Service Manual

SWE80/SWE80H

湖南山河智能机械股份有限公司
HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.

1
 Foreword

Foreword
This manual enables maintenance technician to be familiar with products by instructing proper means to
trouble-shooting and service. Make certain fully understand this manual and use it during every service
process for better result.
This manual includes technical information required in service. For easier reference and
understanding, this manual consists of below chapters with several sections contained
1、safety precautions
This chapter provides safety guidelines during maintenance and service for personnel’s safe
operation。
2、chapter overview
This chapter provides dimensions , technical specifications, and working range information of
complete machine and master parts.。
3、structural function and maintenance standard
This chapter illuminates structure and function of individual parts, and provides reference
about trouble shooting, maintenance and service。
4、test and failure diagnosis
This chapter provides instruction for inspection before or after service, and all adjustment
required in maintenance and service。
5、disassembly and assembly
This chapter provides all procedure that should be followed during disassembly and assembly,
and all safety precautions required in operation.
6、others
This chapter provides hydraulic system & electrical drawing, and air conditioning system
drawing(if equipped with air conditioning).。

(note: design and specification are subject to change without notice and obligation)

2
 Table of contents

TABLE OF CONTENTS
1. SAFETY PRECAUTION…………………………. ...............................................................................1-1
1.1. Basic precaution...................................................................................................................................1-1
1.2. Preparation work ..................................................................................................................................1-1
1.3. Precautions during operation................................................................................................................1-1
2. CHAPTER OVERVIEW……………………. ........................................................................................2-1
2.1. Given dimensional drawing .................................................................................................................2-1
2.1.1 Dimensional drawing ..................................................................................................................2-1
2.1.3 Dimension data ...........................................................................................................................2-1
2.1.2 Working range .............................................................................................................................2-2
2.1.4 Working range data .....................................................................................................................2-2
2.2. Technical specification.........................................................................................................................2-3
2.3. Weight table .........................................................................................................................................2-5
2.4. Engine oil, fuel, coolant .......................................................................................................................2-5
3. STRUCTURAL FUNCTION AND MAINTENANCE STANDARD ....................................................3-1
3.1. Structural function and maintenance standard of mechanism ..............................................................3-1
3.1.1. Engine related parts....................................................................................................................3-1
3.1.2 Radiator, oil cooler, intercooler...................................................................................................3-1
3.1.6 Slwing bear .................................................................................................................................3-2
3.1.7 Track frame, tension spring.........................................................................................................3-2
3.1.8 idler .............................................................................................................................................3-2
3.1.9 Carrier roller................................................................................................................................3-2
3.1.10 Track roller................................................................................................................................3-3
3.1.11 Track shoe .................................................................................................................................3-3
3.1.12 Working device .........................................................................................................................3-3
3.2. Function and maintenance standard for hydraulic device ....................................................................3-4
3.2.1 Hydraulic oil tank........................................................................................................................3-4
3.2.2 Main Pump..................................................................................................................................3-4
3.2.3 Swing motor................................................................................................................................3-7
3.2.4 Pilot oil supply valve.................................................................................................................3-12
3.2.5 Multiple-way valve ...................................................................................................................3-13
3.2.6 Center Slewing Connector ........................................................................................................3-17
3.2.7 Travel motor..............................................................................................................................3-17
3.2.8 Travel pedal valve .....................................................................................................................3-21
3.2.9 Joystick Pilot Control Valve......................................................................................................3-21
3.2.10 Dozer Pilot Control Valve .......................................................................................................3-23
3.2.11 Breaking Control Valve ...........................................................................................................3-23
3.2.12 Hydraulic Oil Return Filter .....................................................................................................3-24
3.2.13 Hydraulic Oil Sucking Filter...................................................................................................3-26
3.2.14 Accessory Oil Way selection Valve.........................................................................................3-27
3.3. Function and maintenance standard of electrical device....................................................................3-28
3.3.1 Multi-function monitor system .................................................................................................3-28
3.3.1 Monitor System.........................................................................................................................3-29
3.3.2 Engine control ...........................................................................................................................3-32
3.3.3 System running .........................................................................................................................3-32
3.3.4 Attention in electric device use and maintenance .....................................................................3-33
4. TEST、ADJUSTMENT AND FAILURE DIAGNOSIS ........................................................................4-1
4.1. Test, adjustment of mechanical structure device..................................................................................4-1
4.2. Test and adjustment of hydraulic device ..............................................................................................4-2
4.2.1 Test and Adjust of Working Device、Swing and Travel Hydraulic Oil in Hydraulic Oil Way ..4-2
4.2.2 Pressure Test of Variable Displacement Pump ............................................................................4-4
4.2.3 Pressure Test of Gear Pump P4 (Pilot Pressure) .........................................................................4-4
4.3.1 Diode Test Procedure ..................................................................................................................4-2
4.3.2 special function of multi-functioned monitor panel ....................................................................4-2
4.3. Failure Diagnosis .................................................................................................................................4-2
4.4.1 inspection before fault diagnosis.................................................................................................4-2
4.4.2 instruction during fault diagnosis................................................................................................4-2
4.4.3 Failure diagnosis and service ......................................................................................................4-2
5. DISASSEMBLY AND ASSEMBLY……… ...........................................................................................5-1
5.1. How to read this manual ......................................................................................................................5-1
5.2. Hydraulic oil cooler disassembly and assembly...................................................................................5-2
3
 Table of contents

5.3. Hydraulic pump disassembly and assembly.........................................................................................5-3

5.4. Rotary motor and swing mechanism disassembly and assembly. ........................................................5-4
5.5. Carrier roller disassembly and assembly..............................................................................................5-5
5.6. Slewing bear disassembly and assembly..............................................................................................5-6
5.7. Central rotary connector disassembly and assembly.........................................................................5-7
5.8. Hydraulic oil tank disassembly and assembly......................................................................................5-7
5.9. Multiple way valve disassembly and assembly....................................................................................5-9
5.10. Pilot control valve disassembly and assembly................................................................................ 5-11
5.11. Travel motor disassembly and assembly ........................................................................................5-12
6. ATTACHMENT DRAWINGS AND OTHERS ......................................................................................6-1
6.1. Hydraulic drawing................................................................................................................................6-1
6.2. Electric system drawing .......................................................................................................................6-2
6.3. Air-condition circuit diagram...............................................................................................................6-1

4

1. SAFETY PRECAUTION
1.1. Basic precaution
Improper operation is quite dangerous.
Before repair and maintenance are carried
out, it is essential to read this manual
carefully.
1. Before lubrication or repair is carried out,
read all the safety notes on labels that are
fixed on the machine.
2. Before any operation, do wear safety
shoes and hard hat. Do not wear loose
work clothes or clothes without buttons.
z Wear safety glasses when knocking
some parts with a hammer.
z Wear safety glasses when polishing
some parts with a grinding wheel.
3. If welding is needed, it should be carried
out by trained skilled welder. During
welding, wear special gloves, apron,
helmet, hard hat and work clothes that
are suitable.
4. When an operation is carried out by two
or more workers, the operating procedure
should be agreed upon before the
operation. Before any operating
procedure begins, you should inform
your partner workers of it. Hang a label
reading “repairing” on the control table
of control room before any work.
5. All tools should be kept in good
condition and operators are required to
learn how to use them.
6. Put the tools and disassembled parts in an
appointed place in the repair shop. Do
put the tools and disassembled parts in a
proper place. Keep the work area clean
and make sure there are no dirty things or
oil stain on the floor. Smoke in the
appointed area only. It is not allowed to
smoke during work hours.
1.2. Preparation work
7. Before you fill oil or carry out any repair,
put the machine in a level and hard
ground, underlay the wheels or tracks
with pads to prevent the machine from
moving.
8. Before operation, lower the push plate,
ridger teeth, bucket and other working
1-1
1. Safety precaution
parts onto the ground. If some working
parts can not be lowered, apply the safety
pin or pad to prevent them from falling
down.
9. When disassembly or assembly is needed,
use pads, lifting jacks or racks to support
the machine before any operation.
10. Clean the steps by which you get on and
off the machine and the pedals. When you
get on or off the machine, use handrails,
steps or gangboards. Do not just jump in or
off the machine. If handrails, steps or
gangboards are not available for use, racks
should be used in sake of safety
1.3. Precautions during operation
11. When disassembling the cover of oil filling
opening, oil drain plug or hydraulic measurement
plug, release them gradually to prevent the oil from
ejecting.
When disconnect or disassemble pipes for
oil, water or gas supply, release the pressure in
pipeline first.
12. When the engine flames out and the water
and oil in the pipeline are hot, be careful to avoid
being scalded.
13．Disconnect battery cable prior to operation.
Make sure to disconnect negative terminal first.
14. When lifting heavy loads of parts, use
winch or crane to check steel rope, chain and hook
for damage.
15. When removing caps under internal
pressure or spring pressure, maintain two bolts on
the other side. With pressure relieved, loosen
bolts to remove .
16. Pay a attention not to crash or damage
cable during parts removal. Failure to do so can
cause electric spark.
17. During pipeline disassembly , prevent any
leakage of fuel or oil from pipeline. In case of any
leakage on the floor, wipe it immediately, because
fuel or oil on the floor can result in personnel
slippery or fire..
18, Do not clean parts with gasoline in normal
situation. However a small amount of gasoline is
allowed in an exceptional case.
19. Make sure to position all parts properly,
and replace defective parts with new ones.
During hose or cable installation, do not let
them make contact with other parts.
20. Make sure all high-pressure hose is free of
distortion during hose installation. Damaged
pipeline is of highly dangerous. Therefore, pay
undivided attention to it during high-pressure hose
installation. In addition, check connecting piece for
proper installation.
21. Always operate with specified tightening
 1. Safety precaution

torque during assembly or disassembly. When

assembling protective parts( e.g. protective guard)
or installing other parts with sharp vibration and
high-speed rotation. Make sure they are properly
installed.
22. When aligning two holes , do not insert
fingers or hands into them so as to prevent finger
from being caught in.
23. Make sure all tools for measuring purpose
are properly installed before attempting hydraulic
pressure measurement or other measuring
procedures.
24. During track disassembly or assembly,
please note that track may disengage out of place
abruptly, make sure the area on both end of the
track is clear of persons.

