Komatsu PC200-6 C10001 and up Hydraulic Excavator Shop Manual - PDF DOWNLOAD by www.heydownloads.com

SEBMOI

Shop Manual

0201 K

PC200 HYDRAULIC EXCAVATOR

SERIAL NUMBERS

PC200-6

- Cl0001

andup

This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.

February 1998

CONTENTS No. of page

GENERAL ..,.........................................................=...........

01-l

STRUCTURE

. ... .. .. . ... .. .. ... .. .. .. .. .. ... .. .. ..

IO-I

TESTING AND ADJUSTING

... .. .. . ... .. .. ... .. ... ... .. .. ... ... .. . .. .

20-I

DISASSEMBLY

MAINTENANCE

00-2 0

OTHERS

AND FUNCTION

AND ASSEMBLY

STANDARD

. .. .. ... ... ... .. .. ... . . ... ... . ...

,....,.,.,.,.,...........................

30-I

40-I

........................................................................... 90-l

Es > E LLI

SAFETY NOTICE

SAFETY

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper

service

and

repair

is extremely

service and repair techniques are both effective designed

manual.

for safe machine

by Komatsu

and safe. Some of these techniques

by Komatsu

To prevent

important

recommended

for the specific

injury to workers,

The cautions

fully. If any dangerous take the necessary

situation

require the use of tools specially

is used to mark safety precautions

these symbols

should

arises or may possibly

always

arise, first consider

Read the Operation carefully

6. Decide

are extremely

dangerous.

and Maintenance

BEFORE operating

Before carrying

read all the precautions

Manual

the machine.

out any greasing

a place

in the repair

are fixed to the machine.

When

carrying

or repairs,

out any operation,

wear safety shoes and helmet.

always

or clothes with buttons

safety glasses when

hitting

parts with a hammer. . Always

wear

safety glasses

trained,

experienced

when

welder

PREPARATIONS FOR WORK 7. Before

adding

oil or making

welding

gloves,

out the work,

apron,

al-

hand

shield, cap and other clothes suited for welding work.

or tracks

ating procedure

with two

always agree on the operbefore

starting.

Always

in-

form your fellow workers before starting any step of the operation.

Before starting

work,

REPAIR signs on the controls

in the operatorâ&#x20AC;&#x2122;s

compartment.

5. Keep all tools in good condition the correct way to use them.

to prevent

and the

from moving. blade,

ripper,

bucket or any other work equipment

starting

work,

to the

If this

equipment

is not

from falling.

lower

and learn

possible,

insert

In addition,

the

be sure

to lock all the control levers and hang warning signs on them. 9. When disassembling

out any operation

or more workers,

repairs,

safety pin or use blocks to prevent the work

ways

hang UNDER

block the wheels

8. Before

any

on hard, level ground,

carry

out welding

carrying

for smok-

ing. Never smoke while working.

ground.

carrying

When

Smoke only in the areas provided

always have a

work. When wear

grind-

etc.

repairs are needed,

keep

places.

keep the work area clean and make

machine

ing parts with a grinder, If welding

Always

park the machine wear

parts. Always

the tools and parts in their correct

Do not wear

missing. . Always

workshop

sure that there is no dirt or oil on the floor.

given on the decals

which

loose work clothes,

care-

safety, and

keep tools and removed in operation

in this

be followed

actions to deal with the situation.

GENERAL PRECAUTIONS Mistakes

The

in this manual

purpose.

the symbol A

accompanying

operation.

and described

the

machine

with

before starting 10. Remove

or assembling, blocks,

jacks

support or stands

work.

all mud and oil from

the steps or

other places used to get on and off the machine. Always

use the handrails,

ladders

steps when

getting

Never

on or off the machine.

jump

impossible

on or off the machine.

to use the handrails,

steps, use a stand to provide

If it is

ladders

safe footing.

00-3

SAFETY

PRECAUTIONS

DURING

19. Be sure to assemble

WORK

original 11. When or

removing

hydraulic

pressure

loosen them spurting Before

the oil filler cap, drain plug

slowly

measuring

to prevent

plugs,

the oil from

disconnecting

or removing

nents of the oil, water the

pressure

or air circuits, completely

first

from

the

and

oil in the circuits

the engine

is stopped,

are hot

so be careful

for the oil and water

carrying

out any work

to cool before

on the oil or water

circuits.

20. When sure

installing that

ful when circuits.

high pressure

they

are

installing Also,

the battery.

Always

the negative

(-1 terminal

remove

the lead from

use a hoist

22. When

aligning

or hand.

ample

capacity.

Install

the lifting

which

has

Use a hoist

or crane

and

the component

operate hit-

part. Do not work with

any

removing

covers which

ternal

pressure

or under

always

leave two

wiring 17. When

are under in-

pressure

from

bolts in position

sides. Slowly

removing

release the pres-

components,

or damage

be careful

the wiring.

may cause electrical removing

piping,

not

Damaged

fires.

stop the fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately.

Fuel or oil

on the floor can cause you to slip, or can even start fires. 18. As a general

rule, do not use gasoline

wash parts. In particular,

use only the mini-

mum

washing

parts.

00-4

measuring

hydraulic

not to get your

pressure,

tool is correctly

of gasoline

when

electrical

removing

tracks of track-type When

removing

rates suddenly,

sure, then slowly loosen the bolts to remove.

to break

Be careful

in a hole.

that the measuring

24. Take care when

from

15. When

16. When

correctly.

check assem-

at the correct

part still raised by the hoist or crane.

on opposite

or rotate at

careful to check

bled before taking any measurements. equipment

to prevent

ting any other

23. When

equipment

When

two holes, never insert your

caught

lifting

parts

parts, always torques.

violently

be particularly

fingers

use

care-

parts such as guards,

vibrate

fingers

are free from damage.

Damaged

connecting

tightening

protective

or parts which high speed,

hoses, make

so be extremely

or installing

use the specified

Check that the wire rope, chains and hooks Always

is be-

tubes for high pressure

check that

or crane.

spring,

by contact

not twisted.

that they are installed

first.

14. When raising heavy components,

places.

be sure

installed.

21. When assembling installing

13. Before starting work, remove the leads from

slowly

parts with new parts.

hoses and wires,

that they will not be damaged

are correctly

not to get burned. Wait

installing

tubes are dangerous,

water

when

Replace any damaged . When

ing operated.

compo-

circuit. 12. The

all parts again in their

places.

with other parts when the machine

out.

remove

NOTICE

or installing

the

machines.

the track, the track sepaso never let anyone stand at

either end of the track.

GENERAL

FOREWORD

FOREWORD GENERAL This

shop

serviceman

manual

has been

an accurate

prepared

as an aid to improve

understanding

repairs and make judgements.

the quality

of the product and by showing

Make sure you understand

of repairs

by giving

the

him the correct way to perform

the contents

of this manual

and use it to full

effect at every opportunity.

This shop manual

mainly

service workshop.

For ease of understanding,

chapters

are further

contains

divided

the necessary

technical

the manual

information is divided

for operations

performed

into the following

chapters;

in a these

into the each main group of components.

STRUCTURE AND FUNCTION This section explains an understanding

the structure

of the structure,

and function

of each component.

but also serves as reference

It serves not only to give

material

for troubleshooting.

TESTING AND ADJUSTING This

section

adjustments

explains

checks

to be made

to be made at completion

Troubleshooting

charts correlating

before

and

after

performing

repairs,

as well

of the checks and repairs.

“Problems”

to “Causes” are also included

in this section.

DISASSEMBLY AND ASSEMBLY This section assembling

MAINTENANCE

explains

the order to be followed

each component,

when

as well as precautions

removing,

installing,

disassembling

to be taken for these operations.

STANDARD

This section gives the judgement

standards

when

inspecting

disassembled

parts.

NOTICE The

specifications

time

and

with

the

contained

without latest

any

advance

in this notice.

shop

manual

Use the

are subject

specifications

to change given

in the

at any book

date. I

00-5

HOW TO READ THE SHOP MANUAL

FOREWORD

HOW TO READ THE SHOP MANUAL VOLUMES

REVISED

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

When

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series

pages.

Electrical volume: Attachments volume:

Each issued as one volume to cover all models

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION

AND

UPDATING

Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.

EDITION

a manual

(@I@@....)

MARK is revised,

is recorded

an edition

on the

bottom

mark of the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. show how to read the 2. Following examples page number. Example 1 (Chassis volume):

Item

Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

10 -3 Item number (IO. Structure and Function) Consecutive page number for each item. Example

2 (Engine volume):

12 - 5 TT lUnit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.

-t

3. Additional

pages:

cated by a hyphen page number.

Additional

00-6

Places that require special atighteninc I tention for the tightening torque torque during assembly. Coat

Places to be coated with adhesives and lubricants, etc.

Xl. water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.

after the

File as in the example.

Example: IO-4

pages are indi-

(-1 and number

1Z-203

Remarks

Symbol

HOISTING INSTRUCTIONS

FOREWORD

HOISTING

INSTRUCTIONS

HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. ,Hooks have maximum strength at the middle portion.

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol &

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I)

Check for removal

of all bolts fastening

the part to the relative 2) Check for existence ing interference

88%

79%

41%

71%

SAW0479

of another

with

100%

parts. the

part caus-

part to be re-

moved.

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.

WIRE ROPES 1) Use

adequate

weight

ropes

depending

of parts to be hoisted,

on the

referring

the table below: 4)

Wire ropes (Standard “Z” or “S” twist ropes without galvanizing)

-I-

Allowable

load

tons

9.8

Rope diameter

1.0

Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN II000 kg) vertically, at various hanging angles.

11.2

13.7

1.4

12.5

15.7

1.6

21.6

2.2

27.5

2.8

suspended. {IO00

35.3

3.6

43.1

4.4

22.4

54.9

5.6

98.1

10.0

When two ropes sling a load vertically, to 19.6 kN 12000 kg1 of total weight This weight

kg) when

hanging

angle.

two

becomes

ropes

make

On the other

ropes are subjected

can be 9.8 kN a 120”

hand,

to an excessive

two force

as large as 39.2 kN (4000 kg) if they sling

176.5

18.0

274.6

28.0

392.2

40.0

a 19.6 kN f2000 kg) load at a lifting angle of 150”. a

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.

2) Sling wire ropes from the middle of the hook.

portion

120

Lifting

angle

(decree)

150 SAD00480

00-7

FOREWORD

COATING Ir The

MATERIALS

recommended

disassembly *

COATING MATERIALS

For coating

Categon/

and

coating assembly

materials

:omatsu code LT-IA

such

materials are

listed

as adhesives,

gasket

not listed below,

use the equivalent

Part No.

Q’w

790-129-9030

150 g

of products

Container

Main l

Tube l

LT-1 B

790-129-9050

20 9 (2 pes.)

I‘olyethylene container

LT-2

0994040030

sealants

and

greases

used

for

below.

I‘olyethylene 50 g

Adhesive:

LT-3

790-I 29-9060 (Set of adhesive and hardening agent)

LT-4

790-129-9040

250 g

Holtz MH 705

790-126-9120

75 g

container

1 kg iardeninc I agent: 500 g

shown

in this list.

applications,

features

Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive and plastic.

or sealant for metal, glass

Can

Adhesives

Three bond 1735

790-129-9140

50 g

F‘olyethylene

Tube

790-129-9130

Quick hardening

Used mainly

F‘olyethylene

container l

r9A-129-9110

50 cc

LG-1

790-129-9010

200 g

Used as heat-resisting ing engine.

1 Loctite 648-50

for machined

holes.

sealant

for repair-

type adhesive

Aron-alpha 201

Used as sealant

container

F‘olyethylene

container

Tube

for adhesion

of metals,

Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals. Features: Resistance to heat, chemicals Used at joint portions subject to high temperatures. Used as adhesive or sealant for gaskets and packing of power train case, etc.

. Features: Resistance to heat . Used as sealant for flange surfaces Gasket sealant

00-8

LG-3

790-l 29-9070

1 kg

Can

rub-

and bolts at high temperature locations, used to prevent seizure. . Used as sealant for heat resistance gasket for high temperature locations such as engine precombustion chamber, exhaust pipe, etc.

COATING MATERIALS

FOREWORD

Category

Precautions

Use Rocky ground, normal river soil

C l

Paved surface

Paved su r-face

Travel in Lo speed when traveling on rough ground such as large boulders and fallen trees.

with obstacles

Use only for ground where “A” and “B” sink and are impossible to use. Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed. The shoes are flat, so they have low gradeability. The shoes are made of rubber, rough ground.

Categories “B” and “C” are wide shoes, so there are restrictions on their use. Therefore, before using, check the restrictions and consider carefully the conditions of use before recommending a suitable shoe width. If necessary, give the customer guidance in their use.

10-10 0

using

Cannot be used on rough ground where there are large obstacles such as boulders and fallen trees. Travel in Hi speed only on flat ground; when it is impossible to avoid traveling over obstacles, lower the travel speed to approx. half of Lo speed.

Normal soil, soft land

when

so be careful when

traveling

When selecting the shoe width, select the narrowest shoe possible within the range that will give no problem with flotation and ground pressure. If a wider shoe than necessary is used, there will be a large load on the shoe, and this may lead to bending of the shoe, cracking of the links, breakage of the pins, loosening of the shoe bolts, or other problems.

$ g :

E20Y06

Hydraulic pump Control valve Junction box Oil cooler

Hydraulic filter Filter (for breaker) Swing motor R.H. travel motor

22D. Travel

speed

solenoid

valve

21. Accumulator 22. EPC solenoid valve 22A. PPC lock solenoid valve 228. Swing brake solenoid valve 22C. 2 step relief solenoid valve

18. Center swivel joint 19. Travel PPC valve 20. Service PPC valve

13. L.H. travel motor 14. Arm holding valve 15. Boom holding valve 16. L.H. PPC valve 17. R.H. PPC valve

9. IO. 11. 12.

5. 6. 7. 8.

1. Bucket cylinder 2. Arm cylinder 3. Boom cylinder 4. Hydraulic tank

STRUCTURE

AND

HYDRAULIC *

FUNCTION

CIRCUIT DIAGRAM

For details of this page, see page 90-5.

HYDRAULIC

CIRCUIT

DIAGRAM

HYDRAULIC TANK

STRUCTURE AND FUNCTION

HYDRAULIC

TANK

SAP02608

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

Sight gauge Hydraulic tank Bypass valve Filter element Oil filler cap Hydraulic oil level sensor Suction strainer

10-14

SPECIFICATIONS Tank capacity: 239 .J? Amount of oil inside tank: 166 .Q Pressure valve Relief cracking pressure: 16.7 f 3.9 kPa (0.17 2 0.04 kg/cm? Suction cracking pressure: 0 - 0.49 kPa (0 - 0.005 kg/cm*} Bypass valve set pressure: 102.9 f 19.6 kPa (1.05 + 0.2 kg/cm21

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

HYDRAULIC

PUMP I

2 f

1. 2. 3. 4. 5.

Front main pump PC valve LS valve Rear main pump PC-EPC valve

Outline l

This pump consists of 2 variable capacity swash plate piston pumps, a PC valve, LS valve, and PC-EPC valve.

it: i.

SAP03204

PdlF port (pump drain) PenF port (front control pressure detection) PBF port (pump pressure input) PAF port (front pump delivery) PAR port (rear pump delivery) PenR port (rear control pressure detection) Psig port (LS set selector pilot) Im (PC mode selector current) PLSR port (rear load pressure input) lsig (LS set selector current) PLSF port (front load pressure input)

Fâ&#x20AC;&#x2122; g* h. i.

j. k. I. EPC basic pressure detection m. Ps port (pump suction)

port

10-15

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

MAIN PUMP HPV95+95

a. b. c. d. e.

PdlF port (pump drain) PBF port (pump pressure input) PAF port (front pump delivery) PAR port (rear pump delivery) Ps port (suction)

lo-16

SAP02786

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

A-A

B-B

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

Shaft (front) Cradle Case (front) Rocker cam Shoe Piston

7. Cylinder 8. 9. 10. 11. 12.

block Valve plate End cap Shaft (rear) Case (rear) Servo piston

10-17

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

SPI

ine

Spline SAP03438

Function . The rotation

and torque transmitted to the pump shaft is converted into hydraulic energy, and pressurized oil is discharged according to the load. It is possible to change the discharge amount by changing the swash plate angle.

Structure . Cylinder

block (7) is supported to shaft (I) by a spline, and shaft (I) is supported by the front and rear bearings. The tip of piston (6) is a concave ball, and shoe (5) is caulked to it to form one unit. Piston (6) and shoe (5) form a spherical bearing.

lo-18

Rocker cam (4) has flat surface A, and shoe (5) is always pressed against this surface while sliding in a circular movement. Rocker cam (4) brings high pressure oil at cylindrical surface B with cradle (21, which is secured to the case, and forms a static pressure bearing when it slides. Piston (6) carries out relative movement in the axial direction inside each cylinder chamber of cylinder block (7). The cylinder block seals the pressure oil to valve plate (8) and carries out relative rotation. This surface is designed so that the oil pressure balance is maintained at a suitable level. The oil inside each cylinder chamber of cylinder block (7) is sucked in and discharged through valve plate (8).

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

Operation 1) Operation of pump i)-

Cylinder block (7) rotates together with shaft (I), and shoe (5) slides on flat surface A. When this happens, rocker cam (4) moves along cylindrical surface B, so angle 01 between center line X of rocker cam (4) and the axial direction of cylinder block (7) changes. (Angle a is called the swash plate angle.) ii) Center line X of rocker cam (4) maintains swash plate angle a in relation to the axial direction of cylinder block (71, and flat surface A moves as a cam in relation to shoe (5). In this way, piston (6) slides on the inside of cylinder block (71, so a difference between volumes E and F is created inside cylinder block (7). The suction and discharge is carried out by this difference F - E. In other words, when cylinder block (7) rotates and the volume of chamber E becomes smaller, the oil is discharged during that stroke. On the other hand, the volume of chamber F becomes larger, and as the volume becomes bigger, the oil is sucked in. iii) If center line X of rocker cam (4) is in line with the axial direction of cylinder block (7) (swash plate angle = 0), the difference between volumes E and F inside cylinder block (7) becomes 0, so the pump does not carry out any suction or discharge of oil. (In actual fact, the swash plate angle never becomes 0.)

sDPo14o9

SDP01410

SDPOl41 I

10-19

STRUCTURE

AND FUNCTION

Control of discharge amount . If swash plate angle a becomes larger, the difference between volumes E and F becomes larger and discharge amount Cl increases. Swash plate angle 0: is changed by servo piston (12). . Servo piston (12) moves in a reciprocal movement (~1 according to the signal pressure from the PC and LS valves. This straight line movement is transmitted through rod (13) to rocker cam (4), and rocker cam (4), which is supported by the cylindrical surface to cradle (2), slides ina rotating movement in direction Cc). . With servo piston (12), the area receiving the pressure is different on the left and right, so main pump discharge pressure (self pressure) PP is always brought to the chamber receiving the pressure at the small diameter piston end. Output pressure Pen of the LS valve is brought to the chamber receiving the pressure at the large diameter piston end. The relationship in the size of pressure PP at the small diameter piston end and pressure Pen at the large diameter end, and the ratio between the area receiving the pressure of the small diameter piston and the large diameter piston controls the movement of servo piston (12).

HYDRAULIC

PUMP

SDP01412

SAP02789

1O-20

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

LS VALVE

SDP01414

a. b. c. d. e. f.

Port Port Port Port Port Port Port

PLS (control valve LS pressure inlet port) PA (pump discharge pressure inlet port) PLP (LS valve signal pressure outlet port) PPL (PC valve signal pressure outlet port) Pa (drain pressure outlet port) Psig (LS control EPC valve output pressure PA (pump discharge pressure inlet port)

1. 2. 3. 4. 5. 6. 7. 8.

inlet port)

Plug Locknut Sleeve Spring Seat Spool Piston Sleeve

E t %

PC VALVE

SDP01415

a. Port Pa (drain pressure outlet port) b. Port PPL (PC valve signal pressure outlet port) c. Port PA (pump discharge pressure inlet port) d. Port PA2 (pump discharge pressure inlet port) e. Port PM (PC mode selector pressure inlet port)

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

Piston Spring Seat Spring Seat Spool

7. 8. 9. 10. 11.

Piston Sleeve Locknut Plug Locknut

1o-21

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

Function (11 LS valve The LS valve detects the load and controls the discharge amount. This valve controls main pump discharge amount 0 according to differential pressure APLS (=PP - PLS) [called the LS differential pressure] (the difference between main pump pressure PP and control valve outlet port pressure PLS). Main pump pressure PP, pressure PLS {called the LS pressure] sent by the control valve output, enter this valve. The relationship between discharge amount 0 and differential pressure APLS, (the difference between main pump pressure PP and LS pressure PLS) (= PP - PLS) changes as shown in the diagram on the right.

(Urnin)

LS differential

2. 2(22. 51 Pressure APLS

iMPa(t~/cmâ&#x20AC;&#x2122;l) SAP03818

(21 PC valve When the pump discharge pressure PPI (selfpressure) and PP2 (other pump pressure) are high, the PC valve controls the pump so that no more oil than the constant flow (in accordance with the discharge pressure) flows even if the stroke of the control valve becomes larger. In this way, it carries out equal horsepower control so that the horsepower absorbed by the pump does not exceed the engine horsepower. In other words, if the load during the operation becomes larger and the pump discharge pressure rises, it reduces the discharge amount from the pump; and if the pump discharge pressure drops, it increases the discharge amount from the pump. The relationship between the average of the front and rear pump discharge pressures (average discharge amount of F, R pumps (PPI + PP2)/2) and pump discharge amount 0 is shown on the right, with the current given to the PC-EPC valve solenoid shown as a parameter. The pump controller senses the actual speed of the engine, and if the speed drops because of an increase in the load, it reduces the pump discharge amount to allow the speed to recover. In other words, when the load increases and the engine speed drops below the set value, the command current to the PC-EPC valve solenoid from the controller increases according to the drop in the engine speed to reduce the pump swash plate angle.

10-22

Pump discharge Pressure averaoe

(PPl tPP2)

SAP03440

STRUCTURE

AND

HYDRAULIC

FUNCTION

OPERATION

Minimum

(1) LS valve 1) When control valve is at neutral position The LS valve is a three-way selector valve, with pressure PLS (LS pressure) from the inlet port of the control valve brought to spring chamber B, and main pump discharge pressure PP brought to port H of sleeve (8). The size of this LS pressure PLS + force Z of spring (4) and the main pump pressure (self pressure) PP determines the position of spool (6). Before the engine is started, servo piston (11) is pushed to the right. (See the diagram on the right) When the engine is started and the control lever is at the neutral position, LS pressure PLS is 0 MPa (0 kg/cm?. (It is interconnected with the drain circuit through the control valve spool.) At this point, spool (6) is pushed to the left, and port C and port D are connected. Pump pressure PP enters the large diameter end

PUMP

direction

of the pump small swash by the

SAP04077

piston from port K, and the same pressure PP also enters port J at the diameter end of the piston, so the plate is moved to the minimum angle difference in area of piston (II).

SOP03713

A-A

1 O-23

STRUCTURE

AND

FUNCTION

HYDRAULIC

Maximum

direction

PUMP

SAP04078

21 Operation .

in maximum direction for pump discharge amount When the difference between main pump pressure PP and LS pressure PLS, in other words, LS differential pressure APLS, becomes smaller (for example, when the area of opening of the control valve becomes larger and pump pressure PP drops), spool (6) is pushed to the right by the combined force of LS pressure PLS and the force of spring (4). When spool (6) moves, port D and port E are joined and connected to the PC valve. When this happens, the PC valve is connected to the drain port, so circuit D - K becomes drain pressure PT. (The operation of the PC valve is explained later.)

1 O-24

For this reason, the pressure at the large diameter end of servo piston (11) becomes drain pressure PT, and pump pressure PP enters port J at the small diameter end, so servo piston (11) is pushed to the right. Therefore, the swash plate moves in the direction to make the discharge amount larger.

STRUCTURE

AND

HYDRAULIC

FUNCTION

Minimum

3) l

Operation in minimum direction for pump discharge amount The following explains the situation if servo piston (11) moves to the left (the discharge amount becomes smaller). When LS differential pressure APLS becomes larger (for example, when the area of opening of the control valve becomes smaller and pump pressure PP rises), pump pressure PP pushes spool (6) to the left. When spool (6) moves, main pump pressure PP flows from port C to port D, and from port K, it enters the large diameter end of the piston.

direction

PUMP

SAP04079

Main pump pressure PP also enters port J at the small diameter end of the piston, but because of the difference in area between the large diameter end and the small diameter end of servo piston (I I), servo piston (11) is pushed to the left. As a result, the swash plate moves in the direction to make angle smaller.

1o-25

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

Minimum direction

41 When servo piston is balanced . Let us take the area receiving the pressure at the large diameter end of the piston as Al, the area receiving the pressure at the small diameter end as AO, and the pressure flowing into the large diameter end of the piston as Pen. If the main pump pressure PP of the LS valve and the combined force of force Z of spring (4) and LS pressure PLS are balanced, and the relationship is A0 x PP = Al x Pen, servo piston (1 I) will stop in that position, and the swash plate will be kept at an intermediate position. (It will stop at a position where the opening of the throttle from port D to port E and from port C to port D of spool (6) is approximately the same.)

1 O-26

SAP04080

At this point, the relationship between the area receiving the pressure at both ends of piston (1 I) is A0 : Al = 1 : 2, so the pressure applied to both ends of the piston when it is balanced becomes PP : Pen = 2 : 1. The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is adjusted so that it is determined when PP - PLS = 2.2 MPa (22.5 kg/ cm*).

STRUCTURE

AND

HYDRAULIC

FUNCTION

Minimum

PC-EPC

Valve

PC prolix // I,

direction

Maximum

PUMP

direction

switch OFF

I_ p

,, I/

SAP03445

(2) PC valve 1) a.

When pump controller is normal When the load on the actuator is small and pump pressures PPI and PP2 are low 0 Movement of PC-EPC solenoid (I) The command current from the pump controller flows to PC-EPC solenoid (I). This command current acts on the PCEPC valve and outputs the signal pressure. When this signal pressure is received, the force pushing piston (2) is changed. On the opposite side to the force pushing this piston (2) is the spring set pressure of springs (4) and (6) and pump pressure PPI (self pressure) and PP2 (other pump pressure) pushing spool (3). Piston (2) stops at a position where the combined force pushing spool (3) is balanced, and the pressure (pressure of port l

C) output from the PC valve changes according to this position. The size of command current X is determined by the nature of the operation (lever operation), the selection of the working mode, and the set value and actual value for the engine speed. Other pump pressure This is the pressure of the pump at the opposite end. For the F pump, it is the R pump pressure For the R pump, it is the F pump pressure

1O-27

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

When connected

, Large diameter :1,/,,/,/,/,,,,,,,,,,,, Maximum

PC-EPC

Valve

PC Prolix II /I

0 Action of spring . The spring load . .

OFF

1 O-28

,, I,

Pump controller

of springs (4) and (6) in the PC valve is determined by the swash plate position. When servo piston (9) moves, piston (71, which is connected to slider (8), also moves to the right or left. If piston (7) moves to the left, spring (6) is compressed, and if it moves further to the left, spring (6) contacts seat (5) and is fixed in position. In other words, the spring load is changed by piston (5) extending or compressing springs (4) and (6).

direction

switch

I_ ?

Self-Reducing Preesure valve

end 1,x, ,

r-+3 â&#x20AC;&#x2122;

SAP03446

If the command current input to PC-EPC valve solenoid (I) changes further, the force pushing piston (2) changes, and the spring load of springs (4) and (6) also changes according to the value of the PC-EPC valve solenoid command current.

STRUCTURE AND FUNCTION

HYDRAULIC PUMP

Port C of the PC valve is connected to port E of the LS valve (see (I) LS valve). Self pressure PPl enters port B and the small diameter end of servo piston (9), and other pump pressure PP2 enters port A. When pump pressures PPI and PP2 are small, spool (3) is on the left. At this point, port C and port D are connected, and the pressure entering the LS valve becomes drain pressure PT. The pressure entering the large diameter end of the piston from port J becomes drain pressure PT, and servo piston (9) moves to the right. In this way, the pump discharge amount moves in the direction of increase. As servo piston (9) moves further, piston (7) is moved to the left by slider (8). Springs (4) and (6) expand and the spring force becomes weaker. When the spring force becomes weaker, spool (3) moves to the right, so the connection between port C and port D is cut, and the pump discharge pressure ports B and C are connected. As a result, the pressure at port C rises, and the pressure at the large diameter end of the piston also rises, so the movement of piston (9) to the right is stopped. In other words, the stop position for piston (9) (= pump discharge amount) is decided at the point where the force of springs (4) and (6) and the pushing force from the PC-EPC valve solenoid and the pushing force created by pressures PPI and PP2 acting on spool (3) are in balance.

lo-29

STRUCTURE

AND

HYDRAULIC

FUNCTION

Minimum

PUMP

direction

SAP03447

When load on actuator is large and pump discharge pressure is high When the load is large and pump discharge pressures PPI and PP2 are high, the force pushing spool (3) to the left becomes larger and spool (3) moves to the position shown in the diagram above. When this happens, as shown in the diagram above, part of the pressurized oil from port A flows out through the LS valve from port C to port D and the pressurized oil flowing from port C to the LS valve becomes approximately half of main pump pressure PP. . When port E and port G of the LS valve are connected (see (I) LS valve), the pressure from port J enters the large diameter end of servo piston (9), and servo piston (9) stops. l

1O-30

If main pump pressure PP increases further and spool (3) moves further to the left, main pump pressure PPI flows to port C and acts to make the discharge amount the minimum. When piston (9) moves to the left, piston (7) is moved to the left. For this reason, springs (4) and (6) are compressed and push back spool (3). When spool (3) moves to the left, the opening of port C and port D becomes larger. As a result, the pressure at port C (= J) drops, and piston (9) stops moving to the left. The position in which piston (9) stops when this happens is further to the left than the position when pump pressures PPI and PP2 are low.

HYDRAULIC PUMP

STRUCTURE AND FUNCTION

The relation

of average

pump

pressure of servo piston (9) forms a bent line because of the double-spring effect of springs (4) and (6). The relationship between average pump pressure (PPI + PP2)/2 and pump discharge amount Q is shown in the figure on the right.

(PPI + PP2)/2 and the position

Puma discharge pressure average

(PPl +PPz) 12 SAP03448

If command voltage X sent to PC-EPC valve solenoid (I) increases further, the relationship between average pump pressure (PPI + PP2)/2, and pump discharge amount Q is proportional to the pushing force of the PC-EPC valve solenoid and moves in parallel. In other words, the pushing force of PC-EPC solenoid (I) is added to the force pushing to the left because of the pump pressure applied to the spool (3), so the relationship between the average pump pressure (PPI + PP2)/2 and 0 moves from @ to @ in accordance with the increase in X.

10-31

STRUCTURE

AND FUNCTION

HYDRAULIC

Maximum

PUMP

direction

IA PC-EPC

Valve

PC Prolix

switch OFF

Pump controller

ON Self-Reducing pressure valve

Resister ,I,

/ SAP03450

2) a.

When pump controller is abnormal and PC prolix switch is ON When load on main pump is light . If there is a failure in the pump controller, turn PC prolix switch ON to switch to the resistor side. In this case, the power source is taken directly from the battery. But if the current is used as it is, it is too large, so use the resistor to control the current flowing to PC-EPC valve solenoid (I). l When this is done, the current becomes constant, so the force pushing piston (2) is also constant. . If main pump pressures PPI and PP2 are low, the combined force of the pump pressure and the force of PC-EPCâ&#x20AC;&#x2122;valve solenoid (I) is weaker than the spring set force, so spool (3) is balanced at a position to the left.

1O-32

At this point, port C is connected to the drain pressure of port D, and the large diameter end of the piston of servo piston (9) also becomes the drain pressure PT through the LS valve. When this happens, the pressure at the small diameter end of the piston is large, so servo piston (9) moves in the direction to make the discharge amount larger.

STRUCTURE

AND

HYDRAULIC

FUNCTION

Minimum PC prolix

PUMP

direction

swi

SAP03451

When main pump load is heavy . In the same way as in the previous item, when the PC prolix switch is ON, the command current sent to PC-EPC valve solenoid (I) becomes constant. For this reason, the force of piston (2) pushing spool (3) is constant. . If main pump pressures PPI and PP2 increase, spool (3) moves further to the left than when the main pump load is light, and is balanced at the position in the diagram above. . In this case, the pressure from port A flows to port C, so servo piston (9) moves to the left (to make the discharge amount smaller) by the same mechanism as explained in Item 2)-b, and stops at a position to the left of the position when the load on the pump is light. In other words, even when the PC prolix switch is ON, the curve for the pump pressure PP and

discharge amount 0 is determined as shown in the diagram for the value of the current sent to the PC-EPC valve solenoid through the resistor. The curve when the PC prolix switch is ON is curve 0, which is to the left of curve @ for when the pump controller is normal.

Pump discharge

~ressur

SAP03452

1o-33

STRUCTURE

AND

CONTROL

FUNCTION

VALVE

CONTROL VALVE 1. 2. 3. 4.

6-spool valve Cover 1 Cover 2 Junction box

a. b. c. d. e. f. g. h. i. j. k. I. m. n. u. v. w. x. y. aa. ab. bb. cc.

Port PPI (from rear main pump) Port PP2 (from front main pump) Port A6 (to arm cylinder head) Port B6 (to arm cylinder bottom) Port A5 (to L.H. travel motor) Port B5 (to L.H. travel motor) Port A4 (to swing motor) Port B4 (to swing motor) Port A3 (to boom cylinder bottom) Port B3 (to boom cylinder head) Port A2 (to R.H. travel motor) Port B2 (to R.H. travel motor) Port Al (to bucket cylinder head) Port Bl (to bucket cylinder bottom) Port T (to tank) Port CPI (to port CP3) Port CP2 (to port CP4) Port cP3 (to port CPI) Port CP4 (to port CP2) Port PLSI (to rear pump control) Port PLS2 (to front pump control) Port TS (to tank) Port BP1 (PPC output pressure for boom RAISE)

1o-34

Outline . This control valve consists of the 6-spool valve (an integrated composition). The junction box is installed to this. . Each valve is formed into one unit by the connection bolt, and the passages are internally connected, so the structure is compact and is very easy to service. . This control valve consists of one spool for one item of the work equipment, so it has a simple structure.

dd. ee. ff. pa. pb. pc. pd. pe. pf. pg. ph. pi. pj. pk. pl. pm. pn. po. pp. pq. pr.

Port PX (from 2-stage relief solenoid valve: pressure rise type) Port BP3 (from travel PPC valve) Port BP2 (from PPC valve) Port PI2 (from arm PPC valve) Port PI1 (from arm PPC valve) Port PI0 (from L.H. travel PPC valve) Port P9 (from L.H. travel PPC valve) Port P8 (from swing PPC valve) Port P7 (from swing PPC valve) Port P6 (from boom PPC valve) Port P5 (from boom PPC valve) Port P4 (from R.H. travel PPC valve) Port P3 (from R.H. travel PPC valve) Port P2 (from bucket PPC valve) Port PI (from bucket PPC valve) Port P-2 (from service PPC valve) Port P-l (from service PPC valve) Port P-4 (from service PPC valve) Port P-3 (from service PPC valve) Port P-6 (from service PPC valve) Port P-5 (from service PPC valve)

CONTROL VALVE

STRUCTURE AND FUNCTION

6-spool

valve

(pressure

rise type) Iff

bl SAP03966

10-35

CONTROL VALVE

STRUCTURE AND FUNCTION

Main (l/5)

structure

A-A

B-B SAP03967

1 O-36

STRUCTURE

AND

FUNCTION

CONTROL

VALVE

(2/5)

SAP03214

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

Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Pressure compensation Arm spool

valve valve valve valve valve valve

(Arm) (L.H. travel) (Swing) (Boom) (R.H. travel) (Bucket)

8. 9. 10. 11. 12. 13. 14.

L.H. travel spool Swing spool Boom spool R.H. travel spool Bucket spool Safety-suction valve Suction valve

1o-37

STRUCTURE

AND

CONTROL

-3

D-D

Iâ&#x20AC;&#x2122;

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

FUNCTION

E-E

F-F

3 G-G

Safety-suction valve Arm spool Pressure compensation valve LS shuttle valve Check valve for arm regeneration Suction valve

1 O-38

VALVE

AA-AA

circuit

7. 8. 9. 10. 11. 12. 13.

H-H

Arm spool Swing spool LS select valve Boom spool Check valve for boom regeneration R.H. travel spool Bucket spool

SAP03215

circuit

STRUCTURE AND FUNCTION

CONTROL VALVE

(415)

K-K

JJ-JJ

1. 2.

Unload spool Main relief valve (Pressure

SAP03968

rise type)

1o-39

CONTROL VALVE

STRUCTURE AND FUNCTION

B/5)

J-J

EE-EE

SAP03199

1. 2. 3.

LS shuttle valve LS select valve LS bypass valve

1O-40

STRUCTURE

AND

FUNCTION

SAFETY-SUCTION

VALVE

CONTROL

FOR SERVICE

VALVE

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

Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve spring Sleeve Adjustment screw Locknut

SBPOO198

SPECIFICATION Part No.

Set pressure

70%70-74800

1 20.58

709-70-75100

1 20.09 MPa (205 kg/cm?

at 5 e/min

7og-yo-753oo

at 190 e/min

709-70-74600

1 24.5 MP (250 kg/cm*) at 5 .Q/min

MPa (210 kg/cm*) at 190 !J/min

16.56 MPa (170 kg/cm?

Use

I 1 For breaker For breaker

(Okada) (Mitsubishi

Krupp)

For breaker (Matsuda) For crusher

(Okada)

10-41

SELF-REDUCING PRESSURE VALVE

STRUCTURE AND FUNCTION

SELF-REDUCING

PRESSURE VALVE

SAP03258

a. b. c. d.

Port PI (from front pump) Port PR (supply to electromagnetic valve, EPC valve) Port T (to hydraulic tank) Port PC (to front pump LS valve)

1 O-42

valve,

PPC

STRUCTURE

AND

FUNCTION

SELF-REDUCING

PRESSURE

VALVE

â&#x20AC;&#x2DC;4

A-A

I. 2. 3. 4. 5.

Control valve block Valve (sequence valve) Spring Screw Poppet

B-B

SAP03259

6. 7. 8. 9. 10.

Spring Spring Spring Spring Ball

(reducing valve pilot) (reducing valve main) (reducing valve) (safety valve)

1o-43

STRUCTURE AND FUNCTION

SELF-REDUCING PRESSURE VALVE

Function l

This valve reduces the discharge pressure of the main pump and supplies it as the control pressure for the solenoid valve and PPC valve.

Operation 1. When engine is stopped . Poppet (5) is pushed

against the seat by spring (6), and the passage from port PR + T is closed. Valve (8) is pushed to the left by spring (7), and the passage from port PI + PR is open. Valve (2) is pushed to the left by spring (3), so the passage between port PI + P2 is closed. (See Fig. I)

HYDRAULIC CIRCUIT DIAGRM

(Fig.

1o-44

SAP03299

SAP03300

STRUCTURE

AND

FUNCTION

At neutral and When load pressure P2 is low (when moving down under own weight (boom LOWER or arm IN)) Note: When load pressure P2 is lower than output pressure PR of the self-reducing pressure valve. . Valve (2) receives force in the direction to close the passage from port PI + P2 from spring (3) and pressure PR (when the engine is stopped, the pressure is 0 MPa (0 kg/cm21). However, when hydraulic oil flows in from port PI, the pressure is balanced so that pressure PI % force of spring (7) + (area Od x pressure PR), and the opening from port PI + P2 is adjusted so that pressure PI is kept at a certain value above pressure PR. . When pressure PR goes above the set pressure, poppet (5) opens, and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (8) + opening of poppet (5) -_j tank port T. As a result, a pressure difference is created on both sides of hole a inside spool (8), so spool (8) moves in the direction to close the opening from port PI + PR. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point, and is supplied as pressure PR. (See Fig. 2)

SELF-REDUCING

PRESSURE

VALVE

SAP03301

When load pressure P2 is high If load pressure P2 increases and the pump discharge amount also increases because of digging operations, pressure PI also increases (pressure PI > force of spring (7) + (area @d x pressure PR), so valve (2) moves to the right to the end of the stroke. As a result, the amount of opening from port PI + P2 increases and the resistance in the passage is reduced, so the loss of engine horsepower is reduced. .

If pressure PR goes above the set pressure, poppet (5) opens and the hydraulic oil flows in the following circuit: port PR + hole a inside spool (8) + opening of poppet (5) + tank port T. As a result, a pressure difference is created on both sides of hole a is inside spool (8), so spool (8) moves in the direction to close the opening from port PI + PR. Pressure PI is reduced to a certain pressure (set pressure) by the amount of opening at this point, and is supplied as pressure PR. (See Fig. 3)

SAP03302

10-45

STRUCTURE

AND

FUNCTION

SELF-REDUCING

PRESSURE

VALVE

When there is abnormal high pressure When pressure PR of the self-reducing pressure valve becomes abnormally high, ball (IO) pushes against the force of spring (91, separates from the seat, and allows hydraulic oil to flow from output port PR + T, so pressure PR goes down. This action protects the equipment at the destination for the hydraulic pressure supply (PPC valve, electromagnetic valve, etc.) from abnormally high pressure. (See Fig. 4)

Y (F i g. 4)

1 O-46

SAP03303

STRUCTURE

AND

CLSS

FUNCTION

CLSS OUTLINE OF CLSS

______--------.

SAP03879

Features CLSS stands for Closed center Load Sensing System, and has the following features.

1) Fine control not influenced by load 2) Control enabling digging even with fine con3)

Structure The CLSS consists of a main pump (2 pumps), control valve, and actuators for the work equipment. . The main pump body consists of the pump itself, the PC valve and LS valve. l

trol Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations Energy saving using variable pump control

1o-47

CLSS

STRUCTURE AND FUNCTION

Basic principle 1) Control of pump swash plate angle l

The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS (the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure of actuator) is constant. (LS pressure APLS = Pump discharge pressure PP - LS pressure PLS)

Actuator

Control

valve --7 ---l /-J-r

I’

1‘PLS PUMP

Passage

I’

c---’

u c___,

Passage

rae

current

SBP03454

If LS differential pressure APLS becomes lower than the set pressure of the LS valve (when the actuator load pressure is high), the pump swash plate moves towards the maximum position; if it becomes higher than the set pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towards the minimum position.

LS differential

pressure

APLS SAP03455

1 O-48

STRUCTURE

2) l

AND

CLSS

FUNCTION

Pressure compensation A pressure compensation valve is installed to the outlet port side of the control valve to balance the load. When two actuators are operated together, this valve acts to make pressure difference AP between the upstream (inlet port) and

downstream (outlet port) of the spool of each valve the same regardless of the size of the load (pressure). In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of openings Sl and S2 of each valve.

Load

comoensation

SBP03456

1o-49

CLSS

STRUCTURE AND FUNCTION

OPERATION FOR EACH FUNCTION Hydraulic

circuit diagram

AND VALVE

for system

rtor

__----- -

,3 _

III, : ,,CP3

-4 P3

--w #ina

‘_>_____’

va!v_e

6 -_ .-

P 12 ------/-I

SAP03969

1O-50

STRUCTURE AND FUNCTION

CLSS

1. Main relief valve (2 step relief) Set pressure: 31.9 MPa (325 kg/cm*) 2. Unload valve Set pressure: 2.9 MPa (30 kg/cm? 3. Bucket spool 4. Pressure compensation valve 5. Safety-suction valve Set pressure: 35.8 MPa (365 kg/cm*) 6. LS shuttle valve 7. R.H. travel spool 8. Suction valve 9. Boom spool 10. Check valve (for boom regeneration circuit) 11. Swing spool 12. L.H. travel spool 13. Arm spool 14. Check valve (for arm regeneration circuit) 15. LS select valve

z 5; z

A. B. C. D. E. F.

To To To To To To

bucket cylinder R.H. travel motor boom cylinder swing motor L.H. travel motor arm cylinder

1o-51

STRUCTURE

AND

CLSS

FUNCTION

SYSTEM DIAGRAM Ir This shows actuator (6A) at the stroke end relief in the merge mode.

SAP03970

IA. IB. 2A. 2B. 3. 4. 5A. 5B. 6A. 6B.

Main pump Main pump Main relief valve Main relief valve Unload valve Junction block Control valve Control valve Actuator Actuator

1o-52

7A. 7B. 8. 9A. 9B. IO. 11. 12.

Pump passage Pump passage LS circuit Tank passage Tank passage Valve Spring LS bypass valve

STRUCTURE

zi > %

Unload

AND

FUNCTION

CLSS

valve

SBPO3219

Function When the pump flow is merged and the control valve group on one side is actuated (with the remaining control valve group at neutral), the sub-unload valve drains the pump flow to the group that is at neutral. l

Operation The pressure in pump passages A is received at the end portion of valve (I). The control valve is at neutral, so the pressure in LS circuit B is 0 MPa 10 kg/cm*). The pressurized oil in pump passage A is stopped by valve (1) and cannot escape, so the pressure rises. When this pressure becomes larger than the force of spring (2), valve (I) moves to the left, ports C and D are interconnected, and the pump pressure flows to tank passage E. In addition, the pressurized oil in LS circuit B passes from orifice f through port D and is drained to tank passage E. Therefore, in this operation, LS pressure + tank pressure. . In this unload operation, pump discharge pressure - LS circuit pressure is greater than the pump LS control pressure, so a signal is sent to set the pump swash plate to the minimum angle. l

SBPO3220

1o-53

STRUCTURE

AND

Introduction

CLSS

FUNCTION

of LS pressure

(LS shuttle

valve)

SEP00123

-1

1. 2. 3.

Main pump Main spool Pressure compensation

valve

Function . LS pressure PLS is the actuator load pressure at the output side of the control valve. l The upstream pressure (= spool meter-in downstream pressure) of pressure compensation valve (3) is taken inside main spool (2) and goes to LS shuttle valve (6). . When this happens, it connects actuator circuit A and LS circuit PLS through check valve (5), and sets so that LS pressure PLS + actuator load pressure. . Introduction hole a inside main spool (2) has a small diameter, so it also acts as a throttle.

1o-54

4. 5. 6.

Valve Check valve LS shuttle valve

Operation . When main spool (2) is operated, pump discharge pressure PP starts to flow to actuator circuit A. . First, this pump discharge pressure PP passes through introduction hole a of main spool (2), and is taken to LS circuit PLS. . When actuator circuit pressure A rises to the necessary pressure, pump pressure PP rises and check valve (5) inside main spool (2) opens. The high pressure of LS circuit PLS then flows to actuator circuit A. . In this way, LS pressure PLS becomes almost the same as actuator circuit pressure A.

STRUCTURE

AND

CLSS

FUNCTION

LS bypass valve

/ a SBPO3221

1. 2. 3. 4. 5.

Main pump Main spool Pressure compensation LS shuttle valve LS bypass plug

valve

Function . The residual pressure in LS circuit PLS is released from orifices b and c. . This reduces the speed of the rise in the LS pressure, and prevents any sudden change in the oil pressure. Furthermore, a pressure loss is generated by the circuit resistance between LS shuttle valve (4) and throttle a of main spool (2) according to the bypass flow from LS bypass plug (5). As a result, the effective LS differential pressure drops, and the dynamic stability of the actuator is increased.

1o-55

STRUCTURE

AND

compensation

Pressure

FUNCTION

CLSS

valve

PP I

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

Main pump Valve Shuttle valve Piston Spring LS shuttle valve

Function When the maximum load pressure is generated during compound operations and during independent operations, and the load pressure is higher than other actuators, the pressure compensation valve acts as a load check valve to prevent reverse flow in the circuit.

1O-56

Operation . If pump pressure PP and LS pressure PLS are lower than actuator circuit B, shuttle valve (3) inside the pressure compensation valve moves to the left in the direction of the arrow to interconnect spring chamber C. . When this happens, piston (4) is pushed to the right in the direction of the arrow by spring (5). . As a results, valve (2) is also pushed to the right in the direction of the arrow by piston (4), so pump outlet circuit A closes. This prevents the oil from flowing back from actuator circuit B to pump outlet circuit A.

STRUCTURE AND FUNCTION

CLSS

From work

LS shuttle equipment

valve

for

other

Upstream pressure of Pressure compensation valve (SPOOI meter-in downstream pressure)

Function . During

\ 4%

compound operations, if the load pressure is lower than the other actuators and the flow of oil starts to increase, the pressure compensation valve carries out compensation. In this case, it tries to make the load pressure for the other actuators greater and reduce the flow of oil.

SPOOI meter-in

upstream

Pressure SBPO3881

Operation . During

compound operations, if the load pressure for the other actuators rises, the oil flow in actuator circuit B tries to increase. When this happens, LS pressure PLS for the other actuator also increases, so this LS pressure PLS pushes shuttle valve (3) of the pressure compensation valve to the right in the direction of the arrow, passes through the passage inside piston (4), and flows to spring chamber C. As a results, piston (4) and valve (2) are pushed to the right in the direction of the arrow, and the outlet side of pump circuit PP is closed, so outlet port pressure A (spool meter-in downstream pressure) becomes the same as the outlet port pressure of the other actuators. Pump pressure PP (spool meter-in upstream pressure) is the same between all actuators, so pump pressure PP and outlet port pressure A become the same between all spools that are being operated. Therefore, the pump flow is divided in proportion to the area of the opening of each valve.

1o-57

STRUCTURE

AND

FUNCTION

CLSS

Shuttle valve inside pressure compensation valve (arm, swing, boom, bucket valve)

SBPO3224

1. 2. 3. 4.

Main pump Valve Shuttle valve inside pressure valve Piston

1 O-58

compensation

Function When holding pressure at port A * LS pressure in spring chamber B Shuttle valve (3) is pushed to the right by the pressure of port A, and the circuit between ports A and PLS is shut off. In this condition, the holding pressure at port A is taken to spring chamber B, and pushes piston (4) to the left to prevent piston (4) and valve (2) from separating. l

STRUCTURE

AND

FUNCTION

CLSS

Shattle

valve

Spool

meter-in

downstream

~fe?.sur e

SBPO3461

<Surface

area ratio

of pressure

compensation

valve> The condition of the flow division changes according to the ratio of the area of portion Al and portion A2 of the pressure compensation valve. Area ratio = A2lAl. When area ratio = 1: Spool meter-in downstream pressure = Max. load pressure, and oil flow is divided in proportion to area of opening of spool. When ratio is more than 1: Spool meter-in downstream pressure > Max. load pressure, and oil flow is divided in a proportion less than area of opening of spool. When ratio is less than 1: Spool meter-in downstream pressure c Max. load pressure, and oil flow is divided in a proportion more than area of opening of spool.

