built-in diagnosing system. 2. Sensor Activating Range Sensor Engine Control Dial

Pressure Sensor

Operation Maximum Speed Minimum Speed Control Lever: Neutral Pilot Control Shut-Off Lever: LOCK Control Lever: Full Stroke Pilot Control Shut-Off Lever: UNLOCK

T5-4-16

Specification 0.3 to 1.0 V 4.0 to 4.7 V 0 to 0.10 MPa (0 to 1.0 kgf/cm2) 3.3 to 3.9 MPa (34 to 40 kgf/cm2)

TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE Apply troubleshooting B procedure when diagnosing from the fault phenomenon. On the front section pages of this group T5-5, there are tables indicating the relationship between machine trouble symptoms and related parts which may cause such trouble if failed. Start the troubleshooting with more probable causes selected by referring to these tables.

• How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

After checking or measuring item (1), select YES (OK) or NO (NOT OK) and proceed to item (2) or (3), as appropriate.

(1)

NO(NOT OK)

• · Key switch: ON

(3)

Special instructions, or reference item are indicated in the spaces under the box. Incorrect measuring or checking methods will render troubleshooting impossible, and may damage components as well.

•

Use the built-in diagnosing system for descriptions in the double-line box.

•

Causes are stated in the thick-line box. Scanning through the thick-line boxes, possible causes can be seen without going through the flow chart.

NOTE: All harness end connectors are seen from the open end side.

Harness

Harness End Connector Open End Side T158-05-03-001

T5-5-1

TROUBLESHOOTING / Troubleshooting B CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES This table indicates the relationship between machine troubles and parts contributing to the cause of the trouble if failed. Engine System Troubleshooting Trouble Symptom

E-1

E-2

Starter does not rotate even if key switch is turned to START position.

Although starter rotates, engine does not start.

z z

z z z z

Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Starter Motor Engine Unit Main Pump / Regulator Shuttle Valve

E-3 Even if engine control dial is rotated, engine speed remains unchanged.

z z

T5-5-2

E-4 Even if key switch is turned OFF, engine does not stop.

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

E-5 Engine speed is slow, or does not increase.

E-6 Quick-idle system is inoperable.

z z

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

E-7

E-8

E-9

Auto-idle system is inoperable.

Even if control lever is operated, speed does not increase (with auto-idle ON).

Engine speed does not increase when a particular function is operated (with auto-idle ON).

z z

z z z z

T5-5-3

TROUBLESHOOTING / Troubleshooting B

Trouble Symptom

E-10 Engine stalls.

Main Controller A ECM Monitor Controller Switch Box Pilot Pressure Sensor Quick-Idle Switch Auto-Idle Switch Battery Relay Starter Relay Starter Relay 1 Starter Relay 2 Flow Rate Decrease Solenoid Valve Relay Preheat Relay 1 Preheat Relay 2 Power Transistor 1 Power Transistor 2 Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Engine Speed Sensor 1 Pump 1 and 2 Control Valve (Signal Control Valve) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Starter Motor Engine Unit Main Pump / Regulator Shuttle Valve Air Heater (1) Air Heater (2)

E-11 Even if preheat switch is pressed, air heater does not operate (Engine is difficult to start).

z z

z z z z z z z z z

z z

T5-5-4

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-5

TROUBLESHOOTING / Troubleshooting B

All Actuator System Troubleshooting A-1 Trouble Symptom

All actuator speeds are slow.

A-2 All actuators are inoperable.

A-3

A-4

Actuator does not stop even if lever is returned to neutral.

SP mode is inoperable.

Parts Main Controller A Switch Box Flow Rate Decrease Solenoid Valve Power Decrease Solenoid Valve Power Increase Solenoid Valve Engine Speed Sensor 1 Spool Main Relief Valve Main Pump / Regulator Pilot Pump Pilot Valve Pilot Relief Valve Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side)

z z

z z z z

z z

z z z z

z z

T5-5-6

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

A-5 E mode is inoperable.

z z

T5-5-7

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B

Front Attachment System Troubleshooting Trouble Symptom

F-1

F-2

F-3

F-4

Some front attachment movement is slow, or is inoperable.

Front attachment drifts remarkably.

Front attachment moves slightly to the opposite direction against the lever operation (boom raise, arm roll-out (BH), arm retract (LD) or bucket close (LD)).

Boom raise is slow at combined arm roll-out (BH)/arm retract (LD) and boom raise operation.

Parts Main Controller A Main Controller B Heavy Lift Switch Boom Mode Selection Switch Flow Rate Decrease Solenoid Valve Relay Power Transistor 1 Heavy Lift Solenoid Valve Boom Mode Selection Solenoid Valve Flow Rate Decrease Solenoid Valve Spool Overload Relief Valve Load Check Valve Shuttle Valve Main Relief Valve Boom Overload Relief Change Valve Main Pump / Regulator Pilot Valve Cylinder Slow-Return Valve Shockless Valve (Signal Control Valve) Arm Flow Rate Control Valve (Signal Control Valve)

z z

z z z z z

Shuttle Valve (Boom Raising Priority) Arm Preference Valve Shuttle Valve (Pilot Selection) Pump 3 Control Valve Shuttle Valve (Pump 3 Control Valve Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side)

T5-5-8

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

F-5

F-6

F-7

F-8

Arm cylinder move unevenly at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation.

Single arm roll-in (BH)/arm extend (LD), bucket roll-in (BH)/ bucket tilt-in (LD) or boom raise operation is slow.

Heavy lift function does not operate.

Boom mode selection function does not operate.

z z z z z z z z z z

z z

z z z z z

T5-5-9

TROUBLESHOOTING / Troubleshooting B

Swing/Travel System Troubleshooting Trouble Symptom

S-1 Swing is unmoving, slow or weak in power.

S-2 Swing drift is large when stopping.

T-1 Both right and left tracks do not rotate or rotate slowly.

T-2 Fast travel is inoperable.

Parts Main Controller B Switch Box Travel Mode Control Solenoid Valve Main Pump / Regulator Spool Overload Relief Valve Load Check Valve Flow Combiner Valve Shuttle Valve (Swing Brake Release) Pump 3 Control Valve Reducing Valve Priority Valve (Signal Control Valve) Flow Combiner Valve Selection Spool (Signal Control Valve) Counterbalance Valve Pilot Valve Shuttle Valve (Pilot Selection) Shuttle Valve (Swing Make-Up) Shockless Valve (Pump 2 Regulator Pressure Pi Circuit Side) Swing Motor Swing Parking Brake Release Valve Swing Reduction Gear Swing Relief Valve Travel Parking Brake Travel Motor Travel Reduction Gear Travel Relief Valve Center Joint

z z z z z

z z

z z z z z z z z

T5-5-10

TROUBLESHOOTING / Troubleshooting B In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

T-3 Slow travel is inoperable.

T-4

T-5

T-6

One side track does not move, moves slowly or mistracks.

Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground.

Machine mistracks during combined travel and front attachment operation.

z z z z

z z

z z z

z z z z

T5-5-11

TROUBLESHOOTING / Troubleshooting B

Other System Troubleshooting Trouble Symptom

O-1

O-2

O-3

O-4

Auto-lubrication indicator comes ON. (Grease pump does not operate.) (Empty grease in pump)

Grease pump operates excessively slow.

Grease pump does not stop operating.

Oil cooler fan motor does not rotate at speed corresponding to hydraulic oil temperature or does not rotate at all.

Parts Main Controller A Main Controller B Auto-Lubrication Selection Switch Proximity Switch Step Light Switch Auto-Lubrication Relay Step Light Relay Power Transistor 3 Oil Cooler Fan Control Solenoid Valve Grease Pump Oil Cooler Fan Motor Drive Pump Oil Cooler Fan Motor Step Light Follow Plate

z z

z z z

z z z z z

T5-5-12

TROUBLESHOOTING / Troubleshooting B NOTE: The trouble symptoms in this table are described provided that each trouble occurs independently.

O-5 Step light does not come ON.

O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds.

O-7 Air conditioner.

T5-5-13

In case more than one trouble occurs at the same time, find out all faulty components while checking all suspected components in each trouble symptom.

TROUBLESHOOTING / Troubleshooting B ENGINE SYSTEM TROUBLESHOOTING E-1 Starter does not rotate even if key switch is turned to START position. This problem is contributed to by many different causes. Diagnose the power system and the relay system separately to locate the cause of the problem.

• The electrical system is diagnosed in this group. In case the starter does not rotate due to failure in the engine unit, refer to the engine service manual. • The same problem will be presented in case either the valve switch or the engine stop switch is activated. Check each switch condition first. • Check for loose harness connections beforehand. 0 V.

(2)

To Relay System Troubleshooting

(T5-5-16)

YES Check for voltage at starter motor terminal C. · Key switch: START Check if voltage at starter motor terminal B is 24 V or over.

24 V

Faulty starter unit, or faulty engine unit.

· Key switch: ON

(1)

To Power System Troubleshooting

(T5-5-15)

Terminal B

Terminal C

Terminal M

T18E-05-05-010

T5-5-14

TROUBLESHOOTING / Troubleshooting B (1) Power System Troubleshooting

Faulty battery reYES lay, or faulty ground wire from battery relay terminal E. Check if voltage at YES battery relay terminal S is 24 V or over. NO Check if voltage at Certain starter battery relay terindicates 0 V minal B connected to corresponding starter is 24 V or over. Âˇ Key switch: ON

(1)

Âˇ Key switch: ON

Check if voltage at battery relay terminal A is 24 V or over.

Broken harness between battery relay terminal S and fuse #10. Broken harness between battery relay terminal A and battery. Broken harness between battery relay terminal B and starter terminal B.

YES

Blown fuse #10, or broken harness between key switch terminal M and battery relay terminal S.

All starters indicate 0 V

Connector Battery Relay

T146-05-04-018

T5-5-15

TROUBLESHOOTING / Troubleshooting B (2) Relay System Troubleshooting

Check if voltage YES at starter relay 1 and 2 terminal S is beyond 24V.

Disconnect starter relay 1 and 2 terYES minal E. Check for continuity between harness end terminal E and vehicle frame.

Broken harness YES between starter relay 1 and starter YES Check for continumotor 1 or starter ity between terrelay 2 and starter minal B and C. motor 2.

Faulty starter relay 1 or 2 ground.

Check if voltage at starter relay connector terminal #1 is beyond 24V. Âˇ Key switch: START

Check if voltage at starter relay 1 and 2 NO output side is beyond 24V.

Faulty starter relay 1 or 2.

Broken harness YES Remove starter between starter relay and starter relay 1 and 2 terrelay 1 or 2. minal #2. Check for continuity between terminal #2 YES Faulty starter relay. and vehicle frame. NO Faulty ground of starter relay termiNO nal #2.

Blown fuse of fuse box 2 terminal #19, or broken harness between key switch terminal G2 and starter relay connector terminal #1.

Connector Starter Relay 1

Starter Relay 2

Starter Relay 1

Starter Relay 2

T18E-05-05-002 T146-05-04-009

T18E-05-05-004 T18E-05-05-003

T5-5-16

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-17

TROUBLESHOOTING / Troubleshooting B E-2 Although starter rotates, engine does not start.

YES YES

YES

Check if air is bled from fuel pipe of engine.

Remove connector 31 poles. Check if voltage at harness end connector terminal #1 is 24V.

· Key switch: ON

YES Check if voltage at input side of fuse NO box 2 terminal #3 is 24V. · Key switch: ON

Remove ECM connector 21 poles. Check if voltage at harness end connector terminals #G and #D is 24V respectively.

· Key switch: OFF

Bleed air from coupling of engine injection pump. Blown fuse of fuse box terminal #3, or broken harness between fuse box and ECM. Broken harness between fuse box and key switch terminal M.

Blown fuse terminal #1, or broken harness between fuse box 2 terminal #2 and ECM.

YES

Faulty engine. (Refer to the Engine Manual)

Check if voltage at fuse box terminal #2 is 24V.

Broken harness between fuse box and key switch terminal M.

Connector ECM Connector 21 Poles

ECM Connector 31 Poles #G

T18E-05-05-005

T5-5-18

T18E-05-04-004

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-19

TROUBLESHOOTING /Troubleshooting B E-3 Even if engine control dial is rotated, engine speed remains unchanged.

â&#x20AC;˘ The engine control dial, ECM and/or harness may have trouble. In those cases, fault code 10 is displayed on the built-in diagnosing system. Refer to Troubleshooting A.

T5-5-20

TROUBLESHOOTING /Troubleshooting B E-4 Even if key switch is turned OFF, engine does not stop.

• The key switch may be faulty. • If the above are not the cause, the engine unit may have trouble.

T5-5-21

TROUBLESHOOTING /Troubleshooting B E-5 Engine speed is slow, or does not increase.

• The engine control dial system of the switch box and/or ECM system may have trouble.

• Check for loose harness connections beforehand.

YES

Disconnect switch box. Check if voltage between harness end connector terminal #2 and terminal #4 matches specification. · Key switch: ON · Specification: 5±0.5 V

Check if resistance between switch box terminals #2 and #4 is normal. Insert probe in switch box connector rear terminals #2 and #3. Check if voltage at those terminals matches specification.

Check if voltage between switch box harness end connector terminal #4 and vehicle frame matches specification. · Key switch: ON · Specification: 5±0.5 V

· Resistance specification: 5±0.5 kΩ · Voltage specification: 0.3 to 1 V

(at maximum speed)

Connect switch box harness end connector terminal #3 and vehicle frame. Disconnect EMC connector 31 poles. Check for continuity between ECM harness end connector terminal #5 and vehicle frame.

Faulty engine control dial.

T5-5-22

TROUBLESHOOTING /Troubleshooting B

YES

Faulty ECM system.

Broken harness between switch box and ECM (sensor system). YES

Faulty ECM system.

Broken harness between switch box and ECM (ground system).

Disconnect ECM connector 31 poles. YES Check for continuity between EMC connector 31 poles terminal #6 and switch box harness end connector terminal #2.

Broken harness between switch box and ECM (power system).

Connector (Harness End Connector Viewed from the Open End Side) Switch Box

ECM Connector 31 Poles

T183-05-04-004

T18E-05-04-004

T5-5-23

TROUBLESHOOTING /Troubleshooting B E-6 Quick-idle system is inoperable.

• Check for loose harness connections beforehand. NOTE: When the auto-idle switch is turned ON, the quick-idle system operates after 3 seconds.

YES

Faulty quick-idle switch.

Disconnect quick-idle switch. Connect harness end connector terminals with a clip. Check if quick-idle system is operated. · Engine: Running · Control lever: Neutral

Disconnect monitor controller connector YES C. Check for continuity between monitor controller terminal #C3

Disconnect monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B11 and quick-idle switch end terminal.

Connector C

T183-05-04-014

B11 T183-05-04-013

T5-5-24

Faulty monitor controller. Broken harness between monitor controller and quick-idle switch.

Connector Monitor Controller Connector B

Disconnect ECM connector 31 poles. Check for continuity YES between monitor controller connector terminal #C3 and ECM connector 31 poles harness end terminal #19.

TROUBLESHOOTING /Troubleshooting B

Broken harness between ECM and monitor controller.

Faulty ECM. YES

ECM Connector 31 Poles

T18E-05-04-004

T5-5-25

TROUBLESHOOTING /Troubleshooting B E-7 Auto-idle system is inoperable.

• The auto-idle system will stop if one of pressure switches is turned ON.

• Check for loose harness connections beforehand.

Disconnect harness from switch box. Check for continuity between switch box connector terminal #8 and vehicle

Connect connector. Disconnect main controller A conYES nector B. Check for continuity between harness end connector terminal #B16 and vehicle frame.

· Key switch: START · Auto-idle switch: ON · Control lever: Neutral

Connect connector. Disconnect main controller A conYES nector A. Check for continuity between main controller terminal #A29 and vehicle frame.

Disconnect ECM YES Faulty ECM. connector 31 poles. Connect main controller conYES nector A terminal #A29 to vehicle frame. Check for continuity between ECM connector 31 Broken harness poles terminal #20 between main conand vehicle frame. NO troller and ECM.

Faulty main controller A.

Broken harness between main controller A and switch box.

Faulty switch box. NO

Connector Main Controller A Connector A

ECM Connector 31 Poles

B16 Connector B

#20

Switch Box

T183-05-04-004

A29

T183-05-04-005

T18E-05-04-004

T5-5-26

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-27

TROUBLESHOOTING /Troubleshooting B E-8 Even if control lever is operated, speed does not increase. (with auto-idle ON)

â&#x20AC;˘ The pilot sensor (front attachment), main controller A and/or harness may have trouble. In either cases, fault code 08 is displayed on the built-in diagnosing system. Refer to Troubleshooting A.

T5-5-28

TROUBLESHOOTING /Troubleshooting B E-9 Engine speed does not increase when a particular function is operated (with auto-idle ON)

Faulty shuttle valve.

Speed does not increase only at certain operation.

T5-5-29

TROUBLESHOOTING /Troubleshooting B E-10 Engine stalls. Install pressure gauge on hose entering flow YES rate decrease solenoid valve input port. Measure the pressure.

• The cause differs according to the engine speed. • If power decrease solenoid valve (SA) has a trouble, the swing speed does not change at E mode.

• The engine speed sensor 1 and/or main controller A may have trouble. In either cases, fault code 05 is displayed on the built-in diagnosing system. Refer to Troubleshooting A. • Check for loose harness connections beforehand. Disconnect lines from flow rate decrease solenoid valve. Check if engine stalls when disconnected lines are connected each other directly.

YES Check if output to flow rate decrease solenoid valve is normal.

Around 850 min-1

Check engine speed.

· Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump flow rate NO cut-off output Disconnect lines from power decrease solenoid valve (SA, SB). Check if YES engine stalls when disconCheck if outnected lines are connected put to flow each other directly. rate decrease solenoid valve is normal.

Below 1400 min-1

Over 1400 min-1

· Built-in diagnosing system: Main controller A Monitor item: Proportional NO valve ON/OFF output: bit 6: #1, 2 pump power decrease solenoid valve output

NOTE: All regulators are unlikely to become inoperable at the same time. Disconnect and check lines from one solenoid valve, then check the other.

Disconnect flow rate decrease solenoid valve. Connect harness end connector terminals with a clip. Check for continuity between harness end connector terminals.

Faulty main controller. YES Disconnect power decrease solenoid valve (SA, SB). Connect harness end connector terminals with a clip. Disconnect main controller A connector A. NO Check for continuity between harness end connector terminals #A19 and #A20 (SB), and terminals #A11 and #A14 (SA). Faulty main controller A.

Faulty engine and fuel system.

Connector Main Controller A Connector A

A19

A20

Connector D

Flow Rate Decrease Solenoid Valve

Power Transistor 1

T183-05-04-011

A14

T183-05-04-010

T183-05-04-008 T183-05-04-009

D14

T5-5-30

TROUBLESHOOTING /Troubleshooting B Faulty pump 1 and/or 2 flow rate control valve in signal control valve.

Less than 3.9 MPa (40Âą1 kgf/cm2)

Faulty shuttle valve (swing make-up), shockless valve or regulator.

3.9 MPa (40Âą1 kgf/cm ) or over NO Check if voltage at YES flow rate decrease solenoid valve relay connector terminal #5 i 24 V

Faulty flow rate decrease solenoid valve. NO

Check if voltage at flow rate decrease solenoid valve relay connector terYES minals #1 and #3 are 24 V.

Blown fuse #14.

NO Check if voltage at flow rate decrease solenoid valve relay YES connector terminal #2 is 24 V.

YES

Faulty flow rate decrease solenoid valve relay, or broken harness between flow rate decrease solenoid valve relay and power transistor 1.

(1) Broken harness between flow rate decrease solenoid valve and flow rate decrease solenoid valve relay. Faulty regulator.

Broken harness between power decrease solenoid valve (SA, SB) and main controller A.

Faulty power decrease solenoid valve.

YES

Flow Rate Decrease Solenoid Valve

Input Port

Flow Rate Decrease Solenoid Valve Relay

Power Decrease Solenoid Valve

T183-05-04-010

T183-05-04-003 T183-05-04-012

T5-5-31

Engine Speed Sensor 1

T146-05-03-006

TROUBLESHOOTING /Troubleshooting B

(1)

YES

Faulty power transistor 1.

Broken harness between power transistor 1 and main controller A.

Check if engine stalls after switching power transistor 1 with power transistor 2 or power transistor 3.

T5-5-32

TROUBLESHOOTING /Troubleshooting B (Blank)

T5-5-33

TROUBLESHOOTING /Troubleshooting B E-11 Preheat does not operate. (Engine is difficult to start)

• This troubleshooting should be applied only when

• If preheat operates again after the preheat opera-

the air heater in the engine does not operate. In case the preheat indicator only does not light, refer to Troubleshooting C. • Preheat operates when temperature of engine suction becomes below 0 °C (32 °F).

tion, turn the key switch OFF and after 5 minutes try to operate preheat. (Preheat does not operate within 5 minutes.) • Preheat stops automatically after 30 seconds with preheat operated.

YES

Disconnect preheat signal relay connector. Check if voltage at preheat signal relay terminal #1 is 24V. · Key switch: ON

Disconnect connector from preheat signal relay terminal #2. YES Check for continuity between harness end connector terminal #2 and vehicle frame.

Check voltage at preheat signal relay terminal #5 is 24V.

YES Faulty preheat signal relay. Check if voltage at preheat signal NO relay terminal #3 is 24V. NO

Broken harness between ECM terminal #1 and preheat signal relay terminal #1.

YES Disconnect ECM connector 2 poles. Check voltage at NO ECM end connector terminal #1 is 24V.

Broken harness between battery and preheat signal relay, or broken fusible link 4. Faulty preheat signal relay terminal #2 ground.

Faulty ECM.

Conector Preheat Signal Relay

(A)

ECM

5 T146-05-04-009

T18E-05-05-002

M T183-05-04-102

1 To ECM 2 To GND T183-05-04-102

T5-5-34

TROUBLESHOOTING /Troubleshooting B YES Check voltage at YES preheat relay terminal M is 24V. Check voltage at YES preheat relay terminal B is 24V. Check for contiYES nuity between preheat relay terminal #2 and vehicle frame. (A)

Check voltage at preheat relay terminal #1 is 24V.

Faulty preheat relay. Broken harness between battery and preheat relay terminal #2, or broken fusible links 7, 8.

Faulty preheat relay terminal #2 ground.

Broken harness between preheat relay terminal #1 and preheat signal relay terminal #5.

YES

(B)

Faulty air heater.

Check for continuity between preheat relay and air heater.

Broken harness between preheat relay and air heater.

T5-5-35

TROUBLESHOOTING / Troubleshooting B ALL ACTUATOR SHOOTING

SYSTEM

TROUBLE-

A-1 All actuator speeds are slow.

• Although speed is satisfactory, in case power is weak, the faulty main relief valve is suspected.

• If the flow rate decrease solenoid valve is bound

•

• • •

in OFF position, the main pump 1, 2 control pressure Pi decreases, so that the main pump 1, 2 delivery volume decreases. If the power decrease solenoid valve is bound in ON position, pilot pressure PG is supplied to the regulator, so that the pump delivery volume decreases. If the engine speed is slow (refer to E-5) or SP mode is inoperable (refer to A-4), faulty pilot system (refer to A-2) is suspected. Faulty engine is suspected when engine speed decreases remarkably after applying a load. Check for loose harness connections beforehand.

YES

YES Check if output to flow rate decrease solenoid valve is normal. Check if power is sufficient.

Disconnect flow rate deYES crease solenoid valve and reconnect line directly. Check if delivery volume from main pump 1, 2 decreases.

Check if output to YES flow rate decrease solenoid valve is normal. · Built-in diagnosing system: Main controller A Monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 pump NO power decrease solenoid valve output Faulty main controller NO

· Built-in diagnosing system: Main controller A Monitor item: Digital output: bit 5: Pump cut-off output NO

Faulty main controller A.

Faulty main relief valve.

T5-5-36

TROUBLESHOOTING / Troubleshooting B Output Port To Main Pump 2 Regulator Port Pi Shuttle Valve (Swing Make-Up) Power Decrease Solenoid Valve SB Power Decrease Solenoid Valve SA

Machine Front Side

Flow Rate Decrease Solenoid Valve

T183-05-04-026

Shockless Valve

T183-05-04-015

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES Disconnect power decrease solenoid valve (SA, SB) output port. Place a plug on port. Disconnected line is left open to atmosphere. Check if symptom appears.

YES Check if fault code 05 is displayed.

Faulty main pump or regulator.

· Mistracks to right: Pump 1 · Mistracks to left: Pump 2 · Swing is slow: Pump 3 Bound power decrease solenoid valve (SA or SB).

NO YES Only main pump 2 output volume decreases. NO

T5-5-37

Faulty shuttle valve (swing make-up) and/or shockless valve. Bound flow rate decrease solenoid valve.

TROUBLESHOOTING / Troubleshooting B A-2 All actuators are inoperable.

• It is unrealistic that all pumps break down at the same time. Faulty pilot system is suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES

YES Check if primary pilot pressure is normal. · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST ti Check if pilot control shut-off lever is released.

YES Faulty pilot pump, or clogged pilot filter. Check if symptom appears after adjusting, disassembling NO and cleaning pilot relief valve.

End

Release pilot control shut-off lever.

T5-5-38

TROUBLESHOOTING / Troubleshooting B A-3 Actuator does not stop even if lever is returned to neutral.

• Bound spool in the pilot valve or bound spool in the control valve is suspected.

YES

Faulty pilot valve. · When control lever is returned to neutral, pilot pressure is routed to spool end in control valve.

Check if actuator stops when pilot control shut-off lever is raised.

Faulty control valve. NO

· Although pilot pressure is not routed to spool end in control valve, spool is kept opened due to binding of spool.

T5-5-39

TROUBLESHOOTING / Troubleshooting B A-4 SP mode is inoperable.

• Faulty power increase solenoid valve ST and engine speed sensor 1 are suspected.

• Check for loose harness connections beforehand.

Find out cause of trouble by tracing other trouble symptoms.

YES Check if swing, travel right YES and travel left single operation speed changes when SP mode switch is turned ON and OFF.

Faulty regulator or main pump.

· Swing ········Main pump 3 · Travel Right ····Main pump 2 · Travel Left·······Main pump 1

Disconnect line from power increase solenoid valve ST output port, then install pressure gauge. Check if output pressure changes in range of 0 to 3.7 MPa (0 to 38 kgf/cm2).

Check if current at power increase solenoid valve ST changes in range of 255 to 416 mA.

· SP mode switch: ON · Turn engine control dial to change engine speed, then observe pilot pressure change.

· Built-in diagnosing system: Main controller A: Monitor item: Power increase output current · Turn engine control dial to change engine speed.

Check if faulty code 05 is displayed on built-in NO diagnosing system.

Faulty engine speed sensor 1 system (refer to Troubleshooting A).

YES

Output Port

Power Increase Solenoid Valve ST

Connector Main Controller A Connector A A3

T183-05-04-016 T183-05-04-008

T5-5-40

TROUBLESHOOTING / Troubleshooting B

Faulty power increase solenoid valve ST.

YES

Connect line to engine speed sensor 1. Disconnect plug receptacle from power increase solenoid valve ST. Connect both disconnected harness end plug receptacles. Check for continuity between main controller A connector A harness end terminals #A4 and #A3.

Broken harness between power increase solenoid valve and main controller A.

YES Disconnect switch box. Check for continuity between switch box end conYES nector terminals #6 and #15. Âˇ SP mode switch: ON NO

Connector Switch Box

T183-05-04-004

T5-5-41

Faulty main controller A, or broken harness between switch box and main controller A.

Faulty switch box, or broken harness between monitor controller and switch box.

TROUBLESHOOTING / Troubleshooting B A-5 E mode is inoperable.

• In case main controller, power decrease solenoid valve or regulator of main pump 3 is inoperable, engine may stall below 1400 min-1 even if E mode switch is turned OFF. • Check for loose harness connections beforehand.

Faulty main controller A.

YES

Check if E mode switch is normal. · E mode switch: ON · Built-in diagnosing system: Main controller A: Monitor item: Digital input: bit 3: E mode SW

Check if output to power decrease solenoid valve is normal. · E mode switch: ON · Built-in diagnosing system: Main controller A monitor item: Proportional valve ON/OFF output: bit 6: #1, 2 Pump power decrease solenoid valve output

Disconnect power decrease solenoid valve (SA). Connect harness end connector terminals #1 and #2 with a clip. Disconnect main controlYES ler connector A. Check for continuity between terminals #A11 and #A14.

Broken harness beNO tween power decrease solenoid valve SA and main controller A.

YES YES

Disconnect main controller A connector B. Check for continuity between harness end conNO nector terminal #B2 and switch box harness end connector terminal #7.

Broken harness between switch box and NO main controller A.

Connector Main Controller A Connector A

A14

Connector B

Faulty switch box dial.

Power Decrease Solenoid Valve

T183-05-04-005

T5-5-42

T183-05-04-010

TROUBLESHOOTING / Troubleshooting B

YES Disconnect power decrease solenoid valve (SA) from line, then connect disconnected line directly. Check if each operation speed increases.

Faulty power decrease solenoid valve (SA).

Faulty main pump 3, or regulator of main pump 3.

Output Port

Power Decrease Solenoid Valve (SA)

Input Port

T18E-05-05-001

T5-5-43

TROUBLESHOOTING / Troubleshooting B FRONT ATTACHMENT SYSTEM TROUBLESHOOTING F-1 Some front attachment movement is slow, or is inoperable.

• If the other operations (travel/swing) are normal, the pilot pump (primary pilot pressure) is considered to be normal.

YES Faulty corresponding cylinder. YES Check for internal oil leakage in corresponding cylinder. Bound corresponding NO control valve spool.

YES Check if corresponding secondary pilot pressure is normal.

Check if corresponding secondary pilot pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Front operation pressure

· Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. · Built-in diagnosing system: Main controller A Monitor item: Main pump 1

NO YES

Faulty corresponding overload relief valve. Bound shockless valve spool in signal control valve (at boom raise only).

Check if secondary NO pressure at signal control valve inlet is normal. NO

T5-5-44

Faulty pilot valve.

TROUBLESHOOTING / Troubleshooting B F-2 Front attachment drifts remarkably.

YES

Faulty pilot valve.

YES Faulty corresponding cylinder. Check if cylinder drift is reduced when pilot shut-off valve is closed.

YES Check if oil leaks in corresponding cylinder.

Faulty corresponding control valve (broken spring, loose spool NO end).

Check if corresponding overload relief valve is NO normal. Âˇ Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. NO

Faulty corresponding overload relief valve.

â&#x20AC;˘ Boom Cylinder Internal Leakage Check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tips onto the ground. 2. Disconnect hoses from the boom cylinder rod side. Drain oil from the hoses and cylinders. (Plug the disconnected hose ends.) T105-07-04-009

3. Retract the arm cylinder to lift the bucket off the ground. If oil flows out of the hose disconnected pipe ends and the boom cylinders are retracted at this time, oil leaks in the boom cylinders. In case no oil flows out of the hose disconnected pipe ends but the boom cylinders are retracted, oil leaks in the control valve.

T5-5-45

TROUBLESHOOTING / Troubleshooting B F-3 Front attachment moves slightly to the opposite direction against the lever operation (boom raise, arm roll-out (BH), arm retract (LD) or bucket close (LD). NOTE: BH: Backhoe LD: Loading Shovel

YES

Check if corresponding load check valve in control valve is normal. Âˇ Disassemble / Visual Inspection

Check if slow-return valve of corresponding cylinder is normal.

Oil leaks in cylinder.

Âˇ Disassemble / Visual Inspection

Faulty load check valve.

Faulty corresponding slow-return valve.

NOTE: 1. During the initial stage of operation, oil pressure and flow rate from the pump is low. Therefore, if the load check valve or slow-return valve is malfunctioning, the oil in the bottom side of the cylinder flows back into the circuit, causing the cylinder rod to temporarily moves to the other direction from the lever operation direction. 2. Since oil pressure and flow rate from the pump is low, if oil leaks from between bottom side (B) and rod side (A) due to faulty cylinder piston ring or cylinder barrel, the cylinder rod is temporary lowered during the initial stage of operation by the load. In addition, cylinder force is reduced, increasing the front attachment drift in this case.

T5-5-46

When the load check valve is faulty:

When the slow return valve is faulty: T141-05-04-001

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-47

TROUBLESHOOTING / Troubleshooting B F-4 Boom raise is slow at combined arm roll-out (BH)/arm retract (LD) and boom raise operation. NOTE: BH: BH: Backhoe LD: Loading Shovel

â&#x20AC;˘ The arm flow rate control valve in the signal control valve is switched at combined boom raise and arm roll-out (BH)/arm retract (LD) operation, so that pilot pressure is applied on both sides of the arm 2 spool. Therefore, the arm 2 spool becomes neutral.

Check if shuttle valve YES (preferential boom raising) is bound or scored. Check if arm 2 spool YES neutral pressure at signal control valve outlet port SE is normal.

YES Check if boom 1 spool selection pressure at signal control valve outlet port #1 is normal.

Check if secondary pressures at signal control valve inlet ports D, A and F are normal.

Bound arm flow rate control valve spool in signal control valve, or faulty shuttle valve.

Bound shockless valve spool in signal control valve.

Faulty pilot valve. NO

Signal Control Valve

Pilot Valve Connecting Side

Control Valve Connecting Side

Port A Port #1

Port D

Port SE

Port F

Control Valve Side

Pilot Valve Side

T178-03-06-016

T5-5-48

T178-03-06-015

TROUBLESHOOTING / Troubleshooting B

Clean or replace shuttle valve (preferential boom raising).

YES

Bound arm 2 spool. NO

T5-5-49

TROUBLESHOOTING / Troubleshooting B F-5 Arm cylinder moves unevenly at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation. NOTE: BH: Backhoe LD: Loading Shovel

â&#x20AC;˘ The arm preference valve is switched at combined arm roll-out (BH)/arm retract (LD) and bucket roll-in (BH)/bucket tilt-in (LD), boom raise or swing operation, so that the pilot pressure to the arm 3 is blocked. Therefore, the arm 3 spool does not move.

Clean or replace arm preference valve.

YES

Check if arm preference valve spool is bound or scored.

YES

Clean or replace shuttle valve (pilot selection).

Check if shuttle valve (pilot selection) is bound or scored.

T5-5-50

Bound swing control valve arm 3 spool.

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-51

TROUBLESHOOTING / Troubleshooting B F-6 Single arm roll-in (BH)/arm extend (LD), bucket roll-in (BH)/bucket tilt-in (LD) or boom raise operation is slow. NOTE: BH: Backhoe LD: Loading Shovel

â&#x20AC;˘ The pump 3 control valve is switched at single arm roll-in/arm extend (LD), bucket roll-in (BH)/bucket tilt-in or boom raise operation, so that pressure oil from the pilot circuit is applied directly to the main pump 3 regulator as flow rate decrease pressure Pi. Therefore, the delivery volume of the main pump 3 increases. (Refer to the pages for the Pilot Circuit and Main Pump 3 Flow Rate Control Circuit in the Hydraulic System group in the SYSTEM section in the Technical Manual (Operational Principle))

Faulty main pump 3 or regulator (main pump 3).

Check if single bucket NO roll-in (BH)/bucket tilt-in (LD) or boom raise operation is slow. Check if shuttle valve (pilot selection) is bound YES or scored.

NO Check if shuttle valve (pump 3 control valve selection) is bound or scored.

YES Check if pump 3 control valve is bound or scored.

Clean or replace shuttle valve (pump 3 control valve selection).

Clean or replace pump 3 control valve.

YES

T5-5-52

TROUBLESHOOTING / Troubleshooting B

YES

Clean or replace shuttle valve (pilot selection).

Faulty pilot valve. NO

T5-5-53

TROUBLESHOOTING / Troubleshooting B F-7 Heavy lift function does not operate.

• If the flow rate does not decrease at heavy lift operation, faulty flow rate decrease solenoid valve system is suspected. Refer to Troubleshooting "E-10 Engine stalls" - "around 850 min-1." • Check for loose harness connections beforehand.

Check if front operation speed is slow after switching heavy lift switch with boom mode selection switch. · Heavy lift switch: ON

Check if front attachment operation speed is slower than normal.

Faulty heavy lift switch.

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift YES switch harness end connector terminal #3 and connector B terminal #B11.

Broken harness between heavy lift switch and main controller A.

Faulty main controller YES A.

· Heavy lift switch: ON

YES

Disconnect heavy lift switch and main controller A connector B. Check for continuity between heavy lift switch harness end connector terminal #3 and connector B harness end connector terminal #B11.

Heavy Lift Solenoid Valve (Upper Side) Output Port

Broken harness between heavy lift switch and main controller A.

Disconnect main controller A connector A and heavy lift solenoid valve. Connect heavy lift solenoid valve harness YES end connector terminal with a clip. Check for continuity between connector A harness end connector terminals #6 and #7.

YES

T183-05-04-017

Connector Heavy Lift Switch

Main Controller A Connector A

Connector B

B11 T183-05-04-101

T5-5-54

T183-05-04-005

Broken harness between main controller A and heavy lift solenoid valve.

Disconnect line from heavy lift solenoid valve output port, then install pressure gauge NO on the port. Check if main control valve main relief selection pressure is 3.9 MPa (40 kgf/cm2).

TROUBLESHOOTING / Troubleshooting B

YES

Faulty shuttle valve in main control valve, or faulty main relief valve.

Faulty heavy lift solenoid valve, or faulty main controller A.

T5-5-55

TROUBLSHOOTING / Troubleshooting B F-8 Boom mode selection function does not operate.

• Check for loose harness connections beforehand. Connect main controller B connector B. Disconnect connector A and boom mode selection solenoid valve SC. Connect boom mode selection solenoid valve SC harness end connector terminals #1 and #2 with a clip. Check for continuity between harness end connector A terminals #A4 and #A3.

YES

Check if output to boom mode selection solenoid valve is normal. · Boom mode selection switch: ON · Built-in diagnosing system: Main controller B Monitor item: Proportional valve ON/OFF output: bit 7: Boom mode selection solenoid valve output

Interchange boom mode selection switch with heavy lift switch and check if system operates properly. · Boom mode selection switch: ON

Disconnect boom mode selection switch and main controller B connector B. Check for continuity NO between boom mode selection switch harness end connector terminal #3 and connector B harness end connector terminal #B12.

YES

Connector Boom Mode Selection Switch

Main Controller B Connector A A3

Connector B

B12

Boom Mode Selection Solenoid Valve SC

T183-05-04-010 T183-05-04-005 T183-05-04-101

T5-5-56

TROUBLSHOOTING / Troubleshooting B

Broken harness between main controller B and boom mode selection solenoid valve SC.

Connect main controller B connector A and boom mode selection YES solenoid valve SC. Install tee and pressure gauge at boom mode selection solenoid valve SC output port. Check if pressure is 3.9 MPa (40 kgf/cm2). Âˇ Boom mode selection switch: ON

Faulty boom mode selection solenoid valve SC.

Faulty overload relief change valve in main control valve, or faulty overload relief valve.

YES

Faulty main controller B.

Broken harness between boom mode selection switch and main controller B. Faulty boom mode selection switch. Output Port

Boom Mode Selection Solenoid Valve SC Front

T183-05-04-015

T5-5-57

TROUBLSHOOTING / Troubleshooting B SWING SYSTEM TROUBLESHOOTING S-1 Swing is unmoving, slow or weak in power.

• Check whether the pilot system is faulty or the main circuit is faulty.

• In case other functions (front attachment and travel) operate normally, the pilot pump is considered to be normal. If the pilot system is displaying a problem, the cause of the trouble may exist in the circuit after the pilot valve. • The brake chatter is heard if a problem exists in the swing parking brake system.

Check if swing YES motor relief pressure is normal.

Check if secondary pilot pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure

· Built-in diagnosing system: Main controller A Monitor item: Main pump pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Faulty swing control valve spool.

Check if shuttle valve NO (swing brake release) is bound or scored.

Check if single YES boom, bucket, arm and swing operations are slower than specification.

Install tee and pressure gauge at main pump 3 port Pi. Check if swing YES pump control pressure varies smoothly, and pump control pressure becomes 0 MPa (0 kgf/cm2) with swing lever in full stroke.

· Specification: Refer to the OPERATIONAL PERFORMANCE TEST section. YES

Check if shuttle valve (pilot selection) or shuttle valve (pump 3 control valve selection) is bound or scored.

NO Clean or replace shuttle valve (pilot selection). NO

Check if shuttle valve (pilot selection) is bound or scored.

Faulty swing control YES valve. Faulty pilot valve.

Port Pi

T183-01-02-006

T5-5-58

TROUBLSHOOTING / Troubleshooting B

YES

Faulty shuttle valve (swing brake release).

Faulty swing parking brake release valve.

YES Check if swing parking brake release valve is NO bound or scored.

Faulty swing motor.

Âˇ When brake shows a trouble after disassembling, also check brake release pressure selection valve. Clean or replace shuttle valve (pilot valve selection) or shuttle valve (pump 3 control valve selection).

YES

Clean or replace shuttle valve (swing make-up).

YES NO Check if shuttle valve (swing make-up) is bound or scored. Check if main NO pump 2 delivery pressure is normal. Âˇ Built-in diagnosing system: Main controller A Monitor item: Main pump 2 pressure

YES

Faulty shockless valve.

Faulty main pump 2 or regulator (main pump 2).

Check if shockless valve plunger is NO bound.

YES Check if pump 3 conYES trol valve is bound. NO

T5-5-59

Faulty pump 3 control valve. Faulty main pump 3 or regulator (main pump 3).

TROUBLSHOOTING / Troubleshooting B S-2 Swing drift is large when stopping

• In case the upperstructure drifts and shakes, valve related parts may be faulty. In case the upperstructure drifts smoothly, spool related parts may be faulty.

Check if secondary pilot pressure is 0 2 YES MPa (0 kgf/cm ) when swing lever is in neutral.

Check if swing relief pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Main pump 3 pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

· Built-in diagnosing system: Main controller A Monitor item: Front attachment operation pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section. Check if symptom appears after switching swing overload relief valve in swing control NO valve with other overload relief valve except boom mode selection in main control valve.

YES Check if swing control valve swing spool operates normally. · Disassemble / Visual inspection

Check if shuttle valve (pilot selection) is NO bound or scored.

YES Faulty swing spool (replace spool or swing control valve).

Faulty swing motor or NO reduction gear box. YES Clean or replace shuttle valve (pilot selection).

YES

T5-5-60

Faulty pilot valve.

Faulty swing relief valve

Faulty swing overload relief valve.

TROUBLSHOOTING / Troubleshooting B TRAVEL SYSTEM TROUBLESHOOTING T-1 Both right and left tracks do not rotate or rotate slowly.

• Both right and left pilot valves, travel motors, and/or control valve spools are unlikely to be faulty at the same time. • In case both travel systems do not operate, the pilot system, which is applied to both side travel motors, may be faulty. If the primary pilot pressure is lower than specification, not only travel but also all operations are affected. As this section describes the troubleshooting of faulty both left and right tracks, refer to T-4 for the trouble on only one track.

Faulty travel parking brake.

YES Install tee to line of travel parking brake release pressure port, then install pressure gauge. Check if travel parking brake release pressure is normal. · Specification: 1.8 MPa (18 kgf/cm2) or over. · Measure pressure in jacking up either side of track.

YES

Faulty shuttle valve (swing brake release).

Check if shuttle valve (swing brake release) is NO faulty. Faulty reducing valve. NO

Brake Release Pressure Port

T183-05-04-100

T5-5-61

TROUBLSHOOTING / Troubleshooting B T-2 Fast travel is inoperable.

• If the other solenoid valves are also not activating, check the fuse.

• Check for loose harness connections beforehand. Disconnect line from reducing 3.9 MPa valve output port, (40 kgf/cm2) then install pressure gauge on the port. Disconnect line from travel mode control solenoid valve output port, YES then install pressure gauge on the port. Measure reducing valve selection pressure. Check if output to travel mode control solenoid valve is normal.

· Travel mode switch: ON

Faulty reducing valve.

1.8 MPa (18 kgf/cm2)

Measure pressure.

Faulty travel motor switch selection mechanism.

3.9 MPa (40 kgf/cm )

· Travel mode switch: ON

Faulty travel mode control solenoid valve, or broken harness between travel mode control solenoid valve and main controller B.

0 MPa (0 kgf/cm2)

Disconnect switch box and main controller B connector B. Check for continuity between switch box harness end connector terminal #5 and connector B harness end connector terminal #B13.

· Travel mode switch: ON · Built-in diagnosing system: Main controller B Monitor item: Propor- NO tional valve ON/OFF output: bit 6: Travel mode control solenoid valve output

YES Faulty main controller B.

Faulty switch box, or broken harness between switch box and main controller B

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve Output Port

Main Controller B Connector B B13

Travel Mode Control Solenoid Valve

T183-05-04-021

T183-05-04-022

T183-05-04-020

Switch Box

Output Port T183-05-04-019

T183-05-04-004

T5-5-62

TROUBLSHOOTING / Troubleshooting B T-3 Slow travel is inoperable.

• Check for loose harness connections beforehand.

YES

Check if output to travel mode control solenoid valve is normal.

Disconnect main controller B connector B. Check for continuity between connector B harness end connector terminal #B13 and vehicle frame.

Faulty switch box, or short-circuited harness between switch box and main controller B.

Faulty main controller B. NO

3.9 MPa (40 kgf/cm2)

Disconnect line from · Travel mode travel mode control switch: ON solenoid valve output · Built-in diagnosing port, then install YES pressure gauge on system: Main controller B the port. Monitor item: ProMeasure reducing portional valve valve selection pres0 MPa ON/OFF output: sure. (0 kgf/cm2) bit 6: Travel mode · Travel mode control solenoid switch: OFF valve output

Faulty travel mode control solenoid valve.

1.8 MPa (18 kgf/cm2) Disconnect line from reducing valve output port, then install pressure gauge on the port. Measure pressure. · Travel mode switch: OFF

Faulty travel motor switch selection mechanism. Faulty reducing valve.

3.9 MPa (40 kgf/cm2)

Connector (Harness End Connector Viewed from the Open End Side) Travel Mode Control Solenoid Valve (Lower Side)

Reducing Valve (Travel Parking Brake)

Main Controller B Connector B

Output Port

T183-05-04-021

Output Port

T183-05-04-020

T183-05-04-019

T5-5-63

TROUBLSHOOTING / Troubleshooting B T-4 One side track does not move, moves slowly or mistracks.

• If only one side of the track does not move, the pilot valve, main control valve, travel motor or center joint may be faulty. • If travel left and bucket open/close (LD) are also slow, the main pump 1 or main pump 1 regulator may be faulty. • If travel right is slow and boom, arm and bucket are slightly slow, the main pump 2 or main pump 2 regulator may be faulty. NOTE: LD: Loading Shovel

Check if secondary travel pressure is normal. · Built-in diagnosing system: Main controller A Monitor item: Travel operation pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

YES Check if travel motor drain oil amount is normal.

Check if travel relief NO pressure of slow speed side is normal. · Built-in diagnosing system: Main controller A Monitor item: Main pump 1 pressure, main pump 2 pressure · Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Check if symptom is YES reversed when right and left travel line hoses are switched each other at the top of center joint.

YES

Faulty pilot valve.

External Oil Leak

Check if symptom is reversed after switching forward travel relief valve with reverse travel one, or right travel relief valve with left one.

Bound main control valve spool, or oil leak in main control valve.

Relationship between Faulty Seal Location and Mistrack Direction Seal When traveling When pivot turn is No. straight performed 1

· Measurement: Refer to the OPERATIONAL PERFORMANCE TEST section.

Seal Location

←

2 2

Left Travel (Forward)

4 Right Travel (Reverse)

Left Travel (Reverse)

6 7

Right Travel (Forward)

External Oil Leak

←

T5-5-64

W183-03-08-001

TROUBLSHOOTING / Troubleshooting B NO

Faulty travel motor. Âˇ When travel parking brake shows a trouble after disassembling, also check brake release pressure selection valve. YES Disassemble travel NO motor servo piston. Check for faulty parts.

Disassemble travel motor counterbalance valve. YES Check for faulty parts.

Faulty travel motor servo piston.

Faulty travel reduction gear. Faulty counterbalance valve.

YES

Faulty travel relief valve.

Faulty center joint.

Arrangement of Pipe Line 1

2 3

1 - Right Travel Reverse 2 - Left Travel Reverse 3 - Left Travel Forward

W142-03-03-002

Machine Front Side

T5-5-65

4 - Right Travel Forward 5 - Drain Hose 6 - Pilot Hose (Travel Mode Selection)

TROUBLSHOOTING / Troubleshooting B T-5 Travel motor runs excessively fast when combined left travel and front attachment operation is performed with left track off the ground.

â&#x20AC;˘ If the priority valve (travel motor overrun protection) in the signal control valve is stuck, the flow combiner valve switches without right travel operating. â&#x20AC;˘ Same phenomenon can be observed when the flow combiner valve is bound.

T5-5-66

TROUBLSHOOTING / Troubleshooting B T-6 Machine mistracks during combined travel and front attachment operation.

Faulty flow combiner valve.

YES

Check if flow combiner valve in main control valve is abnormal.

Faulty flow combiner valve selection spool in signal control valve.

YES

Disconnect hose (G) from signal control valve connecting to flow combiner valve, then install pressure gauge. Measure and check if selection pressure is approx. 3.9 MPa (40 kgf/cm2).

YES

Faulty load check valve in main control valve.

Find out cause of trouble by tracing other trouble symptoms.

Check if load check valve in main control valve is abnormal.

Signal Control Valve Control Valve Connecting Side

Control Valve Side

Hose (G) T183-05-04-025

T5-5-67

TROUBLSHOOTING / Troubleshooting B OTHER SYSTEM TROUBLESHOOTING 0-1 Auto-lubrication indicator comes ON. (Grease pump does not operate.) (Empty grease in pump)

• If the Auto-lubrication indicator light comes ON, damaged lubrication hose or clogged distribution valve is suspected. • If the auto-lubrication selection switch is faulty, the auto-lubrication indicator does not come ON. • Check for loose harness connections beforehand. • In case of manual lubrication, the auto-lubrication indicator always comes ON.

YES

Grease pump does not operate (both auto and manual).

Disconnect grease pump. Check if voltage at harness end connector terminal #1 is 24 V. · Key switch: ON · During grease pump operation

YES Faulty auto-lubrication relay. Connect disconnected connector. Check if grease pump operates after switching NO auto-lubrication relay and other general-purpose relay.

YES

Empty grease in pump.

Faulty grease pump.

Disconnect auto-lubrication relay. Check if voltage between NO harness end connector terminals #1 and #3 is 24 V. Reposition follow plate. · Disconnect grease pump air lubrication hose at quick coupler. · Screw in and position follow plate.

Check if grease still exists.

T5-5-68

Replace with new grease tin.

TROUBLSHOOTING / Troubleshooting B

NO Connect connector. Check if grease pump operates afYES ter switching power transistor 3 with power transistor 1 or power transistor 2.

Disconnect power transistor 3. Check if voltage at harness end connector terminal #5 is 24 V.

Disconnect main controller B connector A. Check for continuity YES between power transistor 3 harness end connector terminal #2 and connector A harness end terminal #A26.

YES

Faulty main controller B. Broken harness between main controller B and power transistor 3. Blown fuse #14, or broken harness between power transistor 3 and fuse #14.

Faulty power transistor 3.

YES

Blown fuse #14, or broken harness between auto-lubrication relay and fuse #14.

Connector Auto-Lubrication Relay

Power Transistor 3

Main Controller B Connector A

T183-05-04-011

T183-05-04-003

A26

T5-5-69

T183-05-04-008

TROUBLSHOOTING / Troubleshooting B O-2 Grease pump operates excessively slow.

Grease pump operates excessively slow.

YES

Reinstall or replace exhaust hose.

Check if coefficient of grease viscosity becomes high due to winter or cold environment.

Check if grease pump exhaust hose is kinked or destroyed.

O-3 Grease pump does not stop operating.

• If the proximity switch is not correctly adjusted, the grease pump does not stop operating.

• Check for loose harness connections beforehand.

Change to AUTO position.

YES YES

Check if manual/auto selection valve near grease pump is in MANUAL position.

End

Adjust proximity switch. Check if grease pump NO stops. Disconnect proximity switch. Check if voltage at proxNO imity switch harness end connector terminal #1 is 24 V. · Key switch: ON

T5-5-70

Push both ends of main controller B connector B YES to securely connect the connector. Check if grease pump stops.

Broken harness beNO tween proximity switch and fuse.

TROUBLSHOOTING / Troubleshooting B Connector (Harness End Connector Viewed from the Open End Side) Proximity Switch

Auto-Lubrication Solenoid Valve Relay

Power Transistor 3

T183-05-04-011

T183-05-04-003

Main Controller B Connector A

A26

Connector B

T183-05-04-005

B10

YES

Overhaul grease pump. NOTE: This trouble is caused by the follow plate packing pinched with the grease pump when changing the grease. When exchanging grease, remove quick coupler from air delivery hose.

NO Check if follow plate packing is damaged.

Find out cause of trouble by tracing other trouble symptoms.

Change grease to EP1. YES YES Faulty auto-lubrication relay.

Disconnect power transistor 3 and main controller B connector Connect proximity YES A. switch harness end Check for continuity connector terminal #2 between connector A and vehicle frame with harness end terminal a clip. #A26 and power tranNO Disconnect main consistor 3 harness end troller B connector B. connector terminal #2. Check for continuity between main controller B harness conNO nector terminal #B10 and vehicle frame.

Connect disconnected YES connector. Disconnect auto-lubrication relay. Check for continuity between auto-lubrication relay terminals #3 and #5.

Check if grease pump stops after switching power transistor 3 with NO power transistor 1 or power transistor 2.

Broken harness between power transistor 3 and main controller B. Broken harness between proximity switch and main controller B. End (Faulty connector connection)

YES

T5-5-71

(1)

TROUBLSHOOTING / Troubleshooting B Proximity Switch Adjustment Procedure 1. Loosen the nut. : 17 mm 2. Slowly tighten the proximity switch by hand until the end of the proximity switch touches the protrusion. 3. Loosen the proximity switch 1/2 to 1 turn. Be sure that the indicator faces in the direction of as the figure on the right.

Indictor Proximity Switch Nut

IMPORTANT: The proximity switch may break. Do not excessively tighten the nuts. 4. Tighten the nut to secure the proximity switch. : 17 mm : 0.78 N⋅m (0.08 kgf⋅m, 0.57lbf⋅ft)

T142-06-04-024

Proximity Switch Nut Adapter

Protrusion

T142-06-04-025

Faulty power transistor 3.

YES

(1) Faulty main controller B. NO

T5-5-72

TROUBLSHOOTING / Troubleshooting B (Blank)

T5-5-73

TROUBLSHOOTING / Troubleshooting B O-4 Fan motor does not rotate at speed corresponding to hydraulic oil temperature or fuel temperature. Fan motor does not rotate at all.

• If the oil cooler fan motor speed control operates normally, the oil cooler fan motor rotates at the corresponding speed to the hydraulic oil temperature. • Check for loose harness connections beforehand.

Install pressure gauge on fan control solenoid valve delivery port. YES Check if pilot pressure is normal by hydraulic oil temperature and fuel temperature (refer to Table 2). Measure hydraulic oil temperature. Disconnect hydraulic oil temperature sensor, then measure sensor resistance. Check if relationship between hydraulic oil temperature and resistance value are correctly. (Refer to Table 1.)

Disconnect fan control solenoid valve wire on one side. Connect tester (amNO meter) between disconnected wire. Check if power is normal by each hydraulic oil temperature (refer to Table 2).

· (If polot pressure to hydraulic oil temperature is different from that to fuel temperature, lower pilot pressure is selected.) YES

Measure oil cooler fan motor drive pump flow rate. Check if flow rate is normal.

Faulty fan motor drive pump.

Faulty hydraulic oil sensor or fuel temperature sensor (fan motor speed control).

Connector Main Controller A B

Fan Control Solenoid Valve

T146-05-04-012

Hydraulic Oil Temperature Sensor T183-05-04-021

C10

T146-05-04-012

C23

Faulty fan motor.

C C1

Disconnect fan control solenoid valve. Connect harness end connector terminals #1 and #2. NO Disconnect main controller A connector A. Check for continuity between harness end connector terminals A6 and A7. YES

· Check fuel temperature sensor in the same procedures.

B22

YES Faulty fan control solenoid valve.

C31 C24

T5-5-74

TROUBLSHOOTING / Troubleshooting B

YES

Faulty main controller A.

Broken harness between oil cooler fan control solenoid valve and main controller A. Fan Control Solenoid Valve

Table 1: Relationship of Sensor (Fan Motor Speed Control) Resistance (Hydraulic oil temperature sensor and fuel temperature sensor are same.) Temperature Resistance (kΩ) (°C) (°F) -30 -22 28.6 -20 -4 16.2±1.6 -10 14 9.56 0 32 5.88 10 50 3.73 20 68 2.45±0.24 30 86 1.65 40 104 1.14 50 122 0.808 60 140 0.534 70 158 0.430 80 176 0.322±0.032 90 194 0.245 100 212 0.189 110 230 0.148 120 248 0.117

Tester A

Delivery Port

T183-05-04-023

Table 2: Relationship between Temperature and Fan Motor Speed Fuel Fan Motor Speed Hydraulic Oil Pilot Pressure from Fan Control Temperature Temperature Solenoid Valve [Current from MC] 66 °C (151 °F) 800→1100 min-1 70 °C (157 °F) 0.99 Mpa (10 kgf/cm2, 142 psi) [285 mA] 69 °C (156 °F) 1100→1400±50 80 °C (176 °F) 0 MPa (0 kgf/cm2, 0 psi) min-1 [200 mA] 63 °C (145 °F) 1100→800 min-1 65 °C (149 °F) 1.36 Mpa (14 kgf/cm2, 199 psi) [309 mA] 66 °C (151 °F) 1400±50→1100 75 °C (167 °F) 0.99 Mpa (10 kgf/cm2, 142 psi) min-1 [285 mA] NOTE: The above fan motor speed shows the motor speed at rated engine speed (1650 min-1).

T5-5-75

Fan Motor Speed Mode Low→Middle Middle→High Middle→Low High→ Middle

TROUBLESHOOTING / Troubleshooting B O-5 Step light does not come ON. â&#x20AC;˘ Check for loose harness connections beforehand.

YES

Faulty step light relay.

YES Check if step light comes ON after switching step light relay with other general-purpose relay.

Check if step light comes ON when connecting main controller B connector B terminal #B11 and vehicle frame. ÂˇMeasure voltage at the terminals from the rear of connector using a piece of clip with connector connected.

Disconnect step light. Check if step light comes ON when connecting NO harness end terminal to vehicle frame.

Step Light

Broken harness between main controller B and step light switch.

Disconnect main controller B connectors A and B. Connect connector A harness end terminal #A27 and connector B harness end terminal #B11 with a clip. Check if step light comes ON.

Faulty step light switch. YES

M183-01-036

Connector Step Light Relay

Step Light Switch

Main Controller B Connector A

Connector B

T183-05-04-003

A27

B11

T183-05-04-024

T5-5-76

T183-05-04-005

TROUBLESHOOTING / Troubleshooting B

YES

Faulty main controller B.

Disconnect step light relay. Connect harness end connector terminal #5 and terminal #3 with a clip. Check if step light comes ON.

Check if voltage at NO step light relay harness end connector terminal #3 is 24 V.

Connect connector. Disconnect step light YES terminal. Check if voltage at harness end terminal is 24 V.

YES

Faulty step light.

Broken harness between step light and step light relay.

Broken harness between step light relay and fuse box 1 fuse #8, or blown fuse #8. Broken harness between step light relay and main controller B.

YES

T5-5-77

TROUBLESHOOTING / Troubleshooting B O-6 Even if step light switch is turned OFF, step light does not come OFF after 60 seconds. â&#x20AC;˘ Check for loose harness connections beforehand.

YES

Check if step light comes OFF after switching step light relay with other general-purpose relay.

Faulty step light relay.

YES

Broken harness between main controller B and step light switch.

Faulty main controller B, or short-circuited harness between step light relay and main controller B.

Disconnect main controller B connector B. Check if step light comes OFF.

Disconnect step light switch. NO Check if step light comes OFF.

Faulty step light switch. YES

T5-5-78

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-79

TROUBLESHOOTING / Troubleshooting B O-7 Malfunction of Air Conditioner The air conditioner has a self-diagnosis function. The self-diagnosis functions to: 1) Display Fault Codes 2) Change Displayed Fault Codes 3) Delete Fault Code 4) End Fault Code Display

• Display Fault Code

1. Press the fan OFF switch to turn the fan OFF. 2. Press and hold both the upper and lower sides of the temperature control switch on the air conditioner control panel at the same time for more than 3 seconds with the key switch ON. NOTE: After operation has been performed, the buzzer will sound.

Temperature Control Switch

Fan OFF Switch

3. If any fault codes are found, the LCD displays the fault codes as E{{. NOTE: If more than one fault code is found, the lower number fault code will be displayed first.

LCD

M178-01-017

Fault Code List Location in Trouble Abnormal circulation air sensor

Fault Code E11 E12

Cause Broken circuit in air circulation sensor Short-circuited circulation air sensor Broken circuit in fresh air sensor Short-circuited fresh air sensor

Abnormal fresh air sensor

E13 E14

Abnormal solar radiation sensor

E18

Short-circuited solar radiation sensor

Abnormal evaporator sensor

E21

Broken circuit in evaporator sensor Short-circuited evaporator sensor Abnormal air vent damper Abnormal air mix damper Abnormal circulation/fresh air damper Broken circuit in water temperature sensor Short-circuited water temperature sensor Abnormal high/low refrigerant pressure

E22 Abnormal damper

E43 E44 E45

Water temperature sensor

E15 E16

Abnormal refrigerant

E51

T5-5-80

Symptom Y value (air flow-in temperature) cannot be adjusted in response to the set-temperature. Operation is controlled under such circumstance as no fresh air sensor is provided. Operation is controlled under such circumstance as no solar radiation sensor is provided. Operation is controlled under such circumstance as the evaporator temperature is set to 10 °C (50 °F). Corresponding damper servo becomes inoperable.

Operation is controlled under such circumstance as the water temperature is set to 60 °C (140 °F). (Warm-up control is not performed.) The compressor clutch is disengaged. (The compressor stops.)

TROUBLESHOOTING / Troubleshooting B • Change Displayed Fault Code

1. When displaying more than one fault code, press either the upper or bottom side of the temperature control switch key. The following fault code is displayed. NOTE: Each time the displayed fault code is changed, the buzzer sounds. In case only one fault code exists, the displayed fault code remains unchanged.

Temperature Control Switch

LCD

• Delete Fault Code

LCD

1. Press and hold both the circulation air switch and the fresh air switch for more than 3 seconds at the same time to delete the fault code. NOTE: After the fault code is deleted, the buzzer will sound. 2. After the fault code has been deleted, the LCD displays E{{.

M178-01-017

Circulation Air Switch

Fresh Air Switch

M178-01-017

Fan OFF Switch

• End Fault Code Display

1. Press the fan OFF switch, or press the upper side of the fan switch key. The self-diagnostic mode is complete.

Fan Switch

T5-5-81

M178-01-017

TROUBLESHOOTING / Troubleshooting B ※ Please fill in all sections and return this AIR CONDITIONER TROUBLE REPORT to Hitachi Tsuchiura Works Quality Assurance Dept. after experiencing a problem with your machine’s air conditioning system. < AIR CONDITIONER TROUBLE REPORT > File No. (1) What Checked by: Model (Serial No. ) Operation Type Manual Semi-Auto Full-Auto Delivery Date Year Month (2) When Date Year Month Day Operating Hour ( h) Time Morning Daytime Evening Night Frequency Every Day Once a Week Once a Month Times per (3) Where Job Site Address State County Town Access Road Condition Paved Not Paved (Gravel Sand Soil) (4) How (Operating Conditions) Weather Fine Cloudy Rain Snow Atmospheric Temperature Very Hot Hot Cold Very Cold Operating Conditions Parking Traveling Working Temperature Control Paint blanks equal to red indicators. / Fill in set-temperature when full-auto operation A/C ON OFF Air Induction Re-Circulation Fresh Air Circulation Control Panel AUTO ON OFF Not Available Fill following items when operated in manual mode or when manual control type unit is used. Vent Position Front Front / Rear Foot Front / Rear and Foot Fan First Second Third Fourth Fifth Sixth (5) How (Problem Symptom) Abnormal Compressor Operation <Check Result> Symptom Not turned ON (1) Is problem reproducible ? Not turned OFF Reproducible Others Not reproducible Uncontrollable air temperature (2) Pressure (To be measured at gauge manifold) Symptom No cool air Low Pressure No warm air High Pressure Others (3) Which parts have been replaced ? Uncontrollable air volume 1 Symptom Air flows in Hi mode only No air flows 2 Small air volume Others ∗ Before replacing the control amplifier, be sure to Uncontrollable vent hole check that the connectors are correctly connected Symptom Vent hole isn’t selected while repeatedly disconnecting and reconnecting Others connectors. Abnormal panel indication Faulty Indicator Vent Hole A/C AUTO Fresh Air Circulation Fan OFF Fan (Lo • •• Hi) Temperature Control Symptom Stays OFF Stays ON Blinks Others

T5-5-82

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-5-83

TROUBLESHOOTING / Troubleshooting B Cooling Circuit

Refrigerant pressure in both high and low pressure sides is low.

Bubbles can be seen in sight glass.

No bubbles are seen in sight glass.

Piping and/or parts are stained with oil, respond to gas detector. No oil stain is found or gas detector doesnâ&#x20AC;&#x2122;t respond. Refrigerant has not been refilled for longer than one season.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume remains unchanged. Air flow volume is reduced. Refrigerant pressure in low pressure side is high. Insufficient Cooling Power

Bubbles can be seen in sight glass.

Refrigerant pressure in high pressure side is low.

Compressor cylinder is extremely hot, emitting a smell.

Heater unit emits hot air.

Refrigerant pressure in high pressure side is high.

Bubbles can be seen in sight glass.

Refrigerant pressure in low pressure side is low.

Condenser is stained and clogged. Even if condenser is sprayed with water, few bubbles appear. Receiver dryer temperature is low.

After cooling at fast speed continuously, cooling power is reduced. Air flow volume is reduced.

Frost forms.

Thermistor doesnâ&#x20AC;&#x2122;t cool. Thermistor cools.

T5-5-84

TROUBLESHOOTING / Troubleshooting B

Gas leaks from pipe joints and/or parts.

Re-tighten or replace parts.

Normal leakage of refrigerant from hoses.

Refill refrigerant.

Improper adjustment (excessive restriction) of expansion valve.

Readjust or replace expansion valve.

Clogged expansion valve.

Remove clog, or replace receiver and/or expansion valve.

Clogged low pressure circuit and/or evaporator.

Remove clog, or replace parts.

Frozen expansion valve or water in circuit.

After evacuation, refill refrigerant and/or replace receiver dryer.

Gas leaks from case.

Seal gaps using vinyl tape or packing compound.

Poor contact of expansion valve temperature sensing cylinder.

Make good contact. Replace temperature sensing stay.

Improper adjustment (excessive open) of expansion valve.

Readjust or replace.

Insufficient compressor discharge (faulty gasket and/or valve).

Replace.

Improper water stop valve wire adjustment and/or faulty stop valve.

Check and readjust or replace.

Poor airtight fitting of outside air damper (outside air induction type). Clogged high pressure circuit before receiver dryer.

Repair.

Remove clog, or replace parts. Clean Condenser.

Excessive refrigerant.

Remove excessive refrigerant to proper level.

Air is mixed in system.

After evacuation, refill refrigerant and/or replace receiver dryer.

Incorrect thermistor location.

Correct thermister location.

Gas leaks from case.

Seal gaps using vinyl tape or packing compound.

Faulty thermistor (stays ON).

Disconnected thermister cord.

Even if function and performance are normal, when air-conditioner is kept operated for a long time with thermistor in max. cooling position and air flow in M or L mode, frost may form.

Instruct user on correct air-conditioner operation. (Reset thermistor to either minimum or middle cooling position or increase air flow.)

T5-5-85

TROUBLESHOOTING / Troubleshooting B Cooling Circuit

Case connection.

Louver resonance. Fan contacts case, or foreign matter enters case.

Blower fan connection.

Noise

Brush friction noise, metal and/or thrust washer contact noise.

Gas blowing sound (roaring).

Gas vibration noise (compressor discharge and/or suction gas noise).

Expansion valve connection, whistle sound, gas blowing sound.

Abnormal noise from expansion valve (Expansion valve is normally functioning.).

Faulty clutch bearing, and/or idle pulley bearing. Clutch disengaging sound. Contact of clutch amature due to resonance, or loose belt and/or screws. Noisy compressor. Compressor rotating sound. Vibration and/or loose screws due to excessive drive belt looseness.

Broken heater core and/or hose. Water leak and/or splash. Clogged case drain port and/or drain hose. Others Absorbed cigarette and dust smell on evaporator fins.

Abnormal smell.

T5-5-86

TROUBLESHOOTING / Troubleshooting B

Repair or replace. Remove foreign matter. Readjust fan motor location. Slight noise is unavoidable. Replace if loud.

No functional problem exists. Provide silencer if intolerable.

Replace expansion valve if whistle sound is heard. Gas flow noise can be slightly heard.

Replace. Repair or replace clutch. Re-tighten screws.

Repair or replace. Re-adjust drive belt.

Replace. Clean.

Clean evaporator. When humidity is high, open door. While rotating fan at approx. 1500 min-1 in L mode for more than 10 minutes, flush smell out by condensed water.

T5-5-87

TROUBLESHOOTING / Troubleshooting B Compressor Compressor doesnâ&#x20AC;&#x2122;t rotate.

Clutch terminal voltage is normal 24 V.

Inoperable cooling system.

Clutch terminal voltage is low. Clutch terminal voltage is 0 V. Bubbles exist even after refrigerant is refilled. Both high and low side pressures are low.

Both compressor and blower motor rotate.

Check for oil and refrigerant leaks from parts other than compressor and pipe joints using gas detector.

Check for oil and refrigerant leaks from compressor (no leaks from parts other than compressor) using gas detector.

Refer to NOTE 1 and 2 on page T5-5-95. Refrigerant has not been refilled for longer than one season. Stain on exterior.

Refrigerant is discharged within 1 to 2 months after being recharged. Check for refrigerant leaks using gas detector. Refrigerant is kept charged for longer than 2 years.

High pressure side is slightly low and low pressure side is high.

Compressor cylinder is not hot. (Refrigerant returns to compressor in liquid form.) No refrigerant returns in liquid form. High pressure side is low.

Bubbles can be seen through sight glass.

Others

High pressure side is high. Temperature is not cooled when compressor is operated at fast speed continuously.

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Air flow from blower is insufficient.

Compressor rotation is abnormally draggy. Overheating is susceptible to occur.

Trouble other than compressor.

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

T5-5-88

TROUBLESHOOTING / Troubleshooting B

Seized clutch.

Replace.

Improper gap between amature and rotor (improper air gap). Replace. Broken or short-circuited core cable. Shaft doesnâ&#x20AC;&#x2122;t rotate (internally locked).

Replace.

Faulty Electrical System.

Faulty mechanical seal, gasket, and/or charge valve. Replace. Oil leaks from oil plug. Oil and refrigerant leaks from front housing, and/or cylinder block joint. Normal leaks from hoses.

Replace. Charge refrigerant.

No leaks (normal).

Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84. Broken valve (See NOTE 3 on page T5-5-95.) Replace. Blown gasket (See NOTE 3 on page T5-5-95.)

Check and adjust oil level.

Excessive oil. Broken clutch bearing due to overly tightened belt.

Replace.

Shaft doesnâ&#x20AC;&#x2122;t rotate. Replace. Shaft rotates draggy.

T5-5-89

TROUBLESHOOTING / Troubleshooting B Compressor

Noise is heard when clutch is OFF.

Abnormal noise

Noise is heard when clutch is ON.

T5-5-90

TROUBLESHOOTING / Troubleshooting B

Broken clutch bearing. Replace. Contact or slip due to poor air gap. Faulty idle pulley bearing. Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Saggy belt. Loose screws.

Broken valve. Replace. Blown gasket. Abnormal internal noise.

Replace.

Vibration due to saggy belt. Refer to the Cooling Circuit Troubleshooting Table on page T5-5-84.

Loose screws.

NOTE: 1. Donâ&#x20AC;&#x2122;t quickly decide that oil is leaking when a stain around the clutch and/or gasket is found. A slight oil seepage will appear due to the seal construction. However, this oil seepage will not cause malfunction. Be sure to accurately check whether oil is leaking or seeping only. 2. When gas detector is used in the high sensitivity range, normal gas leaks from rubber hose surface may be detected. As long as the specified rubber hoses are used, the problem should not occur. (In case a large leaks is detected, the hose may be broken.) 3. After allowing the compressor to idle for 10 to 15 minutes, normal pressure difference between high pressure side and low pressure side is 0.49 MPa (5 kgf/cm2) or less. When the clutch is turned OFF, the pressure difference between high pressure side and low pressure side will disappear within about 10 seconds.

T5-5-91

TROUBLESHOOTING / Troubleshooting B WORK AFTER NENTS

REPLACING

COMPO-

The following work is required after replacing compressor, high pressure hose, low pressure hose, condenser, receiver tank, liquid hose, and air conditioner unit. The same work is required when gas leakage is found. 1. Add compressor oil 2. Charge air conditioner with refrigerant • Purging • Charge air conditioner with refrigerant • Warm up operation • Inspection

ADD COMPRESSOR OIL Compressor oil quantity to be added after component replacement: 180 cm3 (0.19 qt)

T5-5-92

TROUBLESHOOTING / Troubleshooting B CHARGE AIR REFRIGERANT

CONDITIONER

WITH

Necessity of Purging Be sure to purge the air conditioner circuit with a vacuum before charging with refrigerant (R134a) because the following problems can arise if air or other gases remain in the A/C circuit. 1. Pressure rise in the high pressure side Air

If air remains in the air conditioner circuit, this disturbs the heat exchange between refrigerant and air in the condenser, causing pressure to rise in the high pressure side (compressor side). Usually, refrigerant gas is easily liquefied; however, air cannot be liquefied and remains as a gas in the condenser because the temperature at which air liquefies is extremely low. That is, liquidation of the refrigerant gas in the condenser decreases by the amount of air in the circuit, and the gas pressure in the high pressure side increases accordingly.

Pressure increases if air remains in the air conditioner circuit

W115-02-10-001

2. Metal corrosion If air remains in the air conditioner circuit, a chemical reaction between refrigerant and moisture in the air takes place, and as a result, hydrochloric acid, that corrodes metals such as aluminum, copper and iron, is produced.

Hydrochloric acid corrodes metals if moisture exists

Hydrochloric acid

W115-02-10-002

Metal corrosion

3. Plugging of the expansion valve by moisture When high pressure refrigerant gas passes through the expansion valve, gas pressure decreases and temperature drops. Moisture included in high pressure refrigerant gas in the air conditioner circuit freezes at the expansion valve orifice, plugging refrigerant flow. Operation of the air conditioner becomes unstable and cooling efficiency lowers.