1-2
 2. Chapter overview

2. CHAPTER OVERVIEW
2.1. Given dimensional drawing

2.1.1 Dimensional drawing

2.1.3 Dimension data

Model
SWE80 SWE80H
Parameter
Outline dimension (Length x Width x Height) mm 6805X2160X2711 6600X2160X2711

A Distance between crawler wheel mm 2200 2200

B Track length mm 2784 2784

C Platform ground clearance mm 745 745

D Rear platform swing radius mm 1680 1680

E Chassis width mm 2150 2150

Dimension F Track width mm 450 450

G Chassis ground clearance mm 333 333

H Track height mm 638 638

I Total length mm 6805 6600

J Height over cab mm 2711 2711

K Superstructure width mm 2160 2160

2-1
 2. Chapter overview

2.1.2 Working range

2.1.4 Working range data

Model
SWE80 SWE80H
Parameter
A Max digging height mm 6818 6726

B Max dumping height mm 4870 4774

C Max digging depth mm 4192 4284

D Max vertical digging force mm 3365 3564

Working E Max digging radius mm 7176 6951

range
F Max digging reach at ground level mm 7031 6826

G Dozer Max lifting height mm 418 418

H Dozer Max digging depth mm 480 480

R Min swing radius mm 2618 2392

Dozer blade length x width mm 2160X449 2160X449

2-2
 2. Chapter overview

2.2. Technical specification

Engine……………………………………………………………… YANMAR water cooled diesel engine

Model…………………………………………………………… ……….4TNV98-SSU
4TNV98-ZSSU (Optional)
Displacement………………………………………………………………….3.32L
Number of cylinders…………………………………………………………… 4
Output rating………………………………………………….……..…42.9kW/2200rpm
43.4kW/2200rpm (Optional)
Fuel consumption………………………………….……………………… 247g/kw.h
251g/kw.h (Optional)
Air filter…………………………………………………………….…dry-type (engine contain)
Coupling……………………………………………………………… Bowex T48-168 FLE-PA
Radiator…………………………………………………………………..Oil cooler TSL 70

Hydraulic mechanism
Hydraulic pump……………………………………Axial full power pump with variable displacement
Model………………………………………………………………………A10V071DFLR
Flux…….……………………………………………………………………156mL/Min
Working pressure………………………..……………………………………26 MPa
Main control valve……………………………………………………………..9SX12

Hydraulic pilot valve……………………………………… All hydraulic ratio operation are controlled by

2“+”controllers. Travel action is operated by
double-acting pedal or handle. The operation
of pushing the soil or breaking is controlled by
additional pedal or handle.
Model ……………………………………………………………….LH-4TH6NE122-1X/ST43M01
4TH6NRP198-20/M01
2TH6RC198-10/M01
JRCVD-02
Pilot system pressure………………………………………………..……… 3.5MPa
Hydraulic cylinder (standard backhoe)………………Double acting combinative sealed hydraulic cylinder
Boom cylinder…………………………………………………φ115×1311-885mm
Arm cylinder ………………………………………………….φ95×1373-900mm
Bucket cylinder………………………………………………..φ85×1120-730mm
Dozer cylinder…………………………………………………φ120×568-145mm
Slewing hydraulic motor…………………………………………Axial constant displacement motor
Model…………………………………………………………………JMFG-43-05-VBR
Travel hydraulic motor………………………………………… Axial constant displacement motor
Model………………………………………………………………JMV-48/28-01-VBC-RJ-45
Hydraulic oil tank volume…………………………………………………105 L

Hydraulic cooling device

Oil cooler model …………………………………………………….……… TSL 70
Fan drive ……………………………………………………………….… Engine drive
Speed ratio ……………………………………………………….…………… 1.1

Hydraulic oil filter

Oil return filter model ………………………………………………………. RF400B

Swing mechanism
Reductor model and name …………………………………………… GFB9T2 planetary reductor
Speed ratio …………………………………………………….……………… 20.25
Max output torque …………………………………………………..……… 3070N.m
Platform rev ……………………………………………………………..… 11.5 r/min
Slewing bearing and name …………………………………………… Single ball slewing bear
Swing brake ……………………………………………………… Hydraulic brake“+” spring pressure
multiple brake(normally closed)
2-3
 2. Chapter overview

Electric device
Battery……………………………………………………………………… 2×12V, 80Ah
Starter……..…………………………………………………………………12V, 2.2kW
Generator …………………………………………………………………... 12V, 60A

Fuel device
Fuel tank volume …………………………………………………………… 118 L

Travel mechanism
Model and name of travel reductor…………………………………… GFT9T2 travel reductor
Speed ratio…………………………………………………………………… 47.6
Max output torque
Hi-speed………………………………………………………………… 4340N.m
Low-speed……………………………………………………………… 8080N.m

Travel speed
Hi-speed………………………………………………………………… 0~5.0km/h
Low-speed……………………………………………………………… 0~3.2km/h

Grade ability……………………………………………………………………35 degree

Travel brake…………………………………………………………Hydraulic brake “+” spring pressure
multiple brake(normally closed)

Track tension…………………………………………………………………Hydraulic

2-4
 2. Chapter overview

Air conditioner main technical parameter

No. Name Specification
1 Refrigerating output 4.0-4.6KW
2 Heating capacity 5.2-6.0KW
3 Air blowing capacity 400-500m3/h
4 voltage 12/24/V.DC
5 Total power consumption ≤350W
6 Compressor shaft power ≤2.5KW
7 Refrigerant HFC 134a
8 Refrigerant charge amount 1000-1100g
9 Compressor SE5H14
10 Refrigerant oil PAG （sp20）,300ml

2.3. Weight table

SWE80H/weight
No Part name SWE80/weight（KG）
（KG）
1 Complete machine 7750 7542
Upper carriage
2 2251 2219
assembly
Lower carriage
3 3701 3701
assembly
4 Boom 520 606
5 arm 282 282
6 bucket 135 135
7 Deflector 256 —
8 Cab 260 260

9 counterweight 763 763

2.4. Engine oil, fuel, coolant

Engine oil

Intervals(hour)
Part name Qty remark
8 50 100 250 500 1000 2000
Oil level
Engine oil 1 △
checking
7.4 △
Engine oil replacement △
L ★
Engine oil filter replacement 1 △
Note: ★ it’s necessary to change the engine oil after the first 50 operation hours.
Please perform the maintenance procedure as described in the diesel engine’ manual.
The performance of various engine oil is different. API and CCMC STANDARDS are commonly used.
·YANMAR engine company recommends you to use (API) CE4/SG classification SAE15W-40 premium
engine oil for heavy loaded engine.

2-5
 2. Chapter overview

Recommended engine oil name

Engine oil
-20℃-0℃ -10℃-35℃ 25℃-40℃
Supplier
Esso Essolube D-3 10W 30 40

apollo Apollo oil Super Wide 15W-40

Mobil 1310 Mobil Delvac1330 1340 ★

fuchs 15W-40

Fina CF15W-40

Note: the machines are shipped from factory with ★ marked oil.

Fuel system

Intervals (hour)
Part name Qty
8 50 100 200 400 1000 2000
1. discharge the deposits in fuel tank 1 △
2. inspect and discharge the debris
and foreign matter.
1 △★ △
3. drain water and deposit in the
water separator
1 △
4. replace fuel filter. 1 △
Leakage, crack
5. inspect fuel etc.
─ △
hose Crack, bend
etc.
─ △

Note: inspect the precipitator and discharge every 50 hours, replace every 1000 hours.
Recommended fuel：
Only use high-quality diesel fuel(GB252 commonly 0#,10# if in winter) do not use kerosene.

Oil filling
Note: handle fuel with extra care. Shut down engine before oil filling. Never smoke while filling fuel to
fuel tank or working around fuel system.

(1) Refer to section “stop engine” for properly parking excavator and stopping engine.

(2) Inspect fuel gauge and fill fuel if required.

(3) Prevent the fuel system from entry of any dirt, dust, water and other foreign matter。

(4) Make certain not to splash fuel on the machine or the ground at the end of workshift to avoid curdling.

(5) Securely close the engine guard after the fuel filling is made.

2-6
 2. Chapter overview

Cooling system

Interval(hour)
Part name Qty 8 50 100 250 500 1000 2000
1. inspect the cooling water level 1 △
2. inspect and adjust fan belt
1 ※1 △
tension.
3. replace cooling water 20L Twice a year※2
4. clean radiator and external 1 △※3
hydraulic oil
cooler core. internal 1 When replacing cooling water
5. clean condenser (option) 1 △※3

Note: (1) necessary only for the first inspection.

(2) the cooling system has been filled with SUNWARD’ genuine ,long life coolant mixture when
the machines are shipped from SUNWARD. SUNWARD genuine, long life coolant enables
user to replace coolant every year or every 2000 hours whichever comes first.
(3) when the machine is operated in dusty circumstances. Shorten the maintenance interval.
(1) Cooling water：
Fill the radiator with soft and pure water or bottled water.
(2) Antifreeze：
It’s necessary to fill cooling system with mixture of soft water and antifreezing fluid, when the expected
temperature is under 0℃ (32℉). Generally speaking, the ratio of antifreezing fluid is between 30% -60%,if
lower than 30%, the system may rust, if higher than 60%, engine may overheat. The use of mixture of half
water and half glycol antifreezing fluid guarantees the machine can work at -370C all the year. The use of
mixture of 60% water and 40%glycol antifreezing fluid enable the machine to work at-200C.
(3) Anti-rusting agent：
It’s not necessary to add anti-rusting agent to antifreezing fluids when replacing coolant water with new one
mixing approximate 0.43 L(0.4 Usqt) anti-rusting agent.
(4) Replacing interval：
Once a year(autumn) or every 2000 hours whichever comes first.