1o-59

STRUCTURE

AND

CLSS

FUNCTION

Boom regeneration

circuit

RAISE

LOWER

SAP03882

1. 2. 3A. 3B. 4A. 4B. 5. 6.

Main pump Main spool Pressure compensation valve Pressure compensation valve Suction valve (with safety) Suction valve (with safety) Check valve for boom regeneration LS shuttle valve

circuit

Function I) Cylinder head pressure < cylinder bottom pressure (free fall, etc.) . A return flow circuit is provided from the cylinder bottom to the cylinder head so that when the bottom is lowered, the return flow can be used to increase the flow of oil to the cylinder head. Operation . When the cylinder head pressure c cylinder bottom pressure, part of the pressurized oil from the cylinder bottom passes through the notch in spool (2), goes through port B, and enters drain circuit T. The rest of the oil enters regeneration circuit C, opens check valve (51, and passes through ports D and E to flow back to the cylinder head.

1 O-60

STRUCTURE

AND

FUNCTION

CLSS

SAP03883

2) l

Cylinder head pressure > cylinder bottom pressure (digging operations, etc.) Check valve (5) in regeneration circuit C acts to shut off the flow from the cylinder head to the cylinder bottom.

lo-61

STRUCTURE

AND

CLSS

FUNCTION

Arm regeneration

circuit

SAP03884

1. 2. 3A. 3B. 4A. 4B. 5.

Main pump Main spool Pressure compensation valve Pressure compensation valve Suction valve (with safety) Suction valve (with safety) Check valve for arm regeneration

LS shuttle valve

circuit

Function 1) Cylinder head pressure > cylinder bottom pressure . A return flow circuit is provided from the cylinder head to the cylinder bottom so that when the arm is moved in, the flow of oil to the cylinder becomes the pump discharge amount + the return flow, and this increases the cylinder speed. Operation . When the cylinder head pressure > cylinder bottom pressure, the pressurized oil from the cylinder head passes through the notch in spool (21, enters port C and opens check valve (51, then passes through ports D and E to flow back to the cylinder bottom.

1 O-62

STRUCTURE

AND

FUNCTION

CLSS

SAP03885

2) .

Cylinder bottom pressure > cylinder head pressure When the cylinder bottom pressure > cylinder head pressure, check valve (5) is closed by the cylinder bottom pressure and prevents any oil from flowing back from the cylinder bottom to the head end.

1O-63

STRUCTURE

8. *

AND

CLSS

FUNCTION

LS select valve The diagram shows the situation when the swing and left travel are operated at the same time. (BP pressure ON)

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

5 PS 'ONJ

Valve Spring Piston Piston Swing spool L.H. travel spool Arm spool L.H. shuttle valve LS circuit

7 \AI

Function This valve is used to increase the ease of operating the work equipment. It prevents high pressure from being generated when the swing is operated. It also prevents the high LS pressure from the swing circuit from flowing into any other LS circuit when the swing is operated together with the work equipment.

SBP02627

Operation II When pilot pressure BP is OFF . Pilot pressure BP is OFF, so piston (3) is pushed to the left by spring (2). If the swing is then operated, swing LS pressure PI passes through swing spool (5) and enters port A. It pushes valve (I) to the left and connects ports A and B. Therefore, swing LS pressure PI flows to LS shuttle valve (8). 21 When pilot pressure BP is ON . When pilot pressure BP is ON, piston (3) is moved to the right against spring (2) by the BP pressure. It pushes valve (I) to the right and closes the circuit between ports A and B. As a result, swing LS pressure PI stops flowing to LS shuttle valve (8), and even if swing LS pressure PI rises to a high pressure, it does not influence any other LS circuit.

1 O-64

'OFF)

To LS shuttle valve SBP03466

To LS shuttle valve SBP03467

STRUCTURE

AND

FUNCTION

CLSS

OPERATION OF CLSS SYSTEM AS A WHOLE 1. * * *

When all work equipment is at neutral The diagram shows the situation when all work equipment is at neutral. The valves and circuits that are not connected with the explanation of the operation hydraulic system have been omitted. For details of this page, see page 90-15.

10-65-l 0

of the CLSS

STRUCTURE

1. 2A. 28. 3A. 3B. 4A. 4B. 5 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

$ > :: W

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

AND

CLSS

FUNCTION

Hydraulic tank Main pump (front) Main pump (rear) PC valve (front) PC valve (rear) LS valve (front) LS valve (rear) Junction block Bucket spool R.H. travel spool Boom spool Swing spool L.H. travel spool Arm spool Pressure compensation valve (bucket) Pressure compensation valve (without shuttle valve) (R.H. travel) Pressure compensation valve (boom) Pressure compensation valve (swing) Pressure compensation valve (without shuttle valve) (L.H. travel) Pressure compensation valve (arm) Safety-suction valve Suction valve LS shuttle valve (bucket) LS shuttle valve (R.H. travel) LS shuttle valve (boom) LS shuttle valve (L.H. travel) LS shuttle valve (arm) Check valve (for boom regeneration circuit) Check valve (for arm regeneration circuit) Main relief valve Unload valve LS select valve LS check valve LS bypass valve Self-reducing pressure valve

Note: Groups of control valves by main pump circuit . Bucket group: Bucket, R.H. travel, boom . Arm group: Swing, L.H. travel, arm

Operation . When the levers are at neutral, the pump is

at the minimum swash plate angle, and the oil flow is drained from unload valve (28A). The LS pressure is connected to hydraulic tank (I) by LS bypass valve (31). The LS differential pressure APLS (unload pressure -tank pressure) at this point is APLS > pump LS control pressure, so the pump swash plate angle is the minimum.

1 O-65-2 0

STRUCTURE

AND

FUNCTION

2. One side actuated, other side neutral Ir The diagram shows the independent bucket DUMP Sr For details of this page, see page 90-17.

1O-65-3 0

CLSS

operation.

STRUCTURE

AND

FUNCTION

CLSS

Operation

1) Bucket group . When the bucket is operated,

pressurized oil from main pump (28) flows to the bucket group. The swash plate angle of main pump (2B) is controlled to match the operation of bucket spool (6). The LS pressure passing through the inside of bucket spool (6) goes to unload spool (281, and the unload valve is closed.

2) Arm group . When the pump flow is divided,

$ > Ei w

all spools are at neutral, so the oil flow from the minimum swash plate angle of main pump (2A) is all drained from unload valve (28) of the arm group. All spools in the arm group are at neutral, so no LS pressure is generated. If the pump pressure - LS pressure becomes greater than the set pressure of unload valve (281, the unload valve is actuated and the oil is drained. The LS differential pressure APLS at this point is APLS > pump LS control pressure, so the pump swash plate angle is the minimum.

1O-65-4 0

STRUCTURE

3. + *

AND FUNCTION

Arm OUT, standard mode relief (cut-off control) The diagram shows the arm DUMP and standard For details of this page, see page 90-19.

1 O-65-5 0

CLSS

mode

relief.

STRUCTURE AND FUNCTION

CLSS

Operation 1) .

When pump swash plate angle is controlled to minimum When the arm is operated to OUT, if the load increases, the LS pressure passing through the inside of arm spool (II) rises. The LS pressure also goes to unload valve (28) and unload valve (28) is closed. The main circuit pressure rises and is relieved at the standard mode relief pressure. When this happens, the pump pressure sensor detects it and increases the PC-EPC current (electronic cut-off control) to set the pump swash plate angle to the minimum.

1O-65-6 0

STRUCTURE

4. * *

AND

FUNCTION

Bucket DUMP, power max. relief The diagram shows bucket DUMP, relief. For details of this page, see page 90-21.

1 O-65-7 0

CLSS

STRUCTURE

AND

FUNCTION

Operation . Relief valve (27) pilot pressure

CLSS

PB ON.

When the bucket is being operated, if the power max. button is turned ON, pilot pressure PB acts on relief valve (271, so the set pressure of the relief valve is raised.

When the bucket is operated to DUMP and the load increases, pump pressure PI and LS pressure PLSI both rise. When this happens, pilot pressure PB controls relief valve (27) to the same relief pressure as when the power max. button is operated.

1 O-65-8 0

STRUCTURE

5. *

AND

FUNCTION

Boom RAISE For details of this page, see page 90-23.

lo-659 0

CLSS

STRUCTURE

AND

FUNCTION

CLSS

Operation . When the boom

RAISE is operated, main pumps (2A) and (2B) are both at the maximum swash plate angle, and unload valve (28A) is closed. At this point, for the meter-in opening of boom spool (81, even if both pumps are at the maximum swash plate angle, the LS differential pressure is set to be smaller than the pump LS control pressure. In other words, LS differential pressure APLS is APLS c pump LS control pressure, so the pump swash plate angle becomes the maximum. In addition, the flow of main pump (2A) passes through junction block (5) and flows to boom spool (8).

1O-65 10 CD

STRUCTURE

6. *

AND FUNCTION

Swing operated independently For details of this page, see page 90-25.

10-65-11 0

CLSS

STRUCTURE

AND

FUNCTION

CLSS

Operation . When the swing .

is operated, unload valve (28) is closed. When this happens, the oil flow from main pumps (2A, 2B) is controlled by the LS differential pressure and is discharged to match the area of opening of the meter-in of the swing spool.

10-65-12 0

STRUCTURE AND FUNCTION

7. *

Travel operated independently For details of this page, see page 90-27.

lo-6513 0

CLSS

STRUCTURE AND FUNCTION

CLSS

Operation

11 . When the straight travel is operated,

an oil flow supplied from the main pump to match the amount of movement of left and right travel spools (IO) and (7). Main pump (2A) oil flow: To left travel spool (IO) (arm group) Main pump (2B) oil flow: To right travel spool (7) (bucket group) The ability to travel in a straight line is ensured by actuating the pressure compensation valves and interconnecting the right travel and left travel through the pistons of pressure control valves (13) and (16) and through the external piping.

2) . From the above condition

$ t

LLI

I), if the steering control levers are returned (the oil flow is reduced) or operated in opposite directions (FORWARD and REVERSE), the travel junction circuit through the above piston is cut off, and the left and right sides are operated independently to enable the steering to be operated.

1O-65 14 0

STRUCTURE

AND

CLSS

FUNCTION

8. Compound operation Sr The diagram shows boom RAISE + arm IN. For details of this page, see page 90-29. *

ilin I-

lo-6515 0

STRUCTURE

AND FUNCTION

CLSS

Operation I)- When the arm and boom are operated simultaneously, the swash plate angle for both pumps becomes the maximum. When this happens, the load pressure at the boom RAISE side is higher than at the arm side, so the LS pressure passes through ports E and F of boom spool (8). enters LS shuttle valve (22) and is sent to the LS circuit. This LS pressure is transmitted to port G of arm pressure compensation valve (17). and acts to increase the set pressure of the pressure compensation valve. Because of this, the pressure between port H of arm spool (I 1) and port I of pressure compensation valve (17) rises, and spool meter-in LS differential pressure (pump pressure - LS pressure = APL3 becomes the same as that at the boom

end.

2) Because of the above operation,

2i > 8 w

the oil flow is divided in proportion to the size of the opening area of boom spool (8) and the opening area of arm spool (I I). Meter-in LS differential pressure APLS during boom RAISE + arm IN is APLS c boom LS control pressure, so the main pump swash plate angle is set to maximum.

lo-6516 0

SWING MOTOR

STRUCTURE AND FUNCTION

SWING

MOTOR

KMFgOAB-3

SAP03230

a. c. e. d. e.

Port Port Port Port Port

SPECIFICATIONS

MB (from control valve) MA (from control valve) T (to tank) B (from swing brake solenoid

KMFgOAB-3

Type valve)

Theoretical

delivery

Safety valve set pressure

1O-66

87.8 cc/rev 27.9 MPa I285 kg/cm*)

Rated speed

2,260 rpm

Brake releasing pressure

2.1 MPa 121 kg/cm3

SWING MOTOR

STRUCTURE AND FUNCTION

A-A

c-c SAP02633

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

Brake spring Drive shaft Spacer Case Disc Plate Brake ring Brake piston Housing Piston

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Cylinder Valve plate Plate Center shaft Center spring Safety valve Check valve Check valve spring Shuttle valve Shuttle valve spring

1 O-67

STRUCTURE

AND

FUNCTION

SWING

MOTOR

Operation of swing lock 1) When swing lock solenoid valve is deactivated When the swing lock solenoid valve is deactivated, the pressurized oil from the main pump is shut off and port B is connected to the tank circuit. As a result, brake piston (7) is pushed down by brake spring (I), discs (5) and plates (6) are pushed together, and the brake is applied.

When swing lock solenoid valve is excited When the swing lock solenoid valve is excited, the valve is switched and the pressure oil from the main pump enters port B and flows to brake chamber a. The pressure oil entering chamber a overcomes brake spring (I) and pushes brake piston (7) up. As a result, discs (5) and plates (6) are separated and the brake is released.

SAP03472

1O-68

STRUCTURE

AND

SWING

FUNCTION

RELIEF VALVE PORTION I) Outline The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (I). 2. Function When the swing is stopped, the outlet port circuit of the motor from the control valve is closed, but the motor continues to rotate under inertia, so the pressure at the output side of the motor becomes abnormally high, and this may damage the motor. To prevent this, the abnormally high pressure oil is relieved to port S from the outlet port of the motor (high-pressure side) to prevent any damage to the motor.

Operation 11 When starting swing . When the swing control lever is operated to swing right, the pressure oil from the pump passes through the control valve and is supplied to port MA. As a result, the pressure at port MA rises, the starting torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MB through the control valve and returns to the tank. (Fig. I) When stopping swing 21 . When the swing control lever is returned to neutral, the supply of pressure oil from the pump to port MA is stopped. With the oil from the outlet port of the motor, the return circuit to the tank is closed by the control valve, so the pressure at port MB rises. As a result, rotation resistance is generated in the motor, so the braking effect starts. . If the pressure at port MB becomes higher than the pressure at port MA, it pushes shuttle valve A (4) and chamber C becomes the same pressure as port MB. The oil pressure rises further until it reaches the set pressure of relief valve (1). As a result, a high braking torque acts on the motor and stops the motor. (Fig. 2) . When the relief valve (I) is being actuated, the relief oil and oil from port S passes through check valve B (3) and is supplied to port MA. This prevents cavitation at port MA.

MOTOR

From port S

E > %

(Fig.I)

SAP03473

From port S

SAP03474

1O-69

CENTER SWIVEL JOINT

STRUCTURE AND FUNCTION

CENTER SWIVEL JOINT 4-PORT SWIVEL

â&#x20AC;&#x2DC;E2

A-4

A-A

c2 SBPOO249

1. Cover Body 3. Slipper 4. O-ring 5. Shaft

B2. To. L.H. travel motor port PA

seal

Al. From control valve port B2 A2. To R.H. travel motor port PB Bl. From control valve port 85

1O-70

Cl. C2. Dl. D2. El. E2. Tl. T2.

From control valve port A2 To R.H. travel motor port PA From control valve port A5 To L.H. travel motor port PB From travel speed solenoid valve To L.H. and R.H. travel motors port P To tank From L.H. and R.H. travel motors port T

STRUCTURE

AND

FUNCTION

CENTER

SWIVEL

JOINT

6-PORT SWIVEL

1. 2. 3. 4. 5.

Cover Body Slipper seal Oil seal Shaft

Al. A2. Bl. B2. Cl.

From control To R.H. travel From control To. L.H. travel From control

valve port B2 motor port PB valve port B5 motor port PA valve port A2

E2 SBP02643

C2. To R.H. travel motor port PA Dl. From control valve port A5 D2.To L.H. travel motor port PB El. From control valve port A3 E2. Blind Fl. From control valve port B3 F2. Blind Gl. From travel speed solenoid valve G2.To L.H. and R.H. travel motors port P Tl. To tank T2. From L.H. and R.H. travel motors port T

10-71

STRUCTURE AND FUNCTION

TRAVEL MOTOR

TRAVEL MOTOR HMVllO-2

SAP01247

a. b. c. d.

Port Port Port Port

T (to tank) PB (from control valve) P (from travel speed solenoid PA (from control valve)

SPECIFICATIONS HMVI IO-2

valve) Theoretical

delivery

Min.

75.5 cc/rev

Max.

110.7 cc/rev 34.79 MPa (355 kg/cm*}

Set pressure Rated speed Brake releasing

2,673 rpm

Max. capacity

1,460 rpm

pressure

Travel speed switching pressure

1 O-72

Min. capacity

Differential pressure

1.18 MPa {I 2 kg/cm*} 0.78 MPa {8 kg/cm21

TRAVEL MOTOR

STRUCTURE AND FUNCTION

P 0

k-D \

A-A

D-D

1. 2. 3. 4. 5. 6. 7. 8.

Regulator piston Spring Regulator valve Spring Motor case Suction safety valve spring Suction safety valve Check valve

9. IO. 11. 12. 13. 14. 15. 16.

Check valve spring Output shaft Swash plate Retainer guide Pin Piston Retainer Cylinder

17. 18. 19. 20. 21. 22. 23. 24.

SAP02754

Valve plate valve Counterbalance Ring Spool return spring Brake piston Plate Disc Ball

1o-73

STRUCTURE

AND

TRAVEL

FUNCTION

OPERATION OF MOTOR 1) Motor swash plate angle (capacity) mum

at maxi-

The solenoid valve is deactivated, so the pilot pressure oil from the main pump does not flow to port P. For this reason, regulator valve (9) is pushed to the right in the direction of the arrow by spring (IO). Because of this, it pushes check valve (221, and the main pressure oil from the control valve going to end cover (8) is shut off by regulator valve (9). Fulcrum a of swash plate (4) is eccentric to point of force b of the combined force of the propulsion force of cylinder (61, so the combined force of the piston propulsion force acts as a moment to angle swash plate (4) in the direction of the maximum swash plate angle.

1o-74

MOTOR

At the same time, the pressurized oil at regulator piston (15) passes through orifice c in regulator valve (9) and is drained to the motor case. As a result, swash plate (4) moves in the maximum swash plate angle direction, the motor capacity becomes maximum.

STRUCTURE

Motor mum

AND

swash

TRAVEL

FUNCTION

plate angle (capacity)

MOTOR

at mini-

SAP03479

When the solenoid valve is excited, the pilot pressure oil from the main pump flows to port P, and pushes regulator valve (9) to the left in the direction of the arrow. Because of this, the main pressure oil from the control valve passes through passage d in regulator valve (91, enters regulator piston (15) at the bottom, and pushes regulator piston (15) to the right in the direction of the arrow. As a result, swash plate (4) moves in the minimum swash plate angle direction, the motor capacity becomes minimum.

1o-75

TRAVEL MOTOR

STRUCTURE AND FUNCTION

OPERATION OF PARKING 1) When starting to travel

BRAKE

When the travel lever is operated, the pressurized oil from the pump actuates counterbalance valve spool (191, opens the circuit to the parking brake, and flows into chamber A of brake piston (12). It overcomes the force of spring (I I), and pushes piston (12) to the left in the direction of the arrow. When this happens, the force pushing plate (13) and disc (14) together is lost, so plate (13) and disc (14) separate and the brake is released.

SAP03480

21 When stopping travel When the travel lever is placed in neutral, counterbalance valve spool (19) returns to the neutral position and the circuit to the parking brake is closed. The pressurized oil in chamber A of brake piston (12) is drained to the case from the orifice in the brake piston, and brake piston (12) is pushed to the right in the direction of the arrow by spring (II). As a result, plate (13) and disc (14) are pushed together, and the brake is applied. A time delay is provided by having the pressurized oil pass through a throttle in slow return valve (22) when the brake piston returns, and this ensures that the brake still effective after the machine stops. I

'SAP03481

1 O-76

STRUCTURE

AND

TRAVEL

FUNCTION

MOTOR

OPERATION OF BRAKE VALVE l

The brake valve consists of a suction safety valve (18A), counterbalance valve (18) in a circuit as shown in the diagram on the right. (Fig. I) The function and operation of each component is as given below.

1) Counterbalance valve, check valve Function . When traveling downhill, the weight of the machine makes it try to travel faster than the speed of the motor. As a result, if the machine travels with the engine at low speed, the motor will rotate without load and the machine will run away, which is extremely dangerous. To prevent this, these valves act to make the machine travel according to the engine speed (pump discharge amount).

IFio. 11

SAP03482

(F i o. 2)

SAP03483

(F i 0. 3)

SAP03484

Operation when pressure oil is supplied When the travel lever is operated, the pres- I 0A surized oil from the control valve is supplied to port PA. It pushes open suction safety valve (18A) and flows from motor inlet port MA to motor outlet port MB. However, the motor outlet port is closed by suction safety valve (188) and spool (19), so the pressure at the supply side rises. (Fig. 2) l

: > 5

The pressurized oil at the supply side flows from orifice El and E2 in spool (19) to chamber Sl. When the pressure in chamber Sl goes above the spool switching pressure, spool (19) is pushed to the right in the direction of the arrow. As a result, port MB and port PB are connected, the outlet port side of the motor is opened, and the motor starts to rotate. (Fig. 3)

STRUCTURE

AND

Operation of brake when traveling downhill . If the machine tries to run away when traveling downhill, the motor will turn under no load, so the pressure at the motor inlet port will drop, and the pressure in chamber Sl through orifices El and E2 will also drop. When the pressure in chamber Sl drops below the spool switching pressure, spool (19) is returned to the left in the direction of the arrow by spring (201, and outlet port MB is throttled. As a result, the pressure at the outlet port side rises, resistance is generated to the rotation of the motor, and this prevents the machine from running away. In other words, the spool moves to a position where the pressure at outlet port MB balances the pressure at the inlet port and the force generated by the weight of the machine. It throttles the outlet port circuit and controls the travel speed according to the amount of oil discharged from the pump. (Fi.g 4) 2) Safety valve Function l When travel is stopped (or when traveling downhill), the circuits at the inlet and outlet ports of the motor are closed by the counterbalance valve, but the motor is rotated by inertia, so the pressure at the outlet port of the motor will become abnormally high and damage the motor or piping. The safety valve acts to release this abnormal pressure and send it to the inlet port side of the motor to prevent damage to the equipment. Operation 1) When travel is stopped (or when traveling downhill, rotating to right) l When the motor inlet port pressure (pressure PA) goes down, the pressure in chamber Sl also goes down. When it goes below the switching pressure of the spool, spool (19) is returned to the left by spring (20), and outlet port passage Bl is throttled. When this happens, the motor continues to rotate under inertia, so the outlet pressure (pressure MB) rises. (Fig. 5) . If the pressure goes above the set pressure of suction-safety valve (18A), the poppet opens. The oil then passes through large notch Al in counterbalance valve spool (19) and flows to chamber MA in the circuit on the opposite side. (Fig. 6) 2) When rotating to left The operation is the reverse of when rotating to the right. 1 O-78

TRAVEL

FUNCTION

,, ,,,,,,,,,,

e,,,,,,,,,,,,,..

MOTOR

Y,,u ,,,,,,,,,,,,,,,,, I_____*

(Fib 4)

SAP03465

SAP03486

Poppet (Fie. 6)

MA SAP03487

STRUCTURE

3) .

AND

TRAVEL

FUNCTION

When starting travel (or during normal travel) When the travel lever is operated, the pressure oil from the pump moves counterbalance valve spool (19) to the right. When this happens, the passage to the suction-safety valve becomes the circuit flowing through the small notch in the counterbalance valve spool. As a result, a big difference in pressure is created, and the pump pressure rises to provide a powerful drawbar pull. (Fig. 7)

MOTOR

l8A

IF i o. 71

SAP03465

1o-79

VALVE CONTROL

STRUCTURE AND FUNCTION

VALVE CONTROL

SBPO3971

1. 2. 3. 4. 5. 6. 7. 8.

Travel PPC valve Service PPC valve Service pedal L.H. travel lever R.H. travel lever R.H. PPC valve R.H. work equipment lever Control valve

Hydraulic pump Junction box Accumulator EPC solenoid valve L.H. work equipment lever 14. L.H. PPC valve 15. Safety lock lever

9. 10. 11. 12. 13.

Lever positions @ HOLD @ @ @ @ @ @ @

Boom RAISE Boom LOWER Bucket DUMP Bucket CURL HOLD Arm IN Arm OUT

@ @ @I @I 0 @ @

Swing RIGHT Swing LEFT NEUTRAL Travel REVERSE Travel FORWARD LOCK FREE

lo-81

WORK EQUIPMENT.

STRUCTURE AND FUNCTION

WORK EQUIPMENT

SWING

SWING PPC VALVE

PPC VALVE

SW00273

a. b. c. d. e. f.

Port Port Pot-t Port Port Port

1O-82

P (from main pump) T (to tank) P2 (L.H.: Arm IN / R.H.: Boom RAISE) P4 (L.H.: Swing LEFT / R.H.: Bucket DUMP) PI (L.H.: Arm OUT / R.H.: Boom LOWER) P3 (L.H.: Swing RIGHT / R.H.: Bucket CURL)

WORK EQUIPMENT.

STRUCTURE AND FUNCTION

SWING PPC VALVE

D-D

B-B

E-E SBFUO274

1. 3. 4. 5.

Spool Metering spring Centering spring Piston Disc

Nut (for connecting

7. Joint 8. 9. 10. 11.

Plate Retainer Body Filter

lever)

1 O-83

STRUCTURE

AND

FUNCTION

WORK

EQUIPMENT

SWING

PPC VALVE

OPERATION I) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). (Fig. I)

During fine control (neutral + fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed; spool (I) is also pushed by metering spring (2). and moves down. When this happens, fine control hole f is shut off from drain chamber D, and at almost the same time, it is connected to pump pressure chamber PP, so pilot pressure oil from the main pump passes through fine control hole f and goes from port PI to port A. When the pressure at port PI becomes higher, spool (I) is pushed back and fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D to release the pressure at port PI. When this happens, spool (I) moves up or down so that the force of metering spring (2) is balanced with the pressure at port PI. The relationship in the position of spool (1) and body (IO) (fine control hole f is at a point midway between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed proportionally to the amount of movement of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the control valve spool moves to a position where the pressure in chamber A (the same as the pressure at port PI) and the force of the control valve spool return spring are balanced. (Fig.21

1O-84

(Fig.

I) SBPO3493

(F i s. 2)

SBPO3494

STRUCTURE

AND

FUNCTION

During fine control (when control lever is returned) When disc (5) starts to be returned, spool (I) is pushed up by the force of centering spring (3) and the pressure at port PI. When this happens, fine control hole f is connected to drain chamber D and the pressure oil at port PI is released. If the pressure at port PI drops too far, spool (I) is pushed down by metering spring (21, and fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pump pressure is supplied until the pressure at port PI recovers to a pressure that corresponds to the lever position. When the spool of the control valve returns, oil in drain chamber D flows in from fine control hole fâ&#x20AC;&#x2122; in the valve on the side that is not working. The oil passes through port P2 and enters chamber B to fill the chamber with oil. (Fig. 3)

WORK EQUIPMENT

SWING

PPC VALVE

(F i 8. 3) SEPO3495

At full stroke When disc (5) pushes down piston (4), and retainer (9) pushes down spool (I), fine control hole f is shut off from drain chamber D, and is connected with pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI, and pushes the control valve spool. The oil returning from chamber B passes from port P2 through fine control hole fâ&#x20AC;&#x2122; and flows to drain chamber D. (fig. 4)

(Fio. 4) SBPO3496

1O-85

STRUCTURE

AND

TRAVEL

FUNCTION

PPC VALVE

TRAVEL PPC VALVE

I C-4 c

SAP02660

a. b. c. d. e. f.

Port Port Port Pot-t Port Port

1O-86

P (from main T (to tank) PZ (L.H. travel PI (L.H. travel P3 (R.H. travel P4 (R.H. travel

pump) FORWARD) REVERSE) REVERSE) FORWARD)

TRAVEL PPC VALVE

STRUCTURE AND FUNCTION

A-A

B-0

2 0

c-c

1. 2. 3. 4.

Plate Body Piston Collar

SAP02661

5. 6. 7. 8.

Metering spring Centering spring Valve Bolt

1 O-87

STRUCTURE

AND FUNCTION

TRAVEL

PPC VALVE

OPERATION 1) At neutral Ports A and B of the control valve and ports PI and P2 of the PPC valve are connected to drain chamber D through fine control hole f in spool (I). (Fig. I)

Fine control (neutral + fine control) When piston (4) starts to be pushed by disc (5), retainer (9) is pushed. Spool (I) is also pushed by metering spring (2) and moves down. When this happens, fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, and the pilot pressure of the main pump is sent from port A through fine control hole f to port PI. When the pressure at port PI rises, spool (I 1 is pushed back. Fine control hole f is shut off from pump pressure chamber PP. At almost the same time, it is connected to drain chamber D, so the pressure at port PI escapes. As a result, spool (I) moves up and down until the force of metering spool (2) is balanced with the pressure of port PI. The relationship of the position of spool (I) and body (IO) (fine control hole f is in the middle between drain hole D and pump pressure chamber PP) does not change until retainer (9) contacts spool (I). Therefore, metering spring (2) is compressed in proportion to the travel of the control lever, so the pressure at port PI also rises in proportion to the travel of the control lever. In this way, the spool of the control valve moves to a position where the pressure of chamber A (same as pressure at port PI) and the force of the return spring of the control valve spool are balanced. (Fig.2)

1O-88

(Fig.

(F i 8, 2)

SLIP03497

SBPO3498

STRUCTURE

AND

FUNCTION

Fine control (control lever returned) When disc (5) starts to be returned, spool (I 1 is pushed up by the force of centering spring (3) and the pressure at port PI. Because of this, fine control hole f is connected to drain chamber D, and the pressurized oil at port PI is released. If the pressure at port PI drops too much, spool (I) is pushed up by metering spring (2), so fine control hole f is shut off from drain chamber D. At almost the same time, it is connected to pump pressure chamber PP, so the pressure at port PI supplies the pump pressure until the pressure recovers to a pressure equivalent to the position of the lever. When the control valve returns, oil in drain chamber D flows in from fine control hole f of the valve on the side that is not moving. It passes through port P2 and goes to chamber B to charge the oil. (Fig. 3)

TRAVEL

(F i o. 3)

PPC VALVE

SEPO3499

At full stroke Disc (5) pushes down piston (41, and retainer (9) pushes down spool (1). Fine control hole f is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, the pilot pressure oil from the main pump passes through fine control hole f and flows to chamber A from port PI to push the control valve spool. The return oil from chamber B passes from port P2 through fine control hole fâ&#x20AC;&#x2122; and flows to drain chamber D. (Fig. 4)

(Fig.

SBPO3695

1 O-89

SERVICE PPC VALVE

STRUCTURE AND FUNCTION

SERVICE PPC VALVE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. a. b. c. d.

d SBPOO285

1O-90

Pin Cam Ball Piston Cover Sleeve Centering spring Metering spring Spool Body Port Port Port Port

T P A B

(to tank) (from main pump) (to service valve P-l) (to service valve P-2)

STRUCTURE AND FUNCTION

SERVICE PPC VALVE

OPERATION At neutral l

The pressurized oil from the control pump enters from port P and is blocked by spool (9). Ports A and B of the control valve and ports a and b of the PPC valve are connected to drain port T through fine control hole X of spool (9).

SBP03500

When operated . When cam (2) is moved,

metering spring (8) is pushed by ball (31, piston (41, and sleeve (61, and spool (9) is pushed down by this. As a result, fine control hole X is shut off from the drain circuit. At almost the same time, fine control portion Y is connected with port a, and the pressurized oil from port P flows from port a to port A of the control valve.

SFlPO3501

10-91

STRUCTURE AND FUNCTION

When the pressure at port a becomes higher, spool (9) is pushed back by the force acting on the end of the spool. When fine control portion Y closes, fine control hole X is connected to the drain circuit at almost the same time. As a result, spool (9) moves up and down to balance the force at port a and the force at metering spring (8). Therefore, metering spring (8) is compressed in proportion to the amount the control lever is moved. The spring force becomes larger, so the pressure at port a also increases in proportion to the amount the control lever is operated. In this way, the control valve spool moves to a position where the pressure of port A (the same as the pressure at port a) is balanced with the force of the return spring of the control valve spool.

1 O-92

SERVICE PPC VALVE

SBPO3502

STRUCTURE

AND

ACCUMULATOR

FUNCTION

ACCUMULATOR FOR PPC VALVE

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

Gas plug Shell Poppet Holder Bladder Oil port

Specifications Type of gas Gas volume

: Nitrogen : 300 cc

gas

SDP01626

Function The accumulator is installed between the main pump and the PPC valve. Even if the engine is stopped with the work equipment raised, pilot oil pressure is sent to the main control valve by the pressure of the nitrogen gas compressed inside the accumulator, so it is possible to lower the work equipment under its own weight.

Operation . After the engine stops, when the PPC valve is at neutral, chamber A inside the bladder is compressed by the oil pressure in chamber B. . If the PPC valve is operated, the oil pressure in chamber B becomes less than 2.9 MPa (30 kg/cm*), so the bladder expands under the pressure of the nitrogen gas in chamber A. The oil entering chamber B is sent as the pilot pressure to actuate the main control valve.

Before A

After actuation

actuation A

SEP01628

1o-93

STRAIGHT-TRAVEL

STRUCTURE AND FUNCTION

STRAIGHT-TRAVEL Bucket

Boom

SYSTEM Junction

block

1 ---y: _---____p--j--_ Arm DUMP r---‘

/ +c :--I~____I__ ’

I---

Arm

II I I I I iI

motor

FOR"Afl"ERSE

R.H.

travel

motor

“ERSE

CURL

r--lj:

Ij I+-___i__~___

Travel

PPC

Bucket

CURL

RE”

valve

;,p~~------------‘t____------_ c<o>-; I I I ‘-+------__

______

1 I I ‘----,~___________----‘:L___________

+-------___

trave,

,,.