Ice produced at the expansion valve disturbs refrigerant flow, lowering cooling efficiency

Plugged refrigerant flow W115-02-10-003

Low cooling efficiency

T5-5-93

TROUBLESHOOTING / Troubleshooting B Purging Procedure

Gauge Manifold

IMPORTANT: Never mistake the charge hose connections. 1. Close the high and low pressure valves on the gauge manifold (Parts Number 4360564). Connect the high-pressure-side charge hose and the low-pressure-side charge hoses to the high-pressure-side charge valve (“D” marked) and to the low-pressure-side charge valve (“S” marked) located on the compressor, respectively. Connect the charge hose located on the center of the manifold bottom to the vacuum pump (Parts Number 4360565). NOTE: Vacuum Pump Joint Number 4360566).

Adapter

Low Pressure Valve Low Pressure Charge Hose

High Pressure Valve High Pressure Charge Hose

Center Pressure Charge Hose Vacuum Pump

(Parts

W115-02-10-005

Low Pressure Side S Compressor D High Pressure Side T142-02-05-018

Fully Open

2. Open the high pressure and low pressure valves in the gauge manifold. Perform purging for 10 minutes or more by operating the vacuum pump.

Fully Open

In Operation

W115-02-10-005

T5-5-94

TROUBLESHOOTING / Troubleshooting B IMPORTANT: If the pointer returns to 0, retighten the line connections and perform purging again. 3. When the low pressure gauge reading falls below-755 mmHg, stop the vacuum pump and close the high and low pressure valves. Wait for approximately five minutes and confirm that the pointer does not return to 0.

Close Close

In Operation

W115-02-10-005

4. With the high pressure and low pressure valves of the gauge manifold closed, connect the charge hose to the refrigerant container (Parts Number 4347644).

Refrigerant Container

W115-02-10-007

5. Loosen the charge hose connection to the gauge manifold and open the refrigerant container valve to purge air in the charge hose with the refrigerant pressure.

Loosen

Open

W115-02-10-007

T5-5-95

TROUBLESHOOTING / Troubleshooting B IMPORTANT: Always stop the engine when charging the air conditioner with refrigerant. Never position the refrigerant container upside down during charging operation. When changing the refrigerant container during charging operation, be sure to purge air from the charge hose, as shown in step 10. 6. Fully tighten the charge hose connection to the gauge manifold. Open the high pressure valve and refrigerant container valve to charge with refrigerant (R134a). Close the high pressure valve and refrigerant container valve when the high pressure gauge reading reaches 98 kPa (1 kgf/cm2, 14 psi). NOTE: Use warm water of 40 Â°C (104 Â°F) or less to warm the refrigerant container to aid in charging operation.

IMPORTANT: Use the leak tester for R134a. 7. After charging, check the line connections for gas leaks using leak tester (Parts Number 4360567).

T5-5-96

High Pressure Gauge Tighten

Open

W115-02-10-007

W115-02-10-008

TROUBLESHOOTING / Troubleshooting B 8. Confirm that the high pressure and low pressure valves in the gauge manifold and the refrigerant container valve are closed. Start the engine and operate the air conditioner. Operating Conditions of the Air Conditioner: Engine Speed : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum IMPORTANT: Never open the high pressure valve in the gauge manifold. 9. Open the low pressure valve in the gauge manifold and the refrigerant container valve to charge with refrigerant until the bubbles seen in the receiver/drier sight glass disappear.

Open

NOTE: The required refrigerant quantity is 1250 gÂą50 g (3Âą0.01 lb).

Open

10. If the refrigerant container becomes empty during the charging work, replace it with a new refrigerant container as follows: (1) Close the high pressure and low pressure valves on the manifold gauge. (2) Replace the empty container with a new one. (3) Tighten, then slightly loosen the refrigerant container joint. (4) Slightly open the low pressure valve on the manifold gauge. (5) When the refrigerant container joint starts to leak, immediately tighten the refrigerant container joint and close the low pressure valve on the manifold gauge.

W115-02-10-007

11. After charging, close the low pressure valve in the gauge manifold and the refrigerant container valve, and stop the engine.

W115-02-10-007

T5-5-97

TROUBLESHOOTING / Troubleshooting B IMPORTANT: If the air conditioner is operated with very low refrigerant, a bad load will be exerted on the compressor. If the air conditioner is overcharged with refrigerant, cooling efficiency will lower and abnormal high pressure will arise in the air conditioner circuit, causing danger. 12. Start the engine and operate the air-conditioner again. Observe the sight glass of the receiver/drier to check refrigerant quantity. Operating Conditions of the Air Conditioner: Engine Speed : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum NOTE: As the bubbles in the sight glass vary depending on the ambient temperature, check refrigerant quantity confirming the changes in pressure .

Sight Glass

Receiver/Drier

W115-02-10-009

Checking procedures: Stop the air conditioner and wait until refrigerant returns to the balanced pressure. Then, start the air conditioner again. Relation between Refrigerant Quantity and Refrigerant Flow in Sight Glass: Refrigerant Flow in Sight Glass Refrigerant (approx. 1 min. after air conditioner Quantity switch is turned ON) (immediately after)

(approx. 1 mm after)

Adequate

Explanation for Refrigerant Flow in Sight Glass Immediately after the air conditioner is turned ON, few bubbles are seen. Then the flow becomes transparent and shows thin milk white color.

W115-02-10-016

No bubbles are seen after the air conditioner is turned ON.

Overcharged W115-02-10-017

Bubbles are seen continuously after the air conditioner is turned ON.

Not Enough W115-02-10-018

CAUTION: Wait until the high-pressure-side pressure drops to less than 980 kPa (10 kgf/cm2, 142 psi) before attempting to disconnect the high-pressure-side charge hose. Otherwise, refrigerant and compressor oil may spout.

W115-02-10-019

Bubbles exist: Bubbles are seen in refrigerant flow as both liquid refrigerant and refrigerant gas exist, being mixed. W115-02-10-020

Transparent: Refrigerant flow is transparent as only liquid refrigerant exists.

115-02-10-021

Milk white: Refrigerant flow shows thin milk white as oil and refrigerant are separated.

10. After checking refrigerant quantity, disconnect the low-pressure-side charge hose first. Wait for the high-pressure-side pressure to drop to less than 980 kPa (10 kgf/cm2, 142 psi). Disconnect the high-pressure-side charge hose.

T5-5-98

TROUBLESHOOTING / Troubleshooting B Warm-up Operation After charting the air conditioner, carry out warm-up operation five minute to lubricate system with compressor oil. Operating Conditions of the Air Conditioner Engine Speed : Slow Idle Cab Window : Fully Open Cooler Switch : ON Airflow Volume : Maximum Thermo Switch : Maximum Inspection After warm-up operation, carry out gas leak check and performance check. CAUTION: Refrigerant will produce poisonous material if exposed to heat of 1000 Â°C (1800 Â°F) or more. Never bring refrigerant close to a fire. 1. Check the air conditioner for gas leaks using a leak tester. (1) Perform checking under well-ventilated conditions. (2) Thoroughly wipe off dust from the charge hose connections of the compressor. (3) Pay special attention to check the line connections. (4) If any gas leaks are found, retighten the line connections. 2. Performance Check Carry out performance check of the air conditioner after checking each air conditioner component. (1) Check each component for abnormalities. (2) Carry out ON-OFF check of the compressor clutch. (3) Check compressor fan belt tension. (4) Check the coolant level in the radiator. (5) Operate the air conditioner and check the performance.

T5-5-99

Leak Tester

W115-02-10-013

Retighten Line Connection

W115-02-10-014

TROUBLESHOOTING / Troubleshooting B 3. The checklist before the summer season is as follows: (1) Check each air conditioner component for abnormalities. (2) Check the line connections for oil leaks. (3) Check refrigerant quantity. (4) Check the engine cooling circuit. (5) Check belts for wear. Replace if necessary. 4. Off-Season Maintenance (1) During off-season, operate the idler pulley and compressor at least once a month for a short time to check for any abnormal sounds. (2) Do not remove the compressor belts during off-season. Operate the compressor occasionally at slow speed for 5 to 10 minutes with the belt slightly loosened in order to lubricate the machine parts.

T5-5-100

TROUBLESHOOTING / Troubleshooting C TROUBLESHOOTING C (TROUBLESHOOTING FOR MONITOR) PROCEDURE Use troubleshooting C when any monitors, such as gauges or indicators, malfunction.

• How to Read Troubleshooting Flow Charts YES(OK)

•

(2)

After completing the checking and/or measuring procedures in box (1), select YES (OK) or NO (NOT OK) and proceed to box (2) or (3).

(1)

NO(NOT OK)

• · Key switch: ON

(3)

Causes of machine problems are stated in the thick-line box. Scanning quickly through the thick-line boxes allows you to estimate the possible causes before actually following the flow chart.

•

NOTE: All harness end connectors are seen from the open end side.

Harness

Harness End Connector Open End Side

T158-05-03-001

T5-6-1

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PERATURE GAUGE

COOLANT

TEM-

• This troubleshooting procedures should be performed after checking that the other instruments are performing correctly. • Check for loose harness connections beforehand. Gauge Pointer Does Not Move At All

YES

Disconnect coolant temperature sensor terminal (white). Ground harness end terminal to vehicle frame. Check if pointer swings to the right side.

Connect disconnected terminal. Ground monitor controller connector B terminal #B18 to vehicle frame. Check if pointer swings to the right side.

· Key switch: ON NO

· Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

Gauge Pointer Swings Over Scale YES

Disconnect coolant temperature sensor terminal (white). Check if pointer returns to zero.

YES

· Key switch: ON NO

Connect disconnected terminal. Disconnect monitor controller connector B. Check if pointer returns to zero. NO

Gauge Pointer Keeps Moving Unstably YES Disconnect coolant temperature sensor terminal (white). Ground harness end terminal to vehicle frame. Check if pointer swings and is stabilized to the right side. · Key switch: ON

T5-6-2

TROUBLESHOOTING / Troubleshooting C

Coolant Temperature Gauge

Faulty coolant temperature sensor .

Faulty coolant temperature gauge. M183-01-010

YES

Broken harness between coolant temperature gauge and coolant temperature sensor .

Coolant Sensor Resistance Coolant Temperature °C (°F) 25 (77) 40 (104) 50 (122) 80 (176) 95 (203) 105 (221) 120 (248)

Faulty coolant temperate sensor . Short-circuited harness between coolant temperature gauge and sensor .

Resistance (kΩ) 7.6 4.0±0.32 2.7±0.22 0.98 0.6 0.45 0.3±0.02

Connector Monitor Controller Connector B

Faulty coolant temperature gauge.

T183-05-04-013

B18

Faulty coolant temperature sensor .

Faulty coolant temperature gauge.

T5-6-3

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL GAUGE

Connector

• This troubleshooting procedures should be per-

Monitor Controller Connector B

Fuel Sensor

formed after checking that the other instruments are performing correctly. • Check for loose harness connections beforehand. T183-05-04-010

Fuel Gauge Pointer Does Not Move At All

T183-05-04-013

B19

YES Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if pointer swings to the right side.

Connect disconnected connector. Ground monitor controller connector B terminal #B19 to vehicle frame. Check if pointer swings to the right side.

· Key switch: ON NO

· Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

Fuel Gauge Pointer Swings Over Scale YES

Disconnect fuel sensor from connector. Check if pointer returns to zero.

YES

· Key switch: ON NO

Connect disconnected connector. Disconnect monitor controller connector B. Check if pointer returns to zero. NO

Fuel Gauge Pointer Keeps Moving Unstably

YES Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if pointer swings and is stabilized to the right side. · Key switch: ON

T5-6-4

TROUBLESHOOTING / Troubleshooting C Fuel Gauge Upper Limit 1/2

Lower Limit

Faulty fuel sensor.

Faulty fuel gauge.

M183-01-011

Fuel Sensor Float FULL

YES

Broken harness between fuel gauge and sensor.

3/4

257 mm 138.5 mm

R370

22 ° 33°

70.5 mm

Faulty fuel sensor.

228 mm

1/2

27° 28°

338 mm

Electric Resistance

1/4

Short-circuited harness between fuel gauge and sensor.

EMPTY

T107-04-03-020

Faulty fuel gauge.

Faulty fuel sensor.

Faulty fuel gauge.

T5-6-5

Float Position

Resistance (Ω)

Upper Limit (FULL)

10+1.0-0.5

3/4

(19)

1/2

32±3

1/4

(49.5)

Lower Limit (EMPTY)

80+12+2

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF INDICATOR LIGHT CHECK SYSTEM • Check for loose harness connections beforehand. YES Indicator does not come ON when indicator light check operation is performed.

Check power line. · Fuse · Disconnect monitor controller connector C. Check for continuity between harness end terminal #C1 and fuse terminal #7 (fuse box 1).

Check if all indicators do not come ON.

Connector Monitor Controller Connector C C1

T183-05-04-014

T5-6-6

Go to individual troubleshooting according to malfunctioning indicator.

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-7

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF OVERHEAT INDICATOR • Check for loose harness connections beforehand. NOTE: Overheat Switch Operating Temperature: 100 °C (212 °F) or more Indicator Does Not Come ON Even If Engine Overheats Faulty monitor controller or burnt indicator light.

Turn indicator light check switch ON. Check if indicator comes ON. · Key switch: ON

Broken harness between DLU and monitor.

NO Disconnect DLU connector D. Disconnect monitor controller connector B. Check for continuity beYES tween DLU connector D terminal #66 and monitor controller terminal #B6.

Disconnect ECM connector 9 poles and DLU connector C. Check for continuity between ECM terminal #C and DLU terminal #52. YES Check for continuity between ECM terminal #D and DLU terminal #51.

YES Faulty DLU or faulty engine.

Broken harness between ECM and DLU.

Connector DLU Connector D

DLU Connector C

ECM Connector 9 Poles #C

T18E-05-06-002

#66

#51

#52

T5-6-8

T18E-05-06-004

T18E-05-06-003

TROUBLESHOOTING / Troubleshooting C Indicator Comes ON Even If Coolant Temperature Is Low

YES

Faulty engine.

Disconnect ECM connector 9 poles. Check if indicator goes OFF. YES

Disconnect the removed terminal. Disconnect DLU connector D. Check if indicator goes OFF.

Disconnect the removed terminal. Disconnect monitor connector B. NO Check for continuity between harness end connector terminal #6 and vehicle frame.

Faulty DLU.

YES Short-circuited harness between DLU and monitor.

Broken monitor. NO

Monitor Connector #6

T183-05-04-013

T5-6-9

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AIR CLEANER RESTRICTION INDICATOR • Check for loose harness connections beforehand.

YES

Disconnect air cleaner restriction switch. Ground harness end connector (Yellow) side to vehicle frame. Check if indicator comes ON. · Key switch: ON

Even if air cleaner is clogged, indicator does not come ON.

Check if indicator comes ON when key switch is turned ON.

YES

Although air cleaner is not clogged, indicator comes ON. · Disassemble / Visual Inspection · Verify that air cleaner is not moist.

Check if indicator goes OFF when air cleaner restriction switch is disconnected.

YES

· Key switch: ON NO

Disconnect air cleaner restriction switch and monitor controller connector B. Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame. NO

T5-6-10

Disconnect monitor controller connector B. Keep air cleaner restriction switch connector connected to vehicle frame. Check for continuity between monitor controller harness end connector terminal #B7 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty air cleaner restriction switch.

YES

Air Cleaner Restriction Switch

Pressure 5.0 kPa (508Âą48 mmH2O) or lower 5.0 kPa (508Âą48 mmH2O) or more

Faulty monitor controller.

Operation OFF ON

Broken harness between monitor controller and air cleaner restriction switch. Burned indicator light, or faulty monitor.

Connector Monitor Controller Connector B B7

T183-05-04-013

Faulty air cleaner restriction switch.

Short-circuited harness between monitor controller and air cleaner restriction switch.

Faulty monitor controller.

T5-6-11

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF FUEL LEVEL INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand.

YES

Indicator does not come ON even if fuel gauge pointer reaches "E".

Disconnect fuel sensor from connector. Ground harness end connector terminal #2 to vehicle frame. Check if indicator comes ON.

Turn key switch to ON position. Check if indicator comes ON.

YES

Indicator comes ON even if fuel still remains.

Disconnect fuel sensor from connector. Check if indicator goes OFF. Âˇ Key switch: ON

YES Disconnect fuel level sensor and monitor controller connector B. Check for continuity beNO tween monitor controller harness end connector terminal #B19 and vehicle frame. NO

T5-6-12

Disconnect monitor controller connector B. Keep connecting fuel sensor harness end connector connected to vehicle frame. Check for continuity between monitor controller harness end connector terminal #B19 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

Faulty fuel sensor.

YES

Faulty monitor controller.

Broken harness between monitor controller and fuel sensor. Burned indicator light, or faulty monitor controller.

Connector Faulty fuel sensor.

Fuel Sensor

Short-circuited harness between monitor controller and fuel sensor.

T183-05-04-010

Monitor Controller Connector B

Faulty monitor controller.

T183-05-04-013

B19

T5-6-13

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PREHEAT INDICATOR â&#x20AC;˘ Check that all other indicators work correctly. â&#x20AC;˘ Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Air Heater Is Operating Faulty preheat indicator relay.

YES

Check if indicator comes ON after switching preheat indicator relay and other general-purpose relay. Disconnect preheat indicator relay from connector. NO Check if voltage at harness end connector terminal #1 is 24 V.

Connect disconnected connector. Disconnect monitor YES controller connector B. Check for continuity between harness end connector terminal #B20 and vehicle frame.

YES Faulty monitor controller, or burned indicator light.

Broken harness between monitor controller and NO preheat indicator relay.

Broken harness between preheat indicator relay and preheat relay 1 or blown fuse (5A).

Indicator Comes ON Even If Air Heater Is Not Operating YES

Disconnect monitor controller connector B. Check if indicator comes ON.

Faulty monitor controller.

Short-circuited harness between monitor controller and preheat indicator relay.

YES Disconnect preheat indicator relay. Check for continuity beNO tween harness end connector terminal #3 and vehicle frame.

Connect connector. Check if indicator comes ON after switchNO ing preheat indicator relay and other general-purpose relay.

Connector

NO Faulty preheat indicator relay. Short-circuited harness between preheat indicator relay and preheat YES relay 2 or faulty preheat relay 2.

Monitor Controller Connector B

Preheat Indicator Relay

B20 T183-05-04-003

T5-6-14

T183-05-04-014

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF DOWNLOAD INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand. Indicator Does Not Come ON Even If DLU Data Memory Is Full YES Disconnect monitor controller connector C. Check for continuity between terminal #C20 and vehicle frame.

Burnt indicator bulb, or faulty monitor controller.

YES

Faulty DLU.

Broken harness between DLU and monitor controller.

Disconnect DLU connector D. Check for continuity beNO tween terminals #56 and #C20.

Indicator Comes ON Even If Download Is Completed Faulty DLU.

YES

Disconnect DLU connector D. Check if indicator goes OFF.

Disconnect monitor controller connector C. Check for continuity between DLU harness end connector terminal #56 NO and connector C harness end terminal #C20.

Short-circuited harness between DLU and monitor controller.

YES

Faulty monitor controller. NO

Connector Monitor Controller Connector C

DLU Connector D #56

T183-05-04-014 T18E-05-06-002

T5-6-15

C20

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ALTERNATOR INDICATOR • Check for loose harness connections before-

Connector

hand. Monitor Controller Connector A

T183-05-05-001

Alternator indicator stays ON after engine is started. · Engine: Running

Disconnect alternator terminal R, then ground the terminal to vehicle frame. Disconnect connector A of monitor controller. Check for continuity between alternator relay harness end connector terminal #A2 and vehicle frame.

YES

Faulty alternator.

Broken harness between alternator terminal R and monitor controller or faulty monitor controller.

Less than 10 V

Faulty monitor controller, or broken harness between monitor controller and alternator.

YES Measure voltage at alternator terminal R. · Key switch: ON · Engine: Stop Although alternator output is low, alternator indicator does not come ON.

Faulty alternator. Turn key switch ON. Check if indicator comes ON.

10 V or more

Burned alternator indicator light, or faulty monitor controller.

T5-6-16

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-17

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • Check for restricted oil filter. • Check for loose harness connections beforehand.

• Even if the key switch is ON with the engine stopped, the engine oil pressure indicator does not come ON. Even If Engine Oil Pressure Becomes Low With Engine Running, Indicator Does Not Come ON • Check if the engine has trouble by using the fault code monitor at engine side beforehand.

Turn indicator light check switch ON. Check if indicator comes ON.

Connect the connector. Disconnect DLU connector 76C and ECM connector 9 poles. YES Check for continuity between terminals #52 and C. Check for continuity between terminals #51 and D.

Disconnect monitor controller connector C and YES DLU connector 76D. Check for continuity between terminals #55 and #C18.

· Key switch: ON

YES Faulty DLU.

Broken CAN harness. NO Broken harness between DLU and monitor. Faulty monitor controller, or burnt indicator bulb.

Indicator Stays ON After Engine Is Started (Oil Level and Oil Pressure are Normal) • Check if the engine has trouble by using the fault code monitor at engine side beforehand. YES

Faulty DLU.

Broken or short-circuited CAN harness.

Check for continuity of YES CAN harness. Check for shorted-circuited CAN harness. Disconnect DLU connector 76D. Check if indicator goes OFF.

YES

Disconnect harness between DLU and monitor. Check for continuity between terminals #55 and vehicle frame.

Short-circuited harness between monitor and DLU.

Broken monitor. NO

T5-6-18

TROUBLESHOOTING / Troubleshooting C

Connector DLU Connector 76D

DLU Connector 76C

ECM Connector 9 Poles #C

#55

T18E-05-06-002

#51

#52

T18E-05-06-004 T18E-05-06-003

T5-6-19

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF PUMP TRANSMISSION OIL PRESSURE INDICATOR • Check for loose harness connections beforehand. Indicator does not come ON even if pump transmission oil pressure is insufficient. YES

YES

Disconnect pump transmission oil pressure switch. Ground harness end terminal #M4 to vehicle frame. Check if indicator comes ON. · Key switch: ON

Turn key switch to ON position. Check if indicator comes ON.

Connect disconnected terminal. Ground monitor controller connector A terminal #A13 to vehicle frame. Check if indicator comes ON. · Key switch: ON · Connect terminal from the rear of connector using a piece of clip with connector connected.

· Key switch: ON

Indicator stays ON even if engine is started. YES Disconnect pump transmission oil pressure switch. Check if indicator goes OFF. · Key switch: ON · Engine: Stop

Disconnect monitor controller connector A. Keep cab connector disconnected. Check for continuity between monitor harness end connector terminal #A13 and vehicle frame.

T5-6-20

TROUBLESHOOTING / Troubleshooting C

Pump Transmission Oil Pressure Switch Pressure Operation less than 39 to 59 kPa ON (0.4 to 0.6 kgf/cm2) Indication pressure 39 to 59 kPa OFF (0.4 to 0.6 kgf/cm2) or more

Faulty pump transmission oil pressure switch.

YES

Broken harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller. NO

Connector Monitor Controller Connector A

Burned indicator light, or faulty monitor controller.

T183-05-05-001

A13

Faulty pump transmission oil pressure switch, faulty oil pressure system or restricted oil filter.

YES

Short-circuited harness between monitor controller and pump transmission oil pressure switch.

Faulty monitor controller. NO

T5-6-21

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE OIL LEVEL INDICATOR • Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Oil Level is Normal YES

Disconnect engine oil level switch. Ground harness end connector terminal #1 to vehicle frame. Check if indicator comes ON.

Turn key switch to ON position. Check if indicator comes ON.

Connect engine oil level switch. Disconnect monitor controller connector B. Check for continuity between harness end connector terminal #B8 and vehicle frame.

YES

Indicator Does Not Come ON Even If Oil Level Is Lower Than Low

YES

Disconnect engine oil level switch. Check if indicator comes ON.

Check oil level with an oil level gauge. Check if oil level is higher than low limit.

YES

T5-6-22

Disconnect monitor controller connector B. Keep engine oil level switch disconnected. Check for continuity between connector B harness end terminal #B8 and vehicle frame.

TROUBLESHOOTING / Troubleshooting C

YES

Faulty monitor controller.

Connector Monitor Controller Connector B

Broken harness between monitor controller and engine oil level switch.

T183-05-04-013

Faulty engine oil level switch.

Engine Oil Level Switch

Burned indicator light, or faulty monitor controller.

YES

Short-circuited harness between monitor controller and engine oil level switch.

Faulty monitor controller. NO

Faulty engine oil level switch.

Normal.

T5-6-23

T18E-05-06-006

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF COOLANT LEVEL INDICATOR • Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Coolant Level Is Lower than Low • Check if fault cod 235 is displayed on the engine fault code monitor beforehand. • If fault code 235 is displayed, the following troubles may occur. Faulty engine (coolant level sensor or ECM) Broken or short -circuited harness between ECM and coolant level sensor. NO

Turn key switch ON. Check if indicator comes ON.

Burnt indicator bulb, or faulty monitor controller.

YES

Disconnect monitor controller connector B. Disconnect DLU connector 76D. Check for continuity between DLU terminals #76 to 57D and vehicle frame.

YES Faulty DLU.

Indicator Comes ON Even If Coolant Level Is YES Normal YES

Disconnect DLU connector 76D. Check for continuity between DLU end terminal 76-57D and vehicle frame.

Disconnect DLU connector 76C and ECM connector 9 poles. Check for continuity between terminals #76 to 52 and C. Check for continuity between terminals #76 to 51 and D.

Disconnect monitor controller connector B. Check for short-circuited harness between DLU terminals #76 to 57 and monitor controller terminal B9.

Broken harness between DLU and monitor controller.

Disconnect DLU connector 76C and ECM connector 9 poles. Check for continuity between terminals #76 to 52 and C. Check for continuity between terminals #76 to 51 and D.

Disconnect coolant level sensor connector and ECM connector 21 poles. Check for broken or short-circuited harness between terminals below.

Faulty harness between ECM and DLU.

Broken or short-circuited harness between DLU and ECM. NO

YES

Broken or short-circuited harness between ECM and coolant level sensor. Faulty engine. (coolant level sensor or ECM)

· Coolant level sensor Terminals #A and ECM #T Terminals #B and ECM #V Terminals #C and ECM #U Terminals #D and ECM #S Faulty monitor controller. YES

T5-6-24

Broken or short-circuited harness between DLU and monitor controller.

TROUBLESHOOTING / Troubleshooting C

DLU Connector 76D

Monitor Controller

DLU Connector 76C

Connector B #57

T18E-05-06-002

T183-05-04-013

Coolant Level Sensor Connector

ECM Connector 9 Poles #D

T18E-05-06-007

T18E-05-06-003

T5-6-25

#51

#52

T18E-05-06-004

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF LEVEL INDICATOR

HYDRAULIC

OIL

• Check that all other indicators work correctly. • Check that machine is parked on level surface. • Check for loose harness connections beforehand. Indicator Does Not Come ON Even If Hydraulic Oil Level Is Lowered Below Lower Limit

YES

Disconnect hydraulic oil level switch 1. Ground YES harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds. · Key switch: ON

Faulty hydraulic oil level switch 1.

Connect disconnected connector. Disconnect hydraulic oil level switch 2. NO Ground harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds. · Key switch: ON

Turn indicator light check switch ON. Check if indicator comes ON. · Key switch: ON

Disconnect monitor controller connector C and main controller B connector B. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

YES Faulty hydraulic oil level switch 2.

Connect disconnected connector. Disconnect main controller B connector B. Check for continuity between harness end connector terminal #B15 and vehicle frame.

Burned indicator light, faulty monitor controller, or broken harness between monitor controller and main controller B.

YES

Connect monitor controller connector C. Connect main controller B terminal #B15 and harness end connector #B15 with a clip. Check if indicator comes ON.

T5-6-26

TROUBLESHOOTING / Troubleshooting C Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2

T183-05-04-010

T183-05-04-014

C14

B23

B15

T183-05-04-021

Faulty main controller B.

YES Check for continuity YES between harness end connector terminal #B16 and vehicle frame.

Broken harness between hydraulic oil level switch 2 and main controller B.

Broken harness between hydraulic oil level switch 1 and main controller B.

Broken harness between main controller B and hydraulic oil level switch 2.

YES Check if indicator comes ON after YES switching hydraulic oil level switch 1 and hydraulic oil level switch 2.

Disconnect hydraulic oil level switch 1. Check for continuity between main controller B harness end connector terminal #B15 and hydraulic oil level switch 2 harness end connector terminal #1.

Faulty hydraulic oil level switch 2.

YES

Disconnect hydraulic oil level switch 1. Ground harness end connector terminal to vehicle frame. Check if indicator comes ON after 5 seconds.

YES

Faulty hydraulic oil level switch 1.

Faulty main controller B. NO

Broken harness between main controller B and hydraulic oil level switch 1.

T5-6-27

TROUBLESHOOTING / Troubleshooting C Indicator Comes ON Even If Hydraulic Oil Level Is Normal

YES

Faulty hydraulic oil level switch 1.

Disconnect hydraulic oil level switch 1. Check if indicator goes OFF.

Connect disconnected connectors. Disconnect main conNO troller B connector B. Check for continuity between harness end connector terminals #B15, B16 and vehicle frame.

Disconnect hydraulic oil level switch 2. Check if indicator goes OFF.

Disconnect monitor controller connector C. Check for continuity between connector C harness end terminal #C14 and connector B harness end terminal #B23.

Short-circuited harness between hydraulic oil YES level switch 1, 2 and main controller B.

Faulty hydraulic oil level switch 2.

YES

Connector Monitor Controller Connector C

Main Controller B Connector B

Hydraulic Oil Level Switch 1, 2 B16

T183-05-04-010

T183-05-04-014

C14

B23

B15 T183-05-04-021

T5-6-28

TROUBLESHOOTING / Troubleshooting C

YES

Short-circuited harness between monitor controller and main controller B.

Faulty monitor controller or main controller B.

T5-6-29

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-LUBRICATION INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand.

Indicator Comes ON Even If Auto-lubrication System Operates Normally. NOTE: Indicator comes ON when lubrication mode switch is turned to "Manual" position.

24 V

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15.

Disconnect main controller B connector A. Check for continuity between monitor controller connector C harness end terminal #C15 and connector A harness end terminal #A29.

Faulty monitor controller. 0V

Indicator Does Not Come ON Even If Auto-lubrication System is Abnormal or Lubrication Mode Switch is Turned to "Manual" Position. YES

Disconnect monitor controller connector C. Check for voltage at harness end connector terminal #C15. Âˇ Key switch: ON

Turn key switch to ON position. Check if indicator comes ON.

Burned indicator light, or faulty monitor controller.

T5-6-30

TROUBLESHOOTING / Troubleshooting C

Connector Monitor Controller Connector C

Main Controller B Connector A

T183-05-04-014

C15

YES

A29

Short-circuited harness between monitor controller and main controller B.

Faulty main controller B. NO

Faulty main controller B, or broken harness between monitor controller and main controller B.

Faulty monitor controller. 24 V

T5-6-31

T183-05-04-008

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE STOP INDICATOR • Check for loose harness connections beforehand. Even If Engine is Normal, Indicator comes ON. • Check if fault code corresponding to ECM is not displayed beforehand.

Faulty engine stop indicator relay.

Switch stop indicator relay and other general-purpose relay. Check if indicator comes ON. · Key switch: ON

YES Disconnect DLU connector 76D. Check if voltage between YES DLU terminals #76 to #64 and vehicle frame is 24V.

Disconnect DLU connector 76D and monitor connector C. Check for NO short-circuited harness between terminals #67 and vehicle frame.

Faulty DLU.

YES Short-circuited harness between DLU and monitor.

Faulty monitor. NO

Indicator does not come ON even if engine has troubles. Burnt indicator bulb, or faulty monitor controller.

Turn key switch ON. Check if indicator comes

YES

Faulty engine stop indicator relay.

Switch stop indicator relay and other general-purpose relay. YES Check if indicator comes ON. Disconnect DLU connector 76D. Check if voltage beNO tween DLU terminals #76 to #64 and vehicle frame is 24V.

NO DLU Disconnect connector 76D. NO Check if voltage between terminals #8 and #9 is 24V.

NO Faulty DLU.

Broken harness between DLU and relay. (termiYES nals #5 to #64) YES

Faulty DLU.

Check for continuity between monitor C19 YES and terminals #67. Broken harness between NO monitor and DLU.

T5-6-32

TROUBLESHOOTING / Troubleshooting C

Connector DLU Connector D

DLU Connector A #64

Monitor Connector C #8

T18E-05-06-008

T18E-05-06-002

#67

T5-6-33

T18E-05-06-009

#19

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE WARNING INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand.

Indicator comes ON even if engine has no trouble. Short-circuited harness between ECM and monitor controller.

YES Disconnect monitor controller connector C. Check for continuity for vehicle frame and terminal #16.

Faulty monitor controller. NO

Indicator does not come ON even if engine has troubles.

YES

Turn key switch to ON position. Check if indicator comes ON.

Disconnect monitor controller connector C and ECM connector 31 poles. Check for continuity between terminals #C16 and #17. Âˇ Key switch: ON

YES Broken harness between monitor controller and ECM.

Faulty ECM. NO

Burned indicator light, or faulty monitor controller.

T5-6-34

TROUBLESHOOTING / Troubleshooting C

Connector Engine Warning Indicator Relay

ECM Connector 31 Poles

Monitor Controller Connector C #17

T183-05-04-014

T183-05-04-003

C16

T18E-05-04-004

T5-6-35

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF QUICK-IDLE INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand.

Connector Monitor Controller Connector B

T183-05-04-013

Connector C

T183-05-04-014

Indicator comes ON even if quick-idle system is not operating.

Disconnect monitor conYES troller connector B. Check if indicator comes ON. Disconnect quick-idle switch. Check if indicator comes ON.

Disconnect monitor conYES troller connector C. Check if voltage at harness end connector terminal #C3 is 24 V.

Short-circuited harness between quick-idle switch and monitor controller.

Faulty quick-idle switch. NO

Indicator does not come ON even if quick-idle system is operating. Burned indicator light, or faulty monitor controller.

T5-6-36

TROUBLESHOOTING / Troubleshooting C

Faulty quick-idle relay, or short-circuited harness between monitor controller and quick-idle relay.

YES

Faulty monitor controller. NO

T5-6-37

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF AUTO-IDLE INDICATOR â&#x20AC;˘ Check for loose harness connections beforehand.

Connector Switch Box

T183-05-04-004

Monitor Controller Connector B B10

Indicator does not come ON even if auto-idle system is operating.

T183-05-04-013

Burned indicator light, or faulty monitor controller.

YES Disconnect monitor controller connector B. Check if voltage at harness end connector terminal #B10 is 24 V.

Broken harness between switch box and monitor controller.

Indicator comes ON even if auto-idle system is not operating.

YES

Disconnect switch box. Check if indicator comes ON.

YES

Faulty monitor controller.

Short-circuited harness between switch box and monitor controller.

Disconnect monitor controller connector B. Check if indicator comes ON.

Faulty switch box. NO

T5-6-38

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-39

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF HOURMETER • Check for loose harness connections beforehand. Hourmeter Does Not Operate When Engine Is Running Less than 13 V or 33.5 V or more

13 V or more less than 33.5 V

NO Measure voltage at alternator terminal L. · Engine speed: 900 min-1 (rpm) or more.

Connect alternator relay. Disconnect monitor controller connector A. 13 V or more Measure voltage at less than 33.5 V harness end connector terminal #A2.

Check if alternator indicator comes ON. · Engine: Running

Faulty monitor controller.

Broken harness between monitor controller and alternator. Refer to "MALFUNCTION OF ALTERNATOR INDICATOR" (Alternator indicator stays ON after engine is started).

YES

Connector Monitor Controller Connector A

Faulty alternator.

T183-05-05-001

T5-6-40

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-41

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF BUZZER • Check for loose harness connections beforehand. Buzzer sounds continuously key switch is turned ON without starting engine. 10 V or more Measure voltage at monitor controller connector A terminal #A2. · Key switch: ON without starting engine

Faulty alternator.

Faulty monitor controller.

Less than 10 V

Buzzer sounds continuously when engine is started. YES

Check if pump transmission oil pressure indicator comes ON.

Faulty pump transmission oil pressure system.

YES

Check if engine stop indicator comes ON. NO

Buzzer does not sound even if pump transmission oil pressure indicator or engine stop indicator comes ON.

Faulty engine system.

Check if buzzer stops by pressing buzzer cancel switch.

Normal (Engine speed is too slow).

Check if alternator indicator comes ON. Measure voltage at regulator terminal R.

YES

· Engine: Running

T5-6-42

TROUBLESHOOTING / Troubleshooting C Connector

Starter Relay 2 (Harness End)

Monitor Controller Connector A (Harness End)

1 2

T183-05-05-001

YES

Normal.

Faulty monitor controller. NO

less than 13 V

Disconnect alternator terminal R and monitor controller connector A. Check for continuity between terminals R and #A2.

YES

Faulty alternator.

Broken harness between alternator terminal R and monitor panel.

Faulty monitor controller. 13 V or more

T5-6-43

TROUBLESHOOTING / Troubleshooting C MALFUNCTION DISPLAY (LCD)

LIQUID

CRYSTAL

• This section describes the following items: 1 to 7: Displayed in normal condition. 8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning. Main Controller A Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hydraulic Oil Temperature − − Fault Code Main Pump 1 Pressure Main Pump 2 Pressure Main Pump 3 Pressure Front Attachment Operation Pressure Travel Operation Pressure Engine Exhaust Gas Temperature EC Angle Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Hydraulic Oil Cooling Output Current Power Increase Output Current

Causes Refer to T5-6-40 Faulty monitor. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-6-44

TROUBLESHOOTING / Troubleshooting C

• This section describes the following items: 1 to 7: Displayed in normal condition. 8 to 23: Displayed when switched to the build-in diagnosing system. • Check that the machine control is not malfunctioning. Main Controller B Side Display Description Order 1 Hourmeter 2 Trip1 3 Trip2 Engine Actual Speed 4 5 6 7 8 9 10 11 12 13 14 15 16

17 18 19 20 21 22 23

Hydraulic Oil Temperature − − Fault Code Digital Input 0 Digital Input 1 Digital Input 2 Digital Input 3 Digital Output Proportional Valve ON/OFF Output Auto-Lubrication Status 1 Auto-Lubrication Status 2 (upper 4 bits) Auto-Lubrication Status 2 (lower 4 bits) Auto-Lubrication Interval Selection Digital Output 2 (upper 4 bits) Digital Output 2 (lower 4 bits) − − −

Causes Refer to T5-6-40. Faulty monitor. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

Faulty monitor, or faulty communication between monitor and MC. Faulty sensor system detecting corresponding signal. (There should be some abnormality with the machine control. Refer to Troubleshooting B).

T5-6-45

TROUBLESHOOTING / Troubleshooting C MALFUNCTION OF ENGINE TROUBLESHOOTING OPERATION â&#x20AC;˘ Check for loose harness connections beforehand.

Fault code is not displayed when engine has some trouble even if engine diagnostic switch is turned to ON position.

Broken harness between engine fault diagnosing switch A and ground.

NO Check for continuity beYES tween harness end terminal #2 and vehicle frame.

YES Faulty ECM.

Disconnect ECM connector 31 poles. YES Check for continuity between harness end terminals #1 and #18.

Disconnect engine fault diagnosing switch A connector. Check for continuity between terminals.

Broken harness between ECM and engine fault NO diagnosing switch A.

Âˇ Engine fault diagnostic switch: ON Faulty engine fault diagnosing switch A.

Connector ECM Connector 31 Poles

Fault Diagnostic Switch B

Fault Diagnostic Switch A

#18

1 2

3 T18E-05-06-010

#12 T18E-05-04-004

#13

T5-6-46

TROUBLESHOOTING / Troubleshooting C Even if some troubles occur in the engine and engine fault diagnosing switch B is switched, the previous or following fault code is not displayed. NOTE: If only one trouble occurs in the engine and engine fault diagnosing switch B is switched, the fault code does not change.

Faulty engine fault diagnosing switch B.

YES

Disconnect engine fault diagnosing switch B connector. Connect harness end terminals #1 to #3 and #2 to #3. Check if fault code switches.

YES

Âˇ Key switch: ON Âˇ Engine fault diagnosing switch A: ON NO

Disconnect ECM connector 31 poles. Check for continuity between harness end terminals #1 and #13, #2 and #12. NO

T5-6-47

Faulty ECM.

Broken harness between engine fault diagnosing switch B and ECM.

TROUBLESHOOTING / Troubleshooting C (Blank)

T5-6-48

TROUBLESHOOTING / Troubleshooting D TROUBLESHOOTING D PROCEDURES Refer to Troubleshooting D if the engine stop indicator and the engine warning indicator in the cab start flashing by the ECM diagnosis system. Refer to the System section in the Technical Manual (Operational Principle).

T5-7-1

TROUBLESHOOTING / Troubleshooting D Inspection Method When any trouble occurs in the engine control system, one of the following indicators come ON: • • • • •

Monitor Panel

Overheat Indicator Engine Oil Pressure Indicator Coolant Level Indicator Engine Warning Indicator 1 Engine Stop Indicator 1 4

In addition, the following indicators on the engine fault code indicator panel blink or come ON to indicate the fault code or fault level.

• Engine Warning Indicator 2 • Engine Stop Indicator 2 • Engine Protection Indicator ECM (Electronic Control Module) memorizes malfunctions of the engine in the form of fault codes. This fault code can be displayed in two forms: 2

• Indicated by the blinking pattern of the engine warning indicator and engine stop indicator. • Displayed by INSITE (diagnostic tool by CUMMINS CO.)

T183-01-02-013

Engine Fault Code Indicator Panel

When the fault code is displayed, record the fault code (3 digit number), and contact CUMMINS CO. for advise. NOTE: The fault level indicates the seriousness of the trouble which is preset in ECM. The engine warning indicator, engine stop indicator or engine protection indicator comes ON according to the seriousness of the trouble.

T141-05-03-002

M18E-01-009

1 - Engine Warning Indicator 1 2 - Engine Stop Indicator 1 3 - Coolant Level Indicator 4 - Overheat Indicator

T5-7-2

5 - Engine Oil Pressure Indicator 6 - Engine Warning Indicator 2 7 - Engine Stop Indicator 2 8 - Engine Protection Indicator

TROUBLESHOOTING / Troubleshooting D FAULT CODE INDICATION BY INDICATOR BLINKING PATTERN The fault code is indicated by the blinking pattern of the engine warning indicator 2 and engine stop indicator 2 if the engine fault diagnosing switch A and/or B is operated. NOTE: The engine warning indicator 1 and engine stop indicator 1 on the monitor panel may blink when the fault diagnosing switch A and/or B is operated. This does not indicate the fault code. Fault Diagnosing Switch There are two diagnostic switches: A and B. These switches are used to indicate the fault codes. Both diagnostic switches are self-return type, so a fault code is indicated while switches are pressed up or down. Switch A: The fault code is indicated by pressing the switch upward. Switch B: This is used when more than one fault code is memorized. The next fault code is displayed when pressing the switch up once, and previous fault code is displayed when pressing the switch down once. Troubleshooting Procedure 1. Turn key switch to ON position. (Engine: Stop) When Fault Code is Not Memorized: The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come ON in sequence. Then, all three indicators go OFF. When Faulty Code is Memorized: The engine warning indicator 2, engine stop indicator 2 and engine protection indicator come ON in sequence. Then, all three indicators go OFF. After that, the indicator corresponding to the fault level stays ON.

T5-7-3

Fault Diagnosing Switch B

Fault Diagnosing Switch A

M18E-01-009

TROUBLESHOOTING / Troubleshooting D 2. Turn the engine fault diagnosing switch A ON (press upward). The engine warning indicator 2 and engine stop indicator 2 blink in the following sequence. (Three indicators stay ON when no fault code is memorized). • The engine warning indicator 2 blinks once. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the hundredth digit. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the tenth digit. • After approx. one seconds, the engine stop indicator 2 blinks. The blinking number indicates the first digit. • Finally, the engine warning indicator 2 blinks once. 3. The fault code is indicated repeatedly in the above sequence.

Example: in case of Fault Code 132 (Fault code is indicated in three digit number) hundredth number

tenth number

first number

OFF

NOTE: When wires of the engine control system has been disconnected for service, ECM recognizes it as malfunction and stores it in the history. This record remains even if it is reconnected. The diagnostic tool INSITE is required to erase this record. NOTE: The code indicated on the fault code indicator panel shows the trouble occurring currently. The diagnostic tool INSITE is required to indicate the past history.

T5-7-4

one second

T141-05-03-004

TROUBLESHOOTING / Troubleshooting D FAULT CODES FOR QUANTUM ENGINES

S020 3

114 Yellow

QSK60

113 Yellow

QSK45

635 7

QST30

S020 7

QSK23

112 Red

QSK19

Engine Control Module â&#x20AC;&#x201C; Critical internal failure

QSX15

629 12

QSM11

S254 12

DESCRIPTION

QSL9

111 Red

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

Engine Timing Actuator is not responding to ECM commands

635 3

Engine Timing Actuator Circuit shorted high

S020 4

635 4

Engine Timing Actuator Circuit shorted low

115 Red

P190 2

190 2

116 Red

P156 3

156 3

Engine Speed/Position Sensor Circuit lost both of two signals from the magnetic pickup sensor Fuel Timing Pressure Sensor Circuit shorted high

117 Red

P156 4

156 4

118 Yellow

P135 3

119 Yellow

X X

Fuel Timing Pressure Sensor Circuit shorted low

135 3

Fuel Pump Delivery Pressure Sensor Circuit - shorted high

P135 4

135 4

Fuel Pump Delivery Pressure Sensor Circuit - shorted low

121 Yellow

P190 10

190 10

122 Yellow

P102 3

102 3

Engine Speed/Position Sensor Circuit lost one of two signals from the magnetic pickup sensor Intake Manifold Pressure Sensor #1 Circuit - shorted high

123 Yellow

P102 4

102 4

Intake Manifold Pressure Sensor #1 Circuit - shorted low

124* Yellow

102 16

125* None

High Intake Manifold Pressure Left Bank

102 18

Low Intake Manifold Pressure Left Bank

126* Yellow

1129 16

High Intake Manifold Pressure Right Bank

127* None

1129 18

Low Intake Manifold Pressure Right Bank

NOTE: *Denotes Cense Fault codes.

T5-7-5

TROUBLESHOOTING / Troubleshooting D

QSK45

QSK60

129* None

1129 4

Right Bank Intake Manifold Pressure Sensor Circuit Failed Low

QSX15

Right Bank Intake Manifold Pressure Sensor Circuit Failed High

QSL9

1129 3

QSC

128* None

DESCRIPTION

QSB

QST30

FMI

QSK23

SPN QSK19

SID(S) PID(P) FMI

QSM11

FAULT CODE/ LAMP

131 Red

P091 3

091 3

Accelerator Pedal Position Sensor Circuit - shorted high

132 Red

P091 4

091 4

Accelerator Pedal Position Sensor Circuit - shorted low

133 Red

P029 3

974 3

Remote Accelerator Pedal Position Sensor Circuit - shorted high

133 Red

P029 3

29 3

Remote Accelerator Pedal Position Sensor Circuit - shorted high

134 Red

P029 4

974 4

Remote Accelerator Pedal Position Sensor Circuit - shorted low

134 Red

P029 4

29 4

Remote Accelerator Pedal Position Sensor Circuit - shorted low

135 Yellow

P100 3

100 3

Engine Oil Pressure Sensor Circuit shorted high

136* None

1208 3

Pre Filter Oil Pressure Sensor Circuit Failed High

137* None

1208 4

Pre Filter Oil Pressure Sensor Circuit Failed Low

X X

P100 4

100 4

Engine Oil Pressure Sensor Circuit shorted low

143 Yellow

P100 1

100 18

Engine Oil Pressure Low - Warning

143 White

P100 1

100 1

Engine Oil Pressure Low - Warning

144 Yellow

P110 3

110 3

Engine Coolant Temperature Sensor Circuit - shorted high

145 Yellow

P110 4

110 4

Engine Coolant Temperature Sensor Circuit - shorted low

146 Yellow

P110 0

110 16

Engine Coolant Temperature High â&#x20AC;&#x201C; Warning

T5-7-6

141 Yellow

NOTE: *Denotes Cense Fault codes.

X X

TROUBLESHOOTING / Troubleshooting D SID(S) PID(P) FMI

QSB

QSC

QSL9

QSM11

QSX15

QSK19

QSK23

QST30

QSK45

QSK60

SPN

FAULT CODE/ LAMP

147 Red

P091 8

091 8

Accelerator Pedal Position Sensor Circuit - low frequency

148 Red

P091 8

091 8

Accelerator Pedal Position Sensor Circuit - high frequency

151 Red

P110 0

110 0

Engine Coolant Temperature High – Critical

151 White

P110 0

110 0

Engine Coolant Temperature High – Critical

153 Yellow

P105 3

105 3

Intake Manifold Temperature Sensor #1 Circuit - shorted high

154 Yellow

P105 4

105 4

Intake Manifold Temperature Sensor #1 Circuit - shorted low

155 Red

P105 0

105 0

Intake Manifold Temperature #1 High Critical

155 White

P105 0

105 0

Intake Manifold Temperature #1 High Critical

156* Yellow

1131 3

157* Yellow

FMI

DESCRIPTION

X X

1131 4

Left Bank Rear Intake Manifold Temperature Sensor Circuit Failed High Left Bank Rear Intake Manifold Temperature Sensor Circuit Failed Low

158* White

1131 0

High Intake Manifold Temperature Left Bank Rear

159* Yellow

1132 3

161* Yellow

1132 4

Right Bank Front Intake Manifold Temperature Sensor Circuit Failed High Right Bank Front Intake Manifold Temperature Sensor Circuit Failed Low

162* White

1132 0

High Intake Manifold Temperature Right Bank Front

163* Yellow

1133 3

164* Yellow

1133 4

Right Bank Rear Intake Manifold Temperature Sensor Circuit Failed High Right Bank Rear Intake Manifold Temperature Sensor Circuit Failed Low

165* White

1133 0

High Intake Manifold Temperature Right Bank Rear

NOTE: *Denotes Cense Fault codes.

T5-7-7

X X

TROUBLESHOOTING / Troubleshooting D

Rack Position Sensor #1 Circuit shorted Low

172 Red

S023 6

638 6

Rack Actuator Position #1 Circuit grounded circuit

173 Yellow

S023 7

638 7

Rack Actuator - mechanically stuck open

184 Yellow

S233 2

609 2

Engine Control Module Identification Input State Error

185 Yellow

S231 2

639 2

Engine Control Module Network Communication Error

187 Yellow

S232 4

620 4

Sensor Supply Voltage #2 Circuit shorted low

211 None

S216 11

1484 31

Additional OEM/Vehicle Diagnostic Codes have been logged. Check other ECM's for DTC's. OEM Component Failure

175 3

Engine Oil Temperature Sensor Circuit - shorted high

175 3

Engine Oil Temperature Sensor Circuit - shorted high

175 4

Engine Oil Temperature Sensor Circuit - shorted low

175 4

Engine Oil Temperature Sensor Circuit - shorted low

175 0

Engine Oil Temperature High - Critical

175 0

Engine Oil Temperature High - Critical

211* None 212 Yellow

613 14 P175 3

212* Yellow 213 Yellow

P175 4

213* Yellow 214 Red

P175 0

214* White 219 Maint

P17 1

1380 17

Low Oil Level in the Centinel makeup oil tank

219 White

P17 1

1380 1

Low Oil Level in the Centinel makeup oil tank

221 Yellow

P108 3

108 3

Ambient Air Pressure Sensor Circuit â&#x20AC;&#x201C; shorted high

NOTE: *Denotes Cense Fault codes.

T5-7-8

QSK60

733 4

QST30

S024 4

QSK23

167 Yellow

QSK19

QSX15

Rack Position Sensor #1 Circuit shorted high

QSM11

733 3

QSL9

S024 3

DESCRIPTION

QSC

166 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSK45

SPN

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D SPN

Engine Oil Burn Valve Solenoid Circuit – shorted low

225 Yellow

S086 4

1266 4

Engine Oil Replacement Valve Solenoid Circuit - shorted low

227 Yellow

S232 3

620 3

Sensor Supply Voltage #2 Circuit shorted high

231 Yellow

P109 3

109 3

Engine Coolant Pressure Sensor Circuit - shorted high

232 Yellow

P109 4

109 4

Engine Coolant Pressure Sensor Circuit - shorted low

233 Yellow

P109 1

109 18

Engine Coolant Pressure Low Warning

233 White

P109 1

109 1

Engine Coolant Pressure Low Warning

234 Red

P190 0

190 0

Engine Speed High - Cricital

235 Red

P111 1

111 1

Engine Coolant Level Low - Critical

235 White

P111 1

111 1

Engine Coolant Level Low - Critical

237 Yellow

S030 2

644 2

External Speed Input (Multiple Unit Sychronization) - data incorrect

241 Yellow

P084 2

084 2

Vehicle Speed Sensor Circuit - data incorrect

242 Yellow

P084 10

084 10

Vehicle Speed Sensor Circuit tampering has been detected

243 Yellow

P121 4

513 4

Engine Brake Driver #1 Circuit shorted low

245 Yellow

S033 4

647 4

Fan Clutch Circuit - shorted low

252 Yellow

P098 2

098 2

Engine Oil Level #1 Sensor Circuit data incorrect

NOTE: *Denotes Cense Fault codes.

T5-7-9

QSK60

1265 4

QSK45

S085 4

QST30

223 Yellow

QSK19

Ambient Air Pressure Sensor Circuit – shorted low

QSX15

108 4

QSM11

P108 4

DESCRIPTION

QSL9

222 Yellow

FMI

QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

Fuel Shutoff Valve Circuit - shorted low

254 None

S017 4

632 4

Fuel Shutoff Valve Circuit - shorted low

255 Yellow

S017 3

632 3

Fuel Shutoff Valve Circuit - shorted high

259 Red

S017 7

632 7

Fuel Shutoff Valve - stuck open

261 Yellow

P174 0

174 16

Fuel Temperature High - Warning

261 White

P174 0

174 0

Fuel Temperature High - Warning

263 Yellow

P174 3

174 3

Fuel Temperature Sensor Circuit shorted high

264 Yellow

P174 11

174 11

Fuel Temperature Sensor Circuit - data out-of-range

265 Yellow

P174 4

174 4

268 Yellow

P094 2

271 Yellow

X X

QSK60

632 4

QSK45

S017 4

QST30

254 Red

QSK19

Engine Oil Level #1 Low - Critical

QSX15

098 1

QSM11

P098 1

DESCRIPTION

QSL9

253 White

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X X

Fuel Temperature Sensor Circuit shorted low

94 2

Fuel Pressure Sensor Circuit - data incorrect

S126 4

1347 4

High Fuel Pressure Solenoid Valve #1 Circuit - shorted low

272 Yellow

S126 3

1347 3

High Fuel Pressure Solenoid Valve #1 Circuit - shorted high

273 Yellow

S127 4

1348 4

High Fuel Pressure Solenoid Valve #2 Circuit - shorted low

274 Yellow

S127 3

1348 3

High Fuel Pressure Solenoid Valve #2 Circuit - shorted high

275 Yellow

S126 7

1347 7

Fuel Pumping Element #1 (Front) mechanically stuck

276 Yellow

S018 3

633 3

Fuel Injection Control Valve Circuit shorted high

NOTE: *Denotes Cense Fault codes.

T5-7-10

TROUBLESHOOTING / Troubleshooting D

278 Yellow

P073 11

1075 11

Fuel Priming Pump Control Circuit shorted high/low

279 Yellow

S018 4

633 4

281 Yellow

S126 7

282 Yellow

QSC

QSL9 X

Fuel Injection Control Valve Circuit shorted low

1347 7

High Fuel Pressure Solenoid Valve #1 - mechanically stuck

S127 7

1348 7

High Fuel Pressure Solenoid Valve #2 - mechanically stuck

283 Yellow

S221 3

1043 3

284 Yellow

S221 4

1043 4

285 Yellow

S231 9

639 9

Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit shorted high Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit shorted low SAE J1939 Multiplexing PGN Timeout Error

286 Yellow

S231 13

639 13

SAE J1939 Multiplexing Configuration Error

287 Red

P091 2

91 19

SAE J1939 Multiplexing Accelerator Pedal Sensor System Error

288 Red

P029 2

974 19

SAE J1939 Multiplexing Remote Throttle Data Error

292 White

P223 14

1083 14

Auxiliary Temperature Sensor Input # 1 Engine Protection - Critical

293 Yellow

S441 3

441 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

293 Yellow

P223 3

1083 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

293 Yellow

S154 3

1083 3

Auxiliary Temperature Sensor Input # 1 Circuit – shorted high

294 Yellow

S441 4

441 4

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

294 Yellow

P223 4

1083 4

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

NOTE: *Denotes Cense Fault codes.

T5-7-11

QSB

X X

QSK60

Fuel Injection Control Valve mechanically stuck

QSK45

633 7

QST30

S018 7

DESCRIPTION

QSK19

277 Yellow

FMI

QSX15

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

TROUBLESHOOTING / Troubleshooting D

295 Yellow

P108 2

108 2

Ambient Air Pressure Sensor Circuit data incorrect

296 Red

P223 14

1387 14

Auxiliary Pressure Sensor Input # 2 Engine Protection - Critical

296 White

P223 14

1084 14

Auxiliary Pressure Sensor Input # 2 Engine Protection - Critical

297 Yellow

P223 3

1387 3

Auxiliary Pressure Sensor Input # 2 Circuit – shorted high

297 Yellow

P223 3

1084 3

Auxiliary Pressure Sensor Input # 2 Circuit – shorted high

298 Yellow

P223 4

1387 4

Auxiliary Pressure Sensor Input # 2 Circuit – shorted low

298 Yellow

P223 4

1084 4

Auxiliary Pressure Sensor Input # 2 Circuit – shorted low

299 None

S117 14

1384 31

Engine Shutdown Commanded by J1939

299 Yellow

S117 11

1384 31

Engine Shutdown Commanded by J1939

311 Yellow

S001 6

651 6

Injector Solenoid Valve Cylinder #1 Circuit – grounded circuit

312 Yellow

S005 6

655 6

Injector Solenoid Valve Cylinder #5 Circuit – grounded circuit

313 Yellow

S003 6

653 6

Injector Solenoid Valve Cylinder #3 Circuit – grounded circuit

314 Yellow

S006 6

656 6

Injector Solenoid Valve Cylinder #6 Circuit - grounded circuit

315 Yellow

S002 6

652 6

Injector Solenoid Valve Cylinder #2 Circuit – grounded circuit

316 Yellow

S078 3

931 3

318 Yellow

S078 7

931 7

QSK60

QSK45

QST30

Auxiliary Temperature Sensor Input # 1 Circuit – shorted low

QSK19

QSX15

1083 4

QSL9

S154 4

DESCRIPTION

QSC

294 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

X X

Fuel Supply Pump Actuator Circuit shorted high

Fuel Supply Pump Actuator – mechanically stuck

NOTE: *Denotes Cense Fault codes.

T5-7-12

TROUBLESHOOTING / Troubleshooting D

Injector Solenoid Valve Cylinder #4 Circuit - grounded circuit

322 Yellow

S001 5

651 5

Injector Solenoid Valve Cylinder #1 Circuit - open circuit

323 Yellow

S005 5

655 5

Injector Solenoid Valve Cylinder #5 Circuit – open circuit

324 Yellow

S003 5

653 5

Injector Solenoid Valve Cylinder #3 Circuit – open circuit

325 Yellow

S006 5

656 5

Injector Solenoid Valve Cylinder #6 Circuit – open circuit

328 Yellow

S152 7

1348 7

Fuel Pumping Element #2 (Rear) mechanically stuck

329 Yellow

S233 14

1077 14

Fuel System Leakage error

331 Yellow

S002 5

652 5

Injector Solenoid Valve Cylinder #2 Circuit – open circuit

332 Yellow

S004 5

654 5

Injector Solenoid Valve Cylinder #4 Circuit – open circuit

341 Yellow

S253 2

630 2

Engine Control Module – data lost

342 Red

S253 13

630 13

Engine Control Module – out of calibration

343 Yellow

S254 12

629 12

Engine Control Module - Warning internal hardware failure

346 Yellow

S253 12

630 12

Engine Control Module - Warning Software error

349 Yellow

P191 0

191 16

Transmission Output Shaft (Tailshaft) Speed High – Warning

349 Yellow

P191 0

191 0

Transmission Output Shaft (Tailshaft) Speed High – Warning

352 Yellow

S232 4

1079 4

Sensor Supply Voltage #1 Circuit shorted low

NOTE: *Denotes Cense Fault codes.

T5-7-13

QSK60

654 6

QSK45

S004 6

QST30

321 Yellow

QSX15

Real Time Clock - Power Interrupt

QSM11

251 2

QSL9

P251 2

DESCRIPTION

QSC

319 Maint

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

1076 4

Fuel Pump Control Module, Fuel Control Valve Circuit - shorted low

363 Yellow

S251 7

1076 7

Fuel Pump Control Module, Fuel Control Valve - mechanically stuck

364 Yellow

S233 9

1077 9

365 Yellow

S233 4

1077 4

Fuel Pump Control Module, CAN Communication Error - abnormal update rate Fuel Pump Control Module, Supply Voltage Circuit - shorted low

366 Yellow

S233 2

1077 2

Fuel Pump Control Module, Supply Voltage Circuit - data incorrect

367 Yellow

P190 11

1078 11

Fuel Pump Control Module, Increment Angle Time Sensor Error

368 Yellow

S254 8

1078 8

Fuel Pump Control Module, Timing Error

369 Yellow

P190 2

1078 2

Fuel Pump Control Module, Engine Synchronization Error

372 Yellow

S233 11

1077 11

Fuel Pump Control Module, Idle Validation Error

373 Red

S233 3

1077 3

Fuel Pump Control Module, Fuel Shutoff Error

374 Yellow

S233 12

1077 12

Fuel Pump Control Module, Self-Test Error

375 Yellow

S254 2

629 2

Fuel Pump Control Module, Electronic Calibration Code Error

376 Yellow

S233 13

1077 13

Fuel Pump Control Module, Fueling or Engine Speed Mismatch

377 Yellow

S233 7

1077 7

Fuel Pump Control Module, Stuck Relay Error

378 Yellow

S018 5

633 5

Fueling Actuator #1 Circuit - open circuit

379 Yellow

S018 6

633 6

Fueling Actuator #1 Circuit - grounded circuit

NOTE: *Denotes Cense Fault codes.

T5-7-14

QSK60

S251 4

QSK45

362 Yellow

QST30

QSX15

Fuel Pump Control Module, Fuel Control Valve Circuit - shorted high

QSM11

1076 3

QSL9

S251 3

DESCRIPTION

QSC

361 Red

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

TROUBLESHOOTING / Troubleshooting D

382 Yellow

S237 11

626 11

Intake Air Heater (Relay Enable) #2 Circuit - data incorrect

384 Yellow

S237 11

626 11

Start Assist Device Control Circuit Error (Ether Injection)

385 Yellow

S232 3

620 3

OEM Sensor Supply Voltage Circuit shorted high

386 Yellow

S232 3

1079 3

Sensor Supply Voltage #1 Circuit shorted high

387 Yellow

S221 3

1043 3

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted high

389 Yellow

S033 11

647 11

Fan Clutch Circuit Error

391 Yellow

S017 11

632 11

Fuel Shutoff Valve Supply Voltage error

394 Yellow

S020 5

635 5

Timing Actuator #1 Circuit - open circuit

395 Yellow

S020 6

635 6

Timing Actuator #1 Circuit - grounded circuit

396 Yellow

S083 5

1244 5

Fueling Actuator #2 Circuit - open circuit

397 Yellow

S083 6

1244 6

Fueling Actuator #2 Circuit - grounded circuit

398 Yellow

S084 5

1245 5

Timing Actuator #2 Circuit - open circuit

399 Yellow

S084 6

1245 6

Timing Actuator #2 Circuit - grounded circuit

414* Yellow

S250 9

608 9

Data Communication error over the J1587 data link Circuit

415 Red

P100 1

100 1

Engine Oil Pressure Low – Critical

415 White

P100 1

100 1

Engine Oil Pressure Low – Critical

NOTE: *Denotes Cense Fault codes.

T5-7-15

QSK60

QSK45

Intake Air Heater (Relay Enable) #1 Circuit - data incorrect

QST30

626 11

QSK19

QSL9

S237 11

DESCRIPTION

QSX15

QSC

381 Yellow

FMI

QSM11

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

1319 2

Intake Manifold Boost Pressure Imbalance

P111 2

111 2

Engine Coolant Level Sensor Circuit data incorrect

423 Yellow

P156 2

156 2

Fuel Timing Pressure or Timing Actuator Stuck

426 None

S231 2

639 2

SAE J1939 datalink - cannot transmit

426 Yellow

S231 2

639 2

SAE J1939 datalink - cannot transmit

639 2

SAE J1939 datalink - cannot transmit

426* None

X X X

S231

639 9

SAE J1939 not fast enough

428 Yellow

P097 3

97 3

Water in Fuel Sensor Circuit - shorted high

429 Yellow

P097 4

097 4

Water in Fuel Sensor Circuit - shorted low

431 Yellow

S230 2

558 2

Accelerator Pedal Idle Validation Circuit - data incorrect

431 Yellow

P091 2

91 2

Accelerator Pedal Idle Validation Circuit - data incorrect

432 Red

S230 13

558 13

Accelerator Pedal Idle Validation Circuit - out of calibration

432 Red

P091 13

91 13

Accelerator Pedal Idle Validation Circuit - out of calibration

433 Yellow

P102 2

102 2

Intake Manifold Pressure Sensor Circuit - data incorrect

434 Yellow

S251 2

627 2

Power Lost without Ignition Off

435 Yellow

P100 2

100 2

Engine Oil Pressure Sensor Circuit data incorrect

T5-7-16

427 None

NOTE: *Denotes Cense Fault codes.

QST30

QSK19

QSK60

Water in Fuel Indicator High â&#x20AC;&#x201C; Maintenance

QSK45

097 15

QSX15

422 Yellow

DESCRIPTION

QSM11

P097 0

FMI

QSL9

418 WIF / Maint. 419 Yellow

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

441 None

P168 1

168 1

Battery #1 Voltage Low - Warning

442 Yellow

P168 0

168 16

Battery #1 Voltage High - Warning

442 Yellow

P168 0

168 0

Battery #1 Voltage High - Warning

443 Yellow

S221 4

1043 4

Accelerator Pedal Position Sensor Supply Voltage Circuit - shorted low

444 Yellow

S232 1

620 18

OEM Sensor Supply Voltage Low Warning

446* None

N/A

GSP Communication Failure

447* None

N/A

448* None

RPC Number Not Supported

N/A

RPC Argument Mismatch

DESCRIPTION

QST30

QSK60

QSK45

QSX15

Battery #1 Voltage Low - Warning

QSM11

168 18

QSL9

P168 1

QSC

441 Yellow

FMI

QSB

SID(S) PID(P) FMI

QSK19

SPN

FAULT CODE/ LAMP

X X

449 Yellow

P094 0

094 16

Fuel Pressure High - Warning

451 Yellow

P157 3

157 3

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high

451 Red

P157 3

157 3

Injector Metering Rail #1 Pressure Sensor Circuit - shorted high

452 Yellow

P157 4

157 4

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low

452 Red

P157 4

157 4

Injector Metering Rail #1 Pressure Sensor Circuit - shorted low

455 Red

S018 3

633 3

Fuel Control Valve Circuit - shorted high

466 Yellow

S032 4

1188 4

Turbocharger #1 Wastegate Control Circuit - shorted low

467 Yellow

S020 2

635 2

Timing Rail Actuator Circuit - data incorrect

NOTE: *Denotes Cense Fault codes.

T5-7-17

TROUBLESHOOTING / Troubleshooting D

Engine Oil Level Low - Maintenance

471 Maint.

P098 1

98 1

Engine Oil Level Low - Maintenance

472 Maint.

P017 2

1380 2

Engine Oil Level #2 Low – Maintenance

473 Yellow

P017 2

1380 2

Engine Oil Level #2 Low – Warning

1318 9

Exhaust Port Temperature Bank Imbalance

479* None

094 18

Fuel Pressure Low - Warning

483 Yellow

P129 3

1349 3

Injector Metering Rail #2 Pressure Sensor Circuit - shorted high

484 Yellow

P129 4

1349 4

Injector Metering Rail #2 Pressure Sensor Circuit - shorted low

485 Yellow

P129 0

1349 16

Injector Metering Rail #2 Pressure High - Warning

486 Yellow

P129 1

1349 18

Injector Metering Rail #2 Pressure Low - Warning

487 None

S237 1

626 1

Start Assist Device - Canister Empty (Ether Injection)

488 Yellow

P105 0

105 16

Intake Manifold Temperature High – Warningl

489 Yellow

P191 1

191 18

Transmission Output Shaft (Tailshaft) Speed Low – Warning

489 Yellow

P191 1

191 1

Transmission Output Shaft (Tailshaft) Speed Low – Warning

493

S018

1076

Fuel Pump Calibration Trim Circuit

Error

S221 11

1043 11

Engine Speed/Position Sensor #2 (Camshaft) Supply Voltage

T5-7-18

P094 1

NOTE: *Denotes Cense Fault codes.

482 Yellow

496 Yellow

QSK60

98 17

QSK45

P098 1

QST30

471 Maint.

QSK19

Fuel Rail Actuator Circuit - data incorrect

QSX15

633 2

QSM11

S018 2

DESCRIPTION

QSL9

468 Yellow

FMI

QSC

SID(S) PID(P) FMI

QSB

SPN

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

497 Yellow

S114 2

1377 2

Multiple Unit Synchronization Switch Circuit - data incorrect

498 Yellow

P098 3

098 3

499 Yellow

P098 4

514 Red

QSK60 X

098 4

Engine Oil Level Sensor – circuit shorted low

S018 7

633 7

Fuel Control Valve - mechanically stuck

515 Yellow

P091 3

091 3

Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted high

516 Yellow

P091 4

091 4

Accelerator Pedal Frequency Position Sensor Supply Circuit - shorted low

517 Yellow

S251 12

1076 12

Fuel Metering Solenoid - bad device

524 Yellow

P113 2

113 2

OEM Alternate Droop Switch Validation - data incorrect

527 Yellow

P154 3

702 3

Auxiliary Input/Output #2 Circuit shorted high

527 Yellow

S040 3

702 3

Auxiliary Input/Output #2 Circuit shorted high

528 Yellow

P093 2

093 2

OEM Alternate torque validation switch - data incorrect

529 Yellow

S051 3

703 3

Auxiliary Input/Output #3 Circuit shorted high

539 Yellow

S018 11

633 11

Injector Control Valve Electronic Filter (Transorb) Error

546 Yellow

P094 3

94 3

Fuel Delivery Pressure Sensor Circuit shorted high

547 Yellow

P094 4

94 4

Fuel Delivery Pressure Sensor Circuitshorted low

551 Yellow

S230 4

558 4

Accelerator Pedal Idle Validation Circuit - shorted low

551 Red

P091 4

091 4

Accelerator Pedal Idle Validation Circuit - shorted low

553 Yellow

P157 0

157 16

Injector Metering Rail #1 Pressure High - warning level

NOTE: *Denotes Cense Fault codes.

T5-7-19

QST30

QSX15

Engine Oil Level Sensor – circuit shorted high

QSL9

QSC

DESCRIPTION

QSB

QSK45

FMI

QSK19

SID(S) PID(P) FMI

QSM11

SPN

FAULT CODE/ LAMP

X X

TROUBLESHOOTING / Troubleshooting D

QSK60 X

554 Yellow

P157 2

157 2

Fuel Pressure Sensor Error

555 Yellow

P022 0

1264 16

Engine Blowby - Warning Level

555 White

P022 0

1264 0

Engine Blowby - Warning Level

581 Yellow

P015 3

1381 3

Fuel Supply Pump Inlet Pressure Sensor Circuit - shorted high

582 Yellow

P015 4

1381 4

Fuel Supply Pump Inlet Pressure Sensor Circuit â&#x20AC;&#x201C; shorted low

583 Yellow

P015 1

1381 18

Fuel Supply Pump Inlet Pressure Low warning level

595 Yellow

P103 0

103 16

Turbocharger #1 Speed High - warning level

596 Yellow

P167 0

167 16

Electrical Charging System Voltage High - warning level

597 Yellow

P167 1

167 18

Electrical Charging System Voltage Low - Warning Level

598 Red

P167 1

167 1

Electrical Charging System Voltage Low - Critical Level

599 Red

S025 14

640 14

OEM Commanded Dual Output Shutdown

611 None

S151 11

1383 31

Engine Hot Shutdown

611 None

S151 14

1383 31

Engine Hot Shutdown

612* Red

99 1

High Lubricating Oil Filter Restriction

616* None

1173 16

High Turbo Compressor Inlet Temp RB

617* None

1172 0

High Turbo Compressor Inlet Temp LB

621* Yellow

1137 18

Low #1 LB Cylinder Power

X X

NOTE: *Denotes Cense Fault codes.

T5-7-20

QST30

QSK19 X

QSX15

Injector Metering Rail #1 Pressure High - warning level

QSM11

157 0

QSL9

P157 0

DESCRIPTION

QSC

553 Red

FMI

QSB

SID(S) PID(P) FMI

QSK45

SPN

FAULT CODE/ LAMP

TROUBLESHOOTING / Troubleshooting D SPN QSK45

QSK60

623* Yellow

1139 18

Low #3 LB Cylinder Power

624* Yellow

1140 18

Low #4 LB Cylinder Power

625* Yellow

1141 18

Low #5 LB Cylinder Power

626* Yellow

1142 18

Low #6 LB Cylinder Power

627* Yellow

1143 18

Low #7 LB Cylinder Power

628* Yellow

1144 18

Low #8 LB Cylinder Power

631* Yellow

1143 (45) 1145 (60) 18 1329 1

Low #1 RB Cylinder Power

1144 (45) 1146 (60) 18 1329 1

Low #2 RB Cylinder Power

1145 (45) 1147 (60) 18 1329 1

Low #3 RB Cylinder Power

1146 (45) 1148 (60) 18 1329 1

Low #4 RB Cylinder Power

631* Yellow 632* Yellow 632* Yellow 633* Yellow 633* Yellow 634* Yellow 634* Yellow

Low #1 RB Cylinder Power

Low #2 RB Cylinder Power

Low #3 RB Cylinder Power

Low #4 RB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-21

QSX15

Low #2 LB Cylinder Power

QSL9

1138 18

QSC

622* Yellow

DESCRIPTION

QSB

QST30

FMI

QSK19

SID(S) PID(P) FMI

QSM11

FAULT CODE/ LAMP

TROUBLESHOOTING / Troubleshooting D

QSK60

QST30

QSK19

QSX15

QSM11

DESCRIPTION

QSL9

FMI

QSK45

635* Yellow

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

1147 (45) 1149 (60) 18 1329 1

Low #5 RB Cylinder Power

Low #6 RB Cylinder Power

636* Yellow

1148 (45) 1150 (60) 18 1329 1

637* Yellow

1151 18

Low #7 RB Cylinder Power

638* Yellow

1152 18

Low #8 RB Cylinder Power

641* Red

1137 0

High #1 LB Cylinder Exhaust Temperature

642* Red

1138 0

High #2 LB Cylinder Exhaust Temperature

643* Red

1139 0

High #3 LB Cylinder Exhaust Temperature

644* Red

1140 0

High #4 LB Cylinder Exhaust Temperature

645* Red

1141 0

High #5 LB Cylinder Exhaust Temperature

646* Red

1142 0

High #6 LB Cylinder Exhaust Temperature

647* Red

1143 0

High #7 LB Cylinder Exhaust Temperature

648* Red

1144 0

High #8 LB Cylinder Exhaust Temperature

635* Yellow 636* Yellow

Low #5 RB Cylinder Power

Low #6 RB Cylinder Power

649 None

S153 0

1378 0

Change Lubricating Oil and Filter

649 White

S153 11

1378 31

Change Lubricating Oil and Filter

NOTE: *Denotes Cense Fault codes.