2-7
 3. Structural function and maintenance standard

3.1.2 Radiator, oil cooler, intercooler

3. STRUCTURAL FUNCTION
AND MAINTENANCE
STANDARD
3.1. Structural function and maintenance
standard of mechanism

3.1.1. Engine related parts

11
1．muffler 3．Engine installation bracket
2．damper 4．Fan blade

1．
Water tank technical specification：
2．Oil cooler water tank：SH75-13010000
3．condenser oil cooler：TSL70
4．Air director condenser：T0210001
5．Engine outlet water pipe
6．Engine inlet water pipe

3-1
 3. Structural function and maintenance standard

3.1.6 Slwing bear 9．Front cover

Number of track roller：5 pcs

Number of carrier roller：1 pcs

3.1.8 idler

standard
No Inspection Possible
. item Standard Repair remedy
dimension limit
Flange
1 366 —
diameter
Track
1．Outer race of slewing bear carrier
2 336 328 Re-repa
2．Steel ball surface
ir or
3．Inner race of slewing bear diameter
replace
Total
3 100 —
width
Flange
3.1.7 Track frame, tension spring 4 47 —
width
Clearance Standard tolerance
5 between dimensi shaf hol
shaft and on t e
bushing 44 D9 t7 Replace
Interferen Standard tolerance bushing
ce with dimensi shaf hol
6 on
roller and t e
bushing. 53 H7 h7

3.1.9 Carrier roller

1．idler
2．Track frame
3．Carrier roller
4．Travel motor
5．track roller
6．track shoe
7．Central cover
8．Tension spring
3-2
 3. Structural function and maintenance standard

standard Standar tolerance

Inspection Possible Clearance
No Standard d
item Repair limit remedy
dimension 6 between dimensi shaf
hole
Flange shaft and on t
1 120 — Replac
diameter bushing
Track 36 D9 f7 e
2
carrier
90 80 Interferen Standar tolerance bushin
surface d g
ce
diameter dimensi shaf
Re-repair or 7 between hole
3 Total width 180 — on t
replacement roller and
Track
carrier
bushing. 43 H7 t7
4 31 —
surface
width
Flange
5 12.5 — 3.1.11 Track shoe
width
Clearance Standard tolerance
6 of Shaft dimension shaft hole
and
bushing 35 D9 f7 Replace
Interference Standard tolerance bushing
of roller dimension
7 shaft hole
and
bushing. 43 H7 t7

3.1.10 Track roller

standard
Inspection Possible
No Standard Repair
item remedy
dimension limit
1 height 17.5 8
2 thick 26 —
Teeth Re-repair
3 11 —
length or
Teeth replace
4 9 —
length
Teeth
5 13 —
length

3.1.12 Working device

standard Possibl
No Inspectio
Standard Repair e
. n item
dimension limit remedy
Flange
1 139 —
diameter
Track
carrier
2 110 102
face
diameter
Re-rep
Total
3 178 — air of
width
replace
Track
carrier
4 134 —
face 1．bucket
width 2．Bucket link
Internal
5 92 — 3．Idle link
width
4．Bucket cylinder

3-3
 3. Structural function and maintenance standard

5．arm
6．Arm cylinder
7．boom
8．Boom cylinder
9．deflector（SWE80）

Refer to operator’s manual regarding respective

lubricating location

3.2. Function and maintenance standard

for hydraulic device
Fig. pump port

3.2.1 Hydraulic oil tank

3.2.2 Main Pump

Pump: Single variable displacement axial piston

pump.
Specification:

q 71mL/r
P1 280bar
Qmax 155L/min
Qmin 15L/min
Cons. 34KW--136bar/
Power 151L/min
LS
△P 17bar
Max.
Speed 2200rpm
Type:A10VO71DFLR REXROTH
Oil Classes : NAS9
Tightening torque:
pump/engine: M20x50 8.8 550Nm

3-4
 3. Structural function and maintenance standard

Fig. pump structure--A10VO71DFLR

Tab. pump screw tightening torque

3-5
 3. Structural function and maintenance standard

3-6
 3. Structural function and maintenance standard

3.2.3 Swing motor

Ports and Parts of swivel unit

PORT D
to tank
PORT DR

PORT B
PORT A

Lub. Oil
inlet
PORT PG

HY'D MODEL JMFG43-01-VBR

MOTOR &
REDUSER DISPLACEMENT 43cc/rev
PRESSURE 200kg.f/cm2
MOTOR OUPUT TORQUE 14kg.f-m(BACK PRESSURE:0 kgf/cm2
BRAKE RELEASE PRESSURE(PG
PORT) MIN25-MAX50 kg.f/cm2

3-7
 3. Structural function and maintenance standard

GEAR RATIO 1/19.464

TOTAL DISPLACEMENT 836.9cc/rev
THEORETICAL OUPUT TRQUE 266.2kg.f/-m
THEORETICAL BRAKE TORQUE 272.5kg.f-m

Structure of swivel unit

3-8
 3. Structural function and maintenance standard

3-9
 3. Structural function and maintenance standard

3-10
 3. Structural function and maintenance standard

3-11
 3. Structural function and maintenance standard

3.2.4 Pilot oil supply valve

Notes:
this pilot oil unit of SWE78 is make up of pilot oil block(3)、filter(4)、2-speed valve(5),
the pilot oil block is include of shuttle valve、pressure reducing valve、relief valve、
non-return valve、unload valve;
port P: main pump output port P--320bar;
port T: pilot return line, direct to tank;
port ST: Speed Two travel driving control;
port SB: Swing Brake open control, when the safety control valve(unload valve) is open,
the SB supply pilot oil to release brake on excavator's every movements
port PI: Pilot Input supply to the joystick, handle and pedal, PI port pressure is 40bar;
DT1: unload valve, for pilot oil supply safety, 12VDC solenoid valve control;
DT2: 2-speed shift valve, change the travel motor displacement to control travel speed ;

Notes:
One of the two P port is closed, the port P is connect to main pump directly, Pmax=350bar;
3-12
 3. Structural function and maintenance standard

in the pilot oil block, there are the pressure reducing valve(35bar), and relief valve(45bar);
The accumulator volume is 0.32cm3, and the nitrogen pressure is 20~23bar.

3.2.5 Multiple-way valve

main valve working principle

Type: 9SX12L2X/A300
Working principle: LUDV control(Vorteile der lastdruck-unabhängigen Durchflußverteilung ),
that mean is the load independant flow dividing
system character: one pump + flow sharing LS valve control system
4 way-control valve
load independant
speed adaptation for each actuator
no shuttle valve(compared with LS control)

Q[%]

100 p1
p2

p1 < p2
50
A1 A2

0
Feinsteuerbereich Kolbenhub
Fine metering Spool stroke
Q= f(△p,A)
△p1≠△p2
Fig. Principle of throttle

Q[%]

100

50
A1 A2

0
Feinsteuerbereich Kolbenhub
Fine metering Spool stroke

Q= f(A)
△p1=△p2
Fig. Principle of normal LS

3-13
 3. Structural function and maintenance standard

Q[%]

100

50

0
Feinsteuerbereich Kolbenhub
A1 A2 Fine metering Spool stroke

Q= f(A)
△p1=△p2 Fig. Principle of LUDV

F1 F2 Q = f (A, △ p)
F1 < F2
P1 < P2
Orifice: A1 > A2
QV1
QV2
△ p1 = Pp - P1'
P1 △ p2 = Pp - P2'
P2 p2 = P2' = P1'
△ p1 = △ p2 = p
Δp3
△ p = const.
P1'(P2') P2'
A1 and A2
Δp1 Δp2
A1 A2 △ p3 = P2' - P1
QV1 = f (A1)
QV2 = f (A2)

QV1/ QV2= A1/A2

exp. Sections flow

3-14
 3. Structural function and maintenance standard

1. section INLET with ports P, T, LS, with the units of LS relief valve, primary pressure limiting
valve and LS pressure relief valve.
2. section SLEW a1/b1, A1/B1, with two secondary pressure relief valve
3. section BOOM a2/b2,A2/B2, with two secondary pressure relief valve(280bar)
4. section BUCKET a3/b3, A3/B3, with two secondary pressure relief valve(280bar)
5. section STICK a4/b4, A4/B4
6. section AUX a5/b5, A5/B5
7. section TRAVEL-R a6/b6, A6/B6, with two secondary pressure relief valve(280bar)
8. section TRAVEL-L a7/b7, A7/B7
9. section DOZER a8/b8, A8/B8, with two secondary pressure relief valve(280bar)
10. section BOOM SWING a9/b9, A9/B9

Throttle

STRUCTURE OF SX12
3-15
 3. Structural function and maintenance standard

3-16
 3. Structural function and maintenance standard

3.2.6 Center Slewing Connector

3.2.7 Travel motor

Type: JMV-48/28-01-VBC
Features: swash plate axial piston motor with hydraulic mechanic brake, it have two stage for
displacement, and the displacement is q1=22.9/q2=45ml/rev;
parking brake is opened by the pressure of port A or port B;
gear box is included with hydraulic motor, the ratio of gear box is 47.6;
the relief valve on the travel motor is setting on 300bar;
parking brake release pressure is 12bar;

3-17
 3. Structural function and maintenance standard

DR

Port A

2Speed

Port B

MA-MB

SPECIFICATION
INPUT FLOW 82(L/min)
SET PRESS.OF RELIEF V/V 300(kgf/cm2)
HYDRAULICS MOTOR DISPLACEMENT 46.6/27.5(cm3/rev)
MOTOR TOTAL DISPLACEMENT 2123/1253(cm3rve)
TWO SPEED CONTROL PRESS.(Pi) 20-70(kgf/cm2)
AMOUNT OF GEAR OIL 1.2(L)
GEAR RATIO 45.568/1
THEORETICAL OUTPUT TORQUE 1013/598(kgf.m)
REDUCTION THEORETICAL OUTPUT SPEED 3806/65.4(r.p.m)
PARKING THEORETICAL BRAKE TORQUE min 537 (kgf.m)
BRAKE BRAKE RELEASE PRESS. 9 (kgf/cm2)