‘---<?--J I____________________J

rave,

ERSE

FORWARD

~~~~~~~~~~

___________ ---+L __________L,

L-,+L------,+L I I

L.H.travel

Swing

Arm

I I t I

SYSTEM

,,,

travel

REVERSE FORWAR,,

I I I I

SAP03887

Function l

This system interconnects the pressure compensation valves for L.H. and R.H. travel FORWARD and REVERSE with external piping to ensure the ability to travel in a straight line. As shown in the diagram on the right, the left and right ports are interconnected through passage a inside travel pressure compensation valve (I ). By setting the throttle in junction circuit a to a suitable value, it is possible to fulfill the requirements for steering ability and the ability to maintain a straight line.

1o-94

Travel

PPC

Pressure

I /,eft

(right)

STRUCTURE

AND

EPC SOLENOID

FUNCTION

VALVE

EPC SOLENOID FOR PPC LOCK, SWING

VALVE

BRAKE, TRAVEL

SPEED, 2 STEP RELIEF EPC SOLENOID

VALVE

A2 /

ACC Al

ACC

SAP04273

2. 3. 4.

PPC lock EPC solenoid valve Swing brake EPC solenoid valve Travel speed EPC solenoid valve 2 step relief solenoid valve

Al. A2. A3. A4. ACC. Pl. T.

To PPC valve To travel motor To swing motor swing To main relief valve To accumulator From main pump To tank

brake

1o-95 0

STRUCTURE

AND

EPC SOLENOID

FUNCTION

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

VALVE

Connector Movable core Coil Cage Spool Block Spring

SAP03237

Operation When solenoid is deactivated When the signal current does not flow from the PPC lock switch or swing lock switch, solenoid (3) is deactivated. For this reason, spool (5) is pushed fully to the right by spring (6). As a result, the circuit between ports P and A closes and the pressurized oil from the main pump does not flow to the actuator. At the same time, the pressurized oil from the actuator flows from port A to port T, and is then drained to the tank. l

When solenoid is excited When the signal current flows from the PPC lock switch or swing lock switch to solenoid (3), solenoid (3) is excited. For this reason, spool (5) is pushed to the left in the direction of the arrow. As a result, the pressurized oil from the main pump flows from port P through the inside of spool (5) to port A, and then flows to the actuator. At the same time, port T is closed, and this stops the oil from flowing to the tank.

SAP03888 Actuator

Exit

SAP03889

1O-96

STRUCTURE

AND

BOOM HOLDING *

BOOM

FUNCTION

HOLDING

VALVE

For machine equipped with arm holding the same as this valve.

valve, the structure

and function

of arm holding

valve is

B-B A-A

â&#x20AC;&#x2DC;C

SDPO1321

1. 2. 3. 4. 5.

Safety-suction Pilot spring Pilot spool Poppet spring Poppet

valve

a. b. c. d.

Port Port Port Port

T (to tank) Pi (from boom LOWER PPC valve) Cy (to boom cylinder bottom) V (from boom control valve)

1o-97

STRUCTURE

AND FUNCTION

BOOM

HOLDING

VALVE

OPERATION 1) At boom RAISE When the boom is raised, the main pressure from the control valve pushes poppet (5) up in the direction of the arrow. Because of this, the main pressure from the control valve passes through the valve and flows to the bottom end of the boom cylinder.

SBP03507

Boom lever at NEUTRAL When the boom is raised and the control lever is returned to NEUTRAL, the circuit for the holding pressure at the bottom end of the boom cylinder is closed by poppet (5). and at the same time, the oil flowing into poppet (5) through orifice a of poppet (5) is closed by pilot spool (3). As a result, the boom is held in position.

I , I / / / I

: Control lever

SBPO3508

1 O-98

STRUCTURE

AND

FUNCTION

BOOM

HOLDING

VALVE

At boom LOWER When the boom is lowered, the pilot pressure from the PPC valve pushes pilot spool (3) and the pressurized oil in chamber b inside the poppet is drained. When the pressure at port B rises because of the pressurized oil from the bottom end of the boom cylinder, the pressure of the pressurized oil in chamber b is lowered by orifice a. If the pressure in chamber b drops below the pressure at port A, poppet (5) opens the pressurized oil flows from port B to port A, and then flows to the control valve. If any abnormal pressure is generated in the circuit at the bottom end of the boom cylinder, safety valve (I) is actuated.

SBPO3509

1o-99

STRUCTURE

AND

ADDITIONAL *

FOR MACHINE

FUNCTION

ADDITIONAL

FILTER FOR BREAKER

FILTER FOR BREAKER EQUIPPED

WITH

BREAKER

SBPO2669

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

Head cover Element Case Drain plug Valve Spring Spring set plug

10-100

SPECIFICATIONS Rated pressure : 6.86 MPa (70 kg/cm? Flow : 102 Umin Relief valve cracking pressure: 0.34 + 0.049 MPa (3.5 + 0.5 kg/cm*) Filter mesh size : 6 pm Filtering area : 3160 cm*

STRUCTURE AND FUNCTIO N

WORK EQUIPMENT

SBPO2670

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

Arm Bucket cylinder Arm cylinder Boom Boom cylinder Bucket

10-101

STRUCTURE

AND

ACTUAL

FUNCTION

ACTUAL ELECTRICAL WIRING *

DIAGRAM

For details of this page, see page 90-7.

10-102 0

ELECTRICAL

WIRING

DIAGRAM

E20Y06

1. Fuel level

tone)

lamp

relay

tone)

valve

motor lamp

29. Pump

43. Shift

42. Heater

41. Light

40. Heater

front

lamp

down

relay

relay foot

lamp

switch

lock switch

switch

39. PPC lock switch

38. Optional

37. Swing

36. Wiper

35. Radio

box

33. Starting 34. Fuse

panel switch

32. Monitor

31. Speaker

switch

buzzer controller

28. Alarm 30. Horn

motor

27. Wiper

26. L.H. additional

25. Room

24. R.H. additional

23. Starting

22. Alternator lamp

sensor

front

compressor oil level

20. Air conditioner 21. Engine

air heater magnet

sensor

valve

temperature

solenoid

valve

switch

valve solenoid

Intake

water 19. Electrical

speed

17. Travel

relief

16. 2 step 18. Engine

brake

15. Swing

14. PPC lock solenoid

13. Front

12. Battery

11. Battery

(low

alarm

8. Travel 10. Horn

tank

7. Washer

(high

oil pressure

9. Horn

speed

sensor

EPC solenoid

5. Engine

lamp

sensor lamp

6. Engine

4. Rear

3. PC control

2. Working

switch

STRUCTURE AND FUNCTION

ELECTRICAL CIRCUIT DIAGRAM (l/2) * For

details of this page, see page 90-I 1.

ELECTRICAL CIRCUIT DIAGRAM

STRUCTURE AND FUNCTION

W2) *

For details of this page, see page 90-13.

ELECTRICAL CIRCUIT DIAGRAM

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM TOTAL SYSTEM DIAGRAM

Arm

SWinP

Boom

Bucket

lever

L. H. PPC valve

limit

switch

R. H. PPC valve 6-+ R. H Travel Trave PPC valve

L. H Travel

I I I I

@g-q-

T+ I I I

Ensine

2Y!!s25 F

Main DUlllP

Servo valve

Travel

Monitor

Panel

$fzjqqf

Pump controller

~ SAP03972

lo-106

STRUCTURE AND FUNCTION

ELECTRIC CONTROL SYSTEM

1. PUMP CONTROL FUNCTION

----------------__________,

r-------------! !

Control

Junction

valve

block

Engine

I I

I :.

----

LS valve

p--y-

1 PC-EPC

valve

Pump prolix

switch 0

Battery

10A

Fuse box Battery

Pump controller

relay

10-107

STRUCTURE AND FUNCTION

Function l

ELECTRIC CONTROL SYSTEM

Engine

horsepower

The pump controller sets the pump absorption torque to match the engine speed. When the engine is running at high speed, it raises the pump absorption torque to boost the productivity. When the engine is running at low speed, it throttles the pump absorption torque to prevent the engine from stalling.

Ensine

lo-108

speed

SAP03896

STRUCTURE

AND

FUNCTION

ELECTRIC CONTROL

SYSTEM

Pump controller

\ \\

CONTROLLER,

TVC

P /

CN-CO

SAP03228

Input/output

signals

CN-CO1 1 Pin No. 1 2 I

Name Power

source

of signal

1Input/output

(24V)

Input

Name

of signal

Input/output

181

Input

I Engine

1 Pin No.

speed

sensor

Input

EPC solenoid

I-1

output

10-109

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

SWING

LOCK, PPC LOCK, TRAVEL

SPEED SELECT FUNCTION

Sefetu

lock

lever

L. H. PPC valve

Boom

Bucket

ft.H. PPC valve

Main

Ii. H Travel

L. H Travel

relief

PPC limit

lock switch

--I

valve

Trava speed

Travel PPC valve

Enaine

Swing lock m

Battery

Monitor

Panel

Battery relay

SAP03973

10-110

STRUCTURE

AND

FUNCTION

ELECTRIC CONTROL

SYSTEM

Operation I) Swing lock function . The swing can be locked at any position desired by using the swing lock switch (manual). . Operation of swing lock switch

Lock switch

Pilot lamp

Lights up

OFF

Goes out

Operation

Function Swing

lock

ON Swing lock OFF

Swing lock is always actuated, and upper structure does not swing even when swing lever is operated Swing when

lock is canceld, swing

and upper

structure

swings

lever is operated

PPC lock function The PPC lock switch is interconnected with the safety lock lever. When the safety lock lever is at the LOCK position, the PPC lock switch is turned OFF. When the PPC lock switch is turned OFF, the electric current going to the PPC lock solenoid valve is shut off, and the work equipment will not move even if the work equipment control levers are operated.

E z 8

Travel speed select function If the travel speed switch is set to Lo, Hi, the motor volume is switched and travel speed changes.

10-111

ELECTRIC CONTROL SYSTEM

STRUCTURE AND FUNCTION

TRAVEL

SPEED CONTROL

SFJPO4265

1. Shift down foot switch Travel speed switch

Outline . If shift down foot switch (I) is pressed, the

travel speed is set low, even if travel speed switch (2) is at the Hi position (priority is given to the shift down foot switch). Use this switch when it is difficult to operate travel speed switch (2) by hand or when more power is needed to remove the machine from soft ground.

System electrical circuit Opt ion Power FUSE

No.

I /

I ay

II,

Foot

suitch

-CN-M2Y

FUSE

No.

aid

60000~

n ,00001 I

CN-HO2

I SAP04272

10-111-l 0

g z 2

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

MACHINE

MONITOR

SYSTEM

buzzer signal

Snitch

signal

Power Source

Battery

SBPO3898

FUNCTION l

The machine monitor system monitors the machine conditions with sensors mounted on each part of the machine, and processes and displays the condition data to inform the operator of the condition. Details of the information displayed on the monitor panel are as follows: 1. Monitor section which gives an alarm when abnormality occurs in the machine. 2. Pilot section which displays the condition of the machine when operated. 3. Gauge section which always displays the machine condition.

10-l12

In addition, the monitor panel is equipped with switches for each electrical device.

STRUCTURE AND FUNCTION

MACHINE MONITOR SYSTEM

MONITOR PANEL

CNyPl

CN-P2

CN-P3

SXPOOO44

OUTLINE . The monitor panel has monitor/display function and switch function for electrical devices. . CPU (Central Processing Unit) is mounted in the panel, which processes, displays and outputs the data. . The gauge display uses a liquid crystal display (LCD) and the monitor display uses lamps.

Input and output signal CN-Pl

(Monitor panel)

INo.

Signal

1 I/O

1 1 1Power source: t24V

I -

1Power

name

source: t24V

level

I Input I

l-l l-l

I31GND 1 4fGND

10 I Charge

CN-P2 (Light switch)

CN-P3 (Heater switch) No.

Signal

name

I/O

Heater

output

Heater

output

GND

10-113

MACHINE MONITOR SYSTEM

STRUCTURE AND FUNCTION

9 1. 2. 3. 4. 5. z:

Service meter Coolant temperature Fuel level gauge Light switch Heater switch

1 Symbol

0 6. 7. 8. 9.

gauge

Display item

Display range

Engine oil pressure

0.05 MPa lo.5 kg/cm*) or lower

Charge level

When charging level is insufficient

\. ii5EQ w

Coolanttemperature

Preheating pilot lamp Swing lock pilot lamp Charge level caution lamp Engine oil pressure caution

lamp

Display method Normal operation: Upon abnormality:

OFF ON

When abnormlity occurs during engine 1 buzzer sounds.

I running,

SDP00963

SDP00964

Correspoding segment and lower ones al lights up. Only when the level lowers to the leftmost I l one, it flashes.

Preheating

During preheating

When the starting switch is set to â&#x20AC;&#x153;HEATâ&#x20AC;?, this lamp will light up for 30 seconds, and then flashes for 10 seconds to indicate the completion of preheating.

Swing lock

When swing is locked

Lights up when the swing lock switch is ON.

Heater switch

Light switch

10-114

SXPOOO45

Correspoding segment lights up. Only when the rightmost one lights up, the I i segment flashes and the buzzer sounds.

\\i\

Fuel level

Lo: Heater fan Lo Hi: Heater

fan Hi

1: Monitor 2: Monitor

panel lights up panel, head light and work lamp light up

STRUCTURE

. .

AND

SENSORS

FUNCTION

The signals from the sensors are input directly to the panel. One side of the contact-type sensors is always connected to the chassis GND. Classification

of indication

Type Engine

CAUTION

oil pressure

Coolant GAUGE

Sensing

of sensor

Contact

temperature

type

Engine

oil pressure

Normal

Abnormal

Resistance

type

Resistance

type

GROUP Fuel level

type

OFF -

sensor

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

63 Structure

c ircuit

Plug Contact ring Contact Diaphragm Spring Terminal

Operations (ON) pressure: 49 f 19.6 kPa (0.5 r 0.2 kg/cm*)

SBD01537

Coolant

temperature

sensor 1. 2. 3.

w Structure

circuit

Connector Plug Thermistor

SEDOl538

10-l15

SENSORS

STRUCTURE AND FUNCTION

Fuel level sensor

FULL

1. 2. 3. 4.

Float Connector Cover Variable resistance

EMPTY

Structure

circuit

SEP04165

10416

TESTING AND ADJUSTING

Standard

value table for engine related parts . .

20-

Standard

value table for chassis related parts

. 20-

Standard

value table for electrical system . . . . . . . . . 20-

Tools for testing,

Measuring Adjusting

speed . . . . . . . . . . . . . .._...................

20-102

exhaust

color . . . .._.._.........................

20-103

compression

Measuring

blow-by

and adjusting

Measuring

engine

fuel injection

timing

Testing

and adjusting

fan belt tension

Testing

and adjusting

belt tension

conditioner

compressor

Adjusting

engine

Adjusting

fuel control

Testing

20-107

travel

locations

Measuring

for air

Releasing

20-108

lever . . .._....._................... hydraulic

equipment,

swing,

pressure

travel

in hydraulic

20-l IO

Testing

and adjusting

Bleeding

Note

the

following

when

making

judgements

using

the

. . . . . . . . . . . . 20-122

PPC valve . . 20-124

hydraulic

drift

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128

circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130

clearance

circuit . . . . . . 20-I 12

swing

pressure

Testing

pressure . . . . . . . . . . 20-121 pressure

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-125

causing

oil leakage

of swing

circle bearing

. . . . . . 20-131

track shoe tension . . . . . . . 20-132

air . . . . . . . . . . . . . . .._.......................................

Troubleshooting

output

deviation

remaining

20-I 17

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120

valve output

of work equipment

. . . . . . . . . . . 20-108

and LS

. . . . . . . . .._........................

work equipment,

Testing

. . . . 20-I 15

pressure

control

PPC valve

Testing

speed sensor . . . . . . . . . . . . . . . . .._..... 20-109

and adjusting

work

Measuring

. . . 20-106

. . . . . . . .._...................

pressure

solenoid

Adjusting

output

piston input pressure)

circuit oil pressure

20-105

. . . . . . . . .._.............

LS valve

and adjusting

Testing

pressure . . . . . . . . . . . . . . . . . . . . 20-105

oil pressure

PC valve output piston input pressure)

and adjusting

Testing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104

pressure . . . . . . .._...................

(servo

differential

20-101

engine

Measuring Testing

Testing

(servo

. . . . . . . .._.........................

valve clearance

and adjusting

pressure

adjusting,

and troubleshooting Measuring

Testing

standard

20-133

. . . . .._...........................................

value

tables

for testing,

20-201

adjusting,

troubleshooting. 1.

The standard the factory machine

for reference.

has been operated,

The service of various if there

value for a new machine and is given

limit value given in the tables

value when

is the estimated

together

used when

for judging

carrying

shipping

the machine

the progress

of wear

from

after the

out repairs.

value for the shipped

machine

based on the results

with the state of repair and the history of operation

to judge

is a failure.

These

standard

When

carrying

values

are not the standards

out testing,

adjusting,

pins, and use blocks to prevent When

is the value

It is used as a guideline

and as a reference

tests. It is used for reference

given in the table

carrying

out work together

or troubleshooting,

the machine with

used in dealing

from

with claims.

park the machine

on level ground,

insert the safety

moving.

other workers,

always

use signals and do not let unauthorized

people

near the machine. g

When

checking

the water

A Be careful

the water

level, always

is still hot, the water not to get caught

wait for the water

will spurt

to cool down.

If the radiator

cap is removed

when

out and cause burns.

in the fan, fan belt or other

rotating

parts.

20-l 0

TESTING

AND ADJUSTING

STANDARD

VALUE

model

PC200-6 S6D102-1

Engine Item

Measurement

speed

High

idling

Low

idling

condition

Unit

At sudden

rpm

Valve

acceleration

Bosch index

idling

970 + 50

Max.

5.5

7.0

Max.

0.5

2.0

0.51

pressure

Oil temperature: 40 - 60°C (engine

Blow-by

‘ermissible value

0.25

clearance

Compression

2,000

gas color At high

Standard value 2,200 + 70

Rated Exhaust

FOR ENGINE

speed:

250rpm)

MPa kg/cm:

Min. 2.4 {Min. 24.61

Max. {Max.

pressure

Difference between cylinders Min. 1.0 (Min. IO.31

1.2 1231

5.1 {520)

0.34 - 0.52 13.5 - 5.31

0.21 i2.11

(Coolant temperature: operating range) At high idling (SAE15W-40)

Oil pressure

MPa {kg/cm;

At low idling (SAE15W-40) Whole (inside

Oil temperature

Fuel injection

Belt tension

20-2 0

timing

VALUE TABLE FOR ENGINE RELATED PARTS

Machine

Engine

TABLE

Min. {Min.

speed range oil pan)

Before top (B.T.D.C.) Deflection when pressed with finger force of approx. 58.8N{6kg)

dead

center

“C

’ {degree

Fan-tension

0.1 1.0)

80-110

17+

0.07 lo.71

120

17+

Min. 10 Max. 6

mm Fanair conditioner compressor

5-8

PARTS

TESTING

AND ADJUSTING

STANDARD

Item

. Hydraulic

conditions

Jnit

PARTS

RELATED PARTS

model

Measurement

PC200-6

Standard

value

‘ermissible

value

oil temperature: 45 - 55°C

. Coolant temperature:

.-? p Lu

TABLE FOR CHASSIS

VALUE TABLE FOR CHASSIS

Machine Category

VALUE

At 2-pump

relief

Boom control

Within operating range 2-pump relief: Arm relief

valve

2,000+100

rpm

2,000~100

Swing

control

valve

Travel

control

valve

Boom control

lever

9.5kO.5

z P 2 z-. E 8 % z gc

Arm

control

lever

Bucket control

lever

Swing

control

lever

Travel

control

lever

. Center of lever knob . Read max. value to end of travel . Engine stopped . Excluding neutral play

Work equipment, swing Play of control

L’

E 8 6 g ,o 2 .;i z 0”

1 Boom Arm

control control

100 k 10

100 f 10

100 ? IO

100 iI 10

100 f 10

100 + 10

115 * 12

Max. 127 Min. 103

Max.

lever Travel

lever lever

. Engine

Max.

at high idling

. Oil temperature: 45 - 55°C . Fit push-pull scale to center of control lever knob to measure Measure max. value to end of travel

Max.

15.7 f 3.9 II.6 f 0.41

15.7 & 3.9 II.6 f 0.4)

15.7 * 3.9 (I.6 ?Y0.4)

15.7 * 3.9 (1.6 ? 0.41

13.7 + 2.9 II.4 + 0.3)

13.7 ? 2.9 II.4 + 0.31

Bucket control

lever

Swing

control

lever

13.7 * 2.9 (1.4 + 0.31

13.7 f 2.9 (1.4 + 0.31

Travel

control

lever

24.5 ? 5.9 (2.5 ? 0.6)

24.5 ? 5.9 12.5 ? 0.6)

:kgl

20-3 0

TESTING

STANDARD

AND ADJUSTING

Machine Item

VALUE

TABLE FOR CHASSIS

model

Measurement

conditions

Unit

PARTS

PC200-6

Standard

F‘ermissible

value

. Hydraulic Unload

pressure

Boom Arm Bucket Swing Travel Self-reducing pressure valve

oil temperature: 45 - 55°C at high idling

value

I40 + 101

3.9 + 1.0

3.9 k 1.0 (40 * IO}

31.9 k 1.0 I325 + IO)

Max. 33.8 13451 Min. 30.4 I3101

. Engine . All levers at neutral . Pump output pressure . Hydraulic

oil temperature: 45 - 55°C . Relief pressure with engine at high idling (Relieve only circuit to be measured) . Pump outlet port pressure *: For travel, measure oil pressure for relief on one side

MPa {kg/ cm*)

28.9

‘;:,” I295 -‘;a

34.8 ‘;:o” {355 -‘:a

3.2 f 0.2 I33 f 21

Max. 30.9 I3151 Min. 27.4 {280} Max. 33.8 1345) Min. 30.4 {3101 Max. 3.4 I351 Min. 2.9 1301

2.9 f 1.0 130 + 101

2.9 * 1.0 130 ? 101

2.2 f 0.1 {22 * II

2.2 * 0.1 (22 + 11

LS differential pressure

20-4 0

STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

TESTING AND ADJUSTING

Applicable Cats gor

Measurement

Item

PC200-6

model conditions

Work equipment posture

Swing

brake

Unit

Standard

value

‘ermissible

value

Max. reach

deg.

angle TKPOlII5

Max. 100

Max.

130

3.1 f 0.3

Max.

3.7

4.4 f 0.8

Max.

5.6

sec.

24 ? 3.5

Max. 30

!/min

Max. 5

. Engine

at high idling Hydraulic oil temperature: 45-55°C Stop after swinging one turn and measure distance that swing circle

Work equipment posture

Max. reach 90”

Time taken to start swing

TKPOll16

. Engine at high idling oil temperature: 45 - 55°C In H/O mode + H mode Time taken to swing 90” and 180” from starting position

sec.

. Hydraulic

Work equipment posture

Time

taken

180’

Max. reach

to swing

TKPOl115

. Engine at high idling Hydraulic oil temperature: 45-55°C . In H/O mode t H mode Swing one turn, and measure time taken to swing next 5 turns

Hydraulic

drift

of swing

Engine stopped Hydraulic oil temperature: 45-55°C Set machine on 15” slope, and set upper structure at 90” to the side. Make match marks on swing circle outer race and track frame. Measure distance that match marks move apart after 5 minutes. . Engine at high idling

Leakage motor

from

swing

. Hydraulic oil temperature: . Swing lock switch ON . Relieve swing circuit.

45-55X

Max. 10

20-5 0

TESTING

STANDARD

AND ADJUSTING

Applicable Cats gor

TABLE

FOR CHASSIS

model

Measurement

Item

VALUE

Jnit

conditions

PARTS

f I

PC200-6

Standard

value

STD: 40.5 + 5 LC: 44.0 + 5

‘ermissible

value

STD: - 48.5 LC: 39.0 ? 52.0 35.5

BKP-30104

Travel

speed

(1)

Engine at high idling Hydraulic oil temperature: 45 - 55°C In H/O mode Raise track on one side at a time, rotate one turn, then measure time taken for next 5 turns with no load.

sec. STD: 27.5 & 2 LC: 30 + 2.5

speed

(2)

Engine at high idling Hydraulic oil temperature: 45 - 55°C In H/O mode Run up for at least 10 m, and measure time taken to travel next 20 m on flat ground.

. Engine

. Hydraulic

STD: - 31.5 LC: 27.5 - 35

25.5

21 ?C 2.5

Travel

18.5

- 24.5

sec.

13*

12 - 15

200

300

at high idling oil temperature: 45 - 55°C

. Run up for at least 10 m, and Travel

deviation

measure deviation when traveling next 20 m on flat ground. t Use a hard horizontal surface.

10m

t Measure

20-6 0

dimension

BKP00107

Max.

TESTING

AND ADJUSTING

STANDARD

Applicable Item

Hydraulic

Leakage

drift

of travel

conditions

Engine stopped Hydraulic oil temperature: 45 - 55°C Stop machine on 12O slope with sprocket facing straight up the slope. Measure the distance the machine moves in 5 minutes.

Lock Pin TKPOl117

motor

TABLE FOR CHASSIS

model

Measurement

of travel

VALUE

Unit

PARTS

PC200-6 Standard

value

Permissible

value

‘/min

13.6

27.2

Engine at high idling Hydraulic oil temperature: 45 - 55°C Lock shoes and relieve travel circuit. Work

equipment

posture

Total work equipment (hydraulic drift at tip of bucket teeth)

Boom cylinder (amount of retraction of cylinder)

-2

d i

Arm cylinder (amount of extension of cylinder)

Bucket cylinder (amount of retraction of cylinder)

Max.

960

Max.

1,440

BKPOOllO

Place in above posture and measure extension or retraction of each cylinder and downward movement at tip of bucket teeth. Bucket: Rated load Horizontal, fiat ground Levers at neutral Engine stopped Hydraulic oil temperature: 45 - 55°C Start measuring immediately after setting. Measure hydraulic drift every 5 minutes, and judge from results for 15 minutes.

Max.

mm Max.

Max.

160

Max.

240

20-7 0

TESTING

AND ADJUSTING

STANDARD

Applicable

TABLE FOR CHASSIS

model

Measurement

Item

VALUE

PARTS

PC200-6 conditions

Unit

Standard

value

‘ermissible

value

Boom Bucket contact

teeth with

3.5kO.4

Max.

4.3

2.8kO.3

Max.

3.2

3.6kO.4

Max.

4.5

2.9kO.3

Max.

3.5

2.8kO.4

Max.

3.5

2.1?0.3

Max.

2.7

in ground TKPOlll8

z Cylinder extended

fully

Engine at high idling Hydraulic oil temperature: 45 - 55°C . In H/O mode

Arm Cylinder retracted

fully TKPOlll9

X .

Fully

extended

Engine at high idling Hydraulic oil temperature: 45 - 55°C In H/O mode

. .

Bucket Cylinder retracted

fully TKPOIIZO

$ Fully

extended

Engine at high idling Hydraulic oil temperature: 45 - 55°C

set

\ &a’ //////////////////////,

BKP00114

Boom

Max.

1.0

Max.

1.2

Max.

1.0

Max.

2.8

Lower boom and measure time taken from point where bucket contacts ground to point where chassis rises from ground . Engine at low idling . Hydraulic oil temperature: 45 - 55°C

BKP00115

. .

20-8 0

Stop arm suddenly and measure time taken for arm to stop Engine at low idling Hydraulic oil temperature: 45 - 55°C

TESTING

STANDARD

AND ADJUSTING

Applicable Cat6

TABLE FOR CHASSIS

model

Measurement

Item

gor

VALUE

conditions

Bucket

PARTS

PC200-6

Unit

Standard

sec.

Max.

value

1.0

‘ermissible

Max.

value

3.6

Stop bucket suddenly and measure time taken for bucket to stop at bottom and then start again. Engine at low idling Hydraulic oil temperature: 45 - 55°C . Hydraulic

Cylinders

. Center

swivel

joint

oil temperature: 45 - 55°C Engine at high idling Relieve circuit to be measured

4.5

c/mil

. Engine at high idling Hydraulic oil temperature: 45 - 55°C * Use a hard horizontal Travel deviation when work equipment + travel are operated

!--

surface.

20m

-I

Max.

200

Max.

220

BKP00107

Sr Measure

Piston

pump

dimension

See next page

See next

page

20-9 0

TESTING

AND ADJUSTING

PC200-6:

Discharge

TSTANDARD

amount

VALUE

TABLE FOR CHASSIS

PARTS

of main piston pump

(P/mint

300

0 Pump discharge oressure TKPOlOOl

Pump speed: At 2000 rpm, PC current

Check point

cdesiredpmm

Test pump discharge pressure (MPa {kg/cm21)

260 mA

Discharge pressure of other pump (MPa {kg/cm*}) 1

Average pressure

Standard value for discharge amount 0 (E/min)

(MPa {kg/cm*}) 1

Pl + P2

See graph

Judgement standard lower limit Q Wmin) 1

See graph

Sr As far as possible, bring pump discharge pressure PI and P2 as close as possible to the average pressure when measuring. The error is large near the point where the graph curves, so avoid measuring at this point.

20-10 0

TESTING

AND ADJUSTING

STANDARD

VALUE

Zonnectol No.

Judgment

lock switch

Measurement conditions

table

If the condition is as shown below, it is normal

I) Turn starting switch OFF. Disconnect connector X05.

in the table

x05 (male) When

switch

is LOCK

Between

@ - @

Between

@ - @

Min.

1 MR

Max.

1 R

If the condition is within the range shown the table below, it is normal PC-EPC solenoid

Cl3 (male)

Swing holding brake solenoid valve

vo4 (male)

(i) - @?

Between

@ - chassis

Between

Min.

co9 -co1

1) Turn starting switch OFF. 2) Disconnect connector V04.

1 Min. 1 MQ

@ - @

Between

@ - chassis

Model section

1 1) Turn starting switch OFF. 2) Disconnect connector V07.

20 - 60 R

Between

1 Min. 1 MR

If the condition is within the range shown the table below, it is normal selection

1 MQ

If the condition is within the range shown the table below, it is normal vo7 (male)

1) Turn pump prolix switch OFF. 2) Disconnect connector C13.

20 - 60 R

@ - @

-chassis

PPC oil pressure lock solenoid valve 1

7-14R

Between

If the condition is within the range shown the table below, it is normal

Model

SYSTEM

VALUE TABLE FOR ELECTRICAL SYSTEM

Name of component

Swing

TABLE FOR ELECTRICAL

1 in

CO90

- COl@

No continuity

CO90

- COl@

Continuity

1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to harness side.

20-l 1 0

TESTING

AND ADJUSTING

Name of omponent

Power source voltage

STANDARD

ispection nethod

Ionnectol No.

VALUE

Judgment

20 - 30 v

Between

co1

in the table

it is normal @ - @

320 ? 80 mA

If the condition is as shown below, it is normal

co1

in the table

Model

selection

@ - @

No continuity

Model

selection

@ - @

Continuity

If the condition is as shown below, it is normal Kerosene mode

In normal

co1

mode

In kerosene

Alternator

Between alternator terminal and chassis

mode

in the table

@J - @

No continuity

@ - @

Continuity

When enaine is runnina (l/2 throttle or above + 27.<29.5 V sx If the battery is old, or after starting in cold areas, the voltage may not rise for some time. If the condition is as shown below, it is normal

Coolant temperature sensor

PO7 (male)

Normal temperature 1ooâ&#x20AC;?c

(25Â°C)

in the table

Approx. Approx.

If the condition is as shown below, it is normal Engine oil pressure above 70 kPa IO.7 kg/cm*} Engine sensor

20-12 0

oil pressure a

1) Turn starting switch ON. 2) Insert

co1 Between @ - @

Sll

Engine oil pressure below 30 kPa IO.3 kg/cm21

PARTS

Measurement conditions

table

If the condition is as shown

Model selection

FOR ELECTRICAL

If the condition is as shown in the table below, it is normal

below,

PC-EPC solenoid

TABLE

37 - 50 kQ 3.5 - 4.0 kR

in the table

Min.

Man.

1 MD

1 R

T-adapter. 1) Turn starting switch ON. 2) Set throttle lever to FULL. 3) Turn pump prolix switch OFF. 4) Place all levers at HOLD. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to wiring harness end. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect T-adapter to wiring harness end. 1) Start

engine.

I) Turn starting switch OFF. 2) Disconnect connector P07. 3) Insert T-adapter in connector at sensor end. 1) Install oil pressure measurement gauge. 2) Remove wiring harness terminal. 3) Start engine. 4) Contact tester between sensor terminal and chassis ground

g > z

TESTING

sy!Ster n

STANDARD

AND ADJUSTING

Name of component

(Ionnector

VALUE

Judgment

No.

7 â&#x20AC;&#x2122; the blelow,

TABLE FOR ELECTRICAL

Measurement conditions

table

condition is as shown it is normal

in the table

Max.

Fuel level

sensor

PARTS

approx. 12 R

PO6 (male)

1 Approx. 85-110R

1) Turn starting switch OFF. 2) Disconnect connector P06. 3) Drain fuel and remove fuel level sensor. 4) Insert T-adapter in sensor. % Connect the T-adapter to the connector and sensor flange.

is as shown IiF the condition t jelow, it is normal

1) Turn starting switch OFF. 2) Disconnect connector E07.

in the table

1 Engine sensor

speed

h/leasure

E07

[

tj g

Between

with

AC range

@ - @

1 0.5 - 3.0 v

1) Insert T-adapter. 2) Start engine.

1 ) Screw in until speed sensor contacts ring gear, then turn back 1 * l/6 turn. when ad2 ) Sensor should work normally justed as above.

20-13 0

TESTING

TOOLS

AND ADJUSTING

TOOLS FOR TESTING, Check

or measurement

iten

ADJUSTING,

jymbo

FOR TESTING,

Part

No.

Remarks

Name

Multi-tachometer

speed

799-203-8001 or 799-608-1000

Tachometer

Coolant

and oil temperature:

799-101-1502

Digital

799-101-5002

Hydraulic

790-261-1203

Digital

799-401-2320

1 Hydraulic

Digital display

(electrical type)

temperature

gauge

0 - 3,000

L: 60 - 2,000 rpm H: 60 - 19,999 rpm

rpm

-99 - 1,299”C Pressure gauge 2.5, 5.9, 39.2, 58.8 MPa (25, 60, 400, 600 kg/cm*}

tester

1 hydraulic

tester

AND TROUBLESHOOTING

Engine

ADJUSTING,

gauge _ _

Pressure gauge 69 MPa I700 kg/cm*} II 1 1.0 MPa {IO kg/cm’} Both male and female 14 x 1.5 (female PT l/8)

Oil pressure

.790-261-1321

Both male and female 18 x 1.5 (female PT l/8)

Adapter

Both male and female 22 x 1.5 (female PT l/8)

l790-261-1331 4 -

799-401-2700

Differential

pressure gauge

(12V)

790-261-1360

Adapter

Both male and female 14 x 1.5 (female PT l/8)

790-261-1370

Nut

For 14 x 1.5 blind

07003-31419

Gasket

For blind

07040-I

Plug

For 14 x 1.5 blind

Compression

Blow-by

Valve

795-502-1205

Compression

2 -

795-502-1700

Adapter

1 -

799-201-1504

Blow-by

E -

2 -

795-790-1950

Nozzle

799-201-9000

Handy

gauge

0 - 6.9 MPa (0 -70

kg/cm*}

pressure

checker

0 - 4.9 MPa {O - 500 mmHzO1 Orifice

diameter

0 5.613 mm

clearance

1 1

Exhaust

1409

color

Smoke

Checker

Air supply pressure (boost pressure)

799-401-2201

Pressure

gauge

Push-pull

scale

Operating

effort

Work

hydraulic equipment

Measuring resistance

drift

&$$~~ciallyScale

speed

$$!$~~&cial’y

79A-264-02

voltage values

and

Troubleshooting of wiring harnesses and sensors

Measuring

wear

of sprocke

Fuel in-ection timing valve c1earance

and

I N

{O - 30 kg1

0 - 490N {O - 50 kg1

79A-264-0090 Stroke,

-101.3 - 199.9 kPa I-760 - 1,500 mmHg1 0 - 294N

79A-264-0020

Stop 10

799-601-7100

watch

Tester T-adapter

For MIC 13P

799-601-2720 799-601-7330

assembly

Adapter

For S 16P (White) For relay

799-601-7360

796-427-l

190

Wear

795-799-l

130

Adapter

gauge

5P -

20-101 0

TESTING

AND ADJUSTING

MEASURING

ENGINE

SPEED

MEASURING ENGINE SPEED the measuring or installing removing AWhen be careful not to touch any high equipment, parts. temperature Jr Measure the engine speed under the following conditions. Coolant temperature: Within operating range . : 45 - 55Â°C Hydraulic oil temperature l

Installation of tachometer I) Mechanical meter i) Remove the cover under the front pulA ley, then set probe @ of tachometer on stand @ facing pulley (1). ii) Stick silver paper to pulley (I) at one place. iii) Connect probe @ and tachometer A with the cable. the speed, be careful When measuring not to touch any rotating part or high part. temperature

Electric meter Install T-adapter Nl to connector CN-EO7 i) (2) of the engine speed sensor. ii) Connect the power source cable to the battery (24V).

Start the engine, and measure the engine speed when it is set to the conditions for measuring. I) Measuring at low idling and high idling: Measure the engine speed with the fuel control lever set to low idling and high idling. 2) Measuring speed at pump relief: Run the engine at full throttle and measure the engine speed when the pump is relieved. 3) Measure the speed at near the rated speed. Run the engine at full throttle, operate the arm lever, and measure the speed when the arm circuit is relieved.

20-102 0

BLPO2114

TESTING

AND ADJUSTING

MEASURING COLOR

EXHAUST

MEASURING

EXHAUST

GAS COLOR

GAS

When measuring in the field when there is no air or power supply, use smoker checker Gl, when recording official data, use smoke meter G2. * Raise the coolant temperature to the operating range before measuring. AWhen removing or installing the measuring equipment, be careful not to touch any high temperature parts. l

Measuring with handy smoke checker Gl 1) Fit filter paper in tool Gl. 2) Insert the exhaust gas intake port into the exhaust pipe, accelerate the engine suddenly, and at the same time operate the handle of tool Gl to catch the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale provided to judge the condition.

BLPOPlI5

Measuring with smoke meter G2 @ into the outlet port of exI) Insert-probe haust pipe, then tighten the clip to secure it to the exhaust pipe. 2) Connect the probe hose, accelerator switch plug, and air hose to tool G2. j, The pressure of the air supply should be less than 1.47 MPa 115 kg/cm21. 3) Connect the power cord to the AC outlet. * When connecting the port, check first that the power switch of tool G2 is OFF. 4) Loosen the cap nut of the suction pump, then fit the filter paper. * Fit the filter paper securely so that the exhaust gas does not leak. 5) Turn the power switch of tool G2 ON. 6) Accelerate the engine suddenly, and at the same time, depress the accelerator pedal of tool 62 and catch the exhaust gas color on the filter paper. 7) Lay the filter paper used to catch the exhaust gas color on top of unused filter papers (IO sheets or more) inside the filter paper holder, and read the indicated value.

BLPO2116

BLPO2117

20-103 0

TESTING

AND ADJUSTING

ADJUSTING

VALVE

CLEARANCE

ADJUSTING VALVE CLEARANCE 1.

Remove

Using cranking tool Q, rotate the crankshaft in the normal direction until timing pin (I) enters the hole in the gear. Ir This position is the No. 1 cylinder compression top dead center.

When No. 1 cylinder is at compression top dead center, adjust the valves marked 0. Next, rotate the crankshaft one turn (360”) in the normal direction and adjust the valve clearance of the remaining valves marked 0. * Make match marks on the crankshaft pulley or damper, then rotate 360”.

To adjust the valve clearance, loosen locknut (6), then insert feeler gauge F between rocker lever (3) and valve stem (41, and turn adjustment screw (5) until the clearance is a sliding fit. Then tighten locknut (6) to hold the adjustment screw in position. w Locknut : 44.1 + 4.9 Nm (4.5 f 0.5 kgm}

After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 180” each time and adjust the valve clearance of each cylinder according to the firing order. . Firing order : 1 - 5 - 3 - 6 - 2 - 4 * After tightening the locknut, check the valve clearance again. + There is no timing mark on the front pulley, so set to compression top dead center as follows. i) If the firing order is followed, the next cylinder after No. 1 cylinder is No. 5 cylinder, so watch the movement of the No. 2 cylinder valves and rotate in the normal direction. ii) When the clearance of both the intake and exhaust valves of the No. 2 cylinder is 0, the No. 5 cylinder is at compression top dead center. (For the No. 3 cylinder, watch the movement of the No. 4 cylinder valves.)

20-104 a

the cylinder

head cover.

Valve

arrauoement

diagram

lKP00738

TESTING

AND ADJUSTING

MEASURING PRESSURE

MEASURING MEASURING

BLOW-BY PRESSURE COMPRESSION PRESSURE

COMPRESSION

measuring the A When careful not to touch

compression pressure, be the exhaust manifold or muffler, or to get your clothes caught in the fan, fan belt or other rotating parts. 1. Adjust the valve clearance. For details, see ADJUSTING VALVE CLEARANCE. 2. Warm up the engine to make the oil temperature 40 - 60Â°C. 3. Remove the nozzle holder assembly from the cylinder to be measured. 4. Install adapter D2 in the mount of the nozzle holder, then connect pressure gauge Dl. 5. Set tachometer A in position. 6. Disconnect the fuel control rod, place the governor lever of the injection pump in the NO INJECTION position, then crank the engine with the starting motor and measure the compression pressure. Measure the compression pressure at the point where the pressure gauge indicator remains steady. When measuring the compression pressure, measure the engine speed to confirm that it is within the specified range. After measuring the compression pressure, install the nozzle holder assembly.

MEASURING PRESSURE

BLOW-BY

Measure the blow-by pressure under the following conditions. . Coolant temperature: Within operating range . Hydraulic oil temperature: 50 - 80Â°C. 1. Install nozzle E2 of blow-by checker E to blowby hose. 2. Connect the nozzle and gauge with the hose. 3. Run the engine at high idling and relieve the arm circuit. 4. Measure the blow-by at the point where the gauge indicator remains steady.

20-105 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

FUEL INJECTION

TIMING

TESTING AND ADJUSTING FUEL INJECTION TIMING 1.

Testing 1) Using cranking tool Q, rotate the crankshaft in the normal direction until timing pin (I) enters the hole in the gear. 2) Remove plug (2), reverse timing pin (3), and check that pin (3) is meshed with timing pin pointer (4) at the injection pump side.

Adjusting . If the timing pin does not mesh i) Remove the fuel injection pump. For details, see REMOVAL OF FUEL INJECTION PUMP ASSEMBLY. ii) Rotate the camshaft of the injection pump and mesh timing pin (3) with timing pin pointer (4). iii) Install the fuel injection pump assembly. For details, see INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY.

20-106 0

BLPOlO51 1

BLPO1052

TESTING AND ADJUSTING

MEASURING PRESSURE

MEASURING

ENGINE OIL PRESSURE

ENGINE OIL

Measure the engine oil pressure under the following conditions. . Coolant temperature: Within operating range

Remove engine oil low pressure sensor (I), then install the adapter of oil pressure gauge kit Cl and oil pressure gauge C2 (1.0 MPa {IO kg/cm*).

Start the engine, and measure the oil pressure at the low pressure end with the engine at low idling and at the high pressure end with the engine at high idling.

BLPO2123

20- 107 0

TESTING

AND ADJUSTING

TESTING AND ADJUSTING FAN BELT TENSION TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR

TESTING AND ADJUSTING FAN BELT TENSION Testing . Check the deflection of the belt when the belt is pressed with a finger force of approx. 58.8 N {S kg} at a point midway between the tension pulley and fan pulley. Adjusting 1. Loosen mounting bolts (2) and (3), bolt (4), nut (51, and belt tension adjustment bolt (6) of tension pulley (1). 2. Move tension pulley (I) and watch the tension of the fan belt through the clearance from the cylinder block. When the tension is correct, tighten adjustment bolt (6) first, then tighten tension pulley mounting bolts (2) and (31, and nut 3.

(5). After adjusting the belt tension, check again to confirm that the belt tension is within the standard value. After adjusting the belt, run the engine for at least 15 minutes, then measure the deflection of the belt again.

TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR *

1. 2. 3. 4.

If the deflection of the belt when it is pressed at a point midway between the drive pulley and the compressor pulley is not within the standard value, or when carrying out maintenance after replacing the belt, adjust the belt tension as follows. Loosen bolts (I) and (2). Lever with a bar between (3) and (4) to adjust the belt tension. When the position of the compressor is fixed, tighten bolts (2) and (1) to secure in position. After adjusting the belt tension, repeat the above procedure to check that the belt tension is within the standard value.

TLP01003 I

Wtmm

c:“T’

BLPO2128

20-108 0

TESTING

AND ADJUSTING

MEASURING

SPEED SENSOR

1. Screw in until the tip of sensor (I) contacts gear 2. 3. *

(2). When gear (2) contacts sensor (I), turn back 1 f l/6 turn. (a: clearance) Tighten locknut (3). Be particularly careful when securing the sensor wiring to ensure that no excessive force is brought to bear on the wiring. Be careful not to let the tip of the sensor be scratched or to let any iron particles stick to the sensor tip.

BEP01149

20-l 09 0

ADJUSTING

TESTING AND ADJUSTING

ADJUSTING

(when

lever

free)

FUEL CONTROL LEVER

Ena~ne

side

Low idling stop

Hiah

idling

TKP01004

20-110 0

TESTING AND ADJUSTING

ADJUSTING

FUEL CONTROL LEVER

Set the operatorâ&#x20AC;&#x2122;s seat to rear end position. 1. Adjust the mounting dimension of yoke (2) of cable (I) to dimension a. (Both the clutch and engine ends1 * Yoke mounting dimension a: 12 mm 2. Set fuel control lever (3) to the idling position, then adjust the mounting dimension of cable (I 1 to dimension b. Ir Cable mounting dimension b: 217 mm 3. Check that governor lever (4) is in the idling range, then install the cable at the engine end to dimension c. (If it is not within the idling range, adjust with nut d or e.) * Cable mounting dimension c: 239 mm 4. Check the engine speed when fuel control lever (3) is at the idling position. j, Engine idling speed: 970 + 50 rpm (If it is not within the idling range, repeat Step 3 to adjust.) 5. Move fuel control lever (3) (including the play) towards the STOP position until governor lever (4) comes to the STOP position, then adjust stopper bolt (5) so that the clearance between fuel control lever (3) and stopper bolt (5) is 0. * Basic dimension f of stopper bolt: 13 mm * After adjusting, tighten the locknut of the stopper bolt securely. 6. Move fuel control lever (3) (including the play) towards the FULL position until governor lever (4) comes to the STOP position, then adjust stopper bolt (6) so that the clearance between fuel control lever (3) and stopper bolt (6) is 0. Ir Basic dimension g of stopper bolt: 18 mm Ir After adjusting, tighten the locknut of the stopper bolt securely. l

$ > zl LLI

20-l11 0

TESTING

AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTING HYDRAULIC EQUIPMENT, SWING, TRAVEL CIRCUIT *

For details of the adjustment procedure for the variable pressure compensation valve of the service valve, see Service News. Measuring Jr Oil temperature when measuring: 45 - 55Â°C Lower the work equipment completely to the A ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank, then set the safety lock lever to the LOCK position. . Remove pressure pick-up plug (1) or (2) (Thread dia.= 10 mm, Pitch=1.25) of the circuit to be measured, then install oil pressure gauge Cl (58.8 MPa (600 kg/cm*)). (1): Front pump (2): Rear pump 1. Measuring unload oil pressure Run the engine at full throttle and measure the oil pressure with all control levers at HOLD. l

20-112 0

PRESSURE IN WORK

AND ADJUSTlNG

TESTING

HYDRAULIC PRESSURE TESTING AND ADJUSTING SWING, TRAVEL CIRCUIT IN WORK EQUIPMENT,

Measuring pump relief pressure 1) Low setting (oil pressure: 31.9 MPa (325 kg/

cm*}) i)

Measure the pressure when each actuator except the travel actuator is relieved with the engine at full throttle. of the Note that the set pressure * safety valve for the swing motor and head end of the boom is lower than the main relief low set pressure, so the value measured will be the relief pressure of the safety valve. the swing relief When measuring * measure with the swing pressure, lock turned switch ON.

High setting (oil pressure:

34.8 MPa I355 kg/

cm*}) i) When travel is operated Measure the oil pressure when the travel is relieved on each side separately with the engine at full throttle. * To relieve the travel circuit, put block @ under the track shoe grouser, or put block @ between the sprocket and frame to lock the track.

BLP00170

BLPo0171

20-113 0

TESTING

AND ADJUSTING

TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

Adjusting 1) Adjusting high pressure setting Loosen locknut (3), then turn holder (4) to adjust. + Turn the holder to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of holder: Approx. 12.5 MPa I128 kg/cm? w Locknut : 53.9 + 4.9 Nm 6.5 f 0.5 kgml Ir When the high pressure setting is adjusted, the low pressure setting will also change, so adjust the low pressure setting also.

Adjusting low pressure setting Loosen locknut (5), then turn holder (6) to adjust. * Turn the holder to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. * Amount of adjustment for one turn of holder: Approx. 12.5 MPa I128 kg/cm*} w Locknut: 39.2 f 4.9 Nm (4.0 + 0.5 kgm} + Normally, the pressure applied to port PXI is 0 MPa 10 kg/cm*); at the high pressure setting, it is 2.9 MPa (30 kg/cm*}.

Relief

valve

Relief

valve

TKP01005

PXI

BLP0023E I

Swing motor safety valve Loosen locknut (I), then turn adjustment screw (2) to adjust. * Turn the adjustment screw to adjust as follows. To INCREASE pressure, turn CLOCKWISE. To DECREASE pressure, turn COUNTERCLOCKWISE. j, Amount of adjustment for one turn of holder: Approx. 6.7 MPa 168.4 kg/cm*} w Locknut: 90.6 f 12.3 Nm 19.25 f 1.25 kgml

BKP02439

20-114 0

TESTING

AND ADJUSTING

TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) MEASURING * Hydraulic oil temperature when measuring: 45 55Â°C 1. Remove pressure measurement plugs (I), (2), (3), and (4) (Thread dia.=10 mm, Pitch=1.25 mm), and install oil pressure gauge Cl. * Relationship between plug and pressure measured

Install a 39.2 MPa (400 kg/cm*} gauge to the servo valve end, and a 58.8 MPa {SO0 kg/ cm*} gauge to the pump outlet port end. Run the engine at high idling, and measure the oil pressure when the arm IN circuit is relieved. * Check that the servo piston input pressure is approx. l/2 of the pump discharge pressure. BLPO2134

[Reference] If there is any abnormality in the LS valve or servo piston, the servo piston input pressure will be almost the same or 0 of the pump discharge pressure.

TESTING

AND ADJUSTING

TESTING AND ADJUSTING PC VALVE (SERVO PISTON INPUT PRESSURE)

OUTPUT

PRESSURE

ADJUSTING * If the load becomes larger, the engine speed will drop. Or if the engine speed remains normal, the work equipment speed will drop. In such cases, if the pump discharge pressure and LS differential pressure are normal, adjust the PC valve as follows.

1) Loosen locknut (61, and if the speed is slow, turn screw (7) to the right; if the engine speed drops, turn the screw to the left. Ir If the screw is turned to the right, the pump absorption torque will be increased, and if it is turned to the left, the pump absorption torque will be reduced. Ir The adjustment range for the screw is a maximum of 1 turn to the left and 180â&#x20AC;? to the right. Sr Amount of adjustment for one turn of screw: 1.5 mm movement of servo piston stroke

After completing the adjustment, tighten the locknuts. w Locknut (51: 34.3 f 4.9 Nm 13.5 f 0.5 kgm1 Locknut (6): 100.5 f 12.3 Nm I10.25 f 1.25 kgm1

20-116 0

, fffI

TLP00741

BKP0241I

TESTING

AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

PRESSURE

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE * 1.

Oil temperature when measuring: 45 - 55°C Measuring LS valve output pressure (servo piston input pressure) 1) Remove pressure measurement plugs (I), (Z), (31, and (4) (Thread dia.= 10 mm, Pitch=1.25 mm), and install oil pressure gauge Cl. Ir Plug and measured pressure

Install a 39.2 MPa 1400 kg/cm? gauge to the servo valve end, and a 58.8 MPa {600 kg/cm*} gauge to the pump outlet port end. Oil pressure when travel is rotating under no load on one side i) Use the work equipment to raise the track assembly on one side. ii) Run the engine at full throttle, set to the conditions in Table 1, and measure the pump discharge pressure and servo input pressure. For the front pump, measure the oil pressure simultaneously at plugs (I) and (3); for the rear pump, measure the oil pressure simultaneously at plugs (2) and (4). *

Table

pressure MPa {kg/cm?)

Servo inlet port pressure MPa {kg/cm*1

Remarks

Neutral

3.7 + 0.7 (38 * 71

3.7 * 0.7 {38 + 71

About same pressure

Half

6.9 f 1.0 (70 + 101

3.4 f 1.0 (35 & 101

About ‘It2 of pressure

Travel lever

FlLPO2134

Pump

TESTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL

AND ADJUSTING

PRESSURE

Measuring LS differential pressure 1) Measuring with differential pressure gauge i) Remove oil pressure measurement plugs (1) and (2), and install adapter C3 to hoses (5) and (6). ii) Fit differential pressure gauge C4 to the front circuit and rear circuit. * Plug and measured pressure

Front pump discharge oressure I 5 I Front LS pressure

2 Rear pump discharge pressure

6 Rear LS pressure

Connect the pump discharge pressure to the high-pressure side of the differential gauge and the LS pressure to the low-pressure side. iii) Set to the conditions in Table 2 and measure the LS differential pressure. Table 2

I I MAX

MAX

Levers

at neutral

Track Assembly on one side rotate under no load (travel lever operated half way)

2.2 Yh0.1 {22 f I}

Measuring with oil pressure gauge is 2.9 * The maximum differential-pressure f 1.0 MPa {30 f 10 kg/cm*)), so measure with the same gauge. i) Remove oil pressure measurement plugs (1) and (2), fit adapter C3 to hoses (5) and (6), then install the plugs inside hydraulic tester Cl. ii) Install oil pressure gauge Cl (58.8 MPa I600 kg/cm*)) to the measurement plug for the pump discharge pressure. * Use a gauge with a scale in units of 1.0 MPa {IO kg/cm*). (If no 58.8 MPa 1600 kg/cm*) pressure gauge is available, a 39.2 MPa {400 kg/cm*) pressure gauge can be used.) in Table 2 and iii) Set to the conditions measure the pump discharge pressure. Ir Stand directly in front of the indicator and be sure to read it correctly.

20-118 0

ElLPO2409

TESTING AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

iv) Remove oil pressure gauge Cl, then fit LS pressure measurement adapter C3. v) Set to the conditions in Table 2 and measure the LS pressure. * Stand directly in front of the indicator and be sure to read it correctly. (Pump discharge pressure) - (LS pressure) = LS differential pressure

P-Jâ&#x20AC;&#x2122;