T5-7-22

X X

TROUBLESHOOTING / Troubleshooting D

QST30

QSK45

QSK60 X

651* Red

657* Red

1143 1145 0 1144 1146 0 1145 1147 0 1146 1148 0 1147 1149 0 1148 1149 0 1150 0

(30,45) (60)

High #1 RB Cylinder Exhaust Temperature

658* Red

1151 0

652* Red

(30,45) (60)

High #2 RB Cylinder Exhaust Temperature

653* Red

(30,45) (60)

High #3 RB Cylinder Exhaust Temperature

654* Red

(30,45) (60)

High #4 RB Cylinder Exhaust Temperature

655* Red

(30,45) (60)

High #5 RB Cylinder Exhaust Temperature

656* Red

(30,45) (60)

High #6 RB Cylinder Exhaust Temperature

659* None

QSX15

QSL9

QSC

Change Lubricating Oil and Filter

649* None

DESCRIPTION

QSK19

FMI

QSM11

SPN

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

High #7 RB Cylinder Exhaust Temperature

High #8 RB Cylinder Exhaust Temperature

Change fuel filter

661* Yellow

1137 16

High #1 LB Cylinder Power

661* Yellow

1323 0

High #1 LB Cylinder Power

662* Yellow

1138 16

High #2 LB Cylinder Power

662* Yellow

1324 0

High #2 LB Cylinder Power

663* Yellow

1139 16

High #3 LB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-23

TROUBLESHOOTING / Troubleshooting D

QSK45

QSK60

QST30

QSK19

QSX15

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

663* Yellow

1325 0

High #3 LB Cylinder Power

664* Yellow

1140 16

High #4 LB Cylinder Power

664* Yellow

1326 0

High #4 LB Cylinder Power

665* Yellow

1141 16

High #5 LB Cylinder Power

665* Yellow

1327 0

High #5 LB Cylinder Power

666* Yellow

1142 16

High #6 LB Cylinder Power

666* Yellow

1328 0

High #6 LB Cylinder Power

667* Yellow

1143 16

High #7 LB Cylinder Power

668* Yellow

1144 16

High #8 LB Cylinder Power

669* None

Change coolant filter

671* None

1137 4

Cyl #1 LB Exhaust Temp Sens Failed Low

672* None

1138 4

Cyl #2 LB Exhaust Temp Sens Failed Low

673* None

1139 4

Cyl #3 LB Exhaust Temp Sens Failed Low

674* None

1140 4

Cyl #4 LB Exhaust Temp Sens Failed Low

675* None

1141 4

Cyl #5 LB Exhaust Temp Sens Failed Low

676* None

1142 4

Cyl #6 LB Exhaust Temp Sens Failed Low

677* None

1143 4

Cyl #7 LB Exhaust Temp Sens Failed Low

678* None

1144 4

Cyl #8 LB Exhaust Temp Sens Failed Low

NOTE: *Denotes Cense Fault codes.

T5-7-24

TROUBLESHOOTING / Troubleshooting D

QSK60

QSK19

QSX15

QSK45

Change Coolant

QST30

679* None

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

691* None

1172 3

LBF Turbo Comp Inlet Temp Sens Failed High

692* None

1172 4

LBR Turbo Comp Inlet Temp Sens Failed Low

694* None

1173 3

RBF Turbo Comp Inlet Temp Sens Failed High

695* None

1174 4

RBR Turbo Comp Inlet Temp Sens Failed Low

711* Yellow

1143 (45) 1145 (60) 16 1329 0

High #1 RB Cylinder Power

1144 (45) 1146 (60) 16 1330 0

High #2 RB Cylinder Power

1145 (45) 1147 (60) 16 1331 0

High #3 RB Cylinder Power

1146 (45) 1148 (60) 16 1332 0

High #4 RB Cylinder Power

1147 (45) 1148 (60) 16 1333 0

High #5 RB Cylinder Power

1148 (45) 1149 (60) 16

High #6 RB Cylinder Power

711* Yellow 712* Yellow 712* Yellow 713* Yellow 713* Yellow 714* Yellow 714* Yellow 715* Yellow 715* Yellow 716* Yellow

High #1 RB Cylinder Power

High #2 RB Cylinder Power

High #3 RB Cylinder Power

High #4 RB Cylinder Power

High #5 RB Cylinder Power

NOTE: *Denotes Cense Fault codes.

T5-7-25

TROUBLESHOOTING / Troubleshooting D

QSK60

QSK45

QST30

QSK19

QSX15

DESCRIPTION

QSM11

FMI

QSL9

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

716* Yellow

1334 0

High #6 RB Cylinder Power

717* Yellow

1150 0

High #7 RB Cylinder Power

718* Yellow

1151 0

High #8 RB Cylinder Power

1264 3

Crankcase Blowby Pressure Sensor Circuit - shorted high

719 Yellow

P022 3

721* None

727* None

1143 1145 4 1144 1146 4 1145 1147 4 1146 1148 4 1147 1149 4 1148 1150 4 1151 4

728* None

722* None 723* None 724* None 725* None 726* None

729 Yellow

P022 4

(30,45) (60)

Cyl #1 RB Exhaust Temp Sens Failed Low

(30,45) (60)

Cyl #2 RB Exhaust Temp Sens Failed Low

(30,45) (60)

Cyl #3 RB Exhaust Temp Sens Failed Low

(30,45) (60)

Cyl #4 RB Exhaust Temp Sens Failed Low

(30,45) (60)

Cyl #5 RB Exhaust Temp Sens Failed Low

(30,45) (60)

Cyl #6 RB Exhaust Temp Sens Failed Low

Cyl #7 RB Exhaust Temp Sens Failed Low

1152 4

Cyl #8 RB Exhaust Temp Sens Failed Low

1264 4

Crankcase Blowby Pressure Sensor Circuit - shorted low

747* None

Trend Data Memory Nearly Full

748* None

Trend Data Memory Full

749* None

Fault Log Snapshot Data Nearly Full

NOTE: *Denotes Cense Fault codes.

T5-7-26

TROUBLESHOOTING / Troubleshooting D

755 Yellow

Fault Log Snapshot Data Full P157 7

157 7

Injector Metering Rail #1 Pressure Malfunction

QSK60

QST30

QSK19

QSK45

754* None

Engine Speed/Position #2 - Cam sync error

QSX15

723 2

DESCRIPTION

QSM11

S064 2

FMI

QSL9

753 None

SPN QSC

SID(S) PID(P) FMI

QSB

FAULT CODE/ LAMP

756* None

Change Lubricating Oil Filters

757* None

Catastrophic Power Loss - ECM Data Lost

758 Yellow

P129 7

1349 7

Injector Metering Rail #2 Pressure Malfunction

772 Yellow

S118 11

1657 11

Needle Movement Sensor Left Bank

773 Yellow

S119 11

1658 11

Needle Movement Sensor Right Bank

768 Yellow

S009 11

923 11

Output Device Driver (VGT or Transmission shift PWM signal)

777 Yellow

P173 0

1180 0

Turbocharger #1 Turbine Inlet Temperature High - warning level

779 Yellow

S051 11

703 11

Auxiliary Equipment Sensor Input # 3 (OEM Switch)

951 None

P166 2

166 2

Cylinder Power Imbalance between cylinders

1000* None

X X

Vehicle Controller initiated fault log

2154* None

611 3

Post-Filter Oil Pressure Sensor CircuitShorted high

2155* None

611 4

Post-Filter Oil Pressure Sensor CircuitShorted Low

Auxiliary Equipment Sensor Input # 2 (OEM Pressure Sensor) Engine Protection â&#x20AC;&#x201C; Warning Auxiliary Equipment Sensor Input # 3 (OEM Switch) Engine Protection Critical

2194 Yellow

P223 11

1387 11

2195 Red

S051 14

703 14

NOTE: *Denotes Cense Fault codes.

T5-7-27

TROUBLESHOOTING / Troubleshooting D (Blank)

T5-7-28

TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect Power Source Be sure to remove the negative terminals from the batteries first when taking wire harnesses and connectors off for repair or replacement work. Failure to do so can result in damage to the wire harnesses, fuses, and fusible links and, in some cases, cause fire due to short circuit. 2. Color Coding of Wire Harnesses The color codes of the wire harnesses in the electrical system are shown in the table on the light. In some cases, where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color. Code

Color

Red

White

Blue

Green

Yellow

Black

Code

Color

Orange

Brown

Pink

Gray

Violet

Light Green

NOTE: 1) Code BW indicates a black base wire with white fine-line marking. 2) Initials “O” and “Or” both stand for the color orange. 3) Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires.

T5-8-1

TROUBLESHOOTING / Electrical System Inspection 3. Precautions for Connecting and Disconnecting Terminal Connectors 1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself. Be sure to release the lock first before attempting to separate connectors, if a lock is provided. 2) Water-resistant connectors keep water out so that if water enters the connector, water will not easily drain. When checking water-resistant connectors, take extra care not to allow water to enter these types of connectors. In case water should enter this connector, reconnect only after thoroughly drying the connector. 3) Before connecting terminal connectors, check that no terminals are bent or missing. In addition, as most connectors are made of brass, check that no terminals are corroding. 4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock â&#x20AC;&#x153;clicks.â&#x20AC;? 4. Precaution for Using a Circuit Tester 1) Before using a circuit tester, refer to the instructions in the circuit tester manual. Then, set the circuit tester to meet the object to be measured, voltage range and current polarity. 2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram. When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.

T5-8-2

Correct

Incorrect

T107-07-06-001

Correct Rust Bending Separation T107-07-06-002

Wind wire around the probe.

Probe

Sharpen the tip of wire. T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection INSPECTIONS CONNECTORS

FOR

DISCONNECTING

1. Push the lock to disconnect. NOTE: 1) Connectors may not be separated if the lock is pushed while the connectors are pulled. Be sure to push the lock first before pulling the connectors. 2) The lock is provided on the female connector (harness side).

T107-04-05-002

Locations of This Type Connector Hydraulic Oil Level Switch Proximity Switch Washer Boom Mode Selection Switch Air Conditioner Clutch Governor Actuator Monitor Controller Work Light Main Pump Delivery Pressure Sensor Oil Level Switch

Diode Front All Pressure Sensor Starter Relay 2 Buzzer Cancel Switch Air Conditioner Pressure Switch Air Conditioner Sensor Air Compressor Speaker Boost Pressure Sensor

Wiper Motor Flow Rate Decrease Solenoid Valve Travel Pressure Sensor Heavy Lift Switch Auto-Lubrication Timer Switch Air Conditioner Controller Air Conditioner Unit Ambient Air Temperature Sensor ECM Relay Exhaust Gas Temperature Sensor

Coolant Level Sensor Data Link Engine Diagnostic Switch Key Switch DC-DC Controller Room Light ECM Engine Speed Sensor Fuel Sensor

2. Pull to disconnect. Locations of This Type Connector Oil Pressure Sensor Air Vent Select Servo Motor Switch Box Frash Memory A/M Servo Motor Radio Fusible Link

Circulation Servo Motor Preheat Switch Power Transistor Hydraulic Oil Temperature Sensor Thermo-Guard Switch Step Light Switch Sun Exposure Sensor T107-04-05-004

3. Connector to pull apart Use a 10 mm wrench to tighten the screw until the torque mark (convex) appears when re-tightening.

Screw Convex

Locations of This Type Connector DLU

T107-04-05-005

T5-8-3

TROUBLESHOOTING / Electrical System Inspection FUSE INSPECTION Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. Checking fuse continuity with a tester is far superior to sight inspection.

3. Connect the negative probe to the vehicle ground, and touch the outside terminal of each fuse with the positive probe of the tester. When normal continuity of a fuse is intact, the tester will indicate 20 to 25 volts.

1. Turn the key switch ON In doing so, the battery relay is activated by the current from terminal M of the key switch, and electric power is supplied to all circuits except the No.19 fuse circuit and the No.20 fuse circuit.

NOTE: (a) All the inside terminals of the fuses in the fuse box are connected to the power source, while the outside terminals are connected to the accessories. Test all fuses using the same method, except the fuses for the No.19 fuse circuit and the No.20 fuse circuit. (b) To check the fuse for the No.19 fuse circuit and No.20 fuse circuit, turn the key switch to the START position and perform the test as described in (3).

2. Remove the fuse box cover and set the correct voltage measurement range of the tester. (Measurement range: 0 to 30 V)

No.20 Fuse Circuit

No.19 Fuse Circuit

Accessory (Outside)

ďź?

Accessory (Outside)

Power Source (Inside)

T142-06-06-004

T5-8-4

TROUBLESHOOTING / Electrical System Inspection Connection in Fuse Box 1 Fuse No.

Description

Capacity

Connected to

Remarks

Backup

Monitor Controller, DLU

Backup power source,

Controller

Main Controller B

Main power source Power source ON sig.

Power source 3

Power ON SIG.

Main Controller A, Main Controller B

DC-DC Converter

20 A

DC-DC Converter

Power source

MCX SOL

10 A

Main Controller A, Main Controller B

Power source

Travel Alarm

Travel Alarm (Optional)

Power source

Switch Box

Monitor Controller, Main Controller A

Main power source

Step Light

Step Light Relay

Power source Power source

Air Conditioner

BATT

Battery Relay, Battery Relay 2

Power source

Light

20 A

Work Light Relay 1, Work Light Relay 2

Power source

Wiper

20 A

Washer Relay, Wiper Motor

Power source

Air Conditioner

20 A

Power source

Solenoid

15 A

Air Conditioner (Heater) Flow Rate Decrease Solenoid Valve Relay, Power Transistor 1, Power Transistor 2, Power Transistor 3, Auto-Lubrication Relay, Solenoid Valve Relay

Power source

Radio

Radio, Monitor Controller

Power source

Lighter

10 A

Lighter

Power source

Room Lamp

Power source

Horn

10 A

Horn Relay

Power source

Start Repeating Relay

Starter Relay 1

Power source

ECM. ENG. Start, SIG

T18E-01-02-003

18 17 16 15 14 13 12 11

T18E-05-08-002

T5-8-5

TROUBLESHOOTING / Electrical System Inspection Fuse Box 2

T18E-01-02-003

T18E-05-08-001

Connection in Fuse Box 2 Fuse No. 1

Description ECM Main Power Source

Capacity 20 A

Connected to

Remarks

ECM

Main power source

Preheat Switch

Preheat Relay

Preheat Relay 1

Power source

ECM

Power source

DOWN LOAD PC, Satellite Communication Controller

Power source

ECM

DLU Main Power Source

DOWN LOAD PC

OPT5

20 A

OPT6

20 A

Coolant Level Switch

T5-8-6

TROUBLESHOOTING / Electrical System Inspection FUSIBLE LINK INSPECTION • Fusible Link 1 to 4

Pull off the fusible links to visually inspect.

Fusible Link 1 to 4

Fusible Link 5 to 8

• Fusible Link 5 to 8

Check continuity between both ends of the fusible link.

T183-01-02-015

T183-05-08-001

T5-8-7

TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn the key switch OFF. Check voltage between the battery positive terminal and the vehicle. V

Normal Voltage: 24 V NOTE: If voltage is abnormal, recharge or replace the battery. 2. Start the engine. Check voltage between the battery positive terminal and the vehicle. Normal Voltage: 26 to 28 V NOTE: If voltage is abnormal, check the charging system.

ALTERNATOR CHECK T142-06-06-002

In general, the alternator indicator remains off when the alternator is generating power. If the alternator indicator comes on while the engine is running, the alternator might be defective.

Terminal R

Terminal B

Generating Voltage Measurement 1. Measure voltages at terminals R and B after starting the engine. Specification: Terminal R: More than 21 V Terminal B: Approx. 28 V

T18E-05-08-004

T5-8-8

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-8-9

TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK Operate the key switch and the engine control dial as specified to apply voltage to the point to be measured. Check if the specified (standard) voltage is obtained at each point.

Tester Probes: Black (-) Probe :To vehicle (Grounding) Red (+) Probe :To the point to be measured.

24 Voltage Circuits For each 24 voltage circuit, start checking either from the power source side or the actuator side. Thereby, the failed part in each circuit can be located, if any. Engine Power Source Circuit Stopped Stopped Stopped Stopped Stopped Starting Circuit Cranking Cranking Cranking Cranking Cranking Cranking Accessory Circuit Stopped Stopped Stopped Stopped Charging Circuit Running Running Running Running Surge Voltage Prevention Circuit Running-Stopped Running-Stopped

Key Switch

Check Point

Standard

OFF OFF OFF OFF OFF

Between (2) and (1): One Battery Between (3) and (2): One Battery Between (3) and (1): Two Battery Between (4) and (E): Power Source Between (5) and (E): Fusible Link

10 to 12.5 V 10 to 12.5 V 20 to 25 V 20 to 25 V 20 to 25 V

START START START START START START

Between (6) and (E) : Key Switch Between (7) and (E) : Fuse Between (8) and (E) : Starter Relay 1 (Coil) Between (9) and (E) : Starter Relay 1 (Switch) Between (10) and (E): Starter Relay 2 (S) Between (11) and (E): Starter Motor (C)

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ACC ACC ACC ACC

Between (12) and (E): Radio Between (13) and (E): Cigar Lighter Between (14) and (E): Room Light Between (15) and (E): Horn

20 to 25 V 20 to 25 V 20 to 25 V 20 to 25 V

ON ON ON ON

Between (16) and (E): Alternator (B) Between (17) and (E): Battery Relay 1 (B) Between (18) and (E): Alternator (R) Between (19) and (E): Monitor Controller

26 to 30 V 20 to 25 V 20 to 25 V 20 to 25 V

ON-OFF ON-OFF

Between (20) and (E): Load Dump Relay (Coil) Between (21) and (E): Battery Relay (Coil)

20 to 25 V 20 to 25 V

T5-8-10

TROUBLESHOOTING / Electrical System Inspection Power Circuit

Fuse Box 1

Key Switch

DLU

5 Fusible Link

Battery Relay 2 Fuse Box 2

Load Damp Relay Battery Battery Relay 1

Monitor Controller

3 ECM

Main Controller B

T18E-02-03-007

T5-8-11

TROUBLESHOOTING / Electrical System Inspection Starting Circuit Key Switch

Fusible Link 1 Fuse Box 1

1 Pole Junction

Battery Relay 2

Fusible Link 5

Fusible Link 6 Fusible Link 7

Battery Relay 1

Fusible Link 8

Battery

Fuse Box 2

Alternator

Starter Relay

Starter Motor 2

Safety Relay 2

ECM

Starter Motor 1

Safety Relay 1

T5-8-12

T18E-02-03-010

TROUBLESHOOTING / Electrical System Inspection Accessory Circuit 12 13 Fuse Box 1 Radio

Key Switch

Fusible Link #1

Cigar Lighter Cab Light Horn

14 15 Battery Relay 2

Battery Relay 1

Battery T18E-02-03-009

T5-8-13

TROUBLESHOOTING / Electrical System Inspection Charging Circuit Key Switch

Fusible Link 1 Fuse Box 1

Fusible Link 2

17 1 pole Junction

Battery Relay 2

Fusible Link 3

Fusible Link 4 Battery Relay 1 Fusible Link 5 Battery

Fusible Link 6

Fuse Box 2

Fusible Link 7

Alternator

Fusible Link 8

Starter Relay

Air Heater 2 Air Heater 1

Monitor Controller

T18E-02-03-011

T5-8-14

TROUBLESHOOTING / Electrical System Inspection Surge Voltage Prevention Circuit

Key Switch

Fuse Box 1 Fusible link 1 1 Pole Junction

Battery Relay 2

Fusible link 3

Battery Relay 1

20 Load Damp Relay Power Transistor 3

Fusible link 5

Battery

Fusible link 6 Fusible link 7

Alternator

Fusible link 8 Main Controller B Monitor Controller

Safety Relay 2

Safety Relay 1

T18E-02-03-012

T5-8-15

TROUBLESHOOTING / Electrical System Inspection 5-Volt Circuit

Power Source 1

• Voltage between Terminal #1 and Vehicle Frame Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the vehicle frame (ground) under the following conditions.

Signal or Ground 2

Two Polarities

Key Switch: ON Black Probe (Minus) of Tester: Vehicle Frame (Ground) Red Probe (Plus) of Tester: Terminal #1

T107-07-05-006

When the voltage matches 5 ± 0.5 V, the circuit up to terminal #1 is normal.

Power Source Signal Ground 1 3 2 Three Polarities

• Voltage between Terminal #1 and Ground Terminal Turn the key switch OFF. After disconnecting the sensor connector, measure the voltage between machine side harness end connector terminal #1 (5 V power) and the ground terminal (terminal #2 for two polarities, terminal #3 for three polarities) under the following conditions.

T107-07-05-007

Two Polarities

Key Switch: ON Black Probe (Minus) of Tester: Ground Terminal (Terminal #2 or #3) Red Probe (Plus) of Tester: Terminal #1 T107-07-05-008

When the voltage matches 5 ± 0.5 V, the circuit up to terminal #1 or the ground terminal is normal.

Three Polarities

T107-07-05-009

T5-8-16

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Harness

Single-line continuity check Disconnect both end connectors of the harness and check continuity between both ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) to the machine chassis using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.

Ω

Connect to the vehicle frame.

Ω

NOTE: By conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) short-circuited, check continuity between terminals (a) and (c). If the ohm-meter reading is: 0 Ω = Line (B) - (b) has discontinuity. ∞ Ω = Line (A) - (a) has discontinuity. Multi-line short-circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C). If the ohm-meter reading is: 0 Ω = Short-circuit exists between the lines. ∞ Ω = No short-circuit exists between the lines.

T5-8-17

Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present. Multi-line continuity check Disconnect both end connectors of the harness, and short-circuit two terminals, (A) and (B), at one end connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ∞ Ω, either line (A) - (a), or (B) - (b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or, after changing the short-circuit terminals from (A) - (B) to (A) - (C), check continuity once more between terminals (a) and (c).

Connect to the vehicle frame.

If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity

Short-circuit between the harness and the vehicle frame

Ω

T107-07-05-003

First short-circuit

A B C

a b c

Second short-circuit

Ω

T107-07-05-004

Short-circuit between harnesses. A B C

a b c

Ω

T107-07-05-005

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-8-18

MEMO ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................ ........................................................................................................................................................................

Hitachi Construction Machinery Co. Ltd Attn: Publications, Marketing & Product Support Fax: 81-29-831-1162

Hitachi Ref. No.

SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:

MODEL: PUBLICATION NO.:

YOUR NAME: DATE: FAX:

(Located at the right top corner in the cover page)

PAGE NO.: (Located at the bottom center in the page. If two or more revisions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch if required. If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)

THE ATTACHED DIAGRAM LIST (The following diagrams are attached to this manual.) EX1200-5C ELECTRICAL CIRCUIT DIAGRAM (CUMMINS ENGINE SPECIFICATION) EX1200-5C CONNECTORS EX1200-5C BACKHOE HYDRAULIC CIRCUIT DIAGRAM EX1200-5C LOADING SHOVEL HYDRAULIC CIRCUIT DIAGRAM

Attach to Vol. No. : TT-18E-OPE-00

EX1200-5C ELECTRICAL CIRCUIT DIAGRAM (CUMMINS ENGINE SPECIFICATION) MONITOR OVERHEAT INDICATOR

FUSE BOX 1

MONITOR DOWNLOAR LAMP MONITOR COOLANT LEVEL INDICATOR

006

(CAMINS)

CAMINS PROTECTION LAMP CAMINS STOP LAMP MONITOR ENGINE OIL PREURE INDICATOR MONITOR ENGINE STOP LAMP

105

093

106

MITSUBISHI CONNECTION

BACKUP CONTROLLER POWER ON SIGNAL DC-DC CONVERTER

MITSUBISHI

095

LOAD ACC LOAD ALT1 LOAD ALT2

TRAVEL ALARM SWITCH BOX ENTRANCE LIGHT AIR CONDITIONER

SWITCH BOX

107

(MITSUBISHI WIRING)

LOAD ALT LOAD ALT

THIS IS NOT USED FOR CUMMINS

115 CUMMINS CONNECTION

108

(MITSUBISHI WIRING) DISCONNECT MITSUBISHI WIRING AND CONNECT CUMMINS WIRING

103

CHARGE SIGNAL

(MITSUBISHI)

MITSUBISHI ELECTRICAL WIRE PF200-01000 OR EQUIVALENT

CUMMINS

HORN

HEATER

WIPER RADIO LIGHT

CAB OUTSIDE

071

DLU MAIN POWER BACK UP

(CUMMINS WIRING)

116

CAB INSIDE

MONITOR ELECTRICAL POWER INPUT BACKUP ELECTRICAL POWER INPUT GLOW INPUT

ELECTRICAL POWER CIRCUIT

015 HOUR METER DATA COMMUNICATION SERIAL COMMUNICATION TXD SERIAL COMMUNICATION RXD FUEL SIGNAL COOLANT TEMPERATURE SIGNAL

REG INPUT

007

DC-DC CONVERTER

CAB OUTSIDE

CAB INSIDE

LIGHT WIPER HEATER SOLENOID RADIO LIGHTER ROOM LAMP HORN

072

FUSE BOX 2

094

(MITSUBISHI)

ECM MAIN POWER

089

109

(CUMINS)

ECM ON SIGNAL

m a r k e d connectors (16-D , 19-C) are same connectors for each.

DLU MAIN POWER

CONNECT WIRING BETWEEN TERMINALS S AND C OF MITSUBISHI SAFETY RERAY

016

009

LABEL A

ROOM LAMP POWER INPUT

SWITCH BOX

EC DIAL SIGNAL INPUT

017

AUTO-IDLE

EC DIAL SIGNAL INPUT

DLU CONNECTION

018 LIQUID CRYSTAL DISPRAY

WIPER SIGNAL INPUT

062

MITSUBISHI ENGINE WIRING FOR SAFETY RELAY

LIGHT SWITCH OVERHEAT MONITOR CONNECTION

AIR FILTER FUEL LEVEL

DISPRAY SELECTION SW

ROOM RAMP

DLU DOWNLOAD

LUBRICATION MODE SW

057

ALTERNATOR

SIGNAL

ENGINE OIL PRESSURE P/D PRESSURE

020 AUTO-IDLE

FAST

EXHAUST TEMPERATURE ABNORAITY

021 QUICK-IDLE

ENGINE CONTROL DIAL

024

022

MALE SHARE PLUG YAZAKI 7113-1020 WATER PROOF CAP YAZAKI 7120-8018 FEMALE RECEPTACLE YAZAKI 7115-1050 WATER PROOF CAP YAZAKI 7120-1157

DC-DC CONVERTER

090

COMPLETED WIRING FOR CUMMINS FOR CUMMINS

065

FLAT TERMINAL SCREW TERMINAL

TRAVEL MODE SWITCH

067

AUTO LUBLICATION WARNING

113

ENGIN STOP FUEL SIGNAL COOLANT TEMPERATURE SIGNAL

ENGIN WARNING

LUBRICATION MODE LED

(5V PULL-UP)

SUN EXPOSURE SENSOR WITHIN 1m FROM DIVERGING CONNECTOR

PULL UP

RELAY OUTPUT CIRCIT

(INSTALL COVER)

010

FLAT TERMINAL WITH LOCK

066

HYDRAULIC OIL LEVEL WARNING

023

QUICK-IDLE RELAY OUTPUT LIGHT 1 RELAY OUTPUT LIGHT 2 RELAY OUTPUT WIPER C RELAY OUTPUT WIPER B RELAY OUTPUT WIPER A RELAY OUTPUT WASHER RELAY OUTPUT

WATER PROOF PLUG CONNECTOR

LIGHTER

COOLANT LEVEL

ENGINE STOP MONITOR C19 ENGINE OIL PRESSUR MONITOR C18 OVERHEAT B6 COOLANT LEVEL C13

THIS IS NOT USED FOR CUMMINS

FOR CUMMINS

ROOM LAMP POWER INPUT

SLOW

ENGINE OIL LEVEL

073

MITSUBISHI CONNECTION

WIPER VR

PREHEAT DISPRAY RESET SW

CUMINS CONNECTION

064

SIGNAL

112

WIRING FOR START REPEATING RELAY OF MITSUBISHI ENGINE (INSULATE AS FOR CIMMINS ENGINE)

063

WIPER SIGNAL INPUT

118

088

062

WASHER SWITCH

WIPER SIGNAL INPUT

019

111

096 ROOM LAMP

117

110

AIR FILTER WARNING SWITCH INPUT FUEL LEVEL INPUT PREHEAT DLU DOWNLOAD ALTERNATOR EXT EXHAUST TEMPERATURE ABNORALITY SIGNAL INPUT ENGINE OIL LEVEL EXT COOLANT LEVEL EXT HYDRAULIC OIL SWITCH INPUT AUTO LUBRICATION WARNING SWITCH INOUT ENGINE STOP ENGINE WARNING

AIR FILTER WARNING SWITCH INPUT FUEL LEVEL EXT PREHEAT DLU DOWNLOAD ALTERNATOR EXT EXHAUST TEMPERATURE ABNORMALITY ENGINE OIL LEVEL EXT

ENGINE OIL PRESSURE SWITCH INPUT OVERHEAT SWITCH INPUT P/DPRESSURE SIGNAL ENGINE OIL LEVEL SWITCH INPUT ENGINE COOLANT LEVEL SWICH INPUT AUTO -IDLE SWITCH INPUT QUICK -IDLE SWITCH INPUT WASHER SWITCH INPUT LIGHT SWITCH 1 INPUT LIGHT SWITCH 2 INPUT ENGINE STOP BUZZER CANCEL SWIITCH HOUR METER STOP

ENGINE OIL PRESSURE SWITCH INPUT OVERHEAT SWITCH INPUT P/D PRESSURE SIGNAL ENGINE OIL LEVEL SWITCH INPUT ENGINE COOLANT LEVEL SWITCH INPUT AUTO-IDLE SWITCH INPUT QUICK-IDLE SWITCH INPUT WASHER SWITCH INPUT LIGHT SWITCH 1 INPUT LIGHT SWITCH 2 INPUT

HYDRAULIC OIL LEVEL SWITCH AUTO-LUBLICATION CONNECTOR FOR CPT. BOX GROUND

119

RATED

104 077

130

123

(PLUG)

BUZZER CANCEL SWITCH

078

LUBRICATION MODE 1 SIGNAL OUT PUT

114

LUBRICATION MODE 2 SIGNAL OUT PUT

124

WIPER/WASHER MOVE SIGNAL OUT PUT

COMPLETED WIRING

097 079

058

045

HORN RELAY

WEDGE

001

091

(PLUG)

092

059 DIVERGING CONNECTOR

WORK LIGHT

068

HORN SWITCH

CABUPPER RIGHT

069

120

080

MONITOR

FUEL TEMPERATURE SENSOR

098

(PLUG)

060

125

CABUPPER LEFT

COMPLETED WIRING

121 (TANK ASSEMBLY

COMPLETED WIRING

002

COMPLETED WIRING

MONITOR

041

128

044

003 COMPLETED WIRING

004 074 MONITOR SELECTION SWITCH 061

DISPRAY

126

MONITOR

085

CUMINS CONNECTION

CONNECTION

122

011

INSULATION CAP

012

070

081

NEUTRAL

LONG

CHECKER DLU CONNECTION

INSULATION CAP

NITSUBISHI CONNECTION

086

MIDDLE SHORT

040 LABEL B

LABEL A

013

100

101

102

127

099

MCX-B

AUXILIARY GND

JU PREVENTION

CONTROLLER

TRAVRL MODE

082

CUMMINS ADDITIONAL DIODE

NOTE

BLOWER CONTROLLER TEMPERATURE PROTECTION

AIR CONDITIONER CONTROLLER

AIR VENT SELECT SERVO MOTOR

NOTHING

A/M SERVO MOTOR

NOTHING

DRIVE CIRCUIT INPUT SIGNAL PROCESS VOLTAGE CORRECTION

083 CIRCULATION TEMPRERATURE SENSOR FRONT SENSOR

NOTHING NOTHING

HYDRAULIC OIL LEVEL ALARM SWITCH 1

SHIELD LINE

076 HIGH LOW PRESSURE SWITCH

084

HYDRAULIC OIL LEVEL ALARM SWITCH 2

AIR CLEANER CLOG WARNING SWITCH

005

COOLANT TEMPERTURE SENSOR (THW)

AIR CONDITIONER UNIT

VIEWED FROM MATING SURFACE

051 DELIVERY

052 DELIVERY

PRESSURE SENSOR 3

PRESSURE SENSOR 2

PRESSURE SENSOR 1

PUMP 3

048 OIL COOLER FAN OPTIONAL

050 DELIVERY

HEAVY LIFT

TRAVEL MODE

TRAVEL ALARM

PUMP POWER INCREASE

2-SPOOL EHC VALVE

049

PUMP 2 PRESSURE SENSOR(HIGH)

087 TWIST BEAR LINE

PRESSURE FRESH AIR SENSOR

MITSUBISHI DIODE NOTHING

ENTRANCE LIGHT

TRAVEL MODE SWITCH

AUTO-LUBLICATION ALARM

SOLENOID

HYDLAURIC OIL LEVEL ALARM

MAIN

CONTROL PRESSURE

MONITOR SELECTION SWITCH

TRAVEL CONTROL PRESSURE

SOLENOID POWER

ENTRANCE LIGHT SWITCH

SOLENOID

MONITOR SELECTION SWITCH

KEY MAIN SIGNAL POWER

(YELLOW) INSTALL A COVER WITH A ROPE

CHARGE SIGNAL BOOM MODE SELECTOR SWITCH

MAIN

SOLENOID POWER

POWER FOR SENSOR

HEAVY LIFT SWITCH

A20 #1,2 PUMP POWER DECREASE SOLENOID VALVE A19 #1,2 PUMP POWER DECREASE SOLENOID VALVE

A14 #3 PUMP POWER DECREASE SOLENOID VALVE A14 #1 PUMP POWER DECREASE SOLENOID VALVE

m a r k e d connectors (12-H,13-J) are same connectors for each

ENGINE OIL PRESSURE ALARM ENGINE PROTECTION ALARM

KEY MAIN SIGNAL POWER

(RED)

BLOWER MOTOR

BLOWER MAIN RELAY

AIR COMPRESSOR

AIR COMPRESSOR CLUTCH RELAY

FRAME

E MODE SWITCH

FUEL TEMPERATURE SENSOR

FLOOR BLACK

SP MODE SWITCH

ENGINE OIL PRESSURE SIGNAL

FLOW RATE REDUCING SOLENOID VALVE

CONTROLLER DECIDE

CONTROL PRESSURE

TRAVEL CONTROL PRESSURE

HYDRAURIC OIL TEMPERATURE

CHARGE SIGNAL PUMP DELIVERY

PD PRESSURE SIGNAL

POWER FOR SENSOR

BUZZER CANCEL SWITCH SIGNAL

BLACK

MCX-A

PUMP DELIVERY

CIRCULATION SERVO MOTOR

PUMP DELIVERY

FRONT SIDE AIR VENT SELECT SERVO MOTOR

CONTROLLER

129

AIR FILTER WARNING SIGNAL

014

FUEL LEVEL EXT

GROUND WIRE AROUND CAB

MOTION ALARM DIGNAL

008

ENGINE OIL LEVEL EXT

(ORANGE))

053 056

PUMP 1 HYDRAULIC 054 055 OIL TEAVEL TEMPERATURE/S ALL SENSORS

#1,2 JU #3 PUMP PUMP PREVENTION POWER POWER

3-UNIT SOLENOID VALVE

075

FLOW RATE REDUCING SOLENOID VALVE

WITHIN 1m FROM DIVERGING CONNECTOR

CONSENT

CAN DIVERGING CONNECTOR

PRESSURE SENSOR(LOW) REGISTER WEDGE

046

047

1. Separate hamess ground lines to 3 lines (Accessory(A), Control power(B), System control(C). Crimp each other by using the terminal (M10 round) and place them on to the cab floor. 2. GND line for connection of cab floor and cab should be 8mm2 wire. 3. Wire should be 0.5mm2, unless otherwise specified. 4. 0.5 to 1.25mm2 wires are CAVS wire, 2 to 5mm2 wires are AVS, more than 8mm2 wires are AV wire, unless otherwise specified for wires inside cab. 0.5 to 1.25mm2 wires are AVS wire, more than 2mm2 wires are AV wire, unless otherwise specified for wires outside cab. 5. marked wire is AEX wire. 6. marked wire is CHAVX wire. 7. Relays R12 (CHARGE RELAY) and R14 (PREHEAT RELAY(11) on figure #0004223 are noting. 8. Coolant level switch uses only either side of (1) or (2). 9. marked relay is not used for the machine with CUMMINS engine attached.

INTRODUCTION TO THE READER • This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. • Be sure to thoroughly read this manual for correct product information and service procedures.

• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form at the end of this manual. (Note: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-32-7173 FAX: 81-298-31-1162

ADDITIONAL REFERENCES • Please refer to the materials listed below in addition to this manual.

• Operation Manual of the Engine • Parts Catalog of the Engine • Hitachi Training Material

• The Operator’s Manual • The Parts Catalog

MANUAL COMPOSITION • This manual consists of three portions: the Techni-

• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.

• Information included in the Technical Manual (Operational Principle): technical information needed for redeliver and delivery, operation and activation of all devices and systems.

cal Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.

PAGE NUMBER • Each page has a number, located on the center lower part of the page, and each number contains the following information: Example : T 1-3-5 Consecutive Page Number for Each Group Group Number Section Number T: Technical Manual W: Workshop Manual

IN-01

INTRODUCTION SAFETY ALERT SYMBOL AND HEADLINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the potential for personal injury of machine damage. This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

•

CAUTION: Indicated potentially hazardous situation which could, if not avoided, result in personal injury or death.

• IMPORTANT:

Indicates a situation which, if not conformed to the instructions, could result in damage to the machine.

•

NOTE: Indicates supplementary technical information or know-how.

UNITS USED 2

• SI Units (International System of Units) are used in

Example : 24.5 MPa (250 kgf/cm , 3560 psi)

this manual. MKS system units and English units are also indicated in parenthheses just behind SI units.

Quantity Length

Volume Weight Force Torque

To Convert From mm mm L L 3 m kg N N N⋅m N⋅m

Into in ft US gal US qt 3 yd lb kgf lbf kgf⋅m lbf⋅ft

A table for conversion from SI units to other system units is shown below for reference purposees.

Quantity

Multiply By 0.03937 0.003281 0.2642 1.057 1.308 2.205 0.10197 0.2248 1.0197 0.7375

Pressure Power Temperature Velocity Flow rate

IN-02

To Convert From MPa MPa kW kW °C km/h -1 min L/min mL/rev

Into

Multiply By 2

kgf/cm psi PS HP °F mph rpm US gpm cc/rev

10.197 145.0 1.360 1.341 °C×1.8+32 0.6214 1.0 0.2642 1.0

SAFETY RECOGNIZE SAFETY INFORMATION • These are the SAFETY ALERT SYMBOLS. • When you see these symbols on your machine or in this manual, be alert to the potential for personal injury. • Follow recommended precautions and safe operating practices.

001-E01A-0688

SA-688

UNDERSTAND SIGNAL WORDS • On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, or CAUTION - are used with the safety alert symbol. • DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. • WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. • CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. • DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. • Some safety signs don’t use any of the designated signal words above after the safety alert symbol are occasionally used on this machine.

• CAUTION also calls attention to safety messages in this manual.

• To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indicates a situation which, if not avoided, could result in damage to the machine.

•

NOTE indicates an additional explanation for an element of information. 002-E01C-1223

SA-1

SA-1223

SAFETY FOLLOW SAFETY INSTRUCTIONS • Carefully read and follow all safety signs on the machine and all safety messages in this manual.

• Safety signs should be installed, maintained and replaced when necessary. • If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model and serial number when ordering).

SA-003

• Learn how to operate the machine and its controls correctly and safely.

• Allow only trained, qualified, authorized personnel to operate the machine.

• Keep your machine in proper working condition. • Unauthorized modifications of the machine may impair its function and/or safety and affect machine life.

• The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor and/or your authorized dealer before operating or performing maintenance work on the machine. 003-E01C-0003

PREPARE FOR EMERGENCIES • Be prepared if a fire starts or if an accident occurs. • Keep a first aid kit and fire extinguisher on hand. • Thoroughly read and understand the label attached on the fire extinguisher to use it properly. • Be sure to check and service the fire extinguisher at regular intervals following instructions in the fire extinguisher operation manual to maintain it in good operating condition. • Establish emergency procedure guidelines to cope with fires and accidents. • Keep emergency numbers for doctors, ambulance service, hospital, and fire department posted near your telephone. 004-E01B-0437

SA-2

SA-437

SAFETY WEAR PROTECTIVE CLOTHING • Wear close fitting clothing and safety equipment appropriate to the job. You may need: A hard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances.

SA-438

• Avoid wearing loose clothing, jewelry, or other items that can catch on control levers or other parts of the machine. 005-E01B-0438

PROTECT AGAINST NOISE • Prolonged exposure to loud noise can cause impairment or loss of hearing. • Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises.

SA-434 006-E01A-0434

INSPECT MACHINE • Inspect your machine carefully each day or shift by walking around it before you start it to avoid personal injury. • In the walk-around inspection be sure to cover all points described in the “PRE-START INSPECTION” chapter in the operator’s manual.

007-E01A-0435

SA-3

SA-435

SAFETY SAFETY OPERATOR’S STATION • Clean mud or grease from your shoes before getting on the machine. Failure to do so may result in the possibility of your shoes slipping off the pedals, causing a safety hazard. • Don’t leave parts and/or tools lying around the operator’s seat. Always store them in their proper place. • Never attach any thing such as a window hanger close to the windowpane. Never place the bottle in the operator’s station. They may cause a fire and impede visibility. • Don’t listen to music headphone or the radio, and don’t use a cellular telephone in the operator’s station while driving or operating the machine. • Keep inflammable and/or explosive away from the operator’s station. • Be sure to put a cover on the ashtray to completely extinguish match and tobacco. • Don’t leave a lighter anywhere in the operator’s station. The lighter may explode when temperature in the operator’s station increases. 524-E01A-0000

SA-4

SAFETY USE HANDHOLDS AND STEPS • Falling is one of the major causes of personal injury. • When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. • Do not use any controls as hand-holds. • Never jump on or off the machine. Never mount or dismount a moving machine. • Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

SA-439

008-E01A-0439

ADJUST THE OPERATOR'S SEAT • A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. • The seat should be adjusted whenever changing the operator for the machine. • The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. • If not, move the seat forward or backward, and check again.

009-E01A-0378

SA-5

SA-378

SAFETY FASTEN YOUR SEAT BELT • If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. • Prior to operating the machine, thoroughly examine webbing, buckle and attaching hardware. If any item is damaged or worn, replace the seat belt or component before operating the machine. • Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident.

SA-237

• We recommend that the seat belt be replaced every three years regardless of its apparent condition. 010-E01A-0237

MOVE AND OPERATE MACHINE SAFELY • Bystanders can be run over. • Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. • Always keep the travel alarm and horn in working condition (if equipped). It warns people when the machine starts to move. • Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. 011-E01A-0426

SA-6

SA-426

SAFETY OPERATE ONLY FROM OPERATOR'S SEAT • Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. • Start the engine only when seated in the operator's seat. • NEVER start the engine while standing on the track or on ground. • Do not start engine by shorting across starter terminals.

SA-444

• Before starting the engine, confirm that all control levers are in neutral. 012-E01B-0444

JUMP STARTING • Battery gas can explode, resulting in serious injury. • If the engine must be jump started, be sure to follow the instructions shown in the “OPERATING THE ENGINE” chapter in the operator’s manual. • The operator must be in the operator’s seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. • Never use a frozen battery.

SA-032

• Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

013-E01A-0032

KEEP RIDERS OFF MACHINE • Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. • Only the operator should be on the machine. Keep riders off. • Riders also obstruct the operator’s view, resulting in the machine being operated in an unsafe manner. SA-379

014-E01B-0379

SA-7

SAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES • For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions.

018-E01A-0481 SA-481

CONFIRM DIRECTION OF MACHINE TO BE DRIVEN • Incorrect travel pedal/lever operation may result in serious injury death. • Before driving the machine, confirm the position of the undercarriage in relation to the operator’s position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedals/levers are operated to the front. 017-E01A-0491

SA-8

SA-491

SAFETY DRIVE MACHINE SAFELY • Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive. • Be sure to detour around any obstructions. • Avoid crossing over obstacles. Scattered soil, and broken pieces of rocks and/or metal in the vicinity around the machine may be present. Keep people away from the machine.

SA-387

• Driving on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death. • When driving up or down a slope, keep the bucket facing the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) (A) above the ground. • If the machine starts to skid or becomes unstable, immediately lower the bucket to the ground and stop. SA-388

SA-441

SA-589

019-E01C-0492

SA-9

SAFETY AVOID INJURY FROM ROLLAWAY ACCIDENTS • Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: • Select level ground when possible to park machine. • Do not park the machine on a grade. • Lower the bucket and/or other work tools to the ground. • Turn the auto-idle switch and the H/P mode switch off.

SA-391

• Run the engine at slow idle speed without load for 5 minutes to cool down the engine. • Stop the engine and remove the key from the key switch. • Pull the pilot control shut-off lever to LOCK position. • Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. • Position the machine to prevent rolling. • Park a reasonable distance from other machines. 020-E02A-0493

SA-10

SA-392

SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS • If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death. To avoid back-over and swing accidents: • Always look around BEFORE YOU BACK UP AND SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR. • Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE.

SA-383

• USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. • No machine motions shall be made unless signals are clearly understood by both signalman and operator. • Learn the meanings of all flags, signs, and markings used on the job and confirm who has the responsibility for signaling. • Keep windows, mirrors, and lights clean and in good condition. • Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. • Read and understand all operating instructions in the operator’s manual. 021-E01A-0494

SA-11

SA-384

SAFETY AVOID TIPPING DO NOT ATTEMPT TO JUMP CLEAR OF TIPPING MACHINE---SERIOUS OR FATAL CRUSHING INJURIES WILL RESULT MACHINE WILL TIP OVER FASTER THAN YOU CAN JUMP FREE FASTEN YOUR SEAT BELT

• The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death. SA-012

To avoid tipping: • Be extra careful before operating on a grade. • Prepare machine operating area flat. • Keep the bucket low to the ground and close to the machine. • Reduce operating speeds to avoid tipping or slipping. • Avoid changing direction when traveling on grades. • NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. • Reduce swing speed as necessary when swinging loads.

SA-440

• Be careful when working on frozen ground. • Temperature increases will cause the ground to become soft and make ground travel unstable. 025-E01B-0495

AVOID POWER LINES • Serious injury or death can result if the machine or front attachments are not kept a safe distance from electric lines. • When operating near an electric line, NEVER move any part of the machine or load closer than 3 m (10 ft) plus twice the line insulator length. • Check and comply with any local regulations that may apply. • Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site. SA-381 029-E01A-0381

SA-12

SAFETY OBJECT HANDLING • If a lifted load should fall, any person nearby may be struck by the falling load or may be crushed underneath it, resulting in serious injury or death. • When using the machine for craning operations, be sure to comply with all local regulations. • Do not use damaged chains or frayed cables, sables, slings, or ropes. • Before craning, position the upperstructure with the travel motors at the rear. • Move the load slowly and carefully. Never move it suddenly. • Keep all persons well away from the load. • Never move a load over a person's head. • Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or on the ground.

SA-014

• Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. 032-E01A-0014

PROTECT AGAINST FLYING DEBRIS • If flying debris hit eyes or any other part of the body, serious injury may result. • Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. • Keep bystanders away from the working area before striking any object.

031-E01A-0432 SA-432

SA-13

SAFETY PARK MACHINE SAFELY To avoid accidents: • Park machine on a firm, level surface. • Lower bucket to the ground. • Turn auto-idle switch and H/P mode switch off. • Run engine at slow idle speed without load for 5 minutes. • Turn key switch to OFF to stop engine. • Remove the key from the key switch. • Pull the pilot control shut-off lever to the LOCK position.

SA-390

• Close windows, roof vent, and cab door. • Lock all access doors and compartments. 033-E08B-0390

HANDLE FLUIDS SAFELYҥ ҥAVOID FIRES • Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. • Do not refuel the machine while smoking or when near open flame or sparks. • Always stop the engine before refueling the machine. • Fill the fuel tank outdoors.

• All fuels, most lubricants, and some coolants are

SA-018

flammable. • Store flammable fluids well away from fire hazards. • Do not incinerate or puncture pressurized containers. • Do not store oily rags; they can ignite and burn spontaneously. • Securely tighten all fuel and oil filler caps.

034-E01A-0496 SA-019

SA-14

SAFETY SAFETY TRANSPORTING • The danger of tipping is present when loading/unloading the machine onto/from a truck or trailer bed. • Be sure to observe local regulations when transporting the machine on public roads. • Provide an appropriate truck or trailer for transporting the machine. Take the following precautions when loading / unloading the machine: 1) Select firm level ground. 2) Be sure to use a loading dock or ramp. 3) Be sure to have a signal person when loading/unloading the machine. 4) Always turn the auto-idle switch and the H/P mode switch OFF when loading or unloading the machine, to avoid unexpected speed increase due to unintentional operation of a control lever. 5) Always select the slow speed mode with the travel mode switches. In the high speed mode, travel speed may automatically increase. 6) Avoid steering while driving up or down the ramp as it is extremely dangerous. If steering is unavoidable, first move back to the ground or flatbed, modify traveling direction, and begin to drive again. 7) Do not operate any levers besides the travel levers when driving up or down the ramp. 8) The top end of the ramp where it meets the flatbed is a sudden bump. Take care when traveling over it. 9) Prevent possible injury from machine tipping while the upperstructure is rotating. 10) Keep the arm tucked under and rotate the upperstructure slowly for best stability. 11) Securely fasten chain or cables to the machine frame. Refer to "transporting" chapter in the operator's manual for details. S035-E08A-0395

SA-15

SA-395

SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: • Understand service procedures before starting work. • Keep the work area clean and dry. • Do not spray water or steam inside cab. • Never lubricate or service the machine while it is moving. • Keep hands, feet and clothing away from power-driven parts. Before servicing the machine: 1. Park the machine on a level surface. 2. Lower the bucket to the ground.

SA-028

3. Turn the auto-idle switch off. 4. Run the engine at slow idle speed without load for 5 minutes. 5. Turn the key switch to OFF to stop engine. 6. Relieve the pressure in the hydraulic system by moving the control levers several times. 7. Remove the key from the switch. 8. Attach a “Do Not Operate” tag on the control lever. 9. Pull the pilot control shut-off lever to the LOCK position. 10. Allow the engine to cool. • If a maintenance procedure must be performed with the engine running, do not leave machine unattended. • If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work. • Never work under a machine raised by the boom. • Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter of this manual. • Keep all parts in good condition and properly installed. • Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. • Disconnect battery ground cable (−) before making adjustments to electrical systems or before performing welding on the machine. • Don’t operate the machine with a broken windowpane. Failure to do so may cause personal injury. Be sure to repair any broken windowpane before operating the machine. 500-E02B-0497

SA-16

SA-527

SAFETY • Be sure to use incombustible detergent oils to clean parts. Never use flammable materials such as gasoline when cleaning the machine and/or parts. • Illuminate your work area adequately but safety. • Use a portable safety light for working inside or under the machine • Make sure that the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. SA-037 500-E02B-0497

WARN OTHERS OF SERVICE WORK • Unexpected machine movement can cause serious injuly. • Before performing any work on the machine, attach a “Do Not Operate” tag on the on the control lever

S501-E01A-0287

SA-287

SUPPORT MACHINE PROPERLY • Never attempt to work on the machine without securing the machine first. • Always lower the attachment to the ground before you work on the machine. • If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. 519-E01A-0527

SA-17

SA-527

SAFETY STAY CLEAR OF MOVING PARTS â&#x20AC;˘ Entanglement in moving parts can cause serious injury. â&#x20AC;˘ To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

502-E01A-0026

SA-18

SA-026

SAFETY PREVENT PARTS FROM FLYING • Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death. • Do not attempt to remove GREASE FITTING or VALVE ASSEMBRY. • As pieces may fly off, be sure to keep body and face away from valve.

• Travel reduction gears are under pressure.

SA-344

• As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. • Wait for GEAR OIL to cool, then gradually loosen AIR RELEASE PLUG to release pressure. 503-E01B-0344

STORE ATTACHMENTS SAFELY • Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. • Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas.

504-E01A-0034

SA-034

USE TOOLS PROPERLY • Use tools appropriate for the work to be done.

• Makeshift tools, parts, and procedures can create safety hazards. • For loosening and tightening hardware, use the correct size tools to avoid injury caused by slipping wrenches. • Use only recommended replacement parts. (See the parts catalog.)

S522-E01A-0040 SA-040

SA-19

SAFETY PREVENT BURNS Hot spraying fluids:

• After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns. • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

SA-039

• The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap. Hot fluids and surfaces:

• Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well. • Wait for the oil and components to cool before starting any maintenance or inspection work.

SA-225

505-E01B-0498

REPLACE RUBBER HOSES PERIODICALLY • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. • Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)

SA-20

SA-019

SAFETY AVOID HIGH-PRESSURE FLUIDS • Fluids such as diesel fuel or hydraulic oil under pressure can penetrate the skin or eyes causing serious injury, blindness or death. • Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. • Tighten all connections before applying pressure. • Search for leaks with a piece of cardboard; take care to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection.

SA-031

• If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-292

507-E03A-0499

SA-21

SA-044

SAFETY PREVENT FIRES Check for Oil Leaks: • Fuel, hydraulic oil and lubricant leaks can lead to fires. • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts. • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oilcooler flange bolts. • Do not bend or strike high-pressure lines.

SA-019

• Never install bent or damaged lines, pipes, or hoses. Check for Shorts: • Short circuits can cause fires. • Clean and tighten all electrical connections. • Check before each shift or after eight(8) to ten(10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. • Check before each shift or after eight(8) to ten(10) hours operation for missing or damaged terminal caps. • DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: • Spilled fuel and oil, air conditioning refrigerant, windshield washer and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. • Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: • If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting. • Always check key switch function before operating the machine every day: 1. Start the engine and run it at slow idle. 2. Turn the key switch to the OFF position to confirm that the engine stops. • If any abnormalities are found, be sure to repair them before operating the machine. 508-E02B-0019

SA-22

SAFETY Check Heat Shields: • Damaged or missing heat shields may lead to fires. • Damaged or missing heat shields must be repaired or replaced before operating the machine.

508-E02A-0393

EVACUATING IN CASE OF FIRE • If a fire breaks out, evacuate the machine in the following way: • Stop the engine by turning the key switch to the OFF position if there is time. • Use a fire extinguisher if there is time. • Exit the machine.

• In an emergency, if the cab door or front window can not be opened, break the front or rear window panes with the emergency evacuation hammer to escape from the cab. Refer the explanation pages on the Emergency Evacuation Method.

518-E02A-0393

SA-393

SS-1510

BEWARE OF EXHAUST FUMES • Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. • If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe exten-sion to remove the exhaust fumes or open doors and windows to bring enough outside air into the area. 509-E01A-0016 SA-016

SA-23

SAFETY PRECAUTIONS FOR WELDING AND REPAIR WORK WITH GRINDER • Welding may generate gas and/or cause a fire danger. • Perform welding in an open well-equipped location. Keep flammable in a safe place. • Have a qualified only person perform welding. Never allow unqualified personnel to perform welding.

• Grinding may cause a fire danger. Keep flammable in a safe place.

• After completing welding and/or grinding work, be sure to check that no signs of fire such as a wisp of smoke are present in or around the job site.

SA-818

523-E01A-0818

AVOID HEATING NEAR PRESSURIZED FLUID LINES • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS • Do not weld or flame cut pipes or tubes that contain flammable fluids. • Clean them thoroughly with nonflammable solvent before welding or flame cutting them. 510-E01B-0030

SA-24

SA-030

SAFETY REMOVE PAINT BEFORE WELDING OR HEATING • Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. • Avoid potentially toxic fumes and dust. • Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly. SA-029

511-E01A-0029

SA-25

SAFETY PREVENT BATTERY EXPLOSIONS • Battery gas can explode. • Keep sparks, lighted matches, and flame away from the top of battery. • Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. • Do not charge a frozen battery; it may explode. Warm the battery to 16°C ( 60°F ) first. • Do not operate the machine with the battery electrolyte level lower than the lowest allowable limit. Failure to do so may cause the batteries to explode.

SA-032

• Battery electrolyte is poisonous. If the battery should explode, battery electrolyte may be splashed into eyes, possibly resulting in blindness. • Be sure to wear eye protection when checking electrolyte specific gravity.

512-E01B-0032

SERVICE AIR CONDITIONING SYSTEM SAFELY • If spilled onto skin, refrigerant may cause a cold contact burn. • Refer to the freon container for proper use when servicing the air conditioning system. • Use a recovery and recycling system to avoid venting freon into the atmosphere. • Never let the freon stream make contact with the skin. SA-405 513-E01A-0405

SA-26

SAFETY HANDLE CHEMICAL PRODUCTS SAFELY • Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with your machine include such items as lubricants, coolants, paints, and adhesives. • A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. • Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and use recommended equipment.

SA-309

• See your authorized dealer for MSDS’s (available only in English) on chemical products used with your machine. 515-E01A-0309

DISPOSE OF WASTE PROPERLY • Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, filters, and batteries. • Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. • Do not pour waste onto the ground, down a drain, or into any water source. • Air conditioning refrigerants escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. • Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

516-E01A-0226

SA-27

SA-226

SAFETY BEFORE RETURNING THE MACHINE TO THE CUSTOMER • After maintenance or repair work is complete, confirm that: • The machine is functioning properly, especially the safety systems. • Worn or damaged parts have been repaired or replaced. S517-E01A-0435 SA-4.35

SA-28

SECTION AND GROUP CONTENTS

SECTION 1 GENERAL INFORMATION Group 1 Precautions for disassembling and Assembling Group 2 Tightening Torque

SECTION 2 UPPERSTRUCTURE

WORKSHOP MANUAL

Group 1 Cab Group 2 Counterweight Group 3 Pump Device Group 4 Control Valve Group 5 Swing Device Group 6 Pilot Valve Group 7 Pilot Shut-Off Valve Group 8 Shockless Valve Group 9 Solenoid Valve Group 10 Signal Control Valve Group 11 Oil Cooler Fan Motor

SECTION 3 UNDERCARRIAGE

All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice.

Group 1 Swing Bearing Group 2 Travel Device Group 3 Center Joint Group 4 Track Adjuster Group 5 Front Idler Group 6 Upper and Lower Roller Group 7 Track

SECTION 4 FRONT ATTACHMENT Group 1 Front Attachment Group 2 Cylinder Group 3 Bushing and Point

TECHNICAL MANUAL (Operational Principle) SECTION 1 GENERAL Group 1 Specification Group 2 Component Layout SECTION 2 SYSTEM Group 1 Control System Group 2 Hydraulic System Group 3 Electrical System

TECHNICAL MANUAL (Troubleshooting) SECTION 4 OPERATIONAL PERFORMANCE TEST Group 1 Introduction Group 2 Standard Group 3 Engine Test Group 4 Excavator Test Group 5 Component Test

SECTION 1

GENERAL INFORMATION CONTENTS Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1 Maintenance Standard Terminology........ W1-1-7

Group 2 Tightening Torque Tightening Torque Specification.............. W1-2-1 Torque Chart .......................................... W1-2-3 Piping Joint ............................................ W1-2-6 Periodic Replacement of Parts ............. W1-2-10

183W-1-1

(Blank)

183W-1-2

GENERAL / Precautions for Disassembling and Assembling PRECAUTIONS FOR AND ASSEMBLING

DISASSEMBLING

Precautions for Disassembling and Assembling

• Clean the Machine

• Precautions for Disassembling

Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause machine components to be contaminated during disassembling/assembling, resulting in damage to machine components, as well as decreased efficiency in service work.

• Inspect the Machine Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect disassembling of components as well as personal injury. Check and record the items listed below to prevent problems from occurring in the future. • The machine model, machine serial number, and hour meter reading. • Reason for disassembly (symptoms, failed parts, and causes). • Clogging of filters and oil, water or air leaks, if any. • Capacities and condition of lubricants. • Loose or damaged parts.

• Prepare and Clean Tools and Disassembly Area Prepare the necessary tools to be used and the area for disassembling work.

W1-1-1

• To prevent dirt from entering, cap or plug the removed pipes. • Before disassembling, clean the exterior of the components and place on a work bench. • Before disassembling, drain gear oil from the reduction gear. • Be sure to provide appropriate containers for draining fluids. • Use matching marks for easier reassembling. • Be sure to use the specified special tools, when instructed. • If a part or component cannot be removed after removing its securing nuts and bolts, do not attempt to remove it forcibly. Find the cause(s), then take the appropriate measures to remove it. • Orderly arrange disassembled parts. Mark and tag them as necessary. • Store common parts, such as bolts and nuts with reference to where they are to be used and in a manner that will prevent loss. • Inspect the contact or sliding surfaces of disassembled parts for abnormal wear, sticking, or other damage. • Measure and record the degree of wear and clearances.

GENERAL / Precautions for Disassembling and Assembling • Precautions for Assembling

Bleeding Air from Hydraulic System

• Be sure to clean all parts and inspect them for any damage. If any damage is found, repair or replace part. • Dirt or debris on the contact or sliding surfaces may shorten the service life of the machine. Take care not to contaminate any contact or sliding surfaces. • Be sure to replace O-rings, backup rings, and oil seals with new ones once they are disassembled. Apply a film of grease before installing. • Be sure that liquid-gasket-applied surfaces are clean and dry. • If an anti-corrosive agent has been used on a new part, be sure to thoroughly clean the part to remove the agent. • Utilize matching marks when assembling. • Be sure to use the designated tools to assemble bearings, bushings and oil seals. • Keep a record of the number of tools used for disassembly/assembly. After assembling is complete, count the number of tools, so as to make sure that no forgotten tools remain in the assembled machine.

When hydraulic oil is drained, the suction filter or the suction lines are replaced, or the removal and installation of the pump, swing motor, travel motor or cylinder is done, bleed air from the hydraulic system in the following procedures: IMPORTANT: If the engine is started with air trapped in the hydraulic pump housing, damage to the pump may result. If the hydraulic motor is operated with air trapped in the hydraulic motor housing, damage to the motor may result. If the cylinder is operated with air trapped in the cylinder tube, damage to the cylinder may result. Be sure to bleed air before starting the engine.

• Bleeding Air from Hydraulic Pump • Remove the air bleeding plug from the top of the pump and fill the pump housing with hydraulic oil. • After the pump housing is filled with hydraulic oil, temporarily tighten the plug. Then, start the engine and run at slow idle speed. • Slightly loosen the plug to bleed air from the pump housing until hydraulic oil oozes out. • After bleeding all the air, securely tighten the plug.

• Bleeding Air from Travel Motor / Swing Motor • With the drain plug / hose on travel motor / swing motor removed, fill the motor case with hydraulic oil.

W1-1-2

GENERAL / Precautions for Disassembling and Assembling • Bleeding Air from Hydraulic Circuit • After refilling hydraulic oil, start the engine. While operating each cylinder, swing motor and travel motor evenly, operate the machine under light loads for 10 to 15 minutes. Slowly start each operation (never fully stroke the cylinders during initial operation stage). As the pilot oil circuit has an air bleed device, air trapped in the pilot oil circuit will be bled while performing the above operation for approx. 5 minutes. • Reposition the front attachment to check hydraulic oil level. • Stop the engine. Recheck hydraulic oil level. Replenish oil as necessary.

W183-04-02-003

W183-04-02-002

ᓡᒉ

W1-1-3

GENERAL / Precautions for Disassembling and Assembling Floating Seal Precautions A

1. In general, replace the floating seal with a new one after disassembling. If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces. (2) Check the slide surface on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear.

W105-03-05-019

(3) Check O-ring (B) for tears, breaks, deformation or hardening. 2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble. (1) Clean the floating seal and seal mounting bores with cleaning solvent. Use a wire brush to remove mud, rust or dirt. After cleaning, thoroughly dry parts with compressed air.

Correct

Incorrect

(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with touch. (3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring. (4) After installing the floating seal, check that seal ring surface (A) is parallel with seal mating face (C) by measuring the distances (A) and (C) at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

Correct

W105-03-05-020

Incorrect

A B

a=b

aŇ?b W110-03-05-004

W1-1-4

GENERAL / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely. • Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from being damaged and the lifted load from slipping. • Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight. • Do not lift acid or alkali chemicals. • Take care not to allow the sling to become wet. The load may slip. • When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced. • When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load. (Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force. • Avoid using twisted, bound, connected, or hitched slings. • Do not place any object on twisted or bent slings. (Refer to the right illustration.) • When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions. • Avoid dragging slings on the ground, throwing slings or pushing slings with a metal object. • When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged. • Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-5

W162-01-01-009

GENERAL / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

Broken Sewing Thread

W162-01-01-002

Scuffing

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7-years.

W162-01-01-003

Fuzz Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-6

GENERAL / Precautions for Disassembling and Assembling MAINTENANCE STANDARD TERMINOLOGY “Standard” 1. Dimension for parts on a new machine. 2. Dimension of new components or assemblies adjusted to specification.

“Allowable Limit” 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the “Allowable Limit”.

W1-1-7

GENERAL / Precautions for Disassembling and Assembling (Blank)

W1-1-8

GENERAL / Tightening TIGHTENING TORQUE SPECIFICATIONS Bolt Dia. Q’ty (mm) 22 2 Engine cushion rubber mounting bolt(Fan side) 33 2 (Pump side) 27 12 Engine bracket mounting bolt 27 4 Radiator mounting bolt 20 8 Hydraulic oil tank mounting bolt 20 8 Fuel tank mounting bolt 1-7/16ORS fittings for hydraulic hoses and piping 12UNF 4 1-11/1612UNF 4 1/2-13UNF 16 Pump mission mounting bolt 20 12 Pump device mounting bolt(Hexagon wrench) 16 4 Pump mounting bolt(Hexagon wrench) 27 2 Gear pump mounting bolt 20 8 Control valve mounting bolt 16 3 Swing control valve mounting bolt 27 32 Swing device mounting bolt 12 24 Swing motor mounting bolt 12 2 Battery mounting nut 16 8 Cab mounting bolt Cab bed mounting bolt 16 58 Swing bearing mounting bolt(Upperstructure) 36 52 (Undercarriage) 36 50 Travel device mounting bolt 27 52 Travel motor mounting bolt 18 8 Sprocket mounting bolt 27 60 Upper roller mounting bolt 20 24 Lower roller mounting bolt 27 64 Shoe mounting bolt 30 416 Track guard mounting bolt 27 28 Side frame mounting bolt 42 52 Counterweight mounting bolt 45 6 Oil cooler mounting bolt 24 4 Front pin-retaining(Backhoe) Stopper bolt A 20 12 Stopper bolt B 20 12 Front pin-retaining(Loading shovel) 14 20 Stopper bolt A 4 20 Stopper bolt B 18 16 Stopper bolt C 6 12 Stopper bolt D Side cutter mounting bolt 33 12 Descriptions

W1-2-1

Wrench Size mm 32 50 41 30 30 41

N⋅m 740 2550 1030 1030 540 540

Torque (kgf⋅m) (75) (260) (105) (105) (55) (55)

(lbf⋅ft) (540) (1880) (760) (760) (400) (400)

205

(21)

(152)

50 19 17 14 22 30 17 41 19 19 24 24 55 55 41 27 41 30 41 46 41 65 63 36

340 118 390 205 137 390 49 1370 88 34 265 205 2750 2750 1370 295 1370 540 1370 2840 1370 3920 3920 930

(35) (12) (40) (21) (14) (40) (5) (140) (9) (3.5) (27) (21) (280) (280) (140) (30) (140) (55) (140) (290) (140) (400) (400) (95)

(251) (87) (290) (152) (102) (290) (36) (1010) (65) (26) (195) (152) (2030) (2030) (1010) (215) (1010) (400) (1010) (2100) (1010) (2900) (2900) (690)

30 30

390 390

(40) (40)

(290) (290)

30 17 24 19 50

390 540 265 88 2550

(40) (55) (27) (9) (260)

(290) (400) (195) (65) (1880)

GENERAL / Tightening NOTE 1. Apply lubricant (e.g. white zinc B dissolved into spindle oil) to bolts and nuts to reduce friction coefficient of them. 2. Make sure bolt and nut threads are clean before installing. 3. Apply LOCTITE to threads before installilng and tightening swing bearing mounting bolts and lower roller mounting bolts.

W1-2-2

GENERAL / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury. Bolt Types Tighten nuts or bolts correctly to torque specifications. Four different types and grades of bolt are employed. Make sure to employ correct bolts and tighten them correctly when assembling the machine or components. Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart Hexagon T Bolt Bolt Wrench Wrench Dia. Size N⋅m (kgf⋅m) Size M 8 13 6 29.5 (3) M 10 17 8 64 (6.5) M 12 19 10 108 (11) M 14 22 12 175 (18) M 16 24 14 265 (27) M 18 27 14 390 (40) M 20 30 17 540 (55) M 22 32 17 740 (75) M 24 36 19 930 (95) M 27 41 19 1370 (140) M 30 46 22 1910 (195) M 33 50 24 2550 (260) M 36 55 27 3140 (320)

H Bolt, Socket bolt (lbf⋅ft) (22) (47) (80) (130) (195) (290) (400) (540) (690) (1010) (1410) (1880) (2310)

N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-3

(kgf⋅m) (lbf⋅ft) (2) (14.5) (5) (36) (9) (65) (14) (101) (21) (152) (30) (220) (40) (290) (55) (400) (70) (505) (105) (760) (145) (1050) (195) (1410) (245) (1770)

M Bolt N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

(kgf⋅m) (1) (2) (3.5) (5.5) (8) (12) (17) (22) (28) (40) (55) (75) (95)

(lbf⋅ft) (7.2) (14.5) (25.5) (40) (58) (87) (123) (159) (205) (290) (400) (540) (690)

GENERAL / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads. 1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients. The plated bolts require no lubricant. 2. Torque tolerance is Âą10 %. 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that nut and bolt threads are clean before installing. Remove dirt or corrosion, if any. Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening. Equally tighten upper and lower alter-

Tighten diagonally 1

1st to 4th

Tighten from center and diago12

6 4

5 2

2nd to 3rd W105-01-01-003

W1-2-4

GENERAL / Tightening Service Recommendations for Spilt Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified Orings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place. 3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Do not bend it round

Bend along edge sharply

Nut and Bolt Locking RIGHT

• Lock Plate

WRONG

RIGHT

IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

• Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

Bend along edge sharply

RIGHT

WRONG

W105-01-01-009

• Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction. RIGHT

Loosen

WRONG

Tighten

W105-01-01-010

W1-2-5

GENERAL / Tightening PIPING JOINT

IMPORTANT: The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.

M202-07-051

Joint Body

Union Joint Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

37ѯ 30ѯ

IMPORTANT: 1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adapter (1). Be sure to tighten nut (3) to specifications. 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

Description 30ѯmale

37ѯfemale

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm Union Nut 17 19 22 27 32 36 41 17 19 22 27 32 36 41

Wrench Size mm

Tightening Torque

Hose Fittings 17 19 22 27 32 36 41 14 17 19 22 27 32 36

N⋅m (kgf⋅m, lbf⋅ft) 24.5 (2.5,18) 29.5 (3.0,21.5) 39 (4.0,28.5) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 24.5 (2.5,18) 29.5 (3.0,21.5) 39 (4.0,28.5) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151)

NOTE: Tightening torque of 37ѯmale coupling without union is similar to tightening torque of 37ѯfemale.

W1-2-6

GENERAL / Tightening O-ring Seal Joint

O-ring (6) seats against the end face of adapter (7) to seal pressure oil. IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting. 2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (e). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage. 3. Take care not to damage O-ring groove (e) or sealing surface (10). Damage to O-ring (6) will cause oil leakage. 4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9). Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).

Wrench Size mm Union Nut 19 22 27 32 36 41 46

W1-2-7

Wrench Size mm Hose Fittings 17 19 22 27 30,32 36 41

Hose Fittings M104-07-033

Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) 29.5 (3.0,21.5) 69 (7.0,51) 93 (9.5,69) 137 (14.0,101) 175 (18.0,129) 205 (21.0,151) 205 (21.0,151)

GENERAL / Tightening Screw-In Connection PT

Depending on types of screw and sealing, different types of screw fittings are used. IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

30ѯ

Male Tapered Thread

Male Straight Thread W105-01-01-018

Wrench Size mm Hose Fittings 19 22 27 36 41 50 60

Male Tapered Thread Tightening Torque N⋅m (kgf⋅m, lbf⋅ft) FC material SS material 14.5 (1.5,10.5) 34 (3.5,25) 29.5 (3.0,21.5) 49 (5.0,36) 49 (5.0,36) 93 (9.5,69) 69 (7.0,51) 157 (16,116) 108 (11,80) 205 (21,151) 157 (16,116) 320 (33,235) 195 (20,144)

Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads. Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

• Application Procedure

W105-01-01-019

Confirm that the thread surface is clean and, free of dirt or damage. Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp. T-Bolt Type Band Clamp: 4.4 N⋅m ( 0.45 kgf⋅m, 3.25 lbf⋅ft ) Worm Gear Type Band Clamp: 5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

W1-2-8

M114-07-041

T-Bolt Type

Worm Gear Type

M114-07-043

M114-07-042

GENERAL / Tightening Connecting Hose RIGHT

WRONG CAUTION: When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine. Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.

W105-01-01-011

RIGHT

WRONG Rubbing Against Each Other

If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other. Take care so that hoses do not come into contact with moving parts or sharp objects.

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing Against Each Other W105-01-01-013

WRONG

Rubbing Against Each Other

RIGHT

Clamp W105-01-01-014

W1-2-9

GENERAL / Tightening PERIODIC REPLACEMENT OF PARTS To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be defective, replace before starting operation, regardless of the interval. Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary. Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary. Consult your authorized dealer for correct replacement. Periodic Replacement Parts Engine Base Machine Hydraulic System Front Attachment

Fuel hose (Fuel tank to filter) Fuel hose (Fuel tank to injection pump) Heater hose (Heater to engine) Pump suction hose Pump delivery hose Swing hose Boom cylinder line hose Arm cylinder line hose Bucket cylinder line hose Pilot hose

NOTE: Be sure to replace seals, such as O-rings and gaskets, when replacing hoses.