Principle of travel driving motor and valve

3-18
 3. Structural function and maintenance standard

Structure of travel driving unit

3-19
 3. Structural function and maintenance standard

3-20
 3. Structural function and maintenance standard

3.2.8 Travel pedal valve

3.2.9 Joystick Pilot Control Valve

JOYSTICK : REXROTH

3-21
 3. Structural function and maintenance standard

3-22
 3. Structural function and maintenance standard

3.2.10 Dozer Pilot Control Valve

3.2.11 Breaking Control Valve

3-23
 3. Structural function and maintenance standard

Hydraulic Sign

Technical Parameter
(If over the rated parameter in real use, please contact with us!)
Fit for DIN51 524 mineral oil (HL,HLP);
Hydraulic Oil
phospholipase (HFD-R )
Oil Temperature Range ℃ -20 to +80
Viscosity m ㎡/s 10 to 380
Max oil pollution level is NAS1638 in 9 level ,the
Oil Liquid Cleanliness
suggested filter of min filter proportion is β10≥75.
Input Port Pressure bar Max 50
T Port Back Pressure bar Max 3
Control Oil Level L/min Max 16
Slip-ring bar Max 1
Weight Kg about 3.8
Max Operation Torque in Pedal daNm 20
Character Curve: Control Range. Operation Torque
Control Curve 06
Oil Input Port Pressure
Pedal
Swing Angle

Operation Torque in Control Curve 06

Resetting Spring No. 199 567 00
Input Port Pressure 50 bar

Pedal Swing Angle

3.2.12 Hydraulic Oil Return Filter

Introduction
RF400B oil tank overhead oil return filter can filter metal particle caused by hydraulic system
components abrasion and rubber impurity caused by seal parts abrasion etc. It can maintain cleanness of oil
in oil return tank and prolong system lifetime.
3-24
 3. Structural function and maintenance standard

The filter is located in oil tank overhead directly, setting devices of by-pass valve、indicator etc.
within the advantages of compact construction、simple assembly、filter core replace conveniently etc.

3-25
 3. Structural function and maintenance standard

3.2.13 Hydraulic Oil Sucking Filter

Technical Request：
1. Rated Flow：250L/min
2. Max Flow：400L/min
3. Filtering Precision：80μ

3-26
 3. Structural function and maintenance standard

3.2.14 Accessory Oil Way selection Valve

Choosing Valve L7214116A10B020

3-27
 3. Structural function and maintenance standard

3.3. Function and maintenance standard of electrical device

3.3.1 Multi-function monitor system

3-28
 3. Structural function and maintenance standard

3.3.1 Monitor System

•Monitor system inspect the machine status of each part assembled sensors. It disposes and gets the
information from meter panel then notices the machine status to operator.
The meter panel is including:
1. Monitor: Output warning when machine failure.
2. Meter: show the status stably (cooling liquid temperature、hydraulic oil temperature、fuel oil level etc.)
•There are four function keys in monitor panel to realize meter operating function.

Monitor Panel:
(1) Summary

3-29
 3. Structural function and maintenance standard

WZB202 Excavator Digital Monitor Meter adopts advanced big LCD combined display, shock-resistant and
anti-jamming. The meter within microprocessor shows the datum accurately and reliably. LCD shows
handsome figures with high definition. It shows the engine water temperature、fuel oil level、engine work
hour/clock/engine work time in failure happened、oil temperature、oil pressure、rev/voltage/failure code at
the same time. It can display multiple Chinese characters warning、failure code finding and use、maintenance
manual etc in its Chinese character display area which is a multi-function combined monitor meter.
（2）Indication Explain
☆ Water temperature meter: Fan-shaped LCD 、 Chinese characters show and digital real-time
show(fan-shaped sector is divided into 14 segments, 2 segments in yellow area; 8 segments in green area;
4 segments in red area). When the water temperature is too high and reach to warning limit(the signal of
water temperature warning switch is in low level) the water temperature indicator flash、the warning light
turn red、buzzer alarming and with Chinese characters warning indication..
☆ Oil level meter: Fan-shaped LCD、Chinese characters show and digital real-time show (fan-shaped sector
is divided into 10 segments, 2 segments in red area; 8 segments in green area).When the oil level is less
than 1/5,the level indicator flash ; When the oil level is less than 1/10, the level indicator flash、buzzer
alarming and with Chinese characters warning indication..
☆ Work hour meter: 6 digitals show (within 1 decimal). Counting work hour from no charging alarm、no
oil pressure low warning or rev>200r/min, with the indicator flash.
☆ Clock: show the real-time, second signal “:” flash; the signal “:”will be light in clock maintenance
☆ Oil temperature meter: Fan-shaped LCD、Chinese characters indicator and digital real-time show
(fan-shaped sector is divided into 13 segments, 2 segments in yellow area; 8 segments in green area; 3
segments in red area). When the oil temperature is less than 20℃ or mare than 80℃, the oil temperature
indicator flash; when its more than 90℃,oil temperature indicator flash、the warning light turn red 、
buzzer alarming and with Chinese characters warning indication..
☆Oil pressure meter: Fan-shaped LCD、Chinese characters indicator and digital real-time show (fan-shaped
sector is divided into 10 segments, 2 segments in red area; 8 segments in green area). When the low oil
3-30
 3. Structural function and maintenance standard

pressure warning switch alarming(the low oil pressure warning switch is low level), oil pressure
indicator flash, the warning light turn red 、buzzer alarming and with Chinese characters warning
indication..
☆ Electric pressure meter: 4 digitals show. When the voltage is less than 24.5V(adopting 12V battery
when less than 12.5V),the indicator flash、buzzer alarming and with Chinese characters warning
indication; When the voltage is higher than 28.5V(adopting 12V battery when higher than 15.5V),the
indicator flash、buzzer alarming and with Chinese characters warning indication.
☆ Air filter warning: air filter blocking over 3 minutes, the warning light turn red 、buzzer alarming and
with Chinese characters warning indication..
☆ Oil filter warning: oil filter blocking over 9 minutes, the warning light turn red 、buzzer alarming and
with Chinese characters warning indication..
☆ Preheating indication: when preheating input wire connected the anode of battery, preheating light
turn green.
☆ Power charging indication: When engine working, charging warning switch signal alarming(charging
warning switch signal is low level), power charging indicator light turn red.

（3） Key-press Explain

2 3
1 4

①For switching over the clock counter/hour counter; voltage meter/revolution counter/oil temperature
digital display; use、maintenance display.
②In the hour counter status, failure code show key +10,the failure code will add 10 after pressing it;
in clock counter status, it is used for switching over and maintaining the hour and minute.
③In the hour counter status, failure code show key +1,the failure code will add 1 after pressing it; in
clock counter status, it is used for modifying the hour(00～23)or minute (00～59)value.

④After modifying the time, press the key twice; the newly time value will be recorded immediately.

（4）Input and output signal

3-31
 3. Structural function and maintenance standard

No. Code Name Line No. Remark

1 AVSS1.25 Electrical source anode 10
2 AVSS1.25 Electrical source cathode 0
3 AVSS0.85 Air filter switch signal 65
4 AVSS0.85 Oil filter switch signal 64
5 AVSS0.85 Preheating signal 66
6 AVSS0.85 Charging signal 61
7 AVSS0.85 Engine water temperature meter 12
8 AVSS0.85 Fuel oil level meter 11
9 AVSS0.85 Output electrical source+ 52
10 AVSS0.85 Rotational speed signal 60
11 AVSS0.85 Hydraulic oil temperature meter 14
12 AVSS0.85 Oil pressure signal 13
13 AVSS0.85 Oil pressure switch signal 63
14 AVSS0.85 Water temperature signal 62
15 AVSS0.85 485 communication 485-
16 AVSS0.85 485 communication+ 485+

3 Start Switch
4. Accelerograph Pull Wire
3.3.2 Engine control
5. Linkage Unit
6. Start Motor
Summary:
•The engine start and stop are by the start switch
(3).
•The engine rotational speed is regulated by
accelerograph pull wire (4).

3.3.3 System running

(1) Engine Start

After locating the Start Switch in “start”, the
1.
start signal will be transmitted to start motor;
Accumulator Relay
start motor operating and engine starting
2. Accumulator
subsequently.

3-32
 3. Structural function and maintenance standard

(2)Engine rotational speed control
Diesel engine rotational speed is regulated by
accelerograph pull wire. Lifting accelerograph
pull wire handle in the full load location, lowing
it into min load; adjusting between the full load
and min load to control the diesel engine
3.3.4 Attention in electric device use and maintenance
rotational speed; and fine turning accelerograph
by rotating handle.
(3)Engine close
Setting the accelerograph to min rotational
speed, shifting the start switch to “stop”, engine
stop.

1. Use of leading bunched wire and socket

Leading bunched wire is composed of component connected
wire、 connecting or cutting wire socket、and other wire
protector and wire pipe. Leading bunched wire is affected easily
and directly by rain、water、hot or shock which is different form
other wires assembled in box. Otherwise, when in checking and
maintenance, leading bunched wire is to be disassembled and
assembled frequently which is distorted and damaged easily. So please be careful in using leading bunched
wise

2、Main failure of leading bunched wire.

①Socket bad connect (poor connect between pull socket and
socket)
Pull socket and socket are not inserted properly、distorted
within poor
matched or sockets interface rusted and oxidized etc. which will
all lead
to poor connect.

②Connector poor pressure welding and braze welding

Connector stitch and socket stitch touch in the pressure welding
end or
braze welding point, If the wire overloaded and connection area
stripped, it will lead to poor connect or break.