ELPO2140

Oil pressure gauge

Adjusting LS valve When the differential pressure is measured under the conditions above, and the results show that the differential pressure is not within the standard value, adjust as follows. 1) Loosen locknut (7) and turn screw (8) to adjust. . Turn the screw to adjust the differential pressure as follows. To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE Sr Amount of adjustment (LS differential pressure) for one turn of screw: 0.65 MPa 16.6 kg/cm21

BLPOO138

Front PIJ~P LS valve

Rear

PUrnP

LS valve

-.c==

20-119 0

TESTING

AND ADJUSTING

TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE

After adjusting, tighten locknut (7). w Locknut: 56.4 f 7.4 Nm 15.75 + 0.75 kgml Note: Always measure the differential pressure while adjusting.

BKP02410

TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE Measuring * Oil temperature when measuring: 45 - 55Â°C Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then set the safety lock lever to the LOCK position.

1) Remove circuit pressure measurement (I) and install oil pressure MPa {60 kg/cm*}).

gauge

2) Start the engine and measure

plug (5.8

with the en-

gine at full throttle.

BLPO2143

20- 120 0

TESTING AND ADJUSTING

TESTING SOLENOID VALVE OUTPUT PRESSURE

TESTING SOLENOID VALVE OUTPUT PRESSURE Measuring * Oil temperature

when measuring: 45 - 55Â°C Measuring output pressure of ON-OFF solenoid valve I) Disconnect output hose (2) of the solenoid valve, then use adapter C3 in the oil pressure gauge kit to install oil pressure gauge Cl (5.9 MPa (60 kg/cm*}). 2) Measure the solenoid valve output pressure under the conditions in Table 1.

Name of

)lenoid

Safety 1

Operating condition Condition of Oil pressure solenoid(MPa {kg/cm2})

Measurement conditions

lock lever

Hydraulic pressure in PPC valve

at FREE

PPC hydraulic lock Safety

lock lever

No hydraulic pressure in PPC

at LOCK

Min. 2.7 {Min. 281

OFF

0 IO1

valve circuit

Swing or work operated

equipment

lever

Brake

canceled I

2 -

circuit

Min. {Min.

2.7 281

All levers except travel at neutral (5 set after returning to neutral)

Brake

actuated

Travel

speed selector

switch

at Hi

Travel

speed

Travel

speed selector

switch

at Lo

Travel

speed

OFF

0 WI

Travel

lever

OFF

0 (01

0 101 Min. {Min.

2.7 28)

Travel speed

4 -

Remarks

2-stage

relief

operated

Pressure I

/ Motor swash plate angle at minimum Motor swash plate angle at maximum

rise I

Note 1: Operation of solenoid valve ON: Energized (oil pressure generated), OFF: Deenergized (oil pressure: 0) Note 2: The measurement conditions in the table are the typical conditions for measuring the output pressure. In some cases, the solenoid valve may be actuated (ON/OFF) in conditions other than the measurement conditions. When operating the levers, operate slightly and be careful not to move the machine. A

20-121 0

TESTING

MEASURING

AND ADJUSTING

MEASURING PPC VALVE OUTPUT PRESSURE Ir

Oil temperature

Measuring PPC valve output pressure I) Disconnect hose (l).of the circuit to be measured. 2) Install adapter C3 between hose (1) and elbow (2). 3) Install oil pressure gauge Cl (5.9 MPa 160 kg/cm*}) to adapter C3. 4) Run the engine at full throttle, operate the control lever of the circuit to be measured, and measure the oil pressure. % If the output at the control valve end is low, measure the input pressure of the PPC valve. If it is normal, there is defective actuation of the PPC valve.

20- 122 0

when

measuring:

45 - 55Â°C

PPC VALVE

OUTPUT

PRESSURE

TESTING AND ADJUSTING

MEASURING

PPC VALVE OUTPUT PRESSURE

Plug location diagram Interruption

block seen from rear of machine

Arm

R.H.swins

Bucket

Boom

DUMP

RAISE

Bucket

CURL

L.H.swina

Boom

Junction

LOWER

block

,~I____kK?--11

TKP01007

20-123 0

TESTING

ADJUSTING EQUIPMENT VALVE * a

ADJUSTING

AND ADJUSTING

WORK SWING l

PPC

If there is excessive play in the work equipment or swing lever, adjust as follows. Lower the work equipment to the ground and stop the engine. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then set the safety lock lever to the LOCK position.

1. Remove the PPC valve. 2. Remove boot (I). 3. Loosen locknut (2), then screw in disc (3) until it contacts the 4 heads of piston (4). + When doing this, do not move the piston. 4. Screw disc (3) in position, then tighten locknut (2) to the specified torque. m Locknut: 107.8 f 9.8 Nm {II + 1 kgm} 5. Install boot (I). + With the above adjustment, the clearance between disc (3) and piston (4) becomes 0.

20-124 0

WORK

EQUIPMENT

SWING

PPC VALVE

TESTING AND ADJUSTING

TESTING TRAVEL DEVIATION

TESTING TRAVEL DEVIATION +

When traveling on level ground. Set the machine in the travel posture. Ir For the travel posture, extend the bucket and arm cylinder rods fully, and hold the boom angle at 45â&#x20AC;?. Travel for IO m, then measure the deviation A when traveling for the next 20 m. Ir Measure with the engine at high idling. Sr Install the hydraulic pressure gauge and measure the pump discharge pressure at the same time.

Travel

Posture

TDP00328

20m

for

IOm

-I

t Make

Run

Make a mark 10m midway

a mark

at the Doint

Make

a mark

Mark Measure distance

the

amount A at this

of Point TEP00329

ZO-125 0

TESTING

TESTING LOCATIONS EQUIPMENT j,

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

AND ADJUSTING

CAUSING

If there is any hydraulic drift in the work equipment (cylinders), check as follows to determine if the cause is in the cylinder packing or in the control valve. Checking for defective cylinder packing 1) Checking boom and bucket cylinders i) Set in the same posture as when measuring hydraulic drift, and stop the engine. ii) Operate the boom control lever to RAISE or the bucket control lever to CURL. . If the lowering speed increases, the packing is defective. . If there is no change, the boom holding valve (boom) or the control valve (bucket) is defective. 2) Checking arm cylinder i) Operate the arm cylinder to move the arm in fully, then stop the engine. ii) Operate the control lever to arm IN. . If the lowering speed increases, the packing is defective. . If there is no change, the control valve is defective. + If the pressure in the accumulator has dropped, run the engine for approx. 10 seconds to charge the accumulator again before operating. [Reference] If the cause of the hydraulic drift is in the packing, and .the above operations is carried out, the downward movement becomes faster for the following reasons. 1) If the work equipment is set to the above posture (holding pressure applied to the bottom end), the oil at the bottom end leaks to the head end. However, the volume at the head end is smaller than the volume at the bottom end by the volume of the rod, so the internal pressure at the head end increases because of the oil flowing in from the bottom end. 2) When the internal pressure at the head end increases, the pressure at the bottom end also rises in proportion to this. The balance is maintained at a certain pressure (this differs according to the amount of leakage) by repeating this procedure. 3) When the pressure is balanced, the downward movement becomes slower. If the lever is then operated according to the procedure given above, the circuit at the head end is opened to the drain circuit (the bottom end is closed by the check valve), so the oil at the head end flows to the drain circuit and the downward movement becomes faster.

zo- 126 0

HYDRAULIC

DRIFT OF WORK

TOP00333

PC200-6:

1,260kg

BKP00159

TESTING

2. A

Checking boom holding valve reach, Set the work equipment at the maximum and the top of the boom horizontal, then stop the engine. Lock the work equipment control levers and release the pressure inside the hydraulic tank. To prevent danger, never stand under the work equipment. Disconnect pilot hose (I) of the boom I) ing valve, and install a blind plug hose. Ir Blind plug: 07376-50315 Leave the boom holding valve end * If any oil leaks from the port that * open, the boom holding valve is tive.

TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

AND ADJUSTING

holdin the BLPOPl52

open. is left defec-

Checking PPC valve If the hydraulic drift differs when the safety lock lever is in the LOCK or FREE position, (engine running), the PPC valve is defective.

20-127 a

TESTING

MEASURING * 1. +

MEASURING

AND ADJUSTING

OIL LEAKAGE

Hydraulic oil temperature when measuring: 45 - 55Â°C Work equipment cylinder If the hydraulic drift of the work equipment is outside the standard value, measure the leakage inside the cylinder as follows, and judge if the cause of the hydraulic drift is in the cylinder or in the control valve. . If the leakage is with in the standard value, the problem is in the control valve. . If the leakage is greater then the standard value, the problem is in the cylinder. 1) Fully extend the rod of the cylinder to be measured, then stop the engine. 2) Disconnect piping (I) at the head end, then block the piping at the chassis end with a blind plug. &I Be careful not to disconnect the piping at the bottom end. 3) Start the engine and apply the relief pressure to the bottom end of the cylinder with the engine at high idling. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute.

Posture

for

measuring

boom

cylinder

Posture

for

measuring

arm.

TEP00334

bucket

cylinder

TEP00335

Boom

cylinder

~,, TLP00745

Arm

cylinder

TLP00746

20-128 0

MEASURING

TESTING AND ADJUSTING

Bucket

OIL LEAKAGE

-1

cylinder

TLP00747

Disconnect

TEP00337

ZO-129 0

TESTING

AND ADJUSTING

MEASURING RELEASING

Swing motor 1) Disconnect drain hose (I) from the swing motor, then fit a blind plug at the tank end. 2) Set the swing lock switch ON. 3) Start the engine and operate the swing relief with the engine at high idling. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. After measuring, swing 180â&#x20AC;? and measure * again.

Travel motor drain hose (2) from the travel I) Disconnect motor, then fit a blind plug at the hose end. 2) Fit block @ under the track shoe grouser, or fit block @ between the sprocket and frame to lock the track. 3) Start the engine and operate the travel relief with the engine at high idling. When measuring the oil leakage from the travel motor, mistaken operation of the control lever may lead to a serious accident, so always use signals and check when carrying out this operation. 4) Continue this condition for 30 seconds, then measure the oil leakage for the next one minute. When measuring, move the motor slightly * (to change the position between the valve plate and cylinder, and piston and cylinder), and measure several times.

OIL LEAKAGE REMAINING PRESSURE

IN HYDRAULIC

CIRCUIT

,Gw

BLPO2155

RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT *

1. 2.

If the piping between the hydraulic cylinder and the control valve is disconnected, release the remaining pressure from the circuit as follows. The travel ciucuit is an open circuit, so there is no remaining pressure. It is enough to remove the oil filler cap. Loosen the oil filler cap slowly to release the pressure inside the tank. Operate the control levers. * When the levers are operated 2 - 3 times, the pressure stored in the accumulator is removed. Start the engine, run at low idling for approx. 5 minutes, then stop the engine and operate the control levers. * Repeat the above operation 2 - 3 times to release all the remaining pressure.

20- 130 0

BLPO0171

TESTING

AND ADJUSTING

TESTING

CLEARANCE

OF SWING

CIRCLE BEARING

TESTING CLEARANCE OF SWING CIRCLE BEARING

Method of testing clearance of swing circle bearing when mounted on machine 1. Fix a magnet-type dial gauge to the outer circle (or inner circle) of the swing circle, and put the tip of the probe in contact with the inner circle (or outer circle). Set the dial gauge at the front or rear.

frame

Dial

gauge TEP00339

Extend the work equipment to the maximum reach, and set the tip of the bucket to the same height as the bottom of the revolving frame. When this is done, the upper structure will tilt forward, so the front will go down and the rear will rise.

Set the dial gauge to the zero point.

BKP00173

Set the arm more or less at right angles to ground surface, then lower the boom until front of the machine comes off the ground. When this is done, the upper structure will back, so the front will rise and the rear will down.

the the tilt go

Read the value on the dial gauge at this point. The value on the dial gauge is the clearance of the swing circle bearing.

When

Return to the condition in Step 2, and check that the dial gauge has returned to the zero point. If it has not returned to the zero point, repeat Step 2 to 5.

carrying out the measurement, do not put your hand or feet under the undercarriage.

BKP00174

20-131 0

TESTING

AND ADJUSTING

TESTING

AND ADJUSTING

TRACK SHOE TENSION

TESTING AND ADJUSTING TRACK SHOE TENSION TESTING 1. and measure the clearance between the bottom of the track frame and the top of the track shoe. . Clearance a: 303 * 20 mm Measurement position : 4th track roller from the sprocket. PC200-6 ADJUSTING * If the track shoe tension is not within the standard value, adjust as follows. 1 . When the tension is too high: Loosen plug (I) gradually, and release the grease. AThere is danger that the plug may fly out under the high internal pressure of the grease, so never loosen plug (I) more than 1 turn. * If the grease does not come out easily, move the machine backwards or forwards slowy. 2.

If track is too loose: Pump in grease through grease fitting (2). * If the grease cannot be pumped in easily, move the machine backwards and forwards slowly.

20-132 0

BLP00175

BLPO2156

TESTING

AND ADJUSTING

BLEEDING

AIR

BLEEDING AIR Order for operation

and porocedure

Air bleeding

Nature

oil

* Replace

return filter element

* Replace, * Remove

repair pump suction piping

- Replace,

repair control valve

- Replace cylinder * Remove cylinder

* Replace

* Remove

Air bleeding 2

Bleeding air from pomp

Start engine

Bleeding air from cylinder

Bleeding air from swing motor

Bleeding air from travel motor

J+

‘(NoteI)

Start operations

ql\lotel+

’

O I

) I

o+oJ+o

piping

$0’

> I I >

’

0 0 0 0

swing motor swing motor piping

Note 1: Bleed

0 0

* Replace travel motor, swivel travel motor, swivel piping

LLI

procedure

* Remove

ts t z

air

item

of work

* Replace hydraulic - Clean strainer

for bleeding

the air from

the swing and travel

I I

I motors

>o+

only when the oil inside the motor case has been drained.

Bleeding air from pump 1) Loosen air bleed plug (I), and check that oil oozes out from the plug. 2) When oil oozes out, tighten plug (I). m Plug: 17.15 f 2.45 Nm Il.75 f 0.25 kgm1 * If no oil oozes out from the air bleed plug: 3) Leave plug (I) loosened and remove hose (2) and elbow (3). 4) Pour in oil through the elbow mount hole until oil oozes out from plug (I). 5) Fit elbow (3) and install hose (2). 6) Tighten air bleed plug (I). w Plug: 17.15 f 2.45 Nm 11.75 + 0.25 kgml * Precautions when staring the engine After completing the above procedure and starting the engine, run the engine at low idling for 10 minutes.

BLPO2157

BLPO2158

20-133 0

TESTING

AND ADJUSTING

Bleeding air from hydraulic cylinders 1) Start the engine and run at idling for approx. 5 minutes. 2) Run the engine at low idling, then raise and lower the boom 4 - 5 times in succession. * Operate the piston rod to approx. 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat Step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat Steps 2) and 3) to bleed the air from the arm and bucket cylinders. * When the cylinder has been replaced, bleed the air before connecting the piston rod. Be particularly careful not to operate the cylinder to the end of its stroke when the piston rod has been connected to the LOWER end of the boom cylinder.

Bleeding air from swing motor 1) Run the engine at low idling, loosen air bleed plug (I), and check that oil oozes out. * If no oil oozes out from the air bleed plug: 2) Stop the engine, and pour oil into the motor case from plug (1). 3) Tighten air bleed plug (I). m Plug : 166.6 f 16.6 Nm I17 + 2 kgml

Bleeding air from travel motor Run the engine at low idling, loosen air bleed plug (21, and when oil oozes out, tighten the plug again.

20-134 0

BLEEDING

AIR

TROUBLESHOOTING Points to remember Sequence

when

of events in troubleshooting

Precautions

when

.......................................................................................

troubleshooting

..............................................................................................

out maintenance..

carrying

...................................................................................

Checks before troubleshooting..

..........................................................................................................

Connector

locations

Connection Method

types and mounting table for connector

..........................................................................................

pin numbers

of using troubleshooting system

....................................................................................

charts ............................................................................................

20-203 20-204 20-212 20-214 20-220 20-230

....................................................................................

20-301

(E mode) .................................................................................

20-351

Troubleshooting

of engine

(S mode)

Troubleshooting

of electrical

system

Troubleshooting

of hydraulic

and mechanical

Troubleshooting

of machine

monitor

20-202

system

(H mode). ...................................................

(M mode). .................................................................

20-401 20-451

20-201 0

POINTS

TROUBLESHOOTING

POINTS TO REMEMBER A

Stop the machine

When

carrying

allow

any unauthorized

Be extremely

When

disconnecting

When

removing

careful

the internal The aim prevent When

carrying

the negative which

the

basic

and important troubleshooting

of the failure

have

cause

that

would

point

produce

become

no connection

with

impossible

reason,

a waste

when

be disas-

to find

the

carrying to carry

parts,

will

Check the stroke Other

thorough

the

with

what

about

suddenly,

conditions

repairs

the

were

ma-

out

these

same

repairs

kind

carried

of failure

Check the oil level Check

any

or hydraulic

Check the travel

20-202 0

external

ex-

the

machine

of op-

to reenact

symptoms,

investigation

of the then

worse.

investigation

2 - 4 to narrow

of failure,

not

or measure-

may make the problem

in Items

and

in-

down

the

use the troubleshoot-

locate

the

position

of the

exactly.

The basic

procedure

for troubleshooting

Start

from

the simple

Start

from

the most

Investigate

before

the

occurred

Measures to remove . Even if the failure of the failure

be-

will

occur

cause. of oil from

equipment. levers.

other

points. likely

points. parts

or in-

formation.

occur?

problem

of the control

yourself,

it as a real fail-

the method

out?

leakage

with

there

troubleshooting

failure

before

or were

condition

carried

of the

operating out any

To prevent

the piping

spool.

is as follows.

did the failure

been

2) 3)

valve

can be checked

to handle

troubleshooting

flowchart

failure

occurred?

the machine

for

idea

any item that is considered

whether

Troubleshooting . Use the results

ing

apart from

reported?

strange

the failure occur

before

some

etc.

When

causes

Did the failure

Check

items

Confirming failure . Confirm the extent

ment that

prior

fore? 3.

and to

and function.

to form

of the control

so check

spection

occurred

has been

anything

before

Has the

release

swiftly,

the structure

maintenance

carry

failure? 6)

repairs

questions

procedure.

problems

When

various

out troubleshootout

problems

that

there

Had any

for

symptoms.

also lose

to ask user or operator

Have any other

Under

or air, always

out

to understand

this? 4)

so wait

it properly.

ure or as a problem

cause

out troubleshooting

the fixed

the problem

of manhours,

and to carry with

chine

oil, water,

to carry

eration,

it is necessary

Was

from

of the failure,

of the user or operator.

investigation

burns,

first.

be sure to connect

ternally,

any

the fail-

parts will

and at the same time,

the confidence

pressure

the reported

do not hurry immediately

unnecessary

also cause

Points

and do not

parts.

of the battery

and judge

oil or grease,

out and cause

in any rotating

is of course

of the failure.

accordance

signals,

fitted.

to be necessary.

ure or other

For this

spurt

is to ask the operator

sembled.

ing,

may

equipment,

the components.

failure occurs: . Parts that

It will

are securely

to the agreed

(-) terminal

is under

measuring

is to pinpoint

are disassembled

It will

brake

of the failure.

If components

and parking

keep strictly

or to get caught

a location

out troubleshooting,

to disassemble

workers,

is hot, hot water

hot parts

installing

cut to effective

causes

pin, blocks,

troubleshooting.

disconnect

out troubleshooting,

a short

or more

the engine

any

When

TROUBLESHOOTING

near.

starting

always

of troubleshooting

carrying

When

when

the plug or cap from first.

two

to come

before

wiring,

pressure

of possible

and check that the safety

not to touch

reoccurrence

However,

down

WHEN

WHEN TROUBLESHOOTING

with

person

cap is removed

to cool

place,

out the operation

If the radiator the engine

in a level

TO REMEMBER

root

cause

is repaired,

is not repaired,

of failure if the root cause the same failure

again. this, occurred.

always Then,

investigate remove

why the

the root

SEQUENCE OF EVENTS IN TROUBLESHOOTING

TROUBLESHOOTING

SEQUENCE

OF EVENTS IN TROUBLESHOOTING

ber of machine an outline .

Condition

Work

of the prob-

of failure

being

carried

out at the time

of the

TEW00182

failure

srep

Operating

Past history,

2 Determining 1)

environment details

probable

Look

at the

shop

manual

of maintenance,

location

find

TEW00183

of causel

troubleshooting to

etc.

section

locations

of the possible

causes.

TEW00184

/ \

Step 3 ]Preparation 1)

Look

of troubleshooting at the table

the shop

manual

tools

of troubleshooting and prepare

tools

in Step 7

the necessary

tools.

T-adapter

Hydraulic

Look essary

pressure

in the parts replacement

book

gauge and

Iâ&#x20AC;&#x2122; .

kit, etc.

prepare

Pinooint

the nec-

parts. TEW00186

locations

of failure

Decide

action

Before

starting

. 2)

Other

troubleshooting,

check

that

select

matches

locate

and

items

See the Troubleshooting manual,

Eii

out

to take

repair simple failures. . Check before starting

(carrv

troubleshooting)

Section

of the shop

a troubleshooting the

symptoms,

flowchan and

carry

out

troubleshooting. TEW00187

I m !@J-Jhh&

Step 6 Re-enacting

Drive the

failure and

operate

condition

and

the judge

machine if there

confirm

is really

L Step

step

5 Ask

[Go

operator

questions

confirm

details

failure. .

Was there chine

TEW00189

anything

before

strange

the failure

Did the failure

Had any repairs

occur

about

the

ma-

out before

the

occurred?

suddenly?

been carried

failure? TEWOOlSC

20-203 0

POINTS

TROUBLESHOOTING

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil). 1.

POINTS TO REMEMBER ELECTRIC EQUIPMENT

WHEN

HANDLING

Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses. TEW00191

Main failures occurring in wiring harness Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

Improper

insertion

TEW00192

TEW00193

Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.

20-204 0

TROUBLESHOOTING

POINTS

TO REMEMBER

WHEN

CARRYING

Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.

OUT MAINTENANCE

High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. * When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.

TEW00194

& \ TEW00195

TEW00196

20-205 0

TROUBLESHOOTING

POINTS

TO REMEMBER

Removing, installing, wiring harnesses

Disconnecting connectors @ Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand. @

and drying connectors

CARRYING

OUT MAINTENANCE

and

When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. * If the connector is twisted up and down or to the left or right, the housing may break.

I @

WHEN

TBW00485

Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. Ir If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.

TEW00198

20-206 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Connecting connectors

Check the connector visually. I) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). de2) Check that there is no deformation, fective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to * the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. If there is any damage or breakage, re* place the connector.

Clicks into position

TEW00199

Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. Sr If the connector cannot be corrected easily, remove the clamp and adjust the position.

If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.

TBWW487

20-207 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. @ Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.

Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. sr Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassemble.

TEW00196

T-adapter

TEW00203

20-208 0

TROUBLESHOOTING

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

Handling control box Thecontrol box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.

TEW00204

Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.

Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.

II 2.

Points to remember

when

troubleshooting

electric

TEW00206

circuits

I) 2)

Always turn the power OFF before disconnecting or connect connectors. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Ir Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. If the power is turned ON with the connectors still disconnected, unnecessary abnormality * displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. Jr If there is any change, there is probably defective contact in that circuit.

20-209 0

POINTS

TROUBLESHOOTING

POINTS TO REMEMBER HYDRAULIC EQUIPMENT

WHEN

TO REMEMBER

WHEN

CARRYING

OUT MAINTENANCE

HANDLING

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.

1) Be careful of the operating

environment. Avoid adding hydraulic oil, replacing filters, repairing the machine in rain or high winds, places where there is a lot of dust.

or or

2) Disassembly

and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment. F

TEW00207

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or take it back with you for disposal. TEW00208

Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

20-210 0

TROUBLESHOOTING

POINTS

TO REMEMBER

Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.

Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

$ t z Lu

WHEN

CARRYING

OUT MAINTENANCE

TEW00210

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3t.r) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

TEW00211

20-211 0

TROUBLESHOOTING

CHECKS

BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING .ff~~ment

Item 1.

Check

Check for impurities

fuel

level,

type

of fuel

oil level

Add

strainer

Clean,

Check

hydraulic hydraulic

Check

swing

machinery

Check

engine

oil level

Check

coolant

Check

dust

Check

hydraulic

Check for looseness,

corrosion

of battery

Check for

looseness,

corrosion

of alternator

Check

for looseness,

corrosion

of starting

Check

for abnormal

Check

drain

oil drain

Add

oil

Add

oil

level

Add

water

indicator

Clean

Replace

Tighten

or replace

Tighten

or replace

Tighten

or replace

Repair

for oil leakage

Repair

out air bleeding

Bleed

battery

(oil pan oil level),

type

of oil

for clogging

noise,

voltage

Check

battery

Check

for discolored,

Check

for missing

Check

for water

to water

oil level

filter

leaking

for blown,

Check

alternator

wiring

Check operating

motor

wiring

terminal,

wiring

20 - 3ov -

exposed

clamps,

wiring

hanging

on wiring

corroded voltage

terminal,

stopped)

on connectors

Check

wiring

level

burnt,

leaking

terminal,

smell

(engine

electrolyte

20-212 0

fuel

Clean,

Check

Add

Carry

in fuel

Action

wiring

(be particularly

careful

attention

sound of battery

at l/2 throttle

relay (when switch is turned

Replace Add

or replace

Replace

Repair

Disconnect connector

running

air

or terminals)

fuses (engine

or replace

or above)

ON/OFF)

Vter running for several minutes: 27.5 - 29.5 v -

Replace Replace

Replace

and dry

TROUBLESHOOTING

CONNECTOR

TYPES AND MOUNTING

LOCATIONS

LOCATIONS Add. Mounting

Ml2

1KESI 1 3 I,Heater

Ml4

~16

ITerminalI

location

ress

1 K-3

1 2 1Fusible

1 D-3

link

I I Horn (high tone)

1 E-4

Ml7

Wiper

motor

l-l

Ml8

Wiper

switch

K-2

Ml9

Wiper

switch

K-2

M20

Terminal

Horn

M21

Radio

M22

;onPZCtor

Horn

switch

M23

;;nP;Ctor

Horn

switch

M24

2&tor

SpeakerH-4

M26

M27

l-pin connector

Room

M28

KESO

Window

MZ% I~~~~~CtnrI I

(low tone)

E-4 K-l e-3

H-4

I Air conditioner

M31

/ KESO 1 4 I Wiper

M31

I~;~~~CtorI I

G-4

washer ground

I Additional

l:~%torI

I F-7

unit

lamp

I Option

M30

G-4 H-4

speaker

motor (option) connection

front

power

I 1-5

lamp (option)

F-5

1 H-5

motor

I Option

D-9

I ~-6

source

Air conditioner unit powersource

20-214 0

iqi--j

/ AddItional .â&#x20AC;&#x2122;

M42

1 I AddItIonal 12kAorI ..

left front lamp (opt)

G-7

rear lamp (option)

A-8

M43

l-pin connector

PO1

040

PO2

KESI

Light

PO4

Buzzer

PO6

PO7

Engine water temperature

Terminal

Battery

1 16

Option

power

Monitor

source

E-4 H-4

panel

switch

H-5 G-3

I IFuel level sensor

relay

terminal

I c-3 sensor

Q-4

R-8

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING

Mounting

location

/Terminal 1

1 1 Battery

relay terminal

1 R-7

1 RM

ITerminal 1

1 I Battery

relay terminal

I R-T

R05

Travel

Hi-Lo relay

Terminal1 1

so1

Travel pressureswitch (for travel alarm)

M-4

Sl 1

Terminal

Engine

R-3

s12

l-pin connector

PPC hydraulic

lock switch

l-l

s13

l-pin connector

PPC hydraulic

lock switch

J-l

lock switch

K-l

Starting

motor

PPC hydraulic

TO2

Terminal

Revolving

1 TO3

ITerminal I

1 IRevolving

TO5

ITerminal I

1 IFloor

TO6

ITerminal 1 Terminal

frame ground

switch

TO9

Terminal

TIO

ITerminalI

1 IStarting

Tll

ITerminalI

1 I Cab ground

T12

ITerminalI

Starting

connection

Q-6

1 P-6 I F-7

(B)

I l-5 connection

l-5 F-7

switch

(C)

l-5

switch

(RI)

I 1-5

connection

( K-5

switch

vo7 Ix

2 I PPC hydraulic

x05

4 I Swing

switch

o-2

connection

Starting switch (BR) Travel HI-LO floor ground

frame ground connection

ground

1 1Starting ,

terminal

oil pressure

S14

TO7

G-2

(ACC)

lock solenoid

lock switch

I l-5

valve

I M-8 I K-l

pe ~ p:is 1

Mounting

location

LOCATIONS

TROUBLESHOOTING

CONNECTOR

TYPES AND MOUNTING

LOCATIONS

TBPOl125

20-21.6 0

TROUBLESHOOTING

CONNECTOR TYPES AND MOUNTING

T06.TlO

M23

M22 D20 PO4

M12 Ml9 Ml6

HO2

/ Ml7

/ / s12

/ s13

/M36

x05

LOCATIONS

TROUBLESHOOTING

CONNECTOR

TYPES AND MOUNTING

LOCATIONS

El3

vo7

vo4

V06

TO2

El2

TBPOll27

CONNECTION

TROUBLESHOOTING

TABLE FOR CONNECTOR

PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS Ir The terms male and female refer to the pins, while the terms male housing and female refer to the mating

portion

housing

of the housing.

No.

X type connector

of pins

Male (female

Female

housing)

(male

housing)

@El

BEHOOl48

BEH00149

TEW00221

2 TEW00223

4 TEW00225

20-220 0

TEW00226

CONNECTION

TROUBLESHOOTING

No. of pins

SWP type Male

(female

TABLE

FOR CONNECTOR

PIN NUMBERS

connector

housing)

Female

(male

housing)

TEW00235

BLmoo33

TEW00237

TEW00238

__.__. i@El 4

BLPooO34

TEW00240

TEW00239

1 5

BLm0036

BLrn0037

20-221 0

CONNECTION

TROUBLESHOOTING

No. of pins

TABLE FOR CONNECTOR

PIN NUMBERS

M type connector Male (female

Female

housing)

(male

housing)

BLPOC03B

2 I,

s Y 1 TEW00244

TEW00243

2 TEW00246

@ 3’

‘6

TEW00247

TEW00248

BLPOO041

20-222 0

CONNECTION TABLE FOR CONNECTOR

TROUBLESHOOTING

No.

PIN NUMBERS

S type connector

of pins

Male (female

housing)

Female

(male

housing)

16 (White

*’ \4

18 1

16BLW0044

16/

‘7

BEP01697

RFPOlfiSR

16 (White

TEW00256

20-223 a

TROUBLESHOOTING

CONNECTION

No. of pins

TABLE

FOR CONNECTOR

PIN NUMBERS

MIC connector Male

(female

housing)

Female

(male

housing)

1x1

BLPOOO45

ELPOOO46

BLPco046

BLPOoo47

7 \=

"/&__/I 00000 00

BLWO049

BLPOO050

,o),7 17 L

râ&#x20AC;&#x2122; I

BLPO0052

6LPO0051

20-224 0

TEW00259

I TEW00260

TROUBLESHOOTING

CONNECTION

No. of pins

AMP040 Male (female

TABLE FOR CONNECTOR

type connector

housing)

Female

PIN NUMBERS

(male

housing)

f-7 8

BLPcoO54

BLPOOO53

BLPOO055

BLW0056

9 BLPOOO57

TEW00232

TEW00234

20-225 0

TROUBLESHOOTING

No. of pins

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

L type type connector Male (female

housing)

Female

(male

housing)

En m m

TEW00257

20-226 0

TEW00258

TROUBLESHOOTING

No. of pins

CONNECTION

Automobile Male (female

TABLE FOR CONNECTOR

PIN NUMBERS

connector

housing)

Female

(male

housing)

BEH00150

BEHO

BLPOOO64

BDHOOI

BDH00153

3 3

BDH00154

BDH00155

BLPOOO69

BLPcKlO70

20-227 0

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No. of pins

Relay Male

(female

connector

housing)

Female

(male

housing)

EEr 6

BLPOOO74

BLPOOO73

Eir

i-8 i

BLFU0076

20-228 0

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

TROUBLESHOOTING

No. of pins

PA connector Male (female

Female

housing)

(male

housing)

p”1 5

9 BEH00157

BEHO

20-229

METHOD

TROUBLESHOOTING

METHOD 1.

Category

OF USING TROUBLESHOOTING of troubleshooting

Troubleshooting Code No. 1

OF USING

TROUBLESHOOTING

CHARTS

code number Component

s-00

Troubleshooting of engine related parts

E-00

Troubleshooting of electrical system

H-00

Troubleshooting of hydraulic, mechanical system

M-00

Troubleshooting of machine monitor

Method of using troubleshooting table for each troubleshooting mode code number and problem 1) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode (problem with the machine). (See Example (I)) 2) Distinguishing conditions Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a), so go to the appropriate section to carry out troubleshooting. (See Example (2)) If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. chart 3) Method of following troubleshooting YES . , and according to the answer follow either the Check or measure the item inside v YES line or the NO line to go to the next I. (Note: The number written at the top right corner of the 1 is an index number; it does not indicate the order to follow.) . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) . Below the I there are the methods for inspection or measurement, and the judgement values. If the judgement values below the 1 are correct or the answer to the question inside the 1 is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. . Below the I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item I). 4) General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with * (See Example (4)) . The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the I. tools 5) Troubleshooting When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.

20-230 0

$ > i

TROUBLESHOOTING

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem). <Example> (1) M-4 Abnormality (4) Sr

in PPC oil pressure

lock solenoid

system

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Check that fuses 2 is normal.

* *

(2) a) Is not actuated

(safety lock is not released) Divided

b) Remains

actuated

(safetu

into sections

a) and b)

lock is not applied)

(3) Cause

4YES

-Swinglock lever

LOCK: 20 - 30 v RELEASE: Max. 1 V

1 * Turn starting switch OFF. * Disconnect V07. *20-60I2

andS13 . Check PPC oil pressure lock switch as individual part.

Remedy

GotoA Defective contact or disconnection in wiring harness between V07 (female) (2) - HO2 (7) S14(1)-s12

Repair or replace

Defective contact or disconnection in wiring harness between fuse 2 HO6 (4) - V07 (female) (1)

Repair or replace

Defective PPC oil pressure lock switch

Replace

Defective PPC oil pressure lock solenoid switch

Replace

5 YES 30 to H mode (H-3) From A+$%L-J[

*Turn starting switch OFF. * Disconnect S13. * Max.1 R

Table

Iefective contact iisconnection in larness between ;14 (2) - HO2 (5) :hassis ground

or wiring S13 -

?epair or eplace

Safety

lock lever OFF LOCK

Resistance value Max. 1 Q Min. 1 MR

20-231 0

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)

Method

s- 2

charts . .. . . . . . . . . .. . . . . . .. . . . . . . . . . .. . . . . . . .. . . .. . . . . . .. . . . . . . .. . . . . . . . .. . . . . . . .. . .. . . .. . .. . . . . .. . . 20-302

of using troubleshooting

is poor (starting

performance

Starting

20-307 20-307

does not turn.. ........................................................................................................

Engine

smoke comes

out, but engine

Engine

s- 4

Engine stops during

s- 5

Engine does not rotate smoothly

S- 6

Engine

s- 7

Exhaust

S- 8

Oil consumption

s- 9

Oil becomes

S-IO

Fuel consumption

S-l 1

Oil is in cooling

S-l 2

Oil pressure

is poor) ........................................................

..............................................................................................

operations

(hunting)

...........................................................................

(no power). ..............................................................................................

lacks output smoke

..............

is black (incomplete

contaminated

...............................................................

gas is blue). .......................................................

quickly .........................................................................................

is excessive water,

combustion)

(or exhaust

is excessive

or water

................................................................................................ spurts back, or water

s-13

Oil level rises (water,

S-l 4

Water temperature

S-l 5

Abnormal

S-16

Vibration

too high (overheating)

20-312 20-313 .20-314 .20-315 20-316 20-317

.................................................

.20-319

............................................................

noise is made .......................................................................................................... is excessive

20-31 1

20-318

fuel in oil) .............................................................................................

becomes

20-310

level goes down ..........................

lamp lights up (drop in oil pressure)

caution

20-308

does not start (fuel is being injected) ........... 20-309

(follow-up

does not pick up smoothly

s- 3

out (fuel is not being injected)

smoke comes

(2) Engine turns but no exhaust (3) Exhaust

.20-306

takes time) .................................................

Engine does not start ............................................................................................................... (I)

g &

always

...............................................................................................................

20-320 20-321 20-322 20-323

20-30 1 0

TESTING

AND ADJUSTING

METHOD

OF USING

OF USING TROUBLESHOOTING

TROUBLESHOOTING

CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the userâ&#x20AC;&#x2122;s level. [Check items] The serviceman carries out simple inspection to narrow down the causes. The items under 0 in the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of 0 that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].

@ \I 4

20-302 0

â&#x20AC;?

(a)

2 % 5

(b)

Cc) Cd)

Causes I

TESTING

AND ADJUSTING

METHOD

OF USING

TROUBLESHOOTING

CHARTS

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with 0. Check each of the [Questions] and [Check items] in turn, and marked the 0 or Q in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. %I. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. z-2. Use the n in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

Confirm recent repair history

3~2

Degree of use

Operatred for long period

arm

20-303 0

TESTING

AND ADJUSTING

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.

combustion) s-7 Exhaust gas is black (incomplete General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel injection . Excessive injection of fuel

20-304 a

TESTING

AND ADJUSTING

METHOD

OF USING

TROUBLESHOOTING

CHARTS

Five causes Step 1 Clarify the relationship between the three symptoms in the [Questions] and [Check items1 section and the five Cause items in the vertical I column.

Three symptoms

------Jt

Step 2 Add up the total of Oand 0 marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (I) Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 (3) Clogged, seized injection nozzle: 0 (4) Defective contact of valve, valve seat: 0 (5) Worn piston ring, cylinder: 0 Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

20-305 0

S-l

TESTING AND ADJUSTING

S-l

Starting

performance

is poor (starting

always takes time)

General causes why exhaust smoke comes out but engine takes time to start . Defective electrical system . Insufficient supply of fuel . Insufficient intake of air . Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1) * Battery charging rate ~

. .

The specific gravity should exceed the value for the charging rate of 70% in the above table. In cold areas the specific gravity must exceed the value for the charging rate of 75% in the above table.

Legend 0 : Possible causes (judging from Questions and check items) d : Most orobable causes fiudaina from Questions and Check items) n : Possible causes due to length of use (used for a long period) l : Items to confirm the cause Confirm recent repair history Degree of use of machine 1Operated for long period Gradually bet; Ease of starting

WV v er I I I I I I I I I I I I I I I I I lOjO\ I I I I IW I I I I I I IOlOl

plug is loosened Leakage from fuel piping There is hunting from engine (rotation is irregular)

not return (Carry out inspection after pump is removed) When fuel cap is inspected directly, it is found to be clogged w~)ooo z; ““““%a,:,, Rernedy$~~~~$~~~$~$~$$ rzQJJJ~~uulx<e”uK

20-306 0

. 0 z-

TESTING

s-2

AND ADJUSTING

S-2 Engine does not start

(I) Engine does not turn

Causes

General causes why engine does not turn . Internal parts of engine seized * If internal parts of the engine are seized, carry out troubleshooting for â&#x20AC;&#x153;Engine stops during operationsâ&#x20AC;?. . Defective electrical system

Legend 0: Possible causes (judging from Questions and check items) 0 n

: Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period) : Items to confirm the cause.

When starting turned

switch

to START, pinion

moves out, but

Specific

gravity

For the following OFF, connect

of electrolyte, conditions

voltage 1)

of battery

5). turn the starting

connected,

switch

C of starting

motor are

B and terminal

+ 0

B and terminal

B terminal

0 and starting a

is connected

5) There is no 24V between

battery

relay terminal

M and

When ring gear is inspected

2 Ls IL s v:

C of safety relay are

engine starts

4) Engine starts when safety switch terminal

terminal

are

engine starts

3) When terminal connected,

at ON

C of starting

engine starts

2) When terminal connected,

B and terminal

switch

the cord, and carry out troubleshooting

1) When terminal

motor

is low

directly,

tooth

/@I

1 I

surface is

found to be chipped

20-307 0

TESTING

AND ADJUSTING

s-2

(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)

Check that the monitor panel does not display any abnormality in the governor control system. General causes why engine turns but no exhaust smoke comes out Supply of fuel impossible . Supply of fuel is extremely small . Improper selection of fuel (particularly in winter)

Standards

for use of fuel Ambient temprature

Type of fuel

-22 -4 .30 -20

14 -10

32 0

50 10

68 20

86 30

104Â°F 40Â°C

Diesel fuel

0: 0 A:

20-308 0

Possible causes (judging from Questions and check items)

: Most probable causes (judgingfrom Questionsand Check items) Possible causes due to length of use (used for a long period)

Causes

TESTING

s-2

AND ADJUSTING

(3) Exhaust smoke comes not start (Fuel is being injected) * .

. . .

out but engine

does

General causes why exhaust smoke comes out but engine does not start Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel and oil

Causes

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause. m

Operated

When engine

is cranked with starting

for long period

motor,

1) Little fuel comes out even when injection

pump

sleeve nut is loosened 2) No fuel comes out even when fuel filter air bleed olua is loosened There is leakage from fuel piping When exhaust starting

manifold

is touched

engine, temperature

When fuel filter is drained. Remove

immediately

after

of some cylinders

is low

no fuel comes out

head cover and check

directly

When control rack is pushed, it is found to be heavy, or does not return When ._P

5 2

P rl z .L I-

compression

pressure

is measured,

it is found to be low

When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged When air cleaner element is inspected directly, it is found to be clogged Heater

mount

does

not become

Either specific gravity of electrolyte _ When feed pump is operated,

warm or voltage of battery is low

operation

is too light or too heavy

1 When iniection nozzleistested asindividual part, spray condition isfoundto be poor When fuel cap is inspected

directly,

%## a

1 1.1 1 IO 7 0

##+rt a I 1.1 I

I I ll I

it is found to be clogged

Remedy

20-309 0

TESTING

AND ADJUSTING

s-3

S-3 Engine does not pick up smoothly

(follow-up

is poor) Causes

General . . . .

causes why engine does not pick up smoothly Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) a : Possible causes due to length of use (used for a long period)

â&#x20AC;&#x2122;â&#x20AC;&#x2122;H I t Engine

pick-up suddenly

became poor

Color of exhaust gas

Black

Mud is stuck to fuel tank cap There is leakage from fuel piping High idling speed under no load is normal, but speed suddenly drops when load is applied There is hunting from engine (rotation is irregular) When exhaust manifold is touched immediately engine,

20. Blow-by

temperature

of some cylinders

after is low

gas is excessive

When air cleaner element is inspected directly, it is found to be clogged When fuel filter, strainer are inspected directly, they are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged

20-3 10 0

IQI lolol

Clanging sound is heard from around cylinder head

starting

lol

Blue under light load 0

Ial I I I

TESTING AND ADJUSTING

s-4

S-4 Engine stops during operations General causes why engine stops during operations . Seized parts inside engie . Insufficient supply of fuel . overheating * If there is overheating and the engine stops, carry out troubleshooting for overheating. . Failure in main piston pump Ir If the engine stops because of a failure in the main piston pump, carry out troubleshooting for the hydraulic system (H MODE).

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) A:

Possible causes due to length of use (used for a long period)

Abnormal Condition when

it is found to be abnormal

noise was heard

Causes

TESTING

AND ADJUSTING

s-5

S-5 Engine does not rotate smoothly

(hunting)

General causes why engine does not rotate smoothly . Air in fuel system . Defective governor mechanism . Defective electric governor mechanism * If hunting does not occur when the rod between the governor motor and the injection pump is disconnected, troubleshoot by using the electrical system troubleshooting (E mode).

Questions and check items) om Questions and Check items) of use (used for a long period)

Condition

of hunting

Replacement

of filters has not been carried out according

When feed pump is operated,

1 When governor

lever is moved

When injection improperly

.-F ij 2 L x2 7

it is found to be stiff

pump is tested, governor

is found to be

adjusted

When control

l 0

When fuel cap is inspected

directly,

it is found to be clogged

is inspected

directly,

it is found to 0

be clogged

found to be clogged

it is found to be heavy, or

does not return

When fuel filter, strainer

I.1

rack is pushed,

When feed pump strainer

I.1

are inspected

directly,

they are

a z ii 5â&#x20AC;&#x2DC;0 zb L

20-312 0

2â&#x20AC;?

TESTING AND ADJUSTING

S-6 Engine lacks output

S-6

(no power)

General causes why engine lacks output insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used (if non-specified fuel is used, output drops) . Lack of output due to overheating * If there is overheating and insufficient output, carry out troubleshooting for overheating.

. . . .

Causes

Legend

20-3 13 0

TESTING

s-7

AND ADJUSTING

S-7 Exhaust smoke is black (incomplete combustion) Causes I

I,,

General causes why exhaust smoke is black . Insufficient intake of air . Improper condition of fuel injection . Excessive injection of fuel

Legend 0: Possible causes (judging from Questions and check items) 0 : Moss probable causes (judging from Questions and Check items) A:

Possible causes due to length of use (used for a long period) to confirm the cause.

l : Items

Confirm

Operated

Degree of use of machine

Color of exhaust

gas

for long period

1 Suddenly

became black

1 Gradually

became black

I Blue under light load

Non-specified

101

I loI

I I I lol I I I I I I I I I I

Gradually

0 00

fuel is being used

Noise of interference

Muffler

Suddenly

Power was lost

Exhaust

nnn

Engine oil must be added more frequently

Clanging

recent repair history

is heard from around

sound is heard from around

turbocharaer

cylinder

head

noise is abnormal is crushed

Leakage of air between

turbocharger

and head, loose clamp

I I I I I I Iol I I I I lol I lo1 I I 101 I I I I I I I I I I 101 I I I )

1 I

I.1

10 I

.-P i; _?

E : :

When muffler

is removed,

exhaust

color returns to normal

When control rack is pushed, it is found to be heavy, or does not return

20-314 0

S-8

TESTING AND ADJUSTING

S-8 Oil consumption

is excessive (or exhaust smoke is blue)

Do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) General causes why oil consumption is excessive . Abnormal combustion of oil . External leakage of oil . Wear of lubrication system Causes

Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period) l : Items to confirm the cause. Confirm

recent repair history

When compression

pressure is measured, it is found to be low

When breather element is inspected, it is found to be clogged with dirly oil There is external C

2 6

Pressure-tightness Excessive

test of oil cooler shows there is leakage

play of turbocharger

I I

O.f

, I.1

shaft

Inspect rear seal directly When intake manifold

leakage of oil from engine

is removed,

dust is found

inside

When intake manifold is removed, inside is found to be dirty with oil

0 0

20-315 0

TESTING

AND ADJUSTING

s-9

S-9 Oil becomes contaminated

quickly

General causes why oil becomes contaminated quickly . Intake of exhaust gas due to internal wear . Clogging of lubrication passage . Improper fuel . Improper oil used . Operation under excessive load

Possible causes (judging from Questions and check items)

Color of exhaust gas

Amount

of blow-by

Excessive

gas

None When oil filter is inspected,

metal particles

are found

When exhaust pipe is removed, inside is found to be dirty with oil Engine oil temperature

rises quickly

!!2 0

0 0

5 L

S-IO

TESTING AND ADJUSTING

S-10 Fuel consumption

is excessive

General causes why fuel consumption is excessive . Leakage of fuel . Improper condition of fuel injection . Excessive injection of fuel

Causes

Legend 0 0 n