W1-2-10

Replacement Intervals Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years Every 2 years

SECTION 2

UPPERSTRUCTURE CONTENTS Group 1 Cab

Disassemble Main Control Valve 2 (5-Spool Section) ............................. W2-4-16

Remove and Install Cab ...................... W2-1-1

Assemble Main Control Valve 2

Dimensions of the Cab Glass ............ W2-1-15

(5-Spool Section) ............................. W2-4-18 Disassemble Main Control Valve 1

Group 2 Counterweight

(4-Spool Section) ............................. W2-4-20

Remove and Install Counterweight ...... W2-2-1

Assemble Main Control Valve 1 (4-Spool Section) ............................. W2-4-28

Group 3 Pump Device

Disassemble Main Control Valve 2

Remove and Install Pump Device ........ W2-3-1

(4-Spool Section) ............................. W2-4-34

Disassemble Pump Transmission........ W2-3-4

Assemble Main Control Valve 2

Assemble Pump Transmission ............ W2-3-6

(4-Spool Section) ............................. W2-4-36

Disassemble Main Pump ..................... W2-3-8

Disassemble Manifold ....................... W2-4-38

Assemble Main Pump........................ W2-3-12

Assemble Manifold ............................ W2-4-40

Maintenance Standard ...................... W2-3-14

Disassemble Swing Control Valve 1... W2-4-42

Disassemble Regulator(Main Pump) . W2-3-16

Assemble Swing Control Valve 1 ....... W2-4-48

Assemble Regulator(Main Pump) ...... W2-3-20

Disassemble Swing Control Valve 2... W2-4-52

Disassemble Pump of

Assemble Swing Control Valve 2 ....... W2-4-54

Oil Cooler Fan Motor ....................... W2-3-26 Assemble Pump of Oil Cooler Fan Motor ....................... W2-3-30

Group 5 Swing Device

Maintenance Standard ...................... W2-3-32

Remove and Install Swing Device........ W2-5-1

Disassemble Regulator(Pump for

Disassemble Swing Reduction Gear .... W2-5-6

Driving Oil Cooler Fan Motor) .......... W2-3-34

Assemble Swing Reduction Gear....... W2-5-12 Disassemble Swing Motor ................. W2-5-16

Assemble Regulator(Pump for Driving Oil Cooler Fan Motor) .......... W2-3-38 Configuration of Pilot Pump ............... W2-3-44

Assemble Swing Motor ...................... W2-5-20 Disassemble and Assemble Swing Parking Brake Releasing Valve ........ W2-5-24

Configuration of Pump for Lubricating Pump Transmission ....... W2-3-46

Group 4 Control Valve Remove and Install Control Valve ........ W2-4-1 Disassemble Main Control Valve 1 (5-Spool Section)............................... W2-4-6 Assemble Main Control Valve 1 (5-Spool Section)............................. W2-4-10

183W-2-1

Maintenance Standard....................... W2-5-26

Group 6 Pilot Valve

Group 11 Oil Cooler Fan Motor

Remove and Install Right Pilot Valve ... W2-6-1 Remove and Install Left Pilot Valve ..... W2-6-5 Remove and Install Travel Pilot Valve.

Remove and Install Oil Cooler Fan Motor ........................................ W2-11-1 Disassemble Oil Cooler Fan Motor .... W2-11-4

Remove and Install Bucket Pilot

Assemble Oil Cooler Fan Motor ......... W2-11-6

Valve(for Loading Shovel Only) .......... W2-6-9 Disassemble Front Pilot Valve ........... W2-6-14 Assemble Front Pilot Valve................ W2-6-18 Disassemble Travel Pilot Valve.......... W2-6-22 Assemble Travel Pilot Valve .............. W2-6-26 Disassemble Pilot Valve for Bucket Opening / Closing ................ W2-6-32 Assemble Pilot Valve for Bucket Opening / Closing ................ W2-6-34

Group 7 Pilot Shut-Off Valve Remove and Install Pilot Shut-off Valve ............................ W2-7-1 Disassemble Pilot Shut-off Valve ......... W2-7-4 Assemble Pilot Shut-off Valve.............. W2-7-6

Group 8 Shockless Valve Remove and Install Front Attachment Shockeless Valve .............................. W2-8-1 Disassemble and Assemble the Shockless Valve ................................ W2-8-3

Group 9 Solenoid Valve Remove and Install Solenoid Valve...... W2-9-1 Disassemble 2-Spool EHC Valve (Boost Solenoid Valve, Control Solenoid Valve for Oil Cooler Fan) ..... W2-9-4 Assemble 2-Spool EHC Valve (Boost Solenoid Valve, Control Solenoid Valve for Oil Cooler Fan) ..... W2-9-6 Configuration of Solenoid Valve ........... W2-9-8

Group 10 Signal Control Valve Remove and Install Signal Control Valve ................................... W2-10-1 Pilot Port ........................................... W2-10-3

183W-2-2

UPPERSTRUCTURE / Cab REMOVE AND INSTALL CAB Removal CAUTION: Seat (1) weight: 40 kg (90 Ib)

1. Remove seat mounting socket bolts (2) (4 used) to remove seat (1).

ϖ 6 mm W183-02-01-040

2. Remove bolts (8) (2 used) from rear side of the cab. Remove bolts (3) (3 used) inside of rear box (7). ϖ 13 mm 7

3. Disconnect cigarette lighter connector (4), buzzer cancel switch connector (5) and troubleshooting switch connector (6), from inside of rear box (7). Then remove rear box (7).

4 5 6

4. Remove duct (9) with facing up.

W183-02-01-002

W2-1-1

UPPERSTRUCTURE / Cab 5. Remove caps (12) (5 used) from duct cover (11) with a screwdriver. Remove screws (10) (5 used) with a screwdriver to remove duct cover (11).

10 11

W183-02-01-039

IMPORTANT: If connector (13) of ECM wiring is removed, the engine will fail to be started. After cab has been removed, remove ECM from the cab and secure it on floor. Be sure to connect connector (13). 13

6. Disconnect wiring connectors (13, 14 and 15) from the right side in the cab.

ECM

15 W183-02-01-018

7. Remove bolts (19) (4 used) and press duct (17) into duct (18) to remove duct (17) from the duct (16) side.

Ď&#x2013; 17 mm

W2-1-2

W183-02-01-003

UPPERSTRUCTURE / Cab 8. Remove bolts (25) (7 used) to remove bracket (24). (2 places both left and right)

Ď&#x2013; 17 mm

9. Disconnect DC-DC converter connector (27), radio antenna connector (30) and step light connector (31) from rear side of the cab. 10. Remove bolts (32) (4 used) to remove wiper motor cover (33). Disconnect wiper motor connector (22) and head light connector (23).

33 24

Ď&#x2013; 13 mm

11. Remove joint (21) from vinyl hose (20) for the window washer. NOTE: If joint (21) is not installed to vinyl hose (20), it should be cut off with a cutter, etc. Therefore, joint (part No. 4254237) should be used when reassambling.

28 W183-02-01-035

Joint (21)

W183-02-01-036

12. Remove screws (28) (8 used) with screwdriver to remove covers (26 and 29).

W2-1-3

UPPERSTRUCTURE / Cab 13. Remove bolts (34) (2 used) to remove the mirror. Remove the chain. ϖ 13 mm

Mirror

34 Chain

CAUTION: Cab weight: 630 kg (1390 Ib) M183-01-033

14. Attach wire ropes to the top of the cab.

15. Remove nuts (35) (10 used) and cab mounting bolts (36) (6 used), lift and remove the cab by a crane. ϖ 17 mm ϖ 24 mm

W183-02-01-029

35 36

16. Remove screws (37) (8 used) with a screwdriver to remove ECM from the cab. Secure the removed ECM on floor and connect connector (13).

W183-02-01-001

13 ECM

W183-02-01-018

W2-1-4

UPPERSTRUCTURE / Cab Installation 1. Remove ECM connector which is secured on floor. Install ECM on the cab with screws (37) (8 used).

13 ECM

CAUTION: Cab weight: 630 kg (1390 Ib) W183-02-01-018

2. Attach wire rope to the top of the cab. Hoist and install the cab by a crane.

W183-02-01-029

3. Secure the cab with nuts (35) (10 used) and mounting bolts (36) (6 used). ϖ ϖ ϖ ϖ

17 mm 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 24 mm 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

35 36

W183-02-01-001

4. Install the mirror with bolts (34) (2 used). Attach the chain. ϖ 13 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

Mirror

34 Chain

M183-01-033

W2-1-5

UPPERSTRUCTURE / Cab 5. Install covers (26 and 29) with screws (28) (8 used).

20 22

6. Connect joint (21) to window washer vinyl hose (20) in wiper motor cover (33). Connect harness of wiper motor (22) and head light (23). 7. Install wiper motor cover (33) with bolts (32) (4 used). ϖ 13 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

33 24

25 26

8. Connect DC-DC converter connector (27) radio antenna connector (30) and step light connector (31) at the rear side of the cab. 9. Install bracket (24) with bolts (25) (7 used). (2 places both right and left) ϖ 17 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

28 W183-02-01-035

W2-1-6

UPPERSTRUCTURE / Cab 10. Press duct (17) into duct (18) and insert duct (17) into duct (16). Then tighten it with bolts (19) (4 used).

ϖ 17 mm ϖ 50 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W183-02-01-003

11. Connect cable connectors (13, 14 and 15) at right in the cab.

13 ECM

15 W183-02-01-018

12. Install duct cover (11) with screws (10) (5 used). Install caps (12) (5 used). 10 11

W183-02-01-039

W2-1-7

UPPERSTRUCTURE / Cab 13. Install duct (9) at rear inside of the cab. 3

14. Connect the harness of cigarette lighter (4), buzzer cancel switch (5) and troubleshooting switch (6) in rear box (7).

4 5

15. Install rear box (7) with bolts (3) (3 used) and (8) (2 used).

ϖ 13 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W183-02-01-002

CAUTION: Seat (1) weight: 40 kg ( 90 Ib) 16. Install seat (1) with socket bolts (2) (4 used). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m 14.5 Ibf⋅ft)

W183-02-01-040

W2-1-8

UPPERSTRUCTURE / Cab Remove cab bed (only for loading shovel) 1. Remove pilot valve. ( Refer to Remove and Install Pilot Valve section on page W2-6-1) Ď&#x2013; 13 mm, 17 mm, 19 mm, 22 mm

W178-02-07-002

2. Remove pilot shut-off valve. (See Remove and Install Pilot Shut-Off Valve on page W2-7-1) Ď&#x2013; 17 mm, 19 mm

W178-02-08-001

CAUTION: The floor plate (1) assembly weight: 200 kg (440 Ib) 3. Install eyebolts (M10, Pitch 1.5) into the bolt holes in floor plate (1) (3 places). Pass wire ropes through them and hoist by a crane to remove the floor plate (1) assembly.

Eyebolt

NOTE: It is easy to adjust the wire ropes length and level the frame if a chain block is used.

W183-02-01-024

W2-1-9

UPPERSTRUCTURE / Cab IMPORTANT: Attach identification tags to pipes to aid reassembling.

Upper Side

4. Disconnect all pipes and connectors from cab bed. ϖ 19 mm, 22 mm, 27 mm NOTE: Cap all disconnected pipes. Cab Bed

W183-02-01-019

2,3,4,5

5. Remove bolts (2) (8 used), washers (3) (8 used) and spring washers (4) (8 used) to remove plates (5) (4 used). ϖ 19 mm 6. Attach wire at the top corners (2 places) of the fender assembly (6). Put two iron bars under the fender, then secure the iron bars with wire. 6

7. Do the same work as procedure 6 at the opposite side for hoisting fender assembly.

CAUTION: The fender assembly (6) weight: 180 kg (400 Ib)

W183-02-01-020

Cab Bed

8. Remove bolts (7) (6 used) to remove the fender assembly (6) from cab bed. ϖ 24 mm

CAUTION: The fender assembly (8) weight: 150 kg (330 Ib) 9. Remove the fender assembly (8) from cab bed by same method as in procedure 6 to 8.

Iron Bar

6 W183-02-01-032

W2-1-10

UPPERSTRUCTURE / Cab 10. Remove bolts (10) (4 used) from cab bed to remove bracket (9) and cushion rubber (11). (10 places)

Cab Bed

Section

Ď&#x2013; 19 mm

CAUTION: Cab bed weight: 590 kg (1300 Ib) 11. Install eyebolts (M12, Pitch 1.75) into the screw holes for cab bed bolts (10) (4 places). Remove cab bed mounting bolts (12) (28 used) and hoist by a crane to remove cab bed from the frame.

W183-02-01-027

Ď&#x2013; 19 mm Eyebolt Cab Bed

Frame

W183-02-01-026

W2-1-11

UPPERSTRUCTURE / Cab Install Cab Bed (only for loading shovel) CAUTION: Cab bed weight: 590 kg (1300 Ib)

Eyebolt

1. Hoist cab bed by a crane and install it onto the frame with bolts (12) (28 used).

Cab Bed

ϖ 19 mm

Frame

ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W183-02-01-026

2. Install bracket (9) and cushion rubber (11) onto cab bed with bolts (10) (4 used). (10 places)

Section

ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W183-02-01-027

2,3,4,5 Handrail

CAUTION: The fender assembly (8) weight: 150 kg (330 Ib) 3. Hoist the fender assembly (8) by a crane and install it to the cab bed with bolts (7) (6 used). ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft) 6

CAUTION: The fender assembly (6) weight: 180 kg (400 Ib)

4. Install the fender assembly (6) onto cab bed by same method as in procedure 3.

W183-02-01-020

Cab Bed

5. Install plates (5) (4 used) onto handrail with spring washers (4) (8 used), washers (3) (8 used) and bolts (2) (8 used). ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W2-1-12

UPPERSTRUCTURE / Cab Upper Side

6. Connect all pipes and connectors into cab bed. Pilot hose (Except cooler hose) ϖ 22 mm ϖ 40 N⋅m (4.1 kgf⋅m, 30.0 Ibf⋅ft) ϖ 27 mm ϖ 95 N⋅m (9.7 kgf⋅m, 70 Ibf⋅ft) Cooler hose ϖ 19 mm ϖ 120 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft) ϖ 27 mm ϖ 300 N⋅m (30.5 kgf⋅m, 220 Ibf⋅ft)

Cab Bed

CAUTION: The floor plate (1) assembly weight: 200 kg (440 Ib) 7. Hoist the floor plate (1) assembly by a crane and place it while aligning the cushion rubber screw part of cab bed with the bolt hole in floor plate (1).

W183-02-01-019

Screw Part

8. Install pilot shut-off valve. (Refer to Remove and Install Shut-off Valve section on page W2-7-1) ϖ ϖ ϖ ϖ

17 mm 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 19 mm 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

Cushion Rubber

W183-02-01-028

W178-02-08-001

W2-1-13

UPPERSTRUCTURE / Cab 9. Install pilot valve. (Refer to Remove and Install Pilot Valve section on page W2-6-1) ϖ 13 mm ϖ ϖ ϖ ϖ ϖ ϖ ϖ

10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft) 17 mm 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 19 mm 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 22 mm 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft)

W178-02-07-002

W2-1-14

UPPERSTRUCTURE / Cab Dimensions of the Cab Glass Unit: mm

Chamfer along the Periphery

NOTE: 1 mm=0.03937 in

4-R61 561.5

(5 mm) 843

382

1026±1

Chamfer along the Periphery

2-R61

(5 mm)

907±1

R241

R191

NOTE: Material: JIS R3211, R3212 or equivalent

1088.5±1

Chamfer along the Periphery

4-R91

(8.8 mm)

1530 +1.5 -0.5

887 +1.5 -0.5

W183-02-01-033

W2-1-15

UPPERSTRUCTURE / Cab Unit: mm NOTE: 1 mm=0.03937 in NOTE: Material: JIS R3211, R3212 or equivalent Chamfer Here

398±1

346±1

Chamfer Here Chamfer Here

Chamfer Slightly Unless Polish Chamfered

Chamfer Here

2-R5

2-R79

2-R5

2-φ12.2±1

2-φ12.2±1 40

2-R79

(4 mm)

756±1

Chamfer Slightly Unless Polish Chamfered

(4 mm)

39.5 +0 -1 39.5

291.5

-1

398±1

291.5

397±1

582±1

Chamfer along the Periphery

4-R61

(5 mm)

738±1

748.5±1

Chamfer along the Periphery

3-R61

(5 mm)

406±1

R141

778.5±1

W183-02-01-034

W2-1-16

UPPERSTRUCTURE / Cab Unit: mm NOTE: 1 mm=0.03937 in NOTE: Material: JIS R3211, R3212 or equivalemt Chamfer along the Periphery

(5 mm)

582±1

4-R61

902±1

W183-02-01-010

W2-1-17

UPPERSTRUCTURE / Cab Cab Glass Installation Method 1. Install mounting rubber along the glass periphery. Apply bonding agent (cemedine 366 standard) onto the rubber connecting ends to stick together. Mounting Rubber NOTE: Rubber aging will cause the contraction of rubber, be sure to leave a little extra, install by pressing and sticking. 2. After installing glass assembly on the cab, insert the stopper into rubber.

Mounting Rubber Section Glass

Stopper

Cab W216-02-01-003

W2-1-18

UPPERSTRUCTURE / Counterweight REMOVE AND INSTALL COUNTERWEIGHT Removal CAUTION: Counterweight weight: 17500 kg (38580 Ib) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Set the wire rope taut by a crane.

Frame W183-02-02-002

CAUTION: Watch out for the power-wrench reaction bar’s movement. Take care not to be hit by the reaction bar. 2. With a power wrench, remove bolts (1) (8 used) and washers (2) (8 used). ϖ 65 mm

W183-02-02-001

3. Remove the counterweight by a crane.

W2-2-1

UPPERSTRUCTURE / Counterweight Installation ӸCAUTION: Counterweight weight: 17500 kg (38580 Ib) 1. Install lifting accessories and wire ropes to sling brackets on the top of the counterweight. Then, lift the counterweight by a crane.

2. Align the bolt hole in the counterweight with the hole in the frame and place the counterweight onto the frame.

Frame W183-02-02-002

CAUTION: Watch out for the power-wrench reaction bar’s movement. Take care not to be hit the reaction bar. IMPORTANT: Apply lubricant to bolts (1) before installing. 3. Install bolts (1) (8 used), and washers (2) (8 used). With a power wrench, tighten bolts (1) (8 used) ϖ 65 mm ϖ 2350 N⋅m (240 kgf⋅m, 1730 Ibf⋅ft) W183-02-02-001

Remove lifting counterweight.

accessories

from

the

W2-2-2

UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE Cap

CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure before removing it.

W183-01-01-001

Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2. : 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank. NOTE: Run the vacuum pump continously while working on the hydraulic system.

W2-3-1

W183-04-02-003

W183-04-02-002

Wooden Blocks

UPPERSTRUCTURE / Pump Device Removal Pump Transmission

Eyebolt

1. Disconnect all hydraulic lines and electric cables from the pump and pump transmission.

ϖ 13 mm, 17 mm, 19 mm, 22 mm, 27 mm, Main Pump

36 mm, 41 mm ϖ 8 mm, 10 mm

NOTE: Cap the disconnected pipes.

CAUTION: Main pump weight: 160 kg (350 Ib) 1

2. Install eyebolt (M12) into the hoisting holes (2 places) in the main pump. Attach a wire to the two eyebolts and hoist by a crane. 2

3. Remove socket bolts (1) (4 used) to remove the 3-Tandem Pump main pump. ϖ 17 mm 4. Remove the other two pumps in accordance with the procedure 2 to 3.

CAUTION: 3-tandem pump weight: 55 kg (120 Ib) 5. Install eyebolt (M8) into the hoisting holes (2 places ) in the 3-tandem pump. Attach a wire to the two eyebolts and hoist by a crane. 6. Remove socket bolts (2) (4 used) to remove the 3-tandem pump. ϖ 14 mm

CAUTION: Pump transmission weight: 530 kg (1170 Ib) 7. Attach a wire to both left and right parts of bracket (3) for the pump transmission and hoist by a crane. 8. Remove the mounting bolts (4) (16 used) from the pump transmission. Then remove the pump transmission. ϖ 19 mm

W2-3-2

W183-02-04-011

Tool Size

Tightening Torque N⋅m

(kgf⋅m)

Ibf⋅ft

Remarks

13 mm

(2)

14.5

Bolt

17 mm

(5.1)

Bolt

19 mm

29.5

(3)

21.5

Hose

ϖ 22 mm

(7)

Hose

27 mm

(9.5)

Hose

36 mm

175

(18)

130

Hose

41 mm

205

(21)

152

Hose

ϖ 8 mm

(5.1)

108

(11)

10 mm

Socket Bolt Socket Bolt

UPPERSTRUCTURE / Pump Device Installation IMPORTANT: After installing the pump, be sure to perform break-in operation to prevent burning.

NOTE: As for wrench size and tightening torque, refer to Removal. 1. Hoist the pump transmission by a crane.

BREAK-IN OPERATION PROCEDURE: 1. Fill hydraulic oil into the pump casing. 2. Start the engine and run at slow idle speed for 20 minutes, check for oil leaks while running at slow idle. 3. Increase the engine speed to the fast idle speed. Raise and lower the boom for 20 minutes repeatedly. (Do not operate the control levers quickly. Slowly move the levers to full stroke.)

2. Install the pump transmission onto the engine with bolts (4) (16 used). ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) 3. Hoist the 3-tandem pump by a crane. Install the 3-tandem pump onto the pump transmission with socket bolts (2) (4 used). ϖ 14 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

Eyebolt

Pump Transmission Air Bleeding Position

4. Hoist the main pump by a crane or hoist. Install the main pump onto the pump transmission with socket bolts (1) (4 used). ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

Main Pump

5. Install the other two main pump in accordance with the procedure 4. 6. Connect all hydraulic lines and electric cables to the pumps and pump transmission. 7. Bleed air trapped inside of the pumps. (Refer to

1 Air Bleeding Position

page W1-1-2) 3-Tandem Pump

W183-02-03-001

W2-3-3

UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP TRANSMISSION 1

2 3 4 5 6 7 8 9 10

15 16 20 21

31,32

17 18

22 23

Pump Side

24 11

33 25 26 27

29 14 13

34,35 Engine Side

W183-02-04-008 W183-02-04-010

123456789-

Bolt (3 Used) Spring Washer (3 Used) Cover O-Ring Disc Spring Roller Bearing Retaining Ring Stopper Gear

10 11 12 13 14 15 16 17 18 -

Roller Bearing Casing Oil Seal Bolt (10 Used) Cover Air Breather Reducer Pipe Elbow

19 20 21 22 23 24 25 26 27 -

W2-3-4

O-Ring Ball Bearing Gear Spacer Retaining Ring Ball Bearing Ball Bearing (3 Used) Gear (3 Used) Spacer (3 Used)

28 29 30 31 32 33 34 35 36 -

Retaining Ring (3 Used) Ball Bearing (3 Used) Cover (3 Used) Socket Bolt (12 Used) Spring Washer (12 Used) O-Ring (3 Used) Bolt (4 Used) Spring Washer (4 Used) Cover

UPPERSTRUCTURE / Pump Device Disassemble Pump Transmission • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. Remove retaining rings (23 and 28) and spacers (22 and 27) from gears (21 and 26) to remove ball bearings (20, 24, 25 and 29) with puller respectively.

CAUTION: The pump transmission weight: 530 kg (1170 Ib) 1. Place the pump transmission with the pump side facing up. Ȁ 2. Remove socket bolts (31) (12 used) and spring washers (32) (12 used) from casing (11) to remove cover (30) (3 used) and O-ring (33) (3 used). ϖ 17 mm 3. Remove bolts (34) (4 used) and spring washers (35) (4 used) from casing (11) to remove cover (36) and O-ring (19). ϖ 24 mm 4. Remove bolts (1) (3 used) and spring washers (2) (3 used) from casing (11) to remove cover (3) and O-ring (4). ϖ 22 mm CAUTION: The gear (21) assembly weightϖ ϖ 20 kg (40 Ib) The gear (26) assembly weight: 30 kg (70 Ib) 5. Install eyebolts (M10, Pitch 1.5) into the two hoisting holes in the gears (21 and 26) assembly to remove the gears (21 and 26) assembly from casing (11).

W2-3-5

CAUTION: Casing (11) weight: 300 kg (660 Ib) 7. Place casing (11) with its engine side facing up. Ȁ 8. Remove bolts (13) (10 used) from casing (11) to remove cover (14). ϖ 19 mm 9. Remove oil seal (12) from cover (14).

CAUTION: The gear (9) assembly weight: 40 kg (90 Ib) 10 Install eyebolts (M10, Pitch 1.5) into the two hoisting holes of the gear (9) assembly. Remove the gear (9) assembly from casing (11) and disc spring (5). 11. Remove retaining ring (7) and stopper (8) from gear (9). Remove the inner race of roller bearings (6 and 10) with puller.

UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP TRANSMISSION Pump Side

25 26

Engine Side

13 14 15 16 30

31,32

18 A

4 7 8 9

1,2 3

5 10

34,35 19 20 22 21

W183-02-04-010

23 24 11 W183-02-04-009

Section A-A

123456789-

Bolt (3 Used) Spring Washer (3 Used) Cover O-Ring Disc Spring Roller Bearing Retaining Ring Stopper Gear

10 11 12 13 14 15 16 17 18 -

Roller Bearing Casing Oil Seal Bolt (10 Used) Cover Air Breather Reducer Pipe Elbow

19 20 21 22 23 24 25 26 27 -

W2-3-6

O-Ring Ball Bearing Gear Spacer Retaining Ring Ball Bearing Ball Bearing (3 Used) Gear (3 Used) Spacer (3 Used)

28 29 30 31 32 33 34 35 36 -

Retaining Ring (3 Used) Ball Bearing (3 Used) Cover (3 Used) Socket Bolt (12 Used) Spring Washer (12 Used) O-Ring (3 Used) Bolt (4 Used) Spring Washer (4 Used) Cover

UPPERSTRUCTURE / Pump Device Assemble Pump Transmission

8. Press in ball bearings (29) (3 used) at the engine side of gears (26) (3 used), and install spacers (27) and retaining rings (28) (3 used for each).

CAUTION: Gear (9) weight: 31 kg (70 Ib) 1. Install stopper (8) and retaining ring (7) to gear (9). Press in the inner race of roller bearing (10) to the engine side and press in the inner race of roller bearing (6) to the pump side. CAUTION: Casing (11) weight: 300 kg (660 Ib) 2. Place casing (11) with the engine side facing up.

CAUTION: The gear (21) assembly weight: 20 kg (40 Ib) The gear (26) assembly weight: 30 kg (70 Ib) 9. Install the gears (21 and 26) assembly into casing (11). 10. Press ball bearing (20) into the gear (21) assembly.

CAUTION: The gear (9) assembly weight: 40 kg (90 Ib) 3. Place disc spring (5) and the outer race of roller bearing (6) into casing (11), and install the gear (9) assembly. IMPORTANT: Apply grease on the inner diameter and THREEBOND on the outer diameter of oil seal (12).

11. Press ball bearings (25) (3 used) into the gear (26) assemblies (3 used). 12. Install O-ring (4) to cover (3). Install cover (3) to casing (11) with bolts (1) (3 used) and spring washers (2) (3 used). ϖ 22 mm ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

4. Install oil seal (12) into cover (14) and press in the outer race of roller bearing (10).

13. Install O-ring (19) to cover (36). Install cover (36) to casing (11) with bolts (34) (4 used) and spring washers (35) (4 used).

5. Install cover (14) to casing (11) with bolts (13) (10 used).

ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft) CAUTION: Casing (11) weight: 300 kg (660 Ib) 6. Place casing (11) with the engine side facing down. 7. Press in ball bearing (24) at the engine side of gear (21), and install spacer (22) and retaining ring (23).

W2-3-7

14. Install O-rings (33) (3 used) to covers (30) (3 used). Install covers (30) (3 used) to casing (11) with socket bolts (31) (12 used) and spring washers (32) (12 used). ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

UPPERSTRUCTURE / Pump Device DISASSEMBLE MAIN PUMP 17

18 16

15 20 22

10 9

23 24

7 8

4 28

26 48

36 32 33

44 43

35 40 49

31 50

30 51 52 53

W183-02-04-001

12345678910 11 12 13 14 -

Socket Bolt (4 used) Cover O-Ring Oil Seal Shaft Bearing Spacer Retaining Ring Nut Adjusting Screw Spring Pin (2 Used) Stopper Backup Ring O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Housing Tilt Pin Regulator Socket Bolt (4 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used) O-Ring (2 Used) O-Ring Cover Washer (4 Used)

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W2-3-8

Socket Bolt (4 Used) Swash Plate Bushing Plunger (9 Used) Retainer Plate Spherical Bushing Spacer Cylinder Block Valve Plate Bearing O-Ring O-Ring (10 Used) Cover Adjusting Screw

43 44 45 46 47 48 49 50 51 52 53 -

Nut Booster O-Ring O-Ring Cover Socket Bolt (6 Used) Spring Pin (2 Used) Pin Spring (9 Used) Shoe (9 Used) Shoe Plate

UPPERSTRUCTURE / Pump Device Disassemble Main Pump • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 Before starting the disassembly work.

5. Take out cylinder block (36) from housing (15). Now you can see plungers (32) (9 used), shoes (52) (9 used), spherical bushing (34) and retainer plate (33) all connected together on cylinder block (36).

IMPORTANT: Do not remove adjusting bolts (10 and 42) and nuts (9 and 43), the oil flow rate setting may change as a consequence.

NOTE: Grasp cylinder (36) with two hands and slowly take it out while turning it to left and right lightly.

1. Remove plugs (24) (2 used) and O-rings (23) (2 used) to bleed hydraulic oil in the pump.

6. Remove retainer plate (33) from the cylinder block (36) assembly. At this time, plungers (32) (9 used) and shoes (52) (9 used) are still connecting with retainer plate (33).

ϖ 36 mm 2. Remove socket bolts (18) (4 used) to remove regulator (17).

7. Remove plungers (32) (9 used) and shoes (52) (9 used) from retainer plate (33).

ϖ 6 mm

8. Remove spherical bushing (34) from cylinder block (36) to remove spacer (35) and springs (51) (9 used).

3. Remove socket bolts (48) (6 used) to remove cover (47), booster (44) and O-rings (45 and 46). ϖ 8 mm IMPORTANT: Be careful as valve plate (37) may come off together with cover (41) when removing the cover. As for bearing (38), do not remove unless necessary; replace with a new one when removed.

IMPORTANT: As for oil seal (4), do not remove it unless necessary; replace with a new one when removed. 9. Remove socket bolts (1) (4 used) to remove cover (2) and O-ring (3). ϖ 6 mm

4. Remove socket bolts (29) (4 used) to remove cover (41), O-rings (39) and (40) (10 used), spring pins (49) (2 used), valve plate (37) and pin (50). ϖ 17 mm

10. Remove cover (27) from housing (15) by tapping with a plastic hammer. At this moment, remove O-rings (26), (25) (2 used) and spring pins (11) (2 used). 11. Remove swash plate (30) and shoe plate (53) from housing (15). 12. Remove shaft (5) from cover (27) by tapping with a plastic hammer.

W2-3-9

UPPERSTRUCTURE / Pump Device

15 12 22

7 8

W183-02-04-001

W2-3-10

UPPERSTRUCTURE / Pump Device IMPORTANT: Servo piston (22) is connected to tilt pin (16) with LOCTITE. Take care not to damage servo piston (22) when disassembling. 13. Remove stoppers (12 and 19), servo piston (22), and tilt pin (16) from housing (15). 14. Remove retaining ring (8) from shaft (5) and remove spacer (7) and bearing (6).

W2-3-11

UPPERSTRUCTURE / Pump Device ASSEMBLE MAIN PUMP

11 12

13,14 26

22 16

31 19 20,21 40 39 38

43 42 47

48 5

2 46

23,24

1 29

25 30 53 52 33

34 32 35 51 36 37

50 41 45

W183-02-04-002

12345678910 11 12 13 14 -

Socket Bolt (4 Used) Cover O-Ring Oil Seal Shaft Bearing Spacer Retaining Ring Nut Adjusting Screw Spring Pin (2 Used) Stopper Backup Ring O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Housing Tilt Pin Regulator Socket Bolt (4 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used) O-Ring (2 Used) O-Ring Cover Washer (4 Used)

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W2-3-12

Socket Bolt (4 Used) Swash Plate Bushing Plunger (9 Used) Retainer Plate Spherical Bushing Spacer Cylinder Block Valve Plate Bearing O-Ring O-Ring (10 Used) Cover Adjusting Screw

43 44 45 46 47 48 49 50 51 52 53 -

Nut Booster O-Ring O-Ring Cover Socket Bolt (6 Used) Spring Pin (2 Used) Pin Spring (9 Used) Shoe (9 Used) Shoe Plate

UPPERSTRUCTURE / Pump Device Assemble Main Pump IMPORTANT: Apply LOCKTITE (Medium strength) on the interface of servo piston (22) and tilt pin (16). 1. Install tilt pin (16), servo piston (22) and stoppers (12) and (19) into housing (15).

IMPORTANT: Apply grease on valve plate (37). 10. Install spring pins (49) (2 used), pin (50) and O-rings (40) (10 used) to cover (41), then install valve plate (37) on it. NOTE: Install valve plate (37) while aligning the pin hole in the plate with pin (50).

2. Install bearing (6), spacer (7) and retaining ring (8) onto shaft (5). 3. Assemble spring pins (11) (2 used). O-rings (25) (2 used) and (26) onto cover (27), and install cover (27) into housing (15).

11. Install the housing (15) assembly to cover (41) with socket bolts (29) (4 used) and washers (28) (4 used). ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

4. Align swash plate (30) which is connected with shoe plate (53) with tilt pin (16), and install them to housing (15).

12. Align booster (44) with shaft (5) spline, and install it onto shaft (5).

NOTE: Check the swash plate by hand to ensure that it moves smoothly after installing swash plate (30).

13. Install O-rings (45 and 46) to cover (47). Then install cover (47) to cover (41) with socket bolts (48) (6 used). ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

5. Install oil seal (4) and O-ring (3) onto cover (2). 6. Press shaft (5) into cover (27) and install cover (2) with socket bolt (1) to cover (27). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

14. Align the feedback lever of regulator (17) with tilt pin (16) and install regulator (17) with socket bolts (18) (4 used) (Refer to W2-3-8). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

7. Install springs (51) (9 used), spacer (35) and spherical bushing (34) to cylinder block (36).

15. Install O-rings (23) (2 used) and plugs (24) (2 used).

8. Assemble plungers (32) (9 used) and shoes (52) (9 used) to retainer plate (33) which is to be installed to cylinder block (36). 9. Install the cylinder block (36) assembly onto shaft (5).

W2-3-13

ϖ 36 mm ϖ 147 N⋅m (15 kgf⋅m 108 Ibf⋅ft)

UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARD 1. Clearance between plunger (32) outer diameter (d) and cylinder block (36) bore diameter (D). d

DПd

Unit: mm (in) Standard

Allowable Limit

0.047 (0.002)

0.094 (0.004)

W117-02-02-009

2. Free length (L) of spring (51) L

Unit: mm (in) Standard

Allowable Limit

49.5 (1.95)

48.0 (1.89) L W117-02-02-010

3. Clearance (e) between plunger (32) and shoe (52) and thickness (t) of shoe (52) e

Unit: mm (in) Standard

Allowable Limit

0ϡ0.1 (0~0.004)

0.35 (0.014)

Unit: mm (in) Standard

Allowable Limit

6.5 (0.26)

6.3 (0.25)

e t

W117-02-02-011

4. Height from the reverse face of retainer plate (33) to the top of spherical bushing (34) H-h

Stand

Unit: mm (in) Standard

Allowable Limit

16.5 (0.65)

15.5 (0.61)

W117-02-02-012

W2-3-14

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-15

UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR (MAIN PUMP)

13 12 11 10 9 8

7 6

25 26

31 30

54 55

33 45

46 48

40 57

35 36

61 44

60 66

42 74 41

68 73

69 70 71 72

65 64 63

W183-02-04-014

W2-3-16

UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 17 18 19 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -

Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used) Cover O-Ring Seat (2 Used) Ball (2 Used) Stopper (2 Used)

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 -

W2-3-17

Cover O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) Cover O-Ring Socket Bolt (2 Used) Socket Bolt (2 Used) O-Ring O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Nut Nut Adjusting Screw Socket Bolt (4 Used)

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Retaining Ring O-Ring Supporting Plug Pin Housing Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring Stopper Ball Seat O-Ring O-Ring O-Ring

UPPERSTRUCTURE / Pump Device

12 11 10 9 8 7 6

24 26

20 19

30 29

54 55

33 45

39 40 57

35 36

61 44

60 66

43 67

42 74 41

68 73

69 70 71 72

65 63

W183-02-04-014

W2-3-18

UPPERSTRUCTURE / Pump Device Disassemble Regulator (Main Pump) • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

9. Remove bolts (57) (4 used) to remove cover (53), stopper (12), piston (11), springs (10 and 9), spring sheet (8), stopper (31), spring (30) and spring seat (29).

1. Remove socket bolts (45) (2 used) and (46) (2 used) to remove the regulator from main pump. ϖ 6 mm IMPORTANT: Do not remove adjusting bolts (49, 50 and 56) and nuts (51, 54 and 55), the oil flow rate setting of the pump will change as a consequence. 2. Remove socket bolts (33) (4 used) to remove covers (34 and 39). ϖ 5 mm

ϖ 5 mm IMPORTANT: Do not remove pin (66) from supporting plug (65) and put marks on supporting plugs (60 and 65) to prevent confusing them. 10. Remove retaining rings (58 and 63) from housing (62) to remove supporting plugs (60 and 65) using bolts (M6). IMPORTANT: Do not remove pin (27) from lever (26).

3. Remove O-ring (35) from cover (34). 4. Remove O-ring (40), seat (36), ball (37) and stopper (38) from cover (39). 5. Remove O-rings (68 and 72), seat (71), ball (70), stopper (69) and pin (67) from housing (62). 6. Remove socket bolts (42) (2 used) and (41) (2 used) to remove cover (43) and O-rings (44, 73 and 74). ϖ 5 mm 7. Remove pin (1), sleeve (2), O-rings (3 and 4), sleeve (5) and compensating piston (6) from housing (62).

11. Remove lever (26) from housing (62) with a pincers etc. to remove pilot piston (28). 12. Remove pin (24) from feedback lever (23) with a copper bar from the supporting plug (60) hole to remove feadback lever (23), sleeve (19) and spool (20). ϖ 4 mm IMPORTANT: Do not remove pins (21 and 61) from lever (22). 13. Remove lever (22) with a pincers etc. from housing (62) to remove compensating rod (7).

8. Remove retaining ring (14) from housing (62) to remove spring seat (15) and springs (16 and 17).

W2-3-19

UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (MAIN PUMP) 60 59

40 38 37

69 70

Section A-A

72 71 39

36 35 34 33

65 64 63

W183-02-04-006

15 16 18

19 25

24 26

28 29

30 31

W117-02-02-023

62 32

43 55

41 53

68 66

67 W183-02-04-015

Section B-B 3

9 10 11

48 13

54 49

51 50

W2-3-20

W183-02-04-005

UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 17 18 19 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Piston Stopper O-Ring Retaining Ring Spring Seat Spring Spring Retaining Ring Sleeve

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 -

Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used) Cover O-Ring Seat (2 Used) Ball (2 Used) Stopper (2 Used)

39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 -

W2-3-21

58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 -

Retaining Ring O-Ring Supporting Plug Pin Housing Retaining Ring O-Ring Supporting Plug Pin Pin O-Ring Stopper Ball Seat O-Ring O-Ring O-Ring

UPPERSTRUCTURE / Pump Device

40 38 37

60 59

Section A-A

W183-02-04-006

15 16 18

65 64 63 20

24 26

28 29

30 31

W117-02-02-023

62 32

41 53

W183-02-04-015

Section B-B 3

9 10 11

W2-3-22

W183-02-04-005

UPPERSTRUCTURE / Pump Device Assemble Regulator 1. Insert compensating rod (7) and lever (22) into housing (62). 2. Align pin (61) of lever (22) with the pin hole in housing (62) inside. Align pin (21) with stepped joint portion of compensating rod (7) to install lever (22) into housing (62). 3. Assemble retaining ring (18) to sleeve (19) and insert sleeve (19) and spool (20) into housing (62). IMPORTANT: Check spool (20) that it should move smoothly before installing feedback lever (23). Be sure to install spool (20) and feedback lever (23) in correct direction. Do not make any mistakes while doing this. 4. Align the pin hole in feedback lever (23) with the pin hole in spool (20), and install pin (24) from the mounting hole of supporting plug (60). 5. Insert pilot piston (28) and lever (26) into housing (62). IMPORTANT: Check pilot piston (28) that it should move smoothly before installing lever (26). 6. Align pin (27) of lever (26) with stepped joint portion of pilot piston (28) to install lever (26). 7. Install O-rings (59 and 64) to supporting plugs (60 and 65) respectively.

9. Insert supporting plug (60) into housing (62) and install retaining ring (58). 10. Install O-ring (32) onto stopper (31). 11. Install spring seat (29), spring (30) and stopper (31) to housing (62). 12. Install O-ring (13) onto stopper (12). 13. Place O-ring (52) in housing (62) where spring seat (8), springs (9 and 10), piston (11) and stopper (12) should be inserted. Install cover (53) to housing (62) with socket bolts (57) (4 used). ϖ 5 mm ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 14. Install spring (16), spring seat (15) and retaining ring (14) onto spool (20). 15. Place O-ring (4) to sleeve (5) and install sleeve (5), compensating piston (6), O-ring (3), sleeve (2) and pin (1) into housing (62). 16. Assemble spring (17), O-rings (44, 73 and 74) into housing (62) and install cover (43) with socket bolts (42) (2 used) and (41) (2 used). ϖ 5 mm ϖ 12 N⋅m (1.2 kgfcm, 8.7 Ibf⋅ft) 17. Place O-ring (40) to cover (39) and then install stopper (38), ball (37) and seat (36).

8. Align pin (66) of supporting plug (65) with the pin hole of lever (26) to insert the pin and install retaining ring (63).

W2-3-23

UPPERSTRUCTURE / Pump Device

35 34 33

69 70

72 71 39

W117-02-02-023

W183-02-04-006

Section A-A

46 W183-02-04-015

Section B-B 62

W183-02-04-005

W2-3-24

UPPERSTRUCTURE / Pump Device 18. Place O-ring (35) to cover (34) and install covers (39 and 34) into housing (62) with socket bolts (33) (4 used). ϖ 5 mm ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 19. Install stopper (69), ball (70), seat (71) and O-ring (72) into housing (62). 20. Install O-ring (68) to housing (62). 21. Install the regulator onto the pump with socket bolts (45) (2 used) and (46) (2 used). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-3-25

UPPERSTRUCTURE / Pump Device DISASSEMBLE PUMP OF OIL COOLER FAN MOTOR 18

16 15 14 22

23 24

5 3 1

25 26

43 41

32 30

42 52

53 54

W183-02-04-016

12345678910 11 12 13 14 -

Socket Bolt (4 Used) Cover O-Ring Oil Seal Shaft Bearing Spacer (2 Used) Retaining Ring Nut Adjusting Screw Spring Pin Stopper Backup Ring O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Housing Tilt Pin Regulator Socket Bolt (4 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used) O-Ring (2 Used) O-Ring Cover Socket Bolt (4 Used)

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W2-3-26

Swash Plate Bushing Shoe Plate Shoe (9 Used) Plunger (9 Used) Retainer Plate Spherical Bushing Spring (9 Used) Cylinder Block Valve Plate Bearing O-Ring O-Ring (10 Used) Cover

43 44 45 46 47 48 49 50 51 52 53 54 -

Adjusting Screw Nut O-Ring Retaining Ring Coupling Sub Plate Socket Bolt (4 Used) Sub Plate Socket Bolt (4 Used) O-Ring Spring Pin (2 Used) Pin

UPPERSTRUCTURE / Pump Device Disassemble Pump of Oil Cooler Fan Motor • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. Remove cylinder block (37) from housing (15) with plugers (33) (9 used), shoes (32) (9 used), spherical bushing (35) and retainer plate (34) still attached on the cylinder block.

IMPORTANT: Do not remove adjusting bolts (10 and 43) and nuts (9 and 44), the oil flow rate setting may change as a consequence.

NOTE: Hold cylinder block (37) with two hands and slowly take it out while turning it lightly to left and right. 7. Remove retainer plate (34) from the cylinder block (37) assembly, with plungers (33) (9 used) and shoes (32) (9 used) still attached on retainer plate (34).

1. Remove plugs (24) (2 used) and O-ring (23) (2 used) to drain hydraulic oil in the pump. ϖ 36 mm 2. Remove socket bolts (18) (4 used) to remove regulator (17) from housing (15).

8. Remove plungers (33) (9 used) and shoes (32) (9 used) from retainer plate (34).

ϖ 6 mm 3. Remove socket bolts (51) (4 used) to remove sub plate (50) and O-ring (52) from sub plate (48). ϖ 10 mm 4. Remove socket bolts (49) (4 used) to remove sub plate (48), O-ring (45), retaining ring (46) and coupling (47) from cover (42). ϖ 8 mm

9. Remove spherical bushing (35) from cylinder block (37) to remove springs (36) (9 used). IMPORTANT: Do not remove oil seal (4) unless necessary; replace with a new one when removed. 10. Remove socket bolts (1) (4 used) to remove cover (2) and O-ring (3). ϖ 6 mm

IMPORTANT: Be careful as valve plate (38) may come off together with cover (42) when removing cover (42). Do not remove bearing (39) unless necessary; replace with a new one when removed.

11. Remove cover (27) from housing (15) by tapping with a plastic hammer. At this moment, remove O-rings (25) (2 used), (26) and spring pins (11) (2 used).

5. Remove socket bolts (28) (4 used) to remove cover (42), O-rings (40), (41) (10 used), spring pins (53) (2 used), valve plate (38) and pin (54) from housing (15). ϖ 17 mm

13. Remove shaft (5) from cover (27) by tapping with a plastic hammer.

12. Remove swash plate (29) and shoe plate (31) from housing (15).

W2-3-27

UPPERSTRUCTURE / Pump Device

16 15 12 22

W183-02-04-016

W2-3-28

UPPERSTRUCTURE / Pump Device IMPORTANT: Be careful not to damage the surface of servo piston (22) while disassembling it since LOCTITE is applied on the joint portion between servo piston (22) and tilt pin (16). 14. Remove stoppers (12 and 19) from housing (15) to remove servo piston (22) and tilt pin (16). 15. Remove retaining ring (8) from shaft (5) to remove spacers (7) (2 used) and bearing (6).

W2-3-29

UPPERSTRUCTURE / Pump Device ASSEMBLE PUMP OF OIL COOLER FAN MOTOR

13,14 22

16 15

20,21 19 41

9 10

11 26 47

2 5

4 8

23,24 46

7 3

25 29 31

34 35

33 36

53 54

W183-02-04-017

12345678910 11 12 13 14 -

Socket Bolt (4 Used) Cover O-Ring Oil Seal Shaft Bearing Spacer (2 Used) Retaining Ring Nut Adjusting Screw Spring Pin Stopper Backup Ring O-Ring

15 16 17 18 19 20 21 22 23 24 25 26 27 28 -

Housing Tilt Pin Regulator Socket Bolt (4 Used) Stopper Backup Ring O-Ring Servo Piston O-Ring (2 Used) Plug (2 Used) O-Ring (2 Used) O-Ring Cover Socket Bolt (4 Used)

29 30 31 32 33 34 35 36 37 38 39 40 41 42 -

W2-3-30

Swash Plate Bushing Shoe Plate Shoe (9 Used) Plunger (9 Used) Retainer Plate Spherical Bushing Spring (9 Used) Cylinder Block Valve Plate Bearing O-Ring O-Ring (10 Used) Cover

43 44 45 46 47 48 49 50 51 52 53 54 -

Adjusting Screw Nut O-Ring Retaining Ring Coupling Sub Plate Socket Bolt (4 Used) Sub Plate Socket Bolt (4 Used) O-Ring Spring Pin (2 Used) Pin

UPPERSTRUCTURE / Pump Device Assemble Pump of Oil Cooler Fan Motor IMPORTANT: Apply grease on valve plate (38). IMPORTANT: Apply LOCTITE (medium strength) on the joint portion between servo piston (22) and tilt pin (16).

10. Install spring pins (53) (2 used), pin (54), valve plate (38) and O-rings (41) (10 used) to cover (42).

1. Install tilt pin (16), servo piston (22) and stoppers (12 and 19) into housing (15). 2. Install spacer (7), bearing (6), spacer (7) and retaining ring (8) onto shaft (5).

NOTE: Install valve plate (38) while aligning the pin hole in valve plate (38) with pin (54). 11. Install the housing (15) assembly with socket bolts (28) (4 used) to cover (42).

3. Assemble spring pin (11), O-rings (25) (2 used) and (26) to cover (27). Install cover (27) to housing (15). 4. Align swash plate (29) with tilt pin (16) when shoe plate (31) has been installed to swash plate (29). Install the swash plate into housing (15).

ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 12. Install coupling (47) to the housing (15) assembly. 13. Place O-ring (45) onto sub plate (48). Install sub plate (48) to cover (42) with socket bolts (49) (4 used).

NOTE: Check the swash plate (29) by hand to ensure it moves smoothly after being installed.

ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 14. Place O-ring (52) onto sub plate (50). Install sub plate (50) to sub plate (48) with socket bolts (51) (4 used).

5. Install oil seal (4) and O-ring (3) to cover (2).

ϖ 10 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

6. Press shaft (5) into cover (27). And install cover (2) to cover (27) with socket bolts (1) (4 used). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 7. Install springs (36) (9 used) and spherical bushing (35) into cylinder block (37). 8. Assemble plungers (33) (9 used) and shoes (32) (9 used) to retainer plate (34). Install retainer plate (34) to cylinder block (37).

15. Align the feedback lever of regulator (17) with tilt pin (16) to install regulator (17) with socket bolts (18) (4 used) (Refer to W2-3-26). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) 16. Install O-rings (23) (2 used) and plugs (24) (2 used).

9. Install the cylinder block (37) assembly onto shaft (5).

W2-3-31

ϖ 36 mm ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

UPPERSTRUCTURE / Pump Device MAINTENANCE STANDARD 1. Clearance between plunger (33) outer diameter (d) and bore inner diameter (D) of cylinder block (37) DĐ&#x;d

Unit: mm (in) Standard

Allowable Limit

0.047 (0.002)

0.094 (0.004)

W117-02-02-009

2. Free lenghth (L) of spring (36) L

Unit: mm (in) Standard

Allowable Limit

49.5 (1.95)

48.0 (1.89) L W117-02-02-010

3. Clearance (e) between plunger (33) and caulking part of shoe(32) and the thickness (t) of the shoe e

Unit: mm (in) Standard

Allowable Limit

0 to 0.1 (0 to 0.004)

0.35 (0.014)

Unit: mm (in) Standard

Allowable Limit

6.5 (0.26)

6.3 (0.25)

e t

W117-02-02-011

4. Height from the reverse face of retainer plate (34) to the top of spherical bushing (35) H-h

Block

Unit: mm (in) Standard

Allowable Limit

16.5 (0.65)

15.5 (0.61)

W117-02-02-012

W2-3-32

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-33

UPPERSTRUCTURE / Pump Device DISASSEMBLE REGULATOR ϑPump for Driving Oil Cooler Fan Motor ϒ

9 8 7 6

25 26

15 13

18 29 28

44 27

43 42

40 36

38 34

49 50

51 52 53

55 56

63 64

W183-02-04-018

W2-3-34

UPPERSTRUCTURE / Pump Device 12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -

W2-3-35

Cover O-Ring O-Ring (3 Used) Socket Bolt Socket Bolt O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Nut Nut Adjusting Screw Socket Bolt (4 Used) Housing

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 -

Pin Pin Supporting Plug O-Ring Retaining Ring Supporting Plug O-Ring Retaining Ring Pin O-Ring O-Ring O-Ring O-Ring Cover Socket Bolt (2 Used) Socket Bolt (2 Used)

UPPERSTRUCTURE / Pump Device

9 8 7 6

25 26

15 13

18 29 28

44 27

43 42

40 36

38 34

49 50

51 52 53

55 56

63 64

W183-02-04-018

W2-3-36

UPPERSTRUCTURE / Pump Device Disassemble Regulator ϑ Pump to drive Oil Cooler Fan Motorϒ ϒ • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

IMPORTANT: Do not remove pin (50) from supporting plug (51) and put marks on supporting plugs (51 and 54) to prevent confusing them. 9. Remove retaining rings (53 and 56) from housing (48) to remove supporting plugs (51 and 54) by using bolt (M6) respectively.

1. Remove socket bolts (36) (2 used) and (37) (2 used) to remove the regulator from the pump. ϖ 6 mm IMPORTANT: Do not remove adjusting bolts (39, 40 and 46) and nuts (41, 44, and 45), the oil flow rate setting will change as a consequence. 2. Remove socket bolts (32) (4 used) to remove cover (33). ϖ 5 mm

IMPORTANT: Do not remove pin (26) from lever (25). 10. Remove lever (25) with a pincers, etc. from housing (48) and pilot piston (27). 11. Remove pin (23) from feedback lever (22) with a copper bar through the hole of supporting plug (51) to remove feedback lever (22), sleeve (18) and spool (19).

3. Remove O-rings (34) and (35) (3 used) from cover (33). 4. Remove socket bolts (63) (2 used) and (64) (2 used) to remove cover (62) and O-rings (59, 60 and 61).

ϖ 4 mm IMPORTANT: Do not remove pins (20 and 49) from lever (21). 12. Remove lever (21) from housing (48) with a pincers, etc. to remove compensating rod (7).

ϖ 5 mm 5. Remove O-ring (58) and pin (57) from housing (48). 6. Remove pin (1), sleeve (2), O-rings (3 and 4), sleeve (5) and compensating piston (6) from housing (48). 7. Remove retaining ring (13) from housing (48) to remove spring seat (14) and springs (15 and 16). 8. Remove socket bolts (47) (4 used) to remove cover (43), stopper (11), springs (10 and 9), spring seat (8), stopper (30), spring (29) and spring seat (28). ϖ 5 mm

W2-3-37

UPPERSTRUCTURE / Pump Device ASSEMBLE REGULATOR (Pump for Driving Oil Cooler Fan Motor) 48

32 47 35 A

Section A-A

W183-02-04-012

W183-02-04-013

54 55 56

14 15 17 19 18 48 24

50 25 26 27 28

29 30

31 43

62 45

57 W183-02-04-004

Section B-B 49

9 10

41 3 1

22 20

W2-3-38

W117-02-02-017

UPPERSTRUCTURE / Pump Device

12345678910 11 12 13 14 15 16 -

Pin Sleeve O-Ring O-Ring Sleeve Compensating Piston Compensating Rod Spring Seat Spring Spring Stopper O-Ring Retaining Ring Spring Seat Spring Spring

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 -

Retaining Ring Sleeve Spool Pin Lever Feedback Lever Pin Pin Lever Pin Pilot Piston Spring Seat Spring Stopper O-Ring Socket Bolt (4 Used)

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 -

W2-3-39

Cover O-Ring O-Ring (3 Used) Socket Bolt Socket Bolt O-Ring Adjusting Screw Adjusting Screw Nut O-Ring Cover Nut Nut Adjusting Screw Socket Bolt (4 Used) Housing

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 -

Pin Pin Supporting Plug O-Ring Retaining Ring Supporting Plug O-Ring Retaining Ring Pin O-Ring O-Ring O-Ring O-Ring Cover Socket Bolt (2 Used) Socket Bolt (2 Used)

UPPERSTRUCTURE / Pump Device

47 35 A

Section A-A

W183-02-04-012

54 55 56

14 15 17 19 18 48

50 25 26 27 28

29 30

W183-02-04-013

22 W183-02-04-004

Section B-B 49

9 10

3 1

W2-3-40

W117-02-02-017

UPPERSTRUCTURE / Pump Device Assemble Regulator 1. Insert compensating rod (7) and lever (21) into housing (48). 2. Align pins (49) of lever (21) with the pin hole in housing (48) inside. Align pin (20) with the stepped part of compensating rod (7) and install lever (21) into housing (48). 3. Place retaining ring (17) onto sleeve (18). Insert sleeve (18) and spool (19) into housing (48). IMPORTANT: Check spool (19) to ensure it moves smoothly before installing feedback lever (22) and do not make any mistake about the facing of spool (19) and feadback lever (22). 4. Align the pin hole in feedback lever (22) with the pin hole in spool (19) and install pin (23) from the mounting hole in supporting plug (51). 5. Insert pilot piston (27) and lever (25) into housing (48). IMPORTANT: Check pilot piston (27) to ensure it moves smoothly before installing lever (25).

9. Insert supporting plug (54) into housing (48) and install retaining ring (56). 10. Install O-ring (31) onto stopper (30). 11. Install spring seat (28), spring (29) and stopper (30) into housing (48). 12. Install O-ring (12) onto stopper (11). 13. Place O-ring (42) into housing (48) and insert spring seat (8), spring (9 and 10) and stopper (11). Install cover (43) to housing (48) with socket bolts (47) (4 used). ϖ 5 mm ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 14. Install spring (15), spring sheet (14) and retaining ring (13) onto spool (19). 15. Place O-ring (4) onto sleeve (5) with which compensating piston (6), O-ring (3), sleeve (2) and pin (1) can be installed into housing (48). 16. Assemble spring (16), O-rings (59, 60 and 61) into housing (48) to which cover (62) can be installed with socket bolts (63) (2 used) and (64) (2 used).

6. Align pin (26) of lever (25) with the stepped part of pilot piston (27) and install lever (25). 7. Install O-rings (52 and 55) onto supporting plugs (51 and 54) respectively.

ϖ 5 mm ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 17. Install O-rings (34) and (35) (3 used) to cover (33).

8. Align pin (50) of supporting plug (51) with the pin hole in lever (25) and insert it, and install retaining ring (53).

W2-3-41

UPPERSTRUCTURE / Pump Device

W183-02-04-013

W183-02-04-012

Section A-A

37 W183-02-04-004

Section B-B

W117-02-02-017

W2-3-42

UPPERSTRUCTURE / Pump Device 18. Install cover (33) to housing (48) with socket bolts (32) (4 used). ϖ 5 mm ϖ 12 N⋅m (1.2 kgf⋅m, 8.7 Ibf⋅ft) 19. Install the regulator onto the pump with socket bolts (36) (2 used) and (37) (2 used). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

W2-3-43

UPPERSTRUCTURE / Pump Device CONFIGURATION OF PILOT PUMP 1

W183-02-04-007

10 C

16 16

Part A

Part B

Section C-C

W183-02-04-019

W2-3-44

UPPERSTRUCTURE / Pump Device

Item

Part Name

Q’ty

Socket Bolt

Washer

Plate

Pressure Plate

Gear Plate

Gear

Flange

Retaining Ring

Oil Seal

Tightening Torque

Wrench Size (mm) (in) 12

N⋅m

(kgf⋅m)

(Ibf⋅ft)

Remarks

(0.47) 34 to 39 (3.5 to 4.0) (25.5 to 29)

When installing, apply a film of grease to the lip

Gear

Coupling

Dowel Pin

O-Ring

Plate

O-Ring

When installing, apply grease

Backup Ring

When installing, apply grease

Seal Plate

When installing, apply grease

W2-3-45

UPPERSTRUCTURE / Pump Device CONFIGURATION OF PUMP FOR LUBRICATING PUMP TRANSMISSION

View D

Detali C

Section B-B

Section A-A

W2-3-46

W117-02-02-020

UPPERSTRUCTURE / Pump Device

Item

Part Name

Q’ty

Bolt

Cover

Driven Gear

Dowel Pin

Plate

Flange

Retaining Ring

Oil Seal

Side Plate A

Side Plate B

O-Ring

Drive Gear

Gasket A

Gasket B

Balance Seal

Tightening Toruqe

Wrench Size (mm) (in) 17

N⋅m

(kgf⋅m)

(Ibf⋅ft)

Remarks

0.67 34 to 39 (3.5 to 4.0) (25.5 to 29)

MAITENANCE STANDARD Plate (5) ㈰ғ0.15 mm (0.006 in)

Drive gear (12), Drive gear (3) ̨ b>̨ 14.96 mm (0.59 in)

W117-02-02-022 W117-02-02-021

W2-3-47

UPPERSTRUCTURE / Pump Device (Blank)

W2-3-48

UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE Cap

W183-01-01-001

W2-4-1

W183-04-02-003

W183-04-02-002

Wooden Blocks

UPPERSTRUCTURE / Control Valve Remove and Install Control Valve NOTE: BH: Backhoe LD: Loading shovel Main Control Valve Front Side

Travel Left (Forward)

Travel Right (Forward) Bucket 1 (Roll-Out)

Bucket 1 (Roll-In)

Boom (Lower)

Travel Right (Reverse)

Boom 1 (Raise) BH: Arm 2 (Roll-Out) LD: Arm 2 (Roll-In)

Front Side

Bucket 2 (Roll-Out)

Boom 2 (Raise)

BH: Arm 2 (Roll-In) LD: Arm 2 (Roll-Out)

Boom 2 (Lower)

Travel Left (Reverse) BH: Arm 1 (Roll-Out) LD: Arm 1 (Roll-In)

BH: Auxiliary LD: Bucket (Open)

BH: Auxiliary LD: Bucket (Close) W183-02-05-020

Bucket 2 (Roll-In) BH: Arm 1 (Roll-In) LD: Arm 1 (Roll-Out)

W183-02-05-021

Swing Control Valve Front Side

Boom 3 (Raise)

Swing (Right) Boom 3 (Lower) BH: Arm 3 (Roll-Out) LD: Arm 3 (Roll-In)

Swing (Left) Bucket 3 (Roll-Out)

Front Side

W183-02-05-022

W2-4-2

Bucket 3 (Roll-In)

BH: Arm 3 (Roll-In) LD: Arm 3 (Roll- Out)

W183-02-05-023

UPPERSTRUCTURE / Control Valve Removal IMPORTANT: Attach identification tags to hoses to aid reassembling.

Main Control Valve

1. Disconnect all hoses, pipes and connectors from control valve. ϖ ϖ ϖ ϖ

Swing Control Valve

19 mm 19 mm 41 mm 12 mm

NOTE: Cap all disconnected hose and pipe ends.

M183-07-031

Main Control Valve

CAUTION: Main control valve weight: 390 kg (860 Ib) Swing control valve weight: 150 kg (330 Ib) 2. Remove bolts (1) (4 used) and (2) (3 used). ϖ 30 mm 3

3. Install eyebolts (M12, Pitch 1.75) to the bolt holes (3) (3 places) and install eyebolts (M14, pitch 2) to the holes (4) (4 places). Hoist by a crane, remove main control valve and swing control valve.

T183-03-03-002

Swing Control Valve

T183-03-03-030

W2-4-3

UPPERSTRUCTURE / Control Valve

NOTE: BH: Backhoe LD: Loading shovel Main Control Valve Front Side

Travel Right (Forward) Bucket 1 (Roll-Out)

Travel Left (Forward)

Bucket 1 (Roll-In))

Boom 1 (Lower)

Travel Right (Reverse)

Boom 1 (Raise) BH: Arm 2 (Roll-Out) LD: Arm 2 (Roll-In)

Front Side

Bucket 2 (Roll-Out)

Boom 2 (Raise)

BH: Arm 2 (Roll-In) LD: Arm 2 (Roll-Out)

Boom 2 (Lower)

Travel Left (Reverse) BH: Arm 1 (Roll-Out) LD: Arm 1 (Roll-In)

BH: Auxiliary LD: Bucket (Open)

BH: Auxiliary LD: Bucket (Close) W183-02-05-020

Bucket 2 (Roll-In) BH: Arm 1 (Roll-In) LD: Arm 1 (Roll-Out)

W183-02-05-021

Swing Control Valve Front Side

Boom 3 (Raise)

Swing (Right) Boom 3 (Lower)

BH: Arm 3 (Roll-Out) LD: Arm 3 (Roll -In)

Swing (Left) Bucket 3 (Roll-Out)

Front Side

W183-02-05-022

W2-4-4

Bucket 3 (Roll-In)

BH: Arm 3 (Roll-In) LD: Arm 3 (Roll-Out)

W183-02-05-023

UPPERSTRUCTURE / Control Valve Installation 1. Install eyebolts (M12, Pitch 1.75) into bolt holes (3) (3 places) and install eyebolts (M14, pitch 2) into bolt holes (4) (4 places).

Main Control Valve

CAUTION: Main control valve weight: 390 kg (860 Ib) Swing control valve weight: 150 kg (330 Ib) 3

2. Hoist main control valve and swing control valve by a crane. Install them with bolts (1) (4 used) and (2) (3 used).

ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) Ȁ 3. Connect all hoses, pipe and connector onto control valve. ϖ ϖ ϖ ϖ ϖ ϖ ϖ ϖ

19 mm 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 19 mm 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft) 41 mm 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft) 12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

T183-03-03-002

Swing Control Valve

IMPORTANT: Be sure to check the hydraulic oil level after assembling. Start engine to check each part for any oil leakage.

T183-03-03-030

Main Control Valve

Swing Control Valve

1 2

W2-4-5

M183-07-031

UPPERSTRUCTURE / Control Valve DISASSEMBLE MAIN CONTROL VLAVE 1 (5-SPOOL SECTION) 8

11 7 Overload Relief Valve

6 6

27 28 29 30 32

4 3

24 26

31 33

2 1

17 16 15 14 13 12

34 35 36

23 19

16 14 13 18

37 38 39 40 41

48 47

43 42 Check Valve

W183-02-05-001

NOTE: BH: Backhoe LD: Loading Shovel 1 - Spool (BH: Auxiliary/ LD: Bucket Open and Close) 2 - Spring Guide (5 Used) 3 - Sleeve (5 Used) 4 - Spring (5 Used) 5 - Spring Guide (5 Used) 6 - Cap (5 Used) 7 - O-Ring (5 Used) 8 - Socket Bolt (10 Used) 9 - O-Ring (2 Used) 10 - Cap (2 Used) 11 - Cover 12 - Cap

13 - Backup Ring (2 Used) 14 15 16 17 18 19 20 21 22 23 24 -

O-Ring (2 Used) Spacer Spring (2 Used) Check Valve Cap Check Valve Spool (Arm 1) Spool (Boom 2) Spool (Bucket 2) Spool (Travel Left) Lock Nut (6 Used)

25 - Adjusting Screw (6 Used) 26 - O-Ring (6 Used) 27 - Spring (6 Used) 28 - Poppet (6 Used) 29 - Seat (6 Used) 30 - O-Ring (6 Used) 31 - Backup Ring (12 Used) 32 - O-Ring (6 Used) 33 - Spring (6 Used) 34 - Spring (6 Used) 35 - Piston (6 Used) 36 - Poppet (6 Used)

W2-4-6

37 - Sleeve (6 Used) 38 39 40 41 42 43 44 45 46 47 48 -

O-Ring (6 Used) Backup Ring (6 Used) O-Ring (6 Used) Overload Relief Valve (6 Used) Cap Chip Backup Ring O-Ring Spring Check Valve Housing

UPPERSTRUCTURE / Control Valve Disassemble Main Control Valve 1 (5-spool section) • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work. • Attach tags to the spools and the places where the spools inserted, in order to prevent misplacement when assembling. Spool 1. Remove socket bolts (8) (10 used) to remove cover (11) from housing (48). ϖ 10 mm

Overload Relief Valve IMPORTANT: Do not disassemble the overload relief valves unless necessary, because the adjustment on the test bench should be carried out, keep overload relief valve with tag attached in order to set it to its original position before being removed. 8. Remove overload relief valves (41) (6 used) (3 for upper and 3 for lower) from housing (48). ϖ 41 mm

2. Slowly take out the spool (1 and 20 to 23) assemblies (5 used) from housing (48) while comfirming their corresponding position in housing (48).

9. Loosen and remove seat (29). Remove springs (33 and 34), piston (35) and poppet (36) from sleeve (37). ϖ 36 mm

3. Remove O-rings (7) (5 used) from housing (48). 4. Clamp the spool (1) assembly in a vise with wooden spatulas inserted at both sides to hold it. 5. Loosen cap (6) while holding spring guide (5) by hand, and remove spring guide (2), sleeve (3), spring (4) and spring guide (5). ϖ 10 mm

IMPORTANT: Put matching marks on adjusting bolts (25) and seat (29) and take a note of the turning amount of adjusting bolt (25). 10. Remove lock nut (24) to remove adjusting bolt (25), spring (27) and poppet (28) from seat (29). ϖ 19 mm ϖ 6 mm

6. Disassemble the spool (20 to 23) assemblies (4 used) in accordance with the procedures 4 to 5. 7. Remove caps (12 and 18) of the opposite spools (20 and 21) to remove spacer (15), spring (16) and check valves (17 and 19) respectively. ϖ 8 mm, 10 mm

Check Valve 11. Loosen and remove cap (42) from housing (48). ϖ 14 mm 12. Remove spring (46) and check valve (47) from housing (48).

NOTE: Spacer (15) is no use on spool (21).

W2-4-7

UPPERSTRUCTURE / Control Valve

48 49

50 51 52 53 54 55 56 57 58 59 61 62 63 64 65 66 67 68 69 70 71

85 82

82 81

72 73 74

80 80 75 76 77 78 79

Overload Relief Valve (Boom Motor Selector)

Overload Relief Valve

W183-02-04-020

41 - Overload Relief Valve (6 Used) 48 - Housing 49 - Overload Relief Valve (Boom Motor Selector) 50 - Cap 51 - O-Ring 52 - Piston 53 - Sleeve 54 - Backup Ring 55 - O-Ring 56 - Lock Nut

57 - Backup Ring 58 - O-Ring 59 - Sleeve

68 - Backup Ring 69 - Seat 70 - Spring

77 - O-Ring 78 - Backup Ring 79 - O-Ring

61 62 63 64 65 66 67 -

71 72 73 74 75 76 -

80 81 82 83 84 85 -

O-Ring Poppet Spring Spring Guide Spring Poppet O-Ring

W2-4-8

Spring Piston O-Ring Backup Ring (2 Used) Poppet Sleeve

Socket Bolt (10 Used) Cover (3 Used) O-Ring (5 Used) Cover (2 Used) O-Ring (2 Used) Plug (2 Used)

UPPERSTRUCTURE / Control Valve 13. Remove socket bolts (80) (10 used) from the lower side of the main control valve to remove covers (81) (3 used) and (83) (2 used) from housing (48). ϖ 10 mm Overload Relief Valve (Boom Motor Selector) IMPORTANT: As for overload relief valve, do not disassemble it unless necessary because its adjustment should be carried out on the test bench if it is removed. Keep overload relief valve with tag attached in order to set it to its original position. 14. Loosen sleeve (76) to remove overload relief valve (49) from housing (48). ϖ 41 mm 15. Remove sleeve (59) from sleeve (76) to remove poppet (75), piston (72), springs (70 and 71), seat (69), poppet (66), spring (65), spring guide (64) and spring (63). ϖ 36 mm ϖ 3 mm NOTE: Take poppet (75) out from the housing (48) side of sleeve (76) by pushing lightly with a round bar. IMPORTANT: Attach matching marks on sleeves (53 and 59) and lock nut (56) and take a note of turning amount of sleeve (53). 16. Loosen lock nut (56) to remove sleeve (53) from sleeve (59). ϖ 30 mm, 36 mm 17. Remove cap (50) to remove piston (52) and poppet (62) from sleeve (53). ϖ 27 mm

W2-4-9

UPPERSTRUCTURE / Control Valve ASSEMBLE MAIN CONTROL VALVE 1 (5-SPOOL SECTION) Check Valve Overload Relief Valve (49) (Boom Motor Selector)

42 44

46 43

Manifold

47 Check Valve W183-02-05-024

Front Side

T183-03-03-029

Overload Relief Valve (Boom Motor Selector) 72

78 74 73 70 66 68 64

54 63 62

W183-02-05-003

42 43 44 45 46 47 48 49 -

Cap Chip Backup Ring O-Ring Spring Check Valve Housing Overload Relief Valve (Boom Motor Selector) 50 - Cap 51 - O-Ring

52 53 54 55 56 57 58 59 -

77 69 67

Piston Sleeve Backup Ring O-Ring Locknut Backup Ring O-Ring Sleeve

61 - O-Ring

61 55 59

62 63 64 65 66 67 68 69 -

Poppet Spring Spring Guide Spring Poppet O-Ring Backup Ring Seat

70 - Spring

W2-4-10

71 72 73 74 75 76 77 78 -

Spring Piston O-Ring Backup Ring (2 Used) Poppet Sleeve O-Ring Backup Ring

79 - O-Ring

UPPERSTRUCTURE / Control Valve Assemble Main Control Valve 1 (5-Spool Section) 1. Place housing (48) on the work bench with the manifold side facing down.

8. Install sleeve (59) into sleeve (76). ϖ ϖ ϖ ϖ

NOTE: Place a soft rag or shop cloth on the work bench. Overload Relief Valve (Boom Motor Selector) 2. Place O-ring (51) onto cap (50) and install poppet (62), piston (52) and cap (50) to sleeve (53). ϖ 27 mm ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft) 3. Install lock nut (56) to sleeve (53) and assemble backup rings (54 and 57) and O-rings (55 and 58). IMPORTANT: As for sleeve (53), it should be screwed in only by the same amount to removal, so that the matching marks can be aligned precisely. 4. Install sleeve (53) into sleeve (59) and secure with lock nut (56). 5. Install spring (63), spring guide (64), spring (65) and poppet (66) into sleeve (59). 6. Install backup rings (74) (2 used) and O-ring (73) onto poppet (75) and install backup ring (68) and O-ring (67) onto seat (69). 7. Assemble backup ring (78) and O-rings (77 and 79) onto sleeve (76), and install poppet (75), piston (72), springs (70 and 71) and seat (69).

36 mm 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 41 mm 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

IMPORTANT: Install overload relief valve (49) to its position where it was removed. Be sure to perform adjustment to the valve on test bench. (Refer to Performance Test and Adjustment for Overload Relief Valve chapter in Technical Manual) 9. Install overload relief valve (49) into housing (48). ϖ 41 mm ϖ 78 N⋅m (8 kgf⋅m, 58 Ibf⋅ft) Check Valve 10. Install check valve (47) and spring (46) into housing (48). IMPORTANT: Chip (43) prevents cap (42) from being pulled, and looseness. Chip (43) will be damaged on cap (42) being removed because it is made of nylon. Be sure to replace chip (43) with a new one and install cap (42). 11. Assemble chip (43), backup ring (44) and O-ring (45) into cap (42) and install cap (42) onto housing (48).