③Wire cutting
Pulling out connectors by holding wires、parts connect wire
when hung by crane or heavy strike wires which all will lead to
pressure welding area stripped、welding point damaged or wire cut off.

3-33
 3. Structural function and maintenance standard

④High pressure water input into connector

Connector is water-proof (immersion proof), but if high
pressure water spray to connector directly, water may put
into connector. Just as connector waterproof structure,
water is hard to input however also hard to vent. So if water put into connector, stitch will be short circuit
because of water. So if water is input, dry the connector before cutting in power at once or adopting other
action.
⑤Connector with oil or sediment
If connector with oil or the connector and socket interface
have oil film, it will lead to poor connect because of oil
insulation.
If connector adhere to oil、grease or sediment, wiping by
cloth or blow by compression air and spray feeler recovery
medium。
★When wiping the joint of connector, please be careful of controlling wiping force to avoid stitch distortion.
★If compression air has oil or water, contact point will be
dirtier; so please separate the oil and water before use
compression air for cleaning.

3. Connector and leading bunched wire disassemble、

assemble and dry
1) Disassemble connector
①Hand holding connector when disassemble it.
When disassemble connectors, holding the connector but
not wire by hand. If the connector is fixed by bolts, bolts
should be loosed completely. Then hold connector by one
hand and hold socket by the other hand and pulling out
each other equally. Connector has the locking pin, press
locking pin by thumb and push the connector.
★Never use hand to pull and draw.

②Disassembling from terminal:

When disassemble the connector from terminal, connector
and terminal should be pulled out equally.
★If distorting the connector at random when disassemble it;
it may damage the shell.

3-34
 3. Structural function and maintenance standard

③Disposal of disassembled connector

Packing the disassembled connector by plastic bag to
prevent the dust、oil or water.
★If lay the disassembled machine for a long time, it will
lead to poor connect easily; So must pack the connector in
the plastic bag.

2) Assemble connector
①Inspect connector appearance
Ⅰ.Check the connector stitch (joint) having oil、sediment and water or not.
Ⅱ.Check the connector stitch distorted、poor connect、rusted and damaged or not.
Ⅲ.Check the connector appearance damaged and cracked or not.
★If the connector appearance have oil、water or sediment, wipe it by cloth;
if it is input water, dry it by blower. But should be careful that
do not too hot, it will lead to short circuit.
★If connector damaged or cracked, should be replaced.
②Assemble the connector firmly
Matching the connector correctly, inserting firmly.
If the connector has locking pin, push and press connector
until listening
inserting click.

③Amendment of rubber case hunch and leading bunched

wire dislocation.
Connector within rubber case must be amended hunch;
Meanwhile, leading bunched wire and wire clip dislocation
must be adjusted to correct location.
★If it is hard to adjust the connector, should dismantle the
clip and adjust
its location.
④If connector wire clip have already been dismantled, must
be restored and check the clip is loose or not.

3-35
 3. Structural function and maintenance standard

3) Leading bunched wire drying

If leading bunched wire have oil or sediment, wipe it off by
dry cloth;
do not wash it by water or vapor. If must wash it by water,
do not use
high pressure water or vapor to spray it directly; If there is
water pouring into connector:
①Dismantled the connector and wipe water off by dry
cloth;
★It is dangerous to blowing connector by air. Because oil in the air will lead to poor connect. So must use
the compression air without oil and water.

②Drying the inside of connector by desiccator.

If water pouring into connector, use desiccator for drying.
★It is good method of using desiccator for drying, but it
will lead distortion and damage of connector and its
accessory because of overheating. Please pay attention to
the drying time.
③Do the connectivity test for connector.
After drying, do the connectivity test for connector in the
condition of bunched wire dismantled; checking the short
circuit between the stitches caused by water.
★After drying completely, spray some feeler recovery
medium and reassemble it.

3-36
 4. Test, adjustment and failure diagnosis

4. TEST、ADJUSTMENT AND
FAILURE DIAGNOSIS
4.1. Test, adjustment of mechanical
structure device

Track shoe tensioner inspection and

adjustment

inspection:
1. travel some distance so as to keep all track
parts in normal stretch state. Then keep the
engine at idle speed, gradually stop the
machine..
2. place a straight rod with sufficient stiffness
somewhere on the track which is between idler
roller and carrier roller.。
3. measure the max clearance “a” between rod
and track shoe..
max clearance allowed: a: 10~25 .

adjustment：

1. in case of overtension:
loosen check-valve to discharge some grease.

note: do not loosen check-valve more

than one full turn to prevent pressurized
grease spraying.。

2. in case of slack
fill grease through nozzle.。
in the event that grease filling failed to
maintain proper track tension, move the
machine back and forth.。

4-1
 4. Test, adjustment and failure diagnosis

4.2. Test and adjustment of hydraulic device

4.2.1 Test and Adjust of Working Device、Swing and Travel Hydraulic Oil in Hydraulic Oil Way

every 10 h every 50 h every 250 h every 500 h every 1000 h

Servicing activity component
(daily) (weekly) (6 months) (12 months) (18 months) annual

MOTOR

Oil level O
Fuel level O
Leakage O
Visual check O
Air filter O/X <> <>
Seating of mounting bolts O
Coolant O
Engine speed regulation O
Exhaust system O
Engine oil O <>(1) <> <>
Oil filter <>(1) <> <>
V-belt: condition and tension O
Cooler fins X
Valve clearance O O
Generator, starter O
Fuel tank X
Water pump O
Fuel filter O <> <>
Cooling system and hoses O
Electrical connections O
Pre-glow system O
Coolant thermostat O
Battery fluid O

O — Check <> —Change/Replace

X — Clean <> (1) —Change/Replace the first time

4-2
 4. Test, adjustment and failure diagnosis

every 10 h every 50 h every 250 h every 500 h every 1000 h

Servicing activity component
(daily) (weekly) (6 months) (12 months) (18 months) annual

HYDRAULIC SYSTEM

Fastening bolts Hydraulic pump O

Leakage (lines, pumps, cylinders) O
Hydraulic oil level O
Oil cooler fins X
Filter insert <>(1) O <> <>
Primary and secondary pressure
O
limiting valves
Hydraulic oil O <>(1) <> <>
Breather filter Filling strainer O
ELECTRICAL
Indicator lamps O
Function of system O
Fastenings O
TRAVEL GEAR
Chain after working O
Chain tension O
Bearring play of tread rollers,
O
track carrierrollers, front idlers
TRAVEL GEAR UNIT

Leakage O
Gear oil <>(1) <> <>
GEAR RING
Bearing system O
Gearing <>
O — Check <> —Change/Replace
X — Clean <> (1) —Change/Replace the first time

4-2
 4. Test, adjustment and failure diagnosis

every 10 h every 50 h every 250 h every 500 h every 1000 h

Servicing activity component
(daily) (weekly) (6 months) (12 months) (18 months) annual

HEATING

Function O
Leakage (cooling and heating
O
circuit)
Seals O
Fan O
WORKING EQUIPMENT
Lubricate lubricating points O O
Bucket teeth (fastening and wear) O
Pin fastening O
Line fastenings O
Piston rods O
Behaviour of hydraulic cylinder
O
under load
Bush bearing play O
Bearing play O
GENERAL
Operating elements O
Hydraulic fittings O
Bolts O
Lights O
Windscreen washing system O
Leakage check - visual check O

O — Check <> —Change/Replace

X — Clean <> (1) —Change/Replace the first time

Maintenance - General (according to Operating Instructions)

The reliability and service-life of machines are to a great extent influenced by care and
maintenance.

Cleaning: In the first 3 months wash the machine only with cold water
(no high-pressure or steam-jet cleaning). After the first three months
the minimum distance between the spraying nozzles and the vehicle must be 30 cm,
and the water temperature shall not be higher than 60°C. Do not use aggressive cleaning
agents.

Therefore, compliance with the specified maintenance work is first of all to the advantage of
the owner of a machine.

Doing the specified maintenance work is made mandatory by the manufacturer. Any default
will lead to restrictions of warranty.

For maintenance work at the engine please cf. the operating instructions for the engine.

If lubricants are used that are not in compliance with the manufacturer.s recommendation any
guarantee becomes extinct.

4-3
 4. Test, adjustment and failure diagnosis

Before starting maintenance and repair at your vehicle, please get informed about any damage
that
occurred.

Before starting maintenance or repair work lower the working equipment to the ground. Apply
locking and safety levers.
- Bleed residual pressure off the hydraulic system.
- Let the engine cool down (hot cooling water).

If work must be done with the machine lifted, it must be appropriately secured (supported).

During maintenance or repair work in a closed room provide for sufficient ventilation.

Dispose of oil filters,oil, etc. as provided by the environmental law.

When working at and/or below the crawler excavator place a warning sign on the driver.s seat
and/or clearly visible and legible at the crawler excavator. Withdraw the ignition key.

4.2.2 Pressure Test of Variable Displacement Pump

Functions: bucket, boom, driving right，arm, driving left, auxiliary hydraulics，swivelling,

dozer blade, auxiliary hydraulics / boom offset
a) Apply manometer at measuring port MP 1.
b) Move bucket cylinder to stop (bottom and rod side).
c) Check pressure and/or adjust it at Primary pressure limiting valve at the main valve
block.
d) Check the functions boom, driving right by following items a - c

4.2.3 Pressure Test of Gear Pump P4（Pilot Pressure ）

Functions: hydraulic pilot control

a) Apply manometer at measuring port MP 4.
b) Actuate joystick.
c) Check pressure and/or adjust it at the pressure reducing valve at the control oil unit.
Pressure Adjust standard：
Type SWE80
Difference Test Item Unit Test Standard Tolerance
Boom Mpa
Bucket Mpa
Arm Mpa
Assistant Mpa
Swing Mpa 26.0 ±1.0
Pressure
Deviation Mpa
Extend &Retract Mpa
Dozer Mpa
Quick Replacement Mpa
P4 Pilot Mpa 3.5 ±0.5

Picture：Measuring ports at the pump

4-4
 4. Test, adjustment and failure diagnosis

LS Pressure

Test
Port for
Pilot
Pressure

Test Port
for Pump

LS Pressure

Position: Main valve block for SWE78LS（Ⅰ）

4-1
 4. Test, adjustment and failure diagnosis

Secondary overflow valve

Boom
Travel Deviation
Arm Breaking Dozer
Swing Bucket

Main overflow valve Secondary overflow

gear box oil level inspection and changing .