: Possible causes (judging from Questions and check items) : Most probable causes (judging from Questions and Check items) : Possible causes due to length of use (used for a long period)

Condition

of fuel

20-317 0

TESTING AND ADJUSTING

S-II

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down General causes why oil is in cooling water Internal leakage in lubrication system . Internal leakage in cooling system

Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judgingfrom Questions and Check items) a:

Possible causes due to length of use (used for a long period)

Hard water is being used as cooling water

yu) 8 E

Engine oil level has risen, oil is cloudy white

6 â&#x20AC;?

Excessive air bubbles inside radiator, spurts back

20-318

TESTING AND ADJUSTING

s-12

S-12 Oil pressure caution lamp lights up (drop in oil pressure) General causes why oil pressure lamp lights up . Leakage, clogging, wear of lubricating system . Defective oil pressure control . Improper oil used (improper viscosity) . Deterioration of oil due to overheating Ir

Standards

for engine

oil selection

Ambient temperature

Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) n : Possible l : Items to

causes due to length of use (used for a long period) confirm the cause.

Replacement

Condition pressure

of filters

when oil lamp lights up

When oil pressure standard

has not been carried out according

value

is measured,

it is found to be within

TESTING

AND ADJUSTING

s-13

S-13 Oil level rises (water, fuel in oil) *

If there is oil in the cooling water, carry out troubleshooting for “Oil is in cooling water”. General causes why oil level rises . Water in oil . Fuel in oil (diluted, and smells of diesel fuel) . Entry of oil from other component

Causes

Legend 0 : Possible causes (judging from Questions and check items1 0 : Most probable causes (judging from Questions and Check items) a: Possible causes due to length of use (used for a long period) l : Items to confirm the cause. Confirm I .P zi % cc

recent repair history

Degree of use of machine

Operated

for long period

When engine is first started, drops of water come from muffler Exhaust

smoke is white

There is oil in radiator Leave radiator abnormal

number

of bubbles

Water pump breather C ‘: m 6

cooling

water

cap open. When engine

hole is clogged

When water pump breather

is run at idling, an

appear, or water spurts back with mud

hole is cleaned,

Oil level goes down in damper

chamber

Oil level goes down in hydraulic

tank

Engine oil smells

water comes out

of diesel fuel

Fuel must be added more frequently 1 Pressure-tightness

test of oil cooler shows there is leakage

I Pressure-tightness test of cylinder head shows there is leakage When compression

pressure is measured, it is found to be low

Remove water pump and inspect directly Remove rear seal and inspect directly When main pump is removed,

0 $

seal is found to be damaged

Remove head cover and inspect directly Remove injection

pump and inspect directly

Defective

of thermostat

contact

seal valve

Remove oil pan and check directlv

20-320 0

I.1

I I I I I I I I I I.1 I I I I I I I I

TESTING AND ADJUSTING

s-14

S-14 Water temperature

becomes too high (overheating)

General causes why water temperature becomes too high . Lack of cooling air (deformation, damage of fan) . Drop in heat dissipation efficiency . Defective cooling circulation system

Possible causes (judging from Questions and check items)

open even at cracking o z

temperature

When water temperature

is measured,

it is found to be normal

When oil cooler is inspected directly, it is found to be clogged When measurement pressure

is made with radiator

cap tester, set 0

is found to be low

When compression

pressure is measured, it is found to be low

Remove oil pan and inspect directly

0 Remedy

t; t; 2% _m E E F 2 aooLCaSd2czbS 0s: 0 0

_m E 28

4 _m 8 2P

20-321 0

s-15

TESTING AND ADJUSTING

S-15 Abnormal

noise is made

Judge if the noise is an internal noise or an external noise. General causes why abnormal noise is made . due to defective parts Abnormality . Abnormal combustion . Air sucked in from intake system Ir

Legend

0 : Possible causes (judging from Questions and check items1 0 : Most probable causes (judgingfrom Questionsand Check items) a : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.

Condition of abnormal

Color of exhaust gas

20-322 0

noise

Causes

TESTING AND ADJUSTING

S-16 Vibration

S-16

is excessive

If there is abnormal noise together with the vibration, carry out troubleshooting for â&#x20AC;&#x153;Abnormal noise is madeâ&#x20AC;?. General causes why vibration is excessive . Defective parts (abnormal wear, breakage) . Improper alignment Abnormal combustion l

Legend 0: Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A: Possible causes due to length of use (used for a long period)

Condition

of vibration

Remove oil pan and inspect directly p ._ E

Remove side cover and inspect directly Inspect directly for loose engine mounting

Inspect inside of output

B z c

Remove front cover and inspect directly

shaft (damper)

Remove

head cover and inspect directly

Injection

pump test shows that injection

a bolts, broken cushion

directly

0 0 amount

is incorrect

20-323 0

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

Judgement Electrical

table for electrical,

hydraulic,

and mechanical

systems . . . . . . . .. . .. . .. . .. . . . . . . .. . . . . . . . . . .. . . . . . . .. . .. 20-352

for each system . . .. . . .. . . . . . . . . .. . . . . . . . .. . . .. . . . . . . .. . . . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. . . . . . .. . .. 20-354

circuit diagram

Failure codes E-l Abnormality a)

system

Engine stops even when throttle When

in PC-EPC control

sudden

Lacks power

load is applied, when throttle

engine

in travel speed selector

E-3 Abnormality

in swing

Swing

Remains

holding

E-4 Abnormality a)

Solenoid

Remains

E-5 Abnormality

(swing

actuated in engine

system

system swing)

. .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . . . . .. 20-359

system

lock is not canceled)

(safety lock is not actuated) starting

(cannot

be locked) .. . . . . . . . . . . .. . . .. . . .. .. . . . . . . . .. . .. . . . . . . .. . . . . . . .. . .. . . . . . . .. . . .. 20-360

lock solenoid

(safety

20-355

speed is slow . . . . . . . .. . . . 20-356

(travel speed does not switch) .. . . . . . . .. . . .. . . . . . 20-358

is not actuated

cannot

in PPC oil pressure is not actuated

stalls. . . . . . ..__..........................................................

brake solenoid

actuated

to STOP position.

lever is at FULL, work equipment

E-2 Abnormality

holding

lever is not returned

system

(engine

.......... .................. .................. ..... 20-361

. .. . . . . . . . . . . .. . . . . . .. . .. . . . . . . . .. .. . . . . . . .. . . . . . . .. .. . . . . . . . .. 20-362

does not start) .__.......................................

20-364

20-351 0

JUDGEMENT HYDRAULIC,

TROUBLESHOOTING

TABLE FOR ELECTRICAL, AND MECHANICAL SYSTEMS

JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, MECHANICAL SYSTEMS

AND

Parts causing failure 1. Insert T-adapter regulator

in pump

connector

2. Turn starting

KOl).

switch to 3.

3. Turn

pump

prolix switch

Is voltage in table

Failure

mode

Does not swin

20-352 0

between

V06

(I) and chassis as shown below?

JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS

TROUBLESHOOTING

Solenoid Swing

holding

1. Insert T-adapter solenoid

2. Turn starting 3.

Is voltage in table

in swing

connector

holding

brake

PPC hydraulic 1. Insert T-adapter connector

(VO4). V04 (I) and (2) as shown

Is voltage in table

below?

(When

solenoid

in PPC hydraulic

lock solenoid

(VO7).

2. Turn starting

switch ON.

between

valve

brake solenoid

switch ON.

between

V07 (I) and (2) as shown

below?

normal)

(When

6 ;; t m .o E -orn PE Eb .-0â&#x20AC;&#x2122; = = A?

normal)

H-l H-2 0

H-3 H-4 H-5 H-6 H-7 H-8

H-9

H-10

20-353 0

ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM

TROUBLESHOOTING

ELECTRICAL CIRCUIT DIAGRAM Starting

FOR E MODE SYSTEM

switch

ioht

pressure

switch

Bracket

,Electrical

Pump

parking

Engine

L____.___._._.J

Pump control

redundancy

speed

Pump control

Engine

brake

box

switch

___-.-. Changeover , I

â&#x20AC;&#x2122;

20-354 0

kerosens

switch

Iect

mode

Jointino:kerosene Cutting off:Diesel

oil

Tb:Poloo8

E-l

TROUBLESHOOTING

E-l

Abnormality

in PC-EPC control system

* Before carrying out troubleshooting, check that all the related connectors are properly Ir Always connect any disconnected connectors before going on to the next step. * Check that fuse 2 is normal. Sr Check that the pump prolix switch is OFF. a)

Engine stops even when applied, engine stalls.

throttle

lever is not returned

to STOP position.

When

sudden

Cause

2 YES YE

;

Is voltage between CO1 (female) (1) and (8) normal?

Does LED of pump regulator

â&#x20AC;&#x2122;

Is LED of pump regulator flashing? *Turn starting switch ON.

CO1 (female)

(11, or

Short

circuit, disconnection, or defective contact in wiring harness

- Turn

starting switch OFF. NO *Disconnect COl. . No continuity between (5) and (10) between (6) and (10)

between (lo),

CO1

(female)

(5) -

Repair or replace

(6) -(IO)

-Continuity

5 Is resistance between Cl3 NO (male) (1) and (2) normal? * T;;;,starting . Disconnect .7-14R 7

switch

YES

Failure of solenoid

Replace

Abnormality regulator

in pump

Disconnection

in wiring

Replace or turn pump prolix switch ON.

C13.

YES

harness

between

CO1

(femalel (7) - CO5 cl)- (31Cl3 (female) (1). between

A-

Cl3

(female)

(2l-

CO1 Ifemale)

Wiring

c NO

Repair or replace

Go to H mode (H-2)

* Disconnect COI. * Min. 1 MR

Replace or turn pump prolix switch ON.

between CO1 (female) (8) and chassis ground

Is continuity YES between CO1 (female) (5) - (10). (6) - (10) normal? 3

* Turn starting switch ON.

Troubleshooting pump regulator

HO6 (4k

load is

Remedy

Short circuit, disconnection, defective contact in wiring harness between fuse (2) -

* Turn starting switch ON. * Disconnect COI. * 20 - 30 v

inserted.

(female) Cl3 Cl3

(2) - co5 (13)

harness

between

CO1

(7) - CO5 (1) - (3) -

(female) (female)

(11, or between (2) - CO5 (4) -

(2) - CO1 (female) circuiting ground

(4) -

with

Repair or reolace

Repair or replace

(13) short

chassis

20-355 0

E-l

TROUBLESHOOTING

Lacks power

when

throttle

lever is at FULL, work

equipment

speed is slow

Remedy

Cause

3 YES

Is resistance YES between CO1 2 - (female) (3) and (4) normal?

YE 1

Is resistance between E07 (male) (I) and (2) normal?

*Turn starting switch OFF. * Disconnect COI. * 500 - 1000 R

* Turn starting switch OFF. * Disconnect E07. ~500-1000R *Turn starting switch ON. . Set throttle lever to FULL.

4 YES Is continuitybetween CO1 (female)(5)and

(10).(61and (101 normal?

*Turn starting NO switch OFF. * Disconnect COl. * No continuity between (5) and (IO) * Continuity between (6) and (10)

20-356 0

Troubleshooting pump regulator

Replace

Short circuit, disconnection, or defective contact in wiring harness between CO1 (female) (3) and E07 (female) (1). or between CO1 (female) (4) and E07 (female) (2)

Repair or replace

Troubleshooting speedsensor

Replace

Abnormality regulator

in pump

Short circuit, disconnection, or defective contact in wiring harness between CO1 (female) (5) and (lo), or between (6) and (IO)

Replace

Repair or replace

E-l

TROUBLESHOOTING

E-l Related

electric

Fuse

box

circuit diagram

Ho6

Pump

CO1 (MICl3)

(S8)

Ensine Engine

controller

speed sensor (input: speed

Machine

select

Machine

select

sensor

EPC solenoid

Kerosene Prolix

select

(GND)

I 2 (+I

mode resister

switch

Revolving

Pump *â&#x20AC;&#x2122;

prolix

snitch

OFF

TKPOI 009

20-357 0

TROUBLESHOOTING

E-2

E-2 Abnormality not switch)

in travel speed selector system (travel speed does

troubleshooting, check that all the reproperly inserted. disconnected connectors before going

Ir *

Before carrying out lated connectors are Always connect any on to the next step. Check that fuse 5 is

YES

normal.

Remedy

Cause

Go toH mode(H-20)

3, I YE Defective travel Hi-Lo relay

Replace

~ (1) and (2) as shown

. Tgu;;,startingswitch N( *20-30V

-Turn starting -__ switch UFI * Disconnect M38.

(male) (1) and (2) * Turn starting switch OFF. * Disconnect V06. *20-60R

* Replace relay. *Turn starting switch ON -TurnHi-Lo switch ON.

1 NO

I NO

5YE!

A{=[

Table

*Turn starting switch ON. *20-30V

Travel

Hi-Lo switch HIGH LOW

E-2 Related

electrical

Resistance value Max. 1 Q Min. 1 MQ

Travel

GotoA

Defective travel Hi-Lo relay switch

Replace

Defective travel Hi-Lo solenoid valve

Replace

Defective contact or disconnection in wiring harness between M38 (female) (1) - HO2 (1) - HO6 (2) - R05 (female) (1) Defective contact or disconnection in wiring harness between fuse (5) HO6 (8) - HO2 (9) - M38 (female) (2). and between R05 (female) (5) - HO3 (15) - M30 - V06 (female) (1) speed

Repair or replace

switch

circuit diagram

HO6 I

(S8)

HO2 I

(S16)

M38

(M2)

Travel

speed

H03(SlGwhite)

relay

M30

VO6

(X2)

â&#x20AC;&#x2122; @t--T--3j 1

,,llr

I, n\

Travel solenoid

speed valve

DO7

1 I

20-358 0

TKPOlOlO

E-3

TROUBLESHOOTING

E-3 Abnormality -)r

in swing holding brake solenoid system

j, *

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the .next step. Check that fuse 2 is normal.

Swing

holding

brake solenoid

is not actuated

(cannot

swing)

Cause

4YEI

as shown in Table Is resrstance between V04 (male) (1) and (2) normal? *Turn starting switch OFF. * Disconnect V04. .20-600

Table

+ Turn startrng switch OFF. * Disconnect X05.

normal?

-Turn starting

IL NC

switch ON. *Swing lock switch LOCK: zo-3ov * Swing lock switch CANCEL: Max. 1 V

* Turn starting switch ON. *20-30V

/ NO

Remedy

Go to H-21 Defective contact or disconnection in wiring harness between V04 (female) (2) - HO2 (3) X05 (female) (4), between X05 (female) (3) - HO2 (5) -chassis ground

Repair or replace

Defective contact or disconnection in wiring harness between fuse 2 HO6 (4) - V04 (female) (1)

Repair or replace

Defective swing lock switch

Replace

Defective swing lock solenoid valve

inserted.

Replace

Swing

holding brake switch CANCEL LOCK

E-3 a) Related

Swine

lock

electric

Resistance value Max. 1 Q Min. 1 MQ

circuit diagram

switch

X05 (M4)

HO2 (S16) r-r--a

DO5 I i

($ BDP00258

20-359 0

E-3

TROUBLESHOOTING

b) Remains

cannot

(swing

actuated

be locked)

Cause

YES

I Is resistance

Remedy

Go to H Mode (H-21) Short ciucuit with chassis ground in wiring harness between V04 (female) (2) - HO2 (3) -X05 (female) (4)

Repair or replace

* Disconnect V04 and X05. between V04 (male) (I) and (2)

* Turn starting switch OFF. * Disconnect V04. *20-60R

Defective swing holding brake switch

Replace

- Disconnect X05. Defective operation of swing holding brake solenoid valve (short circuit with ground at (2))

I NO

Replace

â&#x20AC;&#x2DC;I

Table Swing

E-3 b)

holding brake switch CANCEL LOCK

electric

Resistance value Max. 1 Q Min. 1 MR

circuit diagram

HO6 (S8)

Fuse

vo4 (X2) 3 3

Swing

lock

holding solenoid

SW; tch

HO2 (S16)

Swing brake valve

X05 (M4)

@ ($ BDP00258

20-360 0

E-4

TROUBLESHOOTING

E-4 Abnormality

in PPC oil pressure lock solenoid system

Ir * Ir

check that all the related connectors are properly Before carrying out troubleshooting, Always connect any disconnected connectors before going on the next step. Check that fuses 2 is normal.

Solenoid

is not actuated

(safety

lock is not canceled)

Cause

4YEI

GotoA

chassis normal? Is voltage

YES between V07 (1) 2

Is resistance YES between Sl2 and S13 as shown in Table I?

Is resistance between V07 (male) (1) and (2) normal? 1

-Turn starting switch OFF. * Disconnect ~07. *20-60R

H II 1

and chassis normal?

lock lever . Safety LOCK: 20 - 30 V Max. 1 V RELEASE:

* Turn starting switch ON. *20-30V

inserted.

*Turnstarting

I switch OFF. NO * Disconnect S12 and S13. - Check PPC oil pressure lock switch as individual part.

Defective contact or disconnection in wiring harness between V07 (female) (2) - HO2 (7) S14(1)-s12

Repair or replace

Defective contact or disconnection in wiring harness between fuse 2 HO6 (4) -VO7 (female) (1)

Repair or replace

Defective PPC oil pressure lock switch

Replace

Defective PPC oil pressure lock switch

5 YES Go to H mode (H-3)

. Turn starting switch OFF. * Disconnect S13. - Max.1 R

Table Swing

E-4 a)

Defective contact or disconnection in wiring harness between S13 S14 (2) - HO2 (5) chassis ground

Repair or replace

1 holding brake switch RELEASE LOCK

electric

Resistance value Max. 1 Q Min. 1 MQ

circuit diagram

HO6 (S8)

vo7 (x02) PPC oil

pressure solenoid PPC lock

lock valve

Pressure oil switch

BDP00257

20-36 1 0

E-4

TROUBLESHOOTING

b) Remains

actuated

(safety

lock is not actuated)

1 YES Is resistance between S12 and S13 as shown in table l? NO

*Turn starting switch OFF. - Disconnect S12 and S13.

Table .--.-

Short ciucuit with chassis ground in wiring harness between V07 (female) (2) - HO2 (7) - S14 (I) and s12

Replace wiring harness

Defective PPC oil pressure switch

Replace

Swing

E-4 b)

holding brake switch RELEASE LOCK

electric

Resistance value Max. 1 Q Min. 1 MQ

circuit diagram

vo7 (X02)

HO6 (S8)

Fuse

3 I PPC lock

lock valve

oil Pressure switch

CANCEL

LOCK

g$ s13

20-362 0

!3?

PPC OI I Pressure solenoid

S14 (M2)

a g

HO2 (S16)

(-a ElDP00257

TROUBLESHOOTING

E-5 Abnormality * * * j,

E-5

in engine starting system (engine does not start)

When the starting motor does not turn. Check that fuse 1 is normal. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

YES

YES 3 Is there sound of ES starting motor pinion engaging? ---I

6 1.

* Turn starting switch to START.

voltage between

terminal S and

% Same conditions as in Step 5.

4 starting motor terminal B and chassis normal?

When starting switch is turned OFF, is sound heard from battery relay?

YES r I

NO *Turn starting switch to START. *20-30V

* Turn starting switch ON. *20-30V

. Turn starting switch ON + OFF.

12 Is resistanceof wiring 1 Is voltage and specific gravity of battery normal?

.20-3ov. * Specific gravity: Min. 1.26

switch ON. NO * Remove terminal B.

* Connect (4 end of tester to battery terminal (4 .20-30V h

20-364 0

YES

E-5

TROUBLESHOOTING

Cause

Defective starting motor (motor proper)

qepair or .eplace

Defective starting motor (magnetic switch)

qepair or .eplace

Defective contact or disconnection in wiring harness between safety relay terminal C-T13 (1) -starting motor terminal C

qepair or replace

Defective safety relay

qeplace

Defective alternator

3eplace

Defective contact or disconnection in wiring harness between starting switch terminal C - HO3 (3) - MO.2 (1) - safety relay terminal S

qepair or replace

Defective starting switch (between terminals B and C)

Replace

Defective contact of wiring harness between battery terminal (+) - battery relay terminal B-terminal M starting motor terminal B

Repair or replace

Defective battery relay

Replace

7 Is voltage between starting motor YES terminal C and 8 chassis normal? Is voltage between .x Same conditions safety relay as in Step 5. NO terminal C and 9 chassis normal? _ Is voltage between MO2 % Same conditions NO (female) (2) and as in Step 5. chassis normal?

* Turn starting switch ON. * Max. 13 V

Remedy

YES

Defective contact or disconnection in wiring harness between starting switch terminal BR - HO3 (1) -battery relay terminal BR Defective starting switch (between B and BR) Defective contact or disconnectionin wiring harness between battery relay terminal (+I - battery relay terminal B- Ml1 (1). (2 - Hd3 (2) -fuse 1 - starting switch terminal B (including fusible link)

Lack of battery capacity

Repair wiring harness

Replace

Repair wiring harness

Charge or replace

20-365 0

TROUBLESHOOTING

E-5 Related

Starting

E-5

circuit diagram

electric

Fuse

switch

Starter

Alternator

HO3 (S16white)

Fusible

link

Safety relay

Battery

///

[â&#x20AC;&#x153;\

E08 (Xl) Battery

, \_,\.,

, El2 (X2)

relay

TKPOlOl

20-366 0

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)

Table of failure

modes

H-l

Speeds

H-2

There

and causes . .. . .. . . . . . .. . . . . . . . .. . .. . . . . . . . .. . .. . . . . . . .. . .. . . . . . . .. .. . .. . . . .. . . . . . . . . .. .. . . . . . . . .. . . . . .. . .. . . . . .. 20-402

of all work equipment, is excessive

drop in engine travel,

swing

speed,

or engine

stalls .............................................

.20-408 .20-409

No work equipment, Abnormal

H-5

Fine control

H-6

Boom is slow or lacks power ..............................................................................................

20-412

H-7

Arm is slow or lacks power.. ...............................................................................................

20-414

H-8

Bucket is slow or lacks power..

20-416

H-9

Work equipment

ability

move ..........................................................................

20-406

H-4

noise generated

swing

are slow or lacks power.. .......................

H-3

(around

pump)

is poor or response

(boom,

(but travel and swing

g & 2

travel,

H-10

Excessive

hydraulic

H-l 1

Excessive

time

H-12

Other equipment

H-13

In compound

is poor.. .............................................................

...........................................................................................

drift (boom,

lag (engine

...................................................................................... arm, bucket) .................................................................

at low idling) .........................................................................

moves when

single circuit is relieved .................................................

work equipment

RAISE, boom

with larger load is slow.. ...........................

H-l 4

In swing + boom

H-15

In swing + travel, travel speed drops excessively

H-16

Travel

deviation..

.20-409 .20-409

arm, bucket) does not move

are normal)

operations,

......................................................................

RAISE is slow.. ............................................................... ............................................................

...................................................................................................................

Deviation

is excessive

in normal

Deviation

is excessive

when

travel .......................................................................

starting ...........................................................................

speed is slow.. ...........................................................................................................

20-416 .20-417 .20-418 .20-418 20-418 .20-419 20-419 20-420 20-420 20-420 20-421

H-17

Travel

H-18

Steering

H-19

Travel

H-20

Travel speed does not switch.. ............................................................................................

20-423

H-21

Does not swing .....................................................................................................................

20-424

Does not swing to either

20-424

Does not swing

does not turn easily or lacks power.. .................................................................

does not move (one side only). ...............................................................................

H-22

Swing

acceleration

H-23

Excessive

left or right ..........................................................................

in one direction..

.................................................................................

is poor or swing speed is slow ........................................................

overrun

when

One direction

Both directions..

stopping

swing ...........................................................................

only.. ........................................................................................................ .............................................................................................................. stopping

swing

(one direction

only). ..........................................

H-24

Excessive

shock when

H-25

Excessive

abnormal

noise when

H-26

Excessive

hydraulic

drift of swing ......................................................................................

stopping

swing

............................................................

.20-422 20-423

20-424 .20-426 20-428 20-428 20-428 .20-429 .20-429 20-430

When

swing

lock is ON .................................................................................................

20-430

When

swing

lock is OFF ................................................................................................

20-430

20-401 0

TABLE OF FAILURE

TROUBLESHOOTING

TABLE OF FAILURE MODES AND CAUSES

MODES

AND CAUSES

(l/Z) -

Parts causing failure

Piston pump

-r

s -

3 9 !?

2 I h 0)

9 Failure mode

; ;

Speeds of all work equipment,

swing, travel are slow or lack power

i-e $2 zd

There is excessive drop in engine speed, or engine stalls

2 6

Abnormal

Fine control ability is poor or response is poor

No work equipment,

travel, swing move

noise generated

(around pump)

Boom is slow or lacks power Arm is slow or lacks power r; E .a

Bucket is slow or lacks power

- Boom

does not move

Arm does not move Bucket does not move

z 3

Excessive hydraulic drift Excessive time lag (engine at low idling) Other equipment

moves when single circuit is relieved

$ ,g

In compound

In swing + boom (RAISE), boom is slow

5 8

In swing + travel, travel speed drops excessively Deviation is excessive during normal travel

operations, work equipment

with larger load is slow

Deviation is excessive when startina ~~

Travel speed is slow

B t ;

Steering does not turn or lacks power Does not move (one side only) Travel speed does not switch

1 Both Does not swing Swing acceleration

left and riaht

One direction only is poor

or swing speed is slow

Both left and right One direction only

Excessive overrun

Both left and right

when stopping swing

One direction only

Excessive shock when stopping swing (one direction only) Excessive abnormal Excessive hydraulic 1 drift of swing *

noise when stopping swing When brake ON

1 When

A: When there is an abnormality

20-402 0

I 0 _ _ _ _ _

0 -

brake OFF

In the failure modes, modes for compound

F ?

operations

for both front and rear

are used when independent

operations are normal

-0

2 =

cz 0 0 -

z z -

I L tj -

0 _ -

& ?

-2 -

0 -

ul -

0 0 0 0 0 0 0 0 -

TABLE OF FAILURE MODES AND CAUSES

TROUBLESHOOTING

Control

valve

$ J

6 2” 9

G :

B E

9 3 x 2

“0

i -

I -

0 -

0 0 0 0 0 0 -

-zi 3 9 I k -

z5 .z

2 .g

Y -

a, E a2 i

1” 1” e _c J 1 32

u P

13 -

Y 5 -6 - - - - - - - - -

0 75 - 0 - _ - 0 - - - - - - - - 0 - - c - 0 0 - - - - - - - - - - - - - - - - - - - - - - - 0 - - - -

.k 0

I? -

0 -

2 -

0 -

3 1

Re-

generation dalve

kcz .E 9

I: 1 3

s f

al =

.-6 E 5 2

s z .tj 5 z - - - - - al

2 L

c 0 0 - 0 0 - 0 0 - - - 0 0 - - - - - - - 0 - 0 - 0 - - - - - - - - - - - -

! .-F

0 0 0 0 0 0 0 0 -

H-3

H-6

H-7

H-A

H-5

H-l H-2

H-8

code

3 o 5

2 -

Troubleshooting

H-9 H-10

H-11

H-l 2

H-13

H-17

q---+--

0 -

H-25 H-26

20-403 0

TABLE OF FAILURE MODES AND CAUSES

TROUBLESHOOTING

TABLE OF FAILURE MODES AND CAUSES

(2/2)

Parts causing failure

Solenoid

Swing

valve

motor

2 2 a, 9

Failure mode

Does not swing

when stopping swing

In the failure modes, modes for compound

A: When there is an abnormality

20-404 0

operations

for both front and rear

are used when independent

operations

are normal

0 0

E20Y06

Final drive

Swing machinery

TROUBLESHOOTING

H-l Ir

H-l

Speeds of all work equipments, power

travel, swing are slow or lacks

Check that there is no abnormal normal from the main pump before starting troubleshooting. (If there is any abnormal noise, carry out Troubleshooting H-4.)

YES 4 YE

2 YES -

1 Is output pressure of self-reducing pressure valve normal?

L-t

Is main pump relief pressure normal?

I NO

YES

NO pump (servo piston).

7 Does condition become normal when main relief valve is adjusted? * 30.4 - 33.8 MPa (310 - 345 kg/cm21 * Engine at high idling * Arm IN relieved

x Check and measure circuit oil pressure. For details, see TESTING AND ADJUSTING.

Does condition L become normal when N~ LS valve assembly is replaced?

YES

-1

YES

* Distribution between LS valve and piston

f 30.4 - 33.8 MPa I310 - 345 kg/cm? * Engine at high idling * Arm IN relieved

5 Does condition become normal when NO PCvalve assembly is replaced?

* For details, see TESTING AND ADJUSTING.

Is servo piston input pressure approx. l/2 of main circuit pressure?

* Engine at high idling * Arm IN relieved

Does condition become normal when PC valve is adjusted?

8 YES Does condition _ become normal NO when unload valve is replaced? NO * 3.9 f 1.O MPa {40 i 10 kg/cm21 * Engine at high idling . Arm IN relieved

Note 1:Measuring servo piston input pressure . Measure the input pressure to the large diameter end of the servo piston when the arm is relieved. (Approx. 15.7 MPa (Approx. 160 kg/cm?) [Basically the pressure at the large diameter end is approx. l/2 that of the small diameter end. (For details, see TESTING AND ADJUSTING.)]

20-406 0

TROUBLESHOOTING

H-l

Remedy

Cause

Defective adjustment of PC valve

Adjust

Defective PC valve assembly

Repair or replace

Defective piston pump

Repair or replace

Defective LS valve assembly

Repair or replace

Defective piston pump (servo piston)

Repair or replace

Defective adjustment main relief valve

Adjust

Defective operation of unload valve

Replace

Defective operation of main relief valve

Replace

Defective hydraulic equipment in selfreducing pressure valve output circuit (For details, see TESTING AND ADJUSTING.)

Adjust or replace

20-407 0

TROUBLESHOOTING

H-2

H-2 There is excessive drop in engine speed, or engine stalls * Check that the main relief pressure is normal.

hlzizzL Cause

Remedy

servo or filter inside servo

YES 31 Does condition YES become normal - when PC valve assembly is replaced?

servo or filter

2 Is engine speed normal at arm

Seebelow.

Defective PC valve

Adjust or replace PC valve assembly

Defective LS valve

Adjust or replace LS valve assembly

Defective servo piston

Replace (piston pump assembly)

4 YES Does condition become normal - when LS valve NO assembly is replaced?

-1

See troubleshooting engine (S mode)

Note 1:Replace the defective servo valve assembly with a new part. If the engine the reference value given below, go to troubleshooting for S mode. If it is higher, the servo valve system is defective, so replace it. Note 2:Engine speed at arm relief when engine and pump are normal (reference

Engine speed at arm relief

Min. 1900 rpm

20-408 0

Clean

for

speed is lower than

value)

Conditions . .

Engine at high idling. With arm at end of stroke, move lever slowly to high idling and read engine speed at point where there is maximum drop in speed.

H-3,

TROUBLESHOOTING

H-3 No work equipment,

travel, swing move

Cause

2 [Whenmainpump

H-4

YES

Remedy

Defective self-reducing pressure valve or defective control circuit

Replace

Defective damper

Replace

Defective operation of PPC lock solenoid valve or safety lock lever

Adjust

YE 1 solenoid valve

* Hold outlet hose by hand and operate lock lever.

- Crank with starting motor.

H-4 Abnormal

noise generated

(around pump)

Cause

YES

YIESEl-

Goto4 Improper hydraulic oil

2 NO YE

Are there bubbles inside hydraulic tank?

Is hydraulic tank oil level normal?

- External

object: Cloth, etc.

Change hydraulic oil

Clogged by external object (cloth, etc.) (strainer)

YES

Is suction strainer clogged by NO external object?

Remedy

5 YEI Is suction strainer clogged with metal particles or NG are metal particles stuck to drain plug?

Defect inside pump

Repair or replace

Operate for a short time and watch for any change in symptoms

Inspect again (depending on changes in symptoms)

Lack of hydraulic oil

Add hydraulic oil

20-409 0

H-5

TROUBLESHOOTING

H-5 Fine control ability is poor or response is poor Cause

1 YES

Remedy

Clogged throttle in LS circuit

Clean

Defective LS valve, or defective servo piston

Replace

Is throttle in LS circuit clogged?

20-410 0

TROUBLESHOOTING

H-6

H-6 Boom is slow or lacks power *

When

travel and swing speeds are normal.

Yt 4

YfIS

front and rear pumps normal when boom RAISE

* 30.4 - 33.8 MPa I310 - 345 kg/cm’) * Engine at high h idling

* LS shuttle for R.H. travel and bucket

is relieved?

YES

a pressure compensation valve normal, or does praSS”ra compensation piston move smooth1 ?

- 4.9 i 2.9 MPa (50 k 30 kg/cm*) - Engine at high idling

* It is also possible to check

interchanging other compensation

with

i Ni

valve.

Is output pressure of PPC valve normal? * Min. 2.7 MPa (28 kg/cm’) * Engine at high idling

20-412 0

Note: After checking, always return to original positions.

YES

TROUBLESHOOTING

H-6

Cause

Remedy

Defective boom cylinder piston packing

Correct or replace

Defective operation of control valve spool

Correct or replace

Defective PPC valve

Replace

20-413 0

H-7

TROUBLESHOOTING

H-7 Arm is slow or lacks power *

When

travel and swing speeds

are normal.

6 YES

_ YES Does LS shuttle - valve move smoothly? 4

Does control YES valve spool for arm move smoothly? 1

*Max. 20 cc/min * Engine at high idling

Note 1: After inspection,

20-414 0

Is leakage from arm cylinder normal?

valve normal? * Min. 2.7 MPa {28 kg/cm21 * Engine at high idling

p Are relief pressure * Check LS shuttle YES of F and R pumps for L.H. travel, normal when arm boom, R.H. circuit is relieved? 3 travel and ~ - 30.4 - 33.8 MPa bucket valvefor YES compensation (310 - 345 kg/cm? NO - armnormal,or does compensation * Engine at high pressure 2 pinon idling * It is also possible _ to interchange _ NO with other compensation valve. * See Note 1.

YES 5

do not forget to return the interchanged

valves to the original

position.

H-7

TROUBLESHOOTING

Cause

Remedy

Defective operation of arm regeneration valve or arm counterbalance valve

Correct or replace

Defective arm cylinder piston packing

Correct or replace

Defective operation of LS shuttle valve (LS shuttle for L.H. travel, boom, R.H. travel or bucket)

Correct or replace

Defective safety-suction valve for arm

Replace

Defective operation of arm pressure compensation valve or pressure compensation piston

Correct or replace

Defective operation of control valve spool

Correct or replace

Defective PPC valve

Replace

20-415 0

H-8, 9

TROUBLESHOOTING

H-8 Bucket is slow or lacks power +

When

travel and swing speeds

are normal.

Remedy

Cause

YES Is leakage from - bucket cylinder normal?

Does control valve spoot for bucket move smoothlv?

1 I

valve normal? * Min. 2.1 MPa 128 kg/cmâ&#x20AC;&#x2122;) * Engine at high idling

Repair or replace

Defective bucket cylinder piston packing

Repair or replace

Defective operation of pressure compensation valve for bucket or pressure compensation piston

Repair or replace

Defective operation of control valve spool for bucket

Correct or replace

Defective

Replace

PPC valve

Note 1: After inspection,

H-9

Is pressure compensation valve YES_ for bucket normal, or _ * Max. 20 cc/mir * Engine at high does pressure 2 idling compensation piston move smoothlv? - * It is also possible NO to interchange with other compensation valve. _ * See Note 1.

Defective operation of safety-suction valve for bucket

do not forget to return the interchanged

valves to the original

Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)

When boom, pendently.

arm,

and

bucket

are each

operated

inde-

Remedy

Cause

1 YES Is output pressure of PPC valve normal? * Min. 2.7 MPa {28 kg/cm*} * Engine at high idling

20-416 0

position.

Defective spool

control

valve

Defective

PPC valve

Correct or replace

Replace

H-10

TROUBLESHOOTING

H-10

Excessive hydraulic drift (boom, arm, bucket)

I) Excessive

hydraulic

drift of boom Remedy

Cause

downward movement become faster when * See TESTING AND N ADJUSTING. * It is also possible to measure leakage of cylinder. * Max. 20 cclmin * At relief * Engine at high

safety-suction valve is interchanged? l-l

Defective hydraulic cylinder piston packing

Replace

Defective operation of safety-suction valve

Replace

Defective operation boom lock valve

Correct or replace

idling

2) Excessive

hydraulic

drift of arm or bucket Remedy

Cause

Defective hydraulic cylinder piston packing

YFS 1

Does speed of downward movement _ become faster when lever is operated?

YES 3

Does condition * See TESTING become normal AND NO when safetyYES Is slipper seal of ADJUSTING. suction valve is pressure * It is also possible interchanged? _ compensation valve to measure damaged? leakage of No Or does wessure cylinder. * Max. 20 cc/min + At relief * It is also possible to interchange * Engine at high other compensation valve. idling * See Note 1.

Note 1: After inspection,

with

do not forget to return the interchanged

Defective operation of safety-suction valve

Replace

Defective spool

Replace

control

valve

Damaged slipper seal of pressure compensation valve, or defective operation of pressure compensation piston

Correct or replace

valves to the original

position.

20-417 0

H-II,

TROUBLESHOOTING

H-II

H-12, H-13

Excessive time lag (engine at low idling)

Boom, arm YE 1

I Is wessure

I /

Bucket

1!i.g~;;$t * It is also possible to interchange 10 with other compensation valve. - See Note 1.

Note 1: After inspection,

H-12

do not forget to return the interchanged

Other equipment

Defective safety-suction valve, or defective regeneration valve

Replace

Defective safety-suction valve

Replace

Defective operation of pressure compensation valve or pressure compensation piston

Correct or replace

valves to the original

moves when single circuit is relieved Cause Defective operation of pressure compensation valve slipper seal ~ (The slipper seal in the pressure compensation valve of the circuit that moved is defective.)

H-13

In compound

operations,

work equipment

Combination

Replace (replace pressure compensation valve on side where load is lower)

of compound

operation

Side where

Boom RAISE + arm IN

1 I

load is larger

Boom RAISE I

Boom RAISE + arm OUT

Arm OUT

Boom RAISE + bucket CURL

Boom RAISE

Arm OUT + bucket CURL

Arm OUT

Boom

Arm OUT

20-418 0

LOWER + arm OUT

Remedy

Replace

with larger load is slow

Remedy

Cause Defective operation of pressure compensation valve

position.

TROUBLESHOOTING

H-14, H-15

H-14 In swing + boom RAISE, boom RAISE is slow -k If swing and boom RAISE work normally when operated independently. Cause

Defective operation of LS select valve

t z w

H-15 *

Remedy

Correct or replace

In swing + travel, travel speed drops excessively

See H-14. (When the swing

and travel are normal

in independent

operations.) Cause

Defective operation of LS shuttle valve (LS shuttle for L.H. travel or swing)

Remedy

Correct or replace

20-419 a

H-16

TROUBLESHOOTING

H-16 a)

Travel deviation when starting)

Deviation

is excessive

(deviation

in normal

is excessive in normal travel and

travel

Cause

4YES

* Check as individual part.

normal when rotating under no

Defective travel motor assembly

Correct or replace

Defective operation of control valve spool

Correct or replace

Defective operation of travel pressure compensation valve

Correct or replace

Defective LS valve

Adjust or replace

Defective PPC valve

Replace

Defective self-reducing pressure valve

Replace

* For conditions and standard values, see TESTING AND ADJUSTING.

Is difference between

Remedy

YES

5 NIC * Min. 3.3 MPa (Min. 34 kg/cm21 * Engine at high idling

Deviation

r--

is excessive

when

starting

Cause

Remedy

Defective operation of travel counterbalance valve

Correct or replace

Clogged throttle inside servo of bottom or R pump

Correct or replace

20-420 0

H-17

TROUBLESHOOTING

H-17 *

Travel speed is slow

Check that the spool of the travel PPC valve is moving shooting.

the full stroke before carrying

Cause

4YE$ YES 3

YES -

Ispressure YES compensation valve - normal,or does pressure compensation 2 pistonmovesmoothly?

Does control valve spool move smoothly?

1 pressuresof leftand

* It is also possible to check by

Does condition become normal when suction valve is replaced? NC

NO interchanging with other compensation valve. Note: After checking, always return to original positions. NO

out trouble-

Remedy

Defective operation of control valve suction valve

Correct or replace

Defective travel motor assembly

Correct or replace

Defective operation of pressure compensation valve or pressure compensation piston

Correct or replace

Defective operation of control valve soool

Correct or replace

Defective PPC valve

Replace

Defective self-reducing pressure valve

Replace

normal,and is output - Difference Is output pressure between output of self-reducing pressure in FORWARD and NO Eess,â&#x20AC;&#x153;L7evalVe REVERSE: Within 0.4 MPa + Output pressure: I4 kg/cm? Min. 3.3 MPa * Output pressure: (34 kg/cm*} Min. 2.7 MPa * Engine at high (28 kg/cm? idling * Engine at high idling . Relieve travel circuit

5 YES

20-42 0

H-18

TROUBLESHOOTING

H-18

Steering

does not turn easily or lacks power Cause

Remedy

Defective control valve suction valve

2 Does condition 3

Is travel relief pressure normal?

- Interchange let? and right spoo1s.h

20-422 0

Defective travel motor check valve

Correct or replace

Defective travel motor safety valve

Replace

Defective main relief valve

Replace

!ZZ&-jH--

I * 34.0â&#x20AC;&#x2122;::05 MPa (355% kg/cm? * Engine at-high idling

YES

H-19, H-20

TROUBLESHOOTING

H-19

Travel does not move (one side only) Cause

YES

Remedy

Defective final drive

Correct or replace

Defective operation of suction valve of control valve

Replace

Defective operation of counterbalance valve or travel motor safety valve

Replace

Defective travel motor

Replace

1 Isany foreign material found in oil drained from final drive?

3 YES condition YES becomenormalwhen - left and right suction 2 valvesof controlvalve Does

are interchanged?

Is amount of oil drained from NO travel motor normal?

* Max. 30 e/min * Engine at high idling . Relieve travel circuit.

H-20

Travel speed does not switch

2 Is output

Is travel speed selector electrical circuit normal?

YES

pressure

YES of travel speed selector solenoid 1 valve normal?

* Disconnect connector V06. * Start engine. * Set travel speed switch to Hi * Use tester to check that voltage at chassis wiring harness end of connector V06 (I) is 27.5 - 29.5 V.

. Min. 2.7 MPa {28 kg/cm? * Set travel speed selector switch to Hi. NO

Defective operation of travel motor speed selector servo piston

Replace

Defective operation of travel speed selector solenoid valve

Correct or replace

Defective travel speed selector switch or relay, chassis wiring harness

Correct or

20-423 0

H-21

TROUBLESHOOTING

H-21

Does not swing

a) Does not swing

to either

left or right

Cause

YES

Remedy

Defective swing machinery

Repair or replace

Defective swing holding brake or swing motor

Repair or replace

Defective operation of holding brake cancel solenoid valve

Correct or replace

oil drained from

1swing machinery? NO

* Min. 2.7 MPa (28 kg/cm? * Swing lock switch OFF

b) Does not swing

in one direction

Cause

2 YES Does control YES valve spool for swing move 1 smoothly? Is PPC valve output pressure normal? - Min. 2.7 MPa (28 kg/cm? * Swing lock switch OFF

20-424 0

Defective swing motor safety valve or suction valve

Replace

Defective operation of control valve spool for swing

Correct or replace

Defective PPC valve

Remedy

H-22

TROUBLESHOOTING

H-22 Ir

Swing acceleration

If condition

is normal

when

is poor or swing speed is slow

work equipment

is operated

2 Both left and right

independently.

YES

Does LS shuttle valve move smoothly? NO

6 YES Does condrtron become normal

acceleration poor in both directions YES 4 Does

YES

One direction only (left or right)

* Min.

valve spool for swing move smoothly?

* It is also possible to interchange

with other compensation * See Note 1.

are

pressure of swing motor. . Relief pressure: 27.5 - 30.4 MPa 1280 - 310 kg/cm?

NO *See Note 1. valve. 8

NO LLI

2.7 MPa

(28 kg/cm21 * Engine at high idling * Swing lock switch OFF

Note 1: After inspection,

swing motor interchanged? ~ * Itii;o~W~Ie

compensation valve for swing normal, or does pressore compensation piston move smoothly?

control

output pressure I

20-426 0

YES when left and right safety valves of 5

~ Is pressure

do not forget to return the interchanged

valves to the original

position.

TROUBLESHOOTING

H-22

Cause

Defective swing motor assembly

Replace

Defective operation of LS shuttle valve (all LS shuttles)

Correct or replace

Defective operation of swing motor safety valve

Replace

Defective swing motor suction valve

Replace

Defective operation of pressure compensation valve or compensation piston

Correct or replace

Defective operation of control valve spool for swing

Correct or replace

Defective PPC valve

Replace

20-427 0

H-23

TROUBLESHOOTING

H-23

Excessive overrun when stopping

a) One direction

only

3 YES 2 Is problem reversed YES when left and right output hoses of PPC valves are Does control valve spool for

20-428 0

swing

Remedy motor

1 Defective swing PPC stow return valve

Defective

PPC valve

Correct or replace

Replace

Cause

YES

Is problem reversed when left and right swing PPC slow return valves are interchanged?

b) Both directions

Defective

swing

Repair or replace

Defective swing motor safety valve

Replace

Defective operation of control valve spool for swing

Correct or replace

H-24, H-25

TROUBLESHOOTING

H-24

Excessive shock when stopping

swing (one direction

only)

Remedy

Cause

1 YES Doesconditionbecome normalwhen left and right swingPPC slow return valvesareinterchanged?

Defective swing PPC slow return valve (check valve)

Correct or replace

Defective

Replace

PPC valve

H-25

Excessive abnormal

noise when stopping

YES

swing motor safety valve

1 Is output pressure of swing motor solenoid valve normal? -

swing

YES 2 Does condition become normal - when swing motor

machinery?

1 Lo

Defective swing motor suction valve

Replace

Defective swing machinery

Repair or replace

I1 i$fe;tiw

backPressure 1 F;;zc;

20-429 0

H-26

TROUBLESHOOTING

H-26 a)

Excessive hydraulic drift of swing

When

swing

lock is ON

Cause

1 YES Is output pressure of swing holding brake solenoid valve normal? * Min 2.7 MPa I28 kg/cm? -Turn swing lock switch OFF.

When

swing

Remedy

Defective operation of swing holding brake

Repair or replace

Defective operation of swing lock solenoid valve

Correct or replace

lock is OFF

Cause

BYES

Remedy

Defective swing motor safety valve

Replace

Defective swing motor suction valve

Correct or replace

safety valves are

One direction

only

problem side normal, or compensation piston

both directions (left and excessive

4 YES

Defective control valve spool

Correct or replace

Replace

Roth left and right ]EH-

10 elmin + Engine at high idling * Relieve swing circuit l

20-430 0

Defective pressure compensation valve, or defective operation of pressure compensation piston

Defective swing motor

Repair or replace

TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)

Monitor system electrical circuit diagram . .. . .. . . . . . . . .. . . . . . .. . . . .. . .. . . . . . . . .. . . . . . .. . . .. . . . . . . .. . .. . . . . . . .. . .. . . . . . .. .. . . . . . .. . .. 20-452 M- 1 When the starting switch is turned ON, no display is given .20-453 (lamps do not light up for 3 seconds). ............................................................................ M- 2 When starting switch is turned ON, lamps light up for 3 seconds, 20-453 but then do not go out ...................................................................................................... M- 3 When starting switch is turned ON, some lamps do not light up for 3 seconds ....... 20-454 20-454 a) No gauge lamps light up (caution lamps light up) .................................................. b) Swing lock, preheating lamps do not light up (all gauge lamps light up). .......... 20-454 20-454 c) Charge caution lamp does not light up ..................................................................... 20-454 ................................................ d) Engine oil pressure caution lamp does not light up M-

M-

MMM-

6 7 8

M- 9 M-10 $ t Z ul

M-l 1

M-12

M-13

M-14

M-15

M-16

When power is turned on (before engine is started), charge caution lamp 20-455 does not light up ................................................................................................................ When power is turned on (before engine is started), engine oil pressure 20-455 caution lamp does not light up ......................................................................................... .20-456 not light up.. During preheating, preheating pilot lamp does ...................................... .20-456 When switch is operated, swing lock lamp does not light up ..................................... Engine oil pressure caution lamp lights up when engine is running 20-457 (engine oil pressure is normal) ......................................................................................... .20-457 Charge caution lamp lights up when engine is running.. ............................................. 20-458 Abnormality in coolant temperature gauge. .................................................................... a) After engine is started, level stays at bottom (white range) and 20-458 does not move.. ............................................................................................................ b) After engine is started, level immediately rises .20-458 but indicator enters red range.. .................................... Engine is not overheating 20-458 gauge goes out ........................................................................ c) Coolant temperature 20-459 Abnormality in fuel gauge ................................................................................................. 20-459 a) All fuel gauge segments go out ................................................................................. b) Even when fuel level goes down, fuel gauge continues to show FULL.. ............. 20-459 .20-459 c) Even when tank is filled, fuel gauge does not show FULL .................................... 20-461 Defective operation of alarm buzzer ................................................................................. 20-461 a) Buzzer does not sound ................................................................................................ 20-461 .......................................................... b) Buzzer continues to sound and does not stop 20-462 Engine is running, but service meter does not move .................................................... 20-462 a) Charge caution lamp lights up ................................................................................... .20-462 b) Charge caution lamp does not light up.. .................................................................. 20-463 Night lighting does not light up.. ...................................................................................... 20-463 a) Gauge lighting does not light up ............................................................................... .... 20-463 b) Service meter lighting does not light up (service meter is working normally) 20-464 Wiper does not move, or does not stop moving ............................................................ .20-464 a) Wiper does not move when wiper switch is turned to ON.. .................................. .20-464 b) Wiper moves even when wiper switch is not turned to ON .................................. 20-465 Heater does not work ......................................................................................................... 20-465 a) Does not work at either Hi or Lo.. .............................................................................. 20-465 ........................................................................................... b) Does not work at Lo only. 20-465 c) Does not work at Hi only ............................................................................................