W2-4-11

ϖ 14 mm ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve Overload Relief Valve (41)

40 35 36 38

Front Side

37 33 27

29 26

31 28 30

25 24

34 32

W162-02-04-022

Overload Relief Valve (41)

5-Spool Section 48

T183-03-03-028

6 5

9,10 Upper Side Front Side

11 8 7 21

4 3 2

20 17 16 15

19 16 82

80 81

13,14

T183-03-03-027

W183-02-05-002

Overload Relief Valve (41)

NOTE: BH: Backhoe LD: Loading Shovel 1 - Spool (BH: Auxiliary / LD: Bucket- Open / Close) 2 - Spring Guide (5 Used) 3 - Sleeve (5 Used) 4 - Spring (5 Used) 5 - Spring Guide (5 Used)

13 - Backup Ring (2 Used)

25 - Adjusting Bolt (6 Used)

37 - Sleeve (6 Used)

14 15 16 17 -

O-Ring (2 Used) Spacer Spring (2 Used) Check Valve

26 27 28 29 -

O-Ring (6 Used) Spring (6 Used) Poppet (6 Used) Seat (6 Used)

38 39 40 41 -

678910 11 12 -

18 19 20 21 22 23 24 -

Cap Check Valve Spool (Arm 1) Spool (Boom 2) Spool (Bucket 2) Spool (Travel Left) Lock Nut (6 Used)

30 31 32 33 34 35 36 -

O-Ring (6 Used) Backup Ring (12 Used) O-Ring (6 Used) Spring (6 Used) Spring (6 Used) Piston (6 Used) Poppet (6 Used)

48 80 81 82 83 -

Cap (5 Used) O-Ring (5 Used) Socket Bolt (10 Used) O-Ring (2 Used) Cap (2 Used) Cover Cap

W2-4-12

O-Ring (6 Used) Backup Ring (6 Used) O-Ring (6 Used) Overload Relief Valve (6 Used) Housing Socket Bolt (10 Used) Cover (3 Used) O-Ring (5 Used) Cover (2 Used)

UPPERSTRUCTURE / Control Valve Spool

Overload Relief Valve 12. Install backup rings (31)(2 used) and O-rings (30 and 32) onto seat (29) and O-ring (26) onto adjusting bolt (25). IMPORTANT: As for adjusting bolt (25), it should be screwed in only by the same amount to removal, so that the matching marks can be aligned precisely. 13. Assemble poppet (28), spring (27), adjusting bolt (25) and lock nut (24) onto seat (29). ϖ ϖ ϖ ϖ

19 mm 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft) 6 mm 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

18. Place O-rings (82) (5 used) to the lower side of housing (48) and install covers (81) (3 used) and (83) (2 used) with socket bolts (80) (10 used). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 19. Clamp and hold spool (1) in a vise with wooden spatulas inserted. Assemble spring guide (5), spring (4), sleeve (3) and spring guide (2) into cap (6) and install cap (6) to spool (1). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 20. Assemble four spools (20 to 23) in accordance with the procedure 19.

14. Install poppet (36), piston (35) and springs (33 and 34) into sleeve (37).

21. Assemble check valves (17 and 19), spring (16) and spacer (15) to spools (20 and 21) respectively.

15. Install seat (29) into sleeve (37). ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

NOTE: Spacer (15) is not used in spool (21).

16. Install backup ring (39) and O-rings (40 and 38) to sleeve (37). IMPORTANT: Install overload relief valve (41) to its position where it was removed. Be sure to perform an adjustment to the valve on test bench. (Refer to Performance Test and Adjustment for Overload Relief Valve in Technical manual)

22. Place backup ring (13) and O-ring (14) into cap (12 and 18). Install caps (12 and 18) to spools (20 and 21) respectively. ϖ ϖ ϖ ϖ

8 mm 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 10 mm 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

23. Assemble O-rings (7) (5 used) into housing (48).

17. Install overload relief valves (41) (6 used), 3 for upper and 3 for lower into housing (48). ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-13

UPPERSTRUCTURE / Control Valve Overload Relief Valve (41)

40 35 36 38

Front Side

37 33 27

29 26

31 28 30

25 24

34 32

W162-02-04-022

Overload Relief Valve (41)

5-Spool Section 48

T183-03-03-028

Upper Side Front Side

6 5 11 8 7 21

4 3 2

1 20

17 16 15

19 16 82

80 81

T183-03-03-027

Overload Relief Valve (41)

W2-4-14

13,14

13,14 W183-02-05-002

UPPERSTRUCTURE / Control Valve IMPORTANT: Install the spool (1 and 20 to 23) assemblies (5 used) to the positions where they were removed. Insert spools (20 and 22) so that splined plug (85) of cover (83) can enter the slot of spool. 83 85

Spool W183-02-05-031

24. Hold the spring parts of the spools (1 and 20 to 23) assemblies and insert them into housing (48) while turning them slowly. 25. Install cover (11) to housing (48) with socket bolts (8) (10 used). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-15

UPPERSTRUCTURE / Control Valve DISASSEMBLE MAIN CONTROL VALVE 2 (5-SPOOL SECTION)

3 2 1 8

Load Check Valve

12 6

7 9

3 19

2 1 34

30 29

27 26

Holding Valve

37 38 W183-02-05-004

12345678910 -

O-Ring (2 Used) Flange (2 Used) Socket Bolt (8 Used) O-Ring (6 Used) Backup Ring (6 Used) Chip (6 Used) Cap Check Valve (5 Used) Spring (5 Used) Cap

11 12 13 14 15 16 17 18 19 20 -

Check Valve (4 Used) Cap (4 Used) Cap O-Ring Spring Poppet Sleeve Backup Ring O-Ring O-Ring

21 22 23 24 25 26 27 28 29 30 -

Backup Ring Cap O-Ring Socket Bolt (4 Used) Washer (4 Used) Cap O-Ring Piston Cover O-Ring

W2-4-16

31 32 33 34 35 36 37 38 39 -

Backup Ring O-Ring Spring Poppet Cap O-Ring Socket Bolt (4 Used) Washer (4 Used) Housing

UPPERSTRUCTURE / Control Valve Disassemble Main Control Valve 2 (5-Spool Section)

Load Check Valve

• Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. Loosen and remove cap (10) and (12) (4 used) from housing (39).

Holding Valve

7. Pull out check valves (8) (5 used), springs (9) (5 used) and check valves (11) (4 used) from housing (39).

1. Remove socket bolts (24) (4 used) and washers (25) (4 used) to remove cover (29) from housing (39).

ϖ 14 mm

ϖ 12 mm 2. Remove spring (33) and poppet (34) from housing (39). IMPORTANT: In case poppet (16) can not be pulled out from sleeve (17) after long term operation, for the seat surface being deformed, replace sleeve (17) and poppet (16). 3. Remove cap (13) to remove spring (15) and poppet (16) from cover (29). ϖ 10 mm 4. Remove cap (26) to remove piston (28). ϖ 10 mm 5. With a pipe (inner dia 10 mm (0.39 in), outer dia 14 mm (0.55 in)), push out sleeve (17) by tapping it lightly from cap (26) side.

W2-4-17

NOTE: Check valve (11) is not used in cap (10).

UPPERSTRUCTURE / Control Valve ASSEMBLE MAIN CONTROL VALVE 2 (5-SPOOL SECTION) Front Side

Load Check Valve B

A 10 4

Manifold Load Check Valve (B)

W183-02-05-027

W183-02-05-028

Load Check Valve (A)

Holding Valve

7 2

39 W183-02-05-026

Holding Valve 29 27

31,32 33 34

28 20,21

18,19 16 15

12345678910 -

O-Ring (2 Used) Flange (2 Used) Socket Bolt (8 Used) O-Ring (6 Used) Backup Ring Chip (6 Used) Cap Check Valve (5 Used) Spring (5 Used) Cap

11 12 13 14 15 16 17 18 19 20 -

Check Valve (4 Used) Cap (4 Used) Cap O-Ring Spring Poppet Sleeve Backup Ring O-Ring O-Ring

21 22 23 24 25 26 27 28 29 30 -

Backup Ring Cap O-Ring Socket Bolt (4 Used) Washer (4 Used) Cap O-Ring Piston Cover O-Ring

W2-4-18

31 32 33 34 35 36 37 38 39 -

24,25

W183-02-05-029

Backup Ring O-Ring Spring Poppet Cap O-Ring Socket Bolt (4 Used) Washer (4 Used) Housing

UPPERSTRUCTURE / Control Valve Assemble

Main

Control

Valve

(5-Spool

Section) 1. Place housing (39) on work bench with the manifold side down. NOTE: Place a soft rag or shop cloth on the work bench.

7. Assemble O-rings (14 and 27) onto caps (13 and 26) respectively. Then install these caps into cover (29). ϖ 10 mm ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

Load Check Valve

8. Install backup ring (31) and O-rings (30 and 32) to cover (29).

2. Assemble check valves (8) (5 used), springs (9) (5 used) and check valves (11) (4 used) into housing (39).

9. Install cover (29) to housing (39) with socket bolts (24) (4 used) and washers (25) (4 used).

NOTE: Check valve (11) is not used in cap (10) part. IMPORTANT: Chips (6) prevent caps (7, 10 and 12) from being pulled, and looseness. Chips (6) are made of nylon and will be damaged on caps (7, 10 and 12) being removed. Be sure to replace chips (6) with new ones and install caps (7, 10 and 12). 3. Assemble chips (6), backup ring (5) and O-rings (4) onto caps (10) and (12) (4 used), and install caps (10) and (12) (4 used) into housing (39). ϖ 14 mm ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft) Holding Valve 4. Place poppet (34) and spring (33) into housing (39). 5. Assemble backup rings (18 and 21) and O-rings (19 and 20) onto sleeve (17). 6. Assemble piston (28), sleeve (17), poppet (16) and spring (15) into cover (29).

W2-4-19

ϖ 12 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve DISASSEMBLE MAIN CONTROL VALVE 1 (4-SPOOL SECTION) 23 22 24 Main Relief Valve

Make-Up Valve

11 10 9

15 14

13 19

2 1

42 41 40 39 38 37 36

35 34 33 32 31 30 29

26 25

28 27

Overload Relief Valve

60 59 58 57 56 55 54 53 52 51 50 49 62 63 48 64 47 46 65 45 44 66 67 68 69 70 Shuttle Valve

W183-02-05-005

W2-4-20

UPPERSTRUCTURE / Control Valve

12345678910 11 12 13 14 15 16 17 18 -

O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Sleeve (2 Used) Poppet (2 Used) Backup Ring (4 Used) O-Ring (2 Used) Spring (2 Used) O-Ring (2 Used) Backup Ring (2 Used) Cap (2 Used) Make-Up Valve (2 Used) Spool (Arm 2) Spring Guide (4 Used) Sleeve (4 Used) Spring (4 Used) Spring Guide (4 Used) Cap (4 Used)

19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 -

Spool (Boom 1) Spool (Bucket 1) Spool (Travel Right) O-Ring (4 Used) Socket Bolt (8 Used) Cover Sleeve Poppet Spring O-Ring Backup Ring Seat Poppet Spring O-Ring Cap Lock Nut O-Ring

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 -

O-Ring Sleeve Piston Lock Nut O-Ring Adjusting Bolt Main Relief Valve O-Ring (4 Used) Backup Ring (4 Used) O-Ring (4 Used) Sleeve (4 Used) Poppet (4 Used) Piston (4 Used) Spring (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (8 Used) O-Ring (4 Used)

W2-4-21

55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 88 -

Seat (4 Used) Poppet (4 Used) Spring (4 Used) O-Ring (4 Used) Adjusting Bolt (4 Used) Lock Nut (4 Used) Overload Relief Valve (4 Used) Seat O-Ring Ball Cap O-Ring Backup Ring O-Ring Spring Check Valve Housing

UPPERSTRUCTURE / Control Valve

23 22 24 Main Relief Valve

Overload Relief Valve

Make-Up Valve

11 10 9

15 14

13 19

2 1

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44

Shuttle Valve

W183-02-05-005

W2-4-22

UPPERSTRUCTURE / Control Valve Disassemble Main Control Valve 1 (4-Spool Section) • Be sure to thoroughly read “Precaution for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work. • Attach a tag to each spool that should be installed into the corresponding position on the housing in order to prevent misplacement. Spool 1. Remove socket bolts (23) (8 used) to remove cover (24) from housing (88).

Overload Relief Valve IMPORTANT: Do not disassemble the overload relief valve unless necessary. As adjustment on the test bench should be carried out if it is disassembled keep a tag attaching to the valve to ensure that it can be reassembled to the position where it was removed. 7. Remove overload relief valves (61) (4 used) (2 for upper and 2 for lower) from housing (88). ϖ 41 mm

ϖ 10 mm 2. Slowly pull out the spool (13, 19 to 21) assemblies (4 used) from housing (88) while confirming the corresponding position on housing (88). 3. Remove O-rings (22) (4 used) from housing (88). 4. Clamp and hold the spool (13) assembly in a vise with wooden spatulas inserted at both sides. 5. Loosen and remove cap (18) while holding spring guide (17) by a hand to remove spring guide (14), spool (15), spring (16) and spring guide (17).

8. Loosen and remove seat (55) to remove springs (50 and 51), piston (49) and poppet (48) from sleeve (47). ϖ 36 mm IMPORTANT: Put matching marks on adjusting bolt (59) and seat (55) and take a note of the amount to turn adjusting bolt (59). 9. Remove lock nut (60) to remove adjusting bolt (59), spring (57) and poppet (56) from seat (55). ϖ 19 mm ϖ 6 mm

ϖ 10 mm 6. Disassemble the spools (19 to 21) assemblies (3 used) in accordance with the procedure 4 to 5.

Make-Up Valve 10. Loosen sleeve (4) to remove make-up valves (12) (2 used) (1 for upper and 1 for lower) from housing (88). ϖ 41 mm 11. Remove cap (11) to remove spring (8) and poppet (5) from sleeve (4). ϖ 36 mm

W2-4-23

UPPERSTRUCTURE / Control Valve

Main Relief Valve

Overload Relief Valve

43 42 41 40 39 38 37 36

Make-Up Valve

35 34 33 32 31 30 29 26 25

28 27

62 63 64 65 66 67 68 69 70 Shuttle Valve

W183-02-05-005

W2-4-24

UPPERSTRUCTURE / Control Valve Main Relief Valve IMPORTANT: Do not disassemble the main relief valve unless necessary. 12. Loosen cap (34) to remove main relief valve (43) from housing (88). ϖ 41 mm 13. Loosen lock nuts (35 and 40). ϖ 30 mm, 41 mm IMPORTANT: Seat (30) is being pressed in cap (34). Do not remove it. 14. Remove sleeve (25) from cap (34) to remove spring (27) and poppet (26). IMPORTANT: Put matching marks on adjusting bolt (42) and sleeve (38) and take a note of the amount to turn adjusting bolt (42). 15. Remove adjusting bolt (42) from sleeve (38) to remove piston (39), spring (32) and poppet (31). ϖ 22 mm IMPORTANT: Put matching marks on sleeve (38) and cap (34) and take a note of the amount to turn sleeve (38). 16. Remove sleeve (38) from cap (34). ϖ 27mm Shuttle Valve 17. Loosen cap (65) to the remove shuttle valve from housing (88). ϖ 41 mm 18. Remove spring (69) and check valve (70) from housing (88). 19. Remove seat (62) to remove ball (64) cap (65). ϖ 27 mm

W2-4-25

UPPERSTRUCTURE / Control Valve

86 84

75 74 73

80 83

78 82

72 71

72 77

Overload Relief Valve

Check Valve

Make-Up Valve Flow-Combining Valve

71 72 73 74 75 -

Cap Chip (2 Used) Backup Ring O-Ring Spring

76 77 78 79 80 -

Check Valve Cap O-Ring Spring Spacer

81 82 83 84 85 -

W2-4-26

Spool Socket Bolt (8 Used) Cover O-Ring (4 Used) Cover (3 Used)

W183-02-05-018

86 - O-Ring (3 Used) 87 - Plug (3 Used) 88 - Housing

UPPERSTRUCTURE / Control Valve 20. Remove socket bolts (82) (8 used) to remove covers (83), (85) (3 used) and O-rings (84) (4 used) from housing (88). Flow-combining Valve 21. Remove cap (77) to remove spring (79), spacer (80) and spool (81) from housing (88). Ď&#x2013; 46 mm Check Valve 22. Remove cap (71) to remove spring (75) and check valve (76) from housing (88). Ď&#x2013; 14 mm

W2-4-27

UPPERSTRUCTURE / Control Valve ASSEMBLE MAIN CONTROL VALVE 1 (4-SPOOL SECTION) Shuttle Valve

Shuttle Valve 70

Manifold

W162-02-04-023

Check Valve 71 74

73 Front Side

T183-03-03-029

Upper Side

75 76

88 Front Side

W183-02-05-024

Flow-Combining Valve 81

72 79

Check Valve

Flow-Combining Valve

W162-02-04-024

T183-03-03-027

62 63 64 65 66 67 -

Seat O-Ring Ball Cap O-Ring Backup Ring

68 69 70 71 72 -

O-Ring Spring Check Valve Cap Chip (2 Used)

73 74 75 76 77 -

W2-4-28

Backup Ring O-Ring Spring Check Valve Cap

78 79 80 81 88 -

O-Ring Spring Spacer Spool Housing

UPPERSTRUCTURE / Control Valve Assemble Main Control Valve 1 (4-Spool Section) 1. Place housing (88) on the work bench with the manifold side down. NOTE: Place a soft rag or shop cloth on the work bench.

Shuttle Valve 6. Install backup ring (67) and O-rings (66 and 68) onto cap (65) and O-ring (63) to seat (62). 7. Insert ball (64) into cap (65) and install seat (62). ϖ 27 mm ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)

Check Valve 2. Install check valve (76) and spring (75) into housing (88). IMPORTANT: Chips (72) prevent caps (71 and 77) from being pulled, and looseness. Chips (72) will be damaged if caps (71 and 77) are removed because they are made of nylon. Be sure to replace chips (72) with new ones and install caps (71 and 77). 3. Assemble backup ring (73), O-ring (74) and chip (72) onto cap (71) and install cap (71) into housing (88). ϖ 14 mm ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft) Flow-Combining Valve 4. Place O-ring (78) and chip (72) onto cap (77) and install spring (79). 5. Insert spool (81) and spacer (80) into housing (88) and install cap (77). ϖ 46 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

W2-4-29

8. Assemble check valve (70) and spring (69) into housing (88) and install cap (65). ϖ 41 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve Main Relief Valve (43) Main Relief Valve

26 25

27 29 31 36

37 39

35 38 40 42

41 W183-02-05-007

Front Side

Make-Up Valve (12)

Make-Up Valve

T183-03-03-029

3 8

9 11

Front Side

W162-02-04-028

Make-Up Valve

12345678-

O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Sleeve (2 Used) Poppet (2 Used) Backup Ring (4 Used) O-Ring (2 Used) Spring (2 Used)

T183-03-03-027

910 11 12 25 26 27 28 -

O-Ring (2 Used) Backup Ring (2 Used) Cap (2 Used) Make-Up Valve (2 Used) Sleeve Poppet Spring O-Ring

29 30 31 32 33 34 35 36 -

W2-4-30

Backup Ring Seat Poppet Spring O-Ring Cap Lock Nut O-Ring

37 38 39 40 41 42 43 88 -

O-Ring Sleeve Piston Lock Nut O-Ring Adjusting Bolt Main Relief Valve Housing

UPPERSTRUCTURE / Control Valve Make-Up Valve

Main Relief Valve IMPORTANT: Sleeve (38) can be screwed in only by same amount to that of removal so as to align with the matching marks.

15. Assemble backup rings (6) (2 used) and O-ring (7) onto poppet (5) and install backup ring (10) and O-ring (9) onto cap (11). Then install poppet (5) to cap (11).

9. Assemble lock nut (35) and O-rings (36 and 37) onto sleeve (38) and install sleeve (38) to cap (34).

16. Assemble poppet (5), spring (8) and cap (11) into sleeve (4). ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 10. Install poppet (31), spring (32) and piston (39) into cap (34). IMPORTANT:

17. Assemble backup ring (2) and O-rings (1 and 3) onto sleeve (4) and install make-up valve (12) into housing (88).

Adjusting bolt (42) should be screwed in only by same amount to that of removal so as to align with the matching marks.

11. Install lock nut (40) and O-ring (41) onto adjusting bolt (42) and install adjusting bolt (42) into sleeve (38). ϖ ϖ ϖ ϖ

22 mm 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 30 mm 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft)

12. Install backup ring (29) and O-ring (28) into seat (30). 13. Place poppet (26) and spring (27) into sleeve (25) and install sleeve (25) to cap (34). IMPORTANT: Be sure to perform the adjustment to the main relief valve. (Refer to Adjustment of the Main Relief Valve in chapter of Performance Test, Techical Manual) 14. Install main relief valve (43) into housing (88). ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-31

ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve Overload Relief Valve (61)

44 49 48 46

47 51 57

55 58

53 56 54

59 60

50 52

W162-02-04-022

Overload Relief Valve

Front Side

4-Spool Section 24

18 17

T183-03-03-029

Overload Relief Valve

Upper Side

16 15 14

23 22

88 Front Side

19 21 20

82 W183-02-05-025

T183-03-03-027

13 14 15 16 17 18 19 20 21 -

Spool (Arm 2) Spring Guide (4 Used) Sleeve (4 Used) Spring (4 Used) Spring Guide (4 Used) Cap (4 Used) Spool (Boom 1) Spool (Bucket 1) Spool (Travel Right)

22 23 24 44 45 46 47 48 49 -

O-Ring (4 Used) Socket Bolt (8 Used) Cover O-Ring (4 Used) Backup Ring (4 Used) O-Ring (4 Used) Sleeve (4 Used) Poppet (4 Used) Piston (4 Used)

50 51 52 53 54 55 56 57 58 -

W2-4-32

Spring (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (8 Used) O-Ring (4 Used) Seat (4 Used) Poppet (4 Used) Spring (4 Used) O-Ring (4 Used)

59 60 61 82 83 84 85 88 -

Adjusting Bolt (4 Used) Lock Nut (4 Used) Overload Relief Valve (4 Used) Socket Bolt (8 Used) Cover O-Ring (4 Used) Cover (3 Used) Housing

UPPERSTRUCTURE / Control Valve Spool

Overload Relief Valve 18. Assemble backup rings (53) (2 used) and O-rings (52 and 54) onto seat (55) and install O-ring (58) onto adjusting bolt (59).

24. Place O-rings (84) (4 used) to the lower side of housing (88) where cover (83) and (85) (3 used) should be installed with socket bolts (82) (8 used). ϖ 10 mm

IMPORTANT:

Adjusting bolt (59) should be screwed in only by same amount to that of removal so as to align with the matching marks.

19. Assemble poppet (56), spring (57), adjusting bolt (59) and lock nut (60) into seat (55). ϖ ϖ ϖ ϖ

ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 25. Clamp and hold spool (13) in a vise with wooden spatulas inserted at both sides.Assemble spring guide (17), sleeve (15), spring (16) and spring guide (14) onto cap (18) and install cap (18) into spool (13).

19 mm 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft) 6 mm 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

20. Install poppet (48), piston (49) and springs (50 and 51) into sleeve (47).

26. Assemble 3 spools (19 to 21) in accordance with the procedure 25. 27. Place O-rings (22) (4 used) to housing (88).

21. Install seat (55) into sleeve (47). ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 22. Install backup ring (45) and O-rings (44 and 46) onto sleeve (47).

IMPORTANT: Install the 4 spool (13 and 19 to 21) assemblies to their positions where they were disassembled. Insert spools (13 and 19 to 21) so that splined plug (87) of cover (85) can enter the spool’s slot.

IMPORTANT: Install overload relief valve (61) into its position where it was removed. Be sure to perform the adjustment to the valve on test bench. (Refer to the Adjustment of Overload Relief Valve in chapter of Performance Test, Technical Manual) 23. Install overload relief valves (61) (4 used) (2 for upper and 2 for lower) into housing (88). ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

85 87 Spool W183-02-05-031

28. Hold the spring part of each spool (13 and 19 to 21) assemblies to insert it into housing (88) while turning slowly. 29. Install cover (24) to housing (88) with socket bolts (23) (8 used). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-33

UPPERSTRUCTURE / Control Valve DISASSEMBLE MAIN CONTROL VALVE 2 (4-SPOOL SECTION)

42 Load Check Valve

30 3

36 26 12

32 31

4 5

27 18

Slow Return Valve

1 21 20

14 13

Holding Valve

12345678910 11 -

7 8 9

22 23

Socket Bolt (7 Used) Washer (7 Used) O-Ring Manifold Poppet Spring O-Ring Backup Ring Flange Socket Bolt (4 Used) Cap

12 13 14 15 16 17 18 19 20 21 22 -

W183-02-05-008

O-Ring (2 Used) Spring Poppet Sleeve Backup Ring O-Ring O-Ring Backup Ring Cap O-Ring Cover

23 24 25 26 27 28 29 30 31 32 33 -

W2-4-34

Socket Bolt (4 Used) Washer (4 Used) Piston Cap Cap Chip (5 Used) Backup Ring (5 Used) O-Ring (5 Used) O-Ring Backup Ring O-Ring

34 35 36 37 38 39 40 41 42 43 44 -

Spring Poppet Cap Cap (2 Used) Spring (3 Used) Check Valve (3 Used) Cap Check Valve Cap (2 Used) O-Ring (2 Used) Housing

UPPERSTRUCTURE / Control Valve Disassemble Main Control Valve 2 (4-Spool Section) • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

Slow Return Valve 8. Remove socket bolts (10) (4 used) to remove the manifold (4) assembly from housing (44). ϖ 12 mm 9. Remove flange (9) to remove spring (6) and poppet (5) from manifold (4).

Holding Valve 1. Remove socket bolts (23) (4 used) and washers (24) (4 used) to remove the cover (22) assembly from housing (44). ϖ 12 mm 2. Remove spring (34) and poppet (35) from housing (44). IMPORTANT: After long term operation poppet (14) can not be pulled out from sleeve (15) for the seat surface being deformed, replace sleeve (15) and poppet (14). 3. Remove cap (11) to remove spring (13) and poppet (14) from cover (22). ϖ 10 mm 4. Remove cap (26) to remove piston (25). ϖ 10 mm 5. Push out sleeve (15) from cap (26) side with a pipe (inner dia 10 mm (0.39 in), outer dia 14 mm (0.55 in)) while tapping it slightly. Load Check Valve 6. Loosen and remove caps (37) (2 used) and (40) from housing (44). ϖ 14 mm 7. Pull out check valves (39) (3 used), springs (38) (3 used) and check valve (41) from housing (44). NOTE: Check valve (41) is not used in cap (37) part.

W2-4-35

UPPERSTRUCTURE / Control Valve ASSEMBLE MAIN CONTROL VALVE 2 (4-SPOOL SECTION)

Load Check Valve

Slow Return Valve

29 41

39 39

Load Check Valve (B)

W162-02-04-029

W162-02-04-034

Front Side Load Check Valve (A) Holding Valve

T183-03-03-029

Holding Valve 12

Slow Return Valve 11

23,24

13 14

9 8

16,17

5 18,19

4 22

12 26 31

32,33 34 35

W183-02-05-030

3 W183-02-05-009

12345678910 11 -

Socket Bolt (7 Used) Washer (7 Used) O-Ring Manifold Poppet Spring O-Ring Backup Ring Flange Socket Bolt (4 Used) Cap

12 13 14 15 16 17 18 19 20 21 22 -

O-Ring (2 Used) Spring Poppet Sleeve Backup Ring O-Ring O-Ring Backup Ring Cap O-Ring Cover

23 24 25 26 27 28 29 30 31 32 33 -

W2-4-36

Socket Bolt (4 Used) Washer (4 Used) Piston Cap Cap Chip (5 Used) Backup Ring (5 Used) O-Ring (5 Used) O-Ring Backup Ring O-Ring

34 35 36 37 38 39 40 41 42 43 44 -

Spring Poppet Cap Cap (2 Used) Spring (3 Used) Check Valve (3 Used) Cap Check Valve Cap (2 Used) O-Ring (2 Used) Housing

UPPERSTRUCTURE / Control Valve Assemble Main Control Valve 2 (4-Spool Section) 7. Place O-rings (12) onto caps (11 and 26) respectively and into caps (11 and 26) to cover (22).

Load Check Valve

ϖ 10 mm ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

1. Install check valves (39) (3 used), springs (38) (3 used) and check valve (41) into housing (44).

8. Install cover (22) to housing (44) with socket bolts (23) (4 used) and washers (24) (4 used).

NOTE: Check valve (41) is not used in cap (37) part. IMPORTANT: Chips (28) prevents caps (27, 36, 37 and 40) from being pulled, and looseness. Chips (28) will be damaged when caps (27, 36, 37, 40) are removed because they are made of nylon. Be sure to replace chips (28) with new ones and install caps (27, 36, 37 and 40). 2. Assemble O-ring (30), backup ring (29) and chips (28) onto caps (37) (2 used) and (40). Install caps (37) (2 used) and (40) into housing (44).

ϖ 12 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) Slow Return Valve 9. Install O-ring (3) to manifold (4) and install backup ring (8) and O-ring (7) onto flange (9). 10. Insert poppet (5) and spring (6) into manifold (4) to which flange (9) is to be installed. 11. Install the manifold (4) assmebly to housing (44) with socket bolts (10) (4 used).

ϖ 14 mm ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft) Holding Valve 3. Place poppet (35) and spring (34) into housing (44). 4. Assemble backup rings (16 and 19) and O-rings (17 and 18) onto sleeve (15). 5. Assemble piston (25), sleeve (15), poppet (14) and spring (13) into cover (22). 6. Install backcup ring (32) and O-rings (31 and 33) into cover (22).

W2-4-37

ϖ 12 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve DISASSEMBLE MANIFOLD

5-Spool Section

6 5 25

28 24

3 5

1 1 6

5 22

25 Arm Regeneration Valve

26 4 15

4-Spool Section

18 19

W183-02-05-010

1234567-

O-Ring (8 Used) O-Ring (2 Used) O-Ring (11 Used) O-Ring (2 Used) Washer (7 Used) Socket Bolt (7 Used) Check Valve

8910 11 12 13 14 -

Spring Sleeve O-Ring Backup Ring Piston Spool Spring

15 16 17 18 19 20 21 -

W2-4-38

O-Ring Backup Ring O-Ring Sleeve Spring Guide O-Ring Cap

22 23 24 25 26 27 28 -

O-Ring (2 Used) Backup Ring (2 Used) Chip (2 Used) Cap (2 Used) Socket Bolt (14 Used) Washer (14 Used) Manifold

UPPERSTRUCTURE / Control Valve Disassemble Manifold • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. Screw jig (ST 1469) on to sleeve (9) to pull it out, in case it remains in manifold (28). 9

Manifold NOTE: When placing 4-spool and 5-spool sections or manifold on work bench,lay a rag or shop cloth to prevent scratching the mounting surface. 1. Remove socket bolts (6) (6 used) and the socket bolts (7 used) from 4-spool section housing to remove 4-spool section housing from manifold (28). ϖ 14 mm

ST 1469

7. Remove piston (12), spring (8) and check valve (7) from sleeve (9). 8. Remove cap (21) to remove spring guide (19). ϖ 12 mm

2. Remove O-rings (1) (4 used), (3) (5 used) and (4) (1 used) from manifold (28). 3. Remove socket bolts (6) (1 used), (26) (14 used) and the housing bolts (4 used) of 5-spool section to remove 5-spool section housing from manifold (28). ϖ 14 mm 4. Remove O-rings (1) (4 used), (2) (2 used), (3) (6 used) and (4) (1 used) from manifold (28). Arm Regeneration Valve CAUTION: When removing sleeve (18), it will be sprung out due to the action force from spring (14); sleeve (18) should be removed while pressing it. 5. Remove sleeve (18) to remove spring (14) and spool (13) from manifold (28). ϖ 46 mm

W2-4-39

W183-02-05-015

UPPERSTRUCTURE / Control Valve ASSEMBLE MANIFOLD Arm Regeneration Valve

Arm Regeneration Valve 20

13 11,10

W183-02-05-012

Front Side

T183-03-03-029

26,27 Manifold 4-spool Section

5-Spool Section

26,27 1

26,27

Arm Regeneration Valve

26,27 5,6 3 5,6

26,27

4 1 1

26,27

W183-02-05-011

1234567-

O-Ring (8 Used) O-Ring (2 Used) O-Ring (11 Used) O-Ring (2 Used) Washer (7 Used) Socket Bolt (7 Used) Check Valve

8910 11 12 13 14 -

Spring Sleeve O-Ring Backup Ring Piston Spool Spring

15 16 17 18 19 20 21 -

W2-4-40

O-Ring Backup Ring O-Ring Sleeve Spring Guide O-Ring Cap

22 23 24 25 26 27 28 -

O-Ring (2 Used) Backup Ring (2 Used) Chip (2 Used) Cap (2 Used) Socket Bolt (14 Used) Washer (14 Used) Manifold

UPPERSTRUCTURE / Control Valve Assemble Manifold

Manifold

1. Place the manifold (28) housing on work bench with the mounting side of 5-spool section facing up.

7. Assemble O-rings (1) (4 used), (2) (2 used), (3) (6 used) and (4) onto 5-spool section housing interface of manifold (28). 8. Install manifold (28) to 5-spool section housing with socket bolts (6), (26) (14 used), washers (5) and (27) (14 used). Secure socket bolts (4 used) for 5-spool section housing. ϖ 14 mm ϖ 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)

NOTE: Lay a rag or shop cloth on the work bench first in order to avoid damaging the mounting surface, when placing the manifold. IMPORTANT: Chip (24) prevents cap (25) from being pulled, and looseness. Chip (24) will be damaged if cap (25) is removed because it is made of nylon. Be sure to replace chip (24) with a new one and install cap (25). Arm Regeneration Valve 2. Assemble backup ring (16) and O-rings (15 and 17) onto sleeve (18).

9. Assemble O-rings (1) (4 used), (3) (5 used) and (4) (1 used) onto 4-spool section housing interface of manifold (28). 10. Install 4-spool section housing to manifold (28) with socket bolts (6) (6 used) and washers (5) (6 used). Secure socket bolts (7 used) for 4-spool section housing.

3. Assemble piston (12), backup ring (11) and O-ring (10) to sleeve (9) and install sleeve (9) into sleeve (18). 4. Assemble spring (8) and check valve (7) into sleeve (9) and install sleeve (18) into manifold (28). ϖ 46 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft) 5. Assemble spool (13), spring (14) and spring guide (19) into sleeve (18). 6. Place O-ring (20) onto cap (21) and install it to sleeve (18). ϖ 12 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-41

ϖ 14 mm ϖ 245 N⋅m (25 kgf⋅m, 180 Ibf⋅ft)

UPPERSTRUCTURE / Control Valve DISASSEMBLE SWING CONTROL VALVE 1 49

46 45 44 43

Main Relief Valve

41 40 39

23 2 3

38 37 36 35 34 33 32 31 30 29

6 7

8 9 10 11 12 13 14 Overload Re15 lief Valve 16 17 18

W183-02-05-013

12345678910 11 12 13 -

Overload Relief Valve (2 Used) Lock Nut (2 Used) Adjusting Bolt (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Seat (2 Used) O-Ring (2 Used) Backup Ring (4 Used) O-Ring (2 Used) Spring (2 Used) Spring (2 Used) Piston (2 Used)

14 15 16 17 18 19 20 21 22 23 24 25 26 -

Poppet (2 Used) Sleeve (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Housing Spool (Arm 3) Spring Guide (4 Used) Spring (4 Used) Sleeve (4 Used) Spring Guide (4 Used) Cap (4 Used) Spool (Bucket 3)

W2-4-42

27 28 29 30 31 32 33 34 35 36 37 38 39 -

Spool (Swing) Spool (Boom 3) Sleeve Poppet Spring O-Ring Backup Ring Seat Poppet Spring O-Ring Cap Lock Nut

40 41 42 43 44 45 46 47 48 49 50 51 52 -

O-Ring O-Ring Sleeve Piston Lock Nut O-Ring Adjusting Bolt Main Relief Valve O-Ring (4 Used) Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Cover

UPPERSTRUCTURE / Control Valve Disassemble Swing Control Valve 1 • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work. • Attach a tag to each spool to mark the position where it was in order to prevent them from being misplaced. Spool

Overload Relief Valve IMPORTANT: Do not disassemble overload relief valve unless necessary. As adjustment should be carried out on test bench if it is disassembled, keep a tag attaching to the valve to ensure that it can be reassembled to the position where it was removed.

1. Remove socket bolts (49) (8 used) to remove cover (52) from housing (19).

7. Remove overload relief valves (1) (2 used) (1 for upper and 1 for lower) from housing (19).

ϖ 10 mm

ϖ 41 mm

2. Slowly pull out the spool (20 and 26 to 28) assemblies (4 used) from housing (19) while confirming the corresponding position on housing (19).

8. Loosen and remove seat (7) to remove springs (11 and 12), piston (13) and poppet (14) from sleeve (15). ϖ 36 mm

3. Remove O-rings (48) (4 used) from housing (19). 4. Clamp and hold the spool (20) assembly in a vise with wooden spatulas inserted at both sides.

IMPORTANT: Put matching marks on adjusting bolt (3) and seat (7) and take a note of the amount that the bolt has been turned.

5. Loosen and remove cap (25) while holding spring guide (24) with a hand. Remove spring guide (24), sleeve (23), spring (22) and spring guide (21).

9. Remove lock nut (2) to remove adjusting bolt (3), spring (5) and poppet (6) from seat (7). ϖ 19 mm ϖ 6 mm

ϖ 10 mm 6. Disassemble 3 spools (26 to 28) in accordance with the procedure 4 to 5.

Main Relief Valve IMPORTANT: Do not disassemble the main relief valve unless necessary. 10. Remove cap (38) to remove main relief valve (47) from housing (19). ϖ 41 mm

W2-4-43

UPPERSTRUCTURE / Control Valve

46 Main Relief Valve

44 43 42

39 38 36 35 34 31 30 29 Overload Relief Valve

W183-02-05-013

W2-4-44

UPPERSTRUCTURE / Control Valve IMPORTANT: Seat (34) has been pressed in cap (38). Do not disassemble it. 11. Loosen lock nuts (39 and 44) and remove sleeve (29) from cap (38) to remove spring (31) and poppet (30). ϖ 30 mm, 41 mm IMPORTANT: Put matching marks on adjusting bolt (46) and sleeve (42) and take a note of the amount to turn the bolt. 12. Remove adjusting bolt (46) from sleeve (42). Remove piston (43), spring (36) and poppet (35). ϖ 22 mm IMPORTANT:

Put matching marks between sleeve (42) and cap (38) and take a note of the amount that the sleeve has been turned.

13. Remove sleeve (42) from cap (38). ϖ 27 mm

W2-4-45

UPPERSTURCTURE / Control Valve 19

Overload Relief Valve

53 54 55 56

67 67

70 69

66 57 58

59 60 Make-Up Valve 61 62 63

W183-02-05-019

19 53 54 55 56 -

Housing O-Ring Backup Ring O-Ring Sleeve

57 58 59 60 61 -

Poppet Backup Ring (2 Used) O-Ring Spring O-Ring

62 63 64 65 66 -

W2-4-46

Backup Ring Cap Make-Up Valve Socket Bolt (8 Used) Cover (3 Used)

67 68 69 70 -

O-Ring (4 Used) Cover O-Ring Plug

UPPERSTURCTURE / Control Valve Make-Up Valve 14. Remove socket bolts (65) (8 used) to remove covers (68), (66) (3 used) and O-rings (67) (4 used) from housing (19). ϖ 10 mm 15. Loosen sleeve (56) to remove make-up valve (64) from housing (19). ϖ 41 mm 16. Remove cap (63) to remove spring (60) and poppet (57) from sleeve (56). ϖ 36 mm

W2-4-47

UPPERSTURCTURE / Control Valve ASSEMBLE SWING CONTROL VALVE 1 Main Relief Valve (47)

Front Side Main Relief Valve

29 30 32 34 35

31 33

Overload Relief Valve

43 38 39

42 44 46

45 W183-02-05-007

T183-03-03-030

Overload Relief Valve (1) 18 14 13 16

Overload Relief Valve

12345678910 -

T183-03-03-031

Front Side

Overload Relief Valve (2 Used) Lock Nut (2 Used) Adjusting Bolt (2 Used) O-Ring (2 Used) Spring (2 Used) Poppet (2 Used) Seat (2 Used) O-Ring (2 Used) Backup Ring (4 Used) O-Ring (2 Used)

W162-02-04-022

11 12 13 14 15 16 17 18 19 29 -

Spring (2 Used) Spring (2 Used) Piston (2 Used) Poppet (2 Used) Sleeve (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used) Housing Sleeve

W2-4-48

30 31 32 33 34 35 36 37 38 -

Poppet Spring O-Ring Backup Ring Seat Poppet Spring O-Ring Cap

39 40 41 42 43 44 45 46 47 -

Lock Nut O-Ring O-Ring Sleeve Piston Lock Nut O-Ring Adjusting Bolt Main Relief Valve

UPPERSTURCTURE / Control Valve Assemble Swing Control Valve 1

Overload Relief Valve 7. Assemble O-rings (8 and 10) and backup ring (9) onto seat (7). Place O-ring (4) onto adjusting bolt (3).

Main Relief valve IMPORTANT: Sleeve (42) should be screwed on only by the same amount to that of removal so as to align the matching marks. 1. Assemble lock nut (39) and O-rings (40 and 41) onto sleeve (42) and install sleeve (42) into cap (38).

IMPORTANT: Adjusting bolt (3) should be screwed on only by the same amount to that of removal so as to align the matching marks. 8. Assemble poppet (6), spring (5), adjusting bolt (3) and lock nut (2) onto seat (7).

ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

ϖ ϖ ϖ ϖ

2. Assemble poppet (35), spring (36) and piston (43) into cap (38). IMPORTANT:

Adjusting bolt (46) should be screwed on only by the same amount to that of removal so as to align the matching marks.

3. Place lock nut (44) and O-ring (45) onto adjusting bolt (46) and install adjusting bolt (46) into sleeve (42). ϖ 22 mm ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 4. Place O-ring (32) and backup ring (33) onto seat (34). 5. Place poppet (30) and spring (31) into sleeve (29) and install sleeve (29) into cap (38). IMPORTANT: Be sure to perform adjustment to main relief valve. (Refer to the Adjustment of Main Relief Valve in chapter of Performance Test, Technical Manual)

19 mm 34 N⋅m (3.5 kgf⋅m, 25.5 Ibf⋅ft) 6 mm 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

9. Assemble poppet (14), piston (13) and springs (11 and 12) into sleeve (15). 10. Assemble backup ring (17) and O-rings (16 and 18) onto sleeve (15) and install seat (7) into sleeve (15). ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) IMPORTANT: Install overload relief valve (1) into its position where it was removed. Be sure to perform the adjustment to the valve on a test bench. (Refer to the Adjustment of Overload Relief Valve Performance in chapter of Technical Manual) 11. Install overload relief valve (1) (2 used) into housing (19).

6. Install main relief valve (47) into housing (19). ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W2-4-49

ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m 72 Ibf⋅ft)

UPPERSTURCTURE / Control Valve Make-Up Valve (64)

Front Side

53 57

58 55

A T183-03-03-030

W162-02-04-028

Spool 52

Make-Up Valve

24 23 22 49

21 20

19 T183-03-03-031

Front Side

26 65

67 19 20 21 22 23 24 25 -

Housing Spool (Arm 3) Spring Guide (4 Used) Spring (4 Used) Sleeve (4 Used) Spring Guide (4 Used) Cap (4 Used)

26 48 49 52 53 54 55 -

Spool (Bucket 3) O-Ring (4 Used) Socket Bolt (8 Used) Cover O-Ring Backup Ring O-Ring

W2-4-50

56 57 58 59 60 61 62 -

Sleeve Poppet Backup Ring (2 Used) O-Ring Spring O-Ring Backup Ring

66 63 64 65 66 67 68 -

W183-02-05-006

Cap Make-Up Valve Socket Bolt (8 Used) Cover (3 Used) O-Ring (4 Used) Cover

UPPERSTURCTURE / Control Valve IMPORTANT: Install the 4 spools (20 and 26 to 28)

Make-Up Valve 12. Assemble O-ring (59) and backup rings (58) (2 used) onto poppet (57) and install O-ring (61) and backup ring (62) onto cap (63).

assemblies

13. Assemble poppet (57), spring (60) and cap (63) into sleeve (56).

splined plug (70) of cover (66) can

where

they

into were

their

positions

disassembled.

Insert spools (20, 26 and 28) so that enter into the spool’s slot.

ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

66 70

14. Assemble O-rings (53 and 55) and backup ring (54) onto sleeve (56) and assemble make-up valve (64) into housing (19).

Spool

ϖ 41 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

W183-02-05-031

Spool 15. Assemble O-rings (67) (4 used) onto the lower side of housing (19). Install covers (68) and (66) (3 used) to housing (19) with socket bolts (65) (8 used).

19. Hold the spring part of each spool (20 and 26 to 28) assemblies and insert it into housing (19) while turning it slowly. 20. Install cover (52) to housing (19) with socket bolts (49) (8 used). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 16. Clamp and hold spool (20) in a vise with wooden spatulas inserted at both sides. Assemble spring guide (24), sleeve (23), spring (22) and spring guide (21) onto cap (25). Install cap (25) to spool (20). ϖ 10 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft) 17. Assemble 3 spools (26 to 28) in accordance with the procedure 16. 18. Assemble O-rings (48) (4 used) to housing (19).

W2-4-51

UPPERSTURCTURE / Control Valve DISASSEMBLE SWING CONTROL VALVE 2

5 6 4

Load Check Valve

7 31

35 9

40 26

10 20

Holding Valve

Check Valve

W183-02-05-014

12345678910 11 -

Check Valve (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (4 Used) Chip (4 Used) Cap Cap (2 Used) Housing O-Ring Flange Socket Bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Poppet Spring O-Ring Backup Ring Cover Washer (4 Used) Socket Bolt (4 Used) Cap O-Ring Piston Cover

23 24 25 26 27 28 29 30 31 32 -

W2-4-52

Washer (4 Used) Socket Bolt (4 Used) O-Ring Cap Cap O-Ring Spring Poppet Sleeve Backup Ring

33 34 35 36 37 38 39 40 41 42 -

O-Ring O-Ring Backup Ring Backup Ring O-Ring Spring Poppet O-Ring Check Valve Cap

UPPERSTURCTURE / Control Valve Disassemble Swing Control Valve 2 • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

Check Valve 8. Remove socket bolts (18) (4 used) to remove cover (16) from housing (8). ϖ 12 mm

Holding Valve 1. Remove socket bolts (24) (4 used) and washers (23) (4 used) to remove the cover (22) assembly from housing (8). ϖ 12 mm 2. Remove spring (38) and poppet (39) from housing (8). IMPORTANT: In case poppet (30) can not be pulled out from sleeve (31) after long term operation, because of seat surface being deformed, replace sleeve (31) and poppet (30). 3. Remove cap (27) to remove spring (29) and poppet (30) from cover (22). 4. Remove cap (19) to remove piston (21). ϖ 10 mm 5. Lightly tap sleeve (31) to push it out with a pipe (inner dia 10 mm (0.39 in), outer dia 14 mm (0.55 in)) from cap (19) side. Load Check Valve 6. Loosen and remove caps (6), (7) (2 used) and (42) from housing (8). ϖ 14 mm 7. Pull out check valves (1), (41) and spring (2) from housing (8). NOTE: Check valve (41) is not used in caps (6 and 7) part.

W2-4-53

9. Remove spring (13) and poppet (12) from housing (8).

UPPERSTURCTURE / Control Valve ASSEMBLE SWING CONTROL VALVE 2 Check Valve Holding Valve

Front Side

18 16

Check Valve

8 15

14 13 12

Load Check Valve (C)

Load Check Valve (A)

W183-02-05-016

T183-03-03-030

Load Check Valve (B)

Load Check Valve

Holding Valve 42

3 4

4 2

41 1

3 4

5 5

21 34,35

5 1

32,33 30 29

20 19 40

27 31

36,37

W162-02-04-034

W183-02-05-024

W162-02-04-029

23,24

38 39 W162-02-04-037

12345678910 11 -

Check Valve (4 Used) Spring (4 Used) O-Ring (4 Used) Backup Ring (4 Used) Chip (4 Used) Cap Cap (2 Used) Housing O-Ring Flange Socket Bolt (4 Used)

12 13 14 15 16 17 18 19 20 21 22 -

Poppet Spring O-Ring Backup Ring Cover Washer (4 Used) Socket Bolt (4 Used) Cap O-Ring Piston Cover

23 24 25 26 27 28 29 30 31 32 -

W2-4-54

Washer (4 Used) Socket Bolt (4 Used) O-Ring Cap Cap O-Ring Spring Poppet Sleeve Backup Ring

33 34 35 36 37 38 39 40 41 42 -

O-Ring O-Ring Backup Ring Backup Ring O-Ring Spring Poppet O-Ring Check Valve Cap

UPPERSTURCTURE / Control Valve Assemble Swing Control Valve 2 Check Valve

Holding Valve

1. Install poppet (12) and spring (13) into housing (8).

5. Place poppet (39) and spring (38) into housing (8).

2. Place backup ring (15) and O-ring (14) onto cover (16) and install cover (16) into housing (8) with socket bolts (18) (4 used).

6. Assemble O-rings (33 and 34) and backup rings (32 and 35) onto sleeve (31).

ϖ 12 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

7. Assemble piston (21), sleeve (31), poppet (30) and spring (29) into cover (22).

IMPORTANT: Chips (5) prevents caps (6, 7 and 42) from being pulled, and looseness. Chips will be damaged because they are made of nylon when the caps is removed. Be sure to replace chips (5) with new ones and install caps (6, 7 and 42).

8. Assemble backup ring (36) and O-rings (37 and 40) onto cover (22). 9. Assemble O-rings (20 and 28) onto caps (19 and 27) respectively. Then install caps (19 and 27) into cover (22). ϖ 10 mm ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

Load Check Valve 3. Assemble check valves (1) (4 used), springs (2) (4 used) and check valve (41) into housing (8).

10. Install cover (22) to housing (8) with socket bolts (24) (4 used) and washers (23) (4 used).

NOTE: Check valve (41) is not used in caps (6 and 7). 4. Assemble O-rings (3), backup rings (4) and chips (5) onto caps (6), (7) (2 used) and (42) respectively. Then install the caps into housing (8). ϖ 14 mm ϖ 345 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

W2-4-55

ϖ 12 mm ϖ 175 N⋅m (18 kgf⋅m, 130 Ibf⋅ft)

UPPERSTURCTURE / Control Valve (Blank)

W2-4-56

UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground.

W183-04-02-003

2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2.

W183-04-02-002

Wooden Blocks

Ď&#x2013; 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

Cap

NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W2-5-1

UPPERSTRUCTURE / Swing Device 1

Removal

NOTE: Attach identification tags to the hoses for easier distinguishing when assembling.

2 3

16 14

1. Drain oil out through the drain cock, then disconnect hoses (1 to 3, 6 to 17). ϖ 41 mm ϖ 295 N⋅m (30 kgf⋅m, 215 Ibf⋅ft) ϖ 36 mm ϖ 235 N⋅m (24 kgf⋅m, 175 Ibf⋅ft) ϖ 27 mm ϖ118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) ϖ19 mm ϖ 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

12 7

8 9 Front Side

11 10

NOTE: Cap the disconnected hose ends.

W183-02-06-003

2. Remove bolts (4) (16 used). ϖ 41 mm 3. Remove corks (18) (2 used) with a screw driver, and clean bolt holes with a tap (M27, Pitch 3.0)

W183-02-06-006

W2-5-2

UPPERSTRUCTURE / Swing Device 4. Install bolt (M27, Pitch 3.0) (2 used) to the hole mentioned in step 3. Attach nylon sling to motor (20) to get ready to hoist the swing device by a crane. Nylon sling (eye type at both ends): 2 used Ď&#x2013; 41 mm

CAUTION: Swing device weight: 688 kg (1520 Ib)

Swing Device (Front) 19

Bolt Hole

Front Side

Bolt Hole

W183-02-06-004

5. Catch hold of nylon sling tightly and tighten the bolt to raise the swing device slowly until knock pins (19) (2 used) are removed from the swing frame.

Swing Device (Rear) 19

Bolt Hole

Front Side

6. Hoist the swing device by a crane to remove the bolt. Then pull knock pins (19) (2 used) out from the bottom. Ď&#x2013; 41 mm

Bolt Hole

19 W183-02-06-005

7. Remove the other swing device following the same procedure.

Nylon Sling

W155-02-06-012

W2-5-3

UPPERSTRUCTURE / Swing Device Installation

NOTE: Refer to “Removal” section for wrench sizes and tightening torque.

1. Clean the interfaces of swing reduction gear and swing frame. W183-02-06-006

CAUTION: Swing device assembly weight: 688 kg (1520 Ib)

Swing Device (Front) 19

2. Align the swing gear tooth with the holes of knock pin (19) (2 used) and place the swing device to its mouting surface. Tap knock pins (19) (2 used) in, then remove nylon sling.

Bolt Hole

Front Side

3. Install bolts (4) (16 used). Tap new corks (18) (2 used) into bolt holes.

Bolt Hole

W183-02-06-004

ϖ 41 mm ϖ 1370 N⋅m (140 kgf⋅m, 1010 Ibf⋅ft)

Swing Device (Rear) 19

4. Install the other swing device assembly following the same procedure.

Bolt Hole

Front Side

5. Connect hoses (1 to 3 and 6 to 17). IMPORTANT: Be sure to fill the swing motor with hydraulic oil after installing it. Check the oil level. Check for any oil leaks after starting the engine.

Bolt Hole

19 W183-02-06-005

1 17 2 3

16 14

12 7

8 9 Front Side

11 10 W183-02-06-003

W2-5-4

UPPERSTRUCTURE / Swing Device (Blank)

W2-5-5

UPPERSTRUCTURE / Swing Device Disassemble Swing Reduction Gear

1 2

24 23

3 4

25 26

6 7 8

22 9 10 11

31 32

13 14 15

39 38

16 17

34 35 36

18 17

19 20 W142-02-06-002

12345678910 -

Motor Bolt (16 Used) Washer (16 Used) Cover First Stage Sun Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used)

11 12 13 14 15 16 17 18 19 20 -

First Stage Planetary Gear (3 Used) Ring Gear Second Stage Sun Gear Thrust Plate Pin (3 Used) Second Stage Carrier Thrust Plate (6 Used) Second Stage Planetary Gear (3 Used) Ring Gear Knock Pin (2 Used)

W2-5-6

21 22 23 24 25 26 27 28 29 30 -

Spring Pin (3 Used) First Stage Carrier Spacer (12 Used) Sems Bolt (12 Used) Retaining Ring Spacer Bearing Housing Bearing O-Ring

31 32 33 34 35 36 37 38 39 -

Cover Screw (4 Used) Magnet (4 Used) Sleeve O-Ring Oil Seal (2 Used) Shaft Bolt (10 Used) Spring Washer (10 Used)

UPPERSTRUCTURE / Swing Device Disassemble Swing Reduction Gear • Be sure to thoroughly read “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work. CAUTION: Motor weight: 71 kg (160 Ib) 1. Drain out gear oil out from the swing device. Make matching marks on all interfaces of motor (1), cover (4), ring gears (12) and (19) and housing (28). Then loosen and remove bolts (24) (12 used).

CAUTION: The second stage carrier (16) assembly weight: 80 kg (180 Ib) 7. Remove second stage sun gear (13) from the second stage carrier (16) assembly. 8. Install eyebolts (M12, Pitch 1.75) into the three holes in the second stage carrier (16) assembly. Hoist by a crane and remove it from ring gear (19). CAUTION: Ring gear (19) weight: 60 kg (130 Ib)

ϖ 19 mm 2. Install an eyebolt (M22, pitch 1.5) onto motor (1). Hoist by a crane and remove motor (1) from cover (4).

9. Install eyebolts (M12, Pitch 1.75) into the two holes in ring gear (19).Hoist by a crane and remove it from housing (28)

NOTE: Insert a flat head screw driver into the clearance between motor (1) and cover (4) to drive the motor out. It is easy to remove in this way.

NOTE: Insert a flat head screw driver between ring gear (19) and housing (28) to drive ring gear (19) out. It is easy to remove in this way.

3. Loosen and remove bolt (2). Then remove cover (4). ϖ 32 mm

10. Tap knock pins (20) (2 used) out from housing (28).

4. Remove first stage sun gear (5) from the first stage carrier (22) assembly.

11. Remove retaining ring (25), spacer (26) from shaft (37). CAUTION: Housing (28) + shaft (37) + others weight: 340 kg (750 Ib)

CAUTION: The first stage carrier (22) assembly weight: 40 kg (90 Ib) 5. Install eyebolts (M12, pitch 1.75) into the three hoisting holes in the first stage carrier (22) assembly. Hoist by a crane and remove it.

12. Sling the housing (28) body with nylon sling. Hoist by a crane and reverse it. 13. Remove bolt (38) to remove cover (31) from housing (28). ϖ 24 mm

CAUTION: Ring gear (12) weight: 60 kg (130 Ib)

14. Remove O-ring (30), oil seals (36) (2 used) from cover (31).

6. Install eyebolts (M12, Pitch 1.75) into the two hoisting holes in ring gear (12). Hoist by a crane and remove it from ring gear (19). NOTE: Insert a flat head screw driver between ring gears (12) and (19) to drive ring gear (12) out. It is easy to remove in this way.

W2-5-7

UPPERSTRUCTURE / Swing Device

32 33

34 35

W142-02-06-002

W2-5-8

UPPERSTRUCTURE / Swing Device CAUTION: Housing (28) + shaft (37) + others weight: 340 kg (750 Ib)

16. Remove shaft (37) from housing (28) with a press. Press

15. Sling the housing (28) body with a nylon sling and hoist by a crane to reverse it. CAUTION: Before pressing shaft (37), provide a protection cover (outer diamerter: 520 mm (20.5 in), inner diameter: 130 mm (5.1 in), thickness: 25 to 30 mm (1.0 to 1.2 in)). Then use the press to remove shaft (37) while covering housing (28) and bearing (27) with the protection cover. Failure to use the protection cover may result in personal injury due to flying metal fragments if housing (28) and / or bearing (27) is / are broken. Use a press with the capacity less than 30 tons (66000 Ib). Be sure to degrease the housing inside before heating bearing (27). Failure to degrease may cause a fire. 28

Protection Cover

W157-02-06-011

CAUTION: Shaft (37) + bearing (29) weight: 130 kg (290 Ib) 17. Put shaft (37) onto special mounting tool (ST5082).

27 29 34 ST 5082

Protection Cover

W142-02-06-006 W157-02-06-010

W2-5-9

UPPERSTRUCTURE / Swing Device

6 7 8

22 9 10 11

9 32 33

15 16 17

34 35

18 17 21

W142-02-06-002

W2-5-10

UPPERSTRUCTURE / Swing Device 25. Disassemble the second stage carrier (16) assembly in steps 23 to 24.

18. Put special tool (ST 5082) into the guide. NOTE: The dimensions of the guide to pull bearing (29) out are as follows: Height: 290 mm (11.5 in) Outer diameter: 360 mm (14.5 in) Inner diameter: 340 mm (13.5 in) CAUTION: When pressing shaft (37) with a press, the work should be carried out in the guide. 19. Put shaft (37) on the press. Pull bearing (29) and sleeve (34) out from shaft (37). Press

37 29 34 ST 5082

Guide

W183-02-06-002

20. Remove O-ring (35), screws (32) (4 used) and magnets (33) (4 used) from sleeve (34). CAUTION: Housing + others weight: 190 kg (420 Ib) 21. Sling the housing (28) body with a nylon sling. Hoist by a crane to reverse it. 22. Put the thrust plate to bearing (27) and pull bearing (27) out of housing (28) with a press. 23. Push spring pins (8) (3 used) out of first stage carrier (22) with a round bar and by tapping with a hammer. (Diameter: 5.0 mm, Length: 50 mm or more) 24. Remove pins (7) (3 used), first stage planetary gears (11) (3 used), thrust plates (9) (6 used), needle bearings (10) (3 used) and thrust plate (6) from first stage carrier(22). Č&#x20AC;

W2-5-11

NOTE: No needle bearing is used on second stage planetary gear (18).

UPPERSTRUCTURE / Swing Device Assemble Swing Reduction Gear

23 8 9 4

2 3 22

7 10 11 21 18 20

12 19

13 16

17 15 14

25 26 27

28 31 39 30 32 33 35

36 38 W142-02-06-003

12345678910 -

Motor Bolt (16 Used) Washer (16 Used) Cover First Stage Sun Gear Thrust Plate Pin (3 Used) Spring Pin (3 Used) Thrust Plate (6 Used) Needle Bearing (3 Used)

11 12 13 14 15 16 17 18 19 20 -

First Stage Planetary Gear (3 Used) Ring Gear Second Stage Sun Gear Thrust Plate Pin (3 Used) Second Stage Carrier Thrust Plate (6 Used) Second Stage Planetary (3 Used) Ring Gear Knock Pin (2 Used)

W2-5-12

21 22 23 24 25 26 27 28 29 30 -

Spring Pin (3 Used) First Stage Carrier Spacer (12 Used) Sems Bolt (12 Used) Retaining Ring Spacer Bearing Housing Bearing O-Ring

31 32 33 34 35 36 37 38 39 -

Cover Screw (4 Used) Magnet (4 Used) Sleeve O-Ring Oil Seal (2 Used) Shaft Bolt (10 Used) Spring Washer (10 Used)

UPPERSTRUCTURE / Swing Device Assemble Reduction Gear 1. Install needle bearings (10) one after another onto first stage planetary gears (11) (3 used). IMPORTANT: Install thrust plate (6) with the oil slit side facing upward.

10. Install O-ring (30) onto cover (31). 11. Install sleeve (34) onto shaft (37). 12. Heat bearing (29) in an oil pan to the temperature of 110 °C (230 °F) and press shaft (37) using special tool (ST 5082) and a press.

2. Install thrust plate (6) onto first stage carrier (22). Press in

IMPORTANT: Install thrust plate (9) with the oil slit side facing planetary gear (11).

ST 5082

3. Install first stage planetary gears (11) (3 used), thrust plates (9) (6 used) onto first stage carrier (22).

29 34

4. Align pins (7) (3 used) with the spring pin holes in first stage carrier (22), then assemble them.

IMPORTANT: Tap spring pin (8) in with the slit facing the end of pin (7). W183-02-06-001

5. Tap spring pins (8) (3 used) into first stage carrier (22) and pin (7). 7

CAUTION: Housing (28) weight: 180 kg (400 Ib) 13. Lay housing (28) onto a press bench with the motor side facing downward. Then install the shaft (37) assembly onto housing (28) with a press.

Slit

6. Assemble second stage carrier (16) according to steps 2 to 5. NOTE: There is no needle bearing on second stage carrier (16).

14. Align cover (31) with the bolt hole in housing (28) and tighten it with bolt (38) and spring washer (39) temporarily. ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) CAUTION: Housing (28) + shaft (37) + others weight: 340 kg (750 Ib)

IMPORTANT: Apply LOCTITE #262 on screw (32). 7. Install magnets (33) (4 used) onto sleeve (34) with screws (32) (4 used). 8. Apply grease on O-ring (35) and assemble it onto sleeve (34). IMPORTANT: Apply THREEBOND #1215 on the matching surfaces of oil seal (36) for cover (31). 9. Install oil seals (36) (2 used) to cover (31) after applying grease to the inner race of oil seal.

15. Reverse the housing (28) assembly and put on the press bench. IMPORTANT: When presssing bearing (27) onto shaft (37), apply grease both on its inner and outer faces. 16. Heat bearing (27) in an oil pan to the temperature of 80 to 100 °C ( 176 to 212 °F ) and press it onto shaft (37) with a press.

W2-5-13

UPPERSTRUCTURE / Swing Device

23 2 3 22 12 19

13 16

25 26 27

28 31 39

38 W142-02-06-003

W2-5-14

UPPERSTRUCTURE / Swing Device 17. Install spacer (26), retaining ring (25) onto shaft (37).

CAUTION: First stage carrier (22) assembly weight: 40 kg (90 Ib)

NOTE: If shaft (37) is not installed into housing (28) completely, retaining ring (25) can’t be installed.

25. Install the first stage carrier (22) assembly onto second stage sun gear (13).

18. Turn housing (28) inversely and tighten bolts (38) (10 used).

IMPORTANT: When installing first stage sun gear (5), its stepped end should be face downward.

ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 19. Apply THREEBOND #1215 on the mounting surface of ring gear (19) for housing (28). CAUTION: Ring gear (19) weight: about 60 kg (130 Ib) 20. Align the matching mark made when disassembling on ring gear (19), install ring gear (19) onto housing (28). Then tap knock pins (20) (2 used) in.

26. Install first stage sun gear (5) onto first stage carrier (22). 27. Apply THREEBOND #1215 on the mounting surface of cover (4) for ring gear (12) and install cover (4) onto ring gear (12) via washer (3), bolts (2) (16 used). ϖ 32 mm ϖ 540 N⋅m (55 kgf⋅m, 400 Ibf⋅ft) 28. Bond the drain plug round with seal tape and then fill gear oil in after installing into housing (28). ϖ 30 mm Gear oil : 24 L (6.3 US gal, 5.3 UK gal)

CAUTION: The second stage carrier (16) assembly weight: 80 kg (180 Ib) 21. Install eyebolts (M12, Pitch 1.75) into the three hoisting holes in the second stage carrier (16) assembly. Hoist by a crane and assemble into housing (28). Ȁ 22. Install second stage sun gear (13) onto second stage carrier (16). Ȁ 23. Apply THREEBOND #1215 on the mounting surface of ring gear (12) for ring gear (19). CAUTION: Ring gear (12) weight: 60 kg (130 Ib)

CAUTION: Motor (1) weight: 80 kg (180 Ib) 29. Apply THREEBOND #1215 on the mounting surface of motor (1) for cover (4). 30. Remove the adapter of hose 1 on motor (1). Then install eyebolt (ST 0006). (Refer to W2-5-4) 31. Hoist motor (1) by a crane and install cover (4), spacer (23) and sems bolts (24) (12 used) on to the motor. ϖ 19 mm ϖ 88 N⋅m (9 kgf⋅m, 65 Ibf⋅ft)

24. Install eyebolt (M12, Pitch 1.75) into the two hoisting holes in the ring gear (12). Hoist by a crane. Align the matching mark made when disassembling and install onto ring gear (19).

W2-5-15

UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING MOTOR

10 6

11 8

12 13

18 30

21 22

31 32

23 26

27 34

38 41

39 42 43

W142-02-06-004

123456789-

Roller Bearing O-Ring Valve Casing Socket Bolt (4 Used) Poppet (2 Used) Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Valve Plate

10 - Spring (24 Used) 11 - Brake Piston

12 13 14 15 16 17 18 19 20 -

O-Ring Friction Plate (2 Used) Relief Valve (2 Used) Pin (2 Used) Retaining Ring O-Ring Plate (3 Used) Retaining Ring Spacer

21 - Spring 22 - Spacer

23 24 25 26 27 28 29 30 31 -

Rotor Push Rod (12 Used) Spacer Holder Retainer Plate Plunger (9 Used) Thrust Plate Plug O-Ring

32 - Casing 33 - Shaft

W2-5-16

34 35 36 37 38 39 40 41 42 -

Retaining Ring Spacer (2 Used) Roller Bearing Retaining Ring O-Ring Oil Seal Seal Cover Retaining Ring Swing Parking Brake Releasing Valve 43 - Bolt (3 Used)

UPPERSTRUCTURE / Swing Device Disassemble Swing Motor О Be sure to thoroughly read “Precautions for Disassembling and Assembling” on page W1-1-1 before starting the disassembly work.

CAUTION: Swing motor weight: 80 kg (180 Ib)

7. Remove springs (10) (24 used) from casing (32). 8. Install a bolt into screw hole (M8, pitch 1.25) on brake piston (11). Then, remove brake piston (11) from casing (32). 9. Remove O-rings (12 and 17) from casing (32).

1. Remove plug (30) from casing (32) to drain hydraulic oil. ϖ 30 mm Relief Valve IMPORTANT: Do not disassemble relief valve (14). Don’t turn the adjusting screw either. 2. Remove relief valves (14) from valve casing (3). ϖ 27 mm Make-Up Valve 3. Remove plugs (8) (2 used). ϖ 14 mm 4. Remove springs (6) (2 used) and poppets (5) (2 used). 5. Put matching marks on the mating section between valve casing (3) and casing (32). ϖ 17 mm 6. Loosen socket bolts (4) (4 used) to remove valve casing (3) from casing (32). NOTE: Note that valve casing (3) will be raised by spring (10) force. Valve plate (9) may come off together with valve casing (3).Take care not to drop valve plate (9).

W2-5-17

UPPERSTRUCTURE / Swing Device

9 3 2 13

21 22 32

23 26

27 34

39 42 43

W142-02-06-004

W2-5-18

UPPERSTRUCTURE / Swing Device CAUTION: Casing (32) + shaft (33) + rotor (23) assembly weight: 50 kg (110 Ib)

21. Remove plungers (28) (9 used), retainer plate (27), holder (26), spacer (25) and push rods (24) (12 used) from rotor (23).

10. Lay casing (32) horizontally and pull rotor (23) with plunger (28), retainer plate (27) and etc. out from shaft (33) Č&#x20AC; 11. Remove plates (18) (3 used) and friction plates (13) (2 used) from casing (32). 12. Remove thrust plate (29). Č&#x20AC; 13. Remove retaining ring (41) and seal cover (40) from casing (32).

CAUTION: When removing retaining ring (19), be sure to hold spacer (20) with a press or a similar tool. Otherwise, retaining ring (19) and spacer (20) will fly off, causing personal injury. 22. Holding spacer (20) with a press, remove retaining ring (19). 23. Remove spacers (20), (22) and spring (21).

14. Remove shaft (33) from casing (32) by tapping the valve casing (3) mouting side of shaft (33) with a plastic hammer.

24. Loosen bolts (43) (3 used) and remove swing parking brake releasing valve (42) from casing (32).

15. Remove oil seal (39) from seal cover (40).

Ď&#x2013; 10 mm

16. Remove valve plate (9), pins (15) (2 used) and O-ring (2) from valve casing (3). 17. With a puller, remove the outer race of roller bearing (1) from valve casing (3). 18. With a press, remove retaining ring (16) and the inner race of roller bearing (1) from shaft (33). 19. Remove retaining rings (34 and 37) and spacers (35) (2 used) from shaft (33). Take care not to damage the outer surface of oil seal (39) on the shaft. 20. With a press, remove the inner race of roller bearing (36) from shaft (33).

W2-5-19

UPPERSTRUCTURE / Swing Device Assemble Swing Motor 4

19 30 31

Section A-A

15 2

43 42

13 18

12 17 24 25 26

34 35 36

21 23 28 22 27 29

Inner Race Plate

35 37

123456789-

W183-02-06-007

Roller Bearing O-Ring Valve Casing Socket Bolt (4 Used) Poppet (2 Used) Spring (2 Used) O-Ring (2 Used) Plug (2 Used) Valve Plate

10 - Spring (24 Used) 11 - Brake Piston

33 39 12 13 14 15 16 17 18 19 20 -

O-Ring Friction Plate (2 Used) Relief Valve (2 Used) Pin (2 Used) Retaining Ring O-Ring Plate (3 Used) Retaining Ring Spacer

21 - Spring 22 - Spacer

23 24 25 26 27 28 29 30 31 -

Rotor Push Rod (12 Used) Spacer Holder Retainer Plate Plunger (9 Used) Thrust Plate Plug O-Ring

32 - Casing 33 - Shaft

W2-5-20

34 35 36 37 38 39 40 41 42 -

W142-02-06-008

Retaining Ring Spacer (2 Used) Roller Bearing Retaining Ring O-Ring Oil Seal Seal Cover Retaining Ring Swing Parking Brake Releasing Valve 43 - Bolt (3 Used)

UPPERSTRUCTURE / Swing Device Assemble Swing Motor IMPORTANT: When installing the roller bearing (36) inner race to shaft (33), the inner race plate should be facing inward. 1. Install retaining ring (34) and one spacer (35) on shaft (33). Press the inner race of roller bearing (36) onto shaft (33). 2. After installing another spacer (35) on shaft (33), install retaining ring (37). IMPORTANT: When installing the roller bearing (1) inner race to shaft (33), the surface of the inner race with mark should be facing inward. 3. Press the inner race of roller bearing (1) onto shaft (33). Install retaining ring (16).

9. Apply gease to the inner of thrust plate (29) and install it into casing (32). 10. Install spacer (22), spring (21), spacer (20) in that order into rotor (23). 11. With a press to push spacer (20) until retaining ring (19) is installed. Install retaining ring (19). 12. Install push rods (24) (12 used) in rotor (23). Install spacer (25) and holder (26) in rotor (23) in that order. IMPORTANT: Plungers (28) (9 used) should be installed at the center projecting part of retainer plate (27). 13. After installing plungers (28) (9 used) to retainer plate (27), apply a film of hydraulic oil to the plunger holes in rotor (23). Then, insert plungers (28) into rotor (23).

IMPORTANT: When tapping the outer race of roller bearing (36) into casing (32), the surface with mark shall be used as the outer surface. 4. With a metal extension bar and a hammer, install the outer race of roller bearing (36) into casing (32). IMPORTANT: Apply grease to the inner of oil seal (39) inner race. 5. Install oil seal (39) into seal cover (40) with a protection plate and a press.

CAUTION: Casing (32) + shaft (33) + rotor (23) assembly weight: 50 kg(110 Ib) 14. Lay casing (32). Install the rotor (23) assembly onto shaft (33). IMPORTANT: Plate (18) has notches on the outer diameter. Friction plate (13) has notches on the spline teeth. Install plate (18) and friction plate (13) so that notched positions on both parts are aligned with each other. 15. Stand casing (32) upright. Install plates (18) (3 used) and friction plates (13) (2 used) one by one alternately.

6. Install O-ring (38) in casing (32). 7. Tap shaft (33) into casing (32) with a plastic hammer.

16. Install O-rings (17 and 12) in casing (32).

8. Place seal cover (40) onto casing (32) and secure it with retaining ring (41).

W2-5-21

UPPERSTRUCTURE / Swing Device

1 Section A-A

15 2

10 43

12 17

W183-02-06-007

W2-5-22

W142-02-06-008

UPPERSTRUCTURE / Swing Device IMPROTANT: Align the brake piston (11) slit as shown bellow. 32

IMPORTANT: While taking care not to allow valve plate (9) to drop off, align the matching marks (made during disassembly).

Slit

21. Install valve casing (3) to casing (32). Tighten valve casing (3) with socket bolts (4) (4 used).

ϖ 17 mm ϖ 430 N⋅m (44 kgf⋅m, 320 Ibf⋅ft)

W142-02-06-011

17. Install brake piston (11) into casing (32). If brake piston (11) is difficult to install because of the resistance force from O-rings (12) and (17), tap it evenly with a plastic hammer. 18. Install springs (10) (24 used) in brake piston (11). IMPORTANT: When installing roller bearing (1), tap the side where the bearing type is marked with a plastic hammer. 19. Drive the outer race of roller bearing (1) into valve casing (3) with a plastic hammer.

22. Install parking brake releasing valve (42) into casing (32) via bolts (43) (3 used). ϖ 10 mm ϖ 10 N⋅m (1 kgf⋅m, 7.2 Ibf⋅ft) Make-up Valve 23. Install poppets (5) (2 used) and springs (6) (2 used) in valve casing (3). Tighten two plugs (8) with O-rings (7). ϖ 14 mm ϖ 330 N⋅m (34 kgf⋅m, 245 Ibf⋅ft) Relief Valve 24. Install relief valves (14) (2 used) to valve casing (3).