CHECK: - Open the oil level plug.

- The oil level must be at the oil
level inspection orifice.
> CHANGE: - Open the oil filler
and drain plug.
- Drain oil and collect it in an
appropriate vessel.
- Close drain plug and open oil
level plug.
- Fill in fresh oil via the filler
orifice until gear oil emerges from the
inspection orifice.
hydraulic oil change
- Close oil level plug and filler
The hydraulic oil shall be changed
orifice.
only
Warning: It is recommended, as
when warm(approx. 40°C)
specified in the maintenance schedule, to
Before changing the oil
check leakage
withdraw all hydraulic cylinders.
and thus the filling level in the
Turn uppercarriage by 90°.
drive unit continually.
Dispose of waste oil as provided Outlet
by environmental laws.
For gear oil quality - see List of
Lubricants (Chapt. Technical Data)

Washing port

Diesel Oil Tank

4-2
 4. Test, adjustment and failure diagnosis

3) Drain oil into collecting vessel.

4) Check hydraulic oil tank for

contamination and clean it, if
necessary.

5) Replace filter according to

maintenance instructions.

6) Close screw plug properly again.

Hydraulic Oil Tank 7) Fill in clean hydraulic oil via filter
station (filtering 10 mµ).

8) Vent hydraulic pump (see chapt.

Hydraulic Pump).
Outlet port
9) Close hydraulic oil tank properly.

10) Let machine run idle for several

minutes.
1) Open breather filter (width across
36) to unpressurize tank (tank Dispose of old oil as provided by
pressurized). environmental laws.

2) Open drain plug of oil tank

carefully (access from below - chassis
floor).
4.3 electrical device test and adjustment
4.3.1 Diode Test Procedure

(1) When use digital circuit test instrument:

1) Switch the test mode into diode range and confirm display
value.
★ Adopting general circuit test instrument to show the
accumulator inner voltage.
2) Connect the test instrument red feeler(+) with anode(P) of
diode,
Connect the black feeler(-) with cathode(N) of diode, and
confirm display value.
3) Use display value to confirm a special ambipolar sum which is good or not.
●Display value has not any change: disconnect (failure)
●Display value changed: Connect (normal)
Remark: A display value range of silicon diode is 400 to 600.
(2) When use simulated circuit test instrument:
1) Switch the simulated mode into resistance range.
2) Checking indicated needle slewing according to following

4-2
 4. Test, adjustment and failure diagnosis

connection:
i) Connect the test instrument red feeler(+) with anode(P) of diode,
Connect the black feeler(-) with cathode(N) of diode.
ii) Connect the test instrument red feeler(+) with cathode(N) of diode ,
Connect the black feeler(-) with athode(N) of diode.
3) Confirming a special diode is good or not according to indicated needle slew.
● If the indicated needle do not slew in i) but do in ii): Normal
(but the slew width (resistance value) will be different form one circuit test instrument or selected test
range)
●If the indicated needle slew in i) and ii): Failure (inner short circuit)
●If the indicated needle do not slew in i) and ii): Failure (inner broken circuit).
4.3.2 special function of multi-functioned
monitor panel

4.3. Failure Diagnosis

4.4.1 inspection before fault diagnosis

No Item Judge Standard solution

1 Check accumulator terminal、wire loose、corrosion — Screw or Replace
2 Check alternator terminal、wire loose、corrosion — Screw or Replace
3 Check start motor terminal、wire loose、corrosion — Screw or Replace
4 Check accumulator voltage(engine flameout） 10~15V Replace
6 Check accumulator electric eye（Green means — Replace
electric in full, write means under charging）
7 Check wire of fading、burning or flaking — replenish or Replace
8 Check deciduous wire clip or suspended wire — Repair
9 Check moistened wire（check connector or terminal — Dismantle connector
carefully） and drying
10 Check fuse burning out or rust — Replace
11 Check alternator voltage(engine running in over After running several Replace
half accelerograph） minutes:Voltage13V~14.5V

12 Check the noise of accumulator in working — Replace

condition（switch turning between ON/OFF）
13 Check relay pin loose in electric control box，wire — Repair
loose or shell, wire cutting
4.4.2 instruction during fault diagnosis ★ If the electric power switched on but the

1) Cutting off electric power before disconnect or connector disconnected, it will show redundant

connect connector. abnormality.

2) Checking all related connectors inserting is 4) When inspect the circuit(test voltage 、

correct or not before failure diagnosis. resistance、connectivity or current), move related

★Disconnecting or connecting related connectors circuit and connector for several times, check and
several times for testing. test the change of instrument display.
3) Connect all cutting connectors before next ★If the instrument display changed, maybe the
procedure. circuit poor connected.

4-2
 4. Test, adjustment and failure diagnosis

4.4.3 Failure diagnosis and service

Electric circuit failure：

Failure character Cause Solution Remark
Engine cooling water No 1.Sensor wire cutting Repair Resistance range of
temperature meter change water temperature
2.Sensor damaged or Replace or Repair
display sensor is 22
sensor terminal loose
ohm(120°)to 400
Always 1.Sensor damaged Replace ohm.
in full 2.Sensor or circuit Replace or Repair
grounding short circuit
Fuel oil level meter Always 1.Sensor wire cutting Repair Resistance range of
in 2.Sensor damaged or Replace or Repair oil level sensor is 10
full sensor terminal loose ohm (low level) to
180 ohm.(full level)
Always 1.Sensor damaged Replace
empty 2.Sensor or circuit Replace or Repair
grounding short circuit
Hydraulic oil No 1.Sensor wire cutting Repair Resistance range of
temperature meter change 2.Sensor damaged or Replace or Repair oil temperature
display sensor terminal loose sensor is 22 ohm to
400 ohm.
Always 1 .Sensor damaged Replace
in full 2.Sensor or circuit Replace or Repair
grounding short circuit
Oil pressure meter Always 1.Sensor wire cutting Repair Resistance range of
in full 2.Sensor damaged or Replace or Repair oil pressure sensor is
sensor terminal loose 10ohm to 184ohm.
Always 1 .Sensor damaged Replace
empty 2.Sensor or circuit Replace or Repair
grounding short circuit
Rotational speed No 1.Circuit cutting or not Repair
rotation 2.Alternator failure Replace or Repair
al speed
low 2.Alternator belt loose Adjust
rotation
al speed
Air filter plug warning 1.Air filter plug Replace filter core
2.Air filter plug switch Repair
grounding short circuit
Oil filter switch warning 1.Oil filter plug Replace filter core
2.Oil filter switch ground Repair
short circuit
Meter no display 1.Eletric source wire Inspection
cutting
2.Meter inner failure Replace
Pilot no action 1.pilot switch failure Inspection or
Replace
2.pilot electromagnetic Inspection or
valve failure Replace
3. circuit failure Repair
4.electric control box Repair or Replace
failure
Machine no electric power 1.electric source switch Replace
damaged
4-2
 4. Test, adjustment and failure diagnosis

2. whole electric source Replace

fuse burn down.
3.start switch damaged Repair or Replace
4.circuit break Repair
Start switch can not cut off Main point of electric Replace
power supply source burn down

Air-condition failure
Failure character Cause Solution
Electric joint loose leading to abnormal
Inserting joint tightly or repair
sound of clutch
Tighten it moderately, replace it
Belt loose
when damaged
System noise Blowing engine、electric fan loose Resetting tightly
Blowing engine 、 electric fan running
Repair or replace
abnormally
Compressor bearing damaged Replace
Tension pulley bearing damaged Replace
No refrigeration Check short circuit or not and
Fuse burn out
replace
Amplifier damaged Replace
Relay failure Replace
Electric circuit failure Repair or replace
Repair or replace check failure、
Air-condition switch/ controller failure amendment、supply cold-producing
medium
No cold-producing medium
System plug Clean or replace
Belt loose or crack Adjust or replace
Expanding valve failure Clean or replace
Compressor running abnormally Repair or replace
Pressure switch failure Replace
Circuit poor connect Check and repair
Belt loose Adjust belt moderately
Abnormal Air-condition switch adjusted
refrigeration Resetting/increase cold-producing
improperly/cold-producing volume setting
volume setting
less
Water overabundance in system, inner plug Replace desiccator
Refrigeration cold-producing medium superabundance or
Eliminate or supplement
shortage deficiency
Air extracting for vacuum and
System inner air superabundance
supply cold-producing medium
Clutch slipping or abrasion Repair or replace
Expanding valve plug partly Clean
Expanding valve failure Replace
Drying bottle plug Replace
Surface of dust screen or vaporizer too
Clean
dirty
Air-condition vent is plugged by impurity Clearance
Surface of condenser too dirty Clean
4-2
 4. Test, adjustment and failure diagnosis

Compressor failure Repair or replace

Controller use improperly, open the
Close heating mode
heating
Hot water flow controller/ electromagnetic
Clean or replace
warming water valve failure
Warming water valve blocked in opening
location
Mechanical warming water valve located
Close warm water valve
in opening location
Controller failure can not control hot water
flow controller/electromagnetic warming Replace
water valve closed
Waiting until engine water
Engine water temperature too low
temperature higher to use
Controller failure can not control hot water
flow controller/electromagnetic warming Replace
No heating or
water valve opened
heating deficiency
Hot water flow controller/ electromagnetic
Repair or replace
warming water valve circuit failure
Hot water flow controller/ electromagnetic
warming water valve failure
warming water valve blocked in close
Replace
location or in little open location
Mechanical warming water valve closed
Opening warming water valve
or opened too less
Controller heating setting too less Enlarging heating setting
Controller/control panel use improperly, Close cooling mode/air-condition
opened cooling switch
Surface of dust screen too dirty Clean
Air-condition vent is plugged by impurity Clearance