20-451 0

MONITOR

TROUBLESHOOTING

MONITOR

SYSTEM

Monitor panel 7------- â&#x20AC;&#x153;06MESIII

Horn (Hioh 390Hz

SYSTEM

ELECTRICAL

CIRCUIT

DIAGRAM

ELECTRICAL CIRCUIT DIAGRAM

Starting

Fuse FBI

switch

Swins

lock

switch

Alarm

tone)

buzzer

Horn (Low tone) 33OHz

Horn

switch

Wiper

Fuel

level

I IIIII

sensor

I I

switch

_-_-_El

Revolvins frame

Batter relay

lKP01012

20-452 0

M-l,

TROUBLESHOOTING

M-2

M-l When the starting switch is turned ON, no display is given (lamps doe not light up for 3 seconds) j, t

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

Remedy

YES 1

Defective monitor panel

Is voltaoe .I between PO1 (famale) (l)(2) and (3)(4) normal?

Defective contact or disconnection in wiring harness between PO1 (l)(2) and fuse 2, or between PO1 (3)(4) - HO3 (I 1) -chassis ground

*Turn starting switch ON. *20-30V

YES

Is fuse 2 mormal (not blown)?

Blown fuse 2

--L

M-l

electrical

Replace

Repair or replace Replace fuse after inspectins and repairing cause of blown fuse

circuit diagram

PO1 Monitor

Panel

(0401

Fuse

Revolving

EDP00263

M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out * * Ir

Before all the Always before Check

check that carrying out troubleshooting, related connectors are properly inserted. connect any disconnected connectors going on the next step. the fuses 2 before troubleshooting.

Defective monitor panel

Replace

20-453 0

TROUBLESHOOTING

M-3

M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds * * *

Before carrying gout troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. Check the fuse before troubleshooting.

No gauge

lamps light up (caution

inserted.

lamps light up)

Cause

Remedy

Defective monitor panel

Swing lock, preheating lamps do not light up (all gauge lamps light up) 1 YES

Is there disconnection in lamp which does not light up? * Check visually for blown bulb.

Charge

caution

- Check visually for blown bulb.

20-454 0

Replace

Defective monitor panel

Replace

Blown bulb of charge caution lamp

Replace

Blown bulb of engine oil presusure caution lamp

Replace

lamp does not light up

Engine oil pressure

blown bulb.

Blown bulb in lamp which does not light up

caution

lamp does not light up

M-4, M-5

TROUBLESHOOTING

M-4 When power is turned on (before engine is started), caution lamp does not light up *

charge

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next steo.

Remedy

Lamp bulb is blown

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (IO) - HO3 (7) MO2 (2) - E08 (I) - El2 (1) -alternator terminal L

Repair or replace

Defective D14

Replace

Defective alternator

Replace

1 Is voltage I between PO1 (IO) and PO1 (3), (4) normal? t * Turn starting switch ON. *o-5v

* Turn starting NO switch ON. * Disconnect PO1 and D14. *Max. 1OV

M-4 Related

electric

circuit diagram Battery

relay

El 2 (X2)

-A-

GND

TKP01013

M-5 When Dower is turned on (before engine is started), press&e caution lamp does not light-up *

* *

YES

engine oil

Remedy

Cause

Defective monitor panel

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (9) - HO3 (IO) E08 (male) (8)

Repair or replace

Defective engine oil pressure sensor

Replace

Is continuity YES between PO1

engine

oil pressure starting

Turn starting switch ON. .Max.O-5R

M-4 Related Monitor I

electric Panel

circuit diagram PO1 \

(04016) I

HO3

Engine Pressure

(SlGwhite) I

oil switch

TKP01014

20-455 0

TROUBLESHOOTING

M-6, M-7

M-6 During preheating, *

preheating

pilot lamp does not light up

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. If the lamps do not light up for 3 seconds when the starting switch is turned ON, go to M-2.

* Ir

Cause

1 YES

Defective monitor panel

Is voltage between PO1 (13) and (3)(4) normal? * Turn starting switch to HEAT. *20-30V

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (13) and starting switch Rl, or defective starting switch

M-6

Remedy

electrical

Repair or replace

circuit diagram ar

tins

switch

HO3 (S16) 1 6DP00266

M-7 When switch is operated, *

Before Always

carrying connect

out troubleshooting, any disconnected

swing lock lamp does not light up

check that all the related connectors are properly connectors before going on the next step.

2 YES Is there continuity between PO1 (female) (12) and chassis normal?

YES 1 Is there continuity _ between X05 (male) (1) and (2)? * Disconnect X05. * Turn swing lock switch ON.

M-7

Monitor Swing

*Disconnect PO1 *Turn swing lock switch ON.

electrical

lock

GND

Replace

Repair or replace

Defective swing lock switch

Replace

HO3 (S16) (-$

Defective monitor panel Defective contact or disconnection in wiring harness between PO1 (female) (12) - HO3 (9) HO2 (IO) -X05 (female) (I), or X05 (female) (2) HO2 (5) -chassis ground

circuit diagram

PO1 Panel (04016)

(iJ

HO2 (Sl6) J$ 3

X05 (M4)

LOCK7

P OFF /

IiT 1

20-456

inserted.

Swing switch

lock

BOP00267

TROUBLESHOOTING

M-8, M-9

M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil-pressure is normal) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. YES

1 Does engine oil pressure caution go off7

. Disconnect NO engine oil pressure switch terminal or E08. * Start engine.

Remedy

Cause

YES

Is circuit between PO1 (female) (9) and chassis ground insulated?

â&#x20AC;&#x2122;* Turn

starting NO switch OFF. Check continuity between PO1 (female) (9) and chassis ground. *Min. 1 MR

Defective engine oil pressure sensor switch

Replace

Defective monitor panel

Replace

Contact of chassis wiring harness with wiring harness between PO1 (female) (9) - HO3 (10) E08 (male) (8)

Repair or replace

M-8 Related

electric

circuit diagram Panel

Monitor

PO1

(04016)

HO3

Engine Pressure

(SlGwhite)

oil switch

TKP01014

M-9 Charge caution lamp lights up when engine is running It *

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. n â&#x20AC;&#x2DC;

Is voltage YES between PO1 (female) (IO) and (3)(4) normal? lp ~* Start engine. Is voltage between ~20-3ov alternator terminal _ L and chassis ground normal? Start engine. *20-30V l

Cause

YES

3 Is resistance between alternator

YES

- terminal L (wiring NO harness end), IllJrmal? * Disconnect alternator terminal L and POl. * Min. 1 MQ

Monitor Battery chareins

electric Panel

rate

(04016)

GND

Contact of chassis ground with wiring harness between PO1 (female) (10) - HO3 (7) - E08 (2) alternator terminal L

Repair or replace

Replace

Alternator HO3

(S16whi

te)

E08

(Xl)

GND

IReplace

Defective generation of electricity by alternator

circuit diagram

PO1

Defective monitor panel

Defective contact or disconnection in wiring harness between PO1 (female) (10) - HO3 (7) E08 (2) - alternator terminal L

M-9 Related

Remedy

TKPOlOlS

20-457 0

M-10

TROUBLESHOOTING

M-10

Abnormality

in coolant temperature

gauge

Before carrying out troubleshooting, check that all the related connectors are properly Sr Always connect any disconnected connectors before going on the next step. a)

After engine

is started,

level stays at bottom

(white

range)

and does not move Remedy

Cause

YES

&I 2

YES

ctor to PO7 (female).

* Turn starting switch ON. * Short circuit PO1 (6) and (3)(4).

Defective coolant temperature sensor

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (6) - HO3 (5) E08 (6) - PO7 (female) (I), or between PO7 (female) (2) -chassis ground

Repair or replace

3efective monitor panel

Replace

Defective monitor panel

Replace

Defective coolant temperature sensor

Replace

Defective contact between PO1 (female) (3)(4) - HO3 (I 1) -chassis ground

After inspection, repair

Defective coolant temperature sensor

Replace

Defective monitor panel

Replace

After engine is started, level immediately rises Engine is not overheating but indicator enters red range 2

YES

Is resistance YES between PO7 1 r (male) (1) and (2) normal?

Is voltage between PO1 (3)(4) and chassis ground normal? * Start engine. * Max. 0.1 V c)

inserted.

Coolant

* Disconnect P07. * Start engine. * Resistance: Min.4 kR

temperature

gauge

goes out

YES

1 Does lowest level light up? * Turn starting switch ON. - Remove PO7

- Disconnect POl. + Resistance: Min. 1 kR

M-10

Related Monitor

electrical Panel

Engine water temperature GND GND

YES

Is resistance between PO1 (female) (6) (3)(4) normal?

PO1

Iontact chassis ground Nith wiring harness letween PO1 (female) (6) - HO3 (5) - E08 (6) - PO7 female) (1). or leak

Repair or replace

circuit diagram (04016)

HO3

@ 3 4

(SlGwhi

te)

PO7

(X2)

Engine water temperature

sensor

TKP01016

20-458 a

M-II

TROUBLESHOOTING

M-II

Abnormality

in fuel gauge

* *

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

inserted.

all fuel gauge segments

Remedy

go out

Cause

YES 1 I

(female) to chassis ground. *Wait for approx. 1 minute.

qeplace

Defective contact or disconnection in wiring harness between PO1 (female) (7) - HO6 (6) -PO6 (female) (1)

qepair or replace

Defective monitor panel

Replace

Defective monitor panel

qeplace

Contact chassis ground with wiring harness between PO1 (female) (7) - HO6 (6) - PO6 (female) (1)

Repair or replace

Defective fuel level sensor

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (3)(4) - HO3 (11) -chassis ground

After inspection, repair

Defective monitor panel

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (3)(4) - HO3 (11) -chassis ground

After inspection, repair

Defective fuel level sensor

Replace

NO * Turn starting switch ON. * Short circuit PO1 (7) and (3). -Wait for approx. 1 minute.

Even when fuel level goes down, fuel gauge continues to show FULL 3

YES

YES 2 Is resistance of fuel level sensor normal?

YE 1

NO * Remove P06. *Turn starting switch ON. *Wait for approx.1 minute.

* Remove sensor . Move float by NO hand and measure resistance between PO6 (male) and chassis ground. . F position : Max. approx. 12 R E position : Approx. 85 - 110 Q

(3)(4) and chassis * Start engine. * Max. 0.1 V

Defective fuel level sensor (failure in disconnection mode)

Even when

tank is filled, fuel gauge

YES 1

Z YES

(male) -chassis ground * F position : Max. approx. 12 R

* Start enoine. * Max. 0.1 V

does not show

FULL

20-459 0

TROUBLESHOOTING

M-l 1

electrical

M-l 1

circuit diagram

PO 1

Revolving BDPOO270

20-460 0

TROUBLESHOOTING

M-12 Ir

M-12

Defective

operation

of alarm buzzer

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

Buzzer does not sound

YES 1

Does buzzer sound when PO1 (female) (15) and (3) are connected?

Is voltage between PO4 (2) NO and chassis ground normal? *Turn starting switch ON. *20-30V

Buzzer continues

YES k

Defective contact or disconnection in wiring harness between PO4 (female) (1) and PO1 (female) (15), or defective buzzer

Defective contact disconnection in harness between and PO4 (female)

Does buzzer stop when PO1 is removed?

M-12

Monitor

electrical

Repair or replace

Defective monitor panel

Replace

Contact chassis ground with wiring harness between PO4 (female) (1) and PO1 (female) (15)

Repair or replace

circuit diagram

PO1 (04016)

Panel

or wiring fuse 2 (2)

Replace

to sound and does not stop

1 YES

* Remove PO1 * Turn starting switch ON.

Remedy

1 Defective monitor panel

* Connect PO1 (female) (15) and (3). * Turn starting switch ON.

Cause

inserted.

PO4 (M2)

Buzzer

GND

Buzzer

GND

Dll Fuse

3 g-J

BOP00271

20-461 0

M-13

TROUBLESHOOTING

M-13 Engine is running, * *

but service meter does not move

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

a) Charge

caution

lamp lights up Cause

Defective monitor panel

Defective contact or disconnection in wiring harness between PO1 (10) - HO3 (7) - E08 (2) alternator terminal L

YES

IIs resistancebetween 1 7 * Start engine. l20-30V

Is voltage between alternator terminal Land chassis ground normal?

Contact of chassis ground with wiring harness between PO1 (female) (IO) - HO3 (7) E08 (2) -alternator terminal L

NC * Disconnect NO alternator terminal Land POl. *Min. 1 MD

* Start engine. *20-30V

Defective generation of electricity by alternator

b) Charge

caution

Remedy

Replace

Repair or replace

Replace

lamp does not light up Cause

Defective monitor panel

M-13 Related

inserted.

electrical

Remedy

Replace

circuit diagram Alternator

Monitor

chareine

panel

PO1 (04016)

HO3 (Slfiwhite) 7

rate

E08

(Xl)

@ 1 TKPO1015

20-462 0

$ t % Lu

M-14

TROUBLESHOOTING

M-14 *

Night lighting

does not light up

Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step.

Gauge

lighting

does not light up Remedy

Cause

1 Is voltage between PO1 (female) (16) and (3)(4) normal? ~ * Turn starting * Z?grZCl;witch ON. -2O-30V

YES 2 Is voltage between PO2 (3) No

inserted.

~:~u~~~:ma,7 Is voltage between PO2 (4) * Turn starting NO and chassis switch ON. ground normal? *Turn light switch ON. - Turn starting *20-3ov switch ON.

YES

Bulb of night lifhting (inside monitor panel) blown

Replace

Defective contact or disconnection in wiring harness between PO1 (female) (16) and PO2 (female) (3)

Repair or replace

Defective light switch

Replace

Disconnection in wiring harness between PO2 (female) (4) and fuse 4, or blown fuse

Repair or replace

.20-3ov

$ >

Service

meter

lighting

does not light up (service

meter

is working

normally)

Remedy

Cause

Defective monitor panel

M-14

electrical

circuit diagram

PO2 (KESl, 4)

PO1 Monitor

Panel

(()A()

16)

working

lamp

HO3 (S16)

-=.I

Lamp

switch

Lamp

Panel

lighting

Power

source

------I Fuse

1 II

4 I

BDP00272

20-463 0

M-15

TROUBLESHOOTING

M-15 Wiper does not move, or does not stop moving * * *

Before carrying out troubleshooting, check that all the related connectors are properly Always con-ne& any disconnected connectors before going on the next step. Check that fuse 3 is normal.

inserted.

Remedy

Cause a) Wiper

does not move when

wiper

switch

is turned

3 YES -

â&#x20AC;&#x2122; 1

2-p

Is voltage between Ml8 (male) (2) and chassis normal?

Is voltage between M31 (female) (1) and chassis normal?

to ON

YES

*Turn starting NO switch OFF. * Disconnect M31. * Connect T-adapter to M31 (male). * Turn starting switch ON. *Turn wiper switch ON. *20-30V

* Turn starting switch OFF. * Disconnect M18. * Connect NO T-adapter to Ml8 (male). -Turn starting switch ON. -Turn wiper switch ON. *20-30V

between terminals of wiper switch as * Turn starting switch OFF.

Defective wiper motor

Replace

Defective contact or disconnection in wiring harness between Ml8 (female) (2) - HO2 (15) Ml7 (1) - M31 (female) (I), or short circuit with ground

Repair or replace

Defective contact or disconnection in wiring harness between fuse 3 H03(8)-H02(6)-Ml8 (1) -wiper switch terminal B, or between wiper switch terminal L and Ml8 (male) (21, or short circuit with ground

Repair or replace

Defective wiper switch

Replace

b) Wiper

moves even when

wiper

2 YES -

Is continuity between terminals of wiper switch as shown in Fig. l?

Turn starting switch OFF.

* Turn starting switch ON. * Turn wiper switch OFF. * Max. 1 V

20-464

YES

Is voltage between M31 (female) (1) chassis normal? NO

switch

is not turned

to ON

Cause

Remedy

Defective wiper motor

Replace

Power short in wiring harness between Ml8 (female) (2) - HO2 (15) Ml7 (I) - M31 (female) (1)

Repair or replace

Defective wiper switch

Replace

TROUBLESHOOTING

M-15

Fig. 1

Wiper

switch

M 19 (M2)

TKP01017

M-15 Related

electrical

circuit diagram

Window

washer ion)

(Opt

Wiper

switch

Wiper

Fuse

HO3

(Sl

motor

TKP01018

20-465 0

M-16

TROUBLESHOOTING

M-16 * * a)

Heater does not work

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Does not work

at either

lij Ye,â&#x20AC;&#x2122; Go to troubleshooting heater

Isthere

continuity between MO6 (4)

YES

heater switch between terminals of MO6 (male) as shown in Table l? * Turn starting switch OFF. * Disconnect M06.

Table

Remedy

Cause

-Turn starting switch OFF.

Defective contact or disconnection in wiring harness between MO6 (female) (4) and chassis ground

Repair or replace

Defective heater switch

Replace

1 Cause

Does not work

YES

Go to troubleshooting heater

at Hi only2

Heater

electrical

switch

Repair or replace

Defective heater switch

Replace

\ Heater

Heater

Defective contact or disconnection in wiring harness between MO6 (female) (2) and Ml2 (female) (3)

Repair or replace

Defective heater switch

Replace

circuit diagram

MO6 (KES14)

YES

* Heater switch at Hi. * Disconnect M06. -Turn starting NO switch OFF. . Heater switch at Hi.

Defective contact or disconnection in wiring harness between MO6 (female) (3) and Ml2 (female) (2)

Go to troubleshooting heater

M-15

Remedy

at Lo only

Is there continuity YES between Ml2 (female) (2) and 1 chassis ground? Is there continuity P * Disconnect M12. NO between MO6 *Turn starting (male) (3) and (4)? switch OFF. * Heater switch at Lo. * Disconnect M06. NO * Turn starting switch OFF. * Heater switch at Lo.

Ml2

HO5 (L2)

(KES13)

Heater

Fuse

BKP02453

20-466 0

30 DISASSEMBLY

METHOD OF USING MANUAL .................. .30- 3 PRECAUTIONS WHEN CARRYING OUT OPERATION ............................................ 30- 4 SPECIAL TOOL LIST.. .................................. 30- 6 SKETCHES OF SPECIAL TOOLS ............... 30-10 STARTING MOTOR ASSEMBLY Removal and Installation .................... 30-I 1 ALTERNATOR ASSEMBLY Removal and Installation .................... 30-12 AIR CONDITIONER COMPRESSOR ASSEMBLY Removal and Installation .................... 30-13 CONDENSER ASSEMBLY Removal and Installation .................... 30-â&#x20AC;&#x2DC;l4 ENGINE OIL COOLER CORE ASSEMBLY Removal and Installation .................... 30-15 FUEL INJECTION PUMP ASSEMBLY Removal ................................................. 30-I 6 Installation ............................................ 30-19 WATER PUMP ASSEMBLY Removal and Installation .................... 30-21 NOZZLE HOLDER ASSEMBLY Removal and Installation .................... 30-23 TURBOCHARGER ASSEMBLY Removal and Installation .................... 30-24 THERMOSTAT ASSEMBLY Removal and Installation .................... 30-25 CYLINDER HEAD ASSEMBLY Removal ................................................. 30-27 Installation ............................................ 30-31 RADIATOR HYDRAULIC OIL COOLER ASSEMBLY Removal ................................................. 30-34 Installation ............................................ 30-36 ENGINE MAIN PUMP ASSEMBLY Removal ................................................. 30-37 Installation ............................................ 30-41 DAMPER ASSEMBLY Removal and Installation .................... 30-42 FUEL TANK ASSEMBLY Removal and Installation .................... 30-43 l

AND ASSEMBLY

CENTER SWIVEL JOINT ASSEMBLY Removal and Installation .................... Disassembly and Assembly.. .............. FINAL DRIVE ASSEMBLY Removal and Installation .................... Disassembly ........................................... Assembly ............................................... SPROCKET Removal and Installation ..................... SWING MOTOR, SWING MACHINERY ASSEMBLY ..................... Removal and Installation Disassembly .......................................... Assembly ................................................ REVOLVING FRAME ASSEMBLY Removal .................................................. Installation .............................................. SWING CIRCLE ASSEMBLY Removal .................................................. Installation .............................................. IDLER RECOIL SPRING ASSEMBLY ..................... Removal and Installation RECOIL SPRING ASSEMBLY Disassembly .......................................... Assembly ................................................ IDLER ASSEMBLY Disassembly .......................................... Assembly ................................................ TRACK ROLLER ASSEMBLY ..................... Removal and Installation Disassembly ........................................... Assembly ................................................ CARRIER ROLLER ASSEMBLY Removal and Installation ...................... Disassembly .......................................... Assembly ............................................... TRACK SHOE ASSEMBLY Removal and Installation .....................

30-44 30-46 30-47 30-48 .30-51 .30-56

.30-57 .30-59 30-63 30-68 30-69 30-70 30-71

.30-72 .30-73 30-74 .30-75 30-76 .30-78 30-79 30-81 30-83 .30-84 .30-86 .30-88

30-l 0

HYDRAULIC TANK ASSEMBLY Removal ................................................ 30- 89 Installation ............................................ 30- 90 MAIN PUMP ASSEMBLY Removal ................................................ 30- 91 Installation ............................................ 30- 93 MAIN PUMP INPUT SHAFT OIL SEAL Removal and Installation ................... .30- 94 CONTROL VALVE ASSEMBLY Removal ................................................ 30- 95 Installation ............................................ 30- 97 Disassembly ........................................ 30- 98 Assembly .............................................. 30-103 MAIN RELIEF VALVE ASSEMBLY Disassembly and Assembly.. ............. .30-109 PC VALVE ASSEMBLY Removal and Installation .................. ..30- 1 IO LS VALVE ASSEMBLY .................. ..30- 1 12 Removal and Installation PC-EPC VALVE ASSEMBLY .................. ..30- 1 13 Removal and Installation SOLENOID VALVE ASSEMBLY .................. ..30-114 Removal and Installation WORK EQUIPMENT SWING PPC VALVE ASSEMBLY ................... .30-115 Removal and Installation Disassembly ....................................... ..30-116 Assembly .............................................. 30-I 17 TRAVEL PPC VALVE ASSEMBLY Removal and Installation .................. ..30- 1 18 Disassembly and Assembly.. ............. .30-l 19 BOOM LOCK VALVE ASSEMBLY ................... .30-121 Removal and Installation l

30-2 0

BOOM CYLINDER ASSEMBLY Removal . . .. . . . .. . . . . . . . . . .. . . . . . .. . . . .. . . . . . . . . . .. . . . . . 30-I 22 Installation . . . . . . . .. . . .. . . . . . .. . . . . . . . . . . .. . . .. . . . . . . . . 30-123 ARM CYLINDER ASSEMBLY Removal . . .. . . .. . . . . . . . . .. .. . . . . . .. . . .. . . . . . . . .. .. . . . . . . 30-I 24 Installation . . . . . . . .. . . . . . . . . . .. . . . . . . . .. . .. . . .. . . . . . . .. 30-125 BUCKET CYLINDER ASSEMBLY Removal . . .. . .. . . . . . . . . . .. . . . . . . . .. . . .. . . . . . .. .. . . . . . . . . 30-I 26 Installation . . . . .. . .. . . . . . .. . .. . . . . . . . .. . . .. . . . . . . . . . . .. 30-I 27 HYDRAULIC CYLINDER ASSEMBLY Disassembly . . .. . . .. . . . . . . .. .. . . . . . . .. . . . .. . . . . . . .. 30-128 Assembly .. . . . . . . . . . . . .. . .. . . . . . . .. . . .. . . .. . . . .. . . . . . . . 30-131 WORK EQUIPMENT ASSEMBLY Removal . . . . . . . .. . . .. . . . . . . . .. . .. . . . . . . .. . .. . . . . . . . . .. .. 30-135 Installation . . . . . . . . . . . .. . . . .. . . . . . . .. . . . . . . .. . . .. . . . . . . 30-136 BUCKET ASSEMBLY Removal . . .. . . . .. . .. . . . . . . . .. . . . . . . . . . . .. . .. . . . . . . . . .. .. 30-137 Installation .. . . . . . . .. . . .. . . . . . . . . .. .. . . . . . . .. . . . .. . .. . . 30-138 ARM ASSEMBLY Removal . . .. . . . .. . .. . . . . . . . .. . . . . . . . . . . .. . .. . . . . . . . .. . .. 30-139 Installation . . . . . . . .. . . .. . . . .. . . .. .. .. . . . . . . .. . .. . . . . . . . 30-140 BUCKET ARM ASSEMBLY Removal . . .. .. . . . . . . . . . . .. . . . . . . .. . . . .. . . . . . . . .. . .. . . . . . 30-I 41 Installation . . . . . . .. . . . . .. .. . .. . . . . . . .. . . .. . . . .. . . .. .. .. 30-I 42 BOOM ASSEMBLY Removal . . . . . . . . . . . .. . . . . . . . .. . . .. . . . . . .. . .. .. .. . . . . . . . . 30-I 43 Installation . .. . . . . . . . . . .. . . .. . . . . . . . .. . . .. . . . . . . .. . .. . . 30-I 44 OPERATORâ&#x20AC;&#x2122;S CAB ASSEMBLY Removal and Installation . . . . . . . . .. . .. . . . . ...30-145 COUNTERWEIGHT ASSEMBLY Removal and Installation . . . . . . . .. . .. . . . . . . .. 30-I 46 MONITOR ASSEMBLY Removal and Installation . . . .. . .. . . . . . .. . . ...30-147 l

DISASSEMBLY

AND ASSEMBLY

METHOD

OF USING MANUAL

METHOD

OF USING

MANUAL

When removing or installing unit assemblies @ When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. @ Any special techniques applying only to the installation procedure are marked m, and the same mark is placed after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 0 ASSEMBLY.. .......... Title of operation Precautions related to safety when carrying out &I ...................................................................... the operation 1. XXXX(1) ..................................................... Stepinoperation * ................................................................... Technique or important point to remember when removing XXXX (1). m Indicates that a technique is listed for use 2. a a a a (2): ............................................... during installation 3. 0 0 0 0 assembly (3) ............................................................

Quantity

of oil or water

drained

INSTALLATION OF 0 0 0 0 ASSEMBLY .. ..Titl e of operation Carry out installation in the reverse order to removal. Technique used during installation .............................................................. m * ................................................................... Technique or important point to remember when installing n a n a (2). . Adding water, oil ................................. Step in operation * ............................................................ Point to remember when adding water or oil l

%# .........................................................

Quantity

when filling with oil and water

General precautions when carrying out installation or removal (disassembly are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, these precautions when carrying out the operation.

or assembly) of units so be sure to follow

Listing of special tools @ For details of the description, part number, and quantity of any tools (Al, etc.) that appear the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-3 0

DISASSEMBLY

PRECAUTIONS

AND ASSEMBLY

PRECAUTIONS

WHEN CARRYING

WHEN

CARRYING

OUT

OPERATION

OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work . If the coolant contains antifreeze, dispose of it correctly. . After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. . When draining oil, prepare a container of adequate size to catch the oil. . Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. . To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. . Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. . Check the number and thickness of the shims, and keep in a safe place. . When raising components, be sure to use lifting equipment of ample strength. . When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. . Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. * Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts Nominal number

Plug (nut end)

02 03 04 05 06 10 12

07376-50210 07376-50315 07376-50422 07376-50522 07376-50628 07376-51034 07376-51234

Sleeve nut (elbow end) 07221-20210 07221-20315 07221-20422 07221-20522 07221-20628 07221-21034 07221-21234

(Nut), (Nut), (Nut), (Nut), (Nut), (Nut), (Nut),

Use the two items below as a set

07222-00210 07222-00312 07222-00414 07222-00515 07222-00616 07222-01018 07222-01219

(Plug) (Plug) (Plug) (Plug) (Plug) (Plug) (Plug)

Split flange type hoses and tubes

Nominal number

04 05 3)

I I

Flange (hose end)

Sleeve

07379-00400 07379-00500

If the part is not under hydraulic

Nominal number

Part Number

08 IO 12

07049-008â&#x20AC;&#x2122;. . 07049-01012 07049-01215

16 18

07049-01620 07049-01822

pressure,

., 10 12

head (tube end)

07378-I 0400 07378-I 0500 the following

I I

Split flange 0737 I-30400 07371-30500

corks can be used.

_. 8. 1

t 16 113.51 20

DEW00401

30-4 0

DISASSEMBLY

2. . . . . .

AND ASSEMBLY

PRECAUTIONS

WHEN

CARRYING

OUT OPERATION

Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-PI. After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. j, When using the machine for the first time after repair or long storage, follow the same procedure.

3. .

Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. Ir For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.

. .

30-5 0

DISASSEMBLY

SPECIAL TOOL LIST

AND ASSEMBLY

SPECIAL TOOL LIST Tools with part number 790T-0000000cannot be supplied (they are items to be locally manufactured). W: Cannot be substituted, should always be installed (used) Necessity: 0: Extremely useful if available, can be substituted with commercially available part New/remodel:N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).

Symbol

Component

Part No.

Part Name

ketch

Nature of work, remarks

Removal, installation of cylinder assembly Removal, installation of fuel injection pump assembly

790-331-1110

Wrench

Tightening of cylinder head bolt

795-799-l

Gear

Barring

795-799-l 390

Puller

Removal gear

of drive

Removal, installation of nozzle holder assembly

795-799-l

Puller

Removal holder

of nozzle

Engine, main pump assembly Radiator, hydraulic cooler assembly Control pump assembly Main pump assem-

130

170

796-460-1210

Oil stopper

790-101-2501

Push-puller

'790-101-2510

.Block

'790-101-2520

â&#x20AC;&#x2DC;Screw

,791-l 12-1180

.Nut

bly Removal, installation of servo valve assembly

Disassembly of center swivel assembly

joint

.Washer

D ,790-101-2630

.Leg .Plate

Disassembly, assembly of swing machinen/

30-6 0

,790-101-2560

.Nut

,790-101-2650

.Adapter

796-426-l

Push tool

120

Press fitting bearing

DISASSEMBLY

SPECIAL TOOL LIST

AND ASSEMBLY

Component

rtc$el

Part Name

Part No.

Symbol

796-427-1200

Wrench

Nature of work, remarks

Sketch

Removal, installation of round nut

796T-427-12201

Push tool I

ImIiI I

lOI

, I

2 Disassembly, assembly of final drive assembly

790-101-2510

Block

792-104-3940

Bolt

05180-11613 01643-31645

Nut I

Washer

n n

2 2

01643-32060

Washer

790-105-2100

Jack

790-101-I

102

Pump

790-331-I

110

Wrench

Press fitting of bearing inner race

Tightening of final drive cover mount-

ing bolt 4

791-545-1510

Installer

Compressor (A)

791-685-8005

Compressor (B)

791-635-3160

Extension

791-600-2001

Installation of floating seal

Removal, installation of recoil spring assembly

Removal, press fitting of master

Installation of dust seal on recoil

Removal, installation of track shoe

Removal, installation of road liner (rubber pad type)

Assembly assembly

Disassembly, bly of track assembly

of idler

Removal, press fitting of master pin

T 1

l-l

17 mm

Commercially availableHexagonal socket

790-434-1630

Installer

790-101-1000

Oil pump

Charging with oil, checking for air leakage

790-434-1640

Installer

Installation of floating seal

791-601-1000

Oil pump

Charging with oil, checking for air leakage

790-331-I 110

Wrench

Tightening of track roller assembly mounting bolt

assemroller

-L 3

Installation of floatina seal

30-7 0

DISASSEMBLY

Symbol

Component

Disassembly, bly of carrier

assemroller

Part

No.

Part Name

leces

-sity n

of track

New/ remode

I-

;ketct

Nature of work, remarks Removal, installation of nut

797-101-I

121

Wrench

796-430-I

110

Push

791-434-1650

Installer

Installation of floating seal

791-601-1000

Oil pump

Charging with oil, checking for air leakage

Wrench

Tightening roller bolt

791-463-1141

Push tool

790-201-2740

Spacer

Cylinder repair stand

Replacement of pumr shaft oil seal

lâ&#x20AC;&#x2122;ty

TOOL LIST

790-331-I

110

02-4300

796-720-I 670

Press fitting bearing

of track

Pumo 790-I

A--

tool

assembly

Installation roller

SPECIAL

AND ASSEMBLY

Removal, of oiston

Wrenchassembly

installation assemblv

Replacement pin for wrench assemblv

Expander

Expansion ring

Rubber band

of piston

Clamp

Disassembly, assembly of hydraulic cylinder

796-720-I 660

Rubber band

Clamp Push tool kit

.790-201-1831

.Push tool

~790-101-5021

.Grip

~01010-50816

.Bolt

790-201-1702

Push tool kit

~790-201-1930

.Push tool

.790-101-5021

.Grip

.Bolt

30-8 0

790-201-1702

Push tool kit

~790-201-1940

.Push tool

~790-101-5021

.Grip

~01010-50816

.Bolt

Boom

z F a

DISASSEMBLY

AND ASSEMBLY

SPECIAL TOOL LIST

Component

Part No.

Symbol

Part Name

Disassembly, assembly of hydraulic cylinder

Removal, installation of work equipment assembly Boom assembly

Neces sity

ZYty 1

790-201-1500

Push tool

.790-201-1640

.Push

~790-101-5021

.Grip

.OlOlO-50816

.Bolt

790-201-1980

Plate

790-101-5021

Grip

01010-50816

Bolt

kit

fi$el

Sketch

Nature of work, remarks Bucket

tool

,790-201-1990

Plate

~790-101-5021

Grip

01010-50816

Bolt

796-900-1200

Remover

790-I 01-4000

Puller (490kN (50ton) long) n

790-101-I 102

Pump(294kN(3MonI)

Boom

Arm

Removal foot pin

of boom

30-9 0

SKETCHES OF SPECIAL TOOLS

DISASSEMBLY AND ASSEMBLY

SKETCHES OF SPECIAL TOOLS Note:

Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

G2 Push tool

CKP04076

30-10 0

1 796T-427-1220

DISASSEMBLY

AND ASSEMBLY

STARTING

MOTOR

REMOVAL OF STARTING MOTOR ASSEMBLY a

Disconnect the cable from the negative minal of the battery.

Open engine

Disconnect

Remove

2 bolts (2).

Remove

starting

(-1 ter-

hood.

3 wires

(I).

motor

m assembly

(3).

CLPO3201

INSTALLATION OF STARTING MOTOR ASSEMBLY .

Carry out installation removal.

Starting

in the

reverse

order

mounting bolt : 43 = 6 Nm I4.38 f 0.61 kgm1

motor

Both faces of starting motor gasket : Gasket sealant (LG-I)

30-l 1 0

DISASSEMBLY

ALTERNATOR

AND ASSEMBLY

REMOVAL OF ALTERNATOR ASSEMBLY g

Disconnect the cable from the negative minal of the battery.

1. Open engine

(-) ter-

hood.

Remove fan guard (I) and right fan guard mounting bracket (2).

Disconnect wiring move X-connector

(3) and connector (5) from bracket.

(41, and re-

CLPO3204

Using wrench 0, belt (7). a Be extremely caught when

raise tensioner

(6) and remove

careful not to get your fingers removing the belt.

Remove alternator mounting bolts (8) and (91, then remove alternator assembly (IO).

INSTALLATION OF ALTERNATOR ASSEMBLY l

Carry out removal.

30-12 0

installation

in the

reverse

order

CLPO3205

DISASSEMBLY

AND ASSEMBLY

AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY A

Loosen the flange mounting bolts of the air . conditioner hose, and release the refrigerant (R134a) slowly.

Open engine

Remove

Disconnect

connector

Disconnect

hoses (3).

Loosen adjustment

hood.

fan guard (I).

(2).

bolt (4) and remove

belt (5). m

6â&#x20AC;&#x2122;

CLPO3802

Remove 4 mounting bolts (6), then remove compressor assembly (7).

INSTALLATION CONDITIONER ASSEMBLY .

Carry out removal.

installation

OF AIR COMPRESSOR in the

reverse

order

a Ir

When installing the hoses, check that the Orings are not damaged or deteriorated, then connect the hoses.

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting air conditioner belt tension. Fill with refrigerant (R-134a).

30-13 0

DISASSEMBLY

CONDENSER

AND ASSEMBLY

REMOVAL OF CONDENSER ASSEMBLY 1. Open engine hood (I) and side cover (2) at left side of chassis. 2.

Remove

cover (3) on top of condenser.

Disconnect air conditioner hose (41, then disconnect hose (5) at receiver drier end and hose m (6) at condenser end. * Loosen hoses (41, (5) and (6) slightly and release the refrigerant (R134a) completely before disconnecting hoses. * Fit blind plugs into the condenser port and hoses to prevent the entry of moisture, dust or dirt.

Remove

receiver drier (7) together

Remove

condenser

assembly

with bracket.

(8).

INSTALLATION OF CONDENSER ASSEMBLY l

Carry out installation removal.

in the

reverse

order

Check that the O-rings are not damaged deteriorated, then connect the hoses.

Fill with refrigerant

30-14 0

Wl34a).

DISASSEMBLY

AND ASSEMBLY

ENGINE

OIL COOLER CORE

REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY 1. Open engine

hood.

Remove

adiabatic

Remove turbocharger oil filter (3).

Disconnect connector (4) with alternator wiring, and remove connector bracket (5) of intermediate clamp.

Remove

Remove cooler assembly (6).

cover (I). lubrication

oil cooler cover assembly core

(7) from

hose (2) and

(6).

CLPO3213

oil cooler

cover

INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY .

Carry out installation removal.

m *

Ir m

in the

reverse

order

Sleeve nut (2) of turbocharger lubrication hose : 24 2 4 Nm I2.45 z 0.41 kgm} Oil filter (3) : 13 + 2 Nm il.33 2 0.20 kgm} Or bring the seal surface into contact, then tighten 314 turns.

CLPO3228

Tighten in the order (I) - (14) as shown in the diagram. Mounting bolt (6) of oil cooler cover assembly : 24 t 4 Nm I2.45 = 0.41 kgm}

CLPO3215

30-l 5 0

DISASSEMBLY

FUEL INJECTION

AND ASSEMBLY

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY A

Disconnect the cable from the negative minal of the battery.

Open engine

Remove cover (I) on top of condenser, remove stay (2) at counterweight.

Remove

Disconnect

ter-

hood. then

fan guard (3) and left bracket (4). water temperature

sensor connector

(5). 5.

Remove bracket (6) for compressor hose clamp. * Tighten together with the fuel inlet hose clamp.

Remove lock clips (8) (2 places) and lock bracket (7) of dipstick guide.

Disconnect governor motor rod (9) at governor m end. * Rotate the shaft of the governor motor and do not stop it suddenly. * Always disconnect the guide motor connector before disconnecting the rod.

Disconnect

6 delivery

Disconnect

fuel supply hose (I I) and return hose

tubes (IO).

(12). * Fuel will flow out when the hoses are disconnected, so insert wooden plugs in the hoses to prevent the fuel from leaking.

30-16 0

PUMP

DISASSEMBLY

FUEL INJECTION

AND ASSEMBLY

PUMP

10. Disconnect tube clamp (15) (4 places) and tubes (13) and (14) between fuel filter and fuel injection pump. 11. Remove

lubrication

tube (16).

12. Remove mounting bolt (17) of support at bottom of fuel injection pump.

bracket

13. Using tool A2, rotate engine in normal direction, and push No. 1 cylinder compression top dead center positioning pin (18) into gear. Push the pin light& against the gear and rotate the engine slowly. After determining the TDC position, check if the meshing of the timing pin has come out.

g t z Lu 14. Remove 2 fan belts (191, then move fan tension pulley (20) and adjustment bar (21) towards fan m shaft. * Loosen mounting bolt (23) of adjustment bolt bottom bracket (221, then loosen adjustment bolt (24). 15. Turn cap (25) and remove.

CLPO3226

16. Remove *

washer

(27) and nut (26) inside case. m

Be extremely careful not to drop the nut and washer inside the case when removing.

DISASSEMBLY

AND ASSEMBLY

FUEL INJECTION

PUMP

17. Using tool A3, pull drive gear of fuel injection pump and loosen from shaft.

CLPO3229

18. Remove 4 nuts (28), then remove pump assembly (29).

30-18 0

fuel injection m

DISASSEMBLY

FUEL INJECTION PUMP

AND ASSEMBLY

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

Adjust the governor lever. For details, see TESTING AND ADJUSTING, Adjusting governor motor lever stroke.

Delivery

tube sleeve nut (IO) : 24 f 4 Nm I2.45 f 0.41 kgm}

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting fan belt tension.

Drive nut (26) : 95 + IO Nm 19.7 + 1.01 kgm}

Install the fuel injection pump assembly as follows. Check that the No. 1 cylinder is at compression top dead center. Ir For details, see Removal Step 13. Remove

plug (30), then

remove

timing

(31).

Reverse the position of timing pin (311, align the timing pin groove with pointer (32) inside the pump, then temporarily tighten plug (30). * If the tooth of aligned with the the shaft of the align the pointer

pointer (32) cannot be timing pin hole, rotate fuel injection pump to tooth.

CLP03233

DISASSEMBLY

FUEL INJECTION

AND ASSEMBLY

Align pump camshaft with pump drive gear and install fuel injection pump assembly (29), then tighten nut (28). m Nut (28) : 43 f 6 Nm 14.38 + 0.61 kgm}

Assemble washer (27), and tighten nut (26) temporarily. Ir Be extremely careful not to drop the nut and washer inside the case when installing. m Temporary tightening of nut (26) : 12.5 2 2.5 Nm Il.27 f 0.25 kgm1 Ir This is not the final torque value. * To prevent damage to the timing pin, be careful not to tighten the nut to more than the above tightening torque.

Remove

meshing

of engine

timing

pin (18).

Remove plug (30), reverse position of timing pin (31), then assemble and install plug to fuel injection pump. w Plug : 14.7 Nm Il.5 kgm1

Tighten nut (26) of fuel iniection pump fully. e Nut (26) : 95 + IO Nm (9.7 I 1.01 kgm}

For remaining installation, verse order to removal.

carry

Bleeding air * Bleed the air from fuel system.

30-20 0

PUMP

out in re-

CLP03236

CLP03235

DISASSEMBLY

WATER PUMP

AND ASSEMBLY

REMOVAL OF WATER PUMP ASSEMBLY 1. Drain coolant.

Open engine

Remove fan guard (I), then remove left and right side covers (2) and (3) of fan guard mount.

hood.

(41, then reUsing wrench 0, raise tensioner move belt (5). Be extremely careful not to get your fingers a caught when removing the belt.

bar (7) of fan tension Loosen adjustment (61, then loosen fan belt (8).

Q/--i

pulley m

CLPO3240

Loosen mounting bolt (1 I) of fan pulley (IO) and fan shaft (9) 2 - 3 mm, then move towards radiator.

30-2 1 0

DISASSEMBLY

Remove

WATER PUMP

AND ASSEMBLY

water

pump assembly

(12).

INSTALLATION OF WATER PUMP ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting of fan belt tension.

Refilling with water Sr Add water through

the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

30-22 0

DISASSEMBLY

AND ASSEMBLY

NOZZLE

HOLDER

REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.

Open engine

Disconnect delivery sembly end.

Remove

Remove nozzle holder assembly (3). a Ir If it is difficult to remove the nozzle holder assembly, use tool A4 to remove it. Ir Be careful not to let dirt or dust get into the nozzle holder assembly mount.

hood. tube (I) at nozzle holder asm

spill tube (2).

INSTALLATION OF NOZZLE HOLDER ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

Delivery

Joint bolt : 8 = 2 Nm iO.81 2 0.20 kgm}

tube sleeve nut : 30 2 5 Nm I3.06 z 0.51 kgm1

Nozzle holder assembly . 60 2 5 Nm (6112 t 0.51 kgm1 & Nozzle holder assembly thread portion : Seizure prevention compound (Molycoat 1000) * When assembling the nozzle holder, clean the nozzle holder mount, and check that there is no dirt or dust inside the sleeve before assembling.

30-23 0

DISASSEMBLY

TURBOCHARGER

AND ASSEMBLY

REMOVAL OF TURBOCHARGER

ASSEMBLY

1. Open engine hood, and remove (I) of turbocharger assembly.

adiabatic

cover

Remove air cleaner intake connector (2) and air supply tube (3) between turbocharger and a aftercooler.

Remove

Remove lubrication inlet tube (5) and lubrication return tube (6), then remove turbocharger m assembly (7). * After removing the lubrication tube, close all the ports to prevent the entry of mud or dirt.

connector

clamp

(4). CLPO3245

CLP03246

INSTALLATION OF TURBOCHARGER ASSEMBLY .

Carry out removal.

m w w

30-24 0

installation

in the

reverse

Intake tube band clip : 10 f 2 Nm Il.02

order

+ 0.21 kgm}

inlet tube sleeve nut : 35 = 5 Nm 13.6 + 0.5 Lubrication return tube mounting 24 + 4 Nm 12.45 f 0.41 Turbocharger assembly mounting 10 2 2 Nm il.02 + 0.20 Lubrication

kgm) bolt : kgm) nut : kgm}

THERMOSTAT

AND ASSEMBLY

DISASSEMBLY

REMOVAL OF THERMOSTAT ASSEMBLY 1. Drain coolant. (I)

Open engine hood, and remove fan guard and right side guard mounting bracket (2).

(31, then reUsing wrench 0, raise tensioner move fan belt (4). Be extremely careful not to get your fingers a caught when removing the belt.

Remove alternator assembly top mounting bolt (5) from bracket, then move alternator assembly (6) towards partition plate end. Ir Loosen the mounting bolts at the bottom of the alternator assembly.

CLPO3250

Disconnect hose (8).

Remove

radiator

alternator

inlet hose (7) and aeration

bracket (9).

DISASSEMBLY

Remove

THERMOSTAT

AND ASSEMBLY

housing

thermostat

(IO).

CLPO3252

Remove

(11).

thermostat

I OF ASSEMBLY

INSTALLATION THERMOSTAT .

Carry out installation removal.

Thermostat

in the

reverse

order

housing mounting bolt : 24 + 4 Nm 12.45 2 0.41 kgm}

Refilling with water * Add water through

the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

30-26 0

CLP03253

DISASSEMBLY

AND ASSEMBLY

CYLINDER

HEAD

REMOVAL OF CYLINDER HEAD ASSEMBLY a

Disconnect the cable from the negative minal of the battery.

(-) ter-

1. Drain coolant. 2.

Open engine

Remove fan guard (I), then remove left and right side covers (2) and (3) of fan guard mount.

Remove turbocharger assembly. For details, see REMOVAL OF TURBOCHARGER ASSEMBLY.

Remove

Remove adiabatic plate mounting bracket (5) for turbocharger. * In order to remove mounting bolt (61, do as follows. 1) Remove muffler drain pipe. (main pump end) 2) Loosen muffler mounting U-bolt. m 3) Rotate connector (7) at the muffler end up slightly to a position where it is possible to remove the mounting bolts.

Remove

Disconnect electrical intake air heater wiring (91, water temperature sensor connector (IO), and compressor connector (I I).

Remove mounting bracket (12) of intermediate clamp for wiring and air conditioner hose at engine end.

hood.

exhaust

manifold

cover (4).

(8).

IO. Remove air conditioner belt (131, then remove compressor assembly (14) together with bracket, a and move towards counterweight. 11. Remove mounting dipstick guide.

plate (16) and clamp

(15) of

CLP03.258

30-27 0

DISASSEMBLY

CYLINDER

AND ASSEMBLY

12. Disconnect radiator inlet hose (17), heater (181, and aeration hose (19).

hose

13. Using wrench 0, raise tensioner (20), then remove belt (21). g Be extremely careful not to get your fingers caught when removing the belt. * Before removing the belt, loosen 4 mounting bolts of air conditioner pulley (22). 14. Remove

air conditioner

pulleys (22).

15. Remove alternator assembly top mounting bolt (23) from bracket, then move alternator assembly (24) towards partition plate. Sr Loosen the mounting bolts at the bottom of the alternator assembly.

16. Remove alternator bracket (25), pulley hub (26) and tensioner (20) together with bracket (27). m

30-28 0

HEAD

DISASSEMBLY

AND ASSEMBLY

17. Remove

intake connector

18. Remove

6 delivery

CYLINDER HEAD

(28).

tubes (29).

tubes (30) and (31) between fuel filter and fuel injection pump, then disconnect fuel return hose (32) at fuel filter end. m

19. Disconnect

20. Remove

fuel filter

assembly

(33) together

with

bracket.

21. Remove fuel

intermediate clamps (34) (3 places) of return hose (321, then remove spill tube

(35). 22. Remove

nozzle holder assembly

23. Remove

head cover (37).

(36).

30-29

DISASSEMBLY

AND ASSEMBLY

24. Remove

rocker arm assembly

push rod (39).

Remove

CYLINDER

(38).

26. Remove mounting bolts of cylinder der shown in diagram.

head in orm

I 27. Lift off cylinder

el kg

28. Remove

Cylinder cylinder

head assembly head assembly:

HEAD

CEW00394

(40). 52 kg

head gasket (41).

CLPO3269

30-30 0

DISASSEMBLY

CYLINDER

AND ASSEMBLY

HEAD

OF CYLINDER INSTALLATION HEAD ASSEMBLY .

Carry out removal.

1121 * m

installation

Muffler

in the

reverse

mounting U-bolt : 12 + 2.5 Nm Il.22

order

f; 0.26 kgm}

Tighten the mounting bolts in the order @ @ shown in the diagram on the right. Exhaust manifold mounting bolt : 43 + 6 Nm I4.38 + 0.61 kgm}

Adjust the belt tension. For details, see TESTING AND ADJUSTING, Testing and adjusting air conditioner belt tension.

Pulley hub mounting bolt : 33 z 5 Nm I3.37 = 0.51 kgm1 Tensioner bracket mounting bolt : 24 = 4 Nm i2.45 +. 0.41 kgm}

Exhaust

hose clamp : 10 2 2 Nm Il.02

nut at 24 nut at 30

f 0.20 kgm1

injection pump end : f 4 Nm 12.45 f 0.41 kgm1 nozzle holder end : t 5 Nm I3.06 = 0.51 kgm}

Sleeve

Fuel tube joint bolt (301, (31) : 24 + 4 Nm I2.45 2 0.41 kgm} Fuel hose joint bolt (32) : 30 + 5 Nm (3.06 2 0.51 kgm}

30-3 1 0

DISASSEMBLY

AND ASSEMBLY

CYLINDER

Spill tube joint bolt : 8 t 2 Nm jO.81 + 0.20 kgm)

Nozzle holder assembly : 60 +. 9 Nm (6.12 + 0.92 kgm}

Head cover mounting bolt : 24 f 4 Nm I2.45 + 0.41 kgm}

piij

rx141

Install the rocker arm assembly and cylinder head assembly as follows. Check that there is no dirt or dust on the * cylinder mount surface or inside the cylinder. I) Set cylinder head gasket (41) to cylinder block. * Check that the gasket is aligned correctly with the holes in the block.

2) Raise cylinder head assembly (40) and set to cylinder 3)

30-32 0

block.

Assemble push rod (39). & Add engine oil (15W-40) rod socket portion.

to the push

Fit rocker arm assembly (38). and tighten mounting bolts by hand. Sr Check that the ball portion of the adjustment screw is fitted securely in the socket portion of the push rod. & Put engine oil (15W-40) on the seat surface and thread of the 8 mm and 12 mm diameter mounting bolts.

HEAD

DISASSEMBLY

AND ASSEMBLY

CYLINDER

HEAD

Tighten cylinder head mounting bolts in order shown in diagram. & Put engine oil (15W-40) on the seat surface and thread of the mounting bolts. Cylinder head mounting bolt :

1st step:

Tighten in order @ - @ to 90 t 5 Nm (9.18 2 0.51 kgm}. 2nd step: Tighten in order 0, 8, 0, @, @, @ to 120 z 5 Nm 112.24 = 0.51 kgm}. 3rd step: i) When using tool Al Using angle tightening wrench (tool Al), tighten bolts a further 90â&#x20AC;? in order @ - 8. ii) When not using tool Al Make match marks with a felt pen on bolt and head, then tighten bolt a further 90â&#x20AC;?.

CEW00394

CLPO4084

Tighten rocker arm assembly mounting bolts (diameter: 8 mm). QKl Rocker arm mounting bolt : 24 + 4 Nm (2.25 t 0.41 kgm} 7)

Make ,head

marks on and bolt

cvllnder

Adjust valve clearance. For details, see TESTING AND ADJUSTING, Adjusting valve clearance.

DKP00485

Refilling with water * Refill to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

CLPO1522

DISASSEMBLY

RADIATOR

AND ASSEMBLY

HYDRAULIC OIL COOLER

REMOVAL OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY a

Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove the hydraulic tank strainer, and using tool B, stop the oil. . When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. -

Hydraulic

CLPO3276

tank : Approx. 170 t

Drain coolant.

1. Remove condenser assembly. For details, see REMOVAL OF CONDENSER SEMBLY.

AS-

Remove undercover at bottom of condenser and bottom of radiator. + Set a container under the machine to catch the oil.

Disconnect

Remove

sub-tank

mounting

Remove

coupling

(4) at oil cooler inlet port end. m

Remove holder bracket (6) of oil cooler port tube (5), then disconnect tube.

hoses (I), then remove

sub-tank

(2).

bracket (3).

inlet

CLPO3807

Remove coupling (7) at oil cooler outlet port end, then remove holder bracket (8), and disconnect oil cooler outlet port tube (9). m

CLPO3808

30-34 0

DISASSEMBLY

RADIATOR

AND ASSEMBLY

Remove

Disconnect

HYDRAULIC

OIL COOLER

fan guard (IO). radiator

upper hose (II).

10. Disconnect radiator lower hose (12) and heater hose (13), then remove intermediate clamp (14) m of radiator lower hose.

8 t ::

282

11. Remove

2 clamps

12. Disconnect radiator.

(16) of heater

hose (15).

left and right support

rods (17) of

13. Sling radiator and hydraulic oil cooler assembly (181, remove bottom mounting bolts, then lift off radiator and hydraulic oil cooler assembly slowly. * When raising the radiator and hydraulic oil cooler assembly, be extremely careful not to hit the fan. &I kg

Radiator

hydraulic oil cooler assembly: 112 kg

30-35 0

DISASSEMBLY

AND ASSEMBLY

RADIATOR

INSTALLATION OF RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY .

Carry out installation removal.

in the

reverse

order

piq m

Coupling

: 16.7 = 2 Nm Il.7 + 0.2 kgml

QEI

Radiator

hose band clip : 8.83 = 0.98 Nm IO.9 2 0.1 kgml