IMPORTANT: Install valve plate (9) with the spherical face facing upward. 20. Install O-ring (2), pins (15) (2 used) and valve plate (9) to valve casing (3). NOTE: Apply a film of grease to valve plate (9) to prevent valve plate (9) from coming out of valve casing (3).

W2-5-23

ϖ 27 mm ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft)

UPPERSTRUCTURE / Swing Device DISASSEMBLE AND ASSEMBLE SWING PARKING BRAKE RELEASING VALVE 42 44

53 52 51

W142-02-06-010

42 - Swing Parking Brake Releasing Valve 43 - Bolt (3 Used) 44 - O-Ring 45 - O-Ring

46 - Spring

50 - Spool

53 - Spacer

47 - O-Ring 48 - Spring 49 - Steel Ball

51 - Bushing 52 - Filter

54 - Orifice 55 - Poppet

W2-5-24

UPPERSTRUCTURE / Swing Device Disassemble Valve

Swing Parking Brake Releasing

1. Remove O-rings (44), (45) and (47) from swing parking brake releasing valve (42). 2. Remove springs (46) and (48) from swing parking brake releasing valve (42). 3. Remove spool (50) from swing parking brake releasing valve (42). 4. Remove poppet (55) from swing parking brake releasing valve (42). 5. Remove bushing (51), filter (52), spacer (53) and orifice (54) from poppet (55). Assemble Swing Parking Brake Releasing Valve 1. Install orifice (54), spacer (53), filter (52), bushing (51) onto poppet (55). 2. Install the poppet (55) assembly onto swing parking brake releasing valve (42). 3. Install spool (50) onto swing parking brake releasing valve (42). 4. Install spring (46) onto poppet (55) and install spring (48) onto spool (50). 5. Install O-rings (44), (45) and (47) onto swing parking brake releasing valve (42).

W2-5-25

UPPERSTRUCTURE / Swing Device MAINTENANCE STANDARD Swing Motor 1. Clearance between plunger and rotor bore. D-d

Standard Clearance

Allowable Limit

0.032 mm (0.0013 in)

0.062 mm (0.0024 in)

W107-02-06-138

W107-02-06-139

2. Clearance between plunger top and shoe bottom (δ) Standard Clearance

Allowable Limit

0.3 mm (0.0118 in)

W107-02-06-140

W2-5-26

UPPERSTRUCTURE / Swing Device 3. Shoe Thickness (t) Standard Clearance

Allowable Limit

6.0 mm (0.236 in)

5.8 mm (0.228 in)

W107-02-06-142

4. Friction Plate Thickness Standard Clearance

Allowable Limit

4.0 mm (0.157 in)

3.6 mm (0.142 in)

W107-02-06-143

2 1

Holder (2) Height from Retainer Plate (1) Bottom Face H-h

Standard Clearance

Allowable Limit

7.0 mm (0.276 in)

6.5 mm (0.256 in)

h H W107-02-06-146

If dimension H-h is reduced to below 6.5 mm (0.256 in), replace retainer plate (1) and holder (2).

W2-5-27

UPPERSTRUCTURE / Swing Device (Blank)

W2-5-28

UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL RIGHT PILOT VALVE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it.

W183-04-02-003

W183-04-02-002

Wooden Blocks Cap

Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2. ϖ 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

W183-01-01-001

NOTE: Run the vacuum pump continously while working on the hydraulic system. 1

Removal 1. Remove seat mounting socket bolts (2) (4 used) to remove seat (1).

ϖ 6 mm W183-02-01-040

W2-6-1

UPPERSTRUCTURE / Pilot Valve 2. Remove screw (23), cover (22) to move boot (28) up. 29

ϖ 17 mm 3. Remove screws (20) and (16) to move cover (17) up. Disconnect each harness connectors for key switch (19), air controller (18) and grip (3), then remove cover (17). Remove screws (21), (15) and (13) to remove cover (14).

27 5

26 25 24

4. Remove the connector and bolt (11) for switch box (12) to remove switch box (12).

6 7

8 10

23 22

ϖ 13 mm

20 19 18

IMPORTANT: Attach identification tags on all disconnected hoses to aid in reassembling. 5. Disconnect hoses (30 to 35).

9 11

ϖ 19 mm NOTE: Attach caps to all disconnected hose ends.

6. Loosen nut (4) to remove clips (5) and (26). Disconnect connector (6) to remove grip (3) (with harness). Loosen nut (27) to remove lever (29), washers (24), (25) and boot (28).

W178-02-07-001

ϖ 22 mm ϖ 19 mm 34

7. Remove bolts (9) and (8) (with pin (7)) to remove valve (10).

30 31 32 33

ϖ 13 mm

Installation 1. Secure valve (10) with bolts (9) and (8) (with pin (7)). ϖ 13 mm ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

W178-02-07-002

30 31 32 33 34 -

Hose A3: (To the pilot shut-off valve) Hose C1: (To the signal control valve port B for bucket roll-in) Hose S26: (To the signal control valve port H for boom lower) Hose T3: (To the pilot shut-off valve) Hose S25: (To the signal control valve port B for bucket rollout) 35 - Hose C2: (To the signal control valve port A, D for boom raise)

NOTE: Piping location shows that of JIS pattern.

W2-6-2

UPPERSTRUCTURE / Pilot Valve 2. Connect hoses (30 to 35). ϖ 19 mm ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft) IMPORTANT: If the harness is arranged to the inside of spring pin (7), it may make contact with the moving part of the pilot valve which may damage it. Be sure to arrange the harness to the outside of spring pin (7).

32 33

3. Temporarily tighten nut (27) to lever (29), then install washers (24), (25). Install lever (29) onto valve (10) with nut (27). Install boot (28). Temporarily tighten nut (4) to lever (29), then install grip (3) with nut (4). Pass the harness of grip (3) through the upper hole of boot (28), then connect it to lever (29), via clips (5) and (26). Arrange the harness to the outside of spring pin (7) over bolt (8) head. Connect connector (6). ϖ ϖ ϖ ϖ

30 31

W178-02-07-002

29 3

28 4

27 5

26 25 24

22 mm 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 19 mm 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft)

6 7

23 22 20 19 18

4. Install switch box (12) with bolt (11), then connect the connector. 17

ϖ 13 mm ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft) 5. Connect each harness of key switch (19) and air controller (18).

8 9 11

6. Install cover (14) with bolts (21), (15) and (13). Install cover (17) with bolts (20 and 16). 15

7. Install cover (22) with bolt (23).

13 W178-02-07-001

W2-6-3

UPPERSTRUCTURE / Pilot Valve 8. Install seat (1) with socket bolts (2) (4 used). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft) IMPORTANT: Be sure to check the hydraulic oil level after assembling. Start engine to check each part for any oil leakage.

W183-02-01-040

W2-6-4

UPPERSTRUCTURE / Pilot Valve REMOVE VALVE

AND

INSTALL

LEFT

PILOT

W183-04-02-003

W183-04-02-002

Wooden Blocks Cap

W183-01-01-001

ϖ 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

NOTE: Run the vacuum pump continously while working on the hydraulic system. Removal 1. Remove screw (2) and cover (3) to move boot (1) up. At this time, the console is at the most front position.

Radio

2 3 4

ϖ 17 mm 2. Remove screws (7), (8) to remove cover (9). Remove screws (4), (5) to move cover (6) up to disconnect the radio connector, then remove cover (6).

W2-6-5

5 W178-02-07-003

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Attach identification tags on all disconnected hoses to aid in reassembling. 3. Disconnect hoses (10 to 15). ϖ 19 mm

10 11

NOTE: Attach caps on each disconnected hose ends.

4. Loosen nut (17) to remove clips (28) and (20). Disconnect connector (27) to remove grip (16) (with harness). Loosen nut (19) to remove lever (18), washers (24), (25) and boot (1). ϖ 22 mm ϖ 19 mm

W178-02-07-004

5. Remove bolts (23) and (22) (with pin (21)) to remove valve (26). ϖ 13 mm

10 - Hose A2: (To the pilot shut-off valve) 11 - Hose C5: (To the signal control valve port C, F for boom lower) 12 - Hose S15: (To the signal control valve for right swing) 13 - Hose T2: (To the pilot shut-off valve) 14 - Hose C3: (To the signal control valve port G for arm roll-in) 15 - Hose S16: (To the signal control valve for left swing)

NOTE: Piping location shows that of JIS pattern. 16

Installation 1. Install valve (26) with bolts (23) and (22) (with pin

(21)). ϖ 13 mm ϖ 10 N⋅m (1.0 kgf⋅m, 7.2 Ibf⋅ft)

17 18

1 19 20 21 22 23 24 25 26

2. Connect hoses (10 to 15). ϖ 19 mm ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

W178-02-07-003

W2-6-6

UPPERSTRUCTURE / Pilot Valve IMPORTANT: If the harness is arranged to the inside of spring pin (21), it may make contact with the moving part of the pilot valve which may damage it. Be sure to arrange harness to the outside of spring pin (21).

3. Temporarily tighten nut (19) to lever (18), then install washers (24), (25). Install lever (18) onto valve (26) with nut (19). Install boot (1). Temporarily tighten nut (17) to lever (18), then install grip (16) with nut (17). Pass the harness of grip (16) through the upper hole of boot (1), then connect it to lever (18), via clips (28) and (20). Arrange the harness to the outside of spring pin (21) over bolt (22) head. Connect connector (27). ϖ ϖ ϖ ϖ

22 mm 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft) 19 mm 26 N⋅m (2.0 kgf⋅m, 14.5 Ibf⋅ft)

17 18

1 19 20 21 22 24 25 26 9

Radio

4. Connect the connector of the radio and install cover (6) with screws (4) and (5). Install cover (9) with screws (7), (8).

2 3 4

5. Install cover (3) with screws (2). W178-02-07-003

IMPORTANT: Be sure to check the hydraulic oil level after assembling. Start engine to check each part for any oil leakage.

W2-6-7

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-6-8

UPPERSTRUCTURE / Pilot Valve REMOVE AND INSTALL TRAVEL PILOT VALVE. REMOVE AND INSTALL BUCKET PILOT VALVE (FOR LOADING SHOVEL ONLY) CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it.

W183-04-02-003

W183-04-02-002

Wooden Blocks Cap

Ď&#x2013; 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank. NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W2-6-9

UPPERSTRUCTURE / Pilot Valve Removal 1. Loosen bolts (2) (2 used) at the lower side of the frame. 1

Front Side

NOTE: Do not remove bolt (2). ϖ 19 mm 3 2

2. Remove bolts (1) (3 used) while holding under cover (3) by hand. Move under cover (3) to the front side a bit and remove it out. ϖ 19 mm

W183-02-06-008

3. Loosen bolts (31) (4 used) to remove pedals (33) (2 used) and levers (32) (2 used). ϖ 17 mm

4 32

4. ϑFor loading shovel onlyϒ Loosen bolts (4) (3 used) to remove cover (5). Loosen bolts (6) (2 used) to remove pedal (7). (2 places both left and right) ϖ 17 mm

6 7 8 9

10 30

11 12

29 28

13 14

15 16 22 21

26 25 24

17 19

W183-02-07-005

W2-6-10

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Attach identification tags to pipes and hoses to clarify correct reassembly. 5. Remove hoses (11 to 26) under the cab. Ď&#x2013; 19 mm NOTE: Cap the disconnected pipes and hoses. Hoses (11 to 15, 18 and 23 to 26) are not used in backhoe machine. 6. Remove socket bolts (30) (2 used), spring washers (29) (2 used) and plane washers (28) (2 used) to remove pilot valve (27). Ď&#x2013; 8 mm 7. (For loading shovel only) Remove socket bolts (8) (2 used) and spring washers (9) (2 used) to remove pilot valve (10) which is used to open / close bucket.(2 places both left and right)

11 - Hose SRT: (To pilot valve port T for travel) 12 - Hose RLT: (From pilot valve port T for left side bucket opening / closing) 13 - Hose 14: (To signal control valve port N) 14 - Hose RLP: (From pilot valve port P for left side bucket opening / closing) 15 - Hose SLP: (To pilot valve port P for left side bucket opening / closing) 16 - Hose T4: (To lock valve) 17 - Hose P1: (From lock valve) 18 - Hose SRT: (From pilot valve port T for right side bucket opening / closing) 19 - Hose C7: (To signal control valve port L) 20 - Hose C6: (To signal control valve port K) 21 - Hose C8: (To signal control valve port I) 22 - Hose C9: (To signal control valve port J) 23 - Hose SLP: (From pilot valve port P for travel) 24 - Hose RLP: (To pilot valve port P for right side bucket opening / closing) 25 - Hose 13: (To signal control valve port M) 26 - Hose RLT: (To pilot valve port T for right side bucket opening / closing)

Ď&#x2013; 8 mm

W2-6-11

UPPERSTRUCTURE / Pilot Valve Installation 1. Install pilot valve (27) with socket bolts (30) (2 used), spring washers (29) (2 used) and plane washers (28) (2 used). ϖ 8 mm

ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

2. (For loading shovel only) Install pilot valve (10) for bucket opening / closing with socket bolts (8) (2 used) and spring washers (9) (2 used). (2 places both left and right)

6 7 8 9

ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

10 30

3. Connect hoses (11 to 26) under the cab. ϖ 19 mm ϖ 30 N⋅m (3.0 kgf⋅m, 21.5 Ibf⋅ft)

11 12

NOTE: Hoses (11 to 15, 18 and 23 to 26) are not used in the backhoe machine.

13 14

15 16 22

4. Install pedals (33) (2 used) and lever (32) to pilot valve (27) with bolts (31) (4 used). ϖ 17 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

21 26 25 24

IMPORTANT: Be sure to check the hydraulic oil level after assembling. Start engine to check each part for any oil leakage.

17 19

W183-02-07-005

5. (For loading shovel only) Install pedal (7) to pilot valve (10) for bucket opening / closing with bolts (6) (2 used). Install cover (5) with bolts (4) (3 used). ϖ 17 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W2-6-12

UPPERSTRUCTURE / Pilot Valve 6. Insert under cover (3) to bolts (2) (2 used) from front side. 7. Install bolts (1) (3 used) while holding under cover (3) by hand and secure bolts (2) (2 used).

Front Side

ϖ 19 mm ϖ 90 N]m (9.2 kgf]m, 67 Ibf⋅ft) 3 2

W183-02-06-008

W2-6-13

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE FRONT PILOT VALVES 13

12 14 11

11 10

8 8 7

9 21

4 1

W176-02-07-001

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 -

Retaining Ring (4 Used) Push Rod A (2 Used) Push Rod B (2 Used) Block Socket Bolt (2 Used)

12 13 14 15 16 -

Cam Screw Joint Universal Joint Oil Seal (4 Used) Spring Guide (4 Used)

W2-6-14

17 18 19 20 21 -

Spool (4 Used) Housing O-Ring Dowel Pin (2 Used) O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassemble Front Pilot Valves IMPORTANT: Block (10) and housing (18) are made of aluminum. Too strong a force can deform or damage them. Therefore, be careful when handling them. IMPORTANT: As spool (17) has been selected to match the hole of housing (18), they must be replaced as a set. In addition, the dimensions of balance springs A (3), B(4) and return springs A(5), B(6) as well as those of push rods A(8), B(9) are different. For this reason, be sure to indicate the port number from which it is removed. Port numbers are stamped on housing (18). IMPORTANT: Don’t clamp housing (18) in a vise to remove the screw joint because the strong torque may act on the screw joint.

IMPORTANT: Two kinds of push rods are used. They must be handled in order of port number after removing. 4. Pull push rods (8), (9) out from block (10). 5. With a bamboo spatula, remove oil seals (15) (4 used) from block (10). NOTE: If a metal bar is used, the mating part of the oil seal may be damaged. IMPORTANT: The retaining ring may come off while disassembling. Take care not to drop it. 6. Press springs using special tool (ST 7257) from the top of spring guide (16). Retaining ring (7) will appear. Remove it with a screw driver or similar tool. (4 places) 7

1. Secure screw joint (13) in a vise. Then turn cam (12) with a spanner to remove the screw joint. ϖ 32 mm 2. Clamp the flat surface of housing (18) in a vise slightly. Remove cam (12) from universal joint (14).

ϖ 32 mm

ST 7257

NOTE: The universal joint has been secured on block (10) with LOCTITE. Don’t remove it unless necessary. W176-02-07-005

3. Remove socket bolt (11) to remove block (10). At this time, push rods (8) and (9) are still on the block side. ϖ 6 mm

IMPORTANT: The number of shims has been determined for each port during the performance testing at the factory. Take care not to lose them. Keep them carefully so as to install them to each former port when reassembly. 7. Remove spring guide (16), balance springs (3), (4), return springs (5), (6), shim (2), spacer (1) from spool (17).

W2-6-15

UPPERSTRUCTURE / Pilot Valve

21 20

21 20 19

W176-02-07-001

W2-6-16

UPPERSTRUCTURE / Pilot Valve IMPORTANT: As the spool has been selected to match the hole of the housing, keep them carefully so as to install them to the former port when reassembling. 8. Remove spool (17) from housing (18). Pull it out while turning it slowly. NOTE: The spool and housing must be replaced as assembly. 9. Remove O-rings (19), (21) from housing (18). Donâ&#x20AC;&#x2122;t remove dowel pin (20) unless necessary.

W2-6-17

UPPERSTRUCTURE / Pilot Valve ASSEMBLE FRONT PILOT VALVES

12 15 11 8, 9 7 16 3, 4 5, 6 2 19 1

17 W176-02-07-006

123456-

Spacer (4 Used) Shim (Several) Balance Spring A (2 Used) Balance Spring B (2 Used) Return Spring A (2 Used) Return Spring B (2 Used)

78910 11 -

Retaining Ring (4 Used) Push Rod A (2 Used) Push Rod B (2 Used) Block Socket Bolt (2 Used)

12 13 14 15 16 -

Cam Screw Joint Universal Joint Oil Seal (4 Used) Spring Guide (4 Used)

W2-6-18

17 18 19 20 21 -

Spool (4 Used) Housing O-Ring Dowel Pin (2 Used) O-Ring (2 Used)

UPPERSTRUCTURE / Pilot Valve Assemble Front Pilot Valves IMPORTANT: The pilot valve is susceptible to contamination. Keep parts clean when assembling. NOTE: Table below shows the relations between each port and the components. Take care not to confuse them when assembling.

IMPORTANT: Install spring guide with the protrusion facing up. 3. Install spring guide (16) onto the return spring (3) or (4). 4. Install retaining ring (7) onto ring holder (ST 7255).

Port

Spool

Shim

Push Rods

No.

(17)

(2)

(8), (9)

With outer Same

to Same

the former

one

groove Without outer groove

W176-02-07-008

With outer groove

ST 7255

Without outer groove

Port

Return Springs

Balance Springs

No.

(5), (6)

(3), (4)

Short

Long

Short

Long

5. Insert the spool (17) head into the hole of spring special tool (ST 7257) to press the spring from the top of spring guide (16). Install retaining ring (7) with the ring holder (ST 7255) onto the head of the spool.

ST 7255

ST 7257

Packing Material

IMPORTANT: Make sure of the port hole number, and insert the spool to the former port.

W176-02-07-009

NOTE: Put approx. dia. 8 mm, length 10 mm of packing material into the port hole so as to not only make the work easy to do, but also prevent the spool from lowering to the bottom when compressing the spring.

1. Insert the thinner end of spool (17) into housing (18), then slowly push the spool in while rotating it. NOTE: The spool has been selected to match the hole of the housing. The spool and housing must be replaced as assembly. IMPORTANT: Refer to the table above to assemble them correctly.

6. Assemble the remaining spools (17) (3 used) into housing (18) with the same procedures in step 2 to 5. 7. Install O-rings (19) and (21) (2 used) on to housing (18).

2. Install spacer (1), shim (2), balance spring (3) or (4), return spring (5) or (6) onto spool (17) installed in housing (18).

W2-6-19

UPPERSTRUCTURE / Pilot Valve

14 10

12 15 11 8, 9

W176-02-07-006

W2-6-20

UPPERSTRUCTURE / Pilot Valve 8. Apply grease to the inner face of oil seals (15) (4 used), then install the oil seals (4 used) into block (10) with a bamboo spatula. NOTE: As shown bellow, inserting push rods (8), (9) first, then installing the oil seal. It will prevent the oil seal from entering into the hole.

IMPORTANT: Make sure of the tighteness of cam. 13. Clamp housing (18) carefully in a vise and then install cam (12) to universal joint (14). Tighten the universal joint so that the clearance between the cam and push rod (8), (9) becomes 0 to 0.2 mm (0 to 0.008 in). ϖ 32 mm

§îºіî ⃾֞Ƴἤ

IMPORTANT: Don’t clamp housing (18) in a vise because the strong torque may act on the screw joint.

W176-02-07-007

14. Clamp screw joint (13) in a vise to tighten universal joint (14). Tighten cam (12) with a spanner.

IMPORTANT: Make sure of the position to install the push rod. 9. Install push rods (8), (9) to block (10). When installing the push rods, install the push rods with groove to ports # 1 and # 3, the ones without groove to ports # 2 and # 4, respectively. 10. Apply grease to the ball at the front end of push rods (8), (9). 11. Apply grease to the joint part of universal joint (14) 12. Align the position of dowel pin (20), install the block (10) assembly to housing (18) with socket bolts (11) (2 used). ϖ 6 mm ϖ 19.6 N]m (2 kgf]m, 14.5 Ibf]ft)

W2-6-21

ϖ 32 mm ϖ 88.2 N]m (9 kgf]m, 65 Ibf]ft)

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE TRAVEL PILOT VALVE

1 2

35 34 33 32 31 30

3 4 5 28

8 9 10

26 11 12 25

22 21 20 19 18 14 17 15 16

W176-02-07-002

123456789-

Bolt (2 Used) Cover Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Damper (2 Used) Rubber Seat (2 Used) Socket Bolt (2 Used) Spring Washer (2 Used)

10 11 12 13 14 15 16 17 18 -

Holder Oil Seal (4 Used) O-Ring (4 Used) Bushing (4 Used) Casing O-Ring Plug Spool (4 Used) Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

Spacer (4 Used) Shim (Several) Balance Spring (4 Used) Spring Guide (4 Used) Pusher (4 Used) Spring Pin (2 Used) Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used)

W2-6-22

28 29 30 31 32 33 34 35 -

Socket Bolt (4 Used) Spring Washer (4 Used) Adjusting Bolt (4 Used) Bushing (4 Used) Cam (2 Used) Lock Nut (4 Used) Spring Pin (2 Used) Spring Pin (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassemble Travel Pilot Valve 1. Clamp casing (14) in vise. Loosen bolt (1) to remove cover (2) from holder (10). ϖ 10 mm 2. Remove socket bolts (8) (2 places) to remove holder (10) from casing (14).

7. Remove spring (18) from casing (14). (4 places) IMPORTANT: Put a stand under bracket (26). If holder (10) bears the reaction force, a strong force acts on pin (3) and the pin may deform its shape.

ϖ 8 mm 3. Pull out pusher (23) from casing (14) (4 places). Bushing (13) and oil seal (11) are removed with the pusher. 4. Pull out pusher (23) from bushing (13) with a bamboo spatula to remove oil seal (11). (4 places) IMPORTANT: Make mark on spools so as to easily install them to their former position.

IMPORTANT: The inside of spring pins (24), (25) hole in the bracket is in stepped shape. Therefore the spring pin can only be pulled out from one direction. 8. Put a stand under bracket (26). Push out both spring pins (24), (25) from bracket (26) at the same time using special tool (ST 1237). Remove the bracket from pin (3). (2 places) NOTE: The outside end of the spring pin has been caulked.

5. Pull out the spool (17) assembly from casing (14) while turning the spool. (4 places) Spring guide (22), balance spring (21), shim (20) and spacer (19) are removed with the spool.

24,25 26

NOTE: The spool has been selected to match the hole in the casing. The spool and casing must be replaced as assembly.

27 Caulked Here

IMPORTANT: The number of shims has been determined during the performance testing at the factory. They must be kept together with their spool. 6. Compress balance spring (21). Remove spring guide (22), balance spring (21), shim (20) and spacer (19) from spool (17). (4 places)

Stand

W176-02-07-019

9. Remove socket bolts (28) (2 used) to remove damper (6) and rubber seat (7) from pin (3). Oring (4) is removed with them. (2 places) ϖ 5 mm

W2-6-23

UPPERSTRUCTURE / Pilot Valve

35 34 33 32 31 30 3 5

W176-02-07-002

W2-6-24

UPPERSTRUCTURE / Pilot Valve 10. Remove O-ring (5) from pin (3). (2 places) 11. Place holder (10) with the casing (14) mating surface facing up. IMPORTANT: The holes for spring pins (34), (35) of cam (32) are in stepped-shape. Therefore tap the pins from the bottom of the cam. 12. Push out both spring pins (34), (35) from cam (32) at the same time using special tool (ST 1237). (2 places) NOTE: The spring pin is a double-pin. NOTE: The spring pin is caulked in its hole, so it may feel tight when removing. 13. Remove pin (3) with a round bar and a hammer. At this time, cam (32) is also removed. (2 places) NOTE: Don’t remove bushings (31) (4 used) left on holder (10) unless necessary. When removal is necessary, the bushing special tool (ST 7256) should be used to tap it out. 14. Remove lock nuts (33) (2 used) from cam (32) to remove adjusting bolts (30) (2 used). (2 places) ϖ 13 mm ϖ 4 mm

W2-6-25

UPPERSTRUCTURE / Pilot Valve ASSEMBLE TRAVEL PILOT VALVE

25 27

34, 35

13 22

4 28

20 19 17

W176-02-07-010

15, 16

123456789-

Bolt (2 Used) Cover Pin (2 Used) O-Ring (2 Used) O-Ring (2 Used) Damper (2 Used) Rubber Seat (2 Used) Socket Bolt (2 Used) Spring Washer (2 Used)

10 11 12 13 14 15 16 17 18 -

Holder Oil Seal (4 Used) O-Ring (4 Used) Bushing (4 Used) Casing O-Ring Plug Spool (4 Used) Spring (4 Used)

19 20 21 22 23 24 25 26 27 -

Spacer (4 Used) Shim (Several) Balance Spring (4 Used) Spring Guide (4 Used) Pusher (4 Used) Spring Pin (2 Used) Spring Pin (2 Used) Bracket (2 Used) Spring Pin (2 Used)

W2-6-26

28 29 30 31 32 33 34 35 -

Socket Bolt (4 Used) Spring Washer (4 Used) Adjusting Bolt (4 Used) Bushing (4 Used) Cam (2 Used) Lock Nut (4 Used) Spring Pin (2 Used) Spring Pin (2 Used)

UPPERSTRUCTURE / Pilot Valve Assemble Travel Pilot Valve IMPORTANT: Pay attention to the mounting direction of spring guide (22).

6. If bushing (31) has been removed from holder (10), it shall be installed on the holder using special tool (ST 7256) in the following procedures.

IMPORTANT: Install the former number of shims. 1. Assemble spool (17) into assembly. (4 used) ОȀInsert spacer (19), shim (20), balance spring (21) into the spool in order. ОȀPress balance spring (21) by hand. Install spring guide (22) to the spool with the steppedend facing down.

NOTE: The bushings (4 used) are indentical. ОInsert the bushing into special tool (ST 7256), then tap on the special tool (ST 7256) to install the bushing into the hole of holder. Stop tapping when the bushing end is flush with the inside wall. ST 7256

2. Insert spring (18) to casing (14). (4 places)

31 W176-02-07-016

IMPORTANT: Insert the spool (17) assembly into the former port.

ОInstall the bushing on the opposite side using the same procedure. 31 10

ST 7256

3. Turn and install the spool (17) assembly into casing (14). (4 places)

W176-02-07-015

4. Assemble pusher (23) (4 used). ОȀInstall oil seal (11) onto bushing (13). ОȀApply grease to the inner face of oil seal. ОȀInstall O-ring (12) to the bushing. ОȀInsert pusher (23) to the bushing. ОȀApply grease to the pusher head section.

О Install the bushing in near side as shown bellow. Stop tapping when the bushing end is flush with the outside of holder. 31 10

5. Insert the pusher (23) assembly to holder (10). (4 places).

ST 7256

Holder Outside W176-02-07-014

ОȀInstall the bushing on the opposite side as 31 shown below. ST 7256

W176-02-07-013

W2-6-27

UPPERSTRUCTURE / Pilot Valve

34, 35

14 W176-02-07-010

W2-6-28

UPPERSTRUCTURE / Pilot Valve 7. Place adjusting bolt (30) to cam (32). Tighten the bolt by hand, and then lightly secure it temporarily with lock nut (33). (2 places) NOTE: Adjust the dimensions later. 8. Apply grease on the head (mating surface for pusher (23)) of adjusting bolts (30). (2 places) Ȁ 9. Install O-ring (5) to pin (3), then assemble the pin to holder (10) with cam (32). (2 places)

IMPORTANT: Don’t adjust the adjusting bolt (30) while pressing the pusher (23) head with the adjusting bolt. The standard clearance between the adjusting bolt and pusher must be 0 to 0.2 mm (0 to 0.008 in). 13. Adjust bolt (30) by the following procedures. (2 places)

IMPORTANT: Take care of the inserting direction of the spring pin. IMPORTANT: Tap the spring pin in until it makes contact with the stepped part in hole. 10. Install spring pins (34), (35) to cam (32) using special tool (ST 1237), then secure the cam and pin (3). The spring pins shall be displaced with their slits in 90°. (2 places) 34

Slit

ϖ 13 mm ϖ 4 mm ОȀLoosen lock nut (33). ОȀMove cam (32) to check whether there is play, if none, turn adjusting bolt to adjust. ОȀTurn both adjusting bolts on the left and right alternatively to keep the cam horizontal. ОȀMeasure sizes A and B from both left and right caves on the cam to holder (10). Fine adjust the adjusting bolt to get same distance for both left and right. ОȀSecure the adjusting bolt with a hexagonheaded wrench. Tighten the lock nut to specified torque fist for securing the adjusting bolt. ОȀW hen adjustment is finished, move cam to check that there is a little play. If there is no play, the pusher may be in compressed condition, and adjustment should be carried out again. ϖ 9.8 N]m (1 kgf]m, 7.2 Ibf]ft) 30

W176-02-07-017

11. Caulk the hole edge of cam (32), where spring pins (34), (35) are inserted, with a punch. (2 places) 12. Place holder (10) on the casing (14) assembly and install it with socket bolts (8) (2 used), spring washers (9) (2 used). ϖ 8 mm ϖ 49 N]m (5 kgf]m, 36 Ibf]ft)

W2-6-29

W176-02-07-003

UPPERSTRUCTURE / Pilot Valve

25 27

4 28

W176-02-07-010

W2-6-30

UPPERSTRUCTURE / Pilot Valve IMPORTANT: Place a stand under the bracket. If holder (10) bears the reaction force, a strong force acts on pin (3) and the pin may deform.

14. Install rubber seat (7) to pin (3). (2 places)

15. Apply grease to O-ring (5). (2 places)

IMPORTANT: Pay attention to the direction of damper (6). IMPORTANT: The inner bore of damper (6) is edged-shape. If the damper is pried upward, O-ring (5) will be damaged. 16. With the lever upward, install damper (6) to pin (3) straight without prying. (2 places)

IMPORTANT: The inside of the spring pin hole in the bracket is stepped-shape. Make sure of the direction to insert the spring pin. IMPORTANT: Make sure of the facing direction of the spring pin. 20. Put a stand under the bracket (26). Tap spring pins (24), (25) into the bracket until the spring pin comes to the stepped end using special tool (ST 1237). The spring pins shall be displaced with their slits in 90°.

17. Secure damper (6) to holder (10) with socket bolts (28) (2 used) and spring washers (29) (2 used). (2 places)

Caulked Here

ϖ 8 mm ϖ 7 N]m (0.7kgf]m, 5.1 Ibf]ft)

18. Apply grease to O-ring (4), then press it to the end-most of pin (3). (2 places)

Caulked Here

24, 25

Stand

W176-02-07-011

IMPORTANT: As for the direction to install the bracket, refer to the figure in the disassemble section. Take care not to misassemble it. 19. Install pin (3) into bracket (26), then align the inserting holes of spring pin (24), (25) to fix the pin on bracket.

21. Caulk the hole edge of bracket (26), where spring pins (24), (25) are inserted, with a punch. (2 places) (Refer to the figure above.) 22. Install pin (3) on other bracket (26) as same in steps 19 to 21. 23. Install cover (2) to holder (10) with bolts (1) (2 used). ϖ 10 mm ϖ 5 N]m (0.5 kgf]m, 3.6 Ibf]ft) 24. Apply grease to the spring pin (27) contact part of damper (6). (2 places)

W2-6-31

UPPERSTRUCTURE / Pilot Valve DISASSEMBLE PILOT VALVE BUCKET OPENING / CLOSING

FOR

2 3 17 4 5 6 7

8 9 10 11 12 13

15 16

12345-

Set Screw Cam Bushing (2 Used) Holder Oil Seal (2 Used)

678910 -

O-Ring (2 Used) Bushing (2 Used) Pusher (2 Used) Spring Guide (2 Used) Balance Spring (2 Used)

11 12 13 14 15 -

W2-6-32

Shim (Several) Spacer (2 Used) Spring (2 Used) Spool (2 Used) Casing

W183-02-07-004

16 - Cap (4 Used) 17 - Pin 18 - Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve Disassemble Pilot valve for Bucket Opening / Closing 1. With a vice hold casing (15), remove set screw (1). Ď&#x2013; 5 mm 2. With an adapter bar and a hammer, pull out pin (17) and remove cam (2) at the same time. 3. Remove socket bolts (18) (2 used) to remove holder (4) from casing (15). Ď&#x2013; 6 mm 4. Pull out pusher (8) from casing (15) (2 places). At this moment, bushing (7) and oil seal (5) are on the pusher. 5. Pull out pusher (8) from bushing (7) and remove oil seal (5) with a bamboo spatula. (2 places) IMPORTANT: Keep the two spools with marks on, so that they will be installed easily to the holes where they were. 6. Pull out the spool (14) assembly from casing (15) while turning it. (2 places) Spring guide (9), balance spring (10), shim (11) and spacer (12) are all on the spool. NOTE: As the casing and the spool are precision parts specially made to fit each other, they must be replaced as a set. IMPORTANT: The number of shims is determined during the performance test before delivered, therefore keep the shims together with each spool. 7. Compress balance spring (10) to remove spring guide (9), balance spring (10), shim (11) and spacer (12) from spool (14). (2 places)

W2-6-33

8. Remove spring (13) from casing (15). (2 places)

UPPERSTRUCTURE / Pilot Valve ASSEMBLE PILOT VALVE FOR BUCKET OPENING / CLOSING

2 1 8

7 4 9

10 15

11,12

W183-02-07-001

12345-

Set Screw Cam Bushing (2 Used) Holder Oil Seal (2 Used)

678910 -

O-Ring (2 Used) Bushing (2 Used) Pusher (2 Used) Spring Guide (2 Used) Balance Spring (2 Used)

11 12 13 14 15 -

W2-6-34

Shim (Several) Spacer (2 Used) Spring (2 Used) Spool (2 Used) Casing

16 - Cap (4 Used) 17 - Pin 18 - Socket Bolt (2 Used)

UPPERSTRUCTURE / Pilot Valve Assemble Pilot Valve for Bucket Opening / Closing IMPORTANT: Install spring guide (9) with the stepped part facing the spring.

8. In case bushings (3) (2 used) were removed from holder (4). Install the bushings into the holder as follows using special tool (ST 7131).

IMPORTANT: Place shims by same number that they were disassembled.

NOTE: Both bushings are same parts. ОInsert bushing into special tool (ST 7131) and place special tool (ST 7131) into holder (4) while tapping with a hammer. Stop tapping as the bottom of the bushing is flush with the top surface of holder (4).

1. Insert spacers (12) (2 used), shim (11) and balance springs (10) (2 used) in order onto spools (14) (2 used).

ST 7131

2. Install spring guides (9) (2 used) onto spools (14) (2 used) with the stepped part facing the spring while compressing the balance spring by hand.

4 3

3. Insert spring (13) into casing (15). (2 places)

W183-02-07-003

IMPORTANT: Insert the spool (14) assembly into the port where it was removed. 4. Insert the spool (14) assembly into casing (15) while turning it. (2 places) 5. Place oil seals (5) (2 used) to bushings (7) (2 used) with their inner periphery being applied with grease. 6. Place O-ring (6) onto bushings (7) (2 used) and insert pushers (8) (2 used) with the head of the pusher being applied with grease.

О Install bushing on the opposite by same way.

9. Install holder (4) on the casing (15) assembly and secure it with socket bolts (18) (2 used) ϖ 6 mm ϖ 20 N]m(2 kgf]m, 14.5 Ibf]ft) Ȁ 10. Align the pin holes in cam (2) and holder (4) and install pin (17) while tapping it with a hammer. 11. Install set screw (1).

7. Insert the pusher (8) assembly into holder (4). (2 places)

W2-6-35

ϖ 5 mm ϖ 12 N]m(1.2 kgf]m, 8.7 Ibf]ft)

UPPERSTRUCTURE / Pilot Valve (Blank)

W2-6-36

UPPERSTRUCTURE / Pilot Shut-off Valve REMOVE AND INSTALL PILOT SHUT-OFF VALVE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2.

W183-04-02-003

W183-04-02-002

Wooden Blocks

Ď&#x2013; 4 mm Cap

3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank. NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W2-7-1

UPPERSTRUCTURE / Pilot Shut-off Valve Removal 1. Remove spring (3). IMPORTANT: Attach tags to hoses to aid in assembly. 1

2. Disconnect hoses (6 to 13) and pipes (14,15). ϖ19 mm

2 3 5

3. Remove spring pin (5) to remove lever (1).

4. Remove bolt (2) to remove pilot shut-off valve (4). ϖ17 mm

W178-02-08-001

Installation 1. Install pilot shut-off valve (4) with bolt (2).

12 11

2. Install lever (1) with spring pin (5). 3. Connect hoses (6 to 13) and pipes (14,15).

6 10

4. Install spring (3). Wrench Size (mm)

Tightening Torqne Ibf⋅ft

Remark

N⋅m

(kgf⋅m)

ϖ 17

(5)

Bolt

ϖ 19

(3)

21.5

Hose, Pilot

7 8 9

678910 11 12 13 14 15 -

W2-7-2

Hose T4 Hose A4 Hose A5 Hose P Hose T3 Hose A3 Hose P1 Hose T2 Hose T4 Hose T1

: (To the oil tank) : (To the signal control valve) : (To the signal control valve) : (To 3-pool solenoid valve) : (To the right pilot valve) : (To the right pilot valve) : (To the travel pilot valve) : (To the left pilot valve) : (To the left pilot valve) : (To the travel pilot valve)

W183-02-07-007

UPPERSTRUCTURE / Pilot Shut-off Valve (Blank)

W2-7-3

UPPERSTRUCTURE / Pilot Shut-off Valve DISASSEMBLE PILOT SHUT-OFF VALVE 5

8 9

10 11

W178-02-08-005

1234-

Washer Backup Ring O-Ring Body

5678-

Socket Bolt Retaining Ring Washer Backup Ring

910 11 12 -

W2-7-4

O-Ring Spool Bracket Pin

13 - Socket Bolt

UPPERSTRUCTURE / Pilot Shut-off Valve Disassemble Pilot Shut-Off Valve • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting any repair work. 1. Make matching marks on body (4) and bracket (11). Remove retaining ring (6), washer (7), backup ring (8) and O-ring (9) from body (4) to remove the spool (10) assembly. 2. Remove washer (1), backup ring (2) and O-ring (3) from body (4). 3. Clamp the spool (10) with wooden spatula in a vise. Remove socket bolt (13) and bracket (11). ϖ 4 mm NOTE: Don’t remove pin (12) unless necessary. 4. Remove socket bolt (5) from body (4). ϖ 8 mm

W2-7-5

UPPERSTRUCTURE / Pilot Shut-off Valve ASSEMBLE PILOT SHUT-OFF VALVE

12 13 11

Section Z-Z 10

W178-02-08-006

1 11

T178-03-07-002

1234-

Washer Backup Ring O-Ring Body

5678-

Socket Bolt Retaining Ring Washer Backup Ring

910 11 12 -

W2-7-6

O-Ring Spool Bracket Pin

13 - Socket Bolt

UPPERSTRUCTURE / Pilot Shut-off Valve Assemble Pilot Shut-Off Valve 1. Apply LOCTITE # 262 on socket bolt (5) and install it to body (4). ϖ8 mm ϖ29.4 N⋅m (3.0 kgf⋅m, 21.5 Ibf ⋅ft) 2. Clamp spool (10) with wooden spatula in a vise. Apply LOCTITE # 262 on socket bolt (13), then install bracket (11) on to spool (10). ϖ4 mm ϖ3.9 N⋅m (0.4 kgf⋅m, 2.9 Ibf ⋅ft) 3. Install O-ring (3), backup ring (2) and washer (1) on to body (4). 4. Apply hydraulic oil to spool (10) and install it to body (4). 5. Install O-ring (9), backup ring (8) and washer (7) to body (4), and install retaining ring (6) to spool (10).

W2-7-7

UPPERSTRUCTURE / Pilot Shut-off Valve (Blank)

W2-7-8

UPPERSTRUCTURE / Shockless Valve REMOVE AND INSTALL FRONT ATTACHMENT SHOCKLESSӸ ӸVALVE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2.

W183-04-02-003

W183-04-02-002

Wooden Blocks

ϖ 4 mm

Cap

W183-01-01-001

W2-8-1

UPPERSTRUCTURE / Shockless Valve Removal IMPORTANT: Attach identification tags to hoses to aid reassembly.

For the Boom Lower Pilot Operation Circuit 1

1. Disconnect hoses (1 to 4)

Front Side

ϖ 19 mm 2. Remove bolts (5) (2 used) to remove the shackless valve.

ϖ 13 mm W183-02-09-001

Installation

For Pi Pressure Circuit of Pump 2 Regulator

1. Install the shackless valve with bolts (5) (2 used). ϖ 13 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

Front Side

2. Connect hoses (1 to 4).

ϖ 19 mm ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

T183-05-04-026

1234-

W2-8-2

Hose F80 Hose F90 Hose DH Hose PA

:(To the boom lower spool and holding valve selector valve) :(From the pilot valve) :(To the pi port of pump 2 regulator) :(From the pilot valve)

UPPERSTRUCTURE / Shockless Valve DISASSEMBLE AND SHOCKLESS VALVE

ASSEMBLE

THE

(For the Boom Lower Pilot Operation Circuit and Pi Pressure Circuit of Pump 2 Regulator) 4

3 T183-03-07-008

Item

Part Name

Q’ty

Plug

O-Ring

Body

Spring

Plunger

Ring

Orifice

Wrench Size (mm) : 8

W2-8-3

Tightening Torque N⋅⋅ m

(kgf⋅⋅ m) (Ibf⋅⋅ ft)

(4) (29)

Remarks

UPPERSTRUCTURE / Shockless Valve (Blank)

W2-8-4

UPPERSTRUCTURE / Solenoid Valve REMOVE AND INSTALL SOLENOID VALVE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground.

W183-04-02-003

W183-04-02-002

Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

Cap

NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W2-9-1

UPPERSTRUCTURE / Solenoid Valve

Solenoid Valve Unit

12 11

2 3

2-Spool EHC Valve

9 8 4 7

5 W183-02-10-001

1 - Bolt (2 Used)

4 - Bolt (2 Used)

2 - Booster Solenoid Valve (ST) 3 - Control Solenoid Valve for Oil Cooler Fan (SF)

5 - Bolt (4 Used) 6 - Solenoid Valve for Switching 2-Speed Travel

7 - Solenoid valve for Heavy Lift 8 - Solenoid Valve Flow Rate Reducing 9 - Socket Bolt (4 Used)

W2-9-2

10 - Power Decreasing Solenoid Valve (SA) 11 - Power Decreasing Solenoid Valve (SB) 12 - Solenoid Valve for Boom Mode Selector (SC)

UPPERSTRUCTURE / Solenoid Valve Removal IMPORTANT: Attach tags to the disconnected pipes and hoses for easier reassembly. 1. Disconnect all pipes and electrical cables from each solenoid valve.

Wrench Size (mm)

Tightening Torque

Remarks

N]m

(kgf]m)

Ibf]ft

: 19

29.5

(3)

21.5

Hose

: 22

(4)

Hose

: 27

(6)

Hose

2. Remove bolts (1) (2 used), (4) (2 used), (5) (4 used) and socket bolts (9) (4 used) to remove each solenoid valves. ϖ 13 mm ϖ 20 N]m(2 kgf]m, 14.5 Ibf]ft) ϖ 17 mm ϖ 50 N]m(5.1 kgf]m, 37 Ibf]ft) ϖ 4 mm ϖ 7 N]m(0.7 kgf]m, 5.1 Ibf]ft) Installation NOTE: As for the wrench sizes and tightening torque, refer to Removal Section. 1. Install each solenoid valves with bolts (1) (2 used), (4) (2 used), (5) (4 used) and socket bolts (9) (4 used). Ȁ 2. Connect all pipes and electrical cables to each valve.

W2-9-3

UPPERSTRUCTURE / Solenoid Valve DISASSEMBLE 2-SPOOL EHC VALVE (BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN) 1 3

4 5 6 7 8 9 10 11

14 13

15 16

18 19

W157-02-11-016

12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

Solenoid Spring O-Ring Diaphragm Spool

11 12 13 14 15 -

W2-9-4

Orifice Washer Spring O-Ring O-Ring

16 17 18 19 -

O-Ring Sleeve Plate Washer

UPPERSTRUCTURE / Solenoid Valve Disassemble 2-Spool EHC Valve (Boost Solenoid Valve, Control Solenoid Valve for Oil Cooler Fan) IMPORTANT: Take care not lose spring (7) provided in the groove of solenoid (6) when removing solenoid (6). Don’t turn lock nut (2) and adjusting screw (4). 1. Loosen socket bolts (1) to remove solenoid (6). ϖ 3 mm IMPORTANT: Don’t disassemble orifice (11) provided on spool (10). 2. Pull out spool (10) and remove diaphragm (9), washer (12) and spring (13). 3. Pull sleeve (17) out and remove O-rings (14, 15, 16), washer (19) and plate (18). 4. Disassemble the other solenoid valve according to procedures 1 to 3.

W2-9-5

UPPERSTRUCTURE / Solenoid Valve ASSEMBLE 2-SPOOL EHC VALVE (BOOST SOLENOID VALVE, CONTROL SOLENOID VALVE FOR OIL COOLER FAN)

10 16

W157-02-11-001

12345-

Socket Bolt (2 Used) Lock Nut O-Ring Adjusting Screw Spring

678910 -

Solenoid Spring O-Ring Diaphragm Spool

11 12 13 14 15 -

W2-9-6

Orifice Washer Spring O-Ring O-Ring

16 17 18 19 -

O-Ring Sleeve Plate Washer

UPPERSTRUCTURE / Solenoid Valve Assemble 2-spool EHC valve (Boost Solenoid Valve, Control Solenoid Valve for Oil Cooler Fan)

17 16 15

IMPOTRANT: Apply grease to O-rings (14, 15 and 16) and apply a film of hydraulic oil to sleeve (17).

1. Install washer (19), plate (18) into the housing. Install O-rings (14, 15, 16) on sleeve (17), then insert it into the housing.

Housing W157-02-11-005

IMPORTANT: Take care not to damage the edge portion in the bore of sleeve (17), then insert it into the housing. After inserting spool, check that spool (10) slides in and out smoothly without any restriction about 3 to 5 mm (0.12 to 0.20 in). Apply hydraulic oil to the spool.

17 13 12

Housing W157-02-11-009

2. Install diaphragm (9), washer (12), spring (13) to spool (10). Install spool (10) into sleeve (17).

IMPORTANT: Lock nut (2), adjusting screw (4), spring (5), O-ring (3) are not separated, so no need to assemble them. When assembling solenoid (6), take care not to drop spring (7).

W157-02-11-010

3. Install solenoid (6) with bolt (1). 7

ϖ 3 mm ϖ 2.9 N]m (0.3 kgf]m, 2.2 Ibf]ft)

1 W157-02-11-011

CONFIGURATION OF SOLENOID VLAVE W2-9-7

UPPERSTRUCTURE / Solenoid Valve Solenoid Valve Unit Power Decreasing Valve

Boom Mode Selector Solenoid Valve

21 22 23

Power Decreasing Valve

19 Pilot Relief Valve

18 17

1 2

3 15

4 5

13 12 7 8 11

T183-03-07-003

Item

Parts Name

Q’ty

Plug

Shim

Wrench Tightening Torque Size (mm) Nxm (kgfxm) Ibfxft 22

(5)

Item

Parts Name

Q’ty

O-Ring

Rod

Spring

O-Ring

Stopper

Valve Assembly

Plunger

Gasket

Screw

Spool

Coil Assembly

Casing

Spring

Spool Assembly

Spring Seat

Spring

Pipe

O-Ring

Housing

O-Ring

Spacer

NOTE: Shim (2) is used to adjust pressure.

W2-9-8

Wrench Size (mm)

Tightening Torque Nxm (kgfxm) Ibfxft

29.5

(3)

21.5

UPPERSTRUCTURE / Solenoid Valve Flow Rate Reducing Solenoid Valve 1

Parts Name 123456789-

Socket Bolt Plug O-Ring Spring Cam Ring Spool Casing Spring Seat Solenoid

Q’ty 4 1 2 2 4 1 1 2 1

Wrench Size Ѕ 4 mm

W2-9-9

9 Tightening Torque NĊm (kgfĊm) (Ibfxft) 7 (0.7) (5.1) 49 (5) (36)

W117-02-07-004

UPPERSTRUCTURE / Solenoid Valve Heavy Lift Solenoid. 2- Speed Shift Solenoid for Travel

18 1

17 16

2 15

14 4 13

8 9

W140-02-11-002

Part Name 123456789101112131415161718-

Screw Coil Spacer Housing O-Ring Pipe Seat Spring Housing Spring O-Ring O-Ring O-Ring Body Spool Rod Stopper Plunger

Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Wrench Size Ѕ32 mm

W2-9-10

NĊm 34.3

Tightening Torque (kgfĊm) Ibfxft (3.5) 25.5

UPPERSTRUCTURE / Signal Control Valve REMOVE AND INSTALL SIGNAL CONTROL VALVE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2. Ď&#x2013; 4 mm

W183-04-02-003

W183-04-02-002

Wooden Blocks Cap

W183-01-01-001

W2-10-1

UPPERSTRUCTURE / Signal Control Valve Removal IMPORTANT: Attach tags to hoses and pipes to aid in assembly. Pilot Valve Side

NOTE: When removing pipe of signal control valve, if a SNAP-ON TOOL (GAN850812B: tool size: 19.05 mm) is used, it may be easier to remove the pipe. 1. Disconnect all hoses and pipes from each port. 2. Remove the pressure sensors (swing, travel).

PH A M

D H F

SB G N

3. Remove bolt (20) to remove the signal control valve. : 17 mm

Pilot Valve Side

K SH

Installation 1. Apply LOCTITE to bolt (20) and install the signal control valve.

2. Connect all hoses and pipes to each port.

3. Install the pressure sensors (swing, travel). Wrench size (mm) : 17

Tightening Torque N] ]m

(kgf] ]m)

(Ibf] ]ft) (18)

L Control Valve Side

20 W183-02-11-001

3 5

1 13 2 SK 7 14

Remark

2.5

: 17

5.1

: 19

29.5

(21.5)

Hose

: 24

1.6

(11.5)

Pressure sensor

(37)

I J DF

Hose, pipe Bolt

4 SE 8 6

Pressure Sensor (Swing)

Control Valve Section

SN 11

10 SL Pressure Sensor (Travel)

W2-10-2

W183-02-11-002

UPPERSTRUCTURE / Signal Control Valve PILOT PORT Pilot Valve Side NOTE: BH: Backhoe LD: Loading Shovel Port Name Connected To Port A Right Pilot Valve Port B Right Pilot Valve Port C Left Pilot Valve Port D Port E Port F

Right Pilot Valve Hydraulic Oil Tank Left Pilot Valve

Port G

Left Pilot Valve

Port H Port I Port J Port K Port L Port M

Right Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Travel Pilot Valve Auxiliary Pilot Valve (BH) Bucket Close Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD)

Port N Port SA Port SB Port PI Port PH Port SH Port DF

Pump 1 and 2 Regulator − Pilot Shut-Off Valve Pilot Shut-Off Valve − Hydraulic Oil Tank

W2-10-3

Remark Boom Raise Pilot Pressure Boom Lower, Bucket Roll-Out Pilot Pressure Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Boom Raise Pilot Pressure Returning to Hydraulic Oil Tank Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Forward Pilot Pressure Auxiliary Pilot Valve (BH) Bucket Close Pilot Valve (LD) Auxiliary Pilot Valve (BH) Bucket Open Pilot Valve (LD) Pump 1 and 2 Control Pressure Plug Primary Pilot Pressure Primary Pilot Pressure (Heat Circuit) Plug Returning to Hydraulic Oil Tank

UPPERSTRUCTURE / Signal Control Valve Control Valve Side SM

Control Valve Side 3 5

1 13 2 SK 7 14

4 SE 8 6

Pressure Sensor (Swing)

9 Control Valve Section

SN 11

10 SL Pressure Sensor (Travel)

NOTE: BH: Backhoe LD: Loading Shovel Port Name Connected To Port 1 Control Valve Port 2 − Port 3 − Port 4 − Port 5 − Port 6 Control Valve Port 7

Control Valve

Port 8 Port 9 Port 10 Port 11 Port 12 Port 13

Control Valve Control Valve Control Valve Control Valve Control Valve Control Valve

Port 14

Control Valve

Port SE Port SM Port SN Port SP Port SL Port SK

Shuttle Valve Shuttle Valve Shuttle Valve Shuttle Valve Control Valve −

Remark Boom Raise Pilot Pressure Plug Plug Plug Plug Arm Roll-Out Pilot Pressure (BH) Arm Roll-In Pilot Pressure (LD) Arm Roll-In Pilot Pressure (BH) Arm Roll-Out Pilot Pressure (LD) Bucket Roll-In Pilot Pressure Left Travel Forward Pilot Pressure Left Travel Reverse Pilot Pressure Right Travel Forward Pilot Pressure Right Travel Reverse Pilot Pressure Auxiliary Close Pilot Pressure (BH) Bucket Close Pilot Pressure (LD) Auxiliary Open Pilot Pressure (BH) Bucket Open Pilot Pressure (LD) Boom Raise Priority Pilot Pressure Auxiliary Swing Brake Release Swing Brake Release Combiner Valve Shifting Pressure Plug

W2-10-4

W183-02-11-002

UPPERSTRUCTURE / Oil Cooler Fan Motor REMOVE AND INSTALL OIL COOLER FAN MOTOR CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2.

W183-04-02-003

W183-04-02-002

Wooden Blocks

Ď&#x2013; 4 mm Cap

W183-01-01-001

W2-11-1

UPPERSTRUCTURE / Oil Cooler Fan Motor Removal 1. Disconnect all hoses (1, 2, and 3) from oil cooler fan motor (4). Wrench Size (mm) ϖ 27 mm ϖ 8 mm

Tightening Torque N⋅m (kgf⋅m) Ibf⋅ft 118 (12) 87 50 (5.1) 37

Remarks

1 4

Hose (1) Hose(2, 3)

CAUTION: Fan weight: 22 kg (50 Ib)

2. Remove bolt (7) to remove fan (6) from oil cooler fan motor (4). ϖ 19 mm ϖ 90 N]m (9.2 kgf]m, 67 Ibf]ft) W183-02-11-003

CAUTION: Oil cooler fan motor weight: 24 kg (50 Ib) 3. Remove oil cooler fan motor mounting bolts (5) to remove oil cooler fan motor (4) from bracket (8). ϖ 19 mm ϖ 90 N]m (9.2 kgf]m, 67 Ibf]ft) A

Installation

NOTE: Refer to the Removal section for wrench size and tightening torque. 1. Install oil cooler fan motor (4) to bracket (8) with mounting bolts (5) (4 used). 2. Install fan (6) to oil cooler fan motor (4) with bolt (7).

W183-02-11-004

3. Reconnect hoses (2 and 3) to oil cooler fan motor (4).

4. Fill hydraulic oil in via the hole of hose (1). Connect hose (1). 5. Start the engine and slowly loosen hose (1). Bleed the air until only hydraulic oil comes out.

8 Section A-A

W2-11-2

W183-02-11-005

UPPERSTRUCTURE / Oil Cooler Fan Motor (Blank)

W2-11-3

UPPERSTRUCTURE / Oil Cooler Fan Motor DISASSEMBLE OIL COOLER FAN MOTOR 1 2 3 4 5 6 7

16 17 10 11 13

14 18

15 20

21 22 23 24 25 26 27 29

30 W118-02-09-001

31 12345678-

Housing O-Ring Cover Valve Block Socket Bolt (6 Used) Plug Knock Pin Washer (6 Used)

910 11 12 13 14 15 16 -

Socket Bolt (6 Used) Plate Cylinder Block Shim Spring Seat Disc Spring (4 Used) Center Pin Piston Ring (14 Used)

17 18 19 20 21 22 23 24 -

Plunger (7 Used) Screw (7 Used) Plate Shim Shaft Key Bearing Case

W2-11-4

25 26 27 28 29 30 31 -

Bearing Nut Shim (2 Used) O-Ring Oil Seal Seal Case Retaining Ring

UPPERSTRUCTURE / Oil Cooler Fan Motor Disassemble Oil Cooler Fan Motor • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W11-1 before starting the disassmbly work.

7. Remove piston rings (16) (14 used) from plungers (17) (7 used). Remove shim (12), spring seat (13) and disc springs (14) (4 used) from cylinder block (11).

1. Remove plug (6) to drain hydraulic oil from the motor. ϖ10 mm 2. Remove key (22) from shaft (21). Remove socket bolts (5) (6 used) to remove valve block (4) from cover (3). ϖ5 mm IMPORTANT: Take care not to drop plate (10) when removing cover (3). 3. Remove socket bolts (9) (6 used) to remove cover (3), knock pin (7), O-ring (2) and plate (10). ϖ5 mm 4. Remove retaining ring (31) from housing (1). Remove the shaft (21) assembly from housing (1) with a puller. 5. Remove seal case (30), oil seal (29), O-ring (28) and shims (27) from the shaft (21) assembly. IMPORTANT: Do not remove bearings (25 and 23) unless necessary. They must be replaced with new ones if they are removed. 6. Remove screws (18) (7 used) to remove plate (19), center pin (15), plungers (17) (7 used) and cylinder block (11) from shaft (21).

W2-11-5

UPPERSTRUCTURE / Oil Cooler Fan Motor ASSEMBLE OIL COOLER FAN MOTOR

26 28 25 24

20 19

22 1 2 3

31 27

11 12345678-

Housing O-Ring Cover Valve Block Socket Bolt (6 Used) Plug Knock Pin Washer (6 Used)

910 11 12 13 14 15 16 -

Socket Bolt (6 Used) Plate Cylinder Block Shim Spring Seat Disc Spring (4 Used) Center Pin Piston Ring (14 Used)

17 18 19 20 21 22 23 24 -

8, 9

Plunger (7 Used) Screw (7 Used) Plate Shim Shaft Key Bearing Case

W2-11-6

7 25 26 27 28 29 30 31 -

10 Bearing Nut Shim (2 Used) O-Ring Oil Seal Seal Case Retaining Ring

W183-02-11-006

UPPERSTRUCTURE / Oil Cooler Fan Motor Assembling Oil Cooler Fan Motor NOTE: Refer to the illustration for parts (4, 5, 12 to 14, 16 and 18).

8. Install plug (6) into housing (1).

1. Install piston rings (16) (14 used) onto plungers (17) (7 used). Install shim (12), spring seat (13) and disc springs (14) (4 used) into cylinder block (11). After inserting center pin (15) and plungers (17) (7 used) into plate (19), install them into cylinder block (11). 2. Install shim (20) and plate (19) to shaft (21) with screws (18) (7 used).

3. Install the shaft (21) assembly in housing (1). 4. Install shims (27), O-ring (28), oil seal (29), seal case (30) and retaining ring (31) onto shaft (21). 5. Install key (22) on shaft (21). 6. Install plate (10), knock pin (7), and O-ring (2) to cover (3). Secure cover (3) with socket bolts (9) (6 used). ϖ 5 mm ϖ12 N]m (1.2 kgf]m, 8.7 Ibf]ft) 7. Install valve block (4) to cover (3) with socket bolts (5) (6 used). ϖ 5 mm ϖ12 N]m (1.2 kgf]m, 8.7 Ibf]ft)

W2-11-7

ϖ 10 mm ϖ 59 to 76 N]m (6 to 7.8 kgf]m, 43 to 56 Ibf]ft)

UPPERSTRUCTURE / Oil Cooler Fan Motor (Blank)

W2-11-8

SECTION 3

UNDERCARRIAGE CONTENTS Group 1 Swing Bearing

Group 6 Upper and Lower Roller

Remove and Install Swing Bearing ......... W3-1-1 Disassemble Swing Bearing ................... W3-1-4 Assemble Swing Bearing ........................ W3-1-6

Group 2 Travel Device Remove and Install Travel Device .......... W3-2-1 Disassemble Travel Reducer.................. W3-2-4 Assemble Travel Reducer .................... W3-2-10 Disassemble Travel Motor .................... W3-2-18 Assemble Travel Motor......................... W3-2-22 Disassemble Travel Brake Valve .......... W3-2-26 Assemble Travel Brake Valve ............... W3-2-30 Maintenance Standard ......................... W3-2-32

Remove and Install Upper Roller ............ W3-6-1 Remove and Install Lower Roller ............ W3-6-3 Disassemble Upper Roller ...................... W3-6-6 Assemble Upper Roller........................... W3-6-8 Disassemble Lower Roller .................... W3-6-10 Assemble Lower Roller......................... W3-6-12 Maintenance Standard ......................... W3-6-14

Group 7 Track Remove and Install Tracks ..................... W3-7-1 Maintenance Standard ........................... W3-7-7

Group 3 Center Joint Remove and Install Center Joint............. W3-3-1 Disassemble Center Joint....................... W3-3-4 Assemble Center Joint ........................... W3-3-6 Maintenance Standard ......................... W3-3-10

Group 4 Track Adjuster Remove and Install Track Adjuster ......... W3-4-1 Disassemble Track Adjuster ................... W3-4-2 Assemble Track Adjuster........................ W3-4-8

Group 5 Front Idler Remove and Install Front Idler................ W3-5-1 Disassemble Front Idler ......................... W3-5-2 Assemble Front Idler .............................. W3-5-6 Maintenance Standard ........................... W3-5-8

183W-3-1

(Blank)

183W-3-2

UNDERCARRIAGE / Swing Bearing REMOVE AND INSTALL SWING BEARING Before removing the swing bearing, the uppersturcture must be removed first. For removal and installation of the upperstructure, refer to “Remove and Install Front Attachment” section and “Remove and Install Counterweight” section. In this section, the procedure starts on the premise that the upperstructure has already been removed.

Matching Marks

Removal 1. Put matching marks on swing bearing inner race (1) and track frame (2).

W142-03-01-001

2. Disconnect all lubrication hoses (4 used) to the swing bearing. ϖ 17 mm 3. Remove swing bearing inner race mounting bolts (3) (50 used). ϖ 55 mm W105-03-01-002

CAUTION: Swing bearing weight: 1710 kg (3770 Ib)

ST 9050

4. Attach lifting tool (ST 9050) to the 3 lift holes in swing bearing (4) to hoist and remove swing bearing (4).

W3-1-1

W105-03-01-003

UNDERCARRIAGE / Swing Bearing Installation Clean the track frame and the swing bearing mating surfaces. 1. Apply THREEBOND #1102 to the swing bearing mounting surface on the track frame. CAUTION: Swing bearing weight: 1710 kg (3770 Ib) IMPORTANT: Be sure to align the matching marks. Otherwise, the inner race soft zone will be in the incorrect position.

W105-03-01-003

Front Side

2. Install special tool (ST 9050) to swing bearing (4) and hoist the swing bearing by a crane. Align the swing bearing with the track frame using the matching marks during disassembly.

Soft Zone Position (Inner Race)

Plug Position Soft Zone Position (Outer Race)

3. Tighten swing bearing mounting bolts (3) (50 used). ϖ 55 mm ϖ 2450 N⋅m (250 kgf⋅m, 1810 Ibf⋅ft)

Greasing Hole Positions (4 Places)

W105-03-01-005

4. Re-connect lubrication hoses (4 used) to the swing bearing. ϖ 17 mm ϖ 49 N⋅m (5 kgf⋅m, 36 Ibf⋅ft)

W105-03-01-002

W3-1-2

UNDERCARRIAGE / Swing Bearing (Blank)

W3-1-3

UNDERCARRIAGE / Swing Bearing DISASSEMBLE SWING BEARING 2

10,11

W166-03-01-001

6 7 8

5 10

W111-03-01-008

1 - Outer Race 2 - Seal 3 - Pin

4 - Plug 5 - Seal 6 - Ball (81 Used)

7 - Inner Race 8 - Support (81 Used) 9 - Bolt (50 Used)

W3-1-4

10 - Turn Buckle (3 Used) 11 - Rod (3 Used)

UNDERCARRIAGE / Swing Bearing Disassemble Swing Bearing • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W11-1 before starting the disassembly work.

1. Remove pin (3) located in plug (4) section by driving from the bottom side of the swing bearing. NOTE: Pin (3) head is crimped. Grind off the crimped part. 4

W105-03-01-007

2. Remove plug (4). NOTE: Screw bolt (M10, pitch 1.5) in the threaded hole in plug (4). Tap the bolt head from the bottom side or pull the bolt to remove the plug.

W105-03-01-008

CAUTION: Swing bearing weight: 1710 kg (3770 Ib)

3. Lift swing bearing outer race (1) horizontally slightly by a crane. Remove rods (11) (3 used) and turn buckles (10) (3 used) which fasten seal (5) to remove seals (2 and 5).

A 7

4. Place swing inner race (7) onto a wooden block. Hoist outer race (1) by a crane to strain the sling.

5. While rotating outer race (1), remove balls (6) (81 used) and supports (8) (81 used) from the plug hole. Use bar magnet (A) to take out balls. Use bent wire (B) to remove supports (8).

W3-1-5

W105-03-01-009

W105-03-01-010

UNDERCARRIAGE / Swing Bearing ASSEMBLE SWING BEARING 2

10,11

W166-03-01-001

6 7 8

5 10

W111-03-01-008

1 - Outer Race 2 - Seal 3 - Pin

4 - Plug 5 - Seal 6 - Ball (81 Used)

7 - Inner Race 8 - Support (81 Used) 9 - Bolt (50 Used)

W3-1-6

10 - Turn Buckle (3 Used) 11 - Rod (3 Used)

UNDERCARRIAGE / Swing Bearing Assemble Swing Bearing CAUTION: Swing bearing weight: 1710 kg (3770 Ib) 1. Before assembling the swing bearing inner race and outer race, completely remove any oil on the groove surfaces of seal (2). Then, apply THREEBOND #1735 to the groove and install seal (2). Install seal (5) in the groove on the inner race and fasten the seal with rods (11) and turn buckles (10). (tighten each turn buckle 10 to 15 turns evenly.)

6 5

IMPORTANT: Apply grease to balls (6) (81 used) and supports (8) (81 used). After installing all balls (6) and supports (8), confirm that the clearance between the ball and the support is 40± ±10 mm (1.57± ±0.39 in).

W142-03-01-005

40±10 mm (1.57±0.39 in)

8 W142-03-01-006 W142-03-01-004

Ȁ 2. Lift the outer race (1) by a crane horizontally and match it with the inner race coaxilally. Rotating the outer race, insert balls (6) (81 used), supports (8) (81 used) into the plug hole alternatively with a round bar.

3. Install plug (4) and pin (3) into outer race (1). Crimp the head of pin (3) with a punch. Sufficiently lubricate the swing bearing with grease (Alvania EP2 or equivalent). 4

W142-03-01-007

W3-1-7

UNDERCARRIAGE / Swing Bearing (Blank)

W3-1-8

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground.

W183-04-02-003

W183-04-02-002

Wooden Blocks

Ď&#x2013; 4 mm 3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

Cap

NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W3-2-1

UNDERCARRIAGE / Travel Device Removal The removal procedure starts on the premise that the tracks have been removed. Refer to page W3-7-1 for removal and installation of the track.

1. Remove bolts (7) (8 used) to remove cover (6). Disconnect hoses (2 to 5). Ȁ Bolt (7) ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft) Ȁ Hose (2 to 5) ϖ ϖ ϖ ϖ ϖ ϖ

22 mm 59 N⋅m (6 kgf⋅m, 43 Ibf⋅ft) 27 mm 118 N⋅m (12 kgf⋅m, 87 Ibf⋅ft) 10 mm 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

NOTE: Cap the disconnected hoses and pipes. 2. Attach a wire rope to the travel device hoisting. 6

CAUTION: Travel device weight: 1720 kg (3790 Ib)

W183-03-02-014

3. Remove bolts (1) (26 used) to remove the travel device by a crane. ϖ 41 mm ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf⋅ft) Installation NOTE: As for the wrench sizes and tightening torque, refer to Removal Section. 1. Install travel device with bolts (1) (26 used). 2. Connect hoses (2 to 5). 3. Install cover (6) with bolts (7) (8 used). IMPORTANT: Fill travel motor full of hydraulic oil after installation. In addition, be sure to perform a break-in operation in order to prevent the travel motor from burning out. Break-in Operation Conditions 1. Engine control dial: Min. speed 2. Travel motor switch: Low speed 3. Operation duration: Above 2 minutes

W3-2-2

W111-03-02-002

UNDERCARRIAGE / Travel Device (Blank)

W3-2-3

UNDERCARRIAGE / Travel Device 51

DISASSEMBLE TRAVEL REDUCER

11 12

22 24 33 32

35 45

48 50 12345678910 11 12 13 -

3-Stage Carrier 3-Stage Sun Gear Thrust Plate (8 Used) Needle Bearing (4 Used) 2-Stage Planetary Gear (4 Used) Spring Pin (4 Used) Pin (4 Used) Thrust Plate (6 Used) Needle Bearing (3 Used) 1-Stage Planetary Gear (3 Used) Spring Pin (3 Used) Pin (3 Used) O-Ring

W183-03-02-001

14 15 16 17 18 -

Ring Gear Cover Plug (3 Used) Bolts (26 Used) Spring Washer (26 Used)

27 28 29 30 31 -

Spacer 2-Stage Carrier Roller Bearing (8 Used) 3-Stage Planetary Gear (4 Used) Retaining Ring (4 Used)

40 41 42 43 44 -

Bolt (30 Used) Bolt (2 Used) Lock Plate Bearing Nut Roller Bearing

19 20 21 22 23 -

Socket Bolt (36 Used) Bearing Retaining Ring Seat Propeller Shaft

32 33 34 35 36 -

Spring Pin (4 Used) Pin (4 Used) Bolt (4 Used) Spring Washer (4 Used) Housing

45 46 47 48 49 -

Sprocket Drum Socket Bolt (18 Used) Floating Seal O-Ring

24 - Spacer 25 - 1-Stage carrier 26 - 2-Stage Sun Gear

37 - Support 38 - Roller Bearing 39 - Spring Washer (30 Used)

W3-2-4

50 - Motor 51 - Dummy Plug (2 Used) 52 - Dummy Plug

UNDERCARRIAGE / Travel Device Disassemble Travel Reducer • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

CAUTION: When the pressure is trapped inside the travel device, slowly loosen the air bleeding plug. Do not remove the drain plug to bleed the gear oil until the inside pressure has been completely released. Procede to loosen plug slowly as both plug and gear oil can cause injury by flying off,or spurting out. Be sure to keep your body and face away from the front of the plug.

CAUTION: Travel device weight (Excluding the motor):1590 kg (3510 Ib) 4. Hoist the travel device by a crane and place it on the work bench with cover (15) facing up.

CAUTION: Cover (15) weight: 76 kg (170 Ib) 5. Remove dummy plugs (51) (2 used) and bolts (17) (26 used) to install the eyebolts (M14, Pitch 2) into the two sling holes in cover (15). Hoist cover (15) and remove it from ring gear (14). ϖ 22 mm 6. Remove socket bolts (19) (36 used) from ring gear (14). ϖ 17 mm

CAUTION: Travel device weight: 1720 kg (3790 Ib) 1. Loosen the air bleeding plug (16-A) by 2 to 3 turns and remove drain plug (16-B) to bleed the gear oil from the travel device. Place travel device on the work bench with motor (50) side facing up. ϖ 17 mm

CAUTION: Ring gear (14) weight: 240 kg (530 Ib) 7. Install eyebolts (M14, Pitch 2) into the holes for bolt (17) of ring gear (14) and hoist ring gear by a crane to remove it. 8. Remove O-ring (13) and propeller shaft (23) from drum (46).

16-A

CAUTION:

16-B W111-03-02-006

2. Install eyebolts (M12, Pitch 1.75) into the three sling holes in motor (50) and attach a wire.

1-Stage carrier (25) weight: 90 kg (200 Ib)

assmebly

9. Install eyebolts (M12, Pitch 1.75) into the three sling holes in the 1-stage carrier (25) assembly. Hoist the assembly and remove it from 2-stage carrier (28). 10. Remove 2-stage sun gear (26) from 2-stage carrier (28).

CAUTION: Motor (50) weight: 130 kg (290 Ib) 3. Remove bolts (34) (4 used) to hoist motor (50) by a crane for removal. Remove O-ring (49) from motor (50). ϖ 27 mm

W3-2-5

UNDERCARRIAGE / Travel Device

2 19

W183-03-02-001

W3-2-6

UNDERCARRIAGE / Travel Device CAUTION:

2-Stage carrier (28) weight: 95 kg (210 Ib)

assembly

11. Install eyebolts (M12, Pitch 1.75) into the two sling holes in the 2-stage carrier (28) assembly. Hoist the assembly to remove it from 3-stage carrier (1).

CAUTION: 3-Stage carrier (2) weight: 30 kg (70 Ib) 12. Attach a nylon sling to the gear part of 3-stage sun gear (2) (2 places). Hoist the gear to remove it from 3-stage carrier (1).

CAUTION: 3-Stage carrier (1) assembly weight: 210 kg (460 Ib)

CAUTION: Drum (46) + sprocket (45) + the others weight: 560 kg (1230 Ib) 16. Install eyebolts (M22, Pitch 2.5) into the holes for socket bolts (19) of drum (46). Hoist drum (46) to remove it from housing (36). At this moment, the drum section is connected with the outer race of roller bearing (38) and roller bearing (44). 17. Remove floating seal (48) from housing (36) and support (37) respectively. 18. Remove the inner race of roller bearing (44) from drum (46). 19. Remove dummy plugs (52) (2 used) from sprocket (45). Remove bolts (40) (30 used) from sprocket (45).