4-3

5. DISASSEMBLY AND
ASSEMBLY
5.1. How to read this manual
installation and removal
removal
z Section “removal” includes procedure and
instruction
z All the warning signs and marks which have
been used in the section “removal” are listed
as follow:
★ This mark is used to provide instruction and
attention to operating procedure.
Assemble parts
installation
z Install parts in reverse order unless otherwise
noted.
z All marks and signs used in section
“installation” is as follow:
★ This mark is used to provide instruction and
attention to operating procedure.
assembly and disassembly
Disassembly
2．instructions during the process of assembly
z Section ”disassembly” includes procedure and
instruction
z All the warning signs and marks which have
been use in this section “disassembly” are
listed as follow.
★ This mark is used to provide instruction
and attention to operating procedure.
assembly
z This section “assembly” includes procedure,
precaution and know-how.
z All the sighs and marks are explained and
listed as follow:
★ This mark is used to provide instruction
and attention to operating procedure.
Instruction during operation
The following items should be followed when
attempting any disassembling or assembling
procedure.(removal or installation)
1. instructions during disassembling
z dispose properly if engine coolant contains
antifreezing fluid.
z Always cap or plug hoses when hoses or
steel pipes are removed to prevent them
from entry of dirt ,dust and debris.
z Provide a proper container to catch the oil
discharged
5-1
5. Disassembly and assembly
z Provide mating marks to avoid
re-assembling mistake, prior to
disassembling.
z Do not pull conducting wire to avoid loose
from contact point. When disconnecting
conduct wire ,Hold connector to avoid
excessive force applied to wire.
z Attach marks on the wire or hose to make
certain their position . it helps to avoid
mistake during re-assembling.
z Calculate and inspect the number and
thickness of washers, and keep them at
safe place.
z Make certain to use proper lifting device
with sufficient strength and reliability,
when lifting components.
z Evenly fasten screw in proper sequence
when lifting bolt was used to remove any
components.
z When disassembling any devices, clean
the surrounding area and cover them to
prevent dust or dirt from entering into
them.
★ instructions when working with
pipeline during disassembling.
During the process of disassembly, please
insert the blind plug into the pipe after the
pipeline is disassembled.
z fasten all the nuts and bolts with specified
torque value.
z No distortion or interference is allowed
during hose installation.
z Replace all bushing ,o-ring , cotter pin,
and locking plate with new ones.
z Securely bent cotter pin and locking plate.
z When applying bonding compound, Clean
components and remove all oil and grease.
And then apply 2 or 3 drops to all parts
with thread.
z When applying sealant, clean surface and
remove all oil and grease. If no dirt and
damages are recognized, evenly apply
sealant to it.
z Remove or repair all part’s damage, dent,
burrs and rust.
z Grease all rotary components or sliding
components.
z Apply anti-friction composites to the part
surface, when press- fitting
z Make certain snap rings have been
securely located in the groove. After
assembling snap rings.
z Make wire connector free of oil , dirt and
water, connect securely when connecting
wire with wire connector.
z When using eye bolt, inspect it to make
 5. Disassembly and assembly

certain the bolt free of distortion and

metamorphic. Make sure to completely
fasten it and align it with the lifting hook.
z When fastening counter flange, always
fasten them evenly to prevent that one
side’s flange is over fastened.
★ After the cylinder, main pump and
other hydraulic devices are
disassembled and repaired then
re-assembled, bleed the air for the first
time use. The operation procedure is as
follow:
1) Start the engine and run it with low idle
speed.
2) Operate working device controller to
operate hydraulic cylinder 4-5 times, stop
b. align mounting holes on condenser
the cylinder at a position 100 mm away
bracket(shown in step a fig) with holes on upper oil
from the stroke end
cooler , then according to the fig below to tighten
bolts 1 that secure bracket.。
3) Operate hydraulic cylinder 3-4 times to its
stroke end.。
4) Make the engine run with normal speed,
afterwards.,
★ when using the machine for the first time
after long-term storage or repair, follow
the same procedure.
3．Instruction after operation：
z In the event that engine coolant is drained,
tighten drain valve, refill coolant to
specified level. Run the engine to cycle
coolant in system then check the fluid
level.。
z In the event that hydraulic device has been
disassembled then re-assembled, refill oil 2） secure condenser with bolts in position 1 ,2.
to the specified level. Run the engine to tighten bolts 4 that secure dry bottle 5( as
cycle oil in the system. Then check oil shown in fig)。
level.。
z If repair and disassembly to pipelines or
hydraulic devices are made, bleed the air
after re-assembling components。
z Apply grease with specified volume to
relevant parts of working device.。

5.2. Hydraulic oil cooler disassembly and

assembly

（1） disassembly：with reverse order of assembly 3） Compressor pipeline connection：

（2） assembly
1） a. Seat rubber washer 3 between oil cooler 2
and radiator 1 . install bolt 4 ( with nut attached)
to secure oil cooler 2 to radiator foundation.
a. Air conditioning pipe1 ： compressor D —
condenser U。
b. Air conditioning pipe 2：compressor S—air
conditioning housing outlet,. ， with rubber
sleeve protected.
c. Air conditioning pipe 3:drying bottle inlet —
air conditioning housing inlet.
d. Air conditioning pipe 5 : dry bottle outlet —
condenser x

5-2
 5. Disassembly and assembly

e ： front view of cool-hot pipeline with air

conditioning cover removed.：
hot-water pipeline 1 → engine hot-water outlet;
hot-water pipeline 2 → engine cool water inlet。 5.3. Hydraulic pump disassembly and
assembly

（1） required tool: open end wrench（90-300N.m）

（2） Disassembly: in reverse order of assembly
（3） assembly
1．Coupling installtion:1) place coupler 1 into
engine’s flywheel plate with pneumatic wrench and
sleeve , then tighten the bolt 2。

4） Hydraulic oil cooling circuit pipeline

connection：
a. Hose 1 connection : oil return block 2
–hydraulic oil cooler in( fasten torque applied
to both end of hose : 90 N.m)

2) tighten mounting bolts in the sequence as shown

in the fig。

b. Hose 2 connection: oil cooler outlet → oil

return flange 4 (hose is fixed with hose clamp
3)。

2．Connecting plate installation：

1）as shown in fig , connecting plate is hoisted
and assembled by parts marked 1,2.
2 ） crossly tighten mounting bolts 3.( torque:
60N.m)。

5-3

3．Hydraulic pump and coupler installation：
1）attach coupler2 to hydraulic pump1。
2）make sure the distance between pump mounting
end face 3 and outer end face of coupler teeth is
within 65—70mm。
3）install bolt 5 on the coupler and fasten it with
pneumatic wrench 7 and socket wrench.6.。
4．Hydraulic pump hoisting assembly：
1）install hydraulic pump2 into connecting plate 1,
and align it with mounting hole3。
2）use open end wrench 2 to tighten bolt 1( torque:
240N.m)。
5-4
5. Disassembly and assembly
5.4. Rotary motor and swing mechanism
disassembly and assembly.
（1） required tools: funnel
（2） disassembly：in reverse order of assembly
（3） assembly
1． Slewing motor disassembly and assembly.：
1）main oil port M、DB、A、B and pilot oil port 1
intalllation . tightening torques are listed on below
table。
2）install connector 1 and union2 on rotary motor,
connect oil filler pipe3 and oil discharge pipe4 with
connector 1,2( 5,6 is connection after motor is
installed .) 。

3）completely install gear oil filler pipe3 and plug2
into rotary motor port 4, fill proper amount of gear
oil(1.5L), withdraw oil scale to check oil volume .
2． Install rotary motor：
1）make sure the teeth 4 on rotary motor mesh
properly with slewing bear 2 teeth 1. preinstall bolt
after attaching motor mounting surface to platform
end surface（3）。
2）place rotary motor 1 in position in platform2 as
shown in fig below, crossly tighten bolt 3 to secure
motor to platform( torque: 240 N.m)
5-5
5. Disassembly and assembly
3.rotary motor pipeline connection:：
Pipeline 1: multiple way valve B9→ rotary motor
B ( torque applied to hose end : 70N.m)
Pipeline 2: multiple valve A9 B9→ rotary motor A
(torque applied to hose end: 70 N.m)
Pipeline 3: multiple valve M → oil return block
2# (torque applied to hose end: 90 N.m)
Pipeline 4: multiple pipe DB→ oil tank 12 (torque
applied to hose end: 45 N.m)。
Pipeline 5(6,7): pilot oil source Pv → rotary motor
PG, SH (torque applied to hose end: 45 N.m)。
5.5. Carrier roller disassembly and
assembly
required tools
assembly
1）assemble carrier roller 3.：
a. place carrier roller 3 in position in chain roller
mounting base , press it with holddown
plate2. tighten bolt 1 to secure it.。
 5. Disassembly and assembly

3） the position of weak band on slewing bear is

as shown in the fig n/m, position 1 is of outer weak
band. ,Position 2 is of inner weak band.。
b. evenly tighten bolts on both ends to make sure
the dimension (marked with 4 ) m=2mm。

4）place inner weak bank 1 towards right hand,

align through holes on bottom mounting surface
with internal screw 2.( see fig below）。

c. evenly tighten respective bolt with torque

180N.m

5.6. Slewing bear disassembly and

assembly

（1） disassembly ： with reverse order of

assembly
（2） assembly： 5）rotate slewing bear to set outer weak band2 and
1） apply sealant 2( model:1596) to chassis 1, as internal weak band in opposite position towards
shown in the fig. the left hand of
machine.