Refilling with water * Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-36 0

HYDRAULIC

OIL COOLER

DISASSEMBLY

AND ASSEMBLY

ENGINE

REMOVAL OF ENGINE PUMP ASSEMBLY

MAIN

PUMP

MAIN

n g a

Disconnect the cable from the negative (-) terminal of the battery. Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool B, stop the oil. When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. l

Hydraulic

After disconnecting guish the mounting

Drain coolant.

Remove

engine

CLP03276

tank : Approx. 170 P. the piping, fit tags to distinposition.

hood (1).

$ z zi Lu

lCLPO3299

Remove

main pump top cover (2).

Remove right side cover (3) together with cover mounting frame (4). * Remove the cover at the bottom of the main pump and the cover at the bottom of the engine, then set a container under the main pump to catch the oil.

CLPO3300

Remove connect.

connector

(5) from

bracket,

then dis-

CLPO3612

DISASSEMBLY

ENGINE

AND ASSEMBLY

Disconnect F and R pump discharge hoses (6) and (71, F and R LS pressure hoses (8) and (9), and EPC basic pressure hose (IO). Ir Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

Disconnect pump servo pressure hose (II) and pump drain hose (121, and remove intermediate clamp (13) of hose. * Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

Disconnect suction tube (14) at pump end. Ir Cover the suction tube port portion with plastic.

MAIN

PUMP

CCPO3814

Remove

engine

partition

plates

115), (16), and

(17).

Remove

bracket (18) at counterweight

10. Remove fan guard right side brackets mount.

30-38 0

end.

(191, then remove left and (20) and (21) of fan guard

DISASSEMBLY

ENGINE

AND ASSEMBLY

11. Disconnect oil level sensor connector (22) of oil pan, wiring (23) for oil pressure sensor, and ground connection (24). 12. Remove

intermediate

MAIN

PUMP

(Counterweiahtl

clamp (25) of heater hose.

(Engine

13. Remove governor ernor and bracket, connector (27).

oil

pan)

DLPOO486

control cable (26) from govand disconnect speed sensor

26 $ > z w

CLPO3833

14. Disconnect starting motor wiring (28) and statting motor connectors (29) and (301, and remove from clamp.

15. Disconnect fuel supply hose (31) and fuel return hose (321, then remove intermediate clamp (33).

=32-----

31-----

CLPO3755

30-39 0

DISASSEMBLY

AND ASSEMBLY

ENGINE

MAIN PUMP

16. Disconnect electrical intake air heater wiring (34) and air conditioner connector (35). 17. Remove compressor assembly (36). For details, see REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY. * After removing the compressor assembly, put it on top of the counterweight.

CLP03834

18. Remove fan (371, and move towards

radiator.

19. Remove radiator upper hose (381, radiator lower hose (39), heater hose (40), and air cleaner connector (41).

20. Remove mount bolt, then raise engine and main pump assembly (42) slowly, and lift off. * When removing the engine and main pump assembly, check that all the wiring and piping has been disconnected. m kg Engine, main pump assembly : 770 kg

CLPO3759

30-40 0

DISASSEMBLY

ENGINE

AND ASSEMBLY

MAIN

PUMP

INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

Set the engine mount rubber as shown in the diagram, then install the engine and main pump assembly. Engine mount bolt : 277 d 32 Nm (28.3 = 3.3 kgml

Engine

rear

side

Engine

front

side DKP00487

g > !

Refilling with water * Add water through the water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air * Bleed the air from the main pump. For details, see TESTING AND ADJUSTING, Bleeding air.

30-4 1 0

DISASSEMBLY

DAMPER

AND ASSEMBLY

REMOVAL OF DAMPER ASSEMBLY 1.

Remove main pump assembly. For details, see REMOVAL OF MAIN SEMBLY. Remove

damper

assembly

PUMP AS-

(1).

INSTALLATION ASSEMBLY l

Carry out removal.

30-42 0

installation

OF DAMPER in the

reverse

order

â&#x20AC;&#x2122; CLPO3298

DISASSEMBLY

FUEL TANK

AND ASSEMBLY

REMOVAL OF FUEL TANK ASSEMBLY g

Disconnect the cable from the negative minal of the battery.

1. Loosen fuel. w

drain

valve

(I)

Fuel tank : Approx.

of fuel tank

340 ~2(when

(-1 ter-

and drain

tank is full)

Disconnect fuel supply hose 12) and return hoses (3) and (4).

Remove

handrail

(5), battery case (61, and cover

(7). &I kg

Battery case : 28 kg

Disconnect fuel sensor connector move wiring from clamp.

Sling fuel tank assembly (91, then remove mounting bolts, and lift off fuel tank assembly (9). m Fuel tank assembly : 122 kg k9 &I

INSTALLATION ASSEMBLY l

Carry out removal.

installation

(81, then

re-

OF FUEL TANK

in the

reverse

order

Fuel tank mounting bolt : 277 + 32 Nm 128.3 + 3.2 kgm1

Refilling with fuel (fuel tank) Add fuel.

30-43 0

DISASSEMBLY

AND ASSEMBLY

CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY g Release the remaining pressure in the hydraulic

* 1.

circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure from hydraulic circuit. Mark all the piping with tags to prevent mistakes in the mounting position when installing. Disconnect hoses (I), (21, (3), and (4) between travel motor and swivel joint.

Remove

3. 4. 5. 6.

Disconnect drain hose (6). Disconnect hoses (7) and (8) between control valve and swivel joint. Disconnect travel speed selector hose (9). Disconnect plate (IO).

Remove & kg

30-44 0

elbow

(5).

center swivel joint assembly Center swivel joint assembly

(11). a

: 45 kg

DISASSEMBLY

CENTER

AND ASSEMBLY

SWIVEL

JOINT

INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY l

Carry out installation removal.

in the

reverse

order

m *

Assemble the center swivel as shown in the diagram below. Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air * Bleed the air form the travel motor. For details, see TESTING AND ADJUSTING, Bleeding air.

Center joint

swivel

â&#x20AC;&#x2DC;Sprocket

DKP00488

30-45 0

DISASSEMBLY

CENTER SWIVEL JOINT

AND ASSEMBLY

DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.

Remove

cover (I).

Remove

snap ring (2).

Using tool D, pull out swivel (3) from swivel shaft (5).

Remove O-ring swivel rotor.

(6) and

rotor (4) and ring

slipper

seal

(7) from

ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 1.

Assemble rotor.

slipper seal (7) and O-ring (6) to swivel

Set swivel shaft (5) to block, then using push tool, tap swivel rotor (4) with a plastic hammer to install. & Contact surface of rotor, shaft :

CLPO3841

Grease (GZ-LI) *

When installing the rotor, be extremely careful not to damage the slipper seal and the O-ring.

Install ring (3) and secure with snap ring (2).

Fit O-ring and install cover (I). m Mounting bolt : 31.36 I 2.94 Nm I3.2 + 0.3 kgm}

30-46 0

CLPO3842

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

REMOVAL OF FINAL DRIVE ASSEMBLY 1.

t$ i

Remove sprocket. For details, see REMOVAL OF SPROCKET. Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove

cover (I).

Disconnect 4 travel motor hoses (2), and lift off m final drive assembly (3). * Be extremely careful not to damage the nipple tool surface of the hose mount. Final drive assembly : 300 kg &l kg * Never use tap hole for cover when slinging final drive assembly.

INSTALLATION OF FINAL DRIVE ASSEMBLY l

Carry out removal.

installation

in the

reverse

order

Final drive mounting bolt: 276.8 2 31.8 Nm 128.25 + 3.25 kgm}

Bleeding air * Bleed the air from the travel motor. tails, see TESTING AND ADJUSTING, ing air.

For deBleed-

Refilling with oil (hydraulic tank) Sr Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-47 0

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

DISASSEMBLY OF FINAL DRIVE ASSEMBLY 1.

Draining oil Remove drain plug and drain oil from final drive case. w

Final drive case : Approx.

4.2 e

Cover Remove mounting bolts, then remove cover (I) using eyebolts 0. * When raising ring gear (12) and cover (I) as one unit, tap the ring gear with a wooden hammer to remove the ring gear. Spacer Remove

12 CLPOl427

spacer (2).

CLPO1417

No. 1 carrier assembly 1) Remove No. 1 carrier assembly

(3).

CLPO1418

Disassemble No. 1 carrier assembly as follows. i) Push in pin (4), and pull out shaft (5) from carrier (6). * After removing the shaft, remove pin ii)

(4). Remove thrust washer 17), gear (8), bearing (9), and thrust washer (IO).

CLPO1419

30-48 0

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

No. 1 sun gear shaft Remove No. 1 sun gear shaft (II).

CLPO1428

Ring gear Remove ring gear (12).

Thrust washer Remove thrust washer

(13).

No. 2 sun gear Remove No. 2 sun gear (14).

CLPO1429

Thrust washer Remove thrust washer

(15).

10. No. 2 carrier assembly 1) Remove No. 2 carrier assembly

(16).

CLPO1430

2) Disassemble

No. 2 carrier assembly as follows. i) Push in pin (17) and pull out shaft (18) from carrier (19). * After removing the shaft, remove pin ii)

(17). Remove thrust washer (20), gear (21), bearing (221, and thrust washer (23).

CLPO1431

30-49 0

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

11. Nut 1) Remove lock plate (24). 2) Using tool Gl, remove nut (25).

CLP01432

12. Hub assembly I) Using eyebolts 0, remove hub assembly from travel motor.

CLPO1433

(26)

CLPO1434

Disassemble i) Remove ii) Remove *

hub assembly as follows. floating seal (27). bearings (28) and (29) from hub

(30). When removing bearing (281, do not hit the resin retainer of the bearing.

Remove

floating

seal (31) from travel motor

(32).

CLPO1436

30-50 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY ASSEMBLY

FINAL DRIVE

OF FINAL DRIVE

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Hub assembly I)

Using push tool, press fit bearings (29) to hub (30).

Usina tool G4, install floating seal (26). Rimove ail oil and grease from the Oring and O-ring contact surface, and dry the parts before installing the floating seal. After installing the floating seal, check that the angle of the floating seal is within 1 mm. After installing the floating seal, coat the sliding surface thinly with engine oil.

(28) and

I 3)

CKP03843

Using tool G4, install floating seal (31) to travel motor (32). * The procedure for installation is the same as in Step 2) above.

CLPO1436

Using eyebolts 0, set hub assembly (26) to travel motor, then using push tool, tap to press fit bearing portion.

CCPO1434

DISASSEMBLY

FINAL DRIVE

AND ASSEMBLY

Nut I) install nut as follows. Using tool G2, push bearing inner race i) portion. Do not heat the bearing with a burner, or directly push or hit the resin retainer. Pushing force: 8.82 - 12.74 kN IO.9 - 1.3 ton) Rotate the hub 2 - 3 times before applying the pushing force to the bearing inner race. ii) Measure dimension a in the condition in Step i) above. iii) Measure thickness b of nut itself. iv) Calculate a - b = c. v) Using tool Gl, tighten nut (25) to a point where dimension d is c$.,.

CLF'03844

CLPO1437

vi)

Using push-pull scale 0, measure tangential force in direction of rotation of hub in relation to motor case. * Tangential force : Max. 294 N (30 kg) * The tangential force is the maximum force when starting rotation.

CLPO3845

vii) Install lock plate (24).

CLPO1438

30-52 0

DISASSEMBLY

* 6

AND ASSEMBLY

Install the diagram. Thread *

lock plate

FINAL DRIVE

as shown

in the

of mounting bolt: Thread tightener (LT-2) Do not coat the tap portion of the nut with thread tightener (LT-2).

GOOD

Install there

to a Place where is no casting notch. lock Plate and saline DLPOO489

No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. Replace thrust washers (20),.(23) and pin (17) with new ones. There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (22) to gear (211, fit top and bottom thrust washers (20) and (231, and set gear assembly in carrier

h CLPO1439

(19). Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (18). * When installing the shaft, rotate the planetary gear. Be careful not to damage the thrust washer. iii) Insert pin (17). Sr After inserting the pin, caulk the pin portion of the carrier. Ir After assembling the carrier assembly, check that gear (21) rotates smoothly. ii)

CLPO1440

Install No. 2 carrier assembly (16). * Align the position so that the three tips of the gear shafts of carrier assembly (16) enter the three hollows in the end face of the motor case, then install.

CLPO1441

30-53 0

DISASSEMBLY

Thrust washer Install thrust washer

(15).

No. 2 sun gear Install No. 2 sun gear (14).

Thrust washer Install thrust washer

FINAL DRIVE

AND ASSEMBLY

(13).

No. 1 sun gear shaft Install No. 1 sun gear shaft (11). CLPO1442

No. 1 carrier assembly I) Assemble No. 1 carrier assembly as follows. * Replace thrust washers (7), ilO) and pin (4) with new ones. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble bearing (9) to gear (8), fit top and bottom thrust washers (7) and (IO), and set gear assembly in carrier (6).

CLP01422

Align position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (5). Ir When installing the shaft, rotate the planetary gear. Be careful not to damage the thrust washer. iii) Insert pin (4). j, After inserting the pin, caulk the pin portion of the carrier. After assembling the carrier assembly, * check that gear (8) rotates smoothly.

ii)

CLP01423

Install No. 1 carrier assembly

(3).

Spacer Install spacer (2).

CLPO1443

30-54 0

DISASSEMBLY

AND ASSEMBLY

FINAL DRIVE

10. Ring gear Fit O-ring to hub end, then using eyebolts 0, align position of bolt holes of hub and ring gear (121, and install. * Remove all grease and oil from the mating surface of the ring gear and hub. * Do not put any gasket sealant on the mating surface of the ring gear and hub under any circumstances.

CLPOl444

11. Cover Using eyebolts 0, fit cover (I), then tighten mounting bolts with angle tightening wrench G3. 6 Mounting surface of cover : Gasket sealant (LG-6) w Mounting bolt : 1st pass: 98 Nm {IO kgm1 2nd pass: Turn 80â&#x20AC;&#x2122;- 90â&#x20AC;?

Refilling with oil Tighten drain plug and add engine oil filler. Q *

oil through

Final drive case : Approx. 4.2 e Carry out a final check of the oil level at the determined position after installing the final drive assembly to the chassis.

CLPO1446

30-55 0

DISASSEMBLY

AND ASSEMBLY

REMOVAL

SPROCKET

OF SPROCKET

Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY.

Swing work equipment 90”, then push up chassis with work equipment and set block @ between track frame and track shoe.

Lift off sprocket

(I).

see

--?\‘_

INSTALLATION .

Carry out removal.

30-56 0

installation

OF SPROCKET in the

reverse

order

mounting bolt : Gasket sealant (LG-6) Sprocket mounting bolt : 465.5 z 24.5 Nm I47.5 2 2.5 kgml

Thread

of sprocket

J‘TX-=T

-c

CLPO4033

DISASSEMBLY

SWING

AND ASSEMBLY

REMOVAL OF SWING SWING MACHINERY ASSEMBLY

MOTOR

AND SWING

MACHINERY

MOTOR,

Lower the work equipment to the ground and stop the engine. Loosen the hydraulic tank oil filler cap slowly to release the pressure inside the hydraulic tank. Then set the safety lock lever to the LOCK position.

Remove

Disconnect swing motor inlet and outlet hoses (3) and (41, and disconnect suction hose (5).

Remove

Disconnect drain hoses (7) and (8), then disconnect pilot hose (9).

Remove 12 mounting bolts (IO) at swing machinery end, then lift off swing motor and swing m machinery assembly (I I). * When removing the swing motor and swing machinery assembly, be careful not to damage the hoses, and lift off slowly. Swing motor, swing machinery assem&l kg bly : 225 kg

hose clamps (I) and (2) (2 places each).

hose clamp

(6).

30-57 0

DISASSEMBLY

SWING MOTOR AND SWING MACHINERY

AND ASSEMBLY

INSTALLATION OF SWING MOTOR, SWING MACHINERY ASSEMBLY l

Carry out installation removal.

Swing

in the

reverse

order

mounting bolt : 549 + 59 Nm (56 +. 6 kgm)

machinery

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air * Bleed the air from the swing motor. For details, see TESTING Bleeding air.

30-58 0

AND ADJUSTING,

DISASSEMBLY

AND ASSEMBLY

SWING

MACHINERY

DISASSEMBLY OF SWING MACHINERY ASSEMBLY 1.

Draining oil Loosen drain plug and drain oil from swing machinery case. b &

Swing

machinery

case : Approx.

5.5 e

Swing motor assembly 1) Set swing motor and swing machinery assembly to block 0. 2) Remove mounting bolts, then remove swing motor assembly (I). No. 1 thrust washer Remove No. 1 thrust washer

CLPO2923

(2).

No. 1 sun gear Remove No. 1 sun gear (3).

No. 1 carrier assembly 1) Remove No. 1 carrier assembly

(4).

/I CLPO2926

DISASSEMBLY

SWING

AND ASSEMBLY

MACHINERY

Disassemble No. 1 carrier assembly as follows. Knock pin (51, and remove shaft (6), gear (7), bearing (8), and thrust washer (9). Ir After removing shaft (61, remove pin (5) from the shaft.

CLPO2927

Ring gear Remove ring gear (IO).

No. 2 thrust washer Remove No. 2 thrust washer

No. 2 sun gear Remove No. 2 sun gear (12).

30-60 0

(11).

DISASSEMBLY

SWING MACHINERY

AND ASSEMBLY

Bolt

Remove holder mounting bolt (13). 10. No. 2 carrier assembly 1) Remove No. 1 carrier assembly

(14).

.PO2931

Disassemble No. 2 carrier assembly as follows. i) Push in pin (15), and knock shaft (16) out from carrier (17). * After removing the shaft, remove pin

18 18 19

(15). ii) Remove thrust washer (18), gear (19), bearing (20), and thrust washer (21). iii) Remove plate (22).

20 21 â&#x20AC;&#x2DC;15 CLPO293

11. Shaft assembly 1) Remove mounting bolts (23). 2) Set shaft and case assembly to press, then using push tool 0, remove shaft assembly (24) from case assembly (25).

CLPO2933

CLPO2934

Disassemble shaft assembly as follows. i) Using push tool 0, remove cover assembly (26) and bearing (27) from shaft ii)

(28). Remove

oil seal (29) from cover (30).

CLPO2935

CLPO2936

30-61 0

DISASSEMBLY

AND ASSEMBLY

12. Bearing Using push tool, remove

bearing

SWING

MACHINERY

(31) from case

(32).

CLPO2937

30-62 0

DISASSEMBLY

AND ASSEMBLY

SWING

MACHINERY

ASSEMBLY OF SWING MACHINERY ASSEMBLY *

Clean all parts and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

Bearing Using push tool 0, (32).

press fit bearing

(27) to case

CLPO2938

Cover assembly 1) Using push tool 0, press fit cover (30). & Outside circumference Gasket * Be careful not to let the (LG-6) get on the oil seal fitting.

oil seal (29) to of oil seal : sealant (LG-6) gasket sealant lip when press

CLPO2939

Fit cover assembly (26) to case (32), and tighten mounting bolts (23). & Cover mounting surface : Gasket sealant (LG-6) m Mounting bolt : 66.2 z 7.4 Nm i6.75 + 0.75 kgm} & Lip of oil seal : Grease (G2-LI)

CLPO2940

Case Assembly Set case assembly (25) to shaft (281, then using push tool 8, press fit bearing inner race portion. * When setting the case assembly to the shaft, be extremely careful not to damage the oil seal.

CLP02941

DISASSEMBLY

SWING

AND ASSEMBLY

MACHINERY

Bearing Using tool F, press fit bearing (31). Sr Press the bearing inner race and outer race at the same time when press fitting. Do not press only the inner race when press fitting. * After press fitting the bearing, check that the case rotates smoothly.

CLPO2942

No. 2 carrier assembly 1) Assemble No. 2 carrier assembly as follows. * There are the remains of the caulking when the pin is inserted at the end face of hole h at the side of the carrier, so remove the caulked metal from the inside diameter of the hole before starting to assemble. i) Assemble plate (22) to carrier (17). bearing (20) to gear (191, fit ii) Assemble top and bottom thrust washers (18) and (21) and set gear assembly to carrier (17). iii) Align with position of pin holes of shaft and carrier, then tap with a plastic hammer to install shaft (16). * When installing the shaft, rotate the planetary gear, and be careful not to damage the thrust washer. iv) Insert pin (15). * After inserting the pin, caulk the pin portion of the carrier.

CLPO2943

h CLPO2944

2) 6.

Install No. 2 carrier assembly

Bolt Tighten & w

(14).

bolt (13). Mounting

bolt : Thread tightener (LT-2) Mounting bolt : 176.5 + 19.6 Nm I18 + 2.0 kgm}

CLPO2931

30-64 0

DISASSEMBLY

AND ASSEMBLY

SWING

MACHINERY

7. No. 2 sun gear Install No. 2 sun gear (12).

No. 2 thrust washer Install No. 2 thrust washer

(I 1).

Ring gear Install ring gear (IO). & Case side mounting surface : Gasket sealant

(LG-6)

10. No. 1 carrier assembly I) Assemble No. 1 carrier assembly as follows. There are the remains of the caulking at * the end face of carrier side hole k made when inserting the pin, so remove the remains of the caulking on the inside diameter of the hole before starting assembly. i) Assemble bearing (8) to gear (71, then fit top and bottom thrust washers (9) and set gear assembly to carrier. CLPO2945

30-65

DISASSEMBLY

SWING

AND ASSEMBLY

MACHINERY

Align pin hole position of carrier and shaft, then tap with plastic hammer and install shaft (6). * Rotate the planet gear when installing the shaft, and be careful not to damage the thrust washer. iii) Insert pin (5). After inserting the pin, caulk the pin * portion of the carrier.

ii)

CLPO2946

iv) Install No. 1 carrier assembly

(4).

CLPO

11. No. 1 sun gear Install No. 1 sun gear (3).

12. No. 1 thrust washer Install No. 1 thrust washer

(2).

.PO2924

30-66 0

DISASSEMBLY

SWING

AND ASSEMBLY

MACHINERY

13. Swing motor assembly Install swing motor assembly (I). & Ring gear side mounting surface : Gasket sealant (LG-6)

CLPO2923

Coat the outside diameter of the hole only at the hole in the ring gear where there is a distinguishing protrusion on the case. (See the diagram on the right.) Mounting bolt : _ 176.5 +. 19.6 Nm I18 I 2.0 kgm}

14. Refilling with oil Tighten drain plug and add engine oil filler to specified level.

oil through

Projection identificati

for

30-67 0

DISASSEMBLY

REVOLVING

AND ASSEMBLY

FRAME

REMOVAL OF REVOLVING FRAME ASSEMBLY 1. Remove 2 boom cylinder assemblies. For details, see REMOVAL OF BOOM CYLINDER ASSEMBLY. 2.

Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY.

Remove countemeight assembly. REMOVAL OF COUNTERWEIGHT

Disconnect top mounting hoses (I), (21, and (3) of swivel joint assembly at swivel joint assembly end.

Remove

Remove mounting bolts, then lift off revolving a frame assembly (5). * Leave 2 bolts @ each at the front and rear, use a lever block to adjust the balance of the revolving frame assembly to the front and rear, and left and right, then remove the remaining bolts, and lift off. a When removing the revolving frame assembly, be careful not to hit the center swivel joint assembly. &I kg

30-68 0

stopper

Revolving

For details, see ASSEMBLY.

link (4).

frame

assembly:

5,200 kg

CLPO3849 I

DISASSEMBLY

AND ASSEMBLY

REVOLVING

FRAME

INSTALLATION OF REVOLVING FRAME ASSEMBLY .

Carry out installation removal.

Mating

surface

in the

reverse

order

of swing circle :

Gasket sealant (LG-I) Thread of revolving frame mounting bolt : Thread tightener (LT-2) Revolving frame mounting bolt :

Refilling * Add fied the the

Bleeding air Ir Bleed the air. For details, see TESTING AND ADJUSTING, Bleeding air.

with oil (hydraulic tank) oil through the oil filler to the specilevel. Run the engine to circulate oil through the system. Then check oil level again.

30-69 0

DISASSEMBLY

SWING CIRCLE

AND ASSEMBLY

REMOVAL OF SWING ASSEMBLY

CIRCLE

Remove revolving frame assembly. For details, see REMOVAL OF REVOLVING FRAME ASSEMBLY.

Remove swing circle mounting bolts (I), leaving m 1 bolt each in front and rear direction. * Swing circle assembly mounting bolts: 32 PCS.

Sling swing circle assembly (2) at three points, then remove remaining mounting bolts.

Lift off swing circle assembly &I kn

30-70 0

Swing

circle assembly

(2).

: 280 kg

A--k

CLPO3850

DISASSEMBLY

AND ASSEMBLY

SWING

CIRCLE

INSTALLATION OF SWING CIRCLE ASSEMBLY .

Carry out removal.

installation

Thread

in the

reverse

order

Swing

circle

start

mark

of swing circle mounting bolt : Thread tightener (LT-2) circle mounting bolt :

m Swing 1st pass: Tighten to 191.2 t 19.6 Nm (19.5 + 2 kgm} 2nd pass: Using the angle of the bolt head as the base, make start marks on the swing circle and socket. 2) Make an end mark at a point (on swing circle) 48k5â&#x20AC;? from the start mark. 3) Tighten so that the start mark on the socket is aligned with the end mark on the swing circle at the 48+5â&#x20AC;? position.

mark DKP00491

Inner

,soft

race

zone race zclne

m *

Set the soft zone S mark on the inside ring of the inner race facing the right side as shown in the diagram, then install to the track frame. Swing circle : Grease (G2-LI) 21.Q.

DLPOO492

30-71 0

DISASSEMBLY

IDLER

AND ASSEMBLY

REMOVAL OF IDLER SPRING ASSEMBLY

Remove track shoe assembly. For details, REMOVAL OF TRACK SHOE ASSEMBLY.

see

Sling idler and recoil spring assembly pull out to the front to remove.

and

Idler

RECOIL SPRING

RECOIL

&I kg

recoil spring assembly

Disconnect recoil spring assembly assembly (2).

(I),

: 275 kg

(3) from idler m

: 140 kg

&Jkg

Idler assembly

r%kg

Recoil spring assembly

: 135 kg

INSTALLATION OF IDLER RECOIL SPRING ASSEMBLY l

Carry out removal.

installation

in the

reverse

order

When installing the idler assembly and recoil spring assembly, assemble so that the position of the greasing plug on the idler is on the outside for the right side of the machine and on the inside for the left side of the machine.

30-72 0

CLPO3855

DISASSEMBLY

AND ASSEMBLY

RECOIL SPRING

DISASSEMBLY OF RECOIL SPRING ASSEMBLY I

I L______-_--_-___-------_-_-__-JL-_-______

Remove piston assembly assembly (I).

Disassembly of recoil spring assembly 1) Set recoil spring assembly (I) to tool HI. g The recoil spring is under large installed load, so be sure to set the tool properly. Failure to do this is dangerous. * Installed load of spring : 108.8 kN {II,100 kg1

$3 > z w

(2) from

ii; ;

-Ll/

CLPO3856

recoil spring

Apply hydraulic pressure slowly to compress spring, and remove lock plate (3), then remove nut (4). j, Compress the spring to a point where the nut becomes loose. * Release the hydraulic pressure slowly and release the tension of the spring. Ir Free length of spring : 558 mm

Remove yoke (6), cylinder (8) from spring (5).

CLPO3857

(71, and dust seal

Disassembly of piston assembly 1) Remove lock plate (IO) from piston (9), then remove valve (I I). 2) Remove snap ring (12), then remove U-packing (13) and ring (14).

30-73 0

DISASSEMBLY

RECOIL SPRING

AND ASSEMBLY

ASSEMBLY ASSEMBLY

OF RECOIL SPRING H2

Assembly of piston assembly 1) Assemble ring (14) and U-packing (13) to piston (91, and secure with snap ring (12). 2) Tighten valve (11) temporarily, and secure with lock plate (IO).

Assembly of recoil spring assembly 1) Using tool H2, install dust seal (8) to cylinder (7).

CLPO3858

2) &

Assemble cylinder (7) and yoke (6) to spring (51, and set in tool HI. Sliding portion of cylinder : Grease (G2-LI)

Apply hydraulic pressure slowly to compress spring, and tighten nut (4) so that installed length of spring is dimension “a”, then secure with lock plate (3). * Installed length “a” of spring : 437 mm

Remove Hl.

recoil spring assembly

(I) from tool CLPO3859

Assemble piston assembly (2) to recoil spring assembly (I). 6 Sliding portion of piston, wear ring: Grease (G2-LI) * Assemble the cylinder assembly so that the mounting position of the valve is 90” to the side. Fill the inside of the cylinder with 300 cc of * grease (G2-LI), then bleed the air and check that grease comes out of the grease hole.

30-74 0

DISASSEMBLY

DISASSEMBLY ASSEMBLY 1. Remove

IDLER

AND ASSEMBLY

OF IDLER

dowel pin (I), then remove seal (3) from

support

(2).

(2) and

Remove floating idler (4).

Pull out idler (4) from shaft (5) and support (7) assembly. It is filled with 80 cc. of oil, so drain the oil at j, this point or lay a cloth to prevent the area from becoming dirty.

CLPO3660

Remove floating seal (6) on opposite side from idler (4) and shaft (5) and support (7) assembly.

CLP03661

Remove dowel from shaft (5).

Remove

pin (8), then remove

bushings

(9) and (IO) from

support

(7)

idler (4).

CLPO3662

CLP03663

30-7.5 0

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY ASSEMBLY 1.

IDLER

OF IDLER

Press fit bushings

(9) and (IO) to idler (4).

CLP022lC

Fit O-ring and install support dowel pin (8).

Using tool Jl, install floating seal (6) to idler (4) and shaft (5) and support (7) assembly. * Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. * Remove all grease and oil from the contact surface of the O-ring and the floating seal.

(7) to shaft (5) with

CLP03661

CKP03667

Assemble idler (4).

shaft (5) land support

(7) assembly

7 4

CLP03866

30-76 0

DISASSEMBLY

AND ASSEMBLY

IDLER

Using tool Jl, install floating seal (3) to idler (4) and support (2). Sr Coat the sliding surface of the floating seal with oil, and be careful not to let any dirt or dust get stuck to it. * Remove all grease and oil from the contact surface of the O-ring and the floating seal.

CLPO3869

I 6.

Install O-ring, then install support (2) with dowel pin (I).

Add oil and tighten

CKP03870

plug.

Oil : Approx.

Plug : 205.8 +. 49 Nm I21 2 5 kgm}

80 cc (SAE30)

2 CLPO3860

30-77 0

DISASSEMBLY

AND ASSEMBLY

TRACK ROLLER

REMOVAL OF TRACK ROLLER ASSEMBLY 1.

Lower work equipment, then loosen lubricator (I), and relieve track tension. m g The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out easily, move the machine backwards and forwards. Remove mounting bolts of track roller, then swing work equipment 90”, jack up machine, and remove track roller assembly (2) towards outside of machine. m r+ kg

Track roller assembly

’ CLPO3872

: 40 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY l

Carry out installation removal.

in the

Adjust the track tension. TESTING AND ADJUSTING, justing track tension.

reverse

order

CLPO3873

For details, see Testing and ad-

Place the plug on the outside of the chassis, and set the track roller assembly in the mounting position. Operate the work equipment levers to lower the machine slowly, then tighten the mounting bolts temporarily. Operate the work equipment levers to lower the machine completely to the ground, then tighten the mounting bolts fully. Track roller assembly mounting bolt:

CLPO3874

1st pass : Tighten to 196 2 19.6 Nm I20 I 2 kgm1 2nd pass : 1. When using tool M. . Using an angle tightening wrench, tighten bolt 90 r 5”. 2. When not using tool M. I) Using the angle of the bolt head as the base, make start marks on the track roller and socket. 2) Make an end mark at a point 90 f 5” from the start mark. 3) Tighten so that the start mark on the socket is aligned with the end mark on the track roller at the 90+5” position.

30-78 0

start

track roller end mark

Socket

start

mark

Socket

DLP00493

DISASSEMBLY

TRACK ROLLER

AND ASSEMBLY

DISASSEMBLY OF TRACK ROLLER ASSEMBLY 1.

Remove

pin (I), then remove

collar (2).

II 3

CLPO2218

Remove floating seal (3) from collar (2) and roller (4).

CLPO2220

Pull out roller (4) from shaft (5). * It is filled with 190 - 215 cc. of oil, so drain the oil at this point or lay a cloth to prevent the area from becoming dirty.

Remove floating seal (6) on opposite roller (4) and shaft (5).

side from

CLP02221

CLPO2222

CLP02223

30-79 0

DISASSEMBLY

AND ASSEMBLY

Remove pin (71, then shaft (5).

Remove

bushings

remove

TRACK ROLLER

collar

(8) from

(9) and (IO) from roller (4.

CLPO2224

30-80 0

CLPO27.25

DISASSEMBLY

AND ASSEMBLY

ASSEMBLY ASSEMBLY

OF TRACK ROLLER

Using push tool 0, (IO) to roller (4).

Assemble

collar

TRACK ROLLER

press fit bushings

(9) and

(8) to shaft (51, and install

(7). 3.

Using

tool

Kl,

install floating

seal (6) to shaft

(5). * When assembling the floating seal, clean the contact surface of O-ring (6~) and floating seal (6a), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. 4.

Assemble

Turn over roller (4) and shaft (5) assembly.

Using

8 CLP00803

Using tool Kl, install floating seals (6) and (3) to roller (4). * For details of the precautions when installing floating seals (6b) and (6d), and (3b) and (3d), see the precaution for Step 3.

shaft (5) to roller (4).

tool Kl,

install floating

seal (3) to collar

CLPO2226

(2). * For details of the precautions

when installing floating seals (3a) and (3c), see the precaution for Step 3.

CLPO3886

CLPO3888

CLPO3887

CLP03889

30-81 0

DISASSEMBLY

Assemble (I).

TRACK ROLLER

AND ASSEMBLY

collar

(2) to shaft (5), and install

CLPO3890

Using tool KS!, apply basic pressure to roller oil filler port, and check for leakage of air from seal. Basic pressure : 0.1 MPa {I kg/cm2) * Method of checking li for The basic pressure shall be maintained 10 seconds and the indicator of the gauge shall not go down.

CLPO3891

10. Using tool K2, fill track roller assembly with oil, then tighten plug (II). Plug : 14.7 t. 4.9 Nm Il.5 + 0.5 kgm} m &

Track roller oil : 190 - 215 cc (SAEBO)

oil

PUMP

1 To vacuum tank DLP00529

30-82 0

CLP

DISASSEMBLY

CARRIER ROLLER

AND ASSEMBLY

REMOVAL OF CARRIER ROLLER ASSEMBLY 1.

Lower work equipment, then loosen lubricator m (I), and relieve track tension. A The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards.

Using hydraulic jack 0, push up track to a position where carrier roller assembly can be removed, then remove carrier roller assembly (2). m

CLP03872

INSTALLATION OF CARRIER ROLLER ASSEMBLY .

Carry out removal.

installation

in the

Adjust the track tension. TESTING AND ADJUSTING, justing track tension.

reverse

order

For details, see Testing and ad-

CLPO3894

Thread of carrier roller assembly mounting bolt:

Thread tightener

(LT-2)

30-83 0

DISASSEMBLY

AND ASSEMBLY

CARRIER

ISASSEMBLY OF CARRIER 3LLER ASSEMBLY 1.

Remove w

2. 3. 4.

ROLLER

plug (I) and drain oil. Carrier

roller assembly

Set carrier roller assembly Remove cover (2). Remove ring (3).

: 230 - 250 cc

on stand 0.

CLPO3895

CLPO3896

5. 6.

CLPO3897

Using tool Ll, remove nut (4). Using push tool 0, pull out shaft assembly (5) from roller (6) with press, then remove inner race (7).

CLPO3898

Remove

outer races (8) and (9) from

roller (6).

Disassembly of shaft assembly 1) Using puller 0, remove inner race (IO).

CLPO3899

8 ZiK

CLPO3900

30-84 0

1 1

----bK3901

DISASSEMBLY

2) 3)

CARRIER ROLLER

AND ASSEMBLY

Remove floating seals (II). Using push tool 0, remove shaft (13).

collar (12) from 0

13 I2 >_CLP03902

CLP03903

30-85 0

DISASSEMBLY

CARRIER ROLLER

AND ASSEMBLY

ASSEMBLY OF CARRIER ROLLER ASSEMBLY 1.

Using push tool 0, (9) to roller (6).

press fit outer races (8) and

Assembly of shaft assembly 1)

i+ -

Using push tool 8, press fit collar (12) to shaft (13). * When press fitting, be careful that there is no scuffing. 6 Fitting portion of shaft : SAEBO Using tool L3, assemble floating seals (II). Ir When assembling the floating seal, clean the contact surface of O-ring (11~) and floating seal (I la), remove all grease and oil, and dry it. Make sure that no dirt or dust sticks to the contact surface of the floating seal. Assemble floating seals (I I), then using tool L2, press fit inner race (IO). Sr For details of the precautions when installing floating seals (11 b) and (I Id), see the precaution for Step 2).

!ZI-&I.I CLPO3904

L--J

Assemble

Using tool L2, press fit inner race (7). * When press fitting the bearing, rotate roller, and press fit to a point where rotation becomes slightly heavier.

roller (6) to shaft assembly

CLPO3905

CLPO1447

(5).

the the

Using tool Ll, tighten nut (4) to a point where drill hole in shaft is aligned with drill hole in nut. cLPo144a

Install ring (3).

Using push-pull smoothly.

cLPo389a

3 scale @, check that

it rotates

0 _

-3 u

@ cLPo3897

30-86 0

CLPO3909

DISASSEMBLY

Fit O-ring

CARRIER ROLLER

AND ASSEMBLY

and install cover (2).

CLPO3910

Using tool L4, apply basic pressure to roller oil filler port, and check for leakage of air from seal. * Basic pressure : 0.1 MPa {I kg/cm*) * Method of checking The basic pressure shall be maintained for 10 seconds and the indicator of the gauge shall not go down.

zs > z

10. Using tool L4, fill carrier oil, then tighten plug (I). G

Carrier

roller

assembly

with

roller oil : 230 - 250 cc (SAE30)

oil

PUMP To

vacuum

tank DLP00494

30-87 0

DISASSEMBLY

AND ASSEMBLY

TRACK SHOE

REMOVAL OF TRACK SHOE ASSEMBLY 1. Stop machine at a point where master pin is midway between idler and carrier roller, and where there is space to lay out track assembly on ground. 2.

Lower work equipment, then loosen lubricator (I), and relieve track tension. m g The adjustment cylinder is under extremely high pressure. Never loosen the lubricator more than one turn. If the grease does not come out, move the machine backwards and forwards. Using tool I, pull out master pin (2). m

Remove tool I, and move machine forward so that position of temporary pin @ is at front of idler, and set block @ in position.

Remove temporary pin 0, and remove dust seal, then drive machine in reverse to lay out track (3). a

CLP03872

CLP03913

INSTALLATION OF TRACK SHOE ASSEMBLY Adjust the track tension. TESTING AND ADJUSTING, justing track tension.

For details, see Testing and ad-

Use tool I and press fit so that the protrusion of the master pin is dimension “a”. Protrusion “a” of master pin : 4 f 2 mm

When assembling the dust seal, coat the bushing contact surface with grease (G2-LI). Replace the shoes with new ones when rubber pads get worn to the same height (or lower) as the heads of their mounting bolts. It is impossible to remove or install mounting bolts once the heads get damaged, crushed or deformed.

30-88 0

LP03914

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

TANK

REMOVAL OF HYDRAULIC TANK ASSEMBLY 1. Drain oil from hydraulic w

Hydraulic

tank.

tank : Approx.

170 e

Remove engine hood (I), pump and control valve top cover (3).

Remove right side cover (4) together mounting frame (5).

Remove engine partition plates (6) and (7) and mounting bracket for partition plate on hydraulic tank side.

Disconnect

Remove pump joint hose (IO).

Remove

Disconnect 7 hydraulic tank return hoses (12). * After disconnecting the hoses, fit tags to distinguish them. * Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

hydraulic

(2),

with cover

oil return tube (8).

suction

LS pressure

top cover

tube

(9) together

hose clamp

with

(11).

9. Sling hydraulic tank assembly (131, then remove mounting bolts, and lift off hydraulic tank as$zJ sembly. &I kg

Hydraulic

tank assembly

: 136 kg

CLPO3820

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

INSTALLATION OF HYDRAULIC TANK ASSEMBLY l

Carry out removal.

installation

in the

reverse

order

Hydraulic

tank drain plug : 68.5 = 10 Nm (6.98 z 1.01 kgm}

Hydraulic

tank mounting bolt : 277 +32 Nm I28.3 f 3.2 kgml

Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Hydraulic tank : Approx. 170 J?. &

Bleeding air * Bleed the air. For details, see TESTING Bleeding air.

30-90 0

AND ADJUSTING,

TANK

DISASSEMBLY

REMOVAL OF MAIN ASSEMBLY A A

MAIN

AND ASSEMBLY

PUMP

Disconnect the cable from the negative (-) terminal of the battery. Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool B, stop the oil. . When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. w

tank : Approx.

Hydraulic

Drain oil from damper

Remove

engine

Remove

main pump top cover (2).

Remove right side cover (3) together mounting frame (4).

Remove nect.

$ & z

CLPO3276

170 .t

case.

hood cover (I).

connector

with cover

(5) from bracket and discon-

I 5.

PUMP

\\\

CLPO3812

Disconnect F and R pump discharge hoses (6) and (7), F and R LS pressure hoses (8) and (9), and EPC basic pressure hose (IO). -)r Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

30-91 0

DISASSEMBLY

MAIN PUMP

AND ASSEMBLY

Disconnect pump servo pressure hose (11) and pump drain hose (12), and remove intermediate clamp (13) of hose. * Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

Disconnect suction tube (14) at pump end. * Cover the suction tube port portion with plastic.

Remove

engine

partition

plates

(15), (16), and

(17).

Remove mounting

muffler drain bracket (19).

pipe

(18)

and

clamp

IO. Remove main pump assembly (20) as follows. 1) Leaving 2 i 3 mounting bolts, remove other mounting bolts. 2) Sling main pump assembly and install 2 guide bolts @ on diametrically opposite sides. 3) Remove remaining mounting bolts, then pull out slowly until main pump assembly separates from spline shaft. m 4) Lift off main pump assembly. A kg

30-92 0

Main pump assembly

: 150 kg

DISASSEMBLY

MAIN

AND ASSEMBLY

PUMP

INSTALLATION OF MAIN PUMP ASSEMBLY .

Carry out removal.

Involute

Mating

in the

reverse

order

spline of main pump : compound (LM-G) Anti-friction surface of main pump case : Gasket sealant (LG-6)

Refilling with oil (damper) Ir Add engine oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Wait for at least 15 minutes, then check the oil level again.

$ ) I2

installation

Damper

: Approx.

0.7 e

Refilling with oil (hydraulic tank) -f Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Bleed the air from main pump. * For details, see TESTING AND ADJUSTING, Bleeding air.

30-93 0

DISASSEMBLY

MAIN PUMP INPUT SHAFT OIL SEAL

AND ASSEMBLY

REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL 1.

Remove main pump assembly. For details, REMOVAL OF MAIN PUMP ASSEMBLY.

Remove

Lever up oil seal (3) with a screwdriver to rem move. * When removing the oil seal, be extremely careful not to damage the shaft.

snap ring (I), then remove

see

spacer (2).

CLPO3916

INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL l

Carry out installation removal.

in the

reverse

order

Lip of oil seal : Grease (G2-LII Coat the outside circumference of the oil seal with grease (G2-LII thinly, then press fit. Using tool N, press fit oil seal (3).

CLPO3917

30-94 0

DISASSEMBLY

AND ASSEMBLY

CONTROL

VALVE

REMOVAL OF CONTROL VALVE ASSEMBLY a

Run the engine at low idling, operate the cylinder to the end of its stroke without relieving the circuit, then lower the work equipment to the ground. For details, see TESTING AND ADJUSTING, Releasing pressure in hydraulic circuit. After stopping the engine, do as follows.

Loosen the oil filler cap slowly to release the pressure inside the tank. Operate the control levers. * Operate the control levers several times to release the pressure in the accumulator. Start the engine and run at low idling for approx. 5 seconds, then stop the engine and operate the control levers. Ir Repeat the above operation several times to release the remaining pressure completely.

$ t z w

Open engine hood, and remove valve top cover (I) and air cleaner top cover (2).

Remove partition plate covers (3) and (4) between engine and control valve, move partition plate cover (5) under intake hose towards engine.

Disconnect pump discharge hoses and remove hose clamp (8).

Remove self-reducing pressure valve (9). Sr The length of the mounting bolts is different. See below. Left side mounting bolts (2 bolts) : L = 120 mm Right side mounting bolts (2 bolts) : L = 125 mm

Disconnect hoses (IO) between control valve and relay block, hose (1 I) between control valve and timing valve, travel valve pilot hose (12),2 boom valve pilot hoses (131, and 2 relief valve pilot hoses (I 4). * After disconnecting the hoses, fit tags to distinguish them. * Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

(6) and (71,

DISASSEMBLY

AND ASSEMBLY

Disconnect

2 travel valve junction

Disconnect 2 LS pressure pilot hoses (16). * After disconnecting the hoses, fit tags to distinguish them.

Remove

Disconnect 10 hoses (19) connected to each valve. Ir After disconnecting the hoses, fit tags to distinguish them. Ir Protect with the sleeve nut to prevent damage to the nipple or elbow taper seal portion.

timing

valve (Iiâ&#x20AC;&#x2122;)

CONTROL

VALVE

hoses (15).

and drain tube (18).

cLPo3aza

16. Disconnect 2 each of bucket valve tube (201, boom valve tube (211, and arm valve tube (22). 11. Disconnect 2 each of right travel valve hose (231, swing valve hose (241, and left travel valve hose (25). 12. Disconnect

2 LS select valve pilot hoses (26).

13. Sling control valve assembly (27). then remove mounting bolts, and lift off control valve assembly. &I kg

30-96 0

Control valve assembly

: 170 kg

DISASSEMBLY

CONTROL

AND ASSEMBLY

VALVE

INSTALLATION OF CONTROL VALVE ASSEMBLY .

Carry out removal.

Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air Ir Bleed the air from the circuit between the valve and the hydraulic cylinder. For details, see TESTING AND ADJUSTING, Bleeding air.

installation

in the

reverse

order

30-97 0

DISASSEMBLY

CONTROL VALVE

AND ASSEMBLY

DISASSEMBLY OF CONTROL VALVE ASSEMBLY (l/3)

-2

,24

27 X

DKP00526

30-98 0

DISASSEMBLY

CONTROL VALVE

AND ASSEMBLY

W3)

/ 34

Bucket valve

’

‘--/

I \

F-F

Gina

41 valve

IO II 12 13 I4 I5

E-E

Travel valve

A-A

.57

D-D Boom valve

Arm valve

DKP00527

30-99 0

CONTROL VALVE

DISASSEMBLY AND ASSEMBLY

(3/3) --

L-L

B-B

J-J

AA-AA

DKP00528

30-100 0

DISASSEMBLY

AND ASSEMBLY

CONTROL

VALVE

The set pressure of the safety valve cannot be adjusted when it is installed on the machine, so do not disassemble. This section explains the procedure for the 6spool valve.

1. Main relief valve Remove main relief valve (2). 2.

Unload valves, safety-suction valves, suction va Ives 1) Remove unload valves (I) and (17). 2) Remove safety-suction valves (23), (221, (271, (18), and (20). 3) Remove suction valves (251, (241, (21), (26), and (19).

Pressure compensation valves Before removing any pressure compensa* tion valve, check and mark its mounting position. 1) Remove bucket DUMP pressure compensation valve (81, R.H. travel REVERSE pressure compensation valve (71, boom RAISE pressure compensation valve (61, right swing pressure compensation valve (51, L.H. travel REVERSE pressure compensation valve (4), and arm OUT pressure compensation valve (3).

2) Remove

bucket CURL pressure compensation valve (IO), R.H. travel FORWARD pressure compensation valve (I I), boom LOWER pressure compensation valve (121, left swing pressure compensation valve (13), L.H. travel FORWARD pressure compensation valve (14), and arm IN pressure compensation valve (15). After removing the pressure compensation valves, remove check valve (35) from each pressure compensation valve mount.

LS select valve Remove LS select valve (38).

30-101 0

DISASSEMBLY

LS shuttle valves, pump merge/divider valve, boom regeneration valve 1) Remove LS shuttle valves (79) and (81). 2) Remove block (80), then remove boom regeneration spring (61) and boom regeneration valve (62).

Remove

Arm control valve 1) Remove case (70), then remove spring (74) and retainer (69). 2) Remove case (66), then remove spring (67) and retainer (78). 3) Remove spool assembly (68). j, Do not disassemble spool assembly

covers (9) and (16).

(68). 8.

Swing control valve 1) Remove case (40), then remove spring (39) and retainer (41). 2) Remove case (43), then remove spring (36) and retainer (42). 3) Remove spool assembly (37). + Do not disassemble spool assembly (37).

R.H. travel, L.H. travel control valves 1) Remove case (47), then remove spring (46) and retainer (48). 2) Remove case (50), spring (44), and retainer (49). 3) Remove spool assembly (45). _j, Do not disassemble spool assembly (45).

30-102 0

CONTROL

AND ASSEMBLY

VALVE

10. Boom control valve 1) Remove case (57), then remove spring (55) and retainer (60). 2) Remove case (64), then remove spring (53) and retainer (63). 3) Remove spool assembly (54). * Do not disassemble spool assembly (54). 11. Bucket control valve 1) Remove case (30), then remove spring (31) and retainer (32). 2) Remove case (34), then remove spring (28) and retainer (33). 3) Remove spool assembly (29). * Do not disassemble spool assembly (29).

DISASSEMBLY

AND ASSEMBLY

CONTROL VALVE

ASSEMBLY OF CONTROL VALVE ASSEMBLY (l/3)

Bucket RH travel Boom Swing LH travel Arm

23 24 25 26 18

27 X

DKP00526

30-103 0

DISASSEMBLY

CONTROL VALVE

AND ASSEMBLY

43 Bucket

F-F Swine valve

valve

IO II 12 I3 I4

E-E Travel valve

A-A

-57

I D-D

Boom valve

Arm valve

I 74

DKP00527

30-104 0

DISASSEMBLY

CONTROL VALVE

AND ASSEMBLY

(3/3)

24 25

18 c-c J-J

AA-AA

OKP00528

30- 105 0

DISASSEMBLY

Coat the sliding surfaces of all parts with engine oil before installing. Bucket control valve spool 1) Assemble spool assembly (29) to valve body. 2) Assemble retainer (33) and spring (28), then fit O-ring to case (34) and install. w Case mounting bolt : 30.87 +. 3.43 Nm i3.15 2 0.35 kgm) 3) Assemble retainer (32) and spring (31) to spool, then fit O-ring to case (30) and install. m Case mounting bolt : 30.87 f 3.43 Nm 13.15 = 0.35 kgm)

Boom control valve spool 1) Assemble spool assembly (54) to valve body. 2) Assemble retainer (63) and spring (53), then fit O-ring to case (64) and install. m Case mounting bolt : 30.87 + 3.43 Nm I3.15 + 0.35 kgm} 3) Assemble spring (56) and piston (59), then install plug (58). m Plug : 107.8 + 14.7 Nm III.0 = 1.5 kgm) 4) Assemble retainer (60) and spring (55), then install case (57). QIGKI Case mounting bolt : 30.87 t. 3.43 Nm I3.15 t: 0.15 kgm)

R.H. travel, 1) 2)

CONTROL

AND ASSEMBLY

L.H. travel control valves Assemble spool assembly (45) to valve body. Assemble retainer (49) and spring (44), then fit O-ring to case (50) and install. QZFI Case mounting bolt : 30.87 + 3.43 Nm I3.15 + 0.15 kgm} Assemble retainer (48) and spring (46) to spool, then fit O-ring to case (47) and install. m Case mounting bolt : 30.87 + 3.43 Nm (3.15 + 0.15 kgm)

Swing control valve spool 1) Assemble spool assembly (37) to valve body. 2) Assemble retainer (42) and spring (36), then fit O-ring to case (43) and install. w Case mounting bolt : 30.87 +. 3.43 Nm 13.15 t 0.15 kgm)

30-106 0

VALVE

Assemble retainer (41) and spring (39), then fit O-ring to case (40) and install. w Case mounting bolt : 30.87 2 3.43 Nm 13.15 +. 0.15 kgm)

Arm control valve 1) Assemble spool assembly (68) to valve body. 2) Assemble retainer (78) and spring (67), then fit O-ring to case (66) and install. D Case mounting bolt : 30.87 2 3.43 Nm (3.15 + 0.15 kgm} 3) Assemble retainer (69) and spring (74), then fit O-ring to case (70) and install. m Case mounting bolt : 30.87 f. 3.43 Nm 13.15 + 0.15 kgml

DISASSEMBLY

AND ASSEMBLY

Covers 1) Fit O-ring to cover (161, then install. 2) Fit O-ring to cover (91, then install. & Mating surface of covers (16), (9) : Seal end 242 or equivalent + Tighten the mounting bolts in the order shown in the diagram on the right. m Mounting bolt : 166.6 +. 9.8 Nm I17 + 1 kgm}

LS shuttle valves, pump merge/divider valve, boom regeneration valve 1) Assemble boom regeneration valve (62) and spring (61) to valve body, then install block

CONTROL

VALVE

CKP00820

(80). * Tighten the mounting bolts in the order shown in the diagram on the right. w Mounting bolt : 166.6 2 9.8 Nm {I7 = 1 kgml Install LS shuttle valves (81) and (79). w Mounting bolt : 66.15 2 7.35 Nm I6.75 f 0.75 kgm}

LS select valve Install LS select valve (38). m LS select valve : 127.4 = 19.6 Nm I13 t 2 kgml 9.

Pressure compensation valves Check the marks made on each pressure compensation valve during disassembly, and install in the correct position. pressure compensation 1) Before installing valves below, install check valve (35). 2) Fit O-ring, then install arm IN pressure compensation valve (15), L.H. travel FORWARD pressure compensation valve (14), left swing pressure compensation valve (131, boom LOWER pressure compensation valve (121, R.H. travel FORWARD pressure compensation valve (II), and bucket CURL pressure compensation valve (IO). w Pressure compensation valves : 392 2 19.6 Nm I40 +. 2 kgm1 3) Fit O-ring, then install arm OUT pressure compensation valve (31, L.H. travel REVERSE pressure compensation valve (4), right swing pressure compensation valve (5), boom RAISE pressure compensation valve (6), R.H. travel REVERSE pressure compensation valve (71, and bucket DUMP pressure compensation valve (8). m Pressure compensation valves : 392 + 19.6 Nm I40 2 2 kgml

30- 107 0

DISASSEMBLY

AND ASSEMBLY

CONTROL

VALVE

valves, suction IO. Unload valves, safety-suction va Ives 1) Fit O-rings and install suction valves (191, (261, (21), (241, and (25). Suction valve : w 147 + 9.8 Nm (15 + 1 kgm} 2) Fit O-rings and install safety-suction valves (181, Wâ&#x20AC;&#x2122;), (221, and (23). valve : Safety-suction 147 2 9.8 Nm I15 +. 1 kgm} Fit O-rings and install unload valves (17) and

m 3)

(I). QZI

CKPOOSZO

Unload