13. Install eyebolts (M12, Pitch 1.75) into the two sling holes in the 3-stage carrier (1) assembly. Hoist the assembly to remove it. 14. Remove bolts (41) (2 used) to remove lock plate (42) from bearing nut (43). ϖ 22 mm

CAUTION: Sprocket (45) weight: 210 kg (460 Ib) 20. Screw puller bolts (M27, Pitch 3, L 70 mm ) into the two pulling holes in sprocket (45) and make sprocket (45) separate from drum (46) slowly.

15. Install jig (ST 3142) to bearing nut (43). Loosen and remove bearing nut (43) from housing (36). ST 3142

NOTE: Apply adhesive on the interface of sprocket and drum. ϖ 41 mm

21. Install eyebolts (M27, Pitch 3) into the two sling holes in sprocket (45). Hoist sprocket (45) to remove it from drum (46). ϖ 41 mm

CAUTION: Drum (46)+the others weight: 290 kg (640 Ib)

W111-03-02-018

22. Hoist drum (46) to reverse it. 23. Remove socket bolts (47) (18 used) to remove support (37) from drum (46). ϖ 10 mm

W3-2-7

UNDERCARRIAGE / Travel Device

11 12

1 7

24 25 33 32

W183-03-02-001

W3-2-8

UNDERCARRIAGE / Travel Device 24. Remove the outer race of roller bearing (38) from drum (46). 25. Remove spacers (24 and 27) from 1-stage carrier (25) and 2-stage carrier (28) respectively. 26. Push out spring pins (32) (4 used) with a round bar from 3-stage carrier (1).

CAUTION: 1-Stage carrier (25) assembly weight: 90 kg (200 Ib) 33. Pull out pins (12) (3 used) from 1-stage carrier (25) to remove 1-stage planetary gears (10) (3 used). 34. Remove thrust plates (8) (6 used) needle bearings (9) (3 used) from 1-stage planetary gears (10) (3 used) respectively.

: 8 mm

CAUTION: 3-Stage carrier (1) assembly weight: 210 kg (460 Ib) 27. Pull out pin (33) (4 used) from 3-stage carrier (1) to remove 3-stage planetary gears (30) (4 used). 28. Remove roller bearings (29) (8 used) and retaining rings (31) (4 used) from 3-stage planetary gears (30) (4 used) respectively. 29. Push out spring pins (6) (4 used) from 2-stage carrier (28) with a round bar. : 6 mm

CAUTION: 2-Stage carrier (28) assembly weight: 95 kg (210 Ib) 30. Pull out pins (7) (4 used) from 2-stage carrier (28) to remove 2-stage planetary gears (5) (4 used). 31. Remove thrust plates (3) (8 used) and needle bearings (4) (4 used) from 2-stage planetary gears (5) (4 used) respectively. 32. Push out spring pins (11) (3 used) from 1-stage carrier (25) with a round bar. : 5 mm

W3-2-9

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL REDUCER 45 39

44 43

37 38

46 13

28 51 16 25 27 2 24 26 23 20

21 10 12

11 15 17 18

9 W183-03-02-002

29 31

1234-

3-Stage Carrier 3-Stage Sun Gear Thrust Plate (8 Used) Needle Bearing (4 Used)

5 - 2-Stage Planetary Gear (4 Used) 6 - Spring Pin (4 Used) 7 - Pin (4 Used) 8 - Thrust Plate (6 Used) 9 - Needle Bearing (3 Used) 10 - 1-Stage Planetary Gear (3 Used) 11 - Spring Pin (3 Used) 12 - Pin (3 Used) 13 - O-Ring

14 15 16 17 -

30 32

Ring Gear Cover Plug (3 Used) Bolt (26 Used)

27 28 29 30 -

18 - Spring Washer (26 Used)

Spacer 2-Stage Carrier Roller Bearing (8 Used) 3-Stage Planetary Gear (4 Used) 31 - Retaining Ring (4 Used)

44 - Roller Bearing

19 20 21 22 23 -

32 33 34 35 36 -

45 46 47 48 49 -

Socket Bolt (36 Used) Bearing Retaining Ring Seat Propeller Shaft

24 - Spacer 25 - 1-Stage carrier 26 - 2-Stage Sun Gear

Spring Pin (4 Used) Pin (4 Used) Bolt (4 Used) Spring Washer (4 Used) Housing

37 - Support 38 - Roller Bearing 39 - Spring Washer (30 Used)

W3-2-10

40 41 42 43 -

Bolt (30 Used) Bolt (2 Used) Lock Plate Bearing Nut

Sprocket Drum Socket Bolt (18 Used) Floating Seal O-Ring

50 - Motor 51 - Dummy Plug (2 Used) 52 - Dummy Plug

UNDERCARRIAGE / Travel Device Assemble Travel Reducer 1. Assemble retaining rings (31) (4 used) and roller bearings (29)(8 used) to 3-stage planetary gears (30) (4 used).

8. Tap spring pins (6) (4 used) into pins (7) (4 used) on 2-stage carrier (28). NOTE: Be sure that the slit part of spring pin (6) faces upwards in relation to end of pin (7) and tap it in.

Č&#x20AC; 2. Assemble 3-stage planetary gears (30) (4 used) into 3-stage carrier (1).

Č&#x20AC;

3. Align spring pin (32) of 3-stage carrier (1) with its mounting holes in pins (33) (4 used) and install it.

Slit

Č&#x20AC; 4. Tap spring pins (32) (4 used) into pins (33) (4 used) on 3-stage carrier (1). NOTE: Be sure to make the slit part of spring pin (32) face the upper part of pin (33) and tap it in. 33 32

Slit

9. Install needle bearings (9) (3 used) into 1-stage carriers (10) (3 used). 10. Align thrust plates (8) (6 used) with pin (12) mounting holes in both ends of 1-stage planetary gear (10). Install 1-stage planetary gears (10) (3 used) into 1-stage carrier (25). 11. Align with spring pin (11) mounting holes in 1stage carrier (25) to install pins (12) (3 used).

5. Install needle bearings (4) (4 used) into 2-stage planetary gears (5) (4 used).

12. Tap spring pins (11) (3 used) into pins (12) (3 used) on 1-stage carrier (25). NOTE: Be sure that the slit part of spring pin (11) faces upwards in relation to the end of pin (12) and tap it in.

6. Align thrust plates (3) (8 used) with pin (7) mounting holes in both ends of 2-stage planetary gear (5). Install 2-stage planetary gears (5) (4 used) into 2stage carrier (28).

12 11

7. Align with spring pin (6) mounting hole in 2-stage carrier (28) to install pin (7) (4 used).

Slit

13. Press outer race of roller bearing (38) into drum (46).

W3-2-11

UNDERCARRIAGE / Travel Device

44 43

45 39

W183-03-02-002

W3-2-12

UNDERCARRIAGE / Travel Device 14. Install support (37) to drum (46) with socket bolts (47) (18 used). ϖ 10 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

20. Hoist drum (46) to place it into housing (36) with equal clearance around drum (46) to housing (36). 21. Tap the inner race of roller bearing (44) into housing (36) with a hammer and adapter bar.

CAUTION: Drum (46) weight:

290 kg (640 Ib) 22. Install bearing nut (43) to housing (36) and screw on it by hand.

15. Hoist drum (46) and reverse it. 16. Install the inner race of roller bearing (44) into drum (46).

23. Install jig (ST 3142) into bearing nut (43) and secure it with a torque wrench. ϖ 41 mm ϖ 590 N⋅m (60 kgf⋅m, 430 Ibf⋅ft)

CAUTION: Sprocket (45) weight: 210 kg (460 Ib) IMPORTANT:

Install sprocket (45) with chamfered facing drum (46).

ST 3142

the

17. Install sprocket (45) to drum (46) with bolts (40) (30 used) and spring washers (39) (30 used). Install dummy plugs (52) (2 used) into the two holes for pulling out sprocket (45). NOTE: Apply LOCTITE #262 on bolt (40). ϖ 41 mm ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf⋅ft)

W111-03-02-018

CAUTION: Drum (46)+sprocket (45)+the others weight: 560 kg (1230 Ib)

24. Tap the up side of sprocket (45) with a plastic hammer after securing bearing nut (43). Then turn drum (46) clockwise and counterclockwise three times respectively.

IMPORTANT: As for the handling of floating seal, refer to the Handling of Floating Seal on page w1-1-4. 18. Hoist drum (46) to reverse it. Install floating seal (48) onto support (37) in housing (36) with bamboo spatula, etc.

CAUTION: Drum (46)+sprocket (45)+the others weight: 560 kg (1230 Ib) 19. Hoist drum (46) to reverse it.

W3-2-13

UNDERCARRIAGE / Travel Device

46 13

25 27 2 24 26 23

41 W183-03-02-002

W3-2-14

UNDERCARRIAGE / Travel Device 25. Again, do the same work as procedure 24 and screw on bearing nut (43) to the specified torque.

CAUTION:

ϖ 41 mm ϖ 590 N]m (60 kgf]m, 430 Ibf]ft) 26. Insert the detent part of lock plate (42) into the slit of housing (36). Align the hole of lock plate (42) with the bolt hole of bearing nut (43) and screw on housing nut (43) in securing direction. 27. Install lock plate (42) to bearing nut (43) with bolts (41) (2 used).

2-Stage carrier (28) weight: 95 kg (210 Ib)

assembly

30. Install eyebolts (M12, Pitch 1.75) into the two sling holes of the 2-stage carrier (28) assembly and hoist it by a crane to install it to 3-stage carrier (1). Ȁ 31. Place spacer (27) into the 2-stage carrier (28) assembly. Ȁ 32. Install 2-stage sun gear (26) into 2-stage carrier (28) with the low part of the teeth facing upward.

NOTE: Apply LOCTITE #262 on bolt (41).

Upper Side

ϖ 22 mm ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf]ft)

CAUTION: 3-Stage carrier (1) assembly weight: 210 kg (460 Ib)

28. Install eyebolts (M12, Pitch 1.75) into the two sling holes of the 3-stage carrier (1) assembly and hoist it by a crane to install it to housing (36).

29. Attach a nylon sling to the gear part of 3-stage sun gear (2) and hoist it by a crane to install it to the 3-stage carrier (1) assembly with the low part of the teeth facing up.

1-Stage carrier (25) weight: 85 kg (190 Ib)

assembly

33. Install eyebolts (M12, Pitch 1.75) into the three sling holes of the 1-stage carrier (25) assembly and hoist it by a crane to install it to 2-stage carrier (28). Ȁ 34. Place spacer (24) into 1-stage carrier (25). Ȁ 35. Insert propeller shaft (23) to the center of the carrier, while meshing propeller shaft (23) with 1stage planetary gear (10).

Upper Side

CAUTION:

W166-03-02-002

36. Install O-ring (13) onto drum (46). Ȁ

W3-2-15

UNDERCARRIAGE / Travel Device Ȁ Ȁ

14 51 16

23 20 34

49 15 17 18

W183-03-02-002

Ȁ Ȁ Ȁ

W3-2-16

UNDERCARRIAGE / Travel Device Ȁ 44. Wind sealing-type tape on plug (16) and install it into cover (15).

CAUTION: Ring gear (14) weight: 240 kg (530 Ib)

ϖ 17 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

37. Install eyebolt (M14, Pitch 2) into ring gear (14) and hoist it by a crane to install it to drum (46). CAUTION: Travel device weight (Excluding Motor): 1590 kg (3510 Ib)

Ȁ 38. Apply LOCTITE#262 on socket bolts (19) (36 used) and then screw on them. ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf]ft)

45. Hoist the travel device to reverse it.

Ȁ 39. If bearing (20) and seat (22) were removed, install them into cover (15). NOTE: Install the bearing with the punched mark side facing up.

Ȁ 46. Fill the gear oil. Gear oil: about 43 L (11.36 Us gallon) Ȁ 47. Install O-ring (49) onto motor (50).

CAUTION: Motor (50) weight: 130 kg (290 Ib)

40. Install retaining ring (21) onto cover (15). Ȁ 41. Apply THREEBOND #1215 on the mounting face of ring gear (14) and cover (15).

CAUTION: Cover (15) weight: 76 kg (170 Ib)

48. Hoist motor (50) and install it into housing (36) while aligning the spline part of propeller shaft (23) with that of motor (50) shaft. Ȁ 49. Put spring washers (35) (4 used) on bolts (34) (4 used) and screw them on.

42. Install eyebolt (M14, Pitch 2) into the sling hole of cover (15) and hoist it by a crane. Install cover (15) to ring gear (14) with bolts (17) (26 used) and spring washers (18) (26 used). NOTE: Apply LOCTITE #262 on bolt (17). ϖ 22 mm ϖ 140 N⋅m (14 kgf⋅m,101 Ibf]ft) 43. Install dummy plugs (51) (2 used) into the two sling holes in cover (15).

W3-2-17

ϖ 27 mm ϖ 300 N⋅m (30.5 kgf⋅m, 220 Ibf⋅ft)

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL MOTOR

7 8

21 12

11 19

18 17 16 15

13 32

33 34 23 24

35 25 27

26 36

W183-03-02-013

123456789-

Case O-Ring (2 Used) Plug (2 Used) O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Shaft Roller Bearing Oil Seal

10 11 12 13 14 15 16 17 18 -

O-Ring (4 Used) Plug (2 Used) O-Ring (2 Used) Steel Ball (2 Used) Swash Plate Plunger Assembly (9 Used) Retainer Plate Retainer Holder Spring (9 Used)

19 20 21 22 23 24 25 26 27 -

Cylinder Block Valve Plate Collar Roller Bearing Socket Bolt (9 Used) Travel Brake Valve Pin Pin (4 Used) Spring (12 Used)

W3-2-18

28 29 30 31 32 33 34 35 36 -

O-Ring Brake Piston Backup Ring O-Ring O-Ring Backup Ring Friction Plate (3 Used) Friction Plate (4 Used) Disc Plate (5 Used)

UNDERCARRIAGE / Travel Device Disassemble Travel Motor

6. Remove friction plates (34) (3 used), (35) (4 used) and disc plates (36) (5 used) from case (1).

• Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

CAUTION: Cylinder block (19) assembly weight: 20 kg (40 Ib)

CAUTION: Travel brake valve (24) assembly weight: 39 kg (90 Ib)

7. Remove the cylinder block (19) assembly from case (1). At this moment, plunger assemblies (15) (9 used), retainer holder (17), retainer plate (16) and springs (18) (9 used) are all connecting with cylinder block (19).

IMPORTANT: Since valve plate (20) will come out with the travel brake valve (24) assembly if the assembly is removed, do not let the plate come off.

NOTE: Hold cylinder block (19) and turning it left and right lightly, with two hands to take it out slowly.

1. Remove socket bolts (23) (9 used) from case (1) to remove the travel brake valve (24) assembly. At this moment, the outer race of roller bearing (22) is connected with the travel brake valve (24) assembly.

8. Remove retainer plate (16) from cylinder block (19). At this moment, plunger assemblies (15) (9 used) are connecting with retainer plate (16).

ϖ 14 mm IMPORTANT: As cylinder block (19) and valve plate (20) are easy to damage, please handle with care.

Ȁ 9. Remove plunger assemblies (15) (9 used) from retainer plate (16). 10.Remove retainer holder (17) and springs (18) (9 used) from cylinder block (19).

2. Remove collar (21) and valve plate (20) from cylinder block (19). Ȁ 3. Remove O-ring (28) from case (1) and springs (27) (12 used) from brake piston (29) respectively.

CAUTION: Case (1) should be fixed firmly. Otherwise, case (1) will move about, injury will occur and the motor parts may be damaged during the removal of brake piston (29).

IMPORTANT: Do not damage friction face of swash plate (14). In addition, piston (6) and steel ball (13) may come out with swash plate (14), in such event keep piston (6) and steel ball (13) from dropping. 11. Remove swash plate (14) from case (1).

4. Install eyebolts (M10) into the two sling holes of brake piston (29) and hoist it by a crane to remove it from case (1). 5. Remove O-rings (31 and 32) and backup rings (30 and 33) from brake piston (29).

W3-2-19

UNDERCARRIAGE / Travel Device

7 9

W183-03-02-013

W3-2-20

UNDERCARRIAGE / Travel Device 12. Remove pistons (6) (2 used), springs (5) (2 used) and steel balls (13) (2 used) from case (1). NOTE: If it is difficult to remove steel ball (13), that means the ball has been set in case (1), so use some kerosene or thinner, etc. to clean grease first, and then with a magnet to take it out from case (1). IMPORTANT: Do not damage the spline part of shaft (7) and contact part of oil seal (9), because oil leakage will occur if they are damaged. 13. Remove shaft (7) from case (1). At this moment, the inner race of roller bearing (8) is connecting with the shaft. 14. Press the inner race of roller bearing (8) to remove it from shaft (7). 15. Remove oil seal (9) from case (1).

W3-2-21

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL MOTOR

27 25 24

9 8 1

123456789-

Case O-Ring (2 Used) Plug (2 Used) O-Ring (4 Used) Spring (2 Used) Piston (2 Used) Shaft Roller Bearing Oil Seal

10 11 12 13 14 15 16 17 18 -

30, 31

32, 33

O-Ring (4 Used) Plug (2 Used) O-Ring (2 Used) Steel Ball (2 Used) Swash Plate Plunger Assembly (9 Used) Retainer Plate Retainer Holder Spring (9 Used)

19 20 21 22 23 24 25 26 27 -

W3-2-22

Cylinder Block Valve Plate Collar Roller Bearing Socket Bolt (9 Used) Travel Brake Valve Pin Pin (4 Used) Spring (12 Used)

28 29 30 31 32 33 34 35 36 -

T183-03-05-003

O-Ring Brake Piston Backup Ring O-Ring O-Ring Backup Ring Friction Plate (3 Used) Friction Plate (4 Used) Disc Plate (5 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Motor CAUTION: Case (1) assembly weight: 54 kg (120 Ib) Cylinder block (19) assembly weight: 20 kg (40 Ib)

IMPORTANT: Apply grease on inside periphery of the oil seal for case (1) at the pressed-in part and outside periphery of the oil seal. 1. Press oil seal (9) into case (1). 2. Assemble springs (5) (2 used), pistons (6) (2 used) and steel balls (13) (2 used) into case (1) while applying grease on steel ball (13).

IMPORTANT: Apply hydraulic oil on the contact parts of swash plate (14) and plunger assembly (15). The inner race of roller bearing (22) is on the front end of shaft (7) and be careful not to damage it. 8. Put case (1) horizontally and install the cylinder block (19) assembly to shaft (7).

3. Press the inner race of roller bearing (8) into shaft (7). Press shaft (7) to install it into case (1).

CAUTION: Case (1) assembly weight: 54 kg (120 Ib) 4. Place the case (1) assembly horizontally with the oil pipe for brake releasing facing down.

9. With travel brake valve (24) facing upward, place the case (1) assembly vertically. 10. Install friction plates (34) (3 used), (35) (4 used) and disc plates (36) (5 used) into case (1). NOTE: First, place two friction plates (34), and then place each of disc plate (36) and friction plate (35) alternately, and finally place one piece of friction plate (34).

IMPORTANT: Install swash plate (14) with its spherical pit aligning with steel ball (13). 5. Install swash plate (14) to case (1). Now, apply more grease on the interfaces of swash plate (14) and case (1). 6. Install springs (18) (9 used) and retainer holder (17) into cylinder block (19). IMPORTANT:

IMPORTANT: Apply grease on the outside of brake piston (29) and the internal diameter of case (1). 11. Assemble backup rings (30 and 33) and O-rings (31 and 32) onto brake piston (29) and install it into case (1).

Apply hydraulic oil in plunger assembly (15) mounting hole of cylinder block (19).

12. Align pin (25) of travel brake valve (24) with the pin hole in valve plate (20) and install collar (21) and valve plate (20) to travel brake valve (24).

7. Assemble plunger assemblies (15) (9 used) with retainer plate (16) and install to cylinder block (19).

13. Install springs (27) (12 used) into brake piston (29).

W3-2-23

UNDERCARRIAGE / Travel Device

T183-03-05-003

W3-2-24

UNDERCARRIAGE / Travel Device

CAUTION: Travel brake valve (24) weight: 39 kg (90 Ib) 14. Place O-ring (28) to case (1) and align pin (26) of travel brake valve (24) with the pin holes in case (1) and brake piston (29). Install travel brake valve (24) to case (1) with socket bolts (23)(9 used).

W3-2-25

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL BRAKE VALVE 1

6 2

11 10

12 13

36 37

18 20

49 10 9 41

23 30 25

27 43

3 2

44 36 40

31 4

41 50

39 38

35 37 W183-03-02-010

12345-

Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Overload Relief Valve (2 Used) 6 - Plug 7 - O-Ring 8 - Spring

14 15 16 17 18 -

910 11 12 13 -

19 - Backup Ring (2 Used) 20 - Poppet (2 Used) 21 - Relief Valve Housing (2 Used) 22 - Piston (2 Used) 23 - Backup Ring (2 Used) 24 - O-Ring (2 Used) 25 - Backup Ring (2 Used) 26 - Spring Seat (2 Used)

Plug (6 Used) O-Ring (6 Used) Orifice Socket Bolt (9 Used) Valve Assembly

O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used)

27 28 29 30 31 -

Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used)

39 40 41 42 43 -

Spring (2 Used) Spring Seat (2 Used) Plug (2 Used) O-Ring (2 Used) Spring (2 Used)

32 - Plug (2 Used) 33 - Nut (2 Used) 34 - Set Screw (2 Used)

44 - Check Valve (2 Used) 45 - Spool 46 - Valve Housing

35 36 37 38 -

47 48 49 50 -

W3-2-26

Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used)

Pin (4 Used) Pin Set Screw Spool Assembly

UNDERCARRIAGE / Travel Device Disassemble Travel Brake Valve

CAUTION: Valve housing (46) assembly weight: 39 kg (90 Ib)

IMPORTANT: Put matching marks on set screw (34) and plug (32) and take a note of the turning amount that set screw (34) has been screwed.

1. Fix the valve housing (46) assembly on a firm work bench.

6. Remove nut (33) from plug (32) to remove set screw (34). ϖ 19 mm ϖ 6 mm

2. Remove plugs (6 and 15) and O-rings (7 and 14) respectively, and remove spring (8). ϖ 10 mm

7. Remove poppet seat (16), poppet (20), relief valve housing (21), piston (22), spring seat (26), spring (27) and spring guide (28) from plug (32).

IMPORTANT: Remove valve assembly (13) while turning it. In case there is a little resistance to turning do not try to pull it out forcedly. Insert it back and try to pull it out again. Do not disassemble valve assembly (13) unless necessary.

Spool 8. Equally loosen socket bolts (35) (4 used) while holding cap (36) to remove cap (36) from valve housing (46). (2 places both left and right) ϖ 10 mm

3. Lightly push valve assembly (13) out. Then pull it out from valve housing (46) while turning it by hand.

NOTE: Tap cap (36) off with a plastic hammer if it can not be removed. Socket bolt (35) loosened should be in its position while tapping cap (36).

4. Remove plug (1) to remove O-ring (2), spring (3) and check valve (4). (2 places both left and right)

9. Remove spring seat (38), spring (39) and spring seat (40) from valve housing (46). (2 places both left and right)

ϖ 14 mm Overload Relief Valve IMPORTANT: Do not disassemble the overload relief valve unless necessary. Attach tags to the valve and keep carefully so that it can be reset to the position where it was removed.

IMPORTANT: Pull out spool assembly (50) while turning it. In case there is a little resistance to turning, do not try to pull it out forcedly. Insert it back and try to pull it again.

5. Loosen plug (32) to remove overload relief valve (5) from valve housing (46). (2 places both left and right)

10. Lightly push spool assembly (50) out. Then pull it out from valve housing (46) while turning it by hand.

ϖ 36 mm

W3-2-27

UNDERCARRIAGE / Travel Device

41 43

44 45

41 50

W183-03-02-010

W3-2-28

UNDERCARRIAGE / Travel Device 11. Clamp spool assembly (50) and hold it by the vise with wooden spatula inserted at both sides. 12. Remove plugs (41) (2 used) to remove springs (43) (2 used) and check valves (44) (2 used) from spool (45).

W3-2-29

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL BRAKE VALVE Overload Relief Valve (5) 16

21 26

27 31

33 34

17я я 19

23я я 25

38 41

37 39

42 A

40 43

44 45

50 14 48

46 5

12345-

Plug (2 Used) O-Ring (2 Used) Spring (2 Used) Check Valve (2 Used) Overload Relief Valve (2 Used) 6 - Plug 7 - O-Ring 8 - Spring

14 15 16 17 18 -

910 11 12 13 -

Plug (6 Used) O-Ring (6 Used) Orifice Socket Bolt (9 Used) Valve Assembly

O-Ring Plug Poppet Seat (2 Used) Backup Ring (2 Used) O-Ring (2 Used)

27 28 29 30 31 -

Section A-A-A

Spring (2 Used) Spring Guide (2 Used) O-Ring (2 Used) Backup Ring (2 Used) O-Ring (2 Used)

39 40 41 42 43 -

4 W183-03-02-016

Spring (2 Used) Spring Seat (2 Used)v Plug (2 Used) O-Ring (2 Used) Spring (2 Used)

32 - Plug (2 Used) 33 - Nut (2 Used) 34 - Set Screw (2 Used)

44 - Check Valve (2 Used) 45 - Spool 46 - Valve Housing

35 36 37 38 -

47 48 49 50 -

W3-2-30

Socket Bolt (8 Used) Cap (2 Used) O-Ring (2 Used) Spring Seat (2 Used)

Pin (4 Used) Pin Set Screw Spool Assembly

UNDERCARRIAGE / Travel Device Assemble Travel Brake Valve 1. Assemble O-rings (7 and 14) onto plugs (6 and 15) respectively. Install valve assembly (13) and plugs (6 and 15) into valve housing (46).

IMPORTANT: Set screw (34) should be screwed on only by the same amount to removal while aligning the matching marks. 6. Install set screw (34) into plug (32) and screw on nut (33).

ϖ 10 mm ϖ 64 N⋅m (6.5 kgf⋅m, 47 Ibf⋅ft)

ϖ ϖ ϖ ϖ

2. Place O-ring (2) onto plug (1). Install check valve (4), spring (3) and plug (1) into valve housing (46). (left and right, 2 places) ϖ 14 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) Overload Relief Valve 3. Assemble O-ring (31) onto plug (32) and assemble backup ring (30) and O-ring (29) onto spring guide (28).

19 mm 65 N⋅m (6.6 kgf⋅m, 48 Ibf⋅ft) 6 mm 16 N⋅m (1.6 kgf⋅m, 11.5 Ibf⋅ft)

IMPORTANT: Install overload relief valve (41) into its position where it was disassembled and be sure to perform the adjustment to the valve on the test bench. (Refer to the Adjustment of Overload Relief Valve in Performance Test chapter, Technical Manual)

4. Assemble backup rings (23 and 25) and O-ring (24) onto piston (22) and assemble backup rings (17 and 19) and O-ring (18) onto poppet seat (16).

7. Install overload relief valves (5) (2 used) into valve housing (46). ϖ 36 mm ϖ 98 N⋅m (10 kgf⋅m, 72 Ibf⋅ft)

5. Assemble spring guide (28), spring (27), spring seat (26), piston (22), relief housing (21), poppet (20) and poppet seat (16) into plug (32).

Spool 8. Place O-rings (42) onto plugs (41) (2 used). Install check valves (44) (2 used), springs (43) (2 used) and plugs (41) (2 used) into spool (45). 9. Insert spool assembly (50) into valve housing (46) while slowly turning it. Ȁ 10. Install O-ring (37) onto cap (36). (left and right, 2 places) Ȁ 11. Assemble spring seat (40), spring (39) and spring seat (38) into valve housing (46) and install cap (36) to it with socket bolts (35) (4 used). (left and right, 2 places) ϖ 10 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

W3-2-31

UNDERCARRIAGE / Travel Device MAITENANCE STANDARD 1. Move the plunger of travel motor up and down to measure the play between plunger and shoe. Unit: mm (in)

Standard Size

Allowable Limit Size

MAX 0.15 (0.0059)

0.4 (0.0157)

W111-03-02-106

2. Clearance between the plunger of travel motor and the rotor. Measure the outer dia of the plunger and the inner dia of the rotor and calculate the clearance. Unit: mm (in)

Standard Size

Allowable Limit Size

MAX 0.045 (0.0018)

0.06 (0.0024)

W111-03-02-107

Check the outer periphery of the plunger visually. Replace it when scratch is found.

3. Measure the outer dia of piston of travel motor and the bore dia for piston operating in casing and calculate the clearance.

W111-03-02-108

Unit: mm (in)

Standard Size

Allowable Limit Size

MAX 0.018 (0.0007)

0.03 (0.0012)

Check the outer periphery of the piston visually and replace it when scratch is found.

W162-03-02-005

W3-2-32

UNDERCARRIAGE / Travel Device 4. Move the piston of the travel motor up and down and measure the clearance between the steel ball and the shoe attached to the piston. Unit: mm (in)

Standard Size

Allowable Limit Size

MAX 0.5 (0.0197)

0.7 (0.028)

W107-02-06-140

Valve

5. Check the tilt selector valve of the travel motor. Measure the clearance between the valve and the bore dia. for valve body. Unit: mm (in)

Standard Size

Allowable Limit Size

MAX 0.018 (0.0007)

0.04 (0.016)

Body

W3-2-33

W111-03-02-109

UNDERCARRIAGE / Travel Device Sprocket

B C D

W105-03-02-241

Unit: mm (in)

Standard Size

Allowable Limit Size

114 (4.49)

104 (4.09)

1038 (40.87)

1028 (40.47)

1128.9 (44.44)

1480 (58.27)

1470 (57.87)

260.4 (10.25)

W3-2-34

Measurements

Clad by welding and finishing

UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JONT CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground.

W183-04-02-003

W183-04-02-002

Wooden Blocks

3. Remove the hydraulic oil tank cap. Connect a vacuum pump and operate it continously to maintain negative pressure in the hydraulic oil tank.

Cap

NOTE: Run the vacuum pump continously while working on the hydraulic system.

W183-01-01-001

W3-3-1

UNDERCARRIAGE / Center Joint Removal 1. Attach tags to all hoses connected to the center joint to aid reconnection. Disconnect hoses (1 to 4 and 7 to 15) and remove adapters. ϖ ϖ ϖ ϖ ϖ ϖ ϖ ϖ

2 1

22 mm 39 N⋅m (4.0 kgf⋅m, 29 Ibf⋅ft) 27 mm 93 N⋅m (9.5 kgf⋅m, 69 Ibf⋅ft) 41 mm 205 N⋅m (21 kgf⋅m, 152 Ibf⋅ft) 50 mm 340 N⋅m (35 kgf⋅m, 255 Ibf⋅ft)

3 4

NOTE: Cap all disconnected hose and pipe ends. 7

2. Remove bolts (6) (2 used) to remove stopper (5).

W142-03-03-002

ϖ 22 mm ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 3. Install eyebolts (PF1) to the holes (2 places) where hoses (1 to 4) were removed to lift the center joint with a wire rope.

16 9

CAUTION: The center joint assembly weight: 52 kg (110 Ib) 4. Remove bolts (17) (4 used). Then, remove the center joint assembly while holding the center joint by a crane. ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

15 10

14 11

Installation NOTE: Refer to “Removal” section above for wrench sizes and tightening torque. CAUTION: The center joint assembly weight: 52 kg (110 Ib) 1. Hoist the center joint assembly and install it onto track frame with bolts (17) (4 used). 2. Connect hoses (1 to 4 and 7 to 16) and adapters. 3. Install stopper (5) with bolts (6) (2 used).

W3-3-2

W183-03-03-002

UNDERCARRIAGE / Center Joint (Blank)

W3-3-3

UNDERCARRIAGE / Center Joint DISASSEMBLE CENTER JOINT

2 3 4

7 8 9

W183-03-03-001

1 - Spindle 2 - Dust Seal 3 - O-Ring

4 - Bushing 5 - Oil Seal (6 Used) 6 - Body

7 - Ring 8 - Retaining Ring 9 - O-Ring

W3-3-4

10 - Cover 11 - Bolt (4 Used)

UNDERCARRIAGE / Center Joint Disassemble Center Joint • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

4. Install removal special tool for center joint (ST 1930) to body (6) with cover (10) mounting bolts (11) (2 used). ϖ 19 mm ST 1020

CAUTION: Center joint weight: 52 kg (110 Ib)

ST 1930

1. Remove bolts (11) (2 used) in diagonal position from cover (10). Install eyebolts (M12, Pitch 1.75) into the holes where bolts (11) were removed. Pass wire through eyebolts and hoist the center joint. Place the center joint on work bench (ST 5099). ϖ 19 mm Eyebolt

W183-03-03-004

5. Turn bolt (ST 1020) on special tool (ST 1930) to press spindle (1) down to remove it out from body (6).

10 11

ST 5099

W183-03-03-003

2. Loosen bolts (11) (2 used) to remove cover (10) from body (6).

IMPORTANT: Take care not to damage the sliding surface of the spindle (1) seal. It is easy to remove seals with 2 pins. Don’t damage the seal grooves by pins. 6. Remove oil seals (5) (6 used) from body (6).

ϖ 19 mm 3. Remove O-ring (9), retaining ring (8) and ring (7) from body (6). IMPORTANT: Put matching marks on body (6) and spindle (1).

Matching Mark

W105-03-03-015

7. Remove dust seal (2) and O-ring (3) from body (6).

W142-03-03-004

W3-3-5

UNDERCARRIAGE / Center Joint ASSEMBLE CENTER JOINT

2 3 4

10 W183-03-08-001

1 - Spindle 2 - Dust Seal 3 - O-Ring

4 - Bushing 5 - Oil Seal (6 Used) 6 - Body

7 - Ring 8 - O-Ring 9 - Retaining Ring

W3-3-6

10 - Cover 11 - Bolt (4 Used)

UNDERCARRIAGE / Center Joint Assemble Center Joint 1. If bushing (4) is removed, be sure to press bushing (4) into body (6).

IMPORTANT: When installing ring (7), its chamfered face shall face inside. 6. Install ring (7) to body (6).

2. Install O-ring (3) and dust seal (2) into body (6).

IMPORTANT: Install retaining ring (9) with the chamfered edge facing the spindle.

3. Install oil seals (5) (6 used) into body (6). 4. Aligning the matching marks put when disassembling, install spindle (1) into body (6). IMPORTANT: Be sure to slowly push spindle (1) into body. Failure to do so may damage seals. Moreover, the clearance between body (6) and spindle (1) is approx 0.05 mm (0.004 in) so that the center of body (6) and spindle (1) can be aligned during installation. In addition, no step is allowed to form at portion A (where ring (7) is installed) shown bellow when assembling.

7. Install retaining ring (9) onto spindle (1). 8. Secure cover (10) to body (6) with bolts (11) (4 used).

1 A

0.05 mm (0.002 in)

W105-03-03-024

5. Tap body (6) with a plastic hammer slightly and evenly. Insert spindle (1) with no step forming at the mounting position between body (6) and ring (7) of spindle (1).

W3-3-7

ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 67 Ibf⋅ft)

UNDERCARRIAGE / Center Joint

2 3 4

10 W183-03-08-001

W3-3-8

UNDERCARRIAGE / Center Joint IMPORTANT: Check for oil leaks while applying oil 2 at pressure of 0.5 Mpa (5 kgf/cm , 71 Psi) to the main port and drain port respectively. Frame Upper Part 3 1

W142-03-03-002

Frame Lower Part 7 13 12 8

W183-03-03-002

1234567-

Hose : (main port 1) Hose : (main port 2) Hose : (main port 3) Hose : (main port 4) Hose : (drain port) Hose : (pilot port) Hose : (pilot port)

8910 11 12 13 -

Hose : (main port 4) Hose : (main port 3) Hose : (drain port) Hose : (main port 1) Hose : (main port 2) Hose : (pilot port)

W3-3-9

UNDERCARRIAGE / Center Joint MAINTENANCE STANDARD

Item

Allowable Limit (basis of judgment) Remedy Wear less than 0.2 mm (0.008 in) Replace Scored, abnormal wear Replace Uneven wear (Wear range is less than Replace 180Â°) Wear Area

Bushing

T157-01-01-040

Body, Spindle

Sliding surfaces with seals Sliding surfaces between body and spindle other than sliding surfaces with seals Sliding surfaces with ring

Sliding with ring Cover

Heavily damaged one by seizure or foreign matter Excessively worn one by seizure or foreign matter, or one having the score of 0.1 mm (0.004 in) or more One having the score of less than 0.1 mm (0.004 in) One that has worn 0.5 mm (0.02 in) or more, or excessively worn One that has worn 0.5 mm (0.02 in) or less One that has scores due to seizure or foreign matter but the damage is less than the allowable wear limit 0.5 mm (0.02 in) and is repairable surfaces One that has worn 0.5 mm (0.02 in) One that has worn less than 0.5 mm (0.02 in) One that has scores due to seizure or foreign matter but the damage is less than the allowable wear limit 0.5 mm (0.02 in) and is repairable

W3-3-10

Replace Replace Finish the surface Replace Finish the surface Finish the surface

Replace Finish the surface Finish the surface

UNDERCARRIAGE / Track Adjuster REMOVE AND INSTALL TRACK ADJUSTER Before removing the track adjuster, the tracks and the front idler must be removed first. For removal and installation of the tracks and the front idler, refer to applicable removal/installation sections. In this section, the procedure starts on the premise that the tracks and the front idler have already been removed. CAUTION: When removing track adjuster (1), track adjuster (1) may fly off by spring force. Donâ&#x20AC;&#x2122;t stand in the removal direction of track adjuster (1) or in places where track adjuster (1) may fly out. The rod screw is loaded by spring force. Be alert that if the rod or screw section is broken, the broken pieces may fly out by spring force, causing personal injury and/or death.

2 1

W142-03-04-002

Removal CAUTION: Track adjuster weight: 650 kg (1430 Ib) 1. Remove track adjuster (1) from track frame (2) by prying it with a crowbar. W166-03-04-002

Installation 1. Install track adjuster (1) into spring guide (3) on track frame (2). Check that the end face of track adjuster (1) comes into contact with the face of plate (4).

W183-03-04-002

W3-4-1

UNDERCARRIAGE / Track Adjuster DISASSEMBLE TRACK ADJUSTER 1

4 5 6

12 11

16 18

W167-03-04-004

17 12345-

O-Ring Socket Bolt (4 Used) Guide Piston Rod Wear Ring (2 Used)

678910 -

Backup Ring U-Ring Plate Retaining Ring Rod

11 12 13 14 15 -

W3-4-2

O-Ring Cylinder Spring Spacer Bracket

16 - Nut 17 - Bolt 18 - Valve

UNDERCARRIAGE / Track Adjuster Disassemble Track Adjuster • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before disassembling work. Use a pump unit which has the maximum 2 pressure of 69 MPa (700 kgf/cm , 9 950 psi) and the flow rate of 8 to 10 liters (2.1 to 2.6 US gal.). Be sure to set the main relief pressure to 49 MPa 2 (500 kgf/cm , 7 110 psi) (80 tons) or lower.

IMPORTANT: Compress spring until the clearance between bracket (15) and nut (16) is approx. 10 mm (0.39 in). 2. Loosen valve (18). Compress track adjuster spring (13) with special tool (ST 4932). Clearance 10 mm (0.39 in)

Be sure to use special tool (ST 4932) for assembly/disassembly of the track adjuster. CAUTION:

16 17

Prevent personal injury. The spring force of the track adjuster is extremely strong. Thoroughly inspect the special tool for any damage. Carefully perform assembly work referring to the procedure below.

W142-03-04-020

3. Remove valve (18) and bolt (17) to remove nut (16).

CAUTION: Track adjuster assembly weight: 650 kg (1430 Ib)

ϖ 30 mm, 150 mm

1. Position the track adjuster on the rest of special tool (ST 4932) by a crane. ST 4932

Rest W142-03-04-019

W3-4-3

UNDERCARRIAGE / Track Adjuster

W167-03-04-004

W3-4-4

UNDERCARRIAGE / Track Adjuster 4. Slowly return the piston of special tool (ST 4932) until spring (13) extends to its free length.

CAUTION: The cylinder (12) assembly weight: 280 kg (620 Ib) 7. Lift and remove the cylinder (12) assembly from spring (13).

ST 4932

Eyebolt

13 W142-03-04-005

Rest

CAUTION: Track adjuster weight (Nut excluded): 640 kg (1410 Ib) 5. Tie bracket (15) and spring (13) together with wire. Fasten a sling belt to spring (13). Lift bracket (15) and spring (13) together out of special tool (ST 4932) by a crane.

W142-03-04-007

CAUTION: Spring weight: 350 kg (770 Ib) 8. Remove the wire fastening spring (13) and bracket (15). Lift and remove spring (13) by a crane.

6. Install eye bolt (M16, Pitch 2) onto piston rod (4). Fasten a sling belt around spring (13) and through eyebolt (M16, Pitch 2). Lift and position the assembly on the rest by a crane, as illustrated.

CAUTION: Bracket weight: 45 kg (100 Ib) 9. Remove spacer (14) and bracket (15) out of the rest.

Eyebolt

Rest

W142-03-04-006

W3-4-5

UNDERCARRIAGE / Track Adjuster

1 3 4 5 6 2

7 8

12 11

W167-03-04-004

W3-4-6

UNDERCARRIAGE / Track Adjuster 10. Remove socket bolts (2) (4 used) and guide (3). Ď&#x2013;14 mm CAUTION: Piston rod weight: 35 kg (80 Ib) 11. Pull out piston rod (4) from cylinder (12). 12. Remove O-ring (1) from guide (3). CAUTION: Cylinder (12) weight: 110 kg (240 Ib) Rod (10) weight: 60 kg (130 Ib) 13. Remove rod (10) and O-ring (11) from cylinder (12). 14. Remove wear rings (5) (2 used), retaining ring (9), plate (8), U-ring (7), backup ring (6) from piston rod (4). 4 5 6

7 9

8 W142-03-04-008

W3-4-7

UNDERCARRIAGE / Track Adjuster ASSEMBLE TRACK ADJUSTER

17 16

11 10

Chamber B

12 1

W142-03-04-016

12345-

O-Ring Socket Bolt (4 Used) Guide Piston Rod Wear Ring (2 Used)

678910 -

Backup Ring U-Ring Plate Retaining Ring Rod

11 12 13 14 15 -

W3-4-8

O-Ring Cylinder Spring Spacer Bracket

16 - Nut 17 - Bolt 18 - Valve

UNDERCARRIAGE / Track Adjuster Assemble Track Adjuster 1. Clean all parts. Install wear rings (5) (2 used), backup ring (6), U-ring (7), plate (8) and retaining ring (9) to piston rod (4). 4

4. Install O-ring (1) on guide (3). Install guide (3) on piston rod (4). Apply LOCTITE #262 to socket bolts (2) (4 used) and tighten the socket bolts.

5 6

IMPORTANT: Fill chamber (B) in cylinder (12) with grease and insert piston rod (4) to completely bleed air from chamber (B) and from the inside of rod (10).

ϖ 14 mm ϖ 210 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

3 W142-03-04-008

1 2

2. Apply a film of grease to O-ring (11) and install it into cylinder (12). Install rod (10) into cylinder (12). 11

10 12 W142-03-04-018

W142-03-04-012

3. Apply grease to U-ring (7), wear rings (5) (2 used), cylinder (12) and piston rod (4). Install piston rod (4) into cylinder (12).

W3-4-9

UNDERCARRIAGE / Track Adjuster

W142-03-04-016

W3-4-10

UNDERCARRIAGE / Track Adjuster CAUTION: Bracket (15) weight: 45 kg (100 Ib) Spring (13) weight: 350 kg (770 Ib) 5. Place bracket (15) and spacer (14) on the rest. Lift and place spring (13) onto the rest. Tie spring (13) and bracket (15) together with pieces of wire.

CAUTION: Track adjuster weight (excluding nut): 640 kg (1410 Ib) 7. Fasten a sling belt around spring (13) through the eyebolt in piston rod (4). Lift and lay the assembly on a clean, secured level surface by a crane. Eyebolt

4 12

14 13

W142-03-04-006

8. Attach a sling belt through the spring part of the assembly. Lift and position the track adjuster assembly on special tool (ST 4932) while balancing it horizontally. Remove the eyebolt.

Rest

W142-03-04-007

ST 4932

CAUTION: Cylinder (12) assembly weight: 280 kg (620 Ib) 6. Install eyebolt (M16, Pitch 2) onto piston rod (4). Lift and position the cylinder (12) assembly in place onto spacer (14) and bracket (15) by a crane.

W142-03-04-005

W3-4-11

UNDERCARRIAGE / Track Adjuster

17 16

W142-03-04-016

W3-4-12

UNDERCARRIAGE / Track Adjuster IMPORTANT: Be sure to slowly compress spring (13) while aligning the center of rod (10) with the center of bracket (15) using a crowbar. Take care not to damage the threads on rod (10). 9. Remove wire from spring (13). Compress spring (13) by operating the cylinder of special tool (ST 4932) until the specified spring length is obtained. (Specified spring length: 800 mm (31.5 in)) 13 ST 4932

11. Tighten valve (18). ϖ 24 mm ϖ 147 N⋅m (15 kgf⋅m, 108 Ibf⋅ft) 12. Retract the cylinder of special tool (ST 4932). CAUTION: Track adjuster weight: 650 kg (1430 Ib) 13. Securely fasten a sling belt to the track adjuster. Lift and remove the track adjuster by a crane. 14. If the spring assembly must be transported, take care not to damage it. Use a firm steel box for transportation of the spring assembly and take all other precautions to insure safe transportation.

Wire

W142-03-04-015

10. Install nut (16) and bolt (17) to rod (10). ϖ 150 mm ϖ 24 mm ϖ 39 N⋅m (4 kgf⋅m, 29 Ibf⋅ft) 16 10

17 18

W142-03-04-020

W3-4-13

UNDERCARRIAGE / Track Adjuster (Blank)

W3-4-14

UNDERCARRIAGE / Front Idler REMOVE AND INSTALL FRONT IDLER Removal Before removing the front idler, the tracks must be removed first. For removal and installation of the tracks, refer to “Remove and Install Tracks” section. In this section, the procedure starts on the premise that the tracks have already been removed. CAUTION: Front idler weight: Approx. 760 kg (1680 Ib) W142-03-05-002

CAUTION: When removing the front idler, the front idler may come out explosively by spring force. Don’t stand in the removal direction of the front idler or in a place where the front idler may come out.

1. Slide the front idler forward, with a crowbar. 1 2

2. Attach sling belts to bearing (1) and yoke (2) sections. Remove the front idler assembly from track frame (3) by a crane.

W142-03-05-003

3. Remove bolts (5) (4 used) to remove guard (4) from yoke (2). ϖ 24 mm

Wooden Blocks W105-03-05-003

4. When storing the front idler, place it on blocks as shown. 3

Installation 1. To install the front idler, simply perform the removal procedures in the reverse order. Apply a film of grease to the sliding surface between track frame (3) and bearing (1) after cleaning.

W3-5-1

1 W142-03-05-005

UNDERCARRIAGE / Front Idler DISASSEMBLE FRONT IDLER 2 1 3 4 6 7

6 5 4 3 2 1

13 14

W142-03-05-001

11 1234-

Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Floating Seal (2 Used)

5678-

Axle Bushing (2 Used) Idler Plug (2 Used)

9 - Yoke 10 - Bolt (4 Used) 11 - Spring Washer (4 Used)

W3-5-2

12 - Guard 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)

UNDERCARRIAGE / Front Idler Disassemble Front Idler • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

IMPORTANT: For handling of floating seal, refer to the section “Precautions for Floating Seal Handling” on page W1-1-4. 5. Remove floating seals (4) (2 used) from bearing (1) and idler (7).

CAUTION: Guard (12) weight: 13 kg (30 Ib) 1. Loosen bolts (13) (4 used) to remove guard (12) from yoke (9). ϖ 24 mm CAUTION: Yoke (9) weight: 13 kg (30 Ib) 2. Loosen bolts (10) (4 used) to remove yoke (9) from bearing (1). Remove plug (8) from bearing (1) to drain oil into a container. ϖ 36 mm ϖ 6 mm 3. Remove pin (2) from bearings (1) (2 used).

CAUTION: Idler assembly weight: Approx. 740 kg (1630 Ib) Axle (5) weight: Approx. 60 kg (130 Ib) Bearing (1) weight: Approx. 40 kg (90 Ib) 4. Push axle (5) out of bearing (1) with a press. Bearing (1) in opposite side shall be pushed out with its axle (5). Press

W105-03-05-008

W3-5-3

UNDERCARRIAGE / Front Idler

6 5

3 1

W142-03-05-001

W3-5-4

UNDERCARRIAGE / Front Idler CAUTION: Axle (5) weight: 60 kg (130 Ib) 6. Press out axle (5) to remove bearing (1) and Oring (3) (2 used). 3

Press

W183-03-05-001

7. In case of replacing bushing (6), remove the bushing with a press and special tool (ST 1915).

Press

ST 1915 Front Idler

W105-03-05-011

W3-5-5

UNDERCARRIAGE / Front Idler ASSEMBLE FRONT IDLER

12 13, 14

W142-03-05-004

1234-

Bearing (2 Used) Pin (2 Used) O-Ring (2 Used) Floating Seal (2 Used)

5678-

Axle Bushing (2 Used) Idler Plug (2 Used)

9 - Yoke 10 - Bolt (4 Used) 11 - Spring Washer (4 Used)

W3-5-6

12 - Guard 13 - Bolt (4 Used) 14 - Spring Washer (4 Used)

UNDERCARRIAGE / Front Idler Assemble Front Idler CAUTION: The axle (5) assembly weight: 75 kg (170 Ib)

CAUTION: Idler weight: 510 kg (1120 Ib) 1. Install bushing (6) (2 used) into idler (7) with a press.

4. Insert axle (5) into idler (7). Install O-ring (3) onto axle (5). 1

CAUTION: Axle (5) weight: 60 kg (130 Ib) Bearing (1) weight: 40 kg (90 Ib)

7 1

2. Install O-ring (3) (1 used) to axle (5). Aligning the pin holes, install axle (5) into bearing (1) and secure with pin (2). Take care not to damage Oring (3). 5 2

W157-03-05-005

5. Install the other floating seals (4) (one pair) into idler (7) and into the other bearing (1).

6. Install bearing (1) onto axle (5), aligning the pin holes, secure them with pin (2).

W105-03-05-014

7. Add engine oil via plug (8) hole on bearing (1). Apply sealant (LOCTITE #503 or equivalent) to plug (8). Tighten plug (8). ϖ 6 mm ϖ 29.5 N⋅m (3 kgf⋅m, 21.5 Ibf⋅ft)

IMPORTANT: For handling of floating seal, refer to the section “Precautions for Floating Seal Handling” on page W1-1-4.

Engine oil: APl CD class SAE30 Quantity: 0.6 L, 0.16 Us gallon

3. Install floating seals (4) (one pair) into idler (7) and into bearing (1).

CAUTIN: Idler (7) weight: 740 kg (1630 Ib) Yoke (9) weight: 13 kg (30 Ib)

7 4

8. Install yoke (9) to bearing (1) and tighten bolts (10) (4 used) with spring washers (11) (4 used). ϖ 36 mm ϖ 390 N⋅m (40 kgf⋅m, 290 Ibf⋅ft)

CAUTION: Guard (12) weight: 13 kg (30 Ib) W157-03-05-006

9. Install guard (12) to yoke (9) with spring washers (14) (4 used) and bolts (13) (4 used). ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 156 Ibf⋅ft)

W3-5-7

UNDERCARRIAGE / Front Idler MAINTENANCE STANDARD

E A

W166-03-05-001

Unit: mm (in)

A B C D E

Standard 123 (4.84) 277 (10.9) 934 (36.77) 980 (38.58) 23 (0.91)

Allowable Limit [85.8 (3.38)] 914 (35.98) 33 (1.3)

Remedy Clad by welding and finish or replace

Axle and Bushing Unit: mm (in)

Axle Bushing NOTE: Values in [

Outer Dia. Inner Dia. Flange Thickness

Allowable Limit 130 (5.12) 130 (5.12) 6 (0.24)

] are just for reference.

W3-5-8

Allowable Limit [129.2 (5.09)] [131 (5.16)] [5.2 (0.20)]

Remedy Replace

UNDERCARRIAGE / Upper And Lower Roller REMOVE AND INSTALL UPPER

ROLLER

Removal CAUTION: Grease pressure in the adjuster cylinder is high. Do not loosen valve (1) quickly or loosen it too much as valve (1) may fly off or high-pressure grease in the adjusting cylinder may spurt out. Loosen carefully, keeping body parts and face away from valve (1). Never loosen grease fitting (2).

W105-03-06-001

1. Loosen valve (1) of adjustor to drain grease. ϖ 24 mm 2 Grease Outlet M104-07-119

IMPORTANT: Use a nonskid cloth between track frame (5) and jack to prevent slipping. 2. Jack tracks (3) up high enough to permit upper roller (4) removal. Insert a wooden block between tracks (3) and track frame (5). Wooden Block

W105-03-06-003

CAUTION: Upper roller weight: 60 kg (430 Ib) 3. Lift upper roller (4) by a crane. Remove bolts (6) (4 used) to remove upper roller (4) from track frame (5).

ϖ 30 mm

5 W105-03-06-005

W3-6-1

UNDERCARRIAGE / Upper And Lower Roller Installation 1. Lift upper roller (4) by a crane. Install upper roller (4) onto track frame (5) with bolts (6) (4 used). ϖ 30 mm ϖ 550 N⋅m (56 kgf⋅m, 400 Ibf⋅ft)

2. Remove the wooden block and jack.

W105-03-06-005

Wooden Block

W105-03-06-003

3. Apply grease from grease fitting (2) of adjustor to adjust tracks tension. Track sag specifications (A): 485 to 515 mm (19.09 to 20.28 in)

NOTE: Check track sag after thoroughly removing soil stuck on the track area.

Grease Outlet M104-07-119

W157-03-06-002

W3-6-2

UNDERCARRIAGE / Upper And Lower Roller REMOVE AND INSTALL LOWER ROLLER 5

Removal 1. Remove the track guard and bolts (1) (4 used) to remove lower roller (5). Ď&#x2013; 41 mm

W105-03-06-008

IMPORTANT: The adjuster cylinder is under high pressure. Be sure to support the raised body with wooden block, etc. 2. Lift one side of the track frame height enough to remove the lower roller. Insert wooden blocks under track frame (2).

W105-03-06-009

CAUTION: The adjuster cylinder is under high pressure. Do not loosen valve (3) quickly or loosen it too much as high-pressure grease in the adjusting cylinder may spurt out. Do not loosen it over 1.5 turns. Loosen carefully, keeping body parts and face away from valve (3). Never loosen grease fitting (4).

W105-03-06-001

3. Loosen track adjuster valve (3) slowly. Discharge the grease till the space is enough for removing the lower roller (5) from the track frame. Ď&#x2013; 24 mm 4

CAUTION: Lower roller weight: 200 kg (440 Ib) 4. Remove lower roller (5) by a fork lift.

W3-6-3

Grease Outlet M104-07-119

UNDERCARRIAGE / Upper And Lower Roller Installation CAUTION: Lower roller weight: 200 kg (440 Ib) 1. Put lower rollers (5) on the tracks frame (2) as per illustration by a fork lift. 2

W105-03-06-011

2. Lower the track frame (2) until the clearance between the track frame and collar (6) for lower roller (5) is very close.

W105-03-06-012

3. Install lower roller (5) onto track frame (2) with bolts (1) (4 used). 5

ϖ 41 mm ϖ 1050 N⋅m (107 kgf⋅m, 770 Ibf)

W105-03-06-008

W3-6-4

UNDERCARRIAGE / Upper And Lower Roller 4. Supply grease through grease fitting (4) to adjust tracks tension. Track sag specifications (A): 485 to 515 mm ϑ19.1 to 20.3 inϒ

Grease Outlet M104-07-119

W157-03-06-002

W3-6-5

UNDERCARRIAGE / Upper And Lower Roller DISASSEMBLE UPPER ROLLER

11 10 9 8

6 5 4 3 2 1

12 W166-03-06-005

1 - Socket Bolt (3 Used) 2 - Plug 3 - Cover

4 - O-Ring 5 - Thrust Plate 6 - Bushing

7 - Roller 8 - Bushing 9 - Floating Seal

W3-6-6

10 - Axle 11 - Bracket 12 - Socket Bolt (3 Used)

UNDERCARRIAGE / Upper And Lower Roller Disassemble Upper Roller • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. When replacing bushings (6) and (8), remove the bushing from the roller using press and special tool (ST 1967). NOTE: Bushings can also be removed by cladding four weld beads on the inside of bushing at 90° intervals. Bushing will shrink enough to permit removal with a hammer.

1. Remove plug (2) to drain oil. ϖ 6 mm 2. Remove socket bolts (1) (3 used) and cover (3). ϖ 17 mm

Press

3. Remove socket bolt (12) (3 used) and thrust plate (5).

ST 1967

ϖ 8 mm 7

4. Remove axle (10) from roller (7). 5. Remove floating seal (9) from roller (7) and bracket (11).

NOTE: Floating seal (9) can be reused if it is not worn. Keep the floating seal in a matched set and put cardboard between seals to protect the sealing face.

W142-03-06-005

7. Pull out axle (10) from bracket (11) with a press.

W3-6-7

UNDERCARRIAGE / Upper And Lower Roller ASSEMBLE UPPER ROLLER

1 5

2 12 3

1 - Socket Bolt (3 Used) 2 - Plug 3 - Cover

4 - O-Ring 5 - Thrust Plate 6 - Bushing

7 - Roller 8 - Bushing 9 - Floating Seal

W3-6-8

W166-03-06-008

10 - Axle 11 - Bracket 12 - Socket Bolt (3 Used)

UNDERCARRIAGE / Upper And Lower Roller Assemble Upper Roller • Before assembly, clean all parts. • Remove all scratches and roughness on the parts with an oil stone. • Replace all O-rings and seals with new ones.

8. Add engine oil via plug (2) hole on cover (3). Engine oil: API CD class SAE30 Quantity: 0.2 L (0.05 Us gallon) 9. Apply LOCTITE #503 or equivalent to plug (2). Tighten plug (2) to cover (3).

1. When necessary to replace bushings, press bushings (6) and (8) in roller (7) with a press. NOTE: Pressure to press in bushings (6) and (8): 20 ton 2. Install axle (10) bracket (11) with a press. IMPORTANT: Apply a coat of grease to the O-ring part of floating seal (9) and a film of hydraulic oil to the steel ring part. For handling of floating seal (9), refer to the section “Precautions for Floating Seal Handling” on page W11-4. 3. Install floating seal (9) to roller (7) and to bracket (11). 4. Insert axle (10) into roller (7). 5. Install thrust plate (5) to axle (10), tighten socket bolts (12) (3 used). ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 6. Apply grease to O-ring (4) and install it to cover (3). Ȁ 7. Install cover (3) to roller (7), and tighten socket bolts (1) (3 used).

ϖ 17 mm

ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft)

W3-6-9

ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

UNDERCARRIAGE / Upper And Lower Roller DISASSEMBLE LOWER ROLLER

5 4

7 5 8

6 1 3 4

W166-03-06-006

1 - Floating Seal (2 Used) 2 - Axle

3 - O-Ring (2 Used) 4 - Collar (2 Used)

5 - Pin (2 Used) 6 - Plug (2 Used)

W3-6-10

7 - Bushing (2 Used) 8 - Roller

UNDERCARRIAGE / Upper And Lower Roller Disassemble Lower Roller • Be sure to thoroughly read “Precautions for Disassembly and Assembly Work” on page W1-1-1 before starting the disassembly work.

6. In case of replacing bushings (7), remove the bushings using press and special tool (ST 1921). Press

CAUTION: Lower roller weight: 200 kg (440 Ib) 1. Remove plugs (6) from collars (4) (2 used) and drain oil. Push out pins (5) (2 used) from collars (4) (2 used) with an adapter bar and hammer. ϖ 6 mm

ST 1921 Roller

2. Press down axle (2) until O-ring (3) comes out of collar (4). Remove collar (4) from axle (2). 3. Remove O-ring (3) from axle (2). Remove axle (2) from roller (8).

W105-03-06-028

4. Remove floating seal (1) from roller (8) and collar (4). 5. Press out axle (2), and remove collar (4) and Oring (3) from axle (2). Press

W105-03-06-027

W3-6-11

UNDERCARRIAGE / Upper And Lower Roller ASSEMBLE LOWER ROLLER

1 - Floating Seal (2 Used) 2 - Axle

3 - O-Ring (2 Used) 4 - Collar (2 Used)

5 - Pin (2 Used) 6 - Plug (2 Used)

W3-6-12

W162-03-06-002

7 - Bushing (2 Used) 8 - Roller

UNDERCARRIAGE / Upper And Lower Roller Assemble Lower Roller CAUTION: Lower roller weight: 120 kg (260 Ib)

4. Insert axle (2) into roller (8). Install O-ring (3) and the other collar (4). Secure them with pin (5).

1. Install bushings (7) (2 used) onto roller (8) with a press. Take care not to dent the flange surface of bushings (7). Apply a coat of grease to O-ring (3) and install it onto axle (2). 2. Press collar (4) onto axle (2) while aligning the pin (5) holes both in axle (2) and collar (4). Secure them with pin (5). Take care not to damage O-ring (3). 5

3 W157-03-06-009

5. Add engine oil via plug (6) hole on collars (4) (2 used). Engine oil: API CD class SAE30 Quantity: 1.5 L (0.4 Us gallon) 6. Apply sealant LOCTITE #503 or equivalent to plugs (6) (2 used). Install plugs (6) (2 used) into collar (4). ϖ 6 mm ϖ 20 N⋅m (2 kgf⋅m, 14.5 Ibf⋅ft)

3 W166-03-06-009

IMPORTANT: Coat grease on O-ring of floating seal and then install it. For handling of floating seal, refer to the section “Precautions for Handling Floating Seal” on page W1-1-4. 3. Install floating seal (1) to roller (8) and to collar (4). 8

1 4

W157-03-06-008

W3-6-13

UNDERCARRIAGE / Upper And Lower Roller MAINTENANCE STANDARD Upper Roller

A B W166-03-06-007

Unit: mm (in)

A B C

Standard 118 (4.65) 240 (9.45) 200 (7.87)

Allowable Limit − − 190 (7.48)

Remedy Clad by welding and finish or replace

Axle and Bushing Unit: mm (in)

Axle Bushing

NOTE: Values in [

Outer Dia. Inner Dia.

Standard 75 (2.95) 75.2 (2.96)

Allowable Limit [74.2 (2.92)] [76.2 (3)]

Flange Thickness

4.5 (0.18)

[3.7 (0.15)]

] are just for reference.

W3-6-14

Remedy Replace

UNDERCARRIAGE / Upper And Lower Roller

Lower Roller

W157-03-06-003

Unit: mm (in)

A B C D

Standard 290 (11.42) 366 (14.4) 38 (1.5) 280 (11.02)

Allowable Limit [328 (12.91)] 262 (10.31)

Remedy Clad by welding and finish or replace

Axle and Bushing Unit: mm (in)

Axle Bushing

NOTE: Values in [

Outer Dia. Inner Dia.

Standard 120 (4.72) 120 (4.72)

Allowable Limit [119.2 (4.69)] [121 (4.76)]

Flange Thickness

6 (0.24)

[5.2 (0.20)]

] are just for reference.

W3-6-15

Remedy Replace

UNDERCARRIAGE / Upper And Lower Roller (Blank)

W3-6-16

UNDERCARRIAGE / Track REMOVE AND INSTALL TRACKS Removal CAUTION: The adjusting cylinder is highly pressurized. Loosening valve (1) quickly or excessively may cause valve (1) to fly off and the highly pressurized grease to spurt out, possibly resulting in personal injury. Do not loosen the valve over 1.5 turns. Be sure to loosen vlave (1) slowly and gradually, keeping face and body parts away from valve (1). In addition, never attempt to loosen grease fitting (2). 1. Rotate the tracks so that master pin (3) is positioned over front idler (4). Put a wooden block under track shoes (5) as shown.

W105-03-07-001

W105-03-07-006

Wooden Block

Loosen the track tension.

NOTE: Slowly turn valve (1) counterclockwise one turn, grease will be released via grease outlet. Ď&#x2013; 24 mm W105-03-07-002

1 Grease Outlet

W3-7-1

M104-07-119

UNDERCARRIAGE / Track 3. Remove pin (6), which is used to secure master pin (3). If it is difficult to remove pin (6) from master link (7), tap in master pin (3) in the inserting direction to make clearance between pin (6) and master pin (3) before attempting to pull out pin (6).

CAUTION: The front idler may jump out of position due to strong spring force when the track is disconnected. Never stand in front of the front idler. Moreover, if the rod or the rod screw is damaged, the damaged part may fly off since strong spring force is always applied to the rod screw. Take necessary precautions to prevent personal injury.

7 3

W142-03-07-001

W105-03-07-005

W3-7-2

UNDERCARRIAGE / Track ST 1970

4. Remove master pin (3) using special tool (ST 1970). IMPORTANT: The direction of removing master pin is as illustrated. Be sure to strike the pin correctly.

W105-03-07-008

Remove master pin in this direction

Master Pin

W166-03-07-002

Boom

5. Raise the machine as illustrated with the angle between the boom and the arm held at 90째 to 110째 and the bucket round bottom section placed on the ground. Put wooden blocks under the track frame to safely support the raised machine.

Arm 90째 to 110째

W105-03-07-012

6. Slowly operate the raised side travel lever in the reverse direction to remove the tracks from the machine.

W105-03-07-011

W3-7-3

UNDERCARRIAGE / Track Installation 1. Raise the machine with the front attachment and put the track under the lower roller so that the sprocket teeth align with the end of the track. Be sure to position the track in the correct direction, as illustrated.

Sprocket Side

Idler Side

W105-03-07-013

CAUTION: Track link assembly weight: 5310 kg (11710 Ib) 2. Lift the track, and place it on sprocket (1). 1

W105-03-07-014

3. With the machine kept raised, slowly turn the raised side sprocket in forward direction to wind the track around the raised track frame (2).

W105-03-07-015

4. Turn sprocket until the end of track (5) comes on front idler (4). Lower the machine and put a wooden block as illustrated.

5 W105-03-07-016

Wooden Block

W3-7-4

UNDERCARRIAGE / Track 5. Install master pin (3), with a hammer and special tool (ST 1971).

ST 1970

IMPORTANT: Master pin (3) is directional. Be sure to install it in correct direction.

W105-03-07-017

Direction for installing the master pin

Master Pin

W166-03-07-002

6. Install pin (6). IMPORTANT: Old pin (6) canâ&#x20AC;&#x2122;t be reused. Replace it with a new one for its easy deformation.

W142-03-07-001

W3-7-5

UNDERCARRIAGE / Track 7. Charge grease to the cylinder through grease fitting to adjust the track tension. Ï&#x2013; 24 mm Track sag specifications (A): 485 to 515 mm (19.09 to 20.28 in) NOTE: Check track sag after thoroughly removing soil stuck on the track area.

W105-03-07-018

W157-03-06-002

W3-7-6

UNDERCARRIAGE / Track MAINTENANCE STANDARD Link Pin and Track Bushing Measure the length of four links: • Do not measure the master-pin-included part of the track. • The work shall be done with the tension on the track.

A W155-03-07-001

Unit: mm (in)

A B

Standard 1041.4 (41.0) 155 (6.1)

Allowable Limit 1061.8 (41.8) [148 (5.83)]

Remedy Clad by welding and finish or replace

Master Pin

W142-03-07-003

Unit: mm (in)

A B NOTE: Values in [

Standard 301 (11.85) 57.8 (2.28)

Allowable Limit [54.8 (2.16)]

] are just for reference.

W3-7-7

Remedy Replace

UNDERCARRIAGE / Track Master Bushing

W105-03-07-023

Unit: mm (in)

A B C

Standard 204 (8.03) 58.65 (2.31) 90 (3.54)

Allowable Limit [61.7 (2.43)] [85 (3.35)]

Remedy Replace

Grouser Shoe

W105-03-07-024

Unit: mm (in)

Shoe A B C

NOTE: Values in [

Standard 302 (11.89) 25 (0.98) 50 (1.97)

600 mm Grouser Allowable Limit â&#x2C6;&#x2019; [26 (1.02)] [45 (1.77)]

] are just for reference.

W3-7-8

Remedy Replace

UNDERCARRIAGE / Track Bushing

W105-03-07-023

Unit: mm (in)

A B C

Standard 222.1 (8.74) 59.15 (2.33) 90 (3.54)

Allowable Limit [60.2 (2.37)] 85 (3.35)

Remedy Replace

W105-03-07-020

Unit: mm (in)

A B

NOTE: Values in [

Standard 319.5 (12.58) 58.15 (2.29)

Allowable Limit [55.2 (2.17)]

] are just for reference.

W3-7-9

Remedy Peplace

UNDERCARRIAGE / Track (Blank)

W3-7-10

SECTION 4

FRONT ATTACHMENT CONTENTS Group 1 Front Attachment Remove and Install Front Attachment..... W4-1-1 Remove and Install Bucket and Arm (Backhoe)............................................. W4-1-2 Remove and Install Bucket and Arm (Loading Shovel) ................................ W4-1-10 Remove and Install Boom (Backhoe, Loading Shovel) ................. W4-1-14 Greasing(Backhoe) .............................. W4-1-18 Greasing(Loading Shovel) .................... W4-1-19

Group 2 Cylinder Remove and Install Cylinder ................... W4-2-1 Disassemble Cylinder ........................... W4-2-35 Assemble Cylinder ............................... W4-2-42 Air Bleeding Procedure......................... W4-2-50 Maintenance Standard ......................... W4-2-51

Group 3 Bushing and Point Remove and Install Bushing ................... W4-3-1 Maintenance Standard ........................... W4-3-6

183W-4-1

(Blank)

183W-4-2

FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL FRONT ATTACHMENT CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Always turn the air breather cap slowly to release any remaining pressure befor removing it. Preparation 1. Park the machine on a level solid surface. Lower the front attachment to the ground. 2. After stopping the engine, move the control levers several times to release any pressure remaining in the system. Rotate the hydraulic oil tank cap approx. 30Â° counterclockwise using a hexagon wrench to release the trapped air in the hydraulic oil tank. Refer to Bleeding Air from Hydraulic System on page W1-1-2. Ď&#x2013; 4 mm

W183-04-02-003

W183-04-02-002

Wooden Blocks Cap

W183-01-01-001

W4-1-1

FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL BUCKET AND ARM (BACKHOE) 2

1 Link A

D Link B B C W183-04-02-003

21, 22

5, 4

9, 8

6 7

12 Section A

Section B

W142-04-01-013

Section D

W118-04-01-011

W183-04-01-006

21, 22 18,19 15, 14 20

13 16

Section C W183-04-01-003

123456-

Bucket Cylinder Arm Cylinder Pin Bolt (3 Used) Spring Washer (3 Used) Stopper

78910 11 12 -

Pin Bolt (3 Used) Spring Washer (3 Used) Stopper Spacer O-Ring (2 Used)

13 14 15 16 17 -

W4-1-2

Pin Bolt (10 Used) Spring Washer (10 Used) Cover (2 Used) Pin

18 19 20 21 22 -

Bolt (2 Used) Spring Washer (2 Used) Plate O-Ring (4 Used) Ring (4 Used)

FRONT ATTACHMENT / Front Attachment Remove Bucket and Arm (Backhoe) CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. 1.

Remove ring (22) at the linkage part of the bucket and link A. Move O-ring to the bucket side. (4 places at left and right)

CAUTION: Pin (7) weight: 95 kg (210 Ib) 4. Remove bolts (8) (3 used), spring washers (9) (3 used) and stopper (10), which are used on pin (7) to mount link B and arm. Then pull pin (7) out. When pin (7) is pulled out half way, hoist it by a crane to remove pin (7). ϖ

21, 22

30 mm

CAUTION: Link A assembly + link B weight: 660 kg (1460 Ib) 5. Hoist link A and link B by a crane and remove from the arm.

Bucket

CAUTION: Spacer (11) weight: 30 kg (70 Ib) Moving of the O-Ring and Ring

W183-04-01-001

6. Remove spacer (11) from link A and remove Orings (12) (2 used) from spacer (11). CAUTION: Cover (16) weight: 25 kg (60 Ib)

Link A Bucket W183-04-01-002

2. Remove bucket cylinder (1). (Refer to W4-2-14)

7. Remove bolts (14) (5 used), spring washers (15) (5 used) and cover (16) from pin (13) to mount bucket and arm. (2 places at left and right). ϖ 32 mm

CAUTION: Link A assembly + link B weight: 660 kg (1460 Ib) Pin (3) weight: 110 kg (240 Ib)

CAUTION: Pin (13) weight: 150 kg (330 Ib) 8. Remove pin (13) out of the pin hole.

3. Holding link A and link B by a crane, remove bolts (4) (3 used), spring washers (5) (3 used) and stopper (6) , which are used on pin (3) to mount bucket and link A.Then pull pin (3) out.

CAUTION: Bucket weight: 4490 kg (9900 Ib) 3 (Standard bucket capacity 5.0 m ) BE bucket weight: 5990 kg (13210 Ib) 3 (BE bucket capacity 7.1 m )

ϖ 30 mm

9. Hoist the bucket by a crane and remove it. 10. Remove arm cylinder (2). (Refer to W4-2-6)

W4-1-3

FRONT ATTACHMENT / Front Attachment

Link A

D Link B B C W183-04-02-003

Section B

W142-04-01-013

Section D

W118-04-01-011

W183-04-01-006

Section A

18,19 20 17

Section C W183-04-01-003

W4-1-4

FRONT ATTACHMENT / Front Attachment 11. Remove the greasing hoses (4 used) from the mounting part of the boom and arm. (2 places at left and right ) Ď&#x2013; 19 mm Greasing Hose

M142-07-082

CAUTION: Arm weight: 3570 kg (7870 Ib) Pin (17) weight: 180 kg (400 Ib) 12. Hoist arm by a crane to remove bolts (18) (2 used), spring washers (19) (2 used) and plate (20) from pin (17) to link boom and arm .Then remove pin (17). Ď&#x2013; 30 mm 13. Hoist the arm by a crane to remove it. Lay down wooden blocks and put the boom on the wooden blocks.

W4-1-5

FRONT ATTACHMENT / Front Attachment

1 Link A

D Link B B C W183-04-02-003

21, 22

5, 4

9, 8

6 7

12 Section A

Section B

W142-04-01-013

Section D

W118-04-01-011

W183-04-01-006

21, 22 18,19 15, 14 20

13 16

Section C W183-04-01-003

123456-

Bucket Cylinder Arm Cylinder Pin Bolt (3 Used) Spring Washer (3 Used) Stopper

78910 11 12 -

Pin Bolt (3 Used) Spring Washer (3 Used) Stopper Spacer O-Ring (2 Used)

13 14 15 16 17 -

W4-1-6

Pin Bolt (10 Used) Spring Washer (10 Used) Cover (2 Used) Pin

18 19 20 21 22 -

Bolt (2 Used) Spring Washer (2 Used) Plate O-Ring (4 Used) Ring (4 Used)

FRONT ATTACHMENT / Front Attachment Install Bucket and Arm (Backhoe) CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

CAUTION: Link B weight: 120 kg (260 Ib) 7. Hoist link B by a crane to align the pin holes of the arm and link B. CAUTION: Pin (7) weight: 95 kg (210 Ib)

CAUTION: Arm weight: 3570 kg (7870 Ib) 1. Start the engine. Raise the boom and hoist the arm by a crane to align the pin hole of the boom with that of the arm. CAUTION: Pin (17) weight: 180 kg (400 Ib) 2. Insert pin (17) into the pin hole. Install bolts (18) (2 used), spring washers (19) (2 used) and plate (20).

8. Hoist pin (7) by a crane and insert it into the pin hole. CAUTION: Link B weight: 120 kg (260 Ib) 9. Hoist the other link B by a crane and install it into pin (7). Install bolts (8) (3 used), spring washers (9) (3 used) and stopper (10). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

CAUTION: Spacer (11) weight: 30 kg (70 Ib) Link A weight: 200 kg (440 Ib)

3. Install arm cylinder (2). (Refer to W4-2-6) CAUTION: Bucket weight: 4490 kg (9900 Ib) 3 (Standard bucket capacity 5.0 m ) BE bucket weight: 5990 kg (13210 Ib) 3 (BE bucket capacity 7.1 m ) 4. Start the engine. Raise the arm and align the pin hole of the arm with that of the bucket. CAUTION: Pin (13) weight: 150 kg (330 Ib)

10. Install O-rings (12) (2 used) onto spacer (11). Then install link A (2 used) to spacer (11). CAUTION: Link A + spacer (11) weight: 430 kg (950 Ib) 11. Pass a metal bar through the pin hole in link A and attach a wire on it. Hoist link A and spacer (11) by a crane. CAUTION: Pin (3) weight: 110 kg (240 Ib)

5. Insert pin (13) into the pin hole. CAUTION: Cover (16) weight: 25 kg (60 Ib) 6. Install bolts (14) (5 used), spring washers (15) (5 used) and covers (16). (2 places at left and right).

12. Align the pin holes of the bucket, link A and spacer (11) and insert pin (3) to install bolts (4) (3 used), spring washers (5) (3 used) and stopper (6).

ϖ 32 mm ϖ 550 N⋅m (56 kgf⋅m, 400 Ibf⋅ft)

W4-1-7

ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

FRONT ATTACHMENT / Front Attachment

1 Link A

D Link B B C W183-04-02-003

21, 22

Section B

W142-04-01-013

W183-04-01-006

Section A 21, 22

Section C

W183-04-01-003

W4-1-8

Section D

W118-04-01-011

FRONT ATTACHMENT / Front Attachment 13. Move bucket O-ring (21) back to its position to install ring (22). (4 places at right and left) 21, 22

Bucket

W183-04-01-001

Moving of the O-Ring and Ring

Link A Bucket W183-04-01-004

14. Install bucket cylinder (1). (Refer to W4-2-14) 15. Attach the hose to the mounting part of the boom and arm. (2 places at right and left) ϖ 19 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft) Greasing Hose

M142-07-082

W4-1-9

FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL BUCKET AND ARM (LOADING SHOVEL) B

W183-04-02-002

Wooden Blocks Greasing Hose

Hydraulic Hose

W183-04-02-027 W183-04-02-023

W183-04-02-010

Wooden Blocks

13 12

9 8

7, 6

5 10

W183-04-01-007

Section A Section B

1234-

Dump Cylinder (2 Used) Bucket Cylinder (2 Used) Arm Cylinder Level Cylinder

5678-

Pin (2 Used) Bolt (6 Used) Spring Washer (6 Used) Stopper (2 Used)

9 - Shim (Several) 10 - O-Ring (2 Used) 11 - Pin (2 Used)

W4-1-10

W166-04-01-015

12 - Bolt (4 Used) 13 - Spring Washer (4 Used) 14 - Plate (2 Used)

FRONT ATTACHMENT / Front Attachment Remove Bucket and Arm (Loading Shovel) CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. 1. Move the O-ring on the mounting part of the bucket and arm to the bucket side. (2 places at right and left)

CAUTION: Bucket + dump cylinder weight: 9520 kg (20990 Ib) 5. Hoist the bucket by a crane and remove it. Put the arm on wooden blocks. 6. Remove arm cylinder (3). Then remove level cylinder (4). (Refer to W4-2-10 Remove and Install the arm cylinder and refer to W4-2-22 Remove and Install the Level Cylinder)

Moving of the O-ring

CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap to relieve pressure.

Arm Bucket W183-04-01-002

2. Remove bucket cylinder (2). (Refer to W4-2-18) CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap to relieve pressure. 3. Stop the engine and operate the lever several times to release the remaining pressure in the hydraulic circuit. Then drain the air out from the hydraulic oil tank.Disconnect the hydraulic hoses (2 used) and greasing hose from the mounting part of the arm and bucket. ϖ 12 mm ϖ 19 mm

7. Stop the engine. Operate the lever several times to release the remaining pressure from hydraulic circuit. Then drain the air out from the hydraulic oil tank. Disconnect the hydraulic hoses (6 used) and greasing hoses (2 used) from the mounting part of the arm and boom. ϖ 12 mm ϖ 19 mm CAUTION: Arm weight: 4200 kg (9260 Ib) Pin (11) weight: 80 kg (180 Ib) 8. Hoist arm by a crane to remove bolts (12) (2 used), spring washers (13) (2 used) and plate (14) from pin (11) to mount arm and boom. Pull pin (11) out. (2 places at right and left) ϖ 30 mm 9. Hoist arm by a crane and remove it. Place boom onto wooden blocks.

CAUTION: Pin (5) weight: 65 kg (140 Ib) 4. Start the engine to hold the arm in position. Remove bolts (6) ( 3 used), spring washers (7) (3 used) and stopper (8) from pin (5) of the bucket and arm. Push pins (5) out and remove shims (9).(2 places at right and left) ϖ 24 mm

W4-1-11

FRONT ATTACHMENT / Front Attachment

W183-04-02-002

Wooden Blocks Greasing Hose

Hydraulic Hose

W183-04-02-027 W183-04-02-023

W183-04-02-010

Wooden Blocks

13 12

9 8

7, 6

5 10

W183-04-01-007

Section A Section B

W4-1-12

W166-04-01-015

FRONT ATTACHMENT / Front Attachment Install Bucket and Arm (Loading Shovel) CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

CAUTION: Bucket (6.5 m ) + dump cylinder weight: 9520 kg (20990 Ib) 5. Start the engine. Raise the arm and align the pin hole of the arm with that of the bucket to install shim (9).

CAUTION: Arm weight: 4200 kg (9260 Ib) CAUTION: Pin (5) weight: 65 kg (140 Ib) 1. Start the engine. Raise the boom up and hoist the arm by a crane. Align the pin hole of the boom with that of the arm.

6. Insert pin (5) into the pin hole. Install bolts (6) (3 used), spring washers (7) (3 used) and stopper (8). (2 places at right and left)

CAUTION: Pin (11) weight: 80 kg (180 Ib)

ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft)

2. Insert pin (11) into the pin hole. Install bolts (12) (2 used), spring washers (13) (2 used) and plate (14). (2 places at right and left)

CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure.

ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 3. Stop the engine. Operate the lever several times to release the remaining pressure from the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Install hydraulic hoses (6 used) and greasing hoses (2 used) to the mounting part of the boom and arm. ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 19 mm 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

7. Stop the engine. Operate the lever several times to release the remaining pressure in the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Install hydraulic hoses (2 used) and the greasing hose to the mounting part of the arm and bucket. ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 19 mm 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

8. Move O-ring (10) having been moved to the bucket side back to its original position and install it. (2 places at right and left) Moving of the O-ring

4. Install level cylinder (4) and then install arm cylinder (3). (Refer to W4-2-22 Remove and Install Level Cylinder and refer to W4-2-10 Remove and Install Arm Cylinder.) Bucket

Arm W183-04-01-004

9. Install bucket cylinder (2). (Refer to W4-2-18)

W4-1-13

FRONT ATTACHMENT / Front Attachment REMOVE AND INSTALL BOOM (BACKHOE, LOADING SHOVEL) A

W183-04-02-003

W183-04-02-002

Hydraulic Hoses Hydraulic Hoses

Greasing Hose

Backhoe

Loading Shovel

W183-04-02-024

W183-04-02-025

6 Section A 1 - Boom Cylinder (2 Used) 2 - Pin (2 Used)

3 - Bolt (4 Used) 4 - Spring Washer (4 Used)

5 - Plate (2 Used)

W4-1-14

4 5

W162-04-01-025

6 - Shim (2 Used)

FRONT ATTACHMENT / Front Attachment Remove Boom CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. 1. Remove the bucket and arm. (Refer to W4-1-2 Backhoe and W4-1-10 Loading Shovel) 2. Remove boom cylinder (1). (Refer to W4-2-2) CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to the pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 3. Stop the engine. Operate the lever several times to release the remaining pressure in the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Disconnect the hydraulic hoses (11 used) from the main frame side. ϖ 12 mmЕ14 mm CAUTION: Boom weight Backhoe: 8860 kg (19530 Ib) BE backhoe: 8580 kg (18920 Ib) Loading shovel: 5690 kg (12540 Ib) Pin (2) weight: 70 kg (150 Ib) 4. Hoist the boom by a crane. Remove bolts (3) (2 used),spring washers (4) (2 used) and plate (5) from pin (2) by which the boom and main frame being installed together. Then remove shims (6). (2 places at right and left) ϖ 30 mm 5. Hoist the boom by a crane and remove the boom.

W4-1-15

FRONT ATTACHMENT / Front Attachment

W183-04-02-003

W183-04-02-002

Hydraulic Hoses Hydraulic Hoses

Greasing Hose

Backhoe

Loading Shovel

W183-04-02-024

W183-04-02-025

6 Section A

W4-1-16

4 5

W162-04-01-025

FRONT ATTACHMENT / Front Attachment Install Boom CAUTION: Boom weight Backhoe: 8860 kg (19530 Ib) Be Backhoe: 8580 kg (18920 Ib) Loading Shovel: 5690 kg (12540 Ib) 1. Hoist the boom by a crane to align the pin holes of the boom and main frame. Install shims (6). (2 places at right and left)

IMPORTANT: When finishing the installing of bucket, arm and boom, carry out the following work. 6. When finishing the installing of bucket, arm and boom, apply grease to all grease fittings shown in the figure. (Refer to W4-1-18)

CAUTION: Pin (2) weight: 70 kg (150 Ib) 2. Insert pin (2) into the pin hole. Install bolts (3) (2 used), spring washers (4) (2 used) and plate (5). (2 places at right and left) ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m,295 Ibf⋅ft) CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 3. Stop the engine. Operate the lever several times to release the remaining pressure in the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Lay down wooden blocks and place the boom on them. Install the hydraulic hoses (11 used) to the main frame side. ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m,101 Ibf⋅ft) 14 mm 210 N⋅m (21.5 kgf⋅m,155 Ibf⋅ft)

4. Install boom cylinder (1). (Refer to W4-2-2) 5. Install the bucket and arm (Refer to W4-1-2 Backhoe paragraph and W4-1-10 Loading Shovel paragraph)

W4-1-17

NOTE: In order to protect the grease fittings around the bucket, a cap is installed. Before greasing, the cap should be removed with a screw driver first. Then carry out greasing.

FRONT ATTACHMENT / Front Attachment GREASING (BACKHOE) C Bucket and Link Joint Pin B A Arm and Link Joint Pin

Bucket and Arm Joint Pin

Boom Foot Arm Side

W183-04-01-005

Boom Cylinder Bottom Side Arm Cylinder Bottom Side Bucket Cylinder Bottom Side Arm Cylinder Rod Side Boom Cylinder Rod Side

Boom Cylinder Rod Side

Development

M142-07-046

Development

Boom Foot Body Side

M142-07-049

Bucket Cylinder Rod Side

Development

W4-1-18

M142-07-045

FRONT ATTACHMENT / Front Attachment GREASING (LOADING SHOVEL)

E A

Arm Cylinder Bottom Pin Level Cylinder Bottom Side

Boom Foot

Arm Foot Bucket Side

Arm Foot Boom Side

Bucket Cylinder Rod Side

Boom Cylinder Bottom Side

M183-01-058

Arm Foot Bucket Side

M142-07-047

Development D

Bucket Cylinder Bottom Side

Level Cylinder Rod Side

Development

M142-07-048

Arm Cylinder Rod Pin

Dump Cylinder Rod Pin Bucket Joint Pin

M142-07-042

Dump Cylinder Bottom Pin

M113-07-012

W4-1-19

FRONT ATTACHMENT / Front Attachment (Blank)

W4-1-20

FRONT ATTACHMENT / Cylinder REMOVE AND INSTALL CYLINDER CAUTION: 1. Escaping fluid under pressure can penetrate the skin and eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic lines. 2. Hydraulic oil may be hot after operation. Hot hydraulic oil may spurt out, possibly causing severe burns. Be sure to wait for oil to cool before starting any repair work. 3. The hydraulic oil tank cap may fly off if removed without releasing internal pressure first. Push the air release valve on top of the hydraulic oil tank to release any remaining pressure. Preparation 1. Park the machine on a solid and level surface with the front attachment positioned as illustrated below.

Wooden Blocks

W183-04-02-003

W183-04-02-002

Wooden Blocks

W4-2-1

FRONT ATTACHMENT / Cylinder Remove and Install Boom Cylinder

Backhoe

W183-04-02-003

Loading Shovel

W183-04-02-002

B: Cylinder Bottom Side

A: Cylinder Rod Side Greasing Hose 1

6 Hydraulic Hose

Greasing Hose Hydraulic Hose

10 W183-04-02-013

3 1

W183-04-02-004

4 8 6

10 10 Section A 1 - Pin (2 Used) 2 - Spacer (2 Used) 3 - Spring Washer (4 Used)

W166-04-01-015

4 - Plate (2 Used) 5 - Bolt (㈐ Used) 6 - Pin (2 Used)

7 - Bolt (㈐ Used) 8 - Spring Washer (4 Used)

W4-2-2

Section B

W183-04-02-014

9 - Plate (2 Used) 10 - Boom Cylinder (2 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. Removal 1. Disconnect greasing hoses (2 used for each one) from boom cylinders (10) (2 used).

CAUTION: Pin (6) weight: 70 kg (150 Ib) 6. Remove bolts (7) (2 used), spring washers (8) (2 used) and plate (9) on the cylinder bottom side to remove pin (6). 7. Hoist boom cylinder (10) by a crane to remove it. Then remove spacer (2). ϖ 30 mm

ϖ 19 mm CAUTION: Boom cylinder weight: 1170 kg (2580 Ibϒ ϒ Pin (1) weight: 70 kgϑ ϑ150 Ibϒ ϒ

8. Remove boom cylinder (10) on the other side by the same procedures.

2. While holding boom cylinder (10) by a crane, remove bolts (5) (2 used), spring washers (3) (2 used), and plate (4) on the cylinder rod side. Drive pin (1) in until pin (1) comes out of the cylinder rod hole. ϖ 30 mm 3. Remove pin (1) of boom cylinder (10) on the other side by the same procedure. 4. Start the engine. Fully retract boom cylinder (10). Secure the rod with a wire wound through the rod hole so that boom cylinder (10) will not extend. CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 5. Stop the engine. Operate the lever several times to release the remaining pressure from the hydraulic circuit. Drain the air out from the hydraulic oil tank and remove the hydraulic hoses (2 used) from each boom cylinders (10) (2 Used). ϖ12 mm, 14 mm Ӹ

W4-2-3

FRONT ATTACHMENT / Cylinder B

Backhoe

W183-04-02-003

Loading Shovel

W183-04-02-002

B: Cylinder Bottom Side

A: Cylinder Rod Side Greasing Hose 1

6 Hydraulic Hose

Greasing Hose Hydraulic Hose

10 W183-04-02-013

3 1

W183-04-02-004

4 8 6

10 10 Section A

W166-04-01-015

W4-2-4

Section B

W183-04-02-014

FRONT ATTACHMENT / Cylinder Installation 8. Connect the greasing hoses (2 used for each side). ϖ 19 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

CAUTION: Boom cylinder weight: 1170kg (2580 Ib) Pin (6) weight: 70 kg (150 Ib) 1. While hoisting boom cylinder (10) by a crane, align the cylinder bottom side pin hole with the boom pin hole. Then, install spacer (2).

9. Release any air remaining in the cylinder. (Refer to page W4-2-50.)

2. Install pin (6) and secure it with bolts (7) (2 used), spring washers (8) (2 used), and plate (9). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 3. Install the other side boom cylinder (10) by the same procedure. 4. Connect the hydraulic hoses (2 used for each side). Remove the wire securing the cylinder rod. ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m,101 Ibf⋅ft) 14 mm 210 N⋅m (21.5 kgf⋅m,155 Ibf⋅ft)

5. Hoist the cylinder rod by a crane and extend the rod so that cylinder rod hole aligns with the main frame hole. CAUTION: Pin (1) weight: 70 kg (150 Ib) 6. Insert pin (1) into the pin hole at the cylinder rod side and install bolts (5) (2 used), spring washers (3) (2 used) and plate (4). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 7. Install the other side boom cylinder (10) by the same procedure.

W4-2-5

FRONT ATTACHMENT / Cylinder Remove and Install Arm Cylinder (Backhoe) B A

W183-04-02-003

B: Cylinder Bottom Side

A: Cylinder Rod Side 2

Hydraulic Hose Greasing Hose

Greasing Hose

W183-04-02-016

Greasing Hose

W166-04-01-020

1 W183-04-02-001

3 5

Section A and B

1 - Pin (2 Used) 2 - Arm Cylinder

3 - Bolt (4 Used)

4 - Spring Washer (4 Used)

W4-2-6

W142-04-01-015

5 - Plate (2 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. Removal 1. Disconnect the greasing hose from the arm cylinder (2) rod side. ϖ 19 mm

CAUTION: Pin weight: 80 kg (180 Ib) 5. Remove bolts (3) (2 used) on the arm cylinder bottom side, spring washers (4) (2 used) and plate (5), to remove pin (1). ϖ 30 mm 6. Remove arm cylinder (2) by a crane.

CAUTION: Arm cylinder weight: 1450 kg (3200 Ib) Pin weight: 80 kg (180 Ib) 2. While holding arm cylinder (2) by a crane, remove bolts (3) (2 used) on the cylinder rod side, spring washers (4) (2 used) and plate (5) to remove pin (1). ϖ 30 mm 3. Start the engine. Fully retract the arm cylinder (2). Secure the rod with a wire wound through the rod hole so that the arm cylinder will not extend. Ȁ CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 4. Stop the engine. Operate the lever several times to release the remaining pressure from the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Loosen the hydraulic hoses (3 used) and greasing hose at bottom side. Then remove them. ϖ 12 mm, 14 mm ϖ 19 mm

W4-2-7

FRONT ATTACHMENT / Cylinder B A

W183-04-02-003

B: Cylinder Bottom Side

A: Cylinder Rod Side 2

Hydraulic Hose Greasing Hose

Greasing Hose

W183-04-02-016

Greasing Hose

W166-04-01-020

1 W183-04-02-001

3 5

Section A and B

W4-2-8

W142-04-01-015

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

7. Connect the greasing hose to side pin (1) for arm cylinder rod end. ϖ 19 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft) 8. Release any air remaining in arm cylinder (2). (Refer to W4-2-50.)

Installation CAUTION: Arm cylinder weight: 1450 kg (3200 Ib) 1. While hoisting arm cylinder (2) by a crane, align the cylinder bottom side pin hole with the boom bracket hole. CAUTION: Pin weight: 80 kg (180 Ib) 2. Hoist and insert pin (1) into the cylinder bottom side pin hole. Install bolts (3) (2 used), spring washers (4) (2 used) and plate (5). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 3. Reconnect the hydraulic hoses (3 used) and greasing hose on the arm cylinder bottom. ϖ ϖ ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 14 mm 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 19 mm 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. While hoisting the cylinder rod by a crane, remove the wire securing the cylinder rod. Ȁ 5. Start the engine. Adjust the height while extending the cylinder rod. Align the pin hole in the cylinder rod side with that of the arm. CAUTION: Pin weight: 80kg (180 Ib) 6. Insert pin (1) into the cylinder rod side pin hole. Install bolts (3) (2 used), spring washers (4) (2 used) and plate (5). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

W4-2-9

FRONT ATTACHMENT / Cylinder Remove and Install Arm Cylinder (Loading Shovel)

B A

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Greasing Hose

Hydraulic Hose Greasing Hose

1 1

W183-04-02-017

W183-04-02-018

2 1 W183-04-02-008

6 1

3 4 2

Section A and B

1 - Pin (2 Used) 2 - Arm Cylinder

3 - Spring Washer (4 Used) 4 - Bolt (4 Used)

5 - Plate (2 Used)

W4-2-10

W118-04-01-005

6 - Dust Seal (4 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

CAUTION: Pin weight: 50 kg (110 Ib) 6. Remove bolt (4) (2 used), spring washers (3) (2 used) and plate (5) on the arm cylinder bottom side, then remove pin (1). ϖ 30 mm

Removal 1. Disconnect the greasing hose from arm cylinder (2) rod.

7. Remove dust seals (6) (2 used). Remove arm cylinder (2) by a crane.

ϖ 19 mm CAUTION: Arm cylinder weight: 980 kg (2160 Ib) Pin weight: 50 kg (110 Ib) 2. While holding arm cylinder (2) with a chainblock, remove bolts (4) (2 used), spring washers (3) (2 used) and plate (5) on the cylinder rod side, and remove pin (1). ϖ 30 mm 3. Remove dust seals (6) (2 used). 4. Start the engine. Fully retract the arm cylinder (2). Secure the rod with a wire wound through the rod hole so that the arm cylinder will not extend. CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 5. Stop the engine. Operate the lever several times to release the remaining pressure from the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Loosen and remove the hydraulic hoses (3 used). ϖ 12 mm, 14 mm ϖ 19 mm

W4-2-11

FRONT ATTACHMENT / Cylinder

B A

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Greasing Hose

Hydraulic Hose

Greasing

1 1

W183-04-02-017

W183-04-02-018

2 1 W183-04-02-008

6 1

3 4 2

Section

A and B

W4-2-12

W118-04-01-005

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. Installation

CAUTION: Pin weight: 50 kg (110 Ib) 6. Insert pin (1) into the cylinder rod side pin hole. Install plate (5), spring washers (3) (2 used), and bolts (4) (2 used). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

CAUTION: Arm cylinder weight: 980 kg (2160 Ib)

7. Connect the greasing hose to arm cylinder (2) rod end side pin (1).

1. While hoisting arm cylinder (2) with a chainblock, install dust seals (6) (2 used) into the cylinder bottom side pin hole, align the cylinder bottom side pin hole with the boom bracket hole.

ϖ 19 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft) 8. Release any air remaining in arm cylinder (2). (Refer to page W4-2-50)

CAUTION: Pin weight: 50 kg (110 Ib) 2. Hoist and insert pin (1) into the cylinder bottom side pin hole. Install plate (5), spring washers (3) (2 used), and bolts (4) (2 used). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 3. Reconnect the hydraulic hoses (3 used) and greasing hose on the arm cylinder bottom. ϖ ϖ ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 14 mm 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 19 mm 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. While hoisting the cylinder rod with a chainblock, remove the wire securing the cylinder rod. Ȁ 5. Install dust seals (6) (2 used) into the cylinder rod hole. Start the engine. Extend the rod so that cylinder rod hole aligns with the arm cylinder pin hole.

W4-2-13

FRONT ATTACHMENT / Cylinder Remove and Install Bucket Cylinder (Backhoe)

W183-04-02-003

B: Cylinder Bottom Side

A: Cylinder Rod Side

Hydraulic Hose

Greasing Hose

5 Wooden Block

W166-04-01-008

1 W166-04-01-009

11 5

2, 3

Section A

Section B

W118-04-01-021

W166-04-01-015

1 - Pin 2 - Spring Washer (3 Used) 3 - Bolt (3 Used)

4 - Stopper 5 - Pin 6 - Spring Washer (2 Used)

7 - Bolt (2 Used) 8 - Plate 9 - Link A

W4-2-14

10 - Bucket Cylinder 11 - Link B (2 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. Removal

CAUTION: Pin (5) weight: 60 kg (130 Ib) 6. While holding bucket cylinder (10) by a crane, remove bolts (7) (2 used) on the cylinder bottom side, spring washers (6) (2 used) and plate (8) to remove pin (5). ϖ 30 mm

1. Disconnect the greasing hose from bucket cylinder (10) bottom.

7. Remove bucket cylinder (10) by a crane.

ϖ 19 mm 2. Lay a wooden block between the arm and bucket cylinder (10). Then, fasten link A (9) and links B (11) (2 used) with a wire and chainblock so that links B (11) (2 used) does not fall when pin (1) is removed. CAUTION: Bucket cylinder weight: 960 kg (2120 Ib) Pin (1) weight: 140 kg (310 Ib) 3. While holding bucket cylinder (10) by a crane, remove bolts (3) (3 used) on the cylinder rod side, spring washers (2) (3 used) and stopper (4) to remove pin (1). When the pin is pulling out half way, hoist by a crane to remove pin (1). ϖ 30 mm 4. Start the engine. Fully retract bucket cylinder (10). Fasten the rod with a wire wound through the rod hole so that bucket cylinder (10) will not extend. CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 5. Stop the engine. Operate the lever several times to release the remaining pressure from the hydraulic circuit. Then drain the air out from the hydraulic oil tank. Remove the hydraulic hoses (3 used) at the cylinder bottom side. ϖ 12 mmЕ14 mm

W4-2-15

FRONT ATTACHMENT / Cylinder

W183-04-02-003

B: Cylinder Bottom Side

A: Cylinder Rod Side 9

Hydraulic Hose

Greasing Hose

5 Wooden Block

W166-04-01-008

1 W166-04-01-009

11 5

2, 3

Section A

W118-04-01-021

Section B W166-04-01-015

W4-2-16

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

6. Remove the wire and chainblock which fastening links A and B to prevent links B (11) (2 used) from dropping. Start the engine and remove the wooden block laid between arm and bucket cylinder (10). 7. Release any air remaining in bucket cylinder (10). (Refer to W4-2-50 ).

Installation CAUTION: Bucket cylinder weight: 960 kg (2120 Ib) 1. While hoisting bucket cylinder (10) by a crane, align the cylinder bottom side pin hole with the bucket cylinder bracket hole. CAUTION: Pin (5) weight: 60 kg (130 Ib) 2. Insert pin (5) into the cylinder bottom side pin hole. Install bolts (7) (2 used), spring washers (6) (2 used) and plate (8). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 3. Reconnect the hydraulic hoses (3 used) and greasing hose on to bucket cylinder (10) bottom side. ϖ ϖ ϖ ϖ ϖ ϖ

12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) 14 mm 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 19 mm 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft)

4. Remove the wire fastening the cylinder rod. Start the engine. Extend the rod. Hoist link A and link B by a crane so that cylinder rod hole aligns with link A and B pin holes. CAUTION: Pin (1) weight: 140 kg (310 Ib) 5. Hoist and insert pin (1) into the cylinder rod side pin hole. Install bolts (3) (3 used), spring washers (2) (3 used) and stopper (4). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

W4-2-17

FRONT ATTACHMENT / Cylinder Remove and Install Bucket Cylinder (Loading Shovel) A

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Greasing Hose

Hydraulic Hose Greasing Hose

9 9

W183-04-02-018

W183-04-02-007

W183-04-02-020

10 6

7 3

8 9

1 4, 5

Section A

Section B W183-04-02-014 W142-04-01-013

1 - Pin (2 Used) 2 - Bucket Cylinder (2 Used) 3 - Stopper (2 Used)

4 - Bolt (6 Used) 5 - Spring Washer (6 Used) 6 - Plate (2 Used)

7 - Bolt ( 4 Used) 8 - Spring Washer (4 Used)

W4-2-18

9 - Pin (2 Used) 10 - Spacer (2 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment. Removal 1. Disconnect the greasing hose from bucket cylinder (2) rod. ϖ 19 mm CAUTION: Bucket cylinder weight: 920 kg (2030 Ib) Pin (9) weight: 50 kg (110 Ib)

CAUTION: Pin (1) weight: 70 kg (150 Ib) 6. While holding bucket cylinder (2) by a crane, remove bolts (4) (3 used), spring washers (5) (3 used) and stopper (3) on the cylinder bottom side to remove pin (1). ϖ 24 mm 7. Remove bucket cylinder (2) by a crane. 8. Remove cylinder on the other side by the same procedure.

2. While holding bucket cylinder (2) by a crane, remove bolts (7) (2 used), spring washers (8) (2 used) and plate (6) on the cylinder rod side to remove pin (9). Then, remove spacer (10). ϖ 30 mm 3. Remove cylinder on the other side by the same procedure. 4. Start the engine. Fully retract bucket cylinder (2). Fasten the rod with a wire wound through the rod hole so that bucket cylinder (2) will not extend. CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure. 5. Stop the engine. Release any remaining air from the hydraulic lines and oil tank. Disconnect hydraulic hoses (4 used) from the cylinder bottom side. ϖ 12 mmЕ14 mmЕ17 mm

W4-2-19

FRONT ATTACHMENT / Cylinder

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Greasing Hose

Hydraulic Hose Greasing Hose

9 9

W183-04-02-018

W183-04-02-020

W183-04-02-007

10 6

7 3

8 9

1 4, 5

Section B Section A

W183-04-02-014 W142-04-01-013

W4-2-20

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

CAUTION: Pin (9) weight: 50 kg (110 Ib) 6. Insert pin (9) into the cylinder rod side pin hole. Install bolts (7) (2 used), spring washers (8) (2 used) and plate (6). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

Installation CAUTION: Bucket cylinder weight: 920 kg (2030 Ib) 1. While hoisting bucket cylinder (2) by a crane, align the cylinder bottom side pin hole.

7. Install bucket cylinder (2) on the other side by the same procedure. 8. Release any air remaining in bucket cylinder (2). (Refer to W4-2-50.)

CAUTION: Pin (1) weight: 70 kg (150 Ib) 2. Insert pin (1) into pin hole, install bolts (4) (3 used), spring washers (5) (3 used) and stopper (3). ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) 3. Reconnect the hydraulic hoses (2 used for each side) and greasing hose on the bucket cylinder. ϖ 12 mm ϖ 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft) ϖ 14 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 4. While hoisting the cylinder rod by a crane, remove the wire fastening the cylinder rod. 5. Install spacer (10) into the cylinder rod hole. Start the engine. Extend the rod so that cylinder rod hole aligns with boom pin hole.

W4-2-21

FRONT ATTACHMENT / Cylinder Remove and Install Level Cylinder (Loading Shovel only)

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Hydraulic Hose Greasing Hose

2 Greasing Hose

W166-04-01-021

W166-04-01-024 W183-04-02-009

3 1

4 5

6 A and B Section

1 - Pin (2 Used) 2 - Level Cylinder

3 - Spring Washer (4 Used) 4 - Bolt (4 Used)

5 - Plate (2 Used)

W4-2-22

W166-04-01-015

6 - Dust Seal (4 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

Removal IMPORTANT: Remove the arm cylinder before removing level cylinder (2). (Refer to W4-2-10 Remove and Install Arm Cylinder.) 1. Disconnect the greasing hoses (2 used) from level cylinder (2). ϖ 19 mm CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure.

6. Stop the engine. Release any pressure remaining in the hydraulic lines and bleed air trapped in the hydraulic oil tank. 7. Remove hydraulic hoses from boom cylinder bottom side (2 places at right and left), level cylinder (2) rod side and bottom side. (Refer to W4-2-2 Remove and Install Boom Cylinder.) ϖ 10 mm, 12 mm CAUTION: Pin (1) weight: 50 kg (110 Ib ) 8. Remove bolts (4) (2 used), spring washers (3) (2 used) and plate (5) on level cylinder (2) bottom side, to remove pin (1). ϖ 30 mm

2. Stop the engine. Operate the lever several times to release the remaining pressure in the hydraulic circuit. Then drain the air out from the hydraulic oil tank.

9. Remove dust seals (6) (2 used) from bottom side. Remove level cylinder (2) by a crane.

3. Remove the hydraulic hoses from the bottom cylinder rod side (2 places at right and left). (Refer to W4-2-2 Remove and Install Boom Cylinder.) ϖ 12 m, 14 mm CAUTION: Level cylinder (2) weight: 710 kg (1570 Ib) Pin (1) weight: 50 kg (110 Ib) 4. Hold level cylinder (2) with a chain block. Remove bolts (4) (2 used), spring washers (3) (2 used), and plate (5) from the rod side, and remove pin (1). ϖ 30 mm 5. Remove dust seals (6) (2 used) from rod side. Start the engine and retract the cylinder. Secure the rod with wire wound through the rod hole so that the cylinder will not extend.

W4-2-23

FRONT ATTACHMENT / Cylinder

W183-04-02-002

A: Cylinder Rod Side

B: Cylinder Bottom Side

Hydraulic Hose Greasing Hose

2 Greasing Hose

W166-04-01-021

W166-04-01-024 W183-04-02-009

3 1

4 5

6 Section A and B

W4-2-24

W166-04-01-015

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

CAUTION: Pin (1) weight: 50 kg (110 Ib) 6. Install pin (1) on the cylinder rod side. Then, install bolts (4) (2 used), spring washers (3) (2 used) and plate (5). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft)

Installation

7. Connect the hydraulic hoses to the boom cylinder rod sides (2 places at right and left). (Refer to W4-2-2 Remove and Install Boom Cylinder.)

CAUTION: Level cylinder weight: 710 kg (1570 Ib) Pin (1) weight: 50 kg (110 Ib)

ϖ ϖ ϖ ϖ

1. Lift level cylinder (2) with a chain block, install dust seals (6) (2 used) into the cylinder bottom side pin hole and align the pin hole in the bottom side. 2. Install pin (1) into the cylinder bottom side and install bolts (4) (2 used), spring washers (3) (2 used) and plate (5). ϖ 30 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 3. Connect the hydraulic hoses to the boom cylinder bottom sides (2 places at right and left), level cylinder (2) rod side and cylinder bottom side. (Refer to W4-2-2 Remove and Install Boom Cylinder.) ϖ ϖ ϖ ϖ

10 mm 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft) 12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

8. Connect the greasing hoses (2 used) to level cylinder (2). ϖ 19 mm ϖ 35 N⋅m (3.6 kgf⋅m, 26.0 Ibf⋅ft) 9. Remove the air bleed plug from the cylinder to bleed any air remaining in the cylinder. (Refer to W4-2-50.)

10 mm 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft) 12 mm 140 N⋅m (14 kgf⋅m, 101 Ibf⋅ft)

4. Remove the wire securing the cylinder rod. Install dust seals (6) (2 used) into the cylinder rod side pin hole. ϖ 10 mm ϖ 108 N⋅m (11 kgf⋅m, 80 Ibf⋅ft) 5. Start the engine. Extend the rod so that cylinder rod hole aligns with arm pin holes.

W4-2-25

FRONT ATTACHMENT / Cylinder Remove and Install Dump Cylinder (Loading Shovel only)

1 Hydraulic Hose

W183-04-02-005

W183-04-02-010

Wooden Block

A: Cylinder Rod Side 1

B: Cylinder Bottom Side 2

3 6 7

10 4 9 8

11 W183-04-02-011

Section A

Section B W166-04-01-028

1 - Dump Cylinder (2 Used) 2 - Pin (2 Used) 3 - Grease Fitting (2 Used)

4 - Socket Bolt (4 Used) 5 - Lock Plate (2 Used) 6 - Adapter (2 Used)

7 - Pin (2 Used) 8 - Stopper (2 Used) 9 - Sems Bolt (6 Used)

W4-2-26

10 - Grease Fitting (2 Used) 11 - Spacer (4 Used)

FRONT ATTACHMENT / Cylinder Removal CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equipment.

Dump Cylinder

Front Cover

1. Lay a wooden block under the bucket. Ȁ 2. Remove the front cover and side cover on the bucket. ϖ 17, 24 mm 3. Remove grease fitting (3) from pin (2) at dump cylinder (1) rod side. ϖ 10 mm

Front

W166-04-01-029

CAUTION: Dump cylinder weight: 160 kg (350 Ib) Pin (2) weight: 20 kg (40 Ib) 4. Hold dump cylinder (1) with a chain block. Remove socket bolts (4) (2 used), and lock plate (5) on the rod side, and remove pin (2). Side Cover

ϖ 17 mm 5. Start the engine and retract dump cylinder (1). Secure the rod with a wire wound through the rod hole so that the cylinder will not extend. CAUTION: If the air breather cap on the hydraulic oil tank is turned quickly, the air breather cap may fly off due to pressure remaining inside. Slowly turn the air breather cap and remove after completely releasing any remaining pressure.

W4-2-27

side M113-07-012

FRONT ATTACHMENT / Cylinder

Hydraulic Hose

W183-04-02-005

B W183-04-02-010

Wooden Block

A: Cylinder Rod Side

B: Cylinder Bottom Side

1 1

6 7

9 8 11 Section B

Section A W166-04-01-028

W4-2-28

W183-04-02-011

FRONT ATTACHMENT / Cylinder 6. Stop the engine. Release any pressure remaining in the hydraulic lines and bleed air trapped in the hydraulic oil tank. Disconnect the hydraulic hoses (2 used) from the cylinder. ϖ 8 mm CAUTIONϖPin (7) weight: 20 kg (40 Ib) 7. Remove adapter (6) and grease fitting (10) from pin (7) at the dump cylinder (1) bottom side. ϖ 19 mm 8. While holding dump cylinder (1) by a crane, remove sems bolts (9) (3 used), and stopper (8) from the cylinder bottom. Remove pin (7) completely. Remove dump cylinder (1) by a crane. ϖ 19 mm 9. Remove spacers (11) (2 used) from the dump cylinder (1) bottom side. 10. Remove dump cylinder (1) on the other side by the same procedure.

W4-2-29

FRONT ATTACHMENT / Cylinder

Hydraulic Hose

W183-04-02-005

B W183-04-02-010

Wooden Block

B: Cylinder Bottom Side

A: Cylinder Rod Side 1

2 1 3 6 10

4 9 8

11 Section B

Section A

W183-04-02-011

W166-04-01-028

1 - Dump Cylinder (2 Used) 2 - Pin (2 Used) 3 - Grease Fitting (2 Used)

4 - Socket Bolt (4 Used) 5 - Lock Plate (2 Used) 6 - Adapter (2 Used)

7 - Pin (2 Used) 8 - Stopper (2 Used) 9 - Sems Bolt (6 Used)

W4-2-30

10 - Grease Fitting (2 Used) 11 - Spacer (4 Used)

FRONT ATTACHMENT / Cylinder CAUTION: When driving the pin with a hammer, metal debris may fly, causing personal injury. Be sure to use proper safety equiment. Installation CAUTION: Dump cylinder weight: 160 kg (350 Ib) Pin (7) weight: 20 kg (40 Ib) 1. While lifting dump cylinder (1) by a chain block, align the pin holes at the bottom side. Install spacers (11) (2 used) into the cylinder bottom side. 2. Install pin (7) into the cylinder bottom side. Install sems bolts (9) (3 used) and stopper (8). ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) 3. Install adapter (6) and grease fitting (10) onto pin (7) at dump cylinder (1) bottom side. ϖ 19 mm ϖ 90 N⋅m (9.2 kgf⋅m, 66 Ibf⋅ft) 4. Connect the hydraulic hoses (2 used) to dump cylinder (1). ϖ 8 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) 5. Hoist the rod side of dump cylinder (1) by a chain block. Then remove the wire to be secured the rod. Start the engine and extend the rod. Align the pin hole in cylinder rod side.

W4-2-31

FRONT ATTACHMENT / Cylinder

Hydraulic Hose

W183-04-02-005

B W183-04-02-010

Wooden Block

A: Cylinder Rod Side 1

B: Cylinder Bottom Side 2 1 3

5 W183-04-02-011

Section B Section A W166-04-01-028

W4-2-32

FRONT ATTACHMENT / Cylinder Front Cover

CAUTIONϖ ϖ Pin (2) weight: 20 kg (40 Ib) 6. Install pin (2) into the cylinder (1) rod side. Then, install socket bolts (4) (2 used) and lock plate (5). ϖ 17 mm ϖ 400 N⋅m (41 kgf⋅m, 295 Ibf⋅ft) 7. Install grease fitting (3) to the end face of pin (2) on the cylinder rod side. ϖ 10 mm ϖ 5.9 N⋅m (0.6 kgf⋅m, 4.3 Ibf⋅ft) 8. Install dump cylinder (1) on the other side by the same procedures.

Front

W166-04-01-029

9. Start the engine and remove the wooden block laid under the bucket. 10. Remove the air bleed plug from the cylinder to bleed air remaining in the cylinder. (Refer to W4-2-50.)

Front cover

11. Install the front cover and side cover on the cylinder rod side. ϖ 17 mm ϖ 50 N⋅m (5.1 kgf⋅m, 37 Ibf⋅ft) ϖ 24 mm ϖ 210 N⋅m (21.5 kgf⋅m, 155 Ibf⋅ft) Side

M113-07-012

W4-2-33

FRONT ATTACHMENT / Cylinder (Blank)

W4-2-34

FRONT ATTACHMENT / Cylinder DISASSEMBLE CYLINDER Boom Cylinder Arm Cylinder

19 15

Bucket Cylinder (Loading Shovel Only)

16 17

Dump Cylinder

(Loading Shovel Only) 17 16 21 22

14 13 23

2 3

4 7 8 9 10 11 12 5 6

W183-04-02-029

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 12 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring

13 14 15 16 17 -

Set Screw Steel Ball Piston Slide Ring (2 Used) Slide Ring (2 Used)

W4-2-35

19 20 21 22 23 -

Cushion Bearing Seal Ring Shim Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Bucket Cylinder (Backhoe)

19 15 16 17

20 17 16 22 14 13 23

2 3

4 7 8 9 10 11 12 5 6

W183-04-02-021

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing

12 13 14 15 16 -

Retaining Ring Set Screw Steel Ball Piston Slide Ring (2 Used)

W4-2-36

17 19 20 22 23 -

Slide Ring (2 Used) Cushion Bearing Seal Ring Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Level Cylinder (Loading Shovel)

16 17 17

16 15

22 23

2 3 4 5 6 7 8 9 10 11 12

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing

12 13 14 15 16 -

Retaining Ring Set Screw Steel Ball Piston Slide Ring (2 Used)

W4-2-37

17 20 21 22 23 -

W183-04-02-022

Slide Ring (2 Used) Seal Ring Shim Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Disassemble Cylinder Boom Cylinder

19 15 16 17

20 17 16 21 22

14 13 23

2 3

4 7 8 9 10 11 12 5 6

W183-04-02-029

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 12 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring

13 14 15 16 17 -

Set Screw Steel Ball Piston Slide Ring (2 Used) Slide Ring (2 Used)

W4-2-38

19 20 21 22 23 -

Cushion Bearing Seal Ring Shim Nut Cylinder Tube

FRONT ATTACHMENT / Cylinder Disassemble Cylinder CAUTION: Cylinder rod (1) weight: Loading Shovel Backhoe Boom: 650 kg 660 kg (1430 Ib) (1460 Ib) Arm: 540 kg 800 kg (1190 Ib) (1760 Ib) Bucket: 520 kg 610 kg (1150 Ib) (1340 Ib) 640 kg(BE) (1410 Ib) Level: 390 kg (860 Ib) Dump: 100 kg (220 Ib)

• Be sure to thoroughly read all “Precautions for Disassembly and Assembly” on page W1-1-1 before starting the disassembly work. • The cylinder structure are similar, so the boom cylinder disassembly procedure is described as an example for all cylinders. The disassembly procedure below starts on the premise that the hydraulic lines and the line securing bands have been removed. CAUTION: Cylinder weight: Loading Shovel Boom cylinder: 1170 kg (2580 Ib) Arm cylinder: 980 kg (2160 Ib) Bucket cylinder:920 kg (2030 Ib)

Backhoe 1170 kg (2580 Ib) 1450 kg (3200 Ib) 1090 kg (2400 Ib) 1170 kg(BE) (2580 Ib)

Level cylinder: 710 kg (1570 Ib) Dump cylinder: 160 kg (350 Ib) 1. Hoist and horizontally secure the cylinder on a work bench by a crane. Then, drain the hydraulic oil from the cylinder.

2. Fully extend cylinder rod (1). Secure the rod end by a crane. Remove socket bolts (3) from cylinder head (4). Ȁ Loading Shovel ϖ Boom, Level 27 mm ϖ Arm 24 mm ϖ Bucket 22 mm ϖ Dump 17 mm Ȁ Backhoe ϖ Boom, Bucket 27 mm ϖ Arm 24 mm IMPORTANT: When removing cylinder rod (1), be sure to pull cylinder rod (1) straight out so as not to damage the sliding surface. 3. While tapping cylinder head (4) with a plastic hammer, remove cylinder head (4) along with cylinder rod (1) from cylinder tube (23).

W102-04-02-027

4. Secure cylinder rod (1) on special tool (ST 5908). Put matching marks on the end faces of cylinder rod (1) and nut (22). ST 5908

W158-04-02-022

W4-2-39

FRONT ATTACHMENT / Cylinder

19 15 16 17

20 17 16 21 22

14 13

4 7 8 9 10 11 12 5 6

W183-04-02-029

W4-2-40

FRONT ATTACHMENT / Cylinder 8. Remove cushion bearing (19) and cylinder head (4) from cylinder rod (1).

5. Remove set screw (13), steel ball (14). NOTE: After set screw (13) was installed, two places were crimped. Remove the crimped places with a grinder to loosen set screw (13).

NOTE: There is no cushion bearing (19) in level cylinder (Loading shovel). 9. Remove wiper ring (2), slide ring (7), backup ring (8), U-ring (9) and buffer ring (10) from cylinder head (4).

Loading Shovel ϖ Boom, Level 17 mm ϖ Arm, Bucket 14 mm ϖ Dump 10 mm

10. Remove retaining ring (12) and bushing (11) from cylinder head (4).

Backhoe ϖ Boom, Arm, Bucket 17 mm 6. Using special tool (ST 5908) for disassembling and assembling cylinder, remove nut (22) and piston (15). Remove nut (22), then remove shim (21) from cylinder rod (1). Ȁ Ȁ Nut turning tool: Loading Shovel Backhoe Boom: 180 mm (7.1 in) 180 mm (7.1 in) (ST 3278) (ST 3278) Arm: 155 mm (6.1 in) 200 mm (7.9 in) (ST 3285) (ST 3279) Bucket: 155 mm (6.1 in) 180 mm (7.1 in) (ST 3285) (ST 3278)

11. Remove O-ring (6) and backup ring (5) from cylinder head (4).

Level: 180 mm (7.1 in) (ST 3278) Dump: 95 mm (3.7 in) (ST 3075) NOTE: There is no shim (21) in bucket cylinder (Backhoe). ST 5908

W158-04-02-022

7. Remove slide rings (16 and 17) (2 used each one) and seal ring (20) from piston (15).

W4-2-41

FRONT ATTACHMENT / Cylinder ASSEMBLE CYLINDER Boom Cylinder 2

Arm Cylinder

7 10

Bucket Cylinder

(Loading shovel only)

8 9 3

Dump Cylinder

5, 6 4

(Loading shovel only)

19 16 17

20 17 21

22 13

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 12 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring

13 14 15 16 17 -

Set Screw Steel Ball Piston Slide Ring (2 Used) Slide Ring (2 Used)

W4-2-42

19 20 21 22 23 -

Cushion Bearing Seal Ring Shim Nut Cylinder Tube

W166-04-02-020

FRONT ATTACHMENT / Cylinder Level Cylinder (Loading Shovel)

Bucket Cylinder (Backhoe)

1 10 11

2 7

8 9 3

5, 6

4 4

23 23

19 16 16

17 16

17 21

W166-04-02-019

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 12 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring

13 14 15 16 17 -

Set Screw Steel Ball Piston Slide Ring (2 Used) Slide Ring (2 Used)

W4-2-43

19 20 21 22 23 -

Cushion Bearing Seal Ring Shim Nut Cylinder Tube

W166-04-02-020

FRONT ATTACHMENT / Cylinder Assemble Cylinder Boom Cylinder 2

7 10

3 5, 6 4

19 16 17

20 17

16 22 13

123456-

Cylinder Rod Wiper Ring Socket Bolt (8 Used) Cylinder Head Backup Ring O-Ring

78910 11 12 -

Slide Ring Backup Ring U-Ring Buffer Ring Bushing Retaining Ring

13 14 15 16 17 -

Set Screw Steel Ball Piston Slide Ring (2 Used) Slide Ring (2 Used)

W4-2-44

19 20 21 22 23 -

Cushion Bearing Seal Ring Shim Nut Cylinder Tube

W166-04-02-020

FRONT ATTACHMENT / Cylinder Assemble Cylinder CAUTION: Cylinder rod (1) weight: Loading Shovel Backhoe Boom: 650 kg 660 kg (1430 Ib) (1460 Ib) Arm: 540 kg 800 kg (1190 Ib) (1760 Ib) Bucket: 520 kg 610 kg (1150 Ib) (1340 Ib) 640 kg(BE) (1410 Ib) Level: 390 kg (860 Ib) Dump: 100 kg (220 Ib)

1. Press bushing (11) into cylinder head (4) using the special tool. Install retaining ring (12) in cylinder head (4). Bushing pressing tool: Dump (loading shovel only): 85 mm(ST 8020) IMPORTANT: Install buffer ring (10) with the lip facing the cylinder bottom. 2. Install buffer ring (10) into cylinder head (4). IMPORTANT: Install U-ring (9) with the lip facing the cylinder bottom.

9. Secure cylinder rod (1) on special tool (ST 5908). Ȁ

ST5908

3. After installing backup ring (8) into cylinder head (4), install U-ring (9). 4. Install slide ring (7) in cylinder head (4). IMPORTANT: Install wiper ring (2) with the lip facing outward. 5. Press wiper ring (2) into cylinder head (4) using the special Tool. Ȁ Ȁ Wiper ring pressing tool Ȁ Dump (loading shovel only) 85 mm(ST 8020) 6. Install O-ring (6) and backup ring (5) around cylinder head (4).

W158-04-02-022

10. Wrap the threaded part on cylinder rod (1) with protecting tape.Rotate and install the cylinder head (4) assembly onto cylinder rod (1). IMPORTANT: Install cushion bearing (19) with the slit facing the cylinder head (4). 11. Install cushion bearing (19) onto cylinder rod (1). NOTE: There is no cushion bearing (19) in level cylinder (loading shovel).

7. In order to prevent the seal ring from going into other slit, install seal ring (20) around piston (15) with a bamboo spatula as a special tool.

IMPORTANT: Install slide rings (16 and 17) with their slits positioned in 180°° opposite each other.

Slit W183-04-02-012

12. Install piston (15) onto cylinder rod (1). 8. Install slide ring (16) (2 used) and (17) (2 used) onto piston (15).

W4-2-45

FRONT ATTACHMENT / Cylinder

21 22

W166-04-02-020

W4-2-46

FRONT ATTACHMENT / Cylinder 13. Install shim (21) and nut (22) onto cylinder rod (1).

CAUTION: If they haven’t been thoroughly degreased, nut (22) will be over tightened because there is oil for lubricating, causing cushion bearing (19) expanding.

NOTE: Shim (21) is not installed on bucket cylinder (backhoe). 14. Tighten nut (22). Nut turning tool: Backhoe Boom 180 mm (ST3278) ϖ38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft) Arm 200 mm (ST3279) ϖ68650 N⋅m (7000 kgf⋅m, 50400 Ibf⋅ft) Bucket 180 mm (ST3278) ϖ43050 N⋅m (4390 kgf⋅m, 31610 Ibf⋅ft) Loading Shovel Boom 180 mm (ST3278) ϖ 38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft) Arm 155 mm (ST3285) ϖ 40300 N⋅m (4110 kgf⋅m, 29590 Ibf⋅ft) Bucket 155 mm (ST3285) ϖ 26200 N⋅m (2670 kgf⋅m, 19220 Ibf⋅ft) Level 180 mm (ST3278) ϖ 38000 N⋅m (3880 kgf⋅m, 27940 Ibf⋅ft) Dump 95 mm (ST3075) ϖ 9800 N⋅m (1000 kgf⋅m, 7200 Ibf⋅ft)

(3) After tightening nut (22) to the specified torque, measure the contour dimensions of cushion bearing (19) at 4 places of A, B, C and D as shown in figure E. Make sure the dimensions are within the specified range. IMPORTANT: If any dimensions are out of the specified range, disassemble it again and then assemble from step 1. Figure E A

Precautions for tightening nut (22) IMPORTANT: The contour dimensions of cushion bearing (19) may be different before and after tightening the nut. Therefore, when tightening nut (22), be sure to check that the contour dimensions are in the specified range. (1) Measure the contour dimensions of cushion bearing (19) only at 4 places of A, B, C and D. Make sure that the dimensions are in the specified range and no deformation on them. IMPORTANT: The parts out of specified range or deformed should be replaced with new ones.

W115-04-01-093

Standard Dimensions Cylinder Boom (Loading Shovel) Arm (Backhoe) Arm (Loading Shovel) Bucket (BE Backhoe) Bucket (Loading Shovel) Bucket (STD Backhoe) Dump (Loading Shovel)

(2) Piston rod (1), nut (22), piston (15) and cushion bearing (19) should be thoroughly cleaned and thoroughly degreased in kerosene or diluent.

W4-2-47

Unit: mm (in) After Tightened

Before Tightening Φ168 Φ198 Φ158 Φ178 Φ158 Φ168 Φ91

-0.235 -0.260 -0.340 -0.369 -0.235 -0.260 -0.270 -0.295 -0.170 -0.195 -0.270 -0.295 -0.170 -0.192

(6.6 (7.8 (6.2 (7.0 (6.2 (6.6 (3.6

-0.009 -0.010 -0.013 -0.015 -0.009 -0.010 -0.011 -0.012 -0.007 -0.008 -0.011 -0.012 -0.007 -0.008

) Φ168 ) Φ198 ) Φ158 ) Φ178 ) Φ158 ) Φ168 )

Φ91

-0.193 -0.218 -0.284 -0.313 -0.188 -0.213 -0.227 -0.252 -0.140 -0.165 -0.226 -0.251 -0.135 -0.157

(6.6 (7.8 (6.2 (7.0 (6.2 (6.6 (3.6

-0.008 -0.009 -0.011 -0.012 -0.007 -0.008 -0.009 -0.010 -0.005 -0.006 -0.009 -0.010 -0.005 -0.006

) ) ) ) ) ) )

FRONT ATTACHMENT / Cylinder

3 4

22 13

W166-04-02-020

W4-2-48

FRONT ATTACHMENT / Cylinder 15. Install steel ball (14) into nut (22) and secure the ball with set screw (13). ϖ ϖ ϖ ϖ ϖ ϖ

19. Install cylinder head (4) into cylinder tube (23). Tighten socket bolts (3) (8 used). Backhoe ϖ 27 mm (Boom, Bucket) ϖ 2460 N⋅m (251 kgf⋅m, 1810 Ibf⋅ft) ϖ 24 mm (Arm) ϖ 1910 N⋅m (195 kgf⋅m, 1410 Ibf⋅ft)

17 mm 180 N⋅m (18.4 kgf⋅m, 132 Ibf⋅ft) 14 mm 97 N⋅m (9.89 kgf⋅m, 71 Ibf⋅ft) 10 mm 57 N⋅m (5.8 kgf⋅m, 42 Ibf⋅ft)

16. Crimp two places around set screw (13) top fringe to prevent set screw (13) from loosening. CAUTION: Cylinder tube (23) weight: Loading Shovel Backhoe Boom: 520 kg 520 kg (1150 Ib) (1150 Ib) Arm: 440 kg 650 kg (970 Ib) (1430 Ib) Bucket: 400 kg 480 kg (880 Ib) (1060 Ib) 530 kg(BE) (1170 Ib) Level: 320 kg (710 Ib) Dump: 60 kg (130 Ib) 17. Horizontally secure cylinder tube (23) on a work bench. CAUTION: Cylinder rod (1) weight: Loading Shovel Backhoe Boom: 650 kg 660 kg (1430 Ib) (1460 Ib) Arm: 540 kg 800 kg (1190 Ib) (1760 Ib) Bucket: 520 kg 610 kg (1150 Ib) (1340 Ib) 640 kg(BE) (1410 Ib) Level: 390 kg (860 Ib) Dump: 100 kg (220 Ib) IMPORTANT: When installing cylinder rod (1) into cylinder tube (23), take care to correctly align them and install the rod staight so as not to damage rings. 18. Insert cylinder rod (1) into cylinder tube (23).

W4-2-49

Loading Shovel ϖ 27 mm (Boom, Level) ϖ 2460 N⋅m (251 kgf⋅m, 1810 Ibf⋅ft) ϖ 24 mm (Arm) ϖ 1910 N⋅m (195 kgf⋅m, 1410 Ibf⋅ft) ϖ 22 mm (Bucket) ϖ 1590 N⋅m (162 kgf⋅m, 1170 Ibf⋅ft) ϖ 17 mm (Dump) ϖ 640 N⋅m (65.26 kgf⋅m, 470 Ibf⋅ft)

FRONT ATTACHMENT / Cylinder AIR BLEEDING PROCEDURE NOTE: The methods to bleed air from loading shovel front are similar. CAUTION: Hydraulic fluid under pressure can penetrate the skin or eyes causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines. Hydraulic oil becomes hot during operation. Disconnecting hydraulic lines soon after operation can result in severe burns. Wait for the oil and components to cool before starting any repair work.

3. Remove the rubber cap. Then remove the air bleeding plug. ϖ 19 mm 4. Bleed air till oil seeps out from the hole. 5. Install the air bleeding plug. Then install the rubber cap. ϖ 19 mm ϖ 44±2.9 N⋅m (4.5±0.3 kgf⋅m, 32.5±2.2 Ibf⋅ft)

1. Park the machine on a solid level surface. Lower the bucket to the ground. 2. Stop the engine. Move all control levers to release pressure remaining in the system. Air Bleeding Plug (Arm Cylinder)

Air Bleeding Plug (Boom Cylinder)

Air Bleeding Plug (Bucket Cylinder)

Air Bleeding Plug Air Bleeding Plug (Boom Cylinder) (Level Cylinder)

W183-04-02-003

Air Bleeding Plug (Boom Cylinder) Air Bleeding Plug (Bucket Cylinder)

Air Bleeding Plug (Dump Cylinder)

Air Bleeding Plug (Arm Cylinder)

W183-04-02-006

W4-2-50

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD Cylinder Tube 1. Tube Section (a)

• Check if any score is present on both outer and inner tube surfaces. 2.

Pin and Bushing Section (b)

• Check if bore dia. (B) wear is 0.5 mm or more than specification. • Check if any score is present on the bore surfaces. IMPORTANT: Take extra care to check the tube bore as it is very difficult. Piston Rod 1. Rod Section (c) • Place two V-blocks 1 m apart on level ground. Lay the cylinder rod across the V-blocks. Rotate the rod one turn and measure the rod deflection using a dial gauge. Measure the deflection in three positions. If one measured deflection is 0.5 mm or more, replace the rod. Check if the rod is bent 0.5 mm or more at length of per 1 m. • Check if the outer diameter (C) wear is 0.02 mm or more at length of per 200 mm. • Check if any score is present on the surface. • Check if the surface is rusting. • Check if the cushion installing section is damaged.

W145-04-01-015

Piston

W166-04-02-023

Dial Gauge Cylinder Rod

W166-04-02-022

1m V Block

2. Pin Bushing Bore Section (d) • Check if the bushing bore (D) wear is 0.2 mm or more than specification. • Check if the bore is scored.

W4-2-51

FRONT ATTACHMENT / Cylinder Hydraulic Pipe 1. Pipe (e) • Check if 0.1 mm or deeper score is present on the contact surface. • Check if the pipe is deformed or damaged.

2. Socket Bolt (f) • Check if the bolt is rusting. • Check if the threads are damaged.

g g

3. O-Ring (g) • Be sure to replace with new one after disassembling.

T182-05-02-004

Piston and Cylinder Head • Check if the exterior and/or interior is scored. • Check if the groove is scored. • Check if seals are damaged and if internal oil leakage exists. • Replace bushing if the base metal is exposed on the slide surface.

Standard Dimension List Unit: mm (in)

Loading Shovel Level Arm Bucket

Cylinder Dia.(A)

Tube

Boom Inner 230 +0.072 230 0

+0.072 0

215

+0.072 0

200

Dump

+0.072 0

140

Backhoe Arm Bucket

Boom

+0.063 0

230

+0.072 0

260

+0.081 0

230 (9.1

(9.1

+0.003 0

) (9.1

+0.003 0

) (8.5

+0.003 0

) (7.9

+0.003 0

) (5.5

+0.002 0

+0.25 +0.05

) (3.5

+0.0098 +0.0020

+0.003 0

) (9.1

) (10.2

+0.003 0

) 240 (9.4

Cylinder Tube Bore Dia. (B)

Bushing 160

+0.006 -0.071

150

+0.25 +0.05

150

+0.25 +0.05

130

+0.25 +0.05

160

+0.006 -0.071

170

+0.25 +0.05

150 (5.9

(6.3

+0.0002 -0.0028

) (5.9

+0.0098 +0.0020

) (5.9

+0.0098 +0.0020

) (5.1

) (6.3

+0.0002 -0.0028

) (6.7

+0.0098 +0.0020

) 150

+0.072 (BE) 0 +0.003 0

)

+0.072 0 +0.003 0

)

+0.25 +0.05 (BE) +0.0098 +0.0020

)

+0.25 +0.05 +0.0098 +0.0020

(5.9 ) Rod Dia. (C) 160 -0.014 160 -0.014 150 -0.014 150 -0.014 85 -0.012 160 -0.014 180 -0.014 160 -0.014 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 -0.032 (BE) Recommended -0.0006 (7.1 -0.0013 ) O.D size after Re-plating -0.014 -0.0006 -0.0006 -0.0006 -0.0006 -0.0006 -0.0006 -0.0005 (6.3 -0.0013 ) (6.3 -0.0013 ) (5.9 -0.0013 ) (5.9 -0.0013 ) (3.3 -0.0013 ) (6.3 -0.0013 ) (7.1-0.0013 ) 170 -0.032 Pistion Rod Bushing Bore 160 Dia. (D) (6.3

+0.25 +0.05

+0.0098 +0.0020

150

+0.25 +0.05

150

+0.25 +0.05

130

+0.006 -0.071

+0.25 +0.05

160

+0.25 +0.05

170

+0.25 +0.05

(6.7

-0.0006 -0.0013

160

+0.25 +0.05

(6.3 ) (5.9

+0.0098 +0.0020

) (5.9

+0.0098 +0.0020

+0.0002 -0.0028

) (5.1

W4-2-52

) (3.5

+0.0098 +0.0020

) (6.3

+0.0098 +0.0020

) (6.7

+0.0098 +0.0020

) 160 (6.3

)

(BE)

+0.0098 +0.0020 +0.25 +0.05 +0.0098 +0.0020

) )

FRONT ATTACHMENT / Bushing and Point REMOVE AND INSTALL BUSHING Backhoe d

Bucket Arm

a 2

W142-04-01-024

Link A

Bucket

2 a: Bucket and Arm

W166-04-02-012

b: Link A and Bucket

Arm

W166-04-02-016

Boom

Arm

Arm Cylinder

Ê&#x2020;: Arm c: Arm and Boom 1 - Dust Seal

W166-04-02-014

2 - Bushing

W4-3-1

W166-04-02-009

FRONT ATTACHMENT / Bushing and Point

e 1

W142-04-01-024

Link B

2 Arm

e: Arm and Link B

Link A W166-04-02-015

f: Link A and Link B 1

Main Frame

W166-04-02-016

Main Frame

2 2 Boom Cylinder

Boom

g: Main Frame

W166-04-02-009

W4-3-2

h: Boom and Main Frame

W166-04-02-009

FRONT ATTACHMENT / Bushing and Point Loading Shovel

b c

d W142-04-01-023

Rear Bucket

Bucket

2 Dump Cylinder

Front Bucket

a: Front Bucket and Rear Bucket 1

b: Bucket

W166-04-02-009

2 Bucket

Bucket

2 Arm W166-04-02-018

d: Bucket

C: Bucket and Arm

1 - Dust Seal

Bucket Cylinder

2 - Bushing

W4-3-3

W166-04-02-009

FRONT ATTACHMENT / Bushing and Point e f

W142-04-01-023

Arm

Main Frame

Boom

2 Boom

2 f: Boom and Main Frame

e: Arm and Boom

W166-04-02-014

Main Frame

2 Boom Cylinder W166-04-02-009

g: Main Frame

W4-3-4

W166-04-02-009

FRONT ATTACHMENT / Bushing and Point Removal 1. Remove dust seal (1) and bushing (2). NOTE: In case the bushing is difficult to remove, use a torch to remove it. Installation 1. Cool bushing (2) in dry ice. 2. Install bushing (2) and dust seal (1). Install bushing (2) using install tools. Bushing Install Tools Backhoe a: Bucket Side .................................. ST Arm Side....................................... ST b: Link A Side ................................... ST Bucket Side .................................. ST c: Arm Side....................................... ST Boom Side .................................... ST d: Arm............................................... ST e: Arm Side....................................... ST Link B Side ................................... ST f: Link A Side ................................... ST Link B Side ................................... ST g: Main Frame .................................. ST h: Main Frame Side .......................... ST Boom Side .................................... ST

Loading Shovel a: Bucket (Front) Side ....................... ST Bucket (Rear )Side........................ ST b: Bucket .......................................... ST c: Bucket Side .................................. ST Arm Side....................................... ST d: Bucket .......................................... ST e: Arm Side....................................... ST Boom Side .................................... ST f: Boom Side .................................... ST Main Frame Side........................... ST g: Main Frame................................... ST

2842 2843 2836 2838 2841 2839 2839 2840 2837 2843 2842 2832 2832 2843

W4-3-5

2840 2829 2831 2833 2834 2829 2843 2832 2843 2832 2832

FRONT ATTACHMENT / Bushing and Point MAINTENANCE STANDARD Pin and Bushing (Backhoe) a

h i

d k

W4-3-6

W142-04-01-024

FRONT ATTACHMENT / Bushing and Point

160 160 180 160 190 160 160 180

(6.3) (6.3) (7.1) (6.3) (7.5) (6.3) (6.3) (7.1)

Unit: mm ( in) Allowable Limit 158. 5 (6.2) 161.5 (6.4) 161.5 (6.4) 158.5 (6.2) 161.5 (6.4) -

Bearing Inner Dia. (Cylinder Side) Pin Dia. Pin Hole Inner Dia. (Boom Side) Bearing Inner Dia. (Cylinder Side) Pin Dia. Bushing Inner Dia. (Boom Side) Bushing Outer Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.

160 160 160 160 170 170 200 170 200

(6.3) (6.3) (6.3) (6.3) (6.7) (6.7) (7.9) (6.7) (7.9)

161.5 (6.4) 158. 5 (6.2) 161.5 (6.4) 168. 5 (6.6) 171.5 (6.8) 171.5 (6.8) -

Pin Dia. Pin Hole Inner Dia. (Boom Side)

170 (6.7) 170 (6.7)

168. 5 (6.6) -

Bearing Inner Dia. (Cylinder Side)

170 (6.7)

171.5 (6.8)

Pin Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.

170 (6.7) 170 (6.7) 195 (7.7)

168.5 (6.6) 171.5 (6.8) -

Bearing Inner Dia. (Cylinder Side)

170 (6.7)

171.5 (6.8)

Pin Dia. Pin Hole Inner Dia. (Arm Side)

150 (5.9) 150 (5.9)

148.5 (5.8) -

Bearing Inner Dia. (Cylinder Side)

150 (5.9)

151.5 (6.0)

Part Name

a: Boom and Main Frame

b: Boom Cylinder and Main Frame

c: Boom Cylinder and Boom

d: Boom and Arm

e: Arm and Cylinder Boom

f: Arm Cylinder and Arm

g: Arm and Bucket Cylinder

Location Pin Dia. Bushing Bushing Bushing Bushing Pin Dia. Bushing Bushing

Inner Dia. (Frame Side) Outer Dia. Inner Dia. (Boom Side) Outer Dia. Inner Dia. (Frame Side) Outer Dia.

W4-3-7

Specification

FRONT ATTACHMENT / Bushing and Point

Part Name

h: Bucket Cylinder and Link

i: Link and Bucket

j: Arm and Bucket

k: Arm and Link

Location

Specification

Unit: mm (in) Allowable Limit

Pin Dia. Bushing Inner Dia. (Link A Side) Bushing Outer Dia.

160 (6.3) 160 (6.3) 190 (7.5)

158.5 (6.2) 161.5 (6.4) -

Bushing Inner Dia (Link B Side) Bushing Outer Dia.

160 (6.3) 190 (7.5)

161.5 (6.4) -

Bearing Inner Dia. (Cylinder Side)

160 (6.3)

161.5 (6.4)

Pin Dia. Bushing Bushing Bushing Bushing

140 140 170 140 170

(5.5) (5.5) (6.7) (5.5) (6.7)

138.5 (5.5) 141.5 (5.6) 141.5 (5.6) -

Pin Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.

160 (6.3) 160 (6.3) 190 (7.5)

158.5 (6.2) 161.5 (6.4) -

Bushing Inner Dia. (Bucket Side) Bushing Outer Dia.

160 (6.3) 190 (7.5)

161.5 (6.4) -

Pin Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.

130 (5.1) 130 (5.1) 155 (6.1)

128.5 (5.1) 131.5 (5.2) -

Bushing Inner Dia. (Link B Side) Bushing Outer Dia.

130 (5.1) 155 (6.1)

Inner Dia.( Link A Side) Outer Dia. Inner Dia. (Bucket Side) Outer Dia.

W4-3-8

FRONT ATTACHMENT / Bushing and Point (Blank)

W4-3-9

FRONT ATTACHMENT / Bushing and Point Pin and Bushing (Loading Shovel)

d a

h g

c b

W4-3-10

W142-04-01-023

FRONT ATTACHMENT / Bushing and Point Unit: mm (in)

(6.3) (6.3) (7.5) (6.3) (7.1) (6.3) (6.3) (7.1) (6.3) (5.9) (5.9) (5.9)

Allowable Limit 158.5 (6.2) 161.5 (6.4) 161.5 (6.4) 158.5 (6.2) 161.5 (6.4) 111.5 (4.4) 148.5 (5.8) -

150 (5.9) 150 (5.9)

151.5 (6.0) 151.5 (6.0)

Pin Dia. Pin Hole Inner Dia. (Boom Side)

160 (6.3) 160 (6.3)

158.5 (6.2) -

Bearing Inner Dia. (Cylinder Side)

160 (6.3)

161.5 (6.4)

Pin Dia. Pin Hole Inner Dia. (Boom Side) Bearing Inner Dia. (Cylinder Side)

130 (5.1) 130 (5.1) 130 (5.1)

128.5 (5.1) 131.5 (5.2)

Pin Dia. Bushing Inner Dia. (Arm Side) Bushing Outer Dia.

160 (6.3) 160 (6.3) 190 (7.5)

158.5 (6.2) 161.5 (6.4) -

Bushing Bushing Pin Dia. Bushing Bushing Bushing Bushing

160 190 140 140 165 140 165

161.5 (6.4) 138.5 (5.5) 139.5 (5.5) 141.5 (5.6) -

Part Name

Location

Pin Dia. Bushing Inner Dia. (Boom Side) Bushing Outer Dia. a: Boom and Main Frame Bushing Inner Dia. (Frame Side) Bushing Outer Dia. Pin Dia. Bushing Inner Dia. (Frame Side) b: Boom Cylinder and Main Frame Bushing Outer Dia. Bearing Inner Dia. (Cylinder Side) Pin Dia. Pin Hole Inner Dia. (Boom Side) c: Level Cylinder and Boom and Arm Pin Hole Inner Dia. (Arm Side) Arm Cylinder and Boom and Arm Bearing Inner Dia. ( Cylinder Rod Side) ( Cylinger Bottom Side) d:

Boom Cylinder and Boom

e: Bucket Cylinder and Boom

Arm and Boom

g: Bucket and Arm

Inner Dia. (Boom Side) Outer Dia. Inner Dia. (Bucket Side) Outer Dia. Inner Dia. (Arm Side) Outer Dia.

W4-3-11

Specification 160 160 190 160 180 160 160 180 160 150 150 150

(6.3) (7.5) (5.5) (5.5) (6.5) (5.5) (6.5)

FRONT ATTACHMENT / Bushing and Point Unit: mm (in)

h: Dump Cylinder and Front Bucket

Pin Dia. Bushing Inner Dia. (Bucket Side) Bushing Outer Dia. Bearing Inner Dia. (Cylinder Side)

90 90 110 90

(3.5) (3.5) (4.3) (3.5)

Allowable Limit 88.5 (3.5) 91.5 (3.6) 91.5 (3.6)

i: Rear Bucket and Front Bucket

Pin Dia. Bushing Bushing Bushing Bushing

130 (5.1) 130 (5.1) 155 (6.1)

128.5 (5.1) 131.5 (5.2) -

130 (5.1) 155 (6.1)

131.5 (5.2) -

Pin Dia. Pin Hole Inner Dia. (Bucket Side) Bearing Inner Dia. (Cylinder Side)

90 (3.5) 90 (3.5)

88.5 (3.5) -

90 (3.5)

91.5 (3.6)

Pin Dia. Bushing Inner Dia. (Bucket Side) Bushing Outer Dia. Bearing Inner Dia. (Cylinder Side)

130 (5.1) 130 (5.1) 155 (6.1)

128.5 (5.1) 131.5 (5.2) -

130 (5.1)

131.5 (5.2)

Part Name

j: Rear Bucket and Dump Cylinder

k: Bucket Cylinder and Rear Bucket

Location

Inner Dia. (Rear Side) Outer Dia. Inner Dia. (Front Side) Outer Dia.

W4-3-12

Specification

FRONT ATTACHMENT / Bushing and Point Side Cutter A B

Section A W142-04-01-020

Unit: mm (in)

Standard 450 (18.0) 145 (6.0)

B C

Allowable Limit 280 (11.0) 90 (3.5)

Remedy Replace

Point (Backhoe)

A D

W142-04-01-021

Unit: mm (in)

A B C D

Standard 315 (12.5) 154 (6.1) 172 (6.8) 172 (6.8)

Allowable Limit 153 (6.0) − − −

W4-3-13

Remedy Replace

FRONT ATTACHMENT / Bushing and Point Point (Loading Shovel)

W142-04-01-022

Unit: mm (in)

A B C D

Standard 329 (13.0) 159 (6.3) 204 (8.0) 204 (8.0)

Allowable Limit 206 (8.1)

W4-3-14

− − −

Remedy

Replace

Hitachi Construction Machinery Co. Ltd

Hitachi Ref. No.

Attn: Publications, Marketing & Product Support Fax: 81-298-31-1162

SERVICE MANUAL REVISION REQUEST FORM NAME OF COMPANY:

MODEL: PUBLECATION NO.:

YOUR NAME:

(Located at the left bottom corner in the cover page)

PAGE NO.: DATE: FAX:

(Located at the bottom center in the page. If two or more revisions are requested, use the comment column)

YOUR COMMENTS / SUGGESTIONS: Attach photo or sketch is required. If your need more space, please use another sheet.

REPLY:

(Copy this form for usage)