2）position eye ring 4 to slewing bear hoist hole,

tighten it to secure lifting chain1 and two hook2 to
the eye ring4 (see fig)。 6）install bolt from underneath the chassis mounting
hole. Tighten the bolts in sequence as （1）→（2）
→ （ 3 ） → （ 4 ） , see fig a.

5-6
 5. Disassembly and assembly

7）apply torque to pre-stressed bolt（M20X55-10.9）

to tighten it with wrench 4, and socket wrench3.
see fig below.
c. upper oil port connector assembly and stop
block 2 assembly: tighten bolt 3 on stop block
with torque : 110N .m)

5.7. Central rotary connector

disassembly and assembly

（1） required tools

（2） disassembly：with reverse order of assembly
（3） assembly: 5.8. Hydraulic oil tank disassembly and
1） central rotary connector 1 assembly（direct oil assembly
port G to travel motor）:
a. under oil port assembly： （1） Disassembly: with reverse order of assembly
（2） assembly
1） using dirt collector to clean up tank interior
through port 1,2 as shown in the fig. inspect
tank interior to secure 11 clearness grade, after
clean-up,。

b. tighten bolt 2 to secure rotary connector 2:

tighten bolt with torque : 65N.m)

2） oil suction pipe installation: position oil suction

5-7
 5. Disassembly and assembly

steel pipe 3 to mounting surface 1 beneath fasten torque at 2,4 position: 30 N.m.
the oil tank, with bolt 4 fastened, using rubber
belt to seal the port. Tighten and install Oil
discharge plug.。

6） With lifting strip is attached to oil tank,

3）oil filter of hydraulic oil tank assembly： hoist and assemble it to platform then fix
a. using bolt2 to fix tank purge cover, place oil it. Fasten bolts with torque : 60N.m.
suction filter core assy 3,4,5,6,7 in the oil suction
pipe. Bolt tighten torque: 50N.m
b. oil cover 9 and rubber seal washer hold down oil
filter spring. 7.

7） Assemble oil suction hose 2 and

inter-transient pipe 3 which is secured by
clamp 4.：
a. tighten and assemble hose 2( hose clamp 1):
oil suction pipe f → inter-transient pipe 3.

4） assemble attachments atop oil tank：

a. fasten press-type oil filter 2 atop oil tank.；
b. with oil filter 3 secured by bolt 4, attach oil
flange 5 to oil filter, with bolt 6. then seal
the port with tape 7. bolt tightened torque:
60 N.m.

b. hose 6 ( hose clamp) assembly: steel pipe at

position marked 5→ main pump 8 inlet port。

5） oil tank side connector1,2,3,4 assembly.

Fasten torque at 1,3 position: 45N.m.
5-8
 5. Disassembly and assembly

8）oil circuit pipeline and wire harness connection:：

a. connector of oil level sensor 1,2,3 assembly:：

5.9. Multiple way valve disassembly and

assembly

（1） disassembly
（2） assembly
1） SWE80 multiple way valve connector
installation：
In fig1：A1B1~A3B3 connector tightening torque：
70N.m
In fig 2：A4B4、A5B5、A7B7、A9B9 connector
tightening torque ：70 N.m
b. hydraulic oil tank’s oil circuit pipeline In fig 3 ： A6B6~A8B8 connector tightening
connection:
torque ：125 N.m
In fig 4：LS connector installation torque：35 N.m
In fig 5、7：T1、T2 oil port connector tightening
torque：180N.m
In fig 6、8：P3 oil port connector tightening torque：
70/ P2 oil port connector torque 180Nm
In fig 9 ： individual pilot oil port connector s
tightening torque: 30N.m.

Respective valve oil connector corresponding to oil

tank 4,5,6,7 is as shown in the following fig.：
Pipeline 4: oil tank t1→ central rotary connector
T；
Pipeline 5: oil tang t2→rotary motor DB；
SWE80S (rotary ) multiple way valve assembly ：
Pipeline 6: oil tank t3 → pilot oil source Tx
In fig 1, A1, B1 is plug, the other oil ports are the
Pipeline 7: oil tank t3 → main Ts
same as the above.。
2 ） position multiple way valve 2 in bracket
1,tighten bolts following sequence as 3→4→5→
6。

5-9
 5. Disassembly and assembly

3）multiple way valve and bracket 5 are hoisted and C：mark selection valve as follow：
assembled at oil tank, tighten bolts in a sequence
as:1→2→3→4.

5）mark multiple way valve connector as follow:：

4）connect multiple way valve with upper oil hose

on central slewing connector.：
a. travel portion on multiple way valve pipeline
connection:（tightening torque applied on hose
end：90N.m）
left travel 7 pipeline: multiple way valve A3→left
travel 7 pipeline: multiple way valve A3→central
rotating connector D；
left travel 9 pipeline: multiple way valve B3→
central rotating connector C；
6）pipeline connection of multiple way valve and
right travel 8 pipeline: multiple way valve A4→
working device steel pipe( see fig)：
central rotating connector B；
a：multiple way valve connects to pipeline of boom
right travel 10 pipeline: multiple way valve B4→
cylinder 7,8,9,10(tightening torque applied to hose
central rotating connector A； end:90N.m)
b. crushing pipeline connection( tighten hose ends pipeline 7：multiple way valve B8→ steel pipe
with torque: 90N.m)
b(right)
pipeline 1: multiple way valve A2 — selection
pipeline 8: multiple way valve B8→ steel pipe
valve P1
a(left)
pipeline 2: multiple way valve B2 — selection
pipeline 9: multiple way valve A8→ steel pipe
valve P2
a(right)
pipeline 3: multiple way valve C1 — central
pipeline 10: multiple way valve A8→ steel pipe
rotating connector F
a(left)
pipeline 4: multiple way valve C4 — central
b：oil reservoir of boom cylinder connects to oil
rotating connector E
port steel pipeline 11,12,13,14 ( tightening
pipeline 5: multiple way valve C2—left crushing
torque applied to hose end:90N.m )。
steel pipe.
Pipeline 11: steel pipeline b (right) →right boom
Pipeline 6: selection valve C3— right crushing
cylinder big reservoir.
steel pipe.
Pipeline 12: steel pipeline a (right) →right boom
cylinder small reservoir
Pipeline 13: steel pipeline b (left) →left boom
5-10
 5. Disassembly and assembly

cylinder big reservoir a ： joystick pilot controlled valve mark and

Pipeline 14: steel pipeline a (left) →left boom connector assembly：
cylinder small reservoir instruction:
1.1tighten connectors in a sequence of →3→4→T
c ： multiple way valve connects to boom steel →P.
pipeline1,2,3,4,5,6( tightening torque: 90N.m) , 1.2 tighten connectors of 1、2、3、4、T、P with
assembly sequence: 2→5→3→6→1→。 torque:30 Nm.
Pipeline 1: multiple way valve A5→ boom steel
pipe A6
Pipeline 2: multiple way valve A6→ boom steel
pipe A6
Pipeline 3: multiple way valve A7→ boom steel
pipe A7
Pipeline 4: multiple way valve B5→ boom steel
pipe B5
Pipeline 5: multiple way valve B6→ boom steel
pipe B6
Pipeline 6: multiple way valve B7→ boom steel
pipe B7
b： pedal pilot controlled valve 1 and rotoray, crush
pedal valve 2,3. oil port mark and connector
assembly.
Instruction:
1.1 torque for respective connector:30Nm

d：boom cylinder a,b oil inlet pipe seat.：

C：pilot oil source valve block1, oil port mark and

connector installation：
Tighten connector P1、Pr、Pv、Bv with torque:：
40N.m

5.10. Pilot control valve disassembly and

assembly

（1） required tools

（2） procedure of replacing pressure
compensate valve seal
（3） disassembly
（4） assembly
1 ） pilot controlled valve mark and connector pipeline 1: oil source block P1→hydraulic pump
assembly： P1
5-11
 5. Disassembly and assembly

pipeline 2: oil source Bv → central rotating

connector G.
pipeline 3: oil source block Pr→ precise oil filter
→ oil collecting block.
Pipeline 4: oil source Pv→ rotating motor PG,BH
pilot oil port.
d：travel pedal valve, rotary, crushing pedal valve
and multiple way valve and oil collecting pipeline
connection.( see fig):
instruction：
1.1 refer to the fig below to connect respective hose
accordingly.
1.2 hose tightening torque:40N.m。

2） joystick pilot controlled valve installation and

pipeline connection:
a：pilot valve installation:：secure valve1 and 3 to
control tank frame with bolt 2.

5.11. Travel motor disassembly and

assembly

（1） Removal
（2） Installation
1）travel motor installation：
a. position travel motor to thought hole 2 on the
chassis motor seat. Tighten and fasten bolt with
torque: 240N.m.

b ： view of joystick pilot controlled valve and

multiple way valve pilot controlled port pipeline
connection.

b. position drive wheel 5 into screw hole 1 on

motor3，fasten bolt with torque :240N.m
c. motor oil connector installation：

5-12
 5. Disassembly and assembly

T、Pconnector：torque：45N.m
A、B connector：torque：135N.m

2） Travel motor pipeline connection：

a. Hose 3 connection: right motor A→ central
slewing A’，left motor A→ central slewing A’
(fasten torque: 70 N.m)。
b. Hose 4 connection: left motor P → central
slewing G’2, right motor P→ central slewing
G’1 ((fasten torque: 45N.m)。
c. Hose 5 connection, left motor B → central
slewing D’, right motor B→ central slewing
B’ (fasten torque : 70 N.m)。
d. Hose 2 connection : left motor T→ central
slewing T’2, right motor T→ central slewing
T’1( fasten torque: 45N.m)。

5-13
 6. Attachment drawings and others

6. ATTACHMENT DRAWINGS AND OTHERS

6.1. Hydraulic drawing

6-1
 6. Attachment drawings and others

6.2. Electric system drawing

6-2
 6. Attachment drawings and others

6.3. Air-condition circuit diagram

6-1