valve assembly : 166.6 + 19.6 Nm (17 +. 2 kgm}

11. Main relief valve . Fit O-ring and install main relief valve assembly (2). Main relief valve : w 53.9 + 4.9 Nm 15.5 + 0.5 kgm1

30-108 0

DISASSEMBLY

MAIN RELIEF VALVE

AND ASSEMBLY

DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY

CKP03919

2. 3. sr

Loosen locknut (91, remove plug (81, then remove retainer (6). Loosen locknut (IO), then remove holder (71, spring (II), seat (121, and poppet (5). Remove ring (I), then remove valve (3) and spring (4). If any abnormality is found in any part after disassembly, replace the whole main relief valve assembly.

$ > i

ASSEMBLY OF MAIN VALVE ASSEMBLY .

Coat the sliding surfaces

RELIEF

with engine

oil.

1. Assemble spring (4) and valve (31, then install ring (I). and 2. Install seat (121, poppet (5), spring (II), holder (71, and secure in position with locknut

(IO). w Locknut : 53.9 2 4.9 Nm 15.5 2 0.5 kgml Fit retainer (61, then install plug (8) and secure in position with locknut (9). w Locknut : 39.7 + 4.9 Nm (4.0 + 0.5 kgml After installing main relief valve to control valve assembly, adjust pressure referring to section TESTING AND ADJUSTING, testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.

30-109 0

DISASSEMBLY

PC VALVE

AND ASSEMBLY

REMOVAL OF PC VALVE ASSEMBLY a a

Disconnect the cable from the negative t-1 terminal of the battery. to the completely Lower the work equipment ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove the hydraulic tank strainer, and using tool B, stop the oil. When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system.

CLPO3276

Hydraulic

tank : Approx.

170 e

There are PC valve assemblies installed to both the front pump and the rear pump, but the procedure for removal is the same.

Remove (2).

Install locknut @ (708-2L-28290). Locknut : w 100.5 +. 12.5 Nm (10.25

nut (I),

then

remove

hose

assembly m

+ 1.25 kgm}

then of loosening, Turn nut (3) in direction tighten at locknut 0 end. Ir Angle of turning for nut (3): Approx. 30â&#x20AC;?

Fit tool to width across flats (22 mm) of hexagonal portion of sleeve (41, then loosen and rem move PC valve assembly (5).

30-110 0

CKP03719

DISASSEMBLY

AND ASSEMBLY

INSTALLATION ASSEMBLY l

Carry out installation removal.

OF PC VALVE

in the

reverse

Nut (2) : 100.5 + 12.5 Nm (IO.25

order

= 1.25 kgml

After installing the PC valve move locknut 0.

Adjust the PC valve assembly. For details, see TESTING AND ADJUSTING, Testing and adjusting PC valve output pressure (servo piston inlet pressure). Nut (3) : 100.5 t: 12.5 Nm {IO.25 +. 1.25 kgml

PC VALVE

assembly,

re-

Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-l 11 0

DISASSEMBLY

AND ASSEMBLY

LS VALVE

REMOVAL OF LS VALVE ASSEMBLY g g

Disconnect the cable from the negative (4 terminal of the battery. Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Remove the hydraulic tank strainer, and using tool B, stop the oil. . When not using tool B, remove the drain plug, and drain the oil from the hydraulic tank and inside the system. w

Hydraulic

tank : Approx.

170 e

There are LS valve assemblies installed to both the front pump and the rear pump, but the procedure for removal is the same.

Disconnect

hose (I).

Fit tool to width across flats (30 mm) of hexagonal portion of sleeve, then loosen and remove LS valve assembly (2). m

INSTALLATION ASSEMBLY l

Carry out installation removal.

OF LS VALVE

in the

reverse

order

Adjust the LS valve assembly. For details, see TESTING AND ADJUSTING, Testing and adjusting LS valve output pressure (servo piston inlet pressure) and LS differential pressure. Sleeve : 139.7 2 12.3 Nm (14.75 + 1.25 kgm}

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

30-112 0

CLP03276

DISASSEMBLY

PC-EPC VALVE

AND ASSEMBLY

REMOVAL OF PC-EPC VALVE ASSEMBLY g A

1. Remove

the main pump

bottom

cover.

Disconnect wiring connectors (I) (2 places). * After disconnecting the connectors, fit tags to distinguish them.

Disconnect

Remove

hose (2).

PC-EPC valve assembly

(3).

INSTALLATION OF PC-EPC VALVE ASSEMBLY l

Carry out installation removal.

in the

reverse

order

Hose sleeve nut : 24.5 + 4.9 Nm I2.5 I 0.5 kgm}

PC-EPC valve assembly mounting 13.3 = 1.5 Nm Il.35 = 0.15 kgm}

bolt :

30-l 13 0

DISASSEMBLY

AND ASSEMBLY

SOLENOID VALVE

REMOVAL OF SOLENOID VALVE ASSEMBLY (-) ter-

Disconnect the cable from the negative minal of the battery.

Remove 3 solenoid wiring connectors (I) from clip and disconnect. Mark the male and female ends of each con* nector with tags to prevent mistakes when connecting.

Disconnect 2 hoses (2) installed to bottom of valve. After disconnecting the hoses, fit tags to dis* tinguish them.

Disconnect 4 hoses (3) installed to top of valve. Ir After disconnecting the hoses, fit tags to distinguish them.

Remove mounting bolts, then remove valve assembly (4).

When

removing

solenoid

part i) When washing valve, (5) and remove.

solenoid

valve as an individual bolt

loosen mounting

INSTALLATION OF SOLENOID VALVE ASSEMBLY l

Carry out removal.

installation

in the

reverse

order

Bolt : 3.9 t 0.39 Nm IO.4 2 0.04 kgm}

CKP01453

30-l 14 0

DISASSEMBLY

WORK EQUIPMENT

AND ASSEMBLY

REMOVAL OF WORK EQUIPMENT SWING VALVE ASSEMBLY l

SWING

PPC

VALVE

PPC

Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove control stand case. For details, see REMOVAL OF CONTROL CASE.

STAND CLPOO821

Remove

joint bolt (I), and disconnect

hose (2). m

Remove mounting bolts, raise PPC valve assembly (3), then disconnect hoses (4) and (5), and m remove. Ir Before disconnecting the hoses, make match marks to show the connecting position.

z z

INSTALLATION OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY l

Carry out removal.

installation

in the

reverse

order

Hose mount joint bolt : 29.4 2 4.9 Nm (3.0 5 0.5 kgm)

QZZI Ir

Hose mount joint bolt : 39.2 + 4.9 Nm (4.0 I 0.5 kgm) If there is excessive play in the control levers, adjust the PPC valve. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.

30-l 15 0

DISASSEMBLY

WORK EQUIPMENT

AND ASSEMBLY

SWING PPC VALVE

DISASSEMBLY OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY l

Remove

nut (I), then remove

disc (2) and boot

(3).

Remove bolts, then remove plate (5). * Do not remove joint (4) unless it is to be replaced.

Remove

Pull out piston (81, and remove retainer (91, springs (IO) and (II), and shim (12). * Spring (IO) consists of a set of two types of springs with different installed loads, so check the mounting position (oil port) and mark with tags to prevent mistakes when installing.

Pull out valve (13) from body (14).

seal (6) and collar (7).

CLP03924

30-l 16 0

DISASSEMBLY

WORK EQUIPMENT.

AND ASSEMBLY

SWING

PPC

VALVE

ASSEMBLY OF WORK EQUIPMENT SWING PPC VALVE ASSEMBLY l

Assemble

valve (13) to body (14).

Assemble

shim

(12)

and

spring

(11) to valve

(13). * When assembling spring (II), set the end with the small coil diameter (inside diameter) at shim (12) end. 3.

Assemble spring (IO), retainer (9), and piston (8). * The number of loops in the coil for spring (IO) is different for each of the hydraulic ports below, so be careful when installing. k

The position of each port is marked on the bottom of the valve body. & Piston : Grease (G2-LB When assembling piston (81, coat the outside of the piston and the inside of the hole in the body with grease. 4.

Fit O-ring to collar (7) and assemble (141, then install seal (6).

Install plate (5). m Mounting bolt : 13.23 2 1.47 Nm (I.35

2 0.15 kgml

(

, 5-7mm

Install joint (4). ,Q& Sliding portion & j,

w * 7.

in body

of joint : Grease (G2-LII, 2 - 4 cc Female thread of body : Thread tightener (LT-21 Coat two places on the female thread with one drop each of Loctite as shown in the diagram. Joint : 44.1 + 4.9 Nm 14.5 f 0.5 kgm1 Keep strictly to the tightening torque.

CKP03925

Assemble boot (3) and disc (2), and tighten with nut (I). & Contact surface of piston and disc : Grease (G2-LI), 0.3 - 0.8 cc m Nut : 112.7 = 14.7 Nm Ill.5 t 1.5 kgm1 j, After assembling the disc, adjust the height of the disc. For details, see TESTING AND ADJUSTING, Adjusting PPC valve.

30417 0

DISASSEMBLY

TRAVEL PPC VALVE

AND ASSEMBLY

REMOVAL OF TRAVEL PPC VALVE ASSEMBLY A

Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

Remove

travel PPC valve undercover.

Remove

floor mat.

Remove

pedals (I) and levers (2).

Remove

cover (3).

Remove

covers (41, then remove

Disconnect 6 PPC hoses (71, then remove PPC valve assembly (8).

Ill

springs

CEPO0426

(5). travel a

CEP00427

INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY l

Carry out installation removal.

in the

reverse

order

Cover mounting

bolt : 19.6 2 1.96 Nm 12.0 + 0.2 kgm}

CEP00428

Hose mount joint bolt : (width across flats : 30 mm) :

39.2 + 4.9 Nm I4.0 + 0.5 kgm1 Hose mount elbow : (width across flats : 22 mm) :

34.3 z 4.9 Nm (3.5 e 0.5 kgm1

Hose mount joint bolt : (width across flat : 17 mm) :

24.5 f 4.9 Nm 12.5 2 0.5 kgm1

I 30-l 18 0

0 CEP00429

DISASSEMBLY

AND ASSEMBLY

TRAVEL PPC VALUE

DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY screws (I), then remove

levers (2).

Remove

Remove mounting bolts (3), then and shaft assembly (41.

Remove mounting bolts (51, then remove plate (6) and damper assembly (7) as one unit. * Check the thickness and mounting position of washer (18). * Never disassemble damper assembly (7).

Remove mounting bolts (8), then remove damper assembly (7) from plate (6).

Remove

Pull out piston (II), and remove retainer (12), springs (13) and (14), and shims (15). * Check the number and thickness of shims (15) for each mounting position, and keep in a safe place.

Pull out valve (16) from

remove

case

seal (9) and collar (IO).

body (17).

CLP03926

30-l 19 0

DISASSEMBLY

TRAVEL PPC VALVE

AND ASSEMBLY

ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY I.

Assemble

valve (16) in body (17). shim

(15)

and

spring

(14) to valve

(16). * Assemble the same number and thickness of shim (15) as was removed during disassem bly. Standard shim thickness : 0.3 mm * Spring (14) is not symmetrical at the top and bottom, so assemble with the small coil diameter (inside diameter) at the shim end. 3.

Assemble (II). &

spring

(13), retainer

(121, and piston

Outside circumference of piston, body hole : Grease (G2-LI)

Fit O-ring to collar (IO) and assemble (171, then install seal (9).

in body

Install damper assembly (7) to plate (61, then tighten mounting bolts (8). & Mounting bolt : Thread tightener (LT-2) m Mounting bolt: 4.41 + 0.49 Nm IO.45 t 0.05 kgm}

Install plate (6) and damper assembly (7) as one unit, then tighten mounting bolts (5). * Check the thickness of washer (18) and assemble in the position checked during disassembly. w Mounting bolt: 30.87 f 3.43 Nm I3.15 = 0.35 kgm)

Install case and shaft assembly (4), then tighten mounting bolts (3). * Check that the out-of-parallel of shaft and damper assembly (7) of case and shaft assembly (4) is less than 0.5. & Rocking portion of shaft, connection of lever and piston :

Grease (G2-LI) w

Mounting bolt: 27.93 z 3.43 Nm 12.85 + 0.35 kgm}

Install levers (21, then tighten screws (I). * Adjust so that lever (2) can slightly move. & Rocking portion of lever pin and plate :

30- 120 0

Screw

Grease (G2-LI) : 8.82 t. 0.98 Nm iO.9 + 0.1 kgm}

CLP03926

DISASSEMBLY

AND ASSEMBLY

BOOM

LOCK VALVE

REMOVAL OF BOOM LOCK VALVE ASSEMBLY A

to the completely Lower the work equipment ground, then release the remaining pressure in the hydraulic circuit. For details, see TESTING Releasing remaining pressure AND ADJUSTING, in hydraulic circuit.

Disconnect

tube (I) and hoses (2).

Disconnect

tube (3).

Remove mounting bolts of bracket (4), then remove boom lock valve (5) together with bracket

CLPO3927

(4).

OF BOOM INSTALLATION LOCK VALVE ASSEMBLY . 0â&#x20AC;? > z LLI

Carry out installation removal.

in the

reverse

order

to CLPO3928

AND

30-121 0

DISASSEMBLY

BOOM

AND ASSEMBLY

CYLINDER

REMOVAL OF BOOM CYLINDER ASSEMBLY a

Extend the arm and bucket fully, lower the work equipment completely to the ground, and put the safety lock lever in the LOCK position.

Disconnect

Sling boom cylinder lock bolt (3).

Remove plate, then remove head pin (4). a * There are shims installed, so check the number and thickness, and keep in a safe place.

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out. * Set stand @ under the cylinder assembly, and adjust the position for slinging. A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

Disconnect

Remove plate, then using forcing screws 0, remove bottom pin (61, and remove boom cylinm der assembly (2). * There are shims installed, so check the number and thickness, and keep in a safe place. I+ kg

30-122 0

grease

hose (I). assembly

(2), and remove m

hoses (5).

Boom cylinder

assembly

: 190 kg

CLPO3929

DISASSEMBLY

BOOM

AND ASSEMBLY

CYLINDER

INSTALLATION OF BOOM CYLINDER ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

a Ir

When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between cylinder rod (7) and plate (8) is below 1 mm. Standard shim thickness : 0.8 mm, 1.5 * mm

6 g *

g *

Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance c between cylinder bottom (9) and bracket (IO) is below 1 mm. Ir Standard shim thickness : 0.8 mm, 1.5 mm

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

CKP03932

CLP03933

CLPO3934

Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30-123 0

DISASSEMBLY

ARM CYLINDER

AND ASSEMBLY

REMOVAL OF ARM CYLINDER ASSEMBLY A

Extend the mm, lower the ground, lever to the

arm cylinder piston rod approx. 200 the work equipment completely to then set the remaining safety lock LOCK position.

Set block @ between

arm cylinder

Remove

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming

plate, then remove

and boom.

head pin (I).

out. A

Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

Disconnect

hoses (2).

Disconnect

grease

Raise arm cylinder assembly, remove plate, remove bottom pin (41, then remove arm cylinder m assembly (5). Sr There are shims installed, so check the number and thickness, and keep in a safe place. &I kg

30-124 0

hose (3).

Arm cylinder

assembly

: 265 kg

CLP03935

DISASSEMBLY

AND ASSEMBLY

ARM CYLINDER

INSTALLATION OF ARM CYLINDER ASSEMBLY l

Carry out removal.

6 A Ir

installation

in the

reverse

order

CLPO3936

Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Greasing after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between cylinder bottom (6) and bracket (7) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.5 mm

Refilling with oil (hydraulic tank) Ir Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30- 125 0

DISASSEMBLY

AND ASSEMBLY

BUCKET CYLINDER

REMOVAL OF BUCKET CYLINDER ASSEMBLY a

Extend the bucket cylinder piston rod approx. 200 mm, lower the work equipment completely to the ground, then set the safety lock lever to the LOCK position.

1. 2.

Set block @ under arm top. Set block @ between link and arm, and block @ between bucket cylinder and arm. m Remove lock bolt (I). Remove plate, then remove head pin (2). 1121 j, There are shims installed, so check the number and thickness, and keep in a safe place. Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming

3. 4.

CLPO3937

out. A

6. 7.

Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. Disconnect 2 hoses (3). Raise bucket cylinder assembly, remove plate, remove bottom pin (41, then remove bucket cylm inder assembly (5). * There are shims installed, so check the number and thickness, and keep in a safe place. Bucket cylinder assembly : 165 kg &I kg

30-126 0

-PO3938

DISASSEMBLY

BUCKET CYLINDER

AND ASSEMBLY

INSTALLATION OF BUCKET CYLINDER ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

m Sr When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm. a

& g *

a *

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between link (6) and link (7) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.5 mm

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance c between cylinder bottom (8) and bracket (9) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.5 mm

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

CKP03932

-PO3939

CLP03940

Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30- 127 0

DISASSEMBLY

AND ASSEMBLY

HYDRAULIC CYLINDER

DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1.

Piston rod assembly 1) Remove piping from cylinder assembly. 2) Remove mounting bolts and disconnect head assembly (I). 3) Pull out piston rod assembly (2). Place a container under the cylinder to * catch the oil.

CLPO3941

Disassemble piston rod assembly as follows. Set piston rod assembly (2) in tool 01. i)

CLPO3778

ii)

Remove stopper screw (3) of piston assembly. Common screw size for boom, arm, * and bucket cylinder: Ml2 x Pitch 1.75

CLPO3779

If the caulking of screw (3) is too strong and it cannot be removed, tighten the screw fully, then fit a tap to the thread and remove the screw.

Tap

I 30- 128 0

DKP00498

DISASSEMBLY

iii)

HYDRAULIC CYLINDER

AND ASSEMBLY

Using tool 02,

remove

piston assembly

(4). . When not using tool 02, use the drill holes (0 10, 4 places) and loosen the piston assembly.

DLPOO499

iv) Remove plunger (5). Boom and arm cylinder only v) *Remove collar (6). Boom and arm cylinder only vi) kemove head assembly (7).

CLPO3782

vii) Remove cap (8), and pull out 12 balls (9), then remove plunger (IO). . Boom and arm cylinder only

CKP03783

Disassembly of piston assembly I) 2) 3) 4)

Remove Remove Remove Remove

rings (II). wear rings (12). piston ring (13). O-ring and backup ring (14).

CLP03784

30- 129 0

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

Disassembly of cylinder head assembly 1) Remove O-ring and backup ring (15). 2) Remove snap ring (161, then remove seal (17). 3) Remove rod packing (18). 4) Remove buffer ring (19). 5) Remove bushing (20).

CYLINDER

dust

CLPO2322

30-130 0

DISASSEMBLY

AND ASSEMBLY

HYDRAULIC

CYLINDER

ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY j, *

Be careful not to damage the packings, dust seals, and O-rings. Do not try to force the backup ring into position. Warm it in warm water (50 - 60Â°C) before fitting it. Assembly of head assembly 1) Using tool 05, press fit bushing (20). 2) Assemble buffer ring (19). 3) Assemble rod packing (18). 4) Using tool 06, install dust seal (17), and secure with snap ring (16). 5) Install backup ring and O-ring (15).

CLPO3786

CLPO3787

19 I8

CLPO2322

Assembly of piston assembly 1) Using tool 03, expand piston ring (13). * Set the piston ring on tool 03, and turn the handle 8 - 10 times to expand the ring. 2) Set tool 04 in position, and compress piston ring (13).

CKP03788

3) 4) 5)

CLPO3789

Install backup ring and O-ring (14). Assemble wear ring (12). Assemble ring (II). * Be careful not to open the end gap of the ring too wide. & Ring groove : Grease (G2-LI)

CLPO3784

30-l 31 0

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

Piston rod assembly 1) Set piston rod assembly

CYLINDER

(2) to tool 01.

CLPO3778

Assemble

head assembly

(7).

Fit O-ring and backup ring to collar (61, then assemble. . Boom and arm cylinder only

Assemble plunger (5). . Boom and arm cylinder only * Check that there is a small amount play at the tip of the plunger. . Arm cylinder only

CLPO3782

Set cushion plunger (IO) to piston rod, then assemble 12 balls (9) and secure with cap (8). l

Arm cylinder

only

CKP03783

Assemble piston assembly (4) as follows. l When using rod and piston again: Wash thoroughly and remove all * metal particles and dirt. i) Screw in piston assembly (41, then use tool 02 to tighten piston assembly (2) so that position of screw thread hole matches. * Remove all burrs and flashes with a file. ii) Tighten screw (3). m Screw (3) : 66.2 + 7.35 Nm 16.75 + 0.75 kgm)

30-132 0

DLP00499

DISASSEMBLY

iii) .

AND ASSEMBLY

Caulk thread

HYDRAULIC CYLINDER

at 2 places with punch.

When using a new part for either or both of rod or piston assembly (2) Ir For the rod with bottom cushion, mark the cushion plug position on the end face of the rod. . Arm cylinder only

DKP00500

Screw in until piston assembly (4) contacts end face of rod, then use tool 02 to tighten. w Piston assembly (4): 294 t 29.4 Nm I30 + 3.0 kgm) * After tightening the piston, check that there is play in plunger (5). . Boom, arm cylinder only

DKP00501

ii)

Machine one of holes used to install screw (3). * Align a drill horizontal with the V-groove of the thread of rod (2) and piston (4), then carry out machining. For the cylinder with bottom * cushion (arm cylinder), avoid the cushion plug position when machining. . Screw machining dimension (mm) CLPO3792

iii)

After machining, wash thoroughly to remove all metal particles and dust.

iv)

Tighten screw (3). m Screw (3) : 66.2 f 7.35 Nm 16.75 r 0.75 kgm}

v) Caulk thread

at 2 places with punch. CLPO3779

30-133 0

DISASSEMBLY

HYDRAULIC

AND ASSEMBLY

CYLINDER

Assemble piston rod assembly (2). & Seal portion : Grease (G2-LI) Ir Set the end gap of the ring horizontal (at side position), align axial center of cylinder tube, then insert. * After inserting, check that the ring is not broken and has not come out, then push in fully. End

~a;

rina DLPOO502

Tighten head assembly bolts. w Mounting bolt :

mounting

Bucket

270-e39Nm

{27.5&4.0kgm)

Arm

373?54Nm

{38.0+5.5kgm}

270+39Nm

{27.5+4.0kgm}

Install piping.

30-134 0

with

Cylinder

Boom 9)

(I)

Tightening

torque

CLPO3941

DISASSEMBLY

WORK EQUIPMENT

AND ASSEMBLY

REMOVAL OF WORK EQUIPMENT ASSEMBLY

$ z c:

Extend the arm and bucket fully, lower the work equipment to the ground, and set the safety lock lever to the LOCK position.

Disconnect

Sling boom cylinder lock bolt (3).

Remove plate, then remove head pin (4) m * There are shims installed, so check the number and thickness, and keep in a safe place.

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out, and lower it onto block. * Disconnect the boom cylinder on the opposite side in the same way. A Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit.

Disconnect hoses (5), and secure it to valve with rope. * Hoses (6) are for machines equipped with an additional attachment circuit.

Disconnect lamp.

Sling work equipment assembly, remove plate, then remove foot pin (7) using tool P, and rem move work equipment assembly (8). * There are shims installed, so check the number and thickness, and keep in a safe place. &I kg

grease

wiring

hose (1). assembly

connector

Work equipment

(2), and remove m

(6) for

assembly

CLPO3929

working

CLPO4028

: 3,300 kg

CLPO4029

30- 135 0

DISASSEMBLY

AND ASSEMBLY

WORK

EQUIPMENT

INSTALLATION OF WORK EQUIPMENT ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.

-t----------

=@=

t a &

& a Ir

Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between cylinder rod (IO) and plate (I I) is below 1 mm. Standard shim thickness : 0.8 mm, 1.5 mm

CKP03932

a Ir

Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance c between boom (12) and bracket (13) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.0 mm, 1.5 mm

Refilling with oil (hydraulic tank) * Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30- 136 0

CLPO3947

CLPO3948

DISASSEMBLY

AND ASSEMBLY

BUCKET

REMOVAL OF BUCKET ASSEMBLY g

Set the back of the bucket facing down, lower the work equipment completely to the ground, and set the safety lock lever to the LOCK position.

Remove

Remove connecting pin (2) between link and bucket. m * There are shims installed, so check the number and thickness, and keep in a safe place.

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out.

Remove

Remove plate (41, the remove connecting pin (5) between arm and bucket. m Jr There are shims installed, so check the number and thickness, and keep in a safe place.

After raising work equipment, nect bucket assembly (6).

el kg

lock bolt (I).

lock bolt (3).

Bucket assembly

swing to discon-

: 650 kg

30- 137 0

DISASSEMBLY

INSTALLATION ASSEMBLY .

BUCKET

AND ASSEMBLY

Carry out installation removal.

OF BUCKET

in the

reverse

order

tightening the locknut, tighten so that Ten clearance a between the plate and nut is 0.5 - 1.5 mm.

& a *

Inside surface of bushing when assembling pin : compound (LM-PI Anti-friction Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance bucket boss (7) and link (8) is b between mm. 1 below * Standard shim thickness : 0.8 mm, 1.5

CKP03932

g * *

Inside surface of bushing when assembling pin : compound (LM-P) Anti-friction Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Set the O-ring at the end face of the bucket

CLPO3952

boss securely. Adjust the shim thickness so that clearance c between arm top (9) and spacer (IO) is 0.5 - 1.0 mm. Standard shim thickness : 0.5 mm, 1.0 * mm CLPO3953

30- 138 0

DISASSEMBLY

REMOVAL

ARM

AND ASSEMBLY

OF ARM ASSEMBLY

Remove bucket assembly. For details, MOVAL OF BUCKET ASSEMBLY.

Secure front link to arm with wire.

Pull in arm so that it is easy to remove pin at arm cylinder head, then lower arm and bucket c linder assembly (I) on to block 0. Set the safety lock lever to the LOCK posii tion.

Set block @ between

Remove pin (2).

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming

arm cylinder

plate, then remove

see RE-

and boom.

arm cylinder

CLPO5181

head m

out. g

$ & z

Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND pressure ADJUSTING, Releasing remaining in hydraulic circuit.

Disconnect 2 hoses (3). * Install blind plugs at the male end and in the disconnected hoses.

Remove plate, then remove connecting pin (4) a between arm and boom. * There are shims installed, so check the number and thickness, and keep in a safe place.

After raising boom, swing to remove bucket cylinder assembly (I ). &I kg

Arm,

bucket cylinder

assembly

arm and

: 950 kg

30- 139 0

DISASSEMBLY

AND ASSEMBLY

INSTALLATION ASSEMBLY l

Carry out installation removal.

6 g

6 A *

ARM

OF ARM

in the

reverse

order

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between boom top (6) and arm bottom (7) is below 1.0 mm. * Standard shim thickness : 0.8 mm

30- 140 0

CLPO3955

DISASSEMBLY

AND ASSEMBLY

BUCKET

REMOVAL OF BUCKET ASSEMBLY

Extend the arm cylinder piston rod approx. 200 to completely mm, lower the work equipment the ground, then set the safety lock lever to the LOCK position.

Set block @I between

Remove pin (1).

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming

plate, then

remove

ARM

arm cylinder

and boom.

arm cylinder

head m CLPO3956

out. A

$ > z

pressure in the hyRelease the remaining draulic circuit. For details, see TESTING AND Releasing remaining pressure ADJUSTING, in hydraulic circuit.

Disconnect hoses (2) and (3). * Install blind plugs at the male end and in the hoses. disconnected

Raise bucket and arm assembly, remove plate, arm pin (4) between then remove connecting and boom, and remove bucket and arm assema bly (5). so check the There are shims installed, * number and thickness, and keep in a safe place. &I kg

Bucket, arm assembly

CLPO3957

: 1,650 kg

30-l 41 0

DISASSEMBLY

AND ASSEMBLY

BUCKET

INSTALLATION OF BUCKET ARM ASSEMBLY .

Carry out installation removal.

in the

reverse

g j,

order

Inside surface of bushing when assembling pin : Anti-friction compound (LM-PI Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance a between boom top (6) and arm bottom (7) is below 1 mm. * Standard shim thickness : 0.8 mm

Refilling with oil (hydraulic tank) + Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.

Bleeding air * Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30-142 0

ARM

,=Q.=

CLPO3955

DISASSEMBLY

AND ASSEMBLY

BOOM

REMOVAL OF BOOM ASSEMBLY 1.

Remove bucket and arm assembly. For details, see REMOVAL OF BUCKET, ARM ASSEMBLY.

Lower boom assembly completely to ground, and set safety lock lever to LOCK position.

Disconnect

Sling boom cylinder lock bolt (3).

grease

hose (I). assembly

(2), and remove a

Remove plate, then remove head pin (4). m Sr There are shim installed, so check the number and thickness, and keep in a safe place.

Start engine, and retract piston rod, then tie piston rod with wire to prevent it from coming out, and lower it onto block. * Disconnect the boom cylinder on the opposite side in the same way. a Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, Releasing remaining pressure in hydraulic circuit. Disconnect rope.

hoses (51, and secure to valve with

Disconnect lamp.

wiring

Raise boom assembly and remove plate, remove foot pin (7) using tool P, then remove boom m assembly (8). * There are shims installed, so check the number and thickness, and keep in a safe place.

el kg

connector

Boom assembly

(6) for

CLPO3929

working

CLPO4028

: 1,650 kg

PO0538

DISASSEMBLY

AND ASSEMBLY

INSTALLATION ASSEMBLY l

Carry out removal.

installation

BOOM

OF BOOM

in the

reverse

order

-=@$ -_

When tightening the locknut, tighten so that clearance a between the plate and nut is 0.5 - 1.5 mm.

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance b between cylinder rod (IO) and plate (II) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.5 mm

_+-_-__r_-

& g Ir

CKP03932

r!d

FLL g j,

Inside surface of bushing when assembling pin : Anti-friction compound (LM-P) Grease after assembling pin : Grease (LM-G) When aligning the position of the pin hole, never insert your fingers in the pin hole. Adjust the shim thickness so that clearance c between boom (12) and bracket (13) is below 1 mm. * Standard shim thickness : 0.8 mm, 1.0 mm, 1.5 mm

Refilling with oil (hydraulic tank) Sr Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. Bleeding air j, Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinder.

30-144 0

CLPO3947

C CLPO3948

DISASSEMBLY

AND ASSEMBLY

OPERATORS

CAB

REMOVAL OF OPERATOR’S CAB ASSEMBLY a

Disconnect the cable from the negative minal of the battery.

Remove

Disconnect speaker wiring (I), room lamp wiring (2), antenna wiring (3), and washer hose (4). * Fit tags to mark the male and female ends of the connectors to prevent mistakes when connecting.

floor mat.

Disconnect

Remove 9 cab mounting bolts. Ir Check the position of the connection.

wiper

motor wiring

connector

chassis

Lift off operator’s

cab asseembly

Operator’s

cab assembly

&I kg

(-) ter-

CLPO4021

(5).

ground

(6).

: 250 kg

CLPO4022

INSTALLATION OF OPERATOR’S CAB ASSEMBLY .

Carry out removal.

installation

in the

reverse

order

CLPO4,023

1024

DISASSEMBLY

AND ASSEMBLY

REMOVAL OF COUNTERWEIGHT

COUNTERWEIGHT

ASSEMBLY

Set eyebolts and sling.

Remove mounting bolts (2) and (3). * Be careful not to lose the shims moving.

Lift off counterweight (I) horizontally with wire or chain block. m Ir Be careful not to hit the engine, radiator and cooler assembly. Counterweight assembly : 3,430 kg r+ kg

@ to counterweight

assembly

(I),

a when re-

b-*4 -

CLPO3959

INSTALLATION OF COUNTERWEIGHT ASSEMBLY .

Carry out installation removal. &

order

of counterweight mounting bolt: Thread tightener (LT-2) Counterweight mounting bolt : 1,323 +. 147 Nm I135 f 15 kgm1

Installing and adjusting counterweight 1) Sling counterweight with crane and set in position on frame. 2) Push counterweight and install shim and mounting bolts (2) and (3), and adjust to following dimensions. . Clearance from revolving frame : 10 f 5 mm (left and right) . Clearance from bodywork door : 10 + 5 mm (left and right) . Stepped difference b from revolving frame in left-to right direction : Max. 5 mm . Stepped difference a from bodywork door in left-to right direction : 10 +4mm . Stepped difference c from bodywork top cover in up-down direction : Max. 5 mm

30- 146 0

reverse

Thread

in the

Door

Unit:mm

-Counterweiaht

2 I: __

a=10+4

Revolving frame

DKP00503

DISASSEMBLY

AND ASSEMBLY

MONITOR

REMOVAL OF MONITOR ASSEMBLY g

Disconnect the cable from the negative minal of the battery.

(-1 ter-

Remove boot (2) from cover (I), raise to top, then remove lever (3). * Check the direction of the lever.

Disconnect

Remove

horn wiring.

cover (I),

and disconnect

3 connectors

CLPO4025

(4). 4.

Remove

monitor

assembly

INSTALLATION ASSEMBLY $ >

â&#x20AC;&#x2122;

8 LLI

Carry out installation removal.

(5) from cover (1). m

OF MONITOR

in the

reverse

order

a w

Mounting nut of monitor assembly : 8.33 + 0.49 Nm IO.85 2 0.05 kgm}

30-l 47 0

MAINTENANCE

STANDARD

Swing machinery ......................................... Swing circle ................................................. Final drive .................................................... Track frame Recoil spring.. ...................... Idler.. .............................................................. Carrier roller ................................................ Track roller.. ................................................. Track shoe.. .................................................. Hydraulic pump.. ........................................ Control valve ............................................... Self-reducing pressure valve ..................... Swing motor.. .............................................. Travel motor ................................................ Work equipment Swing PPC valve.. ....... Travel PPC valve .......................................... Service PPC valve ........................................ Center swivel joint ..................................... Boom holding valve.. .................................. Hydraulic cylinder ...................................... Work equipment.. ....................................... Dimension of work equipment ................. l

40- 2 40- 4 40- 6 40- 8 40-10 40-12 40-13 40-14 40-19 40-20 .40-27 40-28 40-29 .40-30 40-31 40-32 40-33 .40-35 40-36 40-38 40-40

40-l

MAINTENANCE

SWING

STANDARD

SWING MACHINERY

MACHINERY

SAP02735

40-2

MAINTENANCE

SWING MACHINERY

STANDARD

Unit: mm

No.

Remedy

Criteria

Check item

I Standard 1

Clearance

clearance

limit

Backlash between swing motor shaft and No. 1 sun gear -

0.18 - 0.29

Backlash between No. 1 sun gear and No. 1 planetary gear

0.15 - 0.47

1.00

Backlash between No. 1 planetary gear and ring gear

0.17 - 0.55

1.10

Backlash between No. 1 planetary carrier and No. 2 sun gear

0.36 - 0.63

1.20

Backlash between No. 2 sun gear and No. 2 olanetary oear

0.14 - 0.44

0.90

Backlash between No. 2 planetary gear and ring gear

Backlash between carrier and swing

No. 2 planetary pinion

Backlash between swing circle

swing

Clearance planetary

Replace

Wear 10

between carrier

of swing

pinion and

plate and

_._.__ sâ&#x20AC;?rraCe -.._I___ p,mon contact:.._ ,,,9 ..,:+I. yylll~ oil seal

0.16 - 0.51

1 .oo

0.09 - 0.20

0.22 - 1.32

2.00

0.68 - 1.12

Standard

size

125 -!100

Repair

limit

124.7

Apply hard chrome plating recondition, or replace

40-3

MAINTENANCE

SWING

SWING CIRCLE

STANDARD

CIRCLE

lst:294.2f29.4Nm (30i3ksml 2nd:60*6'

Ist:191.3fl9.6Nm (19.5+2kaml 2nd :4af5â&#x20AC;&#x2122; A-A

SAP02736

Unit: Check

No.

Axial clearance (when mounted

Criteria

item

of bearing on chassis)

Standard

clearance

Clearance

limit Replace

0.5 - 1.6

40-4

Remedy

3.2

MAINTENANCE

FINAL DRIVE

STANDARD

FINAL DRIVE

N-l II

2’

‘“II

ii:;

r-----

----

----_---

hi _

----__-

_J- t

SAP01252

40-6

MAINTENANCE

STANDARD

FINAL DRIVE

Unit: mm

No. 1 sun gear and

Backlash

between

Backlash between

No.

1 planetary

No. 2 sun gear and

n No.

2 planetary

Repair

Standard 9

Width

of sprocket

size

limit: 6

Repair

limit

Rebuild or replace

tooth 71

40-7

MAINTENANCE

STANDARD

TRACK FRAME *

Figure shows

TRACK FRAME

RECOIL SPRING

PC200-6.

.â&#x20AC;&#x2122;

8 <

rr---------

_______---

2 ________-__-__

_______

SAP02737

Unit: mm

Check item

Criteria Standard size

Vertical

width

Horizontal

of idler guide

width

Track frame

107

Idler support

105

Track frame

250

40-8

Recoil spring

Tolerance

Repair limit

Rebuild or replace

of idler guide Idler support

Remedy

247.4

Replace

MAINTENANCE

IOLER

STANDARD

IDLER

8 /

4 SBPO2738

40-10

MAINTENANCE

STANDARD

IDLER

Unit: mm

?I > %

Criteria

Check item

Remedy

Standard

Outside

diameter

Repair

size

560

Outside

diameter

limit

of protruding

of tread

520

508 Rebuild or replace

Width

of protrusion

Total width

Width

Clearance bushing

164

of tread

39.5

between

Standard size

shaft and

b I

Clearance support

Interference bushing

between

shaft and

I 9

Side clearance

of idler (each)

Clearance limit

1.5

+0.074 -0.036

0.214 0.424

-0.250 -0.290

-0.110 -0.220

0.03 0.180

Standard interference

k I

Standard clearance

-0.250 -0.350

Standard size

idler and

45.5

65 7

Standard

Replace

Interference limit

+0.089 +0.059

Replace oushing

clearance

0.39 - 1.00

-0.006 -0.072

0.065 0.161 Clearance

1.5

Replace bushing

limit

1 40-H

MAINTENANCE

CARRIER ROLLER

STANDARD

CARRIER ROLLER

14.7i4.9Nm 1.5* 0.5koml

ifi > SBP02739

Unit: mm

No.

Standard 1

Outside diameter (outside)

Remedy

Criteria

Check item

Repair

size

limit

of flange -

165

Rebuild or replace 2

Outside

Width

diameter

of tread

Interference bearing

140

between

shaft and

Interference bearing

between

I Tolerance

Standard size

130

roller and 80

Standard interference

interference limit

Shaft

Hole

0 -0.016

0 -0.012

-0.016 0.012

0 -0.013

-0.021 -0.051

-0.008 0.051

Replace

I Standard 6

Side clearance

clearance

0.01 - 0.18

40-l 2

Clearance

of roller -

limit

MAINTENANCE

STANDARD

TRACK ROLLER

,!!!â&#x20AC;&#x2DC;,I ii/ i I

E > %

III

L-44

SBPO2740

Unit: mm

No.

Check item

Outside diameter (outside)

diameter

Criteria

Standard

of flange

of tread

size

Remedy

Repair limit

188

156

144

Outside

Width

of tread

44.5

Width

of flange

25.5

Clearance bushing

Rebuild or replace

between

shaft and

I 6

Interference bushing

between

-0.215 -0.315

Side clearance

Shaft

Hole

+o. 153 +0.053

+0.030 0

clearance

1.5 Replace bushing

Standard interference

Standard

0.215 0.510-

Tolerance

Standard size

roller and

+0.195 0

Interference limit

0.023 0.153 Clearance

limit Replace

of roller 0.5 - 1.0

1.5

40-13

MAINTENANCE

TRACK SHOE

STANDARD

TRACK SHOE (l/2)

14 \

8 \ II

\ \

23 \

P portion

40-14 0

I I

20a

22 \

shows the link of bushing

press fitting end.

6 ,,I I,:

5 I

---t

SBPO3974

MAINTENANCE

STANDARD

TRACK SHOE

Unit: mm

No.

Remedy

Criteria

Check item

Standard 1

Repair

size

limit

Link pitch 194.25

190.25

When Standard Bushing

outside

Reverse replace

turned

size

diameter

Normal

load

Impact

59.3

Standard

Repair

size

limit

Repair or replace

105 Thickness of link metal (bushing press-fitting portion)

load

54.3

Link height

28.5

160.4 Replace Shoe bolt pitch

8 9

Link

Inside width

84.8

Overall

45.5

width

Tread

Protrusion

of pin

Protrusion

regular

Overall

length

of pin

Overall

length

Thickness

of bushing

Thickness

of spacer

width

40.3

bushing

4.85

220

bushing

Press-fitting

force

Adjust or replace

128.7

metal

10.4 -

Bushing

Repair or replace

Regular

88.2 - 245 kN {9 - 25 ton)

127.4 - 274.4

kN 113 - 2% ton)

Master

pim

78.4 - 147 kN 18 - 15 ton)

: Dry type track link

40-15 0

MAINTENANCE

TRACK SHOE

STANDARD

I 2

I 18

\ I!

Lu I5

SBP03974

Ir P portion

40-16 0

shows the link of bushing

press fitting

end.

MAINTENANCE

STANDARD

TRACK SHOE

Unit: mm

No.

Check item

Remedy

Additinal tightening angle (deg.)

Tightening torque (Nm Ikgm}) a. Regular

Criteria

link 490+49

{50+5}

120~10

Shoe bolt 20 b. Master

No. of shoes (each side) -

Interference between bushing and link

Interference between regular pin and link

Retighten

Tightening torque (Nm Ikgm))

Additinal tightening angle (deg.)

Lower limit torque (Nm {kgm))

link

+0.222 +0.072

-0.138 -0.200

0.210 - 0.422

Tolerance

Clearance between regular pin and bushing

38 -

% 24

Standard clearance

Standard size Shaft

Hole

+0.222 +0.072

+0.902 +0.402

0.180 - 0.830

Adjust or replace

Interference between master pin and link

Tolerance I 25

Clearance between master pin and bushing

Standard clearance

Standard size

Shaft

Hole

-0.200 -0.400

+0.902 +0.402

0.602 - 1.302

% : Dry type track link

40-17

MAINTENANCE

TRACK SHOE

STANDARD

TRIPLE GROUSER

SHOE

SDD01629

Unit: mm

Criteria

Check item

Remedy

Standard

Repair

size

limit

Height 26 2

Thickness

27 Length

of base

Length

40-18

at tip

14 19

Rebuild or replace

MAINTENANCE

STANDARD

HYDRAULIC HPV95

HYDRAULIC PUMP

PUMP

+ 95

40-19

MAINTENANCE

STANDARD

CONTROL VALVE

CONTROL VALVE 6-SPOOL VALVE (l/5) --

166.7*9.8Nm (17*1kml

k- G-I 30.9*3.4Nm (3.15*0.35kml

SAP03975

40-20

MAINTENANCE

CONTROL VALVE

STANDARD

(Z/5)

B-B

SAP03976

Unit: mm

Standard size

Spool return spring

40-21

MAINTENANCE

STANDARD

CONTROL VALVE

(3/5)

H-H

SAP03253

40-22

MAINTENANCE

STANDARD

CONTROL

VALVE

Unit: mm

Piston return spring

40-23

MAINTENANCE

STANDARD

CONTROL VALVE

166.7* 19.6Nm

K-K

75.5*9.8Nm (7.7* 1 koml

L-L SAP03977

Unit: mm

No.

Check item

Criteria Standard

Valve

Relief spring

Unload

40-24

size

I Repair

limit

spring

35 x 10.4

83.3 N 18.5 kg}

66.6 N 16.8 kg}

Remedy

MAINTENANCE

STANDARD

CONTROL VALVE

W5)

127.5*19.6Nm (13*2kml

23.5*3.9Nm 12.4*0.4kml

J-J

JJ-JJ 39.254.9Nm 14*0.5bml

SAP03255

40-25

MAINTENANCE

CONTROL VALVE

STANDARD

SAFETY-SUCTION

VALVE

(FOR SERVICE

VALVE)

147ilONm {15*lkoml

SAP02748

Unit: mm

Standard

Suction

valve spring

Remedy

Criteria

Check item

Repair

size

Free length

limit Installed load

Free length x 0 .D.

Installed length

Installed load

16.3 x 21.3

9.5

2.1 N (0.21 kg}

1.6 N IO.16 kg)

2.1 N (0.21 kg}

1.6 N fO.16 kg}

Replace 2

Piston spring

40-26

20 x 7

MAINTENANCE

STANDARD

SELF-REDUCING

SELF-REDUCING PRESSURE VALVE

PRESSURE VALVE

A-A

SAP03294

Unit: mm No.

Check item

Criteria Standard

Spring (reducing

Spring

pressure

(safety

valve,

valve)

main)

Free length x O.D.

Installed length

Remedy

size

Repair Installed load

Free length

limit Installed load

19.2 x 1.2

16.1

12 kg1 19.6 N

17.7 N Il.8 kg}

16.5 x 7.2

12.7

20.6 N {2.1 kg}

18.6 N II.9 kg}

199.8 N f20.4 kg}

186.2 N {19 kg)

61.7 N 16.3 kg}

58.8 N 16 kg}

pilot) 71 x 18

16.1 x 7.8

13.4

Replace spring if any damages or deformations are found.

40-27

MAINTENANCE

STANDARD

SWING MOTOR

SWING MOTOR KMFgOAB-3

SAP03256

Unit:

No.

Check item

Criteria Standard

CheCK valve spnng

Free lenath x O.D.

Installed length

Shuttle

40-28

valve spring

Remedy

size 1

Installed ..-_-.._load

62.5 x 20.0

35.0

3.5 N IO.36 kg}

16.4 x 8.9

11.5

13.7 N Il.4 kg}

Renair .._r_..

Free _*L lengm

limit

Installed load

2.8 N IO.29 kg}

10.8 N U.1 kg)

I Replace spring if any damages or deformations are found.

MAINTENANCE

TRAVEL MOTOR

STANDARD

TRAVEL MOTOR HMVI IO-2

A-A

\ B-B

c-c SAP02750

Unit: mm Criteria

Check item

No.

Standard

Check valve spring

Repair

size

Free length

limit Installed load

Free length x O.D.

Installed length

Installed load

31.6 x 6.5

24.2

2.55 N lo.26 kg}

2.06 N lo.2 kg}

1.96 N IO.2 kg}

1.57 N IO.16 kg}

411 N 141.9 kg}

329 N 133.5 kg)

Check valve spring

13.0 x 6.5

9.5

Return

58.43 x 30

42.6

spring

Remedy

Replace spring if any damages or deformations are found.

40-29

MAINTENANCE

WORK EQUIPMENT

STANDARD

WORK EQUIPMENT

SWING

SWING PPC VALVE

PPC VALVE

1.5Nm 0.15kPml

A-A

B-B E-E

SAP02751

Unit: mm

Standard

Centering

spring (for P3, P4)

size

MAINTENANCE

TRAVEL

STANDARD

PPC VALVE

TRAVEL PPC VALVE

SAP02752

Unit: mm

-I 1

Criteria

Check item

No.

Metering

Centering

spring

Standard

Remedy Repair

size

Free length

limit

Free length x 0 .D.

Installed length

Installed load

26.5 x 8.15

24.7

16.7 N Il.7 kg}

13.7 N (I.4 kg}

48.1 x 15.5

32.5

107.8 N 111 kg}

86.2 N 18.8 kg}

Replace spring if any damages or deformations are found.

40-31

MAINTENANCE

STANDARD

SERVICE PPC VALVE

SEW0436

Unit: mm Check item

No.

Criteria Standard

Centering

Metering

40-32

spring

size

Remedy Repair

Free length x 0 .D.

Installed length

Installed load

64.6 x 16.6

40.5

26.0 x 10.5

25.0

limit

Free length

Installed load

46.1 N 14.7 kg1

(62.9)

44.1 N t4.5 kg}

25.5 N 12.6 kg1

(25.2)

24.5 N i2.5 kg}

Replace spring if any damages or deformations are found.

MAINTENANCE

STANDARD

CENTER SWIVEL JOINT

CENTER SWIVEL JOINT 4 PORT SWIVEL JOINT

Unit: mm Check item

No.

Criteria

Standard 1

Clearance

between

size

Standard

clearance

Remedy

Clearance

rotor and shaft

limit Replace

0.056 - 0.105

0.111

40-33

MAINTENANCE

STANDARD

6 PORT SWIVEL

CENTER SWIVEL JOINT

JOINT

7 i

E -

-\--iâ&#x20AC;&#x2122;:f -I

_!---

\ -

-.__

SBPO2753

Unit: mm No.

Check item

Criteria

Standard 1

Clearance

between

Standard

clearance

Clearance

rotor and shaft

limit Replace

100

40-34

size

Remedy

0.056 - 0.105

0.111

MAINTENANCE

BOOM HOLDING *

BOOM HOLDING VALVE

STANDARD

VALVE

For machine equipped with arm holding the same as this valve.

valve, the Maintenance

Standard

39*5Nm (4.Ot O.Slarml \

of arm holding

valve is

B-B

SDPO1354

Unit: mm

No.

Standard

Pilot valve spring

Free length x O.D. 26.5 x 11.2

Check valve spring

Remedy

Criteria

Check item

37.2 x 16.2

Repair

size

Free length

limit Installed load

Installed length

Installed load

25.0

4.7 N (0.48 kg}

3.7 N fO.38 kg)

30.0

35.3 N {3.6 kg}

28.4 N 12.9 kg}

Replace spring if any damages or deformations are found.

40-35

MAINTENANCE

HYDRAULIC CYLINDER

STANDARD

HYDRAULIC

CYLINDER

BOOM CYLINDER

270*39Nm (27.5*4koml

SAP02756

ARM CYLINDER

SAP02757

BUCKET CYLINDER

270*39Nm (27.5*4km)

SAP02758

40-36

MAINTENANCE

STANDARD

HYDRAULIC CYLINDER

Unit: mm

No -

Clearance between piston rod and

Clearance between piston rod support pin and bushing

Clearance between cylinder bottom support pin and

40-37

MAINTENANCE

WORK EQUIPMENT

STANDARD

WORK EQUIPMENT

F-F

-11

I II

I A-A

G-G

c-c

E-E

40-38

K-K

SAP02 1763

MAINTENANCE

STANDARD

WORK EQUIPMENT

SBPO2762

Unit: mm

No. -

Criteria

Check item

Remedy

Clearance between connecting pin and bushing of revolving frame and boom 90

-0.036 -0.07 1

+0.342 +0.269

0.305 0.412

1.0

Clearance between connecting pin and bushing of boom and arm

-0.036 -0.071

+0.153 +0.097

0.133 0.224

1.0

Clearance between connecting and bushinq of arm and link

-0.030 -0.076

+0.335 +0.275

0.305 0.411

1.0

Clearance between connecting pin and bushing of arm and bucket

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1 .o

Clearance between connecting pin and bushing of link and bucket

-0.030 -0.076

+0.337 +0.273

0.303 0.413

1.0

-0.076 -0.030

+0.275 +0.335

0.411 0.303 -

1.0

and bushing of link and link Clearance between connecting

Replace

40-39 0

MAINTENANCE

STANDARD

DIMENSION 1.

DIMENSION

OF WORK EQUIPMENT

ARM PORTION

I i-

Alâ&#x20AC;&#x2122;

z-z

x-x

40-40

SAP02764

MAINTENANCE

STANDARD

DIMENSION

OF WORK EQUIPMENT

Unit: mm PCZOO-6

080

361.7?1

187.2kO.5

829.1tl

2,919

2,631.3?1

41O-cl

64OkO.2

6OO-cO.5

458.1

1,486

080

326.5*1

When fitting

080

Arm as individual 18

+o. 1 o

part

pressbushing

311 j.5 325

Min.

1,680

Max.

2,800

40-41 0

MAINTENANCE

DIMENSION

STANDARD

OF WORK EQUIPMENT

BUCKET PORTION

II ,_

16 L

/ II

I3 A-A

40-42

SAP02765

MAINTENANCE

STANDARD

DIMENSION

OF WORK

EQUIPMENT

Unit: mm PC200-6 1

457.620.5

22kO.5

92045'

458.1

1,477.4

159.8

9 10

080

+0.2 o

326.5+1

106

470

022

0140

0190

132

129

107

21 22

I I

348.5+; 38

40-43 0

OTHERS

Hydraulic piping drawing ........................................................................... Hydraulic circuit diagram ........................................................................... Actual electrical wiring diagram (l/2) ....................................................... Actual electrical wiring diagram (2/2) ....................................................... Electrical circuit diagram (l/2) ................................................................... Electrical circuit diagram (2/2) ................................................................... Operation of CLSS svstem as a whole 1. When all workâ&#x20AC;&#x2122;equipment is at neutral ......................................... 2. One side actuated, other side neutral ............................................ 3. Arm OUT, standard mode relief (cut-off controll) ....................... 4. Bucket DUMP, power max. relief .................................................... 5. Boom RAISE.. .................................................................................... ....................................................... 6. Swing operated independently ........................................................ 7. Tavel operated independently 8. Compound operation .......................................................................

90- 3 90- 5 90- 7 go- 9 90-I 1 90-13 90-15 90-17 .90-19 90-21 90-23 90-25 90-27 90-29

90-l 0

STRUCTURE

HYDRAULIC

AND FUNCTION

HYDRAULIC

PIPING DRAWING

â&#x20AC;&#x2DC;13

SBP03964

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Bucket cylinder Arm cylinder Boom cylinder Hydraulic tank Hydraulic filter Filter (for breaker) Swing motor R.H. travel motor Hydraulic pump Control valve Junction box Oil cooler L.H. travel motor Arm holding valve Boom holding valve L.H. PPC valve R.H. PPC valve Center swivel joint Travel PPC valve Service PPC valve Accumulator EPC solenoid valve 22A. PPC lock solenoid valve 22B. Swing brake solenoid valve 22C. 2 step relief solenoid valve 22D. Travel speed solenoid valve

90-3 0

STRUCTURE

AND FUNCTION

ACTUAL ELECTRICAL WIRING (l/2)

ACTUAL

ELECTRICAL

WIRING

DIAGRAM

(l/21

DIAGRAM

SBP04276

STRUCTURE

AND FUNCTION

ACTUAL ELECTRICAL WIRING

ACTUAL

DIAGRAM

ELECTRICAL

WIRING

DIAGRAM

(2/2)

SBPO4277

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Fuel level sensor Working lamp PC control EPC solenoid valve Rear lamp Engine speed sensor Engine oil pressure switch Washer tank Travel alarm Horn (high tone) Horn (low tone) Battery relay Battery Front lamp PPC lock solenoid valve Swing brake solenoid valve 2 step relief solenoid valve Travel speed solenoid valve Engine water temperature sensor Electrical Intake air heater Air conditioner compressor magnet Engine oil level sensor Alternator Starting motor R.H. additional front lamp Room lamp L.H. additional front lamp Wiper motor Alarm buzzer Pump controller Horn switch Speaker Monitor panel Starting switch Fuse box Radio Wiper switch Swing lock switch Optional lamp switch PPC lock switch Heater Light relay Heater relay Shift down foot switch

switch

90-9 0

STRUCTURE

OPERATION

AND FUNCTION

CLSS

OF CLSS SYSTEM AS A WHOLE

1. When all work equipment is at neutral Sr The diagram shows the situation when all work equipment is at neutral. * The valves and circuits that are not connected with the explanation of the operation

of the CLSS hydraulic

system

have been omitted.

11 PL

(

)

I Ii

-5

SAP04167

90-15 0

STRUCTURE

2. *

AND FUNCTION

One side actuated, other side neutral The diagram shows the independent bucket DUMP

CLSS

operation.

Max

Min

Max

I I

I1 )

â&#x20AC;?

SAP04168

90-17 0

STRUCTURE

3. *

AND

FUNCTION

Arm OUT, standard mode relief (cut-off control) The diagram shows the arm DUMP and standard

CLSS

mode relief.

Min

Max\

PLSl

PP-

SAP04169

90-19 0

STRUCTURE

4. *

CLSS

AND FUNCTION

Bucket DUMP, power max. relief The diagram shows bucket DUMP,

relief.

(

( 1

I II

i’i”““““““““‘“““‘i’i”“”

SAP04170

90-2 1 0

STRUCTURE

AND FUNCTION

CLSS

Boom RAISE

Min

iâ&#x20AC;&#x2122;i

Max

jl )

PI (

@-t

SAP04171

90-23 0

STRUCTURE AND FUNCTION

CLSS

Swing operated independently

2B PI

bl 1

SAP04172

90-25 0

STRUCTURE

CLSS

AND FUNCTION

Travel operated

independently

28 PLSl

2A PI

(

SAP04173

90-27 0

CLSS

STRUCTURE AND FUNCTION

8. *

Compound operation The diagram shows boom RAISE + arm IN.

P I

) n Iu

, â&#x20AC;&#x2DC;,

SAP04174

90-29 0

Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 9704186

PROPOSAL FOR MANUAL REVISION

IFOR INTERNAL USE ONLY P

No. PMR

NAME OF COMPANY:

; P

; 1 DEPARTMENT:

MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: =AGE NO:

â&#x20AC;&#x2DC;ROBLEM:

4ttach photo or sketch. f more space is needed, use another sheet. FOR INTERNAL USE ONLY ZORRECTIVE ACTION:

m PFMRl 081696

DATE: