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Hitachi ZX40U, ZX50U Service Manual (Technical Manual+ Workshop Manual + Diagramas) PRIME A+ 657 Páginas
Hitachi ZX40U, ZX50U Service Manual (Technical Manual+ Workshop Manual + Diagramas) PRIME A+ 657 Páginas
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance and
delivery, operation and activation of all devices repair of the machine, tools and devices needed
and systems, operational performance tests, and for maintenance and repair, maintenance stan-
troubleshooting procedures. dards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
UNITS USED
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688 SA-688
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
JUMP STARTING
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
SA-660
014-E01B-0379
018-E01A-0481
SA-481
SA-662
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-664
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade. SA-666
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK
SA-675
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
S501-E01A-0287
SA-287
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
505-E01B-0498
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Clean up Flammables:
SA-22
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-393
In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016
SA-016
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL
CONTENTS
Group 1 Specification
Specifications ............................................ T1-1-1
Working Ranges and Machine
Dimensions for Transportation.................. T1-1-4
1LDT-1-1
(Blank)
1LDT-1-2
GENERAL / Specifications
SPECIFICATIONS
40U
A
C
E
D
J I
G
H
M1LD-12-003
40U
Type
Canopy Cab
Type of Front-End Attachment Boom Swing Type
3 3
Bucket Capacity (Heaped) m (yd ) 0.14 (0.18)
Operating Weightkg kg (lb) 4040 (8910) 4100 (9040)
Basic Machine Weight kg (lb) 3040 (6700) 3100 (6830)
Isuzu CC-4LE2
-1
Engine kW/min 30.5/2200
(PS/rpm) (41.5/2200)
A: Overall Width mm (ft in) 1870 (6 2 )
B: Overall Height mm (ft in) 2610 (8 7 ) 2660 (8 9 )
C: Rear-End Swing Radius mm (ft in) 975 (3 2 )
D: Minimum Ground Clearance mm (ft in) 335 (1 1 )
E: Counterweight Clearance mm (ft in) 650 (2 2 )
F: Engine Cover Height mm (ft in) 1580 (5 2 )
G: Undercarriage Length mm (ft in) 2450 (8 0 )
H: Undercarriage Width mm (ft in) 1950 (6 5 )
I: Sprocket Center to Idler Center mm (ft in) 1960 (6 5 )
400 (1 4 )
J: Track Shoe Width mm (ft in)
(Rubber Crawler)
kPa 23.0 24.0
Ground Pressure
(kgf/cm2, psi) (0.24, 3.3) (0.25, 3.5)
Swing Speed min1 (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.4/2.5 (2.7/1.6)
Gradeability (tan ) 30 (58%)
NOTE: The dimensions do not include the height of the shoe lug.
T1-1-1
GENERAL / Specifications
50U
A
C
E
D
J I
G
H
M1LD-12-003
50U
Type
Canopy Cab
Type of Front-End Attachment Boom Swing Type
Bucket Capacity (Heaped) m3 (yd3) 0.16 (0.21)
Operating Weightkg kg (lb) 4510 (9940) 4570 (10080)
Basic Machine Weight kg (lb) 3500 (7720) 3560 ( 7850)
Isuzu CC-4LE2
Engine kW/min-1 30.5/2200
(PS/rpm) (41.5/2200)
A: Overall Width mm (ft in) 1870 (6 2 )
B: Overall Height mm (ft in) 2610 (8 7 ) 2660 (8 9 )
C: Rear-End Swing Radius mm (ft in) 1000 (3 3 )
D: Minimum Ground Clearance mm (ft in) 335 (1 1 )
E: Counterweight Clearance mm (ft in) 600 (1 12 )
F: Engine Cover Height mm (ft in) 1580 (5 2 )
G: Undercarriage Length mm (ft in) 2450 (8 0 )
H: Undercarriage Width mm (ft in) 2000 (6 7 )
I: Sprocket Center to Idler Center mm (ft in) 1960 (6 5 )
400 (1 4 )
J: Track Shoe Width mm (ft in)
(Rubber Crawler)
kPa 26.0
Ground Pressure 2
(kgf/cm , psi) (0.27, 3.8)
1
Swing Speed min (rpm) 9.0 (9.0)
Travel Speed (fast/slow) km/h (mph) 4.4/2.5 (2.7/1.6)
Gradeability (tan ) 30 (58%)
NOTE: The dimensions do not include the height of the shoe lug.
T1-1-2
GENERAL / Specifications
WORKING RANGES
40U G
L (Left) L (Right)
I
J
F
A
B
M571-11-002
M1LD-12-004
40U
Canopy Cab
A: Maximum Digging Reach mm (ft in) 5690 (18 8 )
B: Maximum Digging Depth mm (ft in) 3400 (11 2 )
C: Maximum Cutting Height mm (ft in) 5650 (18 6 )
D: Maximum Dumping Height mm (ft in) 4000 (13 1 )
E: Transport Height
2610 (8 7 ) 2660 (8 9 )
(Rubber Crawler) mm (ft in)
F: Overall Transport Length mm (ft in) 5300 (17 5 )
G: Minimum Swing Radius mm (ft in) 2030 (6 10 ) 2340 (7 8 )
I: Blade Bottom Highest Position
400 (1 4 )
(above ground level) mm (ft in)
J: Blade Bottom Lowest Position
365 (1 2 )
(above ground level) mm (ft in)
K: Maximum Boom-Swing Angle L60 /R80
L950 (L 3 1 )
L: Offset Distance mm (ft in)
R650 (R 2 2 )
NOTE: The dimensions do not include the height of the shoe lug.
T1-1-3
GENERAL / Specifications
50U G
L (Left) L (Right)
I
J
F
A
B
M571-11-002
M1LD-12-004
50U
Canopy Cab
A: Maximum Digging Reach mm (ft in) 5800 (19 0 )
B: Maximum Digging Depth mm (ft in) 3600 (11 10 )
C: Maximum Cutting Height mm (ft in) 5640 (18 6 )
D: Maximum Dumping Height mm (ft in) 3950 (12 12 )
E: Transport Height
2610 (8 7 ) 2660 (8 9 )
(Rubber Crawler) mm (ft in)
F: Overall Transport Length mm (ft in) 5330 (17 6 )
G: Minimum Swing Radius mm (ft in) 2100 (6 11 ) 2650 (8 8 )
I: Blade Bottom Highest Position
400 (1 4 )
(above ground level) mm (ft in)
J: Blade Bottom Lowest Position
365 (1 2 )
(above ground level) mm (ft in)
K: Maximum Boom-Swing Angle L60 /R80
L950 (L 3 1 )
L: Offset Distance mm (ft in)
R650 (R 2 2 )
NOTE: The dimensions do not include the height of the shoe lug.
T1-1-4
GENERAL / Component Layout
MAIN COMPONENTS
3 4
5
6
7
8
9
22 10
21 11
20 12
13
19
18
17 14
15
16
T1LD-01-02-001
T1-2-1
GENERAL / Component Layout
ELECTRICAL SYSTEM
2
3
6
19
7
18
9
10
17
16
15 11
14 12
13
T1LD-01-02-002
1 - Work Light (Boom) 6 - Overheat Switch 11 - Engine Stop Solenoid 16 - Fusible Link
2 - Horn Switch 7 - Coolant Temperature Sensor 12 - Starter 17 - Horn
(for Glow Timer)
3 - Pilot Shut-Off Switch 8 - Coolant Temperature Sensor 13 - Fuel Pump 18 - Work Light (Base Machine)
(for Coolant Temperature Gauge)
4 - Solenoid Valve Unit 9 - Glow Plug 14 - Fast Speed Travel 19 - Battery
Pedal
5 - Alternator 10 - Engine Oil Pressure Switch 15 - Fuel Sensor
T1-2-2
GENERAL / Component Layout
RELAYS
Seat
View A (Relay Box)
Relay Box
7
2 3
6
4
A
1 5
T1LA-01-02-003
M1LA-01-005
T1-2-3
GENERAL / Component Layout
MONITOR AND SWITCHES
1 2 3
4
M573-01-025
8 7 6
Pilot Filter
W574-02-07-001
T1LD-04-05-001
T1-2-4
GENERAL / Component Specifications
ENGINE
Manufacturer ISUZU
Model 4LE2
Type Diesel, 4-Cycle, Water-cooled, Inline, Direct Injection
Cyl. No.-Bore Stroke 4-85 mm 96 mm 3.35 in 9.30 in)
Piston Displacement 2179 cm3 (85.8 in3)
2.2 +0 -1 +3 +0 -1
Rated Output 30.5 -0 kW / 2200 -25 min (41 -0 PS / 2200 -25 min )
Compression Ratio 18.8
Dry Weight 168 kg (370 lb)
Firing Order 1-3-4-2
Rotation Direction Clockwise (View from fan side)
COOLING SYSTEM
Cooling Fan Dia. 430 mm, 8 Blades (F-Type Blade), Draw-In Type
Fan Pulley Ratio Engine rpm 0.97
Thermostat (Atmospheric Pressure) : Full open temp. 82 C (180 F)
: Cracking temp. 95 C (230 F)
Water Pump Centrifugal Belt Driven Type
LUBRICATION SYSTEM
Lubrication Pump Type Trochoid Pump
Oil Filter Full-Flow Paper Element Type
STARTING SYSYTEM
Motor Magnetic Pinion Shift Type
Voltage / Output 12 V / 2.0 kW
PREHEAT SYSMTEM
Preheating Method Glow Plug
ALTERNATOR
Type Regulator Integrated AC type
Voltage / Output 12 V / 35 A
FUEL SYSTEM
Type BOSCH A Type
Governor Centrifugal All Speed Control
Injection Nozzle Multi-Injection Hole Type
T1-3-1
GENERAL / Component Specifications
PERFORMANCE
Lubricant Consumption Less than 15 mL/hr at Rated Output
Fuel Consumption Ratio Less than 240 g/kW h (177 g/PS h) at Rated Output
Injection Timing 11.5 before T. D. C
-1
Maximum Output Torque More than 145 6 N m at 1600 min
(14.8 0.6 kgm / Approx. 1600 min-1)
2
Injection Pressure 17.7 MPa (180 kgf/cm )
Compression Pressure 3.04 MPa (31 kgf/cm2) at 250 min-1
Valve Clearance (Inlet/Exhaust) 0.4/0.4 mm (when cool)
No Load Speed Slow:1100 25 min-1 Fast:2375 25 min-1
T1-3-2
GENERAL / Component Specifications
Engine Performance Curve (4LE2)
Test Condition: 1. In conformity with JIS D1005 (Performance Test Method for Diesel Engine Used for
Construction Machinery) under standard atmospheric pressure.
2. Equipped with the fan and alternator.
-1
30.5 kW/2200 min
145 N m / Approx. 1600 min-1
(45 PS/2200 rpm) Torque
(14.8 kgf m / Approx. 1600 rpm)
Output 150
kW 10
PS
45
140 9
40 30
130
8
35 25
30
20 0 0
Nm kgf m
25
Fuel Consumption
Ratio
20
15
600
15
10
10 500
5
5
400
g/kW h
0
1200 1400 1600 1800 2000 2200 2400 T1LD-01-03-001
T1-3-3
GENERAL / Component Specifications
ENGINE ACCESSORIES
RADIATOR ASSEMBLY
Type ...............................................................Radiator/Oil Cooler Tandem Type Assembly
Weight ............................................................8.05 kg (17.7 lb)
BATTERY
Capacity ......................................................... 52 Ah (5-Hour Rate), 65 Ah (20-Hour Rate)
Voltage ........................................................... 12 V
Weight ............................................................ 18 kg (39.7 lb)
T1-3-4
GENERAL / Component Specifications
HYDRAULIC COMPONENT
PUMP DEVICE
MAIN PUMP
Model ............................................................. PVK-2B
Type ............................................................... Variable Displacement Swash Plate Pump
Maximum Flow (Theoretical Value) ............... 110 L/min (29.0 US gpm)
PILOT PUMP
Type ............................................................... Trochoid Pump
Maximum Flow (Theoretical Value) ............... 11.0 L/min (2.9 US gpm)
CONTROL VALVE
Model ............................................................. DPK-T04-6P3G-AC-7804B
Type ............................................................... All Pilot Pressure Operated Type
27U
Main Relief Set-Pressure............................... 24.5 MPa (250 kgf/cm2, 3560 psi)
Overload Relief Set-Pressure ........................ 26.5 MPa (270 kgf/cm2, 3840 psi)
(Boom, Arm, Bucket)
11.8 MPa (120 kgf/cm2, 1710 psi) (Blade: Rod Side)
SWING DEVICE
Type ............................................................... Two-Stage Reduction Planetary Gear
Reduction Gear Ratio .................................... 20.615
SWING MOTOR
Model ............................................................. HT32
Type ............................................................... Swash-Plate Type, Fixed Displacement Axial Plunger Motor
T1-3-5
GENERAL / Component Specifications
TRAVEL DEVICE
Model .............................................................PHV-390-53
Type ...............................................................Two-Stage Reduction Planetary Gear
Reduction Gear Ratio ....................................52.73
TRAVEL MOTOR
Type ............................................................... Varivble Displacement Swash-Plate Piston Motor
CYLINDER
40U Boom Arm Bucket
Rod Diameter................................................. 55mm 50 mm 40 mm
Cylinder Bore ................................................. 90 mm 80 mm 70 mm
Stroke............................................................. 670 mm 702 mm 551 mm
Fully Retracted Length................................... 1070 mm 1041 mm 840 mm
Plating Thickness........................................... 30 m or more
Swing Blade
Rod Diameter................................................. 50 mm 55 mm
Cylinder Bore ................................................. 100 mm 100 mm
Stroke............................................................. 575 mm 150 mm
Fully Retracted Length................................... 905 mm 490 mm
Plating Thickness........................................... 30 m or more
Swing Blade
Rod Diameter................................................. 50 mm 55 mm
Cylinder Bore ................................................. 100 mm 100 mm
Stroke............................................................. 575 mm 150 mm
Fully Retracted Length................................... 905 mm 490 mm
Plating Thickness........................................... 30 m or more
T1-3-6
GENERAL / Component Specifications
SOLENOID VALVE UNIT (2-Spool Solenoid Valve with Pilot Relief Valve)
Relief Set Pressure ........................................ 3.9 MPa (40 kgf/cm2, 570 psi)
Solenoid Valve ............................................... A Port Side : Solenoid Valve for Pilot Shut-Off Valve
B Port Side : Travel Mode Switch Solenoid Valve
T1-3-7
GENERAL / Component Specifications
FILTER
Filtration
Fuel Filter ISUZU
8971788181
Air Filter (with mechanical indicator)
(Indicator Operation Pressure : -6.23 kPa 5%)
Full Flow Filter (Paper Type)
Suction Filter (80 Mesh)
Pilot Filter 10 m
ELECTRICAL COMPONENT
OVERHEAT SWITCH
Model ............................................................. ISUZU 894132-3310
Operating Temperature .................................. 110 C (230 F)
FUEL SENSOR
Resistance Value Empty : 90 Full : 10
HORN
Voltage / Current DC 12 V 3 A
Sound Pressure 110 dB (A)
IllUMINATION
Output Work Light : Halogen 12V·55 W
T1-3-8
SECTION 2
SYSTEM
CONTENTS
Group 1 Hydraulic System
Outline ...................................................... T2-1-1
Pilot Circuit................................................ T2-1-2
Main Circuit ............................................... T2-1-6
1LDT-2-1
(Blank)
1LDT-2-2
SYSTEM / Hydraulic System
OUTLINE
Pilot Circuit
Supplies the pressure oil which is delivered from
the pilot pump to the machine operation control
circuit, the pump control circuit, the travel mode
control circuit, and the swing parking brake re-
lease circuit.
Main Circuit
Controls the pressure oil which is delivered from
the main pump to the control valve which in turn
drive the cylinders and the hydraulic motors.
T2-1-1
SYSTEM / Hydraulic System
PILOT CIRCUIT
T2-1-2
SYSTEM / Hydraulic System
Travel Motor
Travel
Mode
Control
Valve
Travel Speed Solenoid
Changeover Valve
Solenoid Valve Unit
Pilot Shut-Off
Solenoid Valve Travel Pilot Valve
Swing Parking
Brake Valve
Revolution
Sensing Valve
PS Valve
T1LD-02-01-001
Control Valve
T2-1-3
SYSTEM / Hydraulic System
Machine Operation Control Circuit
T2-1-4
SYSTEM / Hydraulic System
Swing Motor
Boom Cylinder
Swing
Arm Cylinder
Arm
Bucket Cylinder
Travel Pilot Valve
Bucket
Boom Swing
Boom Swing Cylinder
Boom Swing Pilot Valve
Auxiliary
Travel (Right)
Travel Motor
Blade Cylinder
Blade
T2-1-5
SYSTEM / Hydraulic System
MAIN CIRCUIT
T2-1-6
SYSTEM / Hydraulic System
Unload Valve
Swing Motor
Main Pump
(P1) Boom Cylinder
Blade Cylinder
Bypass Check
Valve
Swing
Oil Cooler
Travel Motor
Arm
Pressure Compensator
Bucket
Bucket Cylinder
Boom Swing
Boom Swing Cylinder
Arm
Cylinder
Auxiliary
Pressure Compensator
Travel (Right)
Travel (Left)
Blade
T2-1-7
SYSTEM / Hydraulic System
Single Operation Circuit (When a control lever is
operated)
T2-1-8
SYSTEM / Hydraulic System
Swing Motor
Differential
Reducing Valve
Boom Cylinder
Swing
Boom Anti-Drift
Valve
Boom
Pressure
Compensator
Main Pump
(P1)
T1LD-02-01-004
T2-1-9
SYSTEM / Hydraulic System
Combined Operation Circuit (Swing and Boom
Combined Operation)
Pump Operation
4. The differential reducing valve converts the differ-
ential pressure in the circuit between, before and
after the control valve spool into the PLS pressure.
The PLS pressure, accordingly, varies depending
on the load pressure change in the control valve.
The PLS pressure delivered from the differential
reducing valve is routed to the main pump and
the pressure compensators to control their opera-
tion. (Refer to COMPONENT OPERATION / Con-
trol Valve group.)
5. The main pump flow rate is controlled so that the
PLS pressure (the differential pressure in the cir-
cuit between before and after the control valve
spool) supplied from the differential reducing
valve and signal pressure (PGR) delivered from
the revolution sensing valve become balance.
(Refer to COMPONENT OPERATION / Pump
Device group.)
NOTE: Signal pressure (PGR) is used to control
the actuator speeds.
6. As mentioned above, the differential reducing
valve converts the differential pressure in the cir-
cuit between before and after the control valve
spool into the PLS pressure and supplies it to
control the main pump so that the main pump de-
livers oil flow meeting the volume the control
valve requires (equivalent to the load pressure in
the control valve).
T2-1-10
SYSTEM / Hydraulic System
Swing
Motor
Boom Cylinder
Pressure PLS
Swing
Spool
Pressure Boom
Compensator Spool
PGR Pressure
T2-1-11
SYSTEM / Hydraulic System
Differential Reducing Valve Operation Pressure Compensator Operation
7. The load pressure from the boom cylinder and the 11. As the swing motor load decreases, pressure
swing motor acts on the shuttle valve. (PL) after the spool is reduced, causing differen-
8. When load pressure (PL) from the boom cylinder tial pressure (PLS) between, before and after the
is higher than load pressure (PL) from the swing spool to increase.
motor, load pressure (PL) from the boom cylinder 12. As the boom cylinder load increases, pressure
passes the shuttle valve. That is, maximum load (PL) after the spool is raised, causing differential
pressure (PLMAX) from among the spools is pressure (PLS) between, before and after the
routed to the differential reducing valve. Delivery spool to decrease.
pressures (P1 and P2) from main pump (P1) and 13. Both spool before pressure (PIN) and after pres-
pilot pump (P2) are also routed to the differential sure (PL) are always routed to the pressure com-
reducing valve. pensator. In addition, pressure PLS from the dif-
9. According to maximum load pressure (PLMAX) ferential reducing valve is acting on the differen-
from the actuators, the differential reducing valve tial reducing valve as the target differential pres-
control the PLS pressure and supplies the con- sure. The pressure compensaor operates so as
trolled PLS pressure to the main pump and the to satisfy the relationship between pressures (PIN,
pressure compensator. (Refer to COMPONENT PL, and PLS) as shown in the following formula:
OPERATION / Control Valve group.) The pres- Pressure PIN = Pressure PL + Pressure PLS
sure relationship between PLS, Pump Delivery (Refer to COMPONENT OPERATION / Control
Pressure (P1) and PLMAX acting on the differen- Valve group.)
tial reducing valve is described in the following 14. When the swing motor load is light, high hydraulic
formula: oil pressure to drive the swing motor is not re-
Pressure PLS = Pressure P Pressure PLMAX quired. When the boom cylinder load is heavy,
The differential reducing valve outputs pressure high hydraulic oil pressure is required to drive the
PLS equivalent to the differential pressure be- boom cylinder. Under this condition, each pres-
tween pump delivery pressure (P) and maximum sure compensator operates as described below,
actuator load pressure (PLMAX). allowing the main pump to supply more hydraulic
10. Depending on change in pressure PLS from the oil to the actuator which requires more hydraulic
differential reducing valve, the pump control op- oil.
eration is performed. As differential pressure (PLS) between before
spool pressure (PIN) and after spool pressure
(PL) in the swing circuit is large, the pressure
compensator is pushed by before spool pressure
(PIN), causing the pressure compensator to move
to the left. Thereby, the pressure compensator
closes the opening port area, restricting the main
hydraulic oil flow to the swing spool via the pres-
sure compensator.
As differential pressure (PLS) between before
spool pressure (PIN) and after spool pressure
(PL) in the boom circuit is small, the pressure
compensator is pushed by after spool pressure
(PL + PLS), causing the pressure compensator to
move to the right. Thereby, the pressure compen-
sator open the opening port area wider, allowing
the main hydraulic oil to flow more to the boom
spool via the pressure compensator.
T2-1-12
SYSTEM / Hydraulic System
Swing
Motor
(Load:
Light)
Pressure
Compensator
Pressure
Pressure PL PIN
Pressure PLS
T2-1-13
SYSTEM / Hydraulic System
(Blank)
T2-1-14
SYSTEM / Electrical System
OUTLINE
The electrical system is roughly classified into the The main functions and construction of the main circuit
main circuit and the monitor circuit. are outlined here:
T2-2-1
SYSTEM / Electrical System
POWER CIRCUIT (KEY SWITCH: OFF)
Fuse Box
Key Switch
Radio
Fusible Link
Battery
From Starter
Relay 1
Starter
Glow Relay
Alternator
T1LA-02-02-001
T2-2-2
SYSTEM / Electrical System
(Blank)
T2-2-3
SYSTEM / Electrical System
INDICATOR LIGHT CHECK CIRCUIT·ACC-
ESSORY CIRCUIT (KEY SWITCH : ON)
T2-2-4
SYSTEM / Electrical System
Key Switch
To Alternator and
Engine Stop Solenoid
Fuse Box
Radio (Optional)
Preheat
Indicator
Auto-Idle System (Optional) Alternator
Indicator
8
Work Light
T1LA-02-02-002
T2-2-5
SYSTEM / Electrical System
PREHEATING CIRCUIT (KEY SWITCH:ON)
T2-2-6
SYSTEM / Electrical System
Key Switch
Fuse Box
Preheat Indicator
Battery
QOS Sensor
Glow Relay
Glow Timer
Monitor Panel and
Switch Panel
Glow Plug
T1LA-02-02-003
T2-2-7
SYSTEM / Electrical System
STARTING CIRCUIT (KEY SWITCH :
START POSITION)
1. When the key switch is turned to the START 11. The current to terminal #3 in starter relay 2 flows
position, terminal B is connected to terminals into the base part in transistor.
BR,R1,C,and ACC in the key switch. 12. Consequently, the current from terminal #1 in
2. The current from terminal BR in the key switch starter relay 1 to terminal #4 in starter relay 2 is
flows to two directions. One current flows to the grounded through the transistor and terminal #2
fuel feed pump via the fuse box and activates the to magnetize starter relay 1
fuel feed pump. 13. Therefore, the contact between terminals #3 and
3. The current from terminal C in the key switch #6 is turned OFF. Then, the current from terminal
flows to the engine start side of the stop solenoid. R1 in the key switch does not flow into terminal
The stop solenoid moves to the engine start side ST in the starter via starter relay 1, stopping the
to release the fuel cut off lever. (The engine can starter.
rotate under this condition.)
4. Terminal L in the alternator is connected to the
ground inside the alternator. The terminal #1 in
starter relay 2 and terminal #3 in the monitor
panel and switch panel are grounded in the
alternator.
5. Therefore, the alternator indicator comes ON.
6. The current from terminal ACC in the key switch
is grounded in the alternator via the fuse box and
terminals #3 to #1 in starter relay 2.
7. As no base current flows to the transistor (base
part) in starter relay 2 , the current from terminal
#1 in the starter relay 1 to terminal #4 in starter
relay 2 is not grounded.
8. The current from terminal R1 in the key switch
flows to terminal ST in the starter via the contact
between terminals #3 and #6 in starter relay 1.
Therefore, the contact in the starter is closed to
rotate the starter.
9. After the engine is started, the alternator starts
generating the electrical power, increasing the
voltage at terminal L in the alternator. Then, the
current from the alternator indicator and terminal
#3 in the monitor panel and switch panel is not
grounded in the alternator, turning the alternator
indicator OFF.
10.At the same time, the current from terminal ACC
in the key switch to terminal L in the alternator via
the fuse box and terminals #3 to #1 in starter
relay 2 is not also grounded.
T2-2-8
SYSTEM / Electrical System
Key Switch
Battery
Starter
ST
Alternator
Stop Solenoid
T2-2-9
SYSTEM / Electrical System
CHARGING CIRCUIT (KEY SWITCH : ON)
1. The key switch is automatically returned to the 4. After the alternator begins to generate electrical
ON position upon releasing it after the engine current, the voltage at terminal L in the alternator
starts. With the key switch ON, terminal B is increases. The current flowing to alternator
connected to terminals BR, R2 and ACC in the terminal L via the alternator indicator and the
key switch. monitor panel and switch panel terminal #3 is not
grounded, turning the charge lamp OFF.
2. Current from the key switch terminal BR flows to
alternator terminal #2, exciting the field coil in side 5. Current from key switch terminal BR flows to the
the alternator. holding side of the stop solenoid, holding the fuel
cut lever in the release position so that the engine
3. As the engine runs, the alternator rotates,
is ready to start.
generating electrical current. Electrical current
flows from alternator terminal B to the battery via
the fusible link, recharging the battery. The
electrical current is maintained constant by a
built-in regulator.
Key Switch
Battery
Alternator
Stop Solenoid
Switch Panel
T2-2-10
SYSTEM / Electrical System
ENGINE STOP CIRCUIT
(KEY SWITCH: OFF)
1. When the key switch is turned from the ON NOTE: Surge voltage to be developed when
position to the OFF position, key switch terminal stopping the engine doesnt arise because
B is disconnected from terminals BR, R2 and the alternator generation circuit is directly
ACC in the key switch. connected to the battery. (The batteries
2. Current to the accessories from key switch function as a condenser.)
terminal R2 and ACC is stopped.
3. Current to the holding side of the stop solenoid
from key switch terminal BR is stopped,
deactivating the stop solenoid. Then, the fuel cut
lever is moved by spring force to the fuel cut
position. Therefore, the fuel isnt supplied,
causing the engine to stop.
Key Switch
Fuse Box
To Each Accessory
Battery
Alternator
Stop Solenoid
T1LA-02-02-006
Holding Side
T2-2-11
SYSTEM / Electrical System
(Blank)
T2-2-12
SECTION 3
COMPONENT OPERATION
CONTENTS
Group 1 Pump Device Group 5 Pilot Valve
Outline ...................................................... T3-1-1 Outline........................................................... T3-5-1
Main Pump P1........................................... T3-1-4 Operation ...................................................... T3-5-4
Power Control........................................... T3-1-5
Flow Rate Control...................................... T3-1-6 Group 6 Travel Device
PS Valve ................................................... T3-1-7 Outline........................................................... T3-6-1
Travel Motor .................................................. T3-6-2
1LDT-3-1
(Blank)
1LDT-3-2
COMPONENT OPERATION / Pump Device
OUTLINE
Main Pump P1
Pilot Pump P2
T1LD-03-01-002
T3-1-1
COMPONENT OPERATION / Pump Device
Hydraulic Diagram
1 2 3 4 5 6
12 11 10 9 8 7
T1LD-03-01-007
T3-1-2
COMPONENT OPERATION / Pump Device
A B
C T1LD-03-01-003
D
View A
View B
6
2
4
D
T1LD-03-01-002
T1LD-03-01-005
7 10 11 12
T1LD-03-01-006
T3-1-3
COMPONENT OPERATION / Pump Device
MAIN PUMP P1
Plunger Cylinder
Block
Shoe Plate
Shaft
T1LD-03-01-005
Swash Plate
T3-1-4
COMPONENT OPERATION / Pump Device
POWER CONTROL
Purpose:
Controls the oil flow rate from main pump P1 so that
the total power to drive main pump P1 and pilot pump
P2 doesnt exceed the engine power.
Operation:
1. When the main pump P1 delivery oil pressure in-
creases more than the load pressure, the in-
creased pressure acts on the plunger.
2. The pressure force on the plunger pushes the
swash plate around the oscillation pin until the
pressure force increases to balance with the
spring force.
3. Then, main pump (P1) decreases the delivery oil
flow rate.
4. Accordingly, depending on the own delivery oil
pressure, the delivery oil flow rate from main
pump (P1) is controlled so that the total power to
drive main pump P1 and pilot pump P2 is main-
tained lower than the engine power.
Spring
Spring Force
Oscillation Pin
T1LD-03-01-005
T3-1-5
COMPONENT OPERATION / Pump Device
FLOW RATE CONTROL
Purpose:
Controls the pump delivery flow rate in response to Operation:
change in loads to the cylinders and the motors. 1. The pressure oil from the PS valve is routed to
the control piston via the orifice, causing the con-
trol piston to push the swash plate.
NOTE: Both pressure PGR (varies in response to
2. The swash plate is moved to tilt until the control
change in the engine speed) from the revo-
piston force becomes to balance with the plunger
lution sensing valve and pressure PLS
swash plate pushing force. (Refer to POWER
(varies depending on the load pressure in
CONTROL on page T3-1-5.)
the control valve) from the control valve dif-
3. The delivery flow rate from main pump P1 varies.
ferential reducing valve act on the PS valve.
4. As the delivery flow rate from main pump P1 var-
Until pressure PGR becomes equal with
ies, the pressure oil supplied to the control valve
pressure PLS, the PS valve operates to
varies.
regulate the pump delivery flow rate.
5. As pressure oil supplied to the control valve var-
ies, pressure PLS from the differential reducing
valve varies.
6. When pressure PLS and PGR, both are routed to
the PS valve on the main pump, become equal,
the main pump swash plate stops tilting.
Plunger
Spring Force
Orifice
PS Valve
T3-1-6
COMPONENT OPERATION / Pump Device
PS VALVE
A
Cross Section A-A
Spring
PS Valve
T1LD-03-01-002
Spring Spool Sleeve
T1LD-03-01-006
T3-1-7
COMPONENT OPERATION / Pump Device
Main Pump Delivery Flow Rate Increase (When a
control lever is operated:)
1. Pressure PGR from the revolution sensing valve 7. The oil in chamber C (9) of control piston (10) is
and pressure PLS from the control valve differen- routed to the pump suction port via orifice (8).
tial reducing valve are routed to chamber A (6) Since swash plate (11) is moved by spring (1)
and B (4) in the PS valve respectively. force, the tilting angle increases, causing the
2. When the actuator load increases, pressure PLS main pump delivery flow rate to increase.
becomes lower than pressure PGR (Pressure
PLS Pressure PGR). Therefore, the pressure NOTE: Orifice (8) is provided to prevent swash
force in chamber A (6) overcomes spring B (3) in plate (11) from being suddenly moved.
chamber B (4) so that spool (5) is moved toward Therefore, swash plate (11) is smoothly
chamber B (4). moved.
3. Then, the oil port on control piston (10) is con-
nected to the pump suction port via PS valve
spool (5) and sleeve (2), releasing the oil pres-
sure behind control piston (10) to the pump suc-
tion port. The pilot pump delivery pressure port is
blocked by PS valve spool (5).
4. The pilot oil pressure from pilot pump (P2) is
routed to port PA.
5. The oil port to control piston (10) is connected to
the pump suction port via PS valve spool (5) and
sleeve (2). Accordingly, the oil pressure behind
the control piston (10) is released to the pump
suction port.
6. Although the oil pressure in the pump suction port
acts on control piston (10), as it is a suction oil
pressure, its pressure force cannot overcome
spring (1) force in the main pump. Accordingly,
control piston (10) is moved toward chamber C
(9).
T3-1-8
COMPONENT OPERATION / Pump Device
PS Valve
Pressure Pump
11 10 9 8 PGR Suction
7 6 5 Port 4 3
T1LD-03-01-005
T1LD-03-01-006
5
3
PS
Valve
4
8
9
Increase 10
Decrease
T1LD-03-01-008
11 6 1
T3-1-9
COMPONENT OPERATION / Pump Device
Main Pump Delivery Flow Rate Decrease (When a
control lever is operated:)
T3-1-10
COMPONENT OPERATION / Pump Device
PS Valve
5
3
PS
Valve 4
8
Increase 10
Decrease
T1LD-03-01-009
11 6 1
T3-1-11
COMPONENT OPERATION / Pump Device
Main Pump Flow Rate Minimization (When con-
trol levers are in neutral:)
Spring
Main Pump
(Unload Valve Delivery Pressure
Operation Pressure)
Pressure PLMAX Pressure PLS
(Zero) T566-03-01-011
T3-1-12
COMPONENT OPERATION / Pump Device
Valve PS
Pressure PLS
Pressure PGR Pump
11 10 9 Suction
5 Port
T1LD-03-01-005
T1LD-03-01-006
PS
Valve
Increase 10
Decrease
T1LD-03-01-010
11 1
T3-1-13
COMPONENT OPERATION / Pump Device
(Blank)
T3-1-14
COMPONENT OPERATION / Revolution Sensing Valve
OUTLINE
Variable Metering
Valve
Differential Reducing
Valve
T566-03-02-001
Port DR
A
View A
T566-03-02-003
Port PGR
T3-2-1
COMPONENT OPERATION / Revolution Sensing Valve
Hydraulic Circuit Diagram
3
2
T566-03-02-013
7 6
T3-2-2
COMPONENT OPERATION / Revolution Sensing Valve
1 5
T566-03-02-001
A
2
View A
B B
T566-03-02-003
3
T566-03-02-002
T3-2-3
COMPONENT OPERATION / Revolution Sensing Valve
OPERATION
Spool (3), piston (7), and spool (8) are illustrated in the
position when the engine is stopped. Spool (3) is
pushed by spring (2) to the right. Both spring (6) force
and spring (9) force are identical to so that piston (7)
and spool (8) are held in the position illustrated.
1 2 3 4 Port PPHI
Variable Metering
Valve
Port PPLO
Differential Reducing
Valve
11 10 9 8 7 6 5
Port DR
T3-2-4
COMPONENT OPERATION / Revolution Sensing Valve
(Blank)
T3-2-5
COMPONENT OPERATION / Revolution Sensing Valve
While the Engine is Running (Output Diagram:
between A and B)
T3-2-6
COMPONENT OPERATION / Revolution Sensing Valve
Variable Metering
Valve
Section C
Section D
Chamber (b)
Chamber (a)
11
Port PGR
9 8 (Pressure 7
PGR)
Hydraulic Oil
Tank
T566-03-02-008
S3 S2 S1
Port PPLO Port PPHI
(Pressure PPLO) (Pressure PPHI)
Section D
Section C
Differential Reducing
Valve
T3-2-7
COMPONENT OPERATION / Revolution Sensing Valve
While the Engine is Running (Output Diagram:
between B and C)
T3-2-8
COMPONENT OPERATION / Revolution Sensing Valve
Port PPHI
Variable Metering
Valve
Section (C)
T3-2-9
COMPONENT OPERATION / Revolution Sensing Valve
(Blank)
T3-2-10
COMPONENT OPERATION / Swing Device
OUTLINE
Valve Unit
Swing Motor
Swing Reduction
Gear
T575-03-02-001
T3-3-1
COMPONENT OPERATION / Swing Device
SWING MOTOR
Valve Plate
Shaft
Rotor
Plunger
Shoe
Swash
Plate
Retainer
Sun Gear
T575-03-02-001
T3-3-2
COMPONENT OPERATION / Swing Device
PARKING BRAKE
Spring
Disc Plate
Rotor
Pilot Shut-Off
Valve Solenoid
Valve
T565-03-02-006
Pilot Pump
T3-3-3
COMPONENT OPERATION / Swing Device
VALVE UNIT
Make-Up Valve
When stopping swing operation, the swing spool is in
neutral by returning the swing lever and the flow rate
to swing motor stops flowing.
But the swing motor rotates by inertia, so cavitation
occurs in the circuit.
To prevent cavitation, when the oil pressure in the
circuit is lower than the pressure at port M (hydraulic
oil tank pressure), the poppet opens to draw hydrau-
lic oil into the circuit so that the pump oil flow rate is
replenished.
Relief Valve
Made-Up
Valve
T565-03-02-002
T3-3-4
COMPONENT OPERATION / Swing Device
Relief Valve
The relief valve functions to reduce shocks devel-
oped when starting or stopping swing movement
(shockless) and to protect the circuit from overload-
ing (relief).
Shockless Operation
When the pressure in the circuit increases, the
pressure oil enters in the piston chamber via the ori-
fice of poppet and housing, to move the piston to the
left.
Piston
The pressure in the spring chamber is kept low dur- Chamber
Poppet Orifice Spring
ing the movement of piston. Therefore, the pressure
at port HP opposes the spring set force only, and
the poppet opens to relieve the hydraulic oil under LP
low pressure whenever the pressure at port HP is
low.
HP
Therefore, the pressure stops temporally increasing
and shocks are retuced when starting or stopping
the swing operation. When the piston moves to the
stroke end, the pressure in the spring chamber be-
S1 S2 Housing Spring
comes equal to the pressure at port HP. As a result, Chamber
T561-02-03-001
Relief Operation
When the pressure in the circuit increases, the force
which acting on poppet (Pressurized Area (S1-
S2) Pressure at Port HP) exceeds the spring force,
so the poppet opens to allow the hydraulic oil to be
relieved. Poppet
pressure.
Piston
LP
HP
T566-03-03-039
T3-3-5
COMPONENT OPERATION / Swing Device
SWING REDUCTION GEAR
First stage ring gear (8) and second stage ring gear
The swing reduction gear is a two-stage planetary- (9) are attached and secured onto the housing.
gear reduction type. The output shaft of swing motor rotates first stage sun
The swing motor rotation force is transmitted to the gear (1). The rotation force is transmitted to second
sun gear. stage sun gear(3) via first stage planetary gear (9) and
The rotation of sun gear is reduced by the planetary first stage carrier(2).
gear and ring gear. This in turn rotates the shaft via the The rotation force of second stage sun gear (3) rotates
carrier. shaft (5) (output shaft) via second stage planetary
gear (7) and second stage carrier (4).
Shaft (5) meshes with the internal gear on swing bear-
ing secured onto the undercarriage to rotate the up-
perstructure.
3
9
8
4
7
5 6
T575-03-02-001
1 - First Stage Sun Gear 4 - Second Stage Carrier 6 - Second Stage Ring Gear 8 - First Stage Ring Gear
2 - First Stage Carrier 5 - Shaft (Output Shaft) 7 - Second Stage Planetary 9 - First Stage Planetary Gear
Gear
3 - Second Stage Sun Gear
T3-3-6
COMPONENT OPERATION / Control Valve
OUTLINE
Boom
Arm
Overload Relief Valve
Bucket
Auxiliary
Travel (Right)
Travel (Left)
T1LD-03-04-001
T3-4-1
COMPONENT OPERATION / Control Valve
Hydraulic Circuit Diagram
40 2
3 1 - Variable Relief Valve 21 - Shuttle Valve (Travel
Left)
2 - Main Relief Valve 22 - Pressure Compensator
4 (Travel Right)
3 - Unload Valve 23 - Shuttle Valve (Travel
39 Right)
4 - Main Shut-Off Valve 24 - Pressure Compensator
(Auxiliary)
38 5 5 - Load Check Valve 25 - Shuttle Valve (Auxiliary)
(swing)
37
6 - Overload Relief Valve 26 - Pressure Compensator
36 (Boom) (Boom Swing)
6 7 - Load Check Valve 27 - Shuttle Valve (Boom
35 (Boom) Swing)
8 - Overload Relief Valve 28 - Pressure Compensator
34 7
(Arm) (Bucket)
9 - Load Check Valve (Arm) 29 - Shuttle Valve (Bucket)
33 10 - Overload Relief Valve 30 - Overload Relief Valve
32 8 (Bucket) (Bucket)
11 - Load Check Valve 31 - Pressure Compensator
9 (Bucket) (Arm)
31 12 - Make-Up Valve (Boom 32 - Shuttle Valve (Arm)
30 Swing)
13 - Load Check Valve (Boom 33 - Overload Relief Valve
10 Swing) (Arm)
14 - Load Check Valve 34 - Pressure Compensator
29 11 (Auxiliary) (Boom)
15 - Load Check Valve 35 - Shuttle Valve (Boom)
12 (Travel Right)
28 16 - Load Check Valve 36 - Boom Anti-Drift Valve
13 (Travel Left)
27
17 - Overload Relief Valve 37 - Overload Relief Valve
(Blade) (Boom)
26 18 - Load Check Valve 38 - Pressure Compensator
14 (Blade) (Swing)
25
19 - Pressure Compensator 39 - Shuttle Valve (Swing)
(Blade)
20 - Pressure Compensator 40 - Differential Reducing
24 15 (Travel Left) Valve
23
22 16
21
17
20
T1LD-03-04-004
19 18
T3-4-2
COMPONENT OPERATION / Control Valve
A A
B B
D D
E E
F F
F F
G G
H H
I I
I I
J J
T1LD-03-04-001
1
Cross Section A-A Cross Section B-B
2
40
C C
T566-03-03-005
3
T566-03-03-006
T566-03-03-007
T566-03-03-008
38 K
T3-4-3
COMPONENT OPERATION / Control Valve
24 15
23
22 16
21
17
20
T1LD-03-04-004
19 18
T3-4-4
COMPONENT OPERATION / Control Valve
Cross Section E-E Cross Section F-F
37 36 35 6
30, 33 K
29, 32 8, 10
K
T566-03-03-011
T566-03-03-010 28, 31 K
34 K
T566-03-03-013
T566-03-03-012 24 K
26 K
Cross Section J-J
Cross Section I-I K 17
K
21, 23
T1LD-03-04-003
T1LD-03-04-002 19 K
20, 22 K
5, 7, 9, 11, 13,
14, 15, 16, 18
T566-03-03-009
T3-4-5
COMPONENT OPERATION / Control Valve
HYDRAULIC CIRCUIT
T3-4-6
COMPONENT OPERATION / Control Valve
Variable Relief
Valve Main Relief Valve
Swing Motor
Control Valve
Swing Spool
Differential Reducing Valve Boom Cylinder
Swing
Overload
Relief Valve
Boom Spool
Hydraulic
Oil Tank
Travel Motor
Arm Spool
Pressure
Compensator
Bucket
Spool
Made-Up Valve
Bucket Cylinder
Boom Swing
Boom Cylinder
Arm
Swing
Cylinder
Spool
Auxiliary Spool
Pressure
Compensator Travel (Right) Spool
Blade Spool
T1LD-02-01-003
T3-4-7
COMPONENT OPERATION / Control Valve
MAIN RELIEF VALVE
Port T
T566-03-03-017
11 10 9
1- Poppet 7- Passage
2- Orifice 8- Spring
3- Spring 9- Holder
4- Spring Chamber 10 - Pilot Poppet
5- Orifice 11 - Sleeve
6- Seat
T3-4-8
COMPONENT OPERATION / Control Valve
OVERLOAD RELIEF VALVE
1- Piston 7- Holder
2- Passage 8- Passage
3- Poppet 9- Sleeve
4- Spring 10 - Passage
5- Pilot Pump 11 - Chamber
6- Spring
T3-4-9
COMPONENT OPERATION / Control Valve
MAKE-UP VALVE
T3-4-10
COMPONENT OPERATION / Control Valve
(Blank)
T3-4-11
COMPONENT OPERATION / Control Valve
MAIN SHUT-OFF VALVE
The pressure oil from the main pump flows to the con- When the main shut-off valve is closed:
trol valve spool via the pressure compensator. The 1. When the pilot shut-off valve solenoid valve
main shut-off valve is activated by the pilot shut-off (dual-stop solenoid) is deactivated (when the pilot
valve solenoid valve. When the main shut-off valve is control shut-off lever is in the LOCK position),
deactivated, the pressure oil from the main pump is pressure PP2 is not routed to the main shut-off
routed to the pressure compensator via the main shut- valve from the pilot shut-off valve solenoid valve
off valve, forcibly closing the pressure compensator (dual-stop solenoid).
main circuit. Therefore, the pressure oil from the main 2. Then, the spool in the pilot shut-off valve solenoid
pump cannot flow to the spool through the pressure valve is held toward the right.
compensator so that even if the control lever is oper- 3. Therefore, notch A is closed and notch B is
ated, the actuator doesnt operate. opened. Consequently, the pressure oil from the
main pump is supplied to the pressure compensa-
tor via the holes in the retainer and notch B, caus-
ing the pressure compensator to close the main
circuit. Thereby, even if the control valve spool is
moved, the main pressure oil is not supplied.
T3-4-12
COMPONENT OPERATION / Control Valve
T566-02-02-013
When Closed:
To the pressure
compensator From the main pump
Spring Spool
Notch A Notch B
Pressure PP2
Port DR1
T566-03-03-022
Retainer
Notch A Notch B
Pressure PP2
T3-4-13
COMPONENT OPERATION / Control Valve
BOOM ANTI-DRIFT VALVE
Boom Cylinder
The boom anti-drift valve is provided in the boom cyl- When Neutral:
inder bottom circuit to reduce the boom cylinder drift. From the control valve
T566-03-03-024
Poppet
Spool
T566-03-03-027
T3-4-14
COMPONENT OPERATION / Control Valve
When lowering the boom:
1. When the boom lower operation is made, the
Piston Section A Sleeve Ball
boom lower pilot oil pressure is routed to the
spool end and the piston, causing the spool and
the piston to move to the right.
2. When the piston is moved to the right, the right tip
of the piston pushes the ball so that the ball be-
comes unseated from the sleeve.
3. Then, the pressure oil in the boom cylinder bot-
tom circuit is returned to the hydraulic oil tank via
the orifice in the poppet, section A, and the pas-
sage around the piston, reducing the oil pressure
in the spring chamber.
4. When the oil pressure in the spring chamber is
reduced, the poppet is closed by spring force only.
Accordingly, when poppet opening force [oil pres-
sure at port A2 pressure receiving area (S1-S2)]
overcomes poppet closing force (spring), the
poppet is opened.
5. Therefore, the pressure oil in the boom cylinder
Boom Lower
bottom circuit is returned to the hydraulic oil tank Pilot Oil
via the poppet and the spool, allowing the boom Pressure
cylinder to move downwards. Spool Circuit T Circuit T2 T566-03-03-025
Boom Cylinder
S2 S1
T566-03-03-026
Spring Spring Spool
Chamber
T3-4-15
COMPONENT OPERATION / Control Valve
UNLOAD VALVE
The unload valve operates in response to pump deliv- 7. Then, notch D is opened, oil pressure P1 is
ery pressure (P1) and maximum load pressure routed to port T via the spool. The opening area
(PLMAX) to control the differential pressure between at notch D varies in proportion to the spool stroke
before and after the spool in the control valve. (depending on variations in the spool pushing
force balance).
NOTE: The differential reducing valve outputs 8. As pressure areas S1, S2, and S3 are all identical,
pressure PLS (Pressure PLS Pressure pressure P1 is maintained so as to match the
P1 Pressure PLMAX). Therefore, pres- formula Pressure P1 = Pressure PLMAX + Pres-
sure P1 must be higher than pressure sure PGR .
PLMAX to output pressure PLS. The un-
load valve controls the differential pressure
between before and after the spool in the
control valve so that pressure P1
( Pressure P1 = Pressure PLMAX + Pres-
sure PGR) is higher than pressure PLMAX. T
Unload Valve
Then, the differential reducing valve out-
puts pressure PLS (Pressure PLS Pres- Pressure
PGR
sure P1 Pressure PLMAX), by which the
pump delivery flow rate is controlled. Pressure
PLMAX
Pressure P1 T1LD-03-04-005
1. The pressure oil flow diverges from port P into
two routes, to the differential reducing valve and Pressure P1 : Oil Pressure in the circuit before
to chamber C through the spool. the spool
2. As pressure P1 routed into chamber C increases, Pressure PLMAX : Maximum oil pressure in all cir-
the spool is pushed to the left by pressure P1 cuits after the spool
force (pressure P1 pressure receiving area S3). Pressure PLS : Reduced pilot oil pressure at the
3. Pressure PGR from port PGR is routed into differential reducing valve
chamber A, increasing the pressure in chamber A Pressure PGR : Oil pressure sent from the revolu-
so that the spool is pushed to the right by pres- tion sending valve
sure force (pressure PGR pressure receiving
area S1).
4. Pressure PLMAX from port PLMAX is routed into
chamber B, increasing the pressure in chamber B
so that the spool is pushed to the right by pres-
sure force (pressure PLMAX pressure receiving
area S2).
5. The pressure forces pushing the spool from both
ends is expressed as below:
Pressure PGR Pressure Receiving Area S1 +
Pressure PLMAX Pressure Receiving Area S2
= Pressure P1 Pressure Receiving Area S3
6. When pressure P1 increases until spool left push-
ing force (Pressure P1 Pressure Receiving
Area S3) overcomes spool right pushing force
(Pressure PGR Pressure Receiving Area S1 +
Pressure PLMAX Pressure Receiving Area S2),
the spool is moved to the left.
T3-4-16
COMPONENT OPERATION / Control Valve
Differential
Reducing Valve
Unload Valve
Pressure P1
T566-03-03-029
Port T Section D
Spool
T3-4-17
COMPONENT OPERATION / Control Valve
DIFFERENTIAL REDUCING VALVE
The differential reducing valve supplies pressure PLS When the right pushing force is stronger:
to main pump valve PS to regulate the pump flow rate. ( Pressure P1 S3 pressure PLS S1) + pres-
sure PLMAX S2)
1. Oil pressure P1 from the main pump is routed into
chamber C so that it acts on the piston, creating 8. The spool is moved to the right.
pressure force (pressure P1 pressure receiving 9. As section D is closed, pressure PP1 from the pi-
area S3) to move the spool to the left. lot pump cannot go through notch D. Section E is
2. Oil pressure PLS from port PLS is routed into opened, the oil pressure in chamber A and from
chamber A via the hole in the sleeve and the pas- port PLS is routed into port DR1 via notch E.
sage in the spool, creating pressure force 10. As described in step 4, the spool is moved so as
(pressure PLS pressure receiving area S1) to to keep the force balance, pressure PLS to con-
move the spool to the right. trol the pump is returned to the hydraulic oil tank
3. Oil pressure PLMAX from port PLMAX is routed that pressure PLS decreases.
into chamber B, creating pressure force (pressure 11. According to the repeated operation as described
PLMAX pressure receiving area S2) to move in step 5 to 7 and 8 to10, pressure PLS is main-
the spool to the right. tained so as to match the pressure balance (PLS
4. Accordingly, the spool moves so as to match the = P1 PLMAX) as described in step 4 since S1,
force balance as expressed in the formula below: S2, and S3 are all identical.
Spool left pushing force (pressure P1 pressure
receiving area S3) = Spool right pushing force
[(pressure PLS pressure receiving area S1) + Pressure
(pressure PLMAX pressure receiving area S2)] PP1 DR1
Differential
When the left pushing force is stronger: Reducing
( Pressure P1 S3 pressure PLS S1) + pres- Valve
sure PLMAX S2)
Pressure
5. The spool is moved to the left. PLMAX
6. As section D is opened, pressure PP1 from the Pressure P1
pilot pump is routed to chamber A and port PLS
Pressure
via notch D. Section E is closed, blocking port PLS T1LD-03-04-006
DR1 (return port to the hydraulic oil tank).
7. As described in step 4, the spool is moved so as
to keep the force balance, pressure PP1 is routed Pressure P1: : Oil Pressure in the circuit before
to port PLS to control the pump so that pressure the spool
PLS increases. Pressure PLS : Reduced pilot oil pressure at the
differential reducing valve
Pressure PLMAX : Maximum oil pressure in all cir-
cuits after the spool
Pressure PP1 : Primary Pilot Oil Pressure
T3-4-18
COMPONENT OPERATION / Control Valve
S1 S2 Piston S3
Chamber
Chamber A B Sleeve Spool Chamber C
T3-4-19
COMPONENT OPERATION / Control Valve
PRESSURE COMPENSATOR
The pressure compensator is located in the circuit be- When the differential pressure between pressure
fore control valve spool (2). The pressure compensa- (PIN) and pressure (PL) is lower than pressure
tor regulates the oil flow rate passing through spool (2) PLS:
so that the differential pressure in the circuit between 8. When the differential pressure between pressure
before and rear spool (2) is kept constant. (PIN) and pressure (PL) is lower than pressure
1. Oil Pressure (PIN) in circuit (1) before spool (2) is PLS, right pushing force becomes stronger than
routed into chamber C (5) via passage (6) in left pushing force so that spool (7) is moved to the
spool (2), creating force [pressure PIN pressure right.
receiving area S3 (4)] that moves spool (7) to the 9. Then, notch (13) becomes gradually wider, in-
left against piston (3). creasing the hydraulic oil passing through notch
2. Oil pressure (PLS) from the differential reducing (13) so that the pressure oil routed into circuit (1)
valve is routed into chamber B (9), creating force before the spool increases. Therefore, pressure
[pressure PLS pressure receiving area S2 (8)] PIN increases, causing the differential pressure
that moves spool (7) to the right. between circuits (1 and 12) to increase.
3. Oil Pressure (PL) in circuit (12) after spool (2) is 10. When spool pushing forces on both sides be-
routed into chamber A (11), creating force comes equal, spool (7) stops moving. Spool (7)
[pressure PL pressure receiving area S1 (10)] keeps moving right and left while repeating opera-
that moves spool (7) to the right. tion in steps 5 to 7 and 8 to 9. Thereby, the differ-
4. Spool (7) is moved so that pressures PIN, PLS, ential pressure between pressure PIN in before
and PL maintain the force balance as described spool side circuit (1) and pressure PL after spool
in the formula below: side (2) is kept equal to pressure PLS so that the
Right pushing force [pressure PLS pressure re- hydraulic oil flow rate passing through spool (2) is
ceiving area S2) + (pressure PL pressure re- maintained constant
ceiving area S1)] = Left pushing force (pressure
PIN pressure receiving area S3)
T3-4-20
COMPONENT OPERATION / Control Valve
1 2
12
Pressure Compensator
T566-03-03-033
11 10 9 8 7 6 5 4 3
From the differential
When the differential pressure is high: reducing valve
1 2 13
12
Pressure Compensator
7 T566-03-03-035
12
Pressure Compensator
T566-03-03-008
7
1- Circuit before spool 5 - Chamber C 8 - Pressure receiving area S2 11 - Chamber A
2- Spool 6 - Passage 9 - Chamber B 12 - Circuit after spool
3- Piston 7 - Spool 10 - Pressure receiving area S1 13 - Notch
4- Pressure receiving area S3
T3-4-21
COMPONENT OPERATION / Control Valve
VARIABLE RELIEF VALVE
The differential reducing valve outputs pressure PLS NOTE: The variable relief valve system operates
to be used to control the pump flow rate. as follows:
NOTE: Pump delivery pressure (P1) and maxi- Control signal pressure (PLS) from the dif-
mum load pressure (PLMAX) are routed to ferential reducing valve is routed to each
the differential reducing valve. Pressure pressure compensator. Pressure PLS is a
PLS is output so as to match the relation signal pressure reduced at the differential
Pressure PLS Pressure P1 Pressure reducing valve from the pilot pressure
PLMAX. The variable relief valve operates (pressure PLS pressure P1 Pressure
to relieve pressure PLMAX (maximum load PLMAX). Pressure P1 is the pump delivery
pressure in the circuit after the spool) so pressure. Pressure PLMAX is the maxi-
that pressure PLMAX doesnt exceed mum load pressure adjusted by the vari-
pump delivery pressure P1. able relief valve.
1. Pressure (PGR) from the revolution sensing valve When the circuit pressure is relieved, the
and load maximum pressure (PLMAX) from the main circuit pressure is equal to the main
spool act on the poppet, creating poppet pushing relief valve set pressure so that both pres-
force [(pressure PGR pressure receiving area sure P1 and pressure PLMAX are equal to
S1) + (pressure PLMAX pressure receiving area the main relief valve relief pressure. There-
S2)] to the right. fore, if the variable relief valve doesnt op-
NOTE: The spring set force of the variable relief erate, pressure PLS may become equal to
valve is equal to that of the main relief zero (0) (pressure P1 - pressure PLMAX).
valve. In case more than one actuator is operated
and the oil pressure to one of them
2. As long as the engine is running, both pressure reaches the relief pressure, signal pressure
PGR and PLMAX act on the poppet so that the (PLS) to the pressure compensator be-
poppet is moved before pressure PLMAX in- comes zero (0) if the variable relief valve
creases to the main relief valve set pressure. doesnt operate. Therefore, all pressure
3. When poppet pushing force [(pressure PGR compensators are closed so that other ac-
pressure receiving area S1) + (pressure PLMAX tuators are stopped.
pressure receiving area S2)] to the right over-
comes the spring force, the poppet is moved, al- As pressure PLS is maintained higher than
lowing pressure PLMAX to return to the hydraulic the pressure difference (pressure P1
oil tank port. Pressure PLMAX) by means of the vari-
able relief valve operation, even though
combine operation including the relieving
actuator is made, other actuators are oper-
able.
Variable Relief
Valve
Pressure
PLMAX
Pressure
PGR T1LD-03-04-008
T3-4-22
COMPONENT OPERATION / Control Valve
S1 S2 Poppet Spring
T3-4-23
COMPONENT OPERATION / Control Valve
(Blank)
T3-4-24
COMPONENT OPERATION / Pilot Valve
OUTLINE
Hydraulic Symbol
T
3 PT 1 2 4 4 PT 2 1 3 3 2 T567-03-04-001
T566-03-05-002
P
P
View A 2 1
A
1 2 3 4
T573-03-04-003
4 3 T585-03-04-005
T3-5-1
COMPONENT OPERATION / Pilot Valve
1 2
P T
T190-02-06-005
1 2
1 2
T554-02-07-009
T3-5-2
COMPONENT OPERATION / Pilot Valve
(Blank)
T3-5-3
COMPONENT OPERATION / Pilot Valve
OPERATION
T3-5-4
COMPONENT OPERATION / Pilot Valve
1 1
2 2
6
3 3 Port T
4 4
7
5 5 Port P
6 Output Port
6
Port T Port T
7 Port P 7 Port P
T3-5-5
COMPONENT OPERATION / Pilot Valve
During Metering or Decompressing (Output
Diagram: C to D)
1. When the control lever is further tilted to move
pusher (2) downward more, hole (7) on spool (6)
is opened to port P, allowing pressure oil in port P
to flow into the output port.
2. Oil pressure in the output port acts on the bottom
Pilot Presure
face of spool (6) so that spool (6) is pushed
upward.
3. However, until upward force acting on the bottom
face of spool (6) overcomes balance spring (4) D
force, balance spring (4) is not compressed. Then,
spool (6) is not raised, allowing oil pressure in the
output port to increase.
4. As oil pressure in the output port increases, force C
to push spool (6) upward increases. When, this
force overcomes balance spring (4) force, A B
balance spring (4) is compressed so that spool Lever Stroke
(6) is moved upward. T567-03-04-002
T3-5-6
COMPONENT OPERATION / Pilot Valve
1 1
2 2
3 3
4 4
5 5
6 6
Port T Port T
7 Port P 7 Port P
T3-5-7
COMPONENT OPERATION / Pilot Valve
Travel Pilot Valve
Control Lever-In Neutral (Pusher Stroke: A to B) Control Lever-Full Stroke (Pusher Stroke: E to F)
When the control lever is in neutral, spool (8) blocks When the control lever is moved to full stroke, pusher
the pressure oil in port P completely. The output port (2) compresses spring (4) and return spring (7) more
is connected to port T through hole (9), so the and pusher (2) is moved down.
pressure at output port becomes equal to the Thereby, spool (8) is pressed directly by the bottom
hydraulic oil tank pressure. of pusher (2). As a result, the lower notch of spool (8)
When the control lever is moved slightly, pusher (2) does not close even if the pressure at output port
and spring guides (3), (5) move downward together, rises.
compressing spring (4), and return spring (7). At this As a result, the pressure at output port becomes
time, as the pressure under spool (8) (output port) is equal to the pressure at port P.
equal to the hydraulic oil tank pressure, spool (8)
moves downward by balance spring (6), while the top
of spool is kept with spring guide (5). This state is
maintained until clearance (A) of spool (8) becomes
zero.
T3-5-8
COMPONENT OPERATION / Pilot Valve
Pusher Stroke: A to B
5
6
7
Port T
8 9
(A) (A)
Port P
T585-03-04-001 T585-03-04-002
Output Port
6
Port T Port T
8
Port P Port P
T585-03-04-003 T585-03-04-004
Output Port Output Port
T3-5-9
COMPONENT OPERATION / Pilot Valve
Boom Swing and Blade Pilot Valves
Control Pedal-In Neutral (Pusher Stroke: A to B) Control Pedal-Full Stroke (Pusher Stroke: E to F)
When the control pedal is in neutral, spool (7) blocks When the control pedal is moved to full stroke,
the pressure oil in port P completely. The output port pusher (2) is moved down until it comes into contact
is connected to port T through the passage in spool with the top of plate (3).
(7), so the pressure at output port becomes equal to Thereby, spool (7) is pressed directly by the bottom
the hydraulic oil tank pressure. of pusher (2). As a result, notch (B) of spool (7) does
When the control pedal is moved slightly, cam (1) not close even if the pressure at output port rises.
moves and pusher (2) and spring guide (4) move As a result, the pressure at output port becomes
downward together, compressing return spring (6). At equal to the pressure at port P.
this time, balance spring (5) pushes spool (7) and
spool (7) moves downward until clearance (A)
becomes ZERO.
While spool (7) moves downward, the output port is
connected to port T and the pressure oil does not
flow into the output port.
D
Control Pedal-Operated (Pusher Stroke: C to D
Metering)
When the control pedal is moved further, the hole on
spool (7) is connected to notch (B). The pressure oil
C
in port P flows into the output port via the hole in
spool (7) from notch (B), so the pressure at output
port increases.
The pressure at output port acts on the bottom of A B Pusher Stroke
spool (7), to push spool (7) upward. T505-02-07-006
T3-5-10
COMPONENT OPERATION / Pilot Valve
Pusher Stroke: A to B
3
4
5
Port T
6
(A)
Clearance (A): 0
Port P
Hole
7
Passage
T1LA-03-04-002
T1LA-03-04-003
Output Port
2
3
Port T Port T
Port P Port P
Hole
7 7
T3-5-11
COMPONENT OPERATION / Pilot Valve
(Blank)
T3-5-12
COMPONENT OPERATION / Travel Device
OUTLINE
Travel Motor
T571-03-05-001
T3-6-1
COMPONENT OPERATION / Travel Device
TRAVEL MOTOR
Shaft
T571-03-05-002
Shoe Plunger
T3-6-2
COMPONENT OPERATION / Travel Device
TRAVEL BRAKE VALVE
Counterbalance Valve
Relief Valve
T571-03-05-003
T3-6-3
COMPONENT OPERATION / Travel Device
Counterbalance Valve
Control Valve
Spool
Orifice Orifice
P1 P2
T3-6-4
COMPONENT OPERATION / Travel Device
Relief Valve
Relief Operation
When the piston moves to the stroke end, the
pressure in the spring chamber becomes equal to
the pressure on port HP. (The relief set force
becomes as the normal setting pressure, so
poppet closes.).
For this reason, the force equal to [Pressure on
Port HP Pressurized Area of Poppet S1] acts on
the opening direction, and the force equal to
[(Pressure in Spring Chamber Pressurized Area
of Poppet S2) Spring Force] acts on the closing
direction.
Accordingly, when the force acting on the opening
direction of the poppet [Pressure on Port HP
Pressurized Area of Poppet S1] becomes larger
than [(Pressure on Spring Chamber
Pressurized Area of Poppet S2) Spring Force],
the poppet opens to relieve the hydraulic oil.
T3-6-5
COMPONENT OPERATION / Travel Device
Travel Speed Changeover Valve
T3-6-6
COMPONENT OPERATION / Travel Device
Swash Swash
At Slow Speed: Plate Rotor Plunger At Fast Speed: Plate Rotor Plunger
Surface (b) Surface (b)
Spring From
Travel
Speed
Change-
Surface (a) over
Valve
Surface (a)
Control
T571-03-05-005
T571-03-05-004
Piston
T3-6-7
COMPONENT OPERATION / Travel Device
TRAVEL REDUCTION GEAR
First Stage
Carrier
T571-03-05-001
T3-6-8
COMPONENT OPERATION / Others (Upperstructure)
SOLENOID VALVE UNIT
Pilot Relief
There are two kinds of solenoid valves; one is the pilot Valve
shut-off valve solenoid valve, the other is the travel Pilot Shut-Off Travel Speed
speed changeover solenoid valve. Valve Changeover
Solenoid Valve Solenoid Valve
Pilot Shut-Off Valve Solenoid Valve
The solenoid valve is switched ON/OFF by the posi-
tion of pilot control shut-off lever to control the pilot
pressure to pilot valve.
When the pilot control shut-off lever is in the LOCK
position, the pilot shut-off switch is OFF. By this ac-
tion, the solenoid valve is OFF, so that pilot pressure
is blocked by the solenoid valve spool. As a conse-
quence, the pressure oil is not delivered to the pilot
valve.
When the pilot control shut-off lever is in the UN-
LOCK position, the pilot shut-off switch is ON. By this
action, the solenoid valve is ON, so the pilot pressure
is supplied to the pilot valve through the solenoid
valve spool.
T532-02-06-002
Pilot Shut-Off Switch
T532-02-06-005
T3-7-1
COMPONENT OPERATION / Others (Upperstructure)
PILOT RELIEF VALVE
From To
Pilot Pump Hydraulic
Oil Tank
Plunger T574-03-06-002
T3-7-2
COMPONENT OPERATION / Others (Undercarriage)
SWING BEARING
The swing bearing supports the upperstructure on the Outer race (1) is bolted to the upperstructure.
undercarriage and allows the upperstructure to rotate Inner race (2) is bolted to the undercarriage.
smoothly. The internal gear meshes with the pinion of the swing
The swing bearing is a single-row ball-type. device.
The major parts of swing bearing are outer race (1),
inner race (2) with internal gear, ball (5), support (4)
and seal (3).
3 5
T507-03-02-001
T3-8-1
COMPONENT OPERATION / Others (Undercarriage)
CENTER JOINT
The center joint is a 360 rotating joint. It allows oil to Body (5) rotates together with the upperstructure
flow to and from travel motors (12) and blade cylinder around spindle (10) during swing operation.
(13) without twisting hoses when the upperstructure is Oil flows into and through the passages in body (5) to
rotated. spindle (10) and then out of spindle (10) to travel mo-
Spindle (10) is fastened to the undercarriage with bolts tor (12) and blade cylinder (13).
(4 used) and body (5) is fastened to the upperstructure Oil seal (11) prevents oil leaks from the clearance be-
with lock pins. tween spindle (10) and body (5).
DR
A
B
C
D
E
F
G
4 D
13 8 G C
F B
9 E A
1 6 DR
7 Hydraulic Circuit
1 6
3
2
2
9
7
8
4 3
12
T554-03-03-001
T3-8-2
COMPONENT OPERATION / Others (Undercarriage)
5
A
B
9
6
1
C
D
E
7
F 2
G
11
3
4 10
3
9
2 1
T554-03-03-002
1 - Port E (Blade Lower) / 5 - Body 8 - Port B (Right Travel For- 11 - Seal
Pressure Oil from Port E ward) / Pressure Oil from
Port B
2 - Port F (Blade Raise) / 6 - Port A (Right Travel Re- 9 - Port D (Left Travel For- 12 - Travel Motor
Pressure Oil from Port F verse) / Pressure Oil from ward) / Pressure Oil from
Port A Port D
3 - Port G (for Travel Speed 7 - Port C (Left Travel Re- 10 - Spindle 13 - Blade Cylinder
Changeover) / Pressure Oil verse) / Pressure Oil from
from Port G Port C
4 - Port DR (Drain) / Pressure
Oil from Port DR
T3-8-3
COMPONENT OPERATION / Others (Undercarriage)
TRACK ADJUSTER
M104-07-119
T507-03-05-001
T3-8-4
SECTION 4
OPERATIONAL PERFORMANCE TEST
CONTENTS
Group 1 Introduction Group 5 Component Test
Operational Performance Test.................... T4-1-1 Primary Pilot Pressure ..................................T4-5-1
Preparation for Performance Tests ............. T4-1-2 Secondary Pilot Pressure .............................T4-5-2
Main Relief Valve Set Pressure ....................T4-5-4
Group 2 Standard Overload Relief Valve Set Pressure ............. T4-5-8
Operational Performance Standard ............. T4-2-1 Swing Motor Drainage ................................T4-5-10
Travel Motor Drainage ................................T4-5-12
Group 3 Engine Test Revolution Sensing Valve Output Pressure T4-5-14
Engine Speed ............................................... T4-3-1 Pump Delivery Pressure .............................T4-5-16
Engine Compression Pressure..................... T4-3-2 Pump Driving Torque ..................................T4-5-18
Valve Clearance ........................................... T4-3-3
Nozzle Check ............................................... T4-3-4
Injection Timing............................................. T4-3-6
1LDT-4-1
(Blank)
1LDT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TEST
Kinds of Tests
1. Base machine performance test is to check the
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
2. Hydraulic component unit test is to check the op-
erational performance of each component such
as hydraulic pump, motor, and various kinds of
valves.
Performance Standards
Performance Standard is shown in tables to evalu-
ate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
THE MACHINE
1. Repair any defects and damage found, such as
oil or water leaks, loose bolts, cracks and so on,
before starting to test.
TEST AREA
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m (65 ft 7 in), and to make a
full swing with the front attachment extended.
3. If required, rope off the test area and provide
signboards to keep unauthorized personnel away.
PRECAUTIONS
1. Before starting to test, agree upon the signals to
be employed for communication among cowork-
ers. Once the test is started, be sure to communi- T105-06-01-003
T4-1-2
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD
This Operational Performance Standard values are The value in ( ) is shown for reference only.
listed below. * The standard measurement condition is as follows;
Refer to the correspondence section in T4-3 and after Engine Speed Control Lever: Full Stroke
for the details of measurement method. Hydraulic Oil Temperature: 50 5 C
T4-2-1
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-2
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-3
OPERATIONAL PERFORMANCE TEST / Standard
T4-2-4
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Be sure to check the engine speed before per-
forming all other tests, since it always affects test
results.
Preparation:
1. Warm up the machine, until the engine coolant
Stopper
temperature reaches 50 C (122 F) or more, and
hydraulic oil temperature is 50 5 C (122 9 F).
2. Move the engine speed control lever from slow
idle to fast idle. Confirm that the fuel injection
pump governor lever comes into contact with the
slow-idle and fast-idle stoppers.
3. Connect an engine tachometer to the fuel injec-
tion line.
Measurement:
1. Slow idle.
Start the engine. Place the engine speed control
lever in the slow idle position and measure the
speed of the engine.
2. Fast idle.
Start the engine. Place the engine speed control
lever in the fast idle position and measure the
speed of the engine.
3. Repeat measurement three times and calculate T1LD-04-03-001
Evaluation:
Refer to T4-2 Operational Performance Standard.
Governor
Lever
T573-04-03-007
Stopper
T4-3-1
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders
to check for a reduction in engine power.
2. Check exhaust gas color. Keep track of engine oil
consumption.
3. Check for abnormalities in the intake system, in-
cluding the air cleaner.
Preparation:
1. Warm up the engine.
2. Disconnect the negative terminal at the battery,
then remove all glow plugs and engine stop sole-
noid connectors.
Reconnect the negative terminal to battery.
3. Install the pressure gauge to the glow plug bore
with an adapter (Isuzu: 5-8840-2656-0). (Be sure
to tighten them sufficiently to prevent air leakage.)
4. Confirm that the batteries are charged.
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder. T571-04-02-001
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-3-2
OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cold.
2. Before removing the head cover, clean the area
around the head cover to prevent the entry of Mark Groove
dust into the engine.
Preparation:
1. Remove the head cover.
2. Locate the top dead center (TDC) in the com-
pression stroke. Align "Mark Groove" on crank
pulley with "TDC Mark" on timing gear case
cover. Crank Pulley
In this position, cylinder No.1 is at the top dead TDC Mark
center in the compression stroke.
Measurement:
1. Measure the valve clearance between the rocker
arm and valve.
2. When the measurement is started from cylinder
No.1, measure the clearances of valves marked Valve
( ) in the table below. Clearance
Cylinder No. 1 2 3 4
Valve I E I E I E I E
Cylinder No.1 at top dead center
Cylinder No.1 at overlap
Evaluation:
Refer to T4-2 Operational Performance Standard.
Adjustment:
If the measured value is not within specification,
loosen the lock nut and adjust valve clearance by
turning the adjusting bolt, then tighten lock nut.
T4-3-3
OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray pat-
tern with a nozzle tester.
Preparation:
1. Remove all nozzle holders and fuel injection pip-
ings from the engine.
Measurement:
CAUTION: Never touch spray directly. The
fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel pene- T107-06-02-006
1. Injection pressure
After attaching the nozzle holder to nozzle tester,
strongly make several strokes of the tester to in-
ject fuel. Then, while operating the tester at ap-
prox. 60 time strokes a minute, measure the fuel
injection pressure.
Use shims in the nozzle holder to adjust the pres-
sure.
2. Spray pattern
For this test, turn the pressure tester knob to by-
pass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several Nozzle Holder
strokes of the tester and check the fuel spray pat-
tern.
T1LA-04-02-002
T4-3-4
OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation:
Normal Abnormal
1. Standard Injection Pressure:
Refer to T4-2 Operational Performance Standard.
T523-06-02-001
T4-3-5
OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Preparation
1. Rotate the crank pulley until No.1 cylinder is at Mark Groove
TDC of the compression stroke.
Align "Mark Groove" on the crank pulley with
"TDC Mark" on the timing gear case cover.
2. Rotate the crank pulley approx. 100 counter-
clockwise.
3. Remove No. 1 injection pipe (1).
4. Remove No. 1 delivery valve holder (2) on injec- Crank Pulley
tion pump (5) to pull out delivery valve (4) and
spring (3). Reinstall delivery valve holder (2) to in- TDC Mark
jection pump (5).
Tightening Torque: 39 to 44 N m (4 to 4.5 kgf m, T533-06-02-001
29 to 33 lbf ft)
5. Turn the key switch to "ON". While supplying fuel 1
from fuel pump, rotate the crank pulley clockwise
slowly until the fuel leak stops at the tip of the de-
livery valve holder. At this moment, the "Mark
Groove" on the crank pulley should be aligned
with "TDC Mark" on the timing gear case cover. If
not, adjust the injection timing.
(11.5 BTDC [Before Top Dead Center] of the
compression stroke)
Adjustment:
1. Remove bolt (7) and nut (6) from injection pump T533-06-02-004
(5).
2. Adjust timing position by increasing or decreasing 2 5
the number of shims (8) between injection pump
(5) and body (9).
3. When delaying timing, increase the number of
shims (8). When advancing timing, decrease the 3
number of shims (8).
4
NOTE: The crank angle will vary 1 per shim 0.1
mm.
T533-06-02-003
7
5
6
8 9
T533-06-02-002
T4-3-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
To check overall performance of travel drive system
(between main pump and travel motor), measure the
time required for the excavator to travel a test track.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Prepare a level and solid test track 20 m (65.5 ft)
in length, with an extra length of 3 to 5 m (9.8 to
16 ft) on both ends for machine acceleration and
deceleration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
4. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
End
Arm roll-in, Bucket roll-in
Start
3 to 5 m (9.8 to 16 ft)
extra length for accelera-
20 m (65.5 ft) tion/deceleration
3 to 5 m (9.8 to 16 ft)
extra length for accelera- T570-06-03-001
tion/deceleration
Measurement:
1. The test should be performed with each mode
(slow and fast travel speeds) in the fast-idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the time required to travel 20 m (65 ft 7
in).
4. After measuring the forward travel speed, turn the
upperstructure 180 and measure the reverse
travel speed.
5. Repeat steps (2) and (4) three times in each di-
rection and calculate the mean values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-1
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
With the track raised off ground, measure the track
revolution cycle time to check the total track drive
system (between main pump and travel motor).
Preparation:
1. Adjust the track sag of both side tracks equally.
2. On the track to be measured, mark one shoe with
chalk.
CAUTION: Support the lifted track securely
with wooden blocks.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-2
OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.5 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end
points to check the performance equilibrium be-
tween both sides of the travel device systems
(between main pump and travel motor).
2. If measured on a concrete surface, the tread de-
viation has a trend to decrease.
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.5 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and de-
celeration.
3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above
the ground with the arm and bucket extended.
4. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Max Distance
20 m T570-06-03-002
Measurement:
1. The test should be performed with each mode
(slow and fast travel speeds) in the fast idle
speed.
2. Start traveling the machine in the acceleration
zone with the travel levers at full stroke.
3. Measure the distance between a straight 20 m
(65.5 ft) line and the tread made by the machine.
4. After measuring the tracking in forward travel,
swing the upperstructure 180 and measure that
in reverse travel.
5. Repeat steps (3) and (4) three times in each di-
rection and calculate the mean values.
Evaluation:
Refer to T 4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-3
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL MOTOR LEAKAGE
Summary:
Measure the amount of travel motor slippage on a
slope, which is due to travel motor inner oil leak.
Preparation:
1. The surface of the test slope must be even, with a
gradient of 20 (11.31 ).
2. Raise the bucket 0.2 to 0.3 m above the ground
with the arm and bucket cylinders fully extended
(rolled in)
3. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement:
1. Measure the slip amount of travel motor at park-
ing. T570-06-03-010
T4-4-4
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
Measure the time required to swing three complete
turns to check the total swing drive system (between
the main pump and swing motor).
Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Place the machine on level, solid ground with
ample space for swinging. Do not conduct this
test on slopes.
3. With the arm rolled out and bucket rolled in, hold Even with
the Boom
the bucket so that the height of arm top pin is Foot Pin.
even with the boom foot pin. The bucket must be
empty. T570-06-03-003
Measurement:
1. Run engine at fast idle speed. Operate swing con-
trol lever fully.
2. Measure the time required to swing 3 turns in one
direction.
3. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
4. Repeat steps (2) and (3) three times each and
calculate the average values.
Evaluation
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-5
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
To check the valve unit performance, measure the
swing drift on the bearing outer circumference when
stopping after a 90 full speed swing.
Mechanical brake for swing parking is installed on
swing motor.
Preparation:
1. Check the lubrication of swing gear and swing
bearing. Make aligning marks on the
2. Place the machine on level, solid ground with swing bearing outer circum-
ference and track frame.
ample space for swinging. Do not conduct this
test on slopes. T570-06-03-004
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of bucket pin is even
with the boom foot pin. The bucket must be
empty.
4. Make the marks on the swing bearing and track
frame.
5. Swing the upperstructure 90 .
6. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-6
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
To check swing parking brake performance, meas-
ure the upperstructure drift after parking the machine
on a slope with the upperstructure positioned 90 to
the slope.
(Mechanical brake for swing parking is installed on
swing device.)
Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: 40U: 210 kg (463 lb)
50U: 240 kg (529 lb)
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of bucket pin is even
with the boom foot pin.
4. Park the machine on a flat slope with a gradient of
15 1 .
5. Climb the slope, then swing the upperstructure
90 toward the slope. Make aligning marks on
the swing bearing circumference and track frame.
6. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T570-06-03-006
Measurement:
1. Start the engine and maintain engine speed at
idle speed. After 5 minutes, measure the differ-
ence between the marks on the swing bearing
circumference and the track frame.
2. Perform the measurement under the following
two conditions: Measure the arc length along the swing
bearing circumference.
When the brake is applied(with the pilot control
shut-off lever in the LOCK position).
When the brake is released(with the pilot control
shut-off lever in the UNLOCK position).
3. Perform the measurement on both right and left
swing directions.
Mark on the track frame
4. Perform the measurement three times in each di-
rection and calculate the average values.
Mark on the swing bearing
Evaluation: T105-06-03-010
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-7
OPERATIONAL PERFORMANCE TEST / Excavator Test
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
To measure the maximum slope angle on which the
upperstructure can swing, park the machine on a
slope with the upperstructure positioned 90 to the
slope.
Preparation:
1. Check the lubrication of swing gear and swing
bearing.
2. Load the bucket with either soil or a weight
equivalent to the weight standard.
Weight: 40U: 210 kg (463 lb)
50U: 240 kg (529 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the bucket so
that the height of bucket pin is even with the
boom foot pin. T570-06-03-006
Measurement:
1. Run engine at fast idle speed. Operate the swing
control lever fully to swing the upperstructure to
the uphill side of slope.
2. If swing is possible, measure the slant angle on
the cab floor.
3. Increase the slope angle. Measure on both right
and left swing directions.
4. Perform the measurement three times.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-8
OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
Measure the swing play with a dial gauge to check
the wear of bearing races and balls.
Preparation:
1. Check the swing bearing mounting bolt for loose-
ness.
2. Check the lubrication of swing bearing. Confirm
that bearing rotation is smooth and noiseless.
T105-06-03-014
3. Install a dial gauge with a magnetic base on the Magnetic Base Dial Gauge
track frame as shown.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the travel
motors.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race as shown. Round Frame Trunk
6. Bucket should be empty.
Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
even with the boom foot pin. Record the dial
gauge reading (h1).
2. Lower the bucket to the ground and use it to raise Even with the
the front idler 0.5 m (20 in). Record the dial gauge Boom Foot Pin.
reading (h2).
3. Calculate bearing play (H) from this data (h1 and T570-06-03-003
h2) as follows:
H = h2 h1
Measurement: [h2]
Evaluation:
Refer to T4-2 Operational Performance Standard.
T570-06-03-007
T4-4-9
OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Boom Cylinder
Summary:
1. To totally check the front attachment function per-
formance (between the main pump and each cyl-
inder) by measuring each cylinder cycle time.
2. Bucket should be empty.
Preparation:
1. Take the following machine position:
T570-06-03-011
T523-06-03-006
Blade Cylinder
T570-06-03-007
T4-4-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Run engine at fast idle speed.
Evaluation:
Refer to T 4-2 Operational Performance Standard.
Remedy:
Refer to T5-2 "Troubleshooting A".
T4-4-11
OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT
Summary: Retraction
Extension
1. With the bucket loaded, measure dig function drift,
which can be caused by oil leakage in the control Retraction
valve and / or boom, arm, bucket, blade and
boom swing cylinders.
Evaluation:
Refer to T4-2 Operational Performance Standard. Arm Cylinder Extension
Remedy:
Refer to T5-2 "Troubleshooting A".
Mark
T110-06-03-001
T506-06-03-001
T4-4-12
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
Use a spring scale to measure the maximum force
needed to move each control lever and pedal.
Measure the operating force at the center of each
lever grip.
Preparation:
1. Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement:
1. Start the engine.
2. Measure the maximum operating force with each T107-06-03-003
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-4-13
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-14
OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. Measure each lever stroke at the lever top using
a ruler.
2. Measure the lever stroke at the grip center of
each control lever.
As for the boom swing pedal, measure the stroke
from the center position to stopper.
3. In case lever stroke play is present in the neutral
position, add half (1/2) the play present to both
side lever strokes.
Preparation:
Maintain the hydraulic oil temperature at 50 5 C
(122 9 F).
T107-06-03-005
Measurement:
1. Stop the engine.
2. Measure the boom, arm, bucket, swing, travel
and blade control lever strokes at the grip top
center from the neutral position to the stroke end.
On the swing pedal, measure the straight dis-
tance between the center and fully depressed po-
sitions at tip of the pedal.
On the engine speed control lever, measure the
distance between the slow and fast idle positions
at center of the top on the grip.
3. Take the measurements by the straight stroke dis-
tances.
4. Conduct the measurement three times.
Calculate the average values.
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-4-15
OPERATIONAL PERFORMANCE TEST / Excavator Test
Engine Speed Control Lever Adjustment
T1LD-04-03-001
Stopper
Bolt
Engine Control
Cable
G
Slow Idle Side
Stopper
T574-04-03-006
Stopper Bolt
40U,50U
Standard Length (F) 25 mm (0.98 in)
Standard Length (G) 30 mm (1.18 in)
T4-4-16
OPERATIONAL PERFORMANCE TEST / Excavator Test
Governor Lever:
T1LD-04-04-001
T4-4-17
OPERATIONAL PERFORMANCE TEST / Excavator Test
(Blank)
T4-4-18
OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank to bleed
air.
3. Disconnect the hose (PF 3/8) at the pilot filter. In-
stall pressure gauge assembly (ST 6932) with tee
(ST 6639) and adapter (ST 6069) to the pilot filter.
Pilot Filter
: 22 mm
Measurement:
Hose
1. Run engine at fast idle speed. (PF3/8)
2. Measure the pressure without load.
3. Perform the measurement three times and calcu-
late the average value.
Evaluation:
Refer to T4-2 Operational Performance Standard.
Adjustment: T1LD-04-05-001
T4-5-1
OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Measurement: T157-05-04-011
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-5-2
OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)
T4-5-3
OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
Preparation:
1. Stop the engine.
2. Turn the filling cap on hydraulic oil tank to bleed
air.
3. Disconnect the hose (PF 3/4) onto the delivery
port in main pump (P1). Install tee (ST 6639),
adapter (ST 6069), and pressure gauge assembly
(ST 6933).
: 36 mm
Measurement: T1LD-03-01-002
Evaluation:
Refer to T4-2 Operational Performance Standard.
T4-5-4
OPERATIONAL PERFORMANCE TEST / Component Test
Main Relief Valve Adjustment Procedure
A A
Adjustment:
Adjust the main relief valves if necessary. The main
relief valves are installed on the position as illus-
trated.
Pressure
Pressure Decrease
Increase
W107-02-05-129
T4-5-5
OPERATIONAL PERFORMANCE TEST / Component Test
Variable Relief Valve Adjustment Procedure Port PLS
Pressure
Pressure
Increase
Decrease
W107-02-05-129
T4-5-6
OPERATIONAL PERFORMANCE TEST / Component Test
Swing Relief Pressure Adjustment Procedure
T561-02-03-001
W107-02-05-129
T4-5-7
OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. With the return circuit from the control valve
blocked, the circuit pressure must be increased
by applying an external load. This checking
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the delivery flow rate of main relief
valve. Accordingly, even if the main relief valve
set pressure can be reset higher than the set
pressure of overload relief valve, the main pump
supplies too much oil to correctly measure the set
pressure of overload relief valve.
The main relief valve has pre-leaking function.
In this case, the set pressure of main relief valve
at pre-leaking function need to be set higher than
that of overload relief valve.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
overload relief valve plus the pressure at pre-
leaking.
Therefore, when the set pressure of overload re-
lief valve must be checked correctly, remove the
overload relief valve assembly from the machine
and check the overload relief valve unit perform-
ance using the test stand and test block prepared
for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the relief
pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its re-
spective specifications, judge that the set pres-
sure of overload relief valve is correct.
T4-5-8
OPERATIONAL PERFORMANCE TEST / Component Test
Overload Relief Valve Adjustment Procedure
: 34 to 39 N m
(3.5 to 4 kgf m, 25 to 29 lbf ft)
4. After the adjustment, check the set pressure.
W107-02-05-129
T4-5-9
OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
1. To check the performance of swing motor, meas-
ure the amount of oil draining from the swing mo-
tor while swinging the upperstructure.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no person or obstacles
within the test track. Make-Up Line
3. The amount of drain oil will change depending on Drain Hose (PF 3/8)
hydraulic oil temperature. Maintain hydraulic oil
temperature at 50 5 C (122 9 F).
Preparation:
1. Warm the hydraulic oil temperature to 50 5 C
(122 9 F). Rotate the swing motor to warm up
the inside of motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank.
3. Disconnect the drain hose at swing motor. In-
stall a plug (PF 3/8) to the disconnected hose end.
Connect hose (ST 6961) onto the drain port of
swing motor.
T1LD-04-05-002
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
Measurement Condition:
1. Before the measurement, set the fuel lever to the
fast idle position, then measure it.
T4-5-10
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Drain Oil Volume at Swing Operation
(1) With the arm rolled out and bucket rolled in,
hold the bucket so that the height of arm top
pin is even with the boom foot pin. The bucket
must be empty.
(2) Start the engine. Operate the swing lever to
the full stroke. After swing speed reaches a Even with the
constant maximum speed, collect the hydraulic Boom Foot
Pin.
oil from drain hose. Measure the time also.
(3) Repeat the measurement more than 3 times in
T570-06-03-003
both clockwise and counterclockwise direc-
tions, and calculate the average value.
(4) The measurement should be at least 45 sec-
onds.
Evaluation:
Refer to T4-2 Operational Performance Standard.
* Conversion of Measured Value into the Per-
Minute Value
Measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the fol-
lowing formula;
Q = 60 q/t
T4-5-11
OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
1. To check the performance of travel motor, meas-
ure the amount of oil draining from the travel mo-
tor, while rotating the travel motor with the meas-
uring side track jacked up.
2. Always secure the test personnels safe during
the measurement. Before the measurement,
make sure there are no personnel or obstacles
within the test track.
3. Evaluate the overall performance of the travel mo-
tor taking the test results such as travel speed
and mistrack amount into consideration together
with this test results.
4. The amount of drain oil will change depending on
hydraulic oil temperature. Maintain the hydraulic
oil temperature at 50 5 C (122 9 F).
Preparation:
1. Warm the hydraulic oil results temperature to
50 5 C (122 9 F). Rotate the travel motor to
warm up the inside of motor.
2. Stop the engine. Turn the filling cap to bleed air
from the hydraulic oil tank. Drain Hose
3. Disconnect the drain hose at the travel motor. In-
stall a plug (PF 3/8) to the disconnected hose end.
Connect hose (ST 6961) onto the drain port of
travel motor.
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft)
Measurement Condition:
1. Set the fuel lever to the fast idle position and
measure at slow travel speed.
T566-04-04-004
T4-5-12
OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
Evaluation:
Refer to T4-2 Operational Performance Standard.
* Conversion of Measured Value into the Per-
Minute Value
Measure the amount of drain oil using a cali-
brated container. Then, convert the measured
drain oil into the per-minute value using the fol-
lowing formula;
Q = 60 q/t
T157-05-04-019
T4-5-13
OPERATIONAL PERFORMANCE TEST / Component Test
REVOLUTION SENSING VALVE OUTPUT
PRESSURE(PRESSURE PGR) Revolution
Sensing Valve
Summary :
Measure pressure PGR at the output port of the revo-
lution sensing valve while running the engine at the
slow and fast idle speeds.
Preparation :
1. Stop the engine.
2. Disconnect the hose (PF 1/4) at revolution sens- Hose
ing valve connection. Install tee (ST 6640),
adapter (ST 6069), and pressure gauge assem-
bly(ST 6932).
: 19 mm
3. Start the engine. Check for oil leakage at the
pressure gauge connection.
4. Maintain hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement :
1. Set the engine speed at slow idle speed and fast
idle speed.
2. Measure the pressure PGR without load at slow
and fast idle speed.
3. Perform the measurement three times and calcu-
T1LD-04-05-001
late the average value.
Evaluation :
Refer to T4-2 Operational Performance Standard.
T4-5-14
OPERATIONAL PERFORMANCE TEST / Component Test
Revolution Sensing Valve Adjustment Procedure Adjusting
Revolution Sensing Valve
Lock Nut Screw
NOTE: Before loosening the lock nut, make the
alignment marks on the adjusting screw,
lock nut and valve. Using these alignment
marks, the number of turns of the adjusting
screw can be checked easily. Variable
Metering
Valve
1. Loosen the variable metering valve lock nut on
the revolution sensing valve.
2. Slightly tighten the variable metering valve adjust-
ing screw so that the variable metering valve Differential
doesnt operate. Tighten the adjusting screw until Reducing
Valve
the adjusting screw end face is retracted from the
lock nut by approximately 1 mm.
: 6 mm
3. Run the engine at the minimum speed (1 075
-1 T566-03-02-002
min ). Loosen the differential reducing valve lock Lock Nut Adjusting Screw
nut. Turn the differential reducing valve adjusting
screw so the pressure PRG matches the value
below. (Variable Metering Valve)
2
Pressure PGR: 0.5 MPa (5 kgf/cm , 71 psi)
: 17 mm Lock Nut
Adjusting
Screw
: 6 mm
4. Increase the engine speed to the maximum
-1
speed (2 330 min ). Loosen the variable metering
Pressure
valve lock nut. Turn the variable metering valve Pressure
Decrease
adjusting screw so the pressure PRG matches Increase
the value below.
2
Pressure PGR: 1.47 MPa (15 kgf/cm , 213 psi)
: 17 mm
: 6 mm W107-02-05-129
W107-02-05-129
T4-5-15
OPERATIONAL PERFORMANCE TEST / Component Test
PUMP DELIVERY PRESSURE
Summary :
Measure the pump delivery pressure at the main pump
delivery port when all the control levers are in neutral.
Preparation :
1. Stop the engine. Delivery Port in
2. Turn the filling cap on hydraulic oil tank to bleed Main Pump (P1)
air.
3. Disconnect the hose (PF 3/8) onto the delivery
port in main pump (P1). Install tee (ST 6639),
adapter (ST 6069), and pressure gauge assembly
(ST 6933).
: 36 mm
4. Start the engine. Check for oil leakage at the
pressure gauge connection.
5. Maintain hydraulic oil temperature at 50 5 C
(122 9 F).
Measurement :
1. Set the engine speed at slow idle speed or fast
idle speed.
2. Turn all the control levers into neutral. Measure
the pump delivery pressure.
3. Perform the measurement three times and calcu-
late the average value. T1LD-03-01-002
Evaluation :
Refer to T4-2 Operational Performance Standard.
T4-5-16
OPERATIONAL PERFORMANCE TEST / Component Test
Unload Valve Adjustment Procedure
Adjusting
Lock Nut Screw
Unload
Pressure Valve
Pressure
Decrease
Increase
T4-5-17
OPERATIONAL PERFORMANCE TEST / Component Test
PUMP DRIVING TORQUE
Summary:
The adjustment of pump driving torque is not recom-
Adjusting
mended. If the adjustment of pump driving torque is Screw
necessary, perform the following procedures.
Adjustment:
1. Loosen the lock nut.
: 4 mm
Point A
Flow
Rate (Q)
Torque Torque
Decrease Increase
Pressure (P)
T4-5-18
SECTION 5
TROUBLESHOOTING
CONTENTS
Group 1 Diagnosing Procedure Group 4 Electrical System Inspection
Introduction ............................................... T5-1-1 Precautions for Inspection and
Diagnosing Procedure ............................... T5-1-2 Maintenance................................................T5-4-1
Fuse Continuity Test ..................................... T5-4-3
Group 2 Troubleshooting A Battery Voltage Check ..................................T5-4-4
Troubleshooting A Procedure....................... T5-2-1 Voltage Check ...............................................T5-4-5
Engine System Troubleshooting .................. T5-2-2 Continuity Check ...........................................T5-4-6
Actuator Operating System
Troubleshooting .......................................... T5-2-6
Front Attachment System
Troubleshooting .........................................T5-2-11
Swing System Troubleshooting .................. T5-2-18
Travel System Troubleshooting.................. T5-2-20
Blade System Troubleshooting................... T5-2-24
Boom Swing System Troubleshooting ....... T5-2-26
Group 3 Troubleshooting B
Troubleshooting B Procedure....................... T5-3-1
Malfunction of Coolant
Temperature Gauge.................................... T5-3-2
Malfunction of Fuel Gauge ........................... T5-3-4
Malfunction of Alternator Indicator................ T5-3-6
Malfunction of Engine Oil Pressure
Indicator ...................................................... T5-3-7
Malfunction of Overheat Indicator ................ T5-3-8
Malfunction of Fuel Level Indicator............... T5-3-9
Malfunction of Buzzer ................................. T5-3-10
Malfunction of Hour Meter ...........................T5-3-11
1LDT-5-1
(Blank)
1LDT-5-2
TROUBLESHOOTING / Diagnosing Procedure
INTRODUCTION
T5-1-1
TROUBLESHOOTING / Diagnosing Procedure
DIAGNOSING PROCEDURE
T107-07-01-003
T5-1-2
TROUBLESHOOTING / Diagnosing Procedure
4. Inspect the actual trouble on the machine
Reproduce the trouble on the machine and make
sure the actual phenomenon.
In case some trouble cannot be actually
confirmed, obtain the details of the malfunction
from the operator.
Also check for any incomplete connections of the
wire harnesses.
6. Trace causes
Before reaching a conclusion, check the most
suspectable causes again. Try to trace what the
real cause of the trouble is.
Make a plan of appropriate repairing procedure,
T107-07-01-005
to avoid consequential malfunctions.
T107-07-01-006
T107-07-01-007
T5-1-3
TROUBLESHOOTING / Diagnosing Procedure
(Blank)
T5-1-4
TROUBLESHOOTING / Troubleshooting A
TROUBLESHOOTING A PROCEDURE
(DIAGNOSIS OF MACHINE BY SYMPTOM)
YES (OK)
(2)
(1) After checking or measuring item (1), select either YES (OK) or NO
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
Key switch: ON
checking methods may result in making troubleshooting impossible, and may damage
components.
The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
T158-05-03-001
T5-2-1
TROUBLESHOOTING / Troubleshooting A
ENGINE SYSTEM TROUBLESHOOTING
No voltage or less
than 12 V at termi-
nal B.
With key switch
positioned as
shown in the table
YES below, check if
each terminal volt-
age on starter is
normal.
Unit: V
Key Switch
OFF ON START
Terminal
B (M8) 12 12 12
#50 (S) 0 0 12 NO
B T523-07-02-001
T5-2-2
TROUBLESHOOTING / Troubleshooting A
Faulty starter.
Faulty battery.
Starter Relay
Connector (View A)
#1
#2
#5 No Harness
#3
#6
View A
T573-05-02-001 T573-05-02-002
T5-2-3
TROUBLESHOOTING / Troubleshooting A
Starter rotates but engine does not start.
YES
Engine Stop
Solenoid
YES
NO
T5-2-4
TROUBLESHOOTING / Troubleshooting A
Connector
T5-2-5
TROUBLESHOOTING / Troubleshooting A
ACTUATOR OPERATING SYSTEM TROU-
BLESHOOTING
· Key switch : ON
· Pilot shut-off lever : RE-
LEASE position
T5-2-6
TROUBLESHOOTING / Troubleshooting A
Disassemble pilot
YES shut-off valve sole-
noid valve. Check YES Faulty main shut-off
if it is abnormal. valve in control
valve.(Spool is stuck.)
Disassemble main
shut-off valve in
control valve.
Check if it is ab- YES Faulty revolution
NO
normal. Disassemble revolu- sensing valve.
tion sensing valve or
variable metering
NO valve. Check if it is
abnormal.
(A)
NO
T5-2-7
TROUBLESHOOTING / Troubleshooting A
All actuators work fast.
YES
Normal.
Check if hydraulic cylin-
der operating time is
normal.
· Refer to OPERATIONAL Faulty revolution sensing
PERFORMANCE TEST. valve.
NO
T5-2-8
TROUBLESHOOTING / Troubleshooting A
Actuators work when control lever is in neutral.
T5-2-9
TROUBLESHOOTING / Troubleshooting A
Actuators never stop even if control lever is re-
turned to neutral.
Faulty counterbalance
YES
valve or faulty relief valve in
travel device.
Disassemble counter-
Travel balance valve and relief
valve in travel device.
Check if they are ab-
normal. Stuck spool in right or left
travel in control valve.
NO
T5-2-10
TROUBLESHOOTING / Troubleshooting A
FRONT ATTACHMENT SYSTEM TROU-
BLESHOOTING
T5-2-11
TROUBLESHOOTING / Troubleshooting A
T5-2-12
TROUBLESHOOTING / Troubleshooting A
T5-2-13
TROUBLESHOOTING / Troubleshooting A
Only specific cylinder works fast.
· Refer to OPERATIONAL
PERFORMANCE TEST.
Faulty pilot valve.
NO
T5-2-14
TROUBLESHOOTING / Troubleshooting A
Front attachment cylinders leaking (drift) is large.
YES Normal.
T5-2-15
TROUBLESHOOTING / Troubleshooting A
When control levers are operated (boom raise,
arm roll-out), front attachment drops briefly, then
begins to work.
T5-2-16
TROUBLESHOOTING / Troubleshooting A
(Blank)
T5-2-17
TROUBLESHOOTING / Troubleshooting A
SWING SYSTEM TROUBLESHOOTING
Check if problem
YES disappears after
control valve spool
is disassembled
and cleaned.
Check if swing motor
YES oil drain amount is
normal
· Refer to
"OPERATIONAL
PERFORMANCE
Faulty swing motor.
TEST". NO
Check if swing
YES motor relief pres-
sure is normal.
· Refer to
"OPERATIONAL
Check if swing PERFORMANCE
pilot secondary TEST".
pressure is nor- Faulty swing motor
mal. NO relief valve.
· Refer to
"OPERATIONAL
PERFORMANCE Faulty pilot valve.
TEST". NO
T5-2-18
TROUBLESHOOTING / Troubleshooting A
T5-2-19
TROUBLESHOOTING / Troubleshooting A
TRAVEL SYSTEM TROUBLESHOOTING
T5-2-20
TROUBLESHOOTING / Troubleshooting A
Travel speed does not change to the fast speed.
· Measure voltage
with a clip without Broken harness be-
disconnecting. tween travel speed
changeover solenoid
NO valve and fuse box.
T5-2-21
TROUBLESHOOTING / Troubleshooting A
One side track doesnt rotate or rotates slow. Ma-
chine mistracks.
Left Travel 5
Forward
Right Travel
Reverse
T555-05-03-001
T563-05-03-002
T5-2-22
TROUBLESHOOTING / Troubleshooting A
T5-2-23
TROUBLESHOOTING / Troubleshooting A
BLADE SYSTEM TROUBLESHOOTING
T5-2-24
TROUBLESHOOTING / Troubleshooting A
Faulty pressure
YES compensator in
control valve.
Disassemble shuttle
valve in control valve.
NO Check if it is abnormal.
Faulty shuttle valve
in control valve.
YES
T5-2-25
TROUBLESHOOTING / Troubleshooting A
BOOM SWING SYSTEM TROUBLESHOOT-
ING
T5-2-26
TROUBLESHOOTING / Troubleshooting B
TROUBLESHOOTING B PROCEDURE
(DIAGNOSIS OF MONITOR)
YES (OK)
(2)
(1) After checking or measuring item (1), select either Yes (OK) or No
(NOT OK) and proceed to item (2) or (3) next.
(3)
NO (NOT OK)
As shown to the left, measuring methods or items to be referred to are indicated in the
spaces under the box. Take care to measure or check correctly. Incorrect measuring or
checking methods may result in making troubleshooting impossible, and may damage
· Key switch: ON components.
The thick-line box indicates the causes. Scanning through thick-line boxes, possible
causes can be focused.
T158-05-03-001
T5-3-1
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF COOLANT TEMPERA-
TURE GAUGE
YES
YES
Disconnect coolant temperature
Coolant temperature sensor terminal, and connect
gauge monitor seg- harness end terminal to vehicle.
ment light moves its Check if all coolant temperature
position unsuitably. monitor segments light up.
· Key switch: ON NO
T5-3-2
TROUBLESHOOTING / Troubleshooting B
1 2 3 4 5 6 7 8 9 10
Faulty coolant tempera- Segment Number T573-05-02-004
ture sensor.
Connector
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-3
TROUBLESHOOTING / Troubleshooting B
MULFUNCTION OF FUEL GAUGE
YES
YES
YES
Disconnect fuel level sensor con-
Fuel gauge monitor nector, and connect harness end
segment light moves connector terminals #1 to #2.
its position unsuitably. Check if all fuel gauge monitor
segments light up stably.
· Key switch: ON
· Use a clip to connect terminals. NO
T5-3-4
TROUBLESHOOTING / Troubleshooting B
Fuel Gauge
Lower Upper
Limit Limit
Faulty fuel level sensor.
Connector
3 2 1
T5-3-5
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF ALTERNATOR INDI-
CATOR
Connector
Monitor Panel
Altenator
6 5 4 3 2 1
12 11 10 9 8 7 3 2 1
T5-3-6
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF ENGINE OIL PRES-
SURE INDICATOR
Connector
Monitor Panel
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-7
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF OVERHEAT INDICA-
TOR
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-8
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF FUEL LEVEL INDICA-
TOR
Even if sufficient fuel is When fuel level sensor With fuel level sensor
in fuel tank, segment is disconnected, check if connector disconnect,
blinks for warning. segment stops blinking. YES Short-circuited harness
disconnect 12P connec- between fuel level sensor
· Key switch: ON tor from monitor panel. and monitor.
· Key switch: ON
Check if there is conti-
nuity between terminal
NO #1 on harness end con-
nector and vehicle.
Faulty fuel gauge or
· Key switch: ON faulty monitor controller.
NO
Connector
3 2 1
6 5 4 3 2 1
12 11 10 9 8 7
T5-3-9
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF BUZZER
Buzzer sounds continuously when engine oil
pressure indicator and overheat indicator light up.
Buzzer sounds 5 times when fuel level indicator
lights up.
Be sure to inspect wiring connection prior to trou-
ble shooting.
T5-3-10
TROUBLESHOOTING / Troubleshooting B
MALFUNCTION OF HOUR METER
Connector
Alternator
3 2 1
T5-3-11
TROUBLESHOOTING / Troubleshooting B
(Blank)
T5-3-12
TROUBLESHOOTING / Electrical System Inspection
PRECAUTIONS FOR INSPECTION AND
MAINTENANCE
T5-4-1
TROUBLESHOOTING / Electrical System Inspection
4. Precaution for using a circuit tester.
Wind a piece of wire Tester Probe
(1) Before using a circuit tester, refer to the
instructions in the circuit tester manual.
Then, set the circuit tester to meet the object to
be measured, voltage range and current
polarity.
Sharpen the end of wire
(2) Before starting the connector test, always T107-07-06-003
check the connector terminal numbers,
referring to the circuit diagram.
When the connector size is very small, and the
standard probe size is too large to be used for
testing, wind a fine piece of sharpened wire or
a pin around the probe to make the test easier.
(3) When performing the connector test with the
circuit tester, be sure to insert the tester probe
from the connector harness side in order not to
damage the terminals in the connector.
T5-4-2
TROUBLESHOOTING / Electrical System Inspection
FUSE CONTINUITY TEST
10
M1LA-07-011
T5-4-3
TROUBLESHOOTING / Electrical System Inspection
BATTERY VOLTAGE CHECK
T5-4-4
TROUBLESHOOTING / Electrical System Inspection
VOLTAGE CHECK
Key Switch
B BR R1 R2 C ACC
PREHEAT
OFF
ON
START
1
2
4
Battery 3
5
6
Relay
8 7 9
10
T5-4-5
TROUBLESHOOTING / Electrical System Inspection
CONTINUITY CHECK Harness
A
Single-line continuity check
Disconnect both end connectors of the harness and
check continuity between ends:
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
NOTE: When the one end connector is far apart Connect to the
vehicle frame. A
from the other, connect one end of
connector (A) or the vehicle frame using a
clip. Then, check continuity of the harness
through the vehicle frame as illustrated.
Connect to the
vehicle frame.
If the ohm-meter reading is: 0 = Continuity
= Discontinuity
A a
Single-line short-circuit check
Disconnect both end connectors of the harness and Short circuit
check continuity between one end connector of the between the
harness and
harness and the vehicle frame: the vehicle
If the ohm-meter reading is: frame.
0 = Short circuit is present.
= No short circuit is present.
T107-07-05-003
Multi-line continuity check First Connected
Disconnect both end connectors of the harness, and
connect two terminals (A) and (B), using a jumper
wire at one end of the connector, as illustrated. Then,
check continuity between terminals (a) and (b) at the
other connector. If the ohm-meter reading is ,
either line (A)-(a), or (B)-(b) is in discontinuity. To find
out which line is discontinued, conduct the single line Second Connected
continuity check on both lines individually, or after
changing the connected terminals from (A)-(B) to
(A)-(C). Check continuity once more between
terminals (a) and (c).
T5-4-6
TROUBLESHOOTING / Electrical System Inspection
5V System Circuit Signal or Ground
Power Source
Voltage between Terminal No. 1 and the vehicle
Turn OFF the key switch, and disconnect the
Two-Polarities
connector. Measure the voltage between terminal
No. 1 (5 V power supply) on the machine harness
end connector and the vehicle (ground) under the
following conditions.
Key Switch: ON V
Black (Negative) Terminal of Tester: Vehicle
(Ground)
Red (Positive) Terminal of Tester: Terminal No. 1
Power T107-07-05-006
Standard Voltage: If 5 0.5 V, the circuit is normal Source Signal Ground
up to terminal No. 1.
Three-Polarities
Key Switch: ON
Black (Negative) Terminal of Tester: Connected to
the ground Terminal (Terminal No. 2 or No. 3)
Red (Positive) Terminal of Tester: Connect to
Terminal No. 1 T107-07-05-008
T107-07-05-009
T5-4-7
TROUBLESHOOTING / Electrical System Inspection
(Blank)
T5-4-8
Many thanks for your purchase.
Happy every day.
QIWEN YE
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2015/1/2 21:22:16]
Workshop Manual
ADDITIONAL REFERENCES
Please refer to the materials listed below in addition • Operation Manual of the Engine
to this manual. • Parts Catalog of the Engine
• Hitachi Training Material
• The Operator’s Manual
• The Parts Catalog
MANUAL COMPOSITION
• Information included in the Technical Manual: • Information included in the Workshop Manual:
technical information needed for redelivery and technical information needed for maintenance and
delivery, operation and activation of all devices repair of the machine, tools and devices needed
and systems, operational performance tests, and for maintenance and repair, maintenance stan-
troubleshooting procedures. dards, and removal/installation and assem-
ble/disassemble procedures.
PAGE NUMBER
Example : T 1-3-5
IN-01
INTRODUCTION
SAFETY ALERT SYMBOL AND HEADLINE
NOTATIONS
This is the safety alert symbol. When you see this IMPORTANT:
symbol, be alert to the potential for personal injury. Indicates a situation which, if not conformed to the
Never fail to follow the safety instructions prescribed instructions, could result in damage to the machine.
along with the safety alert symbol.
The safety alert symbol is also used to draw attention
to component/part weights. NOTE:
To avoid injury and damage, be sure to use appropri- Indicates supplementary technical information or
ate lifting techniques and equipment when lifting heavy know-how.
parts.
UNITS USED
To Convert To Convert
Quantity Into Multiply By Quantity Into Multiply By
From From
2
Length mm in 0.03937 Pressure MPa kgf/cm 10.197
mm ft 0.003281 MPa psi 145.0
Volume L US gal 0.2642 Power kW PS 1.360
L US qt 1.057 kW HP 1.341
°C °F °C×1.8+32
3 3
m yd 1.308 Temperature
Weight kg lb 2.205 Velocity km/h mph 0.6214
-1
Force N kgf 0.10197 min rpm 1.0
N lbf 0.2248 Flow rate L/min US gpm 0.2642
Torque Nm kgf m 1.0197 mL/rev cc/rev 1.0
Nm lbf ft 0.7375
IN-02
SAFETY
RECOGNIZE SAFETY INFORMATION
001-E01A-0688 SA-688
002-E01C-1223
SA-1
SAFETY
FOLLOW SAFETY INSTRUCTIONS
004-E01A-0437
SA-2
SAFETY
WEAR PROTECTIVE CLOTHING
005-E01A-0438
006-E01A-0434 SA-434
INSPECT MACHINE
Inspect your machine carefully each day or shift by
walking around it before you start it to avoid personal
injury.
S007-E01A-0435
SA-435
SA-3
SAFETY
GENERAL PRECAUTIONS FOR CAB
524-E01A-0000
SA-4
SAFETY
USE HANDHOLDS AND STEPS
008-E01B-0439
009-E01A-0378
SA-5
SAFETY
FASTEN YOUR SEAT BELT
010-E01A-0237
011-E01A-0426
SA-6
SAFETY
OPERATE ONLY FROM OPERATOR'S
SEAT
012-E01B-0444
JUMP STARTING
S013-E01A-0032
SA-7
SAFETY
KEEP RIDERS OFF MACHINE
014-E01B-0379
018-E01A-0481
SA-481
SA-500
017-E01A-0491
SA-8
SAFETY
DRIVE MACHINE SAFELY
SA-368
019-E01D-0492
SA-589
SA-9
SAFETY
AVOID INJURY FROM ROLLAWAY
ACCIDENTS
To avoid rollaways:
• Select level ground when possible to park
machine.
• Do not park the machine on a grade.
• Lower the bucket and/or other work tools to the
ground.
• Turn the auto-idle / acceleration seleclter and the
H/P mode switch off.
• Run the engine at slow idle speed without load for
5 minutes to cool down the engine.
• Stop the engine and remove the key from the key
switch.
• Pull the pilot control shut-off lever to LOCK
position.
• Block both tracks and lower the bucket to the
ground. Thrust the bucket teeth into the ground if
you must park on a grade. SA-364
020-E08A-0493
SA-10
SAFETY
AVOID INJURY FROM BACK-OVER AND
SWING ACCIDENTS
S021-E01A-0494
SA-11
SAFETY
AVOID TIPPING
To avoid tipping:
Be extra careful before operating on a grade.
S025-E01B-0495
SA-12
SAFETY
AVOID POWER LINES
029-E01A-0381
OBJECT HANDLING
032-E01A-0014
SA-13
SAFETY
PROTECT AGAINST FLYING DEBRIS
SA-432
031-E01A-0432
To avoid accidents:
• Park machine on a firm, level surface.
• Lower bucket to the ground.
• Turn auto-idle / acceleration selector and H/P
mode switch off.
• Run engine at slow idle speed without load for 5
minutes.
• Turn key switch to OFF to stop engine.
• Remove the key from the key switch.
• Pull the pilot control shut-off lever to the LOCK SA-375
position.
• Close windows, roof vent, and cab door.
• Lock all access doors and compartments.
033-E09B-0390
SA-14
SAFETY
HANDLE FLUIDS SAFELY AVOID FIRES
034-E01A-0496
SA-019
SA-15
SAFETY
SAFETY TRANSPORTING
S035-E08A-0395
SA-16
SAFETY
PRACTICE SAFE MAINTENANCE
To avoid accidents:
S500-E02B-0497
SA-17
SAFETY
• Use a portable safety light for working inside or
under the machine.
• Make sure that the bulb is enclosed by a wire
cage.
The hot filament of an accidentally broken bulb
can ignite spilled fuel or oil.
• Sufficiently illuminate the work site. Use a
maintence work light when working under or
inside the machine.
• Always use a work light protected with a guard. In SA-037
S501-E01A-0287
SA-287
502-E01A-0026
SA-026
SA-18
SAFETY
PREVENT PARTS FROM FLYING
503-E01B-0344
SA-034
504-E01A-0034
SA-040
S522-E01A-0040
SA-19
SAFETY
PREVENT BURNS
Engine oil, gear oil and hydraulic oil also become hot
during operation.
The engine, hoses, lines and other parts become hot
as well.
SA-225
505-E01B-0498
S506-E01A-0019
SA-20
SAFETY
AVOID HIGH-PRESSURE FLUIDS
SA-292
507-E03A-0499
SA-044
SA-21
SAFETY
PREVENT FIRES
Clean up Flammables:
SA-22
SAFETY
Check Emergency Engine Stop Switch:
If a fire breaks out, failure to release pressurized air
inside the hydraulic tank will escalate fire, hampering
fire fighting.
• Check the emergency engine stop switch function
every 250 hours:
1) Start the engine and run it at slow Idle.
2) Turn the emergency engine stop switch to the
EMERG. STOP position.
3) Confirm that both engines stop and that pres-
surized air inside the hydraulic oil tank is re-
leased (a hissing sound should be heard).
• If any abnormalities are found, be sure to repair
them before operating the machine.
S508-E02B-0019
SA-393
In an emergency, if the cab door and/or the front
window cannot be opened, break the front or rear
window panes with the emergency evacuation
hammer to escape from the cab.
Refer to the explanation page on “EMERGENCY
EXIT” in Operator’s Manual.
518-E02B-0393
SS-1510
SA-23
SAFETY
BEWARE OF EXHAUST FUMES
509-E01A-0016
SA-016
SA-24
SAFETY
REMOVE PAINT BEFORE WELDING OR
HEATING
511-E01A-0029
512-E01C-0032
SA-25
SAFETY
SERVICE AIR CONDITIONING SYSTEM
SAFELY
513-E01A-0405
• Check the MSDS before you start any job using a SA-309
hazardous chemical. That way you will know
exactly what the risks are and how to do the job
safely. Then follow procedures and use
recommended equipment.
S515-E01A-0309
SA-26
SAFETY
DISPOSE OF WASTE PROPERLY
S516-E01A-0226
S517-E01A-0435 SA-435
SA-27
SAFETY
(Blank)
SA-28
SECTION 1
GENERAL INFORMATION
CONTENTS
Group 1 Precautions for Disassembling
and Assembling
Precautions for Disassembling and
Assembling ............................................ W1-1-1
Group 2 Tightening
Tightening Torque Specification............... W1-2-1
Torque Chart............................................ W1-2-3
Piping Joint.............................................. W1-2-6
Periodic Replacement of parts............... W1-2-10
Group 4 Painting
Painting ................................................... W1-4-1
1LDW-1-1
Blank
1LDW-1-2
GENERAL / Precautions for Disassembling and Assembling
PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING
Thoroughly wash the machine before bringing it into To prevent dirt from entering, cap or plug the
the shop. Bringing a dirty machine into the shop removed pipes.
may cause machine components to be Before disassembling, clean the exterior of the
contaminated during disassembling/assembling, components and place on a work bench.
resulting in damage to machine components, as Before disassembling, drain gear oil from the
well as decreased efficiency in service work. reduction gear.
Be sure to provide appropriate containers for
draining fluids.
Inspect the Machine Use matching marks for easier reassembling.
Be sure to use the specified special tools, when
Be sure to thoroughly understand all disassem- instructed.
bling/assembling procedures beforehand, to help If a part or component cannot be removed after
avoid incorrect disassembling of components as removing its securing nuts and bolts, do not
well as personal injury. attempt to remove it forcibly. Find the cause(s),
Check and record the items listed below to prevent then take the appropriate measures to remove it.
problems from occurring in the future. Orderly arrange disassembled parts. Mark and
tag them as necessary.
The machine model, machine serial number, and Store common parts, such as bolts and nuts with
hour meter reading. reference to where they are to be used and in a
Reason for disassembly (symptoms, failed parts, manner that will prevent loss.
and causes). Inspect the contact or sliding surfaces of
Clogging of filters and oil, water or air leaks, if disassembled parts for abnormal wear, sticking,
any. or other damage.
Capacities and condition of lubricants. Measure and record the degree of wear and
Loose or damaged parts. clearances.
W1-1-1
GENERAL / Precautions for Disassembling and Assembling
Precautions for Assembling Bleeding Air from Hydraulic System
Be sure to clean all parts and inspect them for When hydraulic oil is drained, the suction filter or the
any damage. If any damage is found, repair or suction lines are replaced, or the removal and instal-
replace part. lation of the pump, swing motor, travel motor or cylin-
Dirt or debris on the contact or sliding surfaces der is done, bleed air from the hydraulic system in
may shorten the service life of the machine. Take the following procedures:
care not to contaminate any contact or sliding
surfaces. IMPORTANT: If the engine is started with air
Be sure to replace O-rings, backup rings, and oil trapped in the hydraulic pump hous-
seals with new ones once they are disassembled. ing, damage to the pump may result.
Apply a film of grease before installing. If the hydraulic motor is operated
Be sure that liquid-gasket-applied surfaces are
with air trapped in the hydraulic mo-
clean and dry.
tor housing, damage to the motor
If an anti-corrosive agent has been used on a
may result.
new part, be sure to thoroughly clean the part to
remove the agent. If the cylinder is operated with air
Utilize matching marks when assembling. trapped in the cylinder tube, damage
Be sure to use the designated tools to assemble to the cylinder may result.
bearings, bushings and oil seals. Be sure to bleed air before starting
Keep a record of the number of tools used for the engine.
disassembly/assembly. After assembling is
complete, count the number of tools, so as to Bleeding Air from Hydraulic Pump
make sure that no forgotten tools remain in the
assembled machine. Remove the air bleeding plug from the top of the
pump and fill the pump housing with hydraulic oil.
After the pump housing is filled with hydraulic oil,
temporarily tighten the plug. Then, start the en-
gine and run at slow idle speed.
Slightly loosen the plug to bleed air from the
pump housing until hydraulic oil oozes out.
After bleeding all the air, securely tighten the plug.
W1-1-2
GENERAL / Precautions for Disassembling and Assembling
Bleeding Air from Hydraulic Circuit
W1-1-3
GENERAL / Precautions for Disassembling and Assembling
Floating Seal Precautions A
(3) Check that the O-ring is not twisted, and that it W105-03-05-020
a a
(4) After installing the floating seal, check that seal
ring surface (A) is parallel with seal mating C
face (C) by measuring the distances (A) and
(C) at point (a) and (b), as illustrated. If these
distances differ, correct the O-ring seating.
b b
a=b a b
W110-03-05-004
W1-1-4
GENERAL / Precautions for Disassembling and Assembling
Precautions for Using Nylon Sling
W1-1-5
GENERAL / Precautions for Disassembling and Assembling
Damaged Appearance
CAUTION: If a load is lifted with a damaged Broken Sewing Thread
nylon sling, serious personal injury may re-
sult. Be sure to visually check the nylon sling
for any damage before using.
W162-01-01-002
Scuffing
2. Before using a nylon sling, visually check the ny-
lon sling for any damage corresponding to exam-
ples shown to the right. If any damage is found,
cut and discard the sling. Even if no damage is
found, do not use slings older than 7-years. W162-01-01-003
Fuzz
Broken Sewing
Thread
W162-01-01-004
Broken Sewing
Thread
W162-01-01-005
Broken Sewing
Thread
Separation of W162-01-01-006
Scoring
Belt
W162-01-01-007
Fuzz Scuffing
Broken Warp
W162-01-01-008
W1-1-6
GENERAL / Precautions for Disassembling and Assembling
MAINTENANCE STANDARD TERMINOL-
OGY
Standard
1. Dimension for parts on a new machine.
Allowable Limit
1. Normal machine performance cannot be accom-
plished after exceeding this limit.
W1-1-7
GENERAL / Precautions for Disassembling and Assembling
(Blank)
W1-1-8
GENERAL / Tightening
W1-2-1
GENERAL / Tightening
W1-2-2
GENERAL / Tightening
TORQUE CHART
Bolt Types
Hexagon
Wrench
Bolt Dia. Wrench
Size
Size M552-07-091 M552-07-090 M157-07-225
Socket Bolt
Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft) Nm (kgf m) (lbf ft)
M6 10 5 3.3 to 4.2 (0.3 to 0.4) (2.4 to 3.1)
M8 13 6 30 (3.1) (22) 20 (2.0) (15.0) 10 (1.0) (7.4)
M10 17 8 65 (6.6) (48) 50 (5.1) (37) 20 (2.0) (15.0)
M12 19 10 110 (11.0) (81) 90 (9.2) (66) 35 (3.6) (26.0)
M14 22 12 180 (18.5) (135) 140 (14.0) (103) 55 (5.6) (41)
M16 24 14 270 (27.5) (200) 210 (21.5) (155) 80 (8.2) (59)
M18 27 14 400 (41.0) (295) 300 (30.5) (220) 120 (12.0) (89)
M20 30 17 550 (56.0) (410) 400 (41.0) (295) 170 (17.0) (125)
M22 32 17 750 (76.5) (550) 550 (56.0) (410) 220 (22.5) (162)
M24 36 19 950 (97.0) (700) 700 (71.5) (520) 280 (28.5) (205)
M27 41 19 1400 (143) (1030) 1050 (107) (770) 400 (41.0) (295)
M30 46 22 1950 (200) (1440) 1450 (148) (1070) 550 (56.0) (410)
M33 50 24 2600 (265) (1920) 1950 (200) (1440) 750 (76.5) (550)
M36 55 27 3200 (325) (2360) 2450 (250) (1810) 950 (97.0) (700)
W1-2-3
GENERAL / Tightening
IMPORTANT: The following items are applied to
both fine and coarse pitch threads.
1. Apply lubricant (i. e. white zinc B
dissolved Into Spindle oil) to
nuts and bolts to reduce their
friction coefficients.
The plated bolts require no lubri-
cant.
2. Torque tolerance is 10 %.
3. Be sure to use bolts of correct
length. Bolts that are too long
cannot be tightened, as the bolt
tip comes into contact with the
bottom of the bolt hole. Bolts
that are too short cannot develop
sufficient tightening force.
4. The torques given in the chart
are for general use only. Do not
use these torques if a different
torque is given for a specific ap-
plication.
5. Make sure that nut and bolt
threads are clean before install-
ing.
Remove dirt or corrosion, if any.
Equally tighten upper and lower Tighten from center and diagonally
alternately Tighten diagonally
1 12 9 4 1 6 7 14
6 3
1st to 4th
4 5
2 13 8 5 2 3 10 11
2nd to 3rd
W105-01-01-003
W1-2-4
GENERAL / Tightening
Service Recommendations for Spilt Flange
Cotter Pin
IMPORTANT: Do not reuse cotter pins. Match the
holes in the bolt and nut while tight- Bend along edge sharply
ening, not while loosening. W105-01-01-009
Tighten
W 105-01-01-010
W1-2-5
GENERAL / Tightening
PIPING JOINT 1 4 3 5 2
30
IMPORTANT: 1. Do not over-tighten nut (3). Ex-
cessive force will be applied to
metal sealing surfaces (4) and (5),
possibly cracking adapter (1). Be Male Union Joint Female Union Joint
sure to tighten nut (3) to specifi-
cations. W105-01-01-017
W1-2-6
GENERAL / Tightening
O-ring Seal Joint 7 6 9
W1-2-7
GENERAL / Tightening
Screw-In Connection
PT PF
Depending on types of screw and sealing, different 30
types of screw fittings are used.
Application Procedure
W105-01-01-019
Confirm that the thread surface is clean and, free of Leave one to two pitch threads uncovered
dirt or damage.
Apply seal tape around threads as shown. Wrap seal
tape in the same direction as the threads.
M114-07-043 M114-07-042
W1-2-8
GENERAL / Tightening
Connecting Hose
WRONG RIGHT
CAUTION: When replacing hoses, be sure to
use only genuine Hitachi service parts. Using
hoses other than genuine Hitachi hoses may
cause oil leaks, hose rupture or Separation of
fitting, possibly resulting in a fire on the ma-
chine.
WRONG RIGHT
Take care so that hoses do not come into
contact with moving parts or sharp objects. Clamp Clamp
Rubbing Against
Each Other
W105-01-01-013
WRONG RIGHT
Rubbing Against
Each Other Clamp
W105-01-01-014
W1-2-9
GENERAL / Tightening
PERIODIC REPLACEMENT OF PARTS
Replacement
Periodic Replacement Parts
Intervals
Fuel hose (Fuel tank to filter) Every 2 years or Every 6000 hours
Engine Fuel hose (Fuel tank to injection pump) Every 2 years or Every 6000 hours
Heater hose (Heater to engine) Every 2 years or Every 6000 hours
Pump suction hose Every 2 years or Every 6000 hours
Basic Machine
Pump delivery hose Every 2 years or Every 6000 hours
Hydraulic Swing hose Every 2 years or Every 6000 hours
System Boom cylinder line hose Every 2 years or Every 6000 hours
Front-End Arm cylinder line hose Every 2 years or Every 6000 hours
Attachment Bucket cylinder line hose Every 2 years or Every 6000 hours
Pilot hose Every 2 years or Every 6000 hours
W1-2-10
GENERAL / Bleeding Air
BLEED AIR FROM HYDRAULIC OIL TANK
Preparation M570-07-005
W1LD-01-03-001
Vacuum Pump
Hose
Adapter
W1LD-01-03-002
W1-3-1
GENERAL / Bleeding Air
(Blank)
W1-3-2
GENERAL / Painting
PAINTING
Section Surfaces to Be Painted Painting Color
Upperstructure Outer cover (Right, Left, Rear, Top) YR1-01[TAXI yellow]
Skirt (Front, Right, Left) SP-424[Dark gray]
Main frame SP-424[Dark gray]
Inner face (Oil tank, Fuel tank) SP-424[Dark gray]
Canopy (Pole) SP-424[Dark gray]
Stay (Front, Right, Left) SP-424[Dark gray]
Lever (Travel, Blade, Fuel, Lock) SP-424[Dark gray]
Pedal (Travel, Boom swing) SP-424[Dark gray]
Floor plate, Seat base SP-424[Dark gray]
Console (Right, Left) SP-424[Dark gray]
Counterweight SP-424[Dark gray]
Undercarriage Track frame (Including idler, upper roller and SP-424[Dark gray]
lower roller)
Swing bearing SP-424[Dark gray]
Blade (Including cylinder) SP-424[Dark gray]
Front attachment Boom, Arm, Bucket and Link (Including cyl- YR1-01[TAXI yellow]
inder)
Swing post (Including cylinder) SP-424[Dark gray]
Canopy (Pole)
Lever
Stay (Front) Skirt (Left)
Swing Bearing
Blade
Counterweight W1LD-01-04-001
Track Frame
W1-4-1
GENERAL / Painting
(Blank)
W1-4-2
SECTION 2
UPPERSTRUCTURE
CONTENTS
Group 1 Canopy Group 6 Pilot Valve
Remove and Install Canopy ............... W2-1-1 Remove and Install Front Pilot Valve ....W2-6-1
Remove and Install Travel Pilot Valve...W2-6-3
Group 2 Counterweight Remove and Install Blade Pilot Valve ...W2-6-5
Remove and Install Remove and Install Boom Swing
Counterweight .................................. W2-2-1 Pilot Valve ...........................................W2-6-7
Disassemble Front Pilot Valve ............W2-6-10
Group 3 Pump Device Assemble Front Pilot Valve .................W2-6-14
Remove and Install Disassemble Travel Pilot Valve ...........W2-6-18
Pump Device .................................... W2-3-1 Assemble Travel Pilot Valve................W2-6-22
Disassemble Pump Device................. W2-3-4 Disassemble Blade and Boom Swing
Assemble Pump Device ..................... W2-3-6 Pilot Valve .........................................W2-6-26
Maintenance Standard ..................... W2-3-10 Assemble Blade and Boom Swing
Pilot Valve .........................................W2-6-28
Group 4 Control Valve
Remove and Install Group 7 Solenoid Valve
Control Valve .................................... W2-4-1 Disassemble and Assemble
Disassemble And Assemble Solenoid Valve ....................................... W2-7-1
Control Valve .................................... W2-4-6
1LDW-2-1
Blank
1LDW-2-2
UPPERSTRUCTURE / Canopy
REMOVE AND INSTALL CANOPY
Removal 2
1
1. Attach sling belt (2) to canopy (1) and hold it.
W1LD-02-01-001
W1LD-02-01-003
W2-1-1
UPPERSTRUCTURE / Canopy
Installation
CAUTION: Canopy weight : 32 kg (71 lb)
2
1. Attach sling belt (2) to canopy (1). Lift the canopy 1
(1) by crane and put it on the frame.
used) . 1
: 24 mm
: 205 N m (21 kgf m, 151 lbf ft)
W1LD-02-01-003
3. Install cover (4) to canopy (1) with screw (3) (4
used).
3 W1LD-02-01-002
W2-1-2
UPPERSTRUCTURE / Counterweight
REMOVE AND INSTALL COUNTERWEIGHT
Removal
: 13 mm
SS-2304
4
3. Open tank cover (3) until lock (4) is locked.
3
: 13 mm
M1LD-07-014
W571-02-02-003
W2-2-1
UPPERSTRUCTURE / Counterweight
W571-02-02-004
W571-02-02-003
W2-2-2
UPPERSTRUCTURE / Counterweight
Installation
W571-02-02-003
: 30 mm (ZX40U, ZX50U)
5
: 392 N m (40 kgf m, 290 lbf ft)
W571-02-02-004
M1LD-07-014
1
: 13 mm
: 9.8 N m (1 kgf m , 7.2 lbf ft)
SS-2304
W2-2-3
UPPERSTRUCTURE / Counterweight
Blank
W2-2-4
UPPERSTRUCTURE / Pump Device
REMOVE AND INSTALL PUMP DEVICE
Removal 1
IMPORTANT: Bleed air from the hydraulic oil tank 5
before any work. (Refer to W1-3-1.)
2
W571-02-03-001
W566-02-03-003
W2-3-1
UPPERSTRUCTURE / Pump Device
Installation
4 M1LD-05-001
W2-3-2
UPPERSTRUCTURE / Pump Device
Blank)
W2-3-3
UPPERSTRUCTURE / Pump Device
DISASSEMBLE PUMP DEVICE
28
7
27 6
26
25
24 5
23
22
21
20
19 4 3
18
17 2
1
16
15
14
13
11
12
10
8
9
49
48 47
46
45
40
39
38
37
31
43
42 30
41 29
44
35
34
36 33
32
W1LD-02-03-001
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring
W2-3-4
UPPERSTRUCTURE / Pump Device
Disassemble Pump Device
10. Remove spring guide (31) from body H (37).
Be sure to thoroughly read Precautions for Remove spring (30), spring holder (29), and
Disassembling and Assembling on page W1-1-1 cylinder block (22) assembly from body S (10).
before starting the disassembly work.
11. Remove plungers(17) (11 used), retainer (18),
1. Remove socket bolts (49) (4 used) to remove holder (19), retainer (20), and needles (21) (3
gear pump (47) from body H (37). used) from cylinder block (22).
: 6 mm
CAUTION: When removing retaining ring
2. Remove collars (46) (2 used) from gear pump (26), push spring (24) with a press. By failing
(47) and coupling (45) from body H (37). to use a press, the spring tends to fly off.
W2-3-5
UPPERSTRUCTURE / Pump Device
ASSEMBLE PUMP DEVICE
2 3 6 7 29 30 19 20 23 24 25 11 26 27 28 31 38 40 39
1
45
5 46
47
48
49
10
43
13 14 15 16 21 18 17 22 32 33 34 35 37 41 42
W1LD-02-03-002
44
48 49
36
W1LD-02-03-003
1- Retaining Ring 14 - Stopper Pin 26 - Retaining Ring 38 - Seal Washer
2- O-Ring 15 - Ceramic Ball (2 Used) 27 - Valve Plate 39 - Bolt
3- Seal Holder 16 - Swash Plate 28 - Needle Bearing 40 - Nut
4- Oil Seal 17 - Plunger (11 Used) 29 - Spring Holder 41 - Choke
5- Shaft 18 - Retainer 30 - Spring 42 - O-Ring
6- Ball Bearing 19 - Holder 31 - Spring Guide 43 - Plug
7- Retaining Ring 20 - Retainer 32 - Control Piston 44 - Socket Bolt (7 Used)
8- *Plug 21 - Needle (3 Used) 33 - Sleeve 45 - Coupling
9- *O-Ring 22 - Cylinder Block 34 - O-Ring 46 - Collar (2 Used)
10 - Body S 23 - Retainer 35 - Spring Pin 47 - Gear Pump
11 - Gasket 24 - Spring 36 - LS Valve 48 - Washer (4 Used)
12 - *Pin (2 Used) 25 - Retainer 37 - Body H 49 - Socket Bolt 4 Used)
13 - Spring
NOTE: As for items with , refer to W2-3-4.
W2-3-6
UPPERSTRUCTURE / Pump Device
Assemble Pump Device
11. Install cylinder block (22) assembly to body S (10).
Be sure to thoroughly read Precautions for Install coupling (45) onto the end of shaft (5).
Disassembly and Assembly Work on page W1-
1-1 before starting the assembly work. 12. Install O-ring (42) onto plug (43). Install choke
(41) and plug (43) into body H (37).
IMPORTANT: When replacing ball bearing (6), : 4 mm (choke)
press the ball bearing down onto : 6 to 9 N m (0.6 to 0.9 kgf m, 4.4 to 6.6
shaft (5) first and install retaining lbf ft)
ring (7) onto the shaft. : 5 mm(plug)
1. Press ball bearing (6) onto shaft (5) to install : 15 to 20 N m (1.5 to 2 kgf m, 11 to 14.5
retaining ring (7). Insert the shaft assembly into lbf ft)
body S (10).
13. Install O-ring (34) onto sleeve (33). Install the
IMPORTANT: Apply grease onto O-ring(2) on the sleeve into body H (37). Install control piston (32)
outer diameter on seal holder(3) and into the sleeve.
oil seal(4) lip part. : 35 mm(sleeve)
2. Install oil seal (4) and O-ring (2) onto seal holder : 50 to 60 N m (5.1 to 6.1 kgf m, 37 to 44
(3). Install seal holder (3) onto shaft (5) using lbf ft)
special tool (ST 7274) to install retaining ring (1).
14. Install spring pin (35) for valve plate (27), valve
3. Install O-ring (9) onto plug (8). Install plug (8) into plate (27), spring guide (31), pins (12) (2 used),
body S (10). and gasket(11) into body h(37).
: 6 mm NOTE: Refer to W2-3-4 as for pin (12).
NOTE: Refer to W2-3-4 as for plug (8) and O-ring
(9).
W2-3-7
UPPERSTRUCTURE / Pump Device
30
46
48
49
47
10
37 W1LD-02-03-002
44
48 49
36
W1LD-02-03-003
W2-3-8
UPPERSTRUCTURE / Pump Device
15. Cover body S (10) with body H (37) aligning pins
(12) (2 used) position. Install and tighten
temporary bolts (M10, length 60 mm) (2 used)
into the socket bolt (44) holes on spring (30) side.
: 8 mm
W2-3-9
UPPERSTRUCTURE / Pump Device
MAINTENANCE STANDARDS
D d
W507-02-04-009
Plunger
W107-02-06-140
W2-3-10
UPPERSTRUCTURE / Control Valve
REMOVE AND INSTALL CONTROL VALVE 1
Removal
Control Valve
CAUTION: Plate weight: 8 kg 3
Control valve weight: 60 kg
3. Remove bolts (4) (4 used) to remove plate (5)
from main frame (6).
: 17 mm
W1LD-02-04-002
8 7 6
W2-4-1
UPPERSTRUCTURE / Control Valve
4. Attach the nylon slings to the caps of control
Nylon 4
valve. Lift control valve (8) with plate (5) and re- Sling
move from the main frame by crane.
Nylon
Sling
Nylon
Sling
5
Nylon 8
Sling
W1LD-02-04-001
W1LD-02-04-002
8 7
W2-4-2
UPPERSTRUCTURE / Control Valve
Installation 4
: 49 N m (5 kgf m) 8 7
Nylon
Sling
4
2. Attach the nylon slings to the caps of control
valve. Lift control valve (8) with plate (5) by crane.
Install the control valve onto the main frame with Nylon
bolts (4) (4 used). Sling
: 17 mm
: 49 N m (5 kgf m)
W2-4-3
UPPERSTRUCTURE / Control Valve
4. Install covers (3, 2, and 1) onto the main frame. 1
: 13 mm
: 10 N m (1.0 kgf m)
M1LD-05-007
Control Valve
3
W2-4-4
UPPERSTRUCTURE / Control Valve
(Blank)
W2-4-5
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE CONTROL VALVE
21
14
20 13 22
18
18
19 23
18
14 13 24
17 25
16 26
27
15 28
29
30
12
11 29
10 33
35
9 31 34
29 32
2
3 1-a
4 29
5
6
7 9 30
8
31
21
30
47 20 1-b 29
48
55
49 54
50 53
51
52
56
57
58 47
59 77
39 48
49 55
40 60 50 54
41 61
42 51 53
43
44 52
1-c 77 56
45 57
46 36 58 47 77
37 76 59 48
75 55
38 74 49
73 54
72 50
71 51 53
70
69
68 52
67 39
66 1-d 77 56
57
65 37 58
40 38 59
41
42
43
44
62
9 1-e
63
64 39
40 37
38
41
42
43
44
45 W1LD-02-04-003
46
W2-4-6
UPPERSTRUCTURE / Control Valve
W2-4-7
UPPERSTRUCTURE / Control Valve
47 77
55
48 54
49 53
50
51 56
77
52 57
58 47 78
59 48 55
49 54
50 53
51
52
56
39 57
40 1-f 58
41 59
37
42 38 39
43 40
44 41 37
46 42
45 43 38 1-g 79
45 44
47 55
46 48 54
49 53
50
51 56
52 57
79 58 47
59 48 55
49 54
50 53
51
52
56
1-h 57
39 58
40 37 59
41 38 39
42
40
43 41
44 42 36
46 37 1-i
43 38
45 44
47 55
48 54
49 53
50
46 51
45 52 56 77
57
58
39 59 55
40 47 54
41
42 48 53
43 36
44 37 1-j 56
38
57
58
39 59
40
41
42
43
46
44 1-k
45
37
38
46 W1LD-02-04-004
45
W2-4-8
UPPERSTRUCTURE / Control Valve
W2-4-9
UPPERSTRUCTURE / Control Valve
Remove and Install Relief Valve and Make-up Valve
22
23
10 35
77
77
78
79
79
77
T1LD-03-04-001
10 - Differential Pressure 23 - Main Relief Valve 77 - Overload Relief Valve (7 Used) 79 - Plug (2 Used)
Reducing Valve
22 - Relief Cut Valve 35 - Safety Lock Valve 78 - Make-Up Valve
W2-4-10
UPPERSTRUCTURE / Control Valve
Removal Installation
1. Remove differential pressure reducing valve (10). 1. Install plugs (79) (2 used).
: 24 mm : 21 mm
: 64 to 68 N m (6.5 to 6.9 kgf m, 47 to 50
2. Remove relief cut valve (22). lbf ft)
: 27 mm
2. Install make-up valve (78).
3. Remove main relief valve (23). : 26 mm
: 26 mm : 59 to 63 N m (6.0 to 6.4 kgf m, 44 to 46
lbf ft)
4. Remove safety lock valve (35).
: 24 mm 3. Install overload relief valves (77) (7 used).
: 26 mm
5. Remove overload relief valves (77) (7 used). : 59 to 63 N m (6.0 to 6.4 kgf m, 44 to 46
: 26 mm lbf ft)
W2-4-11
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BODY
Tie Rod Nut
Unload Section
Washer
B B
1 mm
Function
Section
T1LD-03-04-001
29
A
60
61
32
1 A
Cross Section A-A
T566-03-03-009 Cross Section B-B
W566-02-04-005
W2-4-12
UPPERSTRUCTURE / Control Valve
Disassemble Assemble
IMPORTANT: Take care not to drop off O-rings 1. Install check valve (60), O-rings (29,30,31,and
(29,30,31, and 32). 32) into each section. Install spring (61) into the
bore of check valve (60).
NOTE: As for O-rings (30 and 31), refer to W2-4-6
1. Remove the nuts (4 used). Remove the washers
to 8.
(4 used) and tie rods (4 used) to divide the control
valve into each section.
: 17 mm IMPORTANT: Pay attention to the direction of tie
rod. Install the tie rod with its longer
2. Remove O-rings (29,30,31,and 32) from each thread side facing unload section.
section. Remove spring (61) and check valve (60) IMPORTANT: When installing the function sec-
from each section with a magnet. tions, install them 1mm away from
NOTE: As for O-rings (30 and 31), refer to W2-4-6 the unload section and piping port
to 8. section. Assemble it putting a metal
plate( thickness : 1mm) beneath the
function sections.
W2-4-13
UPPERSTRUCTURE / Control Valve
DISASSEMBLE UNLOAD SECTION
B C C B
9 18 19 12 22
11
A 10
23
8
24
7 6 5 4 3 2 1 28 27 26 25
16 17 13 14 20 21
15 18 18
W2-4-14
UPPERSTRUCTURE / Control Valve
Disassemble Unload Section IMPORTANT: Never loosen the lock nut of relief
cut valve (22). If loosened, the set
Read PRECAUTIONS FOR DISASSEMBLING pressure may be changed.
AND ASSEMBLING (W1-1-1) carefully before 4. Remove relief cut valve (22) from body (1).
disassembling. : 27 mm
IMPORTANT: Never turn the lock nut of relief valve. IMPORTANT: Never loosen the lock nut of differ-
If turned, the set pressure may be ential pressure reducing valve (10).
changed. If loosened, the set pressure may be
1. Remove main relief valve (23) from body (1). changed.
: 26 mm 5. Remove differential pressure reducing valve (10)
from body (1). Remove the piston and spring from
IMPORTANT: Do not remove steel ball (2) from body (1) with a magnet.
spring seat (3). When replacing : 24 mm
these parts, replace them as an as-
sembly. When removing retainer (6) Guide Spring
from body (1), spring (4) and spring
seat (3) tend to come off together
with retainer (6). When removing re- 10
tainer (6), take care not to drop
spring (4) and spring seat (3).
IMPORTANT: Never loosen adjuster (8) and the
nut of retainer (6). If loosened, the
set pressure may be changed.
2. Remove retainer (6) from body (1). Remove
spring (4) and spring seat (3) from body (1) with a
magnet.
: 24 mm
Piston 1 T566-03-03-005
IMPORTANT: When removing piston (26) from
body (1), spring (27) is removed to-
gether with the piston. When remov- 6. Install the bolt (M8, pitch 1.25) into the guide hole
ing piston (26), take care not to drop to pull the guide out of body (1).
off spring (27).
3. Remove plug (24) from body (1). Remove piston 7. Remove plug (15) from body (1). Remove spring
(26) and spring (27) from body (1) with a magnet. (16) and strainer (17) from body (1).
: 8 mm : 8 mm
W2-4-15
UPPERSTRUCTURE / Control Valve
ASSEMBLE UNLOAD SECTION
B C C B
9 18 19 12 22
11
A 10
23
8
24
7 6 5 4 3 2 1 28 27 26 25
16 17 13 14 20 21
15 18 18
W2-4-16
UPPERSTRUCTURE / Control Valve
Assemble Unload Section 5. Install plug (24) into body (1).
: 8 mm
Read PRECAUTIONS FOR DISASSEMBLING : 59 to 69 N m (6 to 7 kgf m, 44 to 51 lbf ft)
AND ASSEMBLING (W1-1-1) carefully before as-
sembling. 6. Insert spring (4) into retainer (6) until spring (4)
comes in contact with adjuster (8) to install spring
Apply grease onto the seals. seat (3) to spring (4).
1. Install strainer (17) , spring (16) , and plug (15) 7. Install the retainer (6) assembly to body (1) while
wound with a seal tape to body(1). taking care not to drop off spring seat (3) and
: 8 mm spring (4).
: 54 to 58 N m (5.5 to 5.9 kgf m, 40 to 43 : 24 mm
lbf ft) : 54 to 59 N m (5.5 to 6.0 kgf m, 40 to 44
lbf ft)
2. Install the guide, piston, and spring to differential 8. 8.Install main relief valve (23) into body (1).
pressure reducing valve (10). Install differential : 26 mm
pressure reducing valve (10) to body (1) while tak- : 69 to 78 N m (7.0 to 8.0 kgf m, 51 to 58
ing care not to drop off the guide, piston, and lbf ft)
spring.
: 24 mm
: 79 to 83 N m (8.1 to 8.5 kgf m, 58 to 61
lbf ft)
Guide Spring
10
Piston 1 T566-03-03-005
W2-4-17
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SPOOL
39
46 45 41 40
53 54
55
43 42 44
1
W566-02-04-005
W2-4-18
UPPERSTRUCTURE / Control Valve
Disassemble Assemble
1. Remove socket bolts (45) (2 used) from body (1). 1. Install the spool (39) assembly into body (1).
Remove cover (46) and O-ring( 44) from body (1).
: 5 mm 2. 2.Install O-ring (53) onto cover (54). Install the
cover onto body (1) with socket bolts (55) (2
2. Pull spool (39) as am assembly out of body (1). used).
NOTE: The spool (39) assembly consists of spool : 5 mm
(39), bolt (43), retainer (42),spring (41), : 10 to 12 N m (1.0 to 1.2 kgf m, 7.4 to 8.9
and retainer (40). lbf ft)
NOTE: Do not remove bolt (43), retainer (42),
spring (41) and retainer (40) from spool 3. Install O-ring (44) onto cover (46). Install the
(39). cover onto body (1) with socket bolts (45) (2
When replacing these parts, replace them used).
as an assembly. : 5 mm
: 10 to 12 N m (1.0 to 1.2 kgf m, 7.4 to 8.9
3. Remove socket bolts (55) (2 used) from body (1) lbf ft)
to remove cover (54) and O-ring (53).
: 5 mm
W2-4-19
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE BOOM SECTION
66 67 70 69 71 72
65
68
63 62 73 74 75 76
1
T566-03-03-010
W2-4-20
UPPERSTRUCTURE / Control Valve
Disassemble Assemble
IMPORTANT: Do not remove choke (63), plug (66), 1. Install poppet (76) into body (1). Install spring (75)
and set screw (74). into the poppet (76) hole.
IMPORTANT: When removing cover (62) from
body (1), piston (68) tends to come IMPORTANT: Apply grease onto O-rings (69 and
off together with cover (62). Take 72). Install sleeve (70) so that spring
care not to drop piston (68). (75) can be aligned with the spring
1. Remove socket bolts (64) (2 used) and (65) (2 mounting position in sleeve (70).
used) from body (1) to remove cover (62) and pis- 2. Install O-rings (69,72) and backup ring (71) onto
ton (68). sleeve (70). Install the sleeve (70) assembly into
: 5 mm body (1).
3. Install piston (68) and O-ring (67) into cover (62).
2. Install the bolt (M12, pitch 1.75) into the sleeve
(70) hole to pull the sleeve (70)assembly out of 4. Install the cover (62) assembly to body (1) with
body (1). socket bolts (65) (2 used) and (64) (2 used) while
taking care not to drop off piston (68).
NOTE: The sleeve (70)assembly consists of
: 5 mm
sleeve (70), steel ball (73), and set screw
: 10 to 12 N m
(74).
(1.0 to 1.2 kgf m, 7.4 to 8.9 lbf ft)
IMPORTANT: Check if spring (75) stays in body
(1).
3. Remove spring (75) and poppet (76) from body
(1) with a magnet.
W2-4-21
UPPERSTRUCTURE / Control Valve
DISASSEMBLE AND ASSEMBLE SHUT-
TLE VALVE AND PRESSURE COMPEN-
SATION VALVE
52 48 47 49 50 51
38 37 36 59 58 57 56
W566-02-04-005
W2-4-22
UPPERSTRUCTURE / Control Valve
Disassemble Assemble
IMPORTANT: When removing the spool (59) as- 5. Install the seat(49) assembly into body (1).
sembly, take care not to drop piston
(58). 6. Install plug (47) into body (1).
5. Remove plug (56). Push the spool (59) assembly : 6 mm
with piston (58) out from plug (38) side by finger : 30 to 34 N m (3.1 to 3.5 kgf m, 22 to 25
and remove the spool (59) assembly with piston lbf ft)
(58) from body (1).
W2-4-23
UPPERSTRUCTURE / Control Valve
(Blank)
W2-4-24
UPPERSTRUCTURE / Swing Device
REMOVE AND INSTALL SWING DEVICE
Removal
M1LD-01-001
Eyebolt
7
Eyebolt
W1LD-02-05-002
10 9 8
W1LD-02-05-003
14
W2-5-1
UPPERSTRUCTURE / Swing Device
Installation
13
CAUTION: Swing device weight: 50 kg
1. Install swing device (13) to the frame with bolts
(14) (8 used).
: 24 mm
: 205 N m (21 kgf m, 151 lbf ft)
M1LD-01-001
W2-5-2
UPPERSTRUCTURE / Swing Device
(Blank)
W2-5-3
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING REDUCTION
GEAR
20
21
1 Swing Motor
22
23 2
4
29
24 5
25 6
7
26
8
9
27
10
11
28 12
13
14
15
19
16
17
18
W571-02-05-005
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-4
UPPERSTRUCTURE / Swing Device
Disassemble Swing Reduction Gear 9. Remove shaft (28) from housing (23) with a
press.
Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before 10. Remove the inner race of roller bearing (24),
disassembling. spring plate (25), thrust plate (26) and plate (27)
from shaft (28) with a press.
CAUTION: Swing motor weight: 13 kg IMPORTANT: Do not remove the outer races of
roller bearings (21) and (24) from
1. Remove socket bolts (1) (4 used) from the swing housing (23). Failure to follow these
motor, then remove the swing motor. instructions will shorten service life
: 6 mm of the bearings as press-fit force of
roller bearing (21 and 24) outer
2. Remove socket bolts (17) (9 used) from ring gear races is reduced. Always replace
(18). housing (23) with a new one if the
: 8 mm bearings are removed.
11. Remove oil seal (22) from housing (23).
3. Remove ring gear (18), first stage carrier (8)
assembly, second stage sun gear (10) and
second stage carrier (13) assembly from housing
(23).
Remove retaining ring (9) from second stage sun
gear (10).
(ST 7313)
W1LD-02-05-001
W2-5-5
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING REDUCTION GEAR
30
2
3
17
6
4
7
5
8
18
15
9
14
10
12 11
16 13
19 20
23 21
22 29
25 24
26
27
28
W571-02-05-004
1- Socket Bolt (4 Used) 9- Retaining Ring 17 - Socket Bolt (9 Used) 25 - Spring Plate
2- O-Ring 10 - Second Stage Sun Gear 18 - Ring Gear 26 - Thrust Plate
3- Retaining Ring (3 Used) 11 - Thrust Plate 19 - Spring Pin (4 Used) 27 - Plate
4- Plate 12 - Pin (4 Used) 20 - Nut 28 - Shaft
5- First Stage Sun Gear 13 - Second Stage Carrier 21 - Roller Bearing 29 - Plug
6- First Stage Planetary Gear 14 - Second Stage Planetary 22 - Oil Seal 30 - Swing Motor
(3 Used) Gear (4 Used)
7 - Needle Bearing (3 Used) 15 - Needle Bearing (4 Used) 23 - Housing
8 - First Stage Carrier 16 - Thrust Plate (4 Used) 24 - Roller Bearing
W2-5-6
UPPERSTRUCTURE / Swing Device
Assemble Swing Reduction Gear
: 5 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
W2-5-7
UPPERSTRUCTURE / Swing Device
3
17
6
4
7
5
8
18
15
14 10
12
11
16
13
20
23
28
W571-02-05-004
W2-5-8
UPPERSTRUCTURE / Swing Device
7. Adjust the roller bearing pre-load. 5) Tighten nut (20) onto shaft (28) using a special
tool (ST 7313).
Starting Torque
: 152 N m (15.5 kgf m, 112 lbf ft)
(ST7313)
17 W1LD-02-05-001
W2-5-9
UPPERSTRUCTURE / Swing Device
30
2
17
8
18
12 10
13
19 20
23
28
W571-02-05-004
W2-5-10
UPPERSTRUCTURE / Swing Device
IMPORTANT: Drive in spring pins (19) (4 used) IMPORTANT: Install retaining ring (9) with its
with its slit facing upward (motor chamfered corner facing upwards.
side).
12. Install retaining ring (9) onto second stage sun
10. Align pin holes on second stage carrier (13) and gear (10). Install second stage sun gear (10) into
pins (12) (4 used), then drive spring pins (19) (4 second stage carrier (13).
used) into the carrier.
13. Install first stage carrier (8) assembly into second
stage carrier (13) assembly.
19 : 8 mm
W571-02-05-007
: 69 N m (7 kgf m, 51 lbf ft)
IMPORTANT: Install second stage carrier (13)
aligning splines so that the pin on 15. Add approx. 0.7 litter (0.185 US gal) of hydraulic
second stage carrier (13) is inserted oil into the swing reduction gear.
into the hole of nut (20). Confirm
dimension A shown in the 16. Install O-ring (2) onto swing motor (30). Install the
illustration is approx. 18.5 mm. If swing motor onto ring gear (18). Tighten socket
dimension A is approx. 27.5 mm, it bolts (1) (4 used).
indicates that pin is not inserted into
the hole on nut (20) properly. : 6 mm
: 29 N m (3 kgf m, 21 lbf ft)
13
Pin
20
W571-02-05-006
W2-5-11
UPPERSTRUCTURE / Swing Device
DISASSEMBLE SWING MOTOR 8
6
5
4
13
14
15
16
17
18
19
20
21
22
11
10
9
30
29
28
27
26
25
24
23 W1LD-02-05-005
1- Friction Plate (2 Used) 9- Collar 17 - Rotor 24 - Cover
2- Disc Plate (2 Used) 10 - O-Ring 18 - Collar 25 - Pin
3- Swash Plate 11 - O-Ring 19 - Spring 26 - Bearing
4- Shaft 13 - Plunger (9 Used) 20 - Washer 27 - Valve Plate
5- Bearing 14 - Retainer 21 - Retaining Ring 28 - Spring (22 Used)
6- O-Ring 15 - Holder 22 - Pin 29 - Brake Piston
7- Case 16 - Pin (3 Used) 23 - Socket Bolt (3 Used) 30 - O-Ring
8- O-Ring
W2-5-12
UPPERSTRUCTURE / Swing Device
Disassemble Swing Motor
CAUTION: Always use a special tool on
Read PRECAUTIONS FOR DISASSEMBLING washer (20) to press spring (19) when
AND ASSEMBLING (W1-1-1) carefully before removing retaining ring (21). If retaining ring
disassembling. (21) is removed without pressing, washer
(20) and spring (19) may fly out, possibly
IMPORTANT: Be careful not to allow valve plate causing serious injury.
(27) to fall when removing cover
(24). 7. Press washer (20) and spring (19) using a special
tool (ST 7314). Remove retaining ring (21) to
1. Put matching marks on cover (24) and case (7). remove washer (20), spring (19) and collar (18)
Loosen socket bolts (23) (3 used). Remove cover from rotor (17).
(24) and valve plate (27) in this order.
: 12 mm
(ST7314)
2. Remove springs (28) (22 used) and O-ring (6)
from case (7).
21
CAUTION: When removing brake piston (29)
using compressed air, be sure to cover the
brake piston with rags to prevent the piston 20
from flying out. 19
3. Remove brake piston (29) and O-ring (30) from
18
case (7) by applying compressed air into the pilot
port on case (7).
W2-5-13
UPPERSTRUCTURE / Swing Device
ASSEMBLE SWING MOTOR
22 23 28 27 21 20 26 24
25
30
29
17
10
11
19 9
18
1
16
2
7
13
8
W555-02-05-003
15 5 4 3 14
W2-5-14
UPPERSTRUCTURE / Swing Device
Assemble Swing Motor
8. Install friction plates (1) (2 used) and disc plates
Read PRECAUTIONS FOR DISASSEMBLING (2) (2 used) to rotor (17) one by one alternately in
AND ASSEMBLING (W1-1-1) carefully before place.
assembling.
IMPORTANT: Do not tap collar (9) with a plastic
IMPORTANT: If ball bearing (5) has been removed, hammer or similar instrument to
press bearing (5) onto shaft (4) install collar (9). Collar (9) and / or
beforehand. case (7) may be damaged. Use a
Press ball bearing (5) until the end of press to install collar (9) into case
ball bearing (5) is flush with the end (7).
surface of case (7).
9. Install O-rings (10) and (11) onto collar (9), and
1. Press shaft (4) and ball bearing (5) assembly into press them into case (7).
case (7).
(ST7314)
21
20
19
17
W1LD-02-05-004
W2-5-15
UPPERSTRUCTURE / Swing Device
23 28 27 24
30
29
W555-02-05-003
W2-5-16
UPPERSTRUCTURE / Swing Device
IMPORTANT: Do not tap brake piston (29) with a
plastic hammer or similar
instrument to install brake piston 29
(29). Brake piston (29) and / or case
(7) may be damaged. Use a press to
install brake piston (29) into case (7)
as the illustration.
11. Install springs (28) (22 used) and O-ring (6) into
case (7).
: 12 mm
: 177 10 N m (18 1 kgf m, 131 7.4 lbf ft)
W2-5-17
UPPERSTRUCTURE / Swing Device
MAINTENANCE STANDARDS
D d
W507-02-04-009
W107-02-06-140
W509-02-04-010
W2-5-18
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL FRONT PILOT 4
VALVE
Removal
reassembly.
8. Remove bolts (14) (8 used) to remove pilot valves
(13) ( 2used) from the lever stand.
: 13 mm
W2-6-1
UPPERSTRUCTURE / Pilot Valve
Installation
5
1. Insert pilot valves (13) (2 used) into the lever
stand and align the matching marks made when
6
disassembling.
7
2. Install pilot valves (13) (2 used) to the lever stand Pilot Shut-off
with bolts (14) (8 used). Lever 8
: 13 mm 9
10
: 10 N m (1 kgf m, 7.4 Ibf ft)
11
16
3. Connect hoses (12) (12 used) to pilot valves (13) 15
(2 used).
: 19 mm
: 29.5 N m (3 kgf m, 22 Ibf ft)
14
4. Insert levers (7) (2 used) (with grip (5)) into boots
13
(4) (2 used). Install levers (7) (2 used) into pilot
Left Stand Pilot
valves (13) (2 used). When installing, lever (7) 12 T532-02-06-002
Shut-off Switch
with horn button should be installed on left side.
W2-6-2
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INASTALL TRAVEL PILOT
VALVE
Removal
W2-6-3
UPPERSTRUCTURE / Pilot Valve
Installation
4
2. Install the cover (8) assembly to the floor with
bolts (11) (4 used). 5
: 13 mm 6
: 10 N m (1 kgf m, 7.4 lbf ft)
W1LA-02-05-006
W2-6-4
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BLADE PILOT
VALVE
Removal 4
1 2 M1LA-05-004
: 19 mm
7
NOTE: Hold hoses (7) (4 used) with a wire to
prevent them from falling down.
W2-6-5
UPPERSTRUCTURE / Pilot Valve
Installation
3 4
1. Install pilot valve (6) to bracket (9) with bolts (5) (2
used). 5
: 13 mm 9
: 10 N m(1 kgf m, 7.4 lbf ft) 6
W1LA-02-06-005
7
4. Install lever (4) with bolts (3) (2 used).
: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft)
4
W2-6-6
UPPERSTRUCTURE / Pilot Valve
REMOVE AND INSTALL BOOM SWING
PILOT VALVE
Removal
1
Floor
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1.)
1. Remove bolts (2) (4 used) and wing bolt (3) to
remove cover (1) from the main frame.
: 13 mm
W1LA-02-05-006
3
3. Remove socket bolts (13) (2 used) to remove
pedal (6) from pilot valve (7).
: 6 mm
4
4. Remove bolts (12) (2 used) from pilot valve (7).
: 13 mm
13
5
5. Remove bolts (11) (2 used) in plate (9).
: 13 mm
6
IMPORTANT: Attach identification tags onto the 12
disconnected hoses to aid in 11
reassembly.
6. Disconnect hoses (10) (4 used) from pilot valve 7
(7). Attach a cap onto the open ends.
: 19 mm 8
10
10
W1LD-02-06-001
W2-6-7
UPPERSTRUCTURE / Pilot Valve
Installation
12
11
3. Install pilot valve (7) assembly to the floor with
bolts (11) (2 used). 7
: 13 mm
: 10 N m(1 kgf m, 7.4 lbf ft)
8
W1LA-02-05-006
3
W2-6-8
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-6-9
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE FRONT PILOT VALVE
13
12
14
11
15
11
10
8
8
7
9
21
6
20
16 21
5
20
4 5
19
3 6
3 18
2
4
1
17
W567-02-06-002
W2-6-10
UPPERSTRUCTURE / Pilot Valve
Disassemble Front Pilot Valve
IMPORTANT: Block (10) and housing (18) are IMPORTANT: Two kinds of push rods are used.
made of aluminium. Too strong a They must be handled in order of
force can deform, or damage them. port number after removing.
Therefore, handle with care.
4. Pull push rods (8) (2 used) and (9) (2 used) out of
IMPORTANT: As spool (17) has been selected to block (10).
match the hole of housing (18), they
must be replaced as a set. In 5. Remove oil seals (15) (4 used) from block (10)
addition, the dimensions of balance with a bamboo spatula.
springs A (3), B (4) and return NOTE: If a metal bar is used, the mating part of oil
springs A (5), B (6) as well as those seal may be damaged.
of push rods A (8), B (9) are different.
For this reason, be sure to indicate IMPORTANT: Retaining ring (7) may come off
the port number from which each is while disassembling. Take care not
removed. Port numbers are stamped to drop it.
on housing (18). 6. Press springs with special tool (ST 7257) from the
top of spring guide (16). Retaining ring (7) will
IMPORTANT: Do not clamp housing (18) in a vise appear. Remove it with a screwdriver or similar
to remove the screw joint (13) tool. (4 places)
because the screw joint may be
damaged. 7
1. Clamp screw joint (13) in a vise. Then turn cam
(12) with a spanner to remove the screw joint.
: 32 mm
W2-6-11
UPPERSTRUCTURE / Pilot Valve
21
20
21
20
19
18
17
W567-02-06-002
W2-6-12
UPPERSTRUCTURE / Pilot Valve
IMPORTANT: As the spool (17) has been selected
to match the hole of the housing (18),
keep them carefully so as to install
them to the former port when
reassembling.
8. Remove spool (17) from housing (18). Pulling it
out while turning it slowly.
NOTE: The spool and the housing must be
replaced as an assembly.
W2-6-13
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE FRONT PILOT VALVE
13
14
12
10
11 15 8, 9
16
3, 4
21 5, 6
2
19
20 1
17
W567-02-06-001
18
W2-6-14
UPPERSTRUCTURE / Pilot Valve
Assemble Front Pilot Valve
IMPORTANT: The pilot valve is susceptible to IMPORTANT: Install spring guide (16), with the
contamination. Keep parts clean protrusion facing upward.
when assembling. 3. Install spring guides (16) (4 used) onto return
springs (3) (2 used) or (4) (2 used).
NOTE: Table below shows the relations between
each port and the components. Take care 4. Install retaining ring (7) onto ring holder (ST
not to confuse them when assembling. 7255).
ST 7255
7
Port Spool Shim Push rods
No. (17) (2) (8), (9)
1 with outer
Same to Same to groove
2 the former the former without outer W176-02-07-008
1 short short
2 long long 17
3 short short
4 long long
Packing Material
IMPORTANT: Make sure of the port hole number 16
and insert the spool (17) to the
former port. W176-02-07-009
1. Insert the thinner end of spools (17) (4 used) to NOTE: Put approx. dia.8 mm, length 10 mm of
housing (18), then push the spool in rotating it. packing material into the port hole so as to
NOTE: The spool has been selected to match the not only make the work easy to do, but also
hole of the housing. The spool and housing prevent the spool from lowering to the
must be replaced as an assembly. bottom when compressing the spring.
IMPORTANT: Refer to the table above to assemble 6. Assemble remained spools (17) (3 used) into
them correctly. housing (18) in the same procedures as step 2 to
2. Install the spacers (1) (4 used), shim (2), balance 5.
springs (3) (2 used) or (4) (2 used), return springs
(5) (2 used) or (6) (2 used) onto spool (17) 7. Install O-rings (19) and (21) (2 used) onto
installed in housing (18). housing (18).
W2-6-15
UPPERSTRUCTURE / Pilot Valve
13
14
12
10
11 15 8, 9
20
W567-02-06-001
18
W2-6-16
UPPERSTRUCTURE / Pilot Valve
8. Apply grease to the inner faces of oil seals (15) (4 IMPORTANT: Make sure of the tighteness of cam.
used), then install the oil seals (4 used) into block 13. Clamp housing (18) carefully in a vise and then
(10) with a bamboo spatula. install cam (12) to universal joint (14).
NOTE: As shown bellow, insert push rods (8) and Tighten the universal joint so that the clearance
(9) first, then install oil seal (15). This between the cam and push rods (8) (2 used) and
prevents the oil seal from entering into the (9) (2 used) becomes 0 to 0.2 mm.
hole. : 32 mm
W176-02-07-007
W2-6-17
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE TRAVEL PILOT VALVE
18 19
20
19
21
7 8 17 20 22
9 21
10 22 23
11 18
16
5 23
17
6 15 24
7
14
16 24 25
5 35
15
12 25
4
14
3 34
4 13
2 3
2 33
1 32
1
26
27
28
29
30
31
W585-02-06-006
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-18
UPPERSTRUCTURE / Pilot Valve
Disassemble Travel Pilot Valve
IMPORTANT: As the spool (23) assemblies (4
Thoroughly read PRECAUTIONS FOR used) are adjusted by the pressure
DISASEMBLING AND ASSEMBLING (W1-1-1) of shim (21), they should not be
prior to disassembling. disassembled. If disassembling the
Spool (23) has been selected to match the hole of spool (23) assemblies, record the
casing (34). number and thickness of shim (21).
The spool and casing must be replaced as an 7. Remove spool (23) assemblies (2 used), O-rings
assembly. (25) (4 used) and (35) (2 used), and springs (24)
Put identification tags on the disassembled parts (4 used) from casing (34).
by port to aid when re-assembling.
8. Remove spring guides (19) (4 used), springs (20)
(4 used), shims (21) (4 used), and washers (22)
IMPORTANT: Put the mating marks onto cam (10), (4 used) from spool (23) assemblies (4 used).
pin (11) and cover (12), casings (13,
34) before disassembling.
1. Clamp the pilot valve in a vise to remove boot (8)
from cover (12).
W2-6-19
UPPERSTRUCTURE / Pilot Valve
5
12
34
26
27
28
29
30
31
W585-02-06-006
W2-6-20
UPPERSTRUCTURE / Pilot Valve
9. 9.Remove plugs (31) (2 used) and O-rings (30) (2
used) from casing (34).
: 6 mm
W2-6-21
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE TRAVEL PILOT VALVE
9
8 11 5
6 10
18 4
3
2
7
12
1
17
16
35
15 13
19
14
31
25
30
20
21
24
22
32
33
23 C C
34
27
29 28 W585-02-06-008
26
Cross SectionC-C
W585-02-06-007
1- O-Ring (4 Used) 10 - Cam (2 Used) 19 - Spring Guide (4 Used) 28 - Steel Ball (2 Used)
2- Bushing (4Used) 11 - Pin (2 Used) 20 - Spring (4 Used) 29 - Seat (2 Used)
3- Packing (4 Used) 12 - Cover (2 Used) 21 - Shim (4 Used) 30 - O-Ring (2 Used)
4- Grease Cup (4 Used) 13 - Casing 22 - Washer (4 Used) 31 - Plug (2 Used)
5- Bushing (4 Used) 14 - Steel Ball (12 Used) 23 - Spool (4 Used) 32 - Plug (3 Used)
6- Steel Ball (4 Used) 15 - Spring Seat (4 Used) 24 - Spring (4 Used) 33 - O-Ring (3 Used)
7- Socket Bolt (4 Used) 16 - Spring (4 Used) 25 - O-Ring (4 Used) 34 - Casing
8- Boot (2 Used) 17 - Piston (4 Used) 26 - Seat (2 Used) 35 - O-Ring (2 Used)
9- Set Screw (2 Used) 18 - Push Rod (4 Used) 27 - Bushing (2 Used)
W2-6-22
UPPERSTRUCTURE / Pilot Valve
Assemble Travel Pilot Valve
7. Install push rods (18) (4 used) and bushing (2)
Thoroughly read PRECAUTIONS FOR assemblies (4 used) to casing (13).
DISASEMBLING AND ASSEMBLING (W1-1-1)
prior to assembling. 8. Install bushings (5)(4 used) to covers (12) (2
Clean the parts and put them by port for used).
assembling.
W585-02-06-005
Lip Part
W2-6-23
UPPERSTRUCTURE / Pilot Valve
9
11
8 10
18 4
12
C C
W585-02-06-008
W585-02-06-007
W2-6-24
UPPERSTRUCTURE / Pilot Valve
10. Install grease cups (4) (4 used) to push rods (18)
(4 used).
W2-6-25
UPPERSTRUCTURE / Pilot Valve
DISASSEMBLE BLADE AND BOOM
SWING PILOT VALVE
20
7 20
8 19
6
9 19
18
4 18 17
10
5 16
17
16
6 15
15
4
11 14
14
3
3 12
13
2
2
21
1
1
W1LA-02-06-001
W2-6-26
UPPERSTRUCTURE / Pilot Valve
Disassemble Blade and Boom Swing Pilot Valve
7. Remove spring guides (19) (2 used), springs (18)
Read PRECAUTIONS FOR DISASEMBLING (2 used), washers (16) (2 used), and shims (17)
AND ASSEMBLING (W1-1-1) carefully before (2 used) from spool (15) assemblies (2 used).
disassembling.
Spool (15) has been selected to match the hole of IMPORTANT: As the spool (15) assemblies (2
casing (21). used) are adjusted by the pressure
The spool and casing must be replaced as an of shim (17), they should not be
assembly. disassembled. If disassembling the
Discriminate between the disassembled parts by spool (15) assemblies, record the
port No. where the parts are located in order to quantity and thickness of shim (17).
avoid confusion. IMPORTANT: Do not remove bushing (4) from
cover (11) unless bushing (4) is
IMPORTANT: Put the mating marks onto cam (9), damaged.
pin (10), cover (11), and casing (21) 8. Pull bushings (4) (2 used) out of cover (11).
before disassembling.
1. Clamp the pilot valve in a vise to remove boot (7)
from cover (11).
2. Remove set screw (8) from cam (9). Pull pin (10)
out to remove cam (9) from cover (11).
: 2 mm
NOTE: LOCTITE is applied onto the set screw.
NOTE: Steel ball (5) cannot be disassembled from
cam (9).
W2-6-27
UPPERSTRUCTURE / Pilot Valve
ASSEMBLE BLADE AND BOOM SWING
PILOT VALVE
8 10
7
9
5
20
3
6
2
11
19
18
14
17
16
12
13
15 W1LA-02-06-002
21
W2-6-28
UPPERSTRUCTURE / Pilot Valve
Assemble Blade and Boom Swing Pilot Valve
8. Apply LOCTITE #241 onto set screw (8). Secure
Read PRECAUTIONS FOR DISASEMBLING cam (9) and pin (10) with set screws (8).
AND ASSEMBLING (W1-1-1) carefully before : 2 mm
assembling. : 5 N m (0.5 kgf m, 3.7 lbf ft)
Clean the parts and put them by port for
assembling. 9. Install boot (7) to cover (11).
W585-02-06-005
Lip Part
W2-6-29
UPPERSTRUCTURE / Pilot Valve
(Blank)
W2-6-30
UPPERSTRUCTURE / Solenoid Valve
DISASSEMBLE AND ASSEMBLE SOLENOID VALVE
1 3 2
W574-02-07-001
W2-7-1
UPPERSTRUCTURE / Solenoid Valve
7
1
8
3
6
9
10
11
12
13
W574-02-07-002
W2-7-2
UPPERSTRUCTURE / Solenoid Valve
Disassemble Solenoid Valve Assemble Solenoid Valve
1. Loosen nut (7), then remove solenoid (8). 1. Install spool (6), washer (5), spring (4) and
washer (3) into housing (13).
: 19 mm
3. Remove guide (1) from housing (13). 3. Install spring (12) and spool (11) into housing
(13).
: 24 mm
: 19 mm
: 4.9 N m (0.5 kgf m, 3.6 lbf ft)
W2-7-3
UPPERSTRUCTURE / Solenoid Valve
Blank
W2-7-4
UPPERSTRUCTURE / Revolution Sensing Valve
REMOVE AND INSTALL REVOLUTION 1 2
SENSING VALVE
Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)
3
1. Open engine cover (1). Insert rod (3) into hole (2)
for the lock to lock engine cove (1).
4 SS-2304
M1LD-07-017
M1LD-07-013
M1LD-07-014
W2-8-1
UPPERSTRUCTURE / Revolution Sensing Valve
4. Disconnect all hoses from revolution sensing 7
valve (8). Cap all the disconnected hoses. Attach 8
tags onto them to aid reassembly.
: 19 mm, 22 mm
M1LD-07-007
W2-8-2
UPPERSTRUCTURE / Revolution Sensing Valve
Installation 7
8
1. Install revolution sensing valve (8) with bolts (7)
(2 used).
: 13 mm
: 19.5 N m (2 kgf m, 14.5 lbf ft)
M1LD-07-007
6
M1LD-07-015
M1LD-07-013
W2-8-3
UPPERSTRUCTURE / Revolution Sensing Valve
5. Align the mating mark on tank cover (5) with that 5
on cover (9).
9 M1LD-07-010
6. Push tank cover (5) downward until tank cover (5)
is locked.
7. Remove rod (3) from hole (2) for the lock. Shut
engine cover (1).
M1LD-07-012
3 2
SS-2304
W2-8-4
UPPERSTRUCTURE / Revolution Sensing Valve
(Blank)
W2-8-5
UPPERSTRUCTURE / Revolution Sensing Valve
DISASSEMBLE REVOLUTION SENSING
VALVE
5
4
4
4 6
2
W566-02-08-001
3 11 12 13 4 14 4
15
2 10 1 9 8 18 17 7 16
W566-02-08-002
W2-8-6
UPPERSTRUCTURE / Revolution Sensing Valve
Disassemble Revolution Sensing Valve
W176-02-06-017
W2-8-7
UPPERSTRUCTURE / Revolution Sensing Valve
ASSEMBLE REVOLUTION SENSING
VALVE
5
4
4
4 6
2
W566-02-08-001
3 11 12 13 4 14 4
15
2 10 1 9 8 18 17 7 16
W566-02-08-002
W2-8-8
UPPERSTRUCTURE / Revolution Sensing Valve
Assemble Revolution Sensing Valve IMPORTANT: Install differential reducing valve (2)
into body (1) with guide (17) assem-
Read PRECAUTIONS FOR DISASSEMBLING bly facing upward. In case differen-
AND ASSEMBLING (W1-1-1) carefully before as- tial reducing valve (2) cannot be in-
sembling. stalled to body (1) by hand, guide
(17) assembly may be off. At this
time check if the sliding surfaces of
1.Install choke (6) and plugs (4) (3 used) to body (1). piston (18) and guide (17) are dam-
: 5 mm aged after pulling differential reduc-
: 9.8 to 11.0 N m ing valve (2) out of body (1).
(1.0 to 1.2 kgf m, 7.2 to 8.1 lbf ft)
: 6 mm
: 30.5 to 34.0 N m
(3.1 to 3.5 kgf m, 22.5 to 25 lbf ft) 5. Install differential reducing valve (2) to body (1)
turning it I to 2 times by hand. Tighten it.
: 24 mm
IMPORTANT: Apply grease onto O-Rings (14, 11). : 79 to 83 N m
2. Install spring (12), spool (13), and O-rings (11, 14) (8.1 to 8.5 kgf m, 58 to 61 lbf ft)
to variable orifice valve (3).
W2-8-9
UPPERSTRUCTURE / Revolution Sensing Valve
(Blank)
W2-8-10
SECTION 3
UNDERCARRIAGE
CONTENTS
Group 1 Swing Bearing Group 6 Upper and Lower Roller
Remove and Install Swing Bearing .......... W3-1-1 Remove and Install Upper Roller ............. W3-6-1
Remove and Install Lower Roller ............. W3-6-3
Group 2 Travel Device Disassemble and Assemble
Remove and Install Travel Device ........... W3-2-1 Lower Roller........................................... W3-6-6
Disassemble Travel Device ..................... W3-2-2 Maintenance Standards ........................... W3-6-8
Assemble Travel Device .......................... W3-2-6
Maintenance Standards......................... W3-2-16 Group 7 Track
Remove and Install Rubber Crawler ........ W3-7-1
Group 3 Center Joint Maintenance Standards ........................... W3-7-3
Remove and Install Center Joint.............. W3-3-1
Disassemble Center Joint........................ W3-3-4
Assemble Center Joint ............................ W3-3-6
1LDW-3-1
Blank
1LDW-3-2
UNDERCARRIAGE / Swing Bearing
REMOVE AND INSTALL SWING BEARING
Removal
1. Put matching marks on inner race (1) of the swing
bearing and track frame (2). Matching Mark
: 19 mm
W507-02-03-002
CAUTION: Swing bearing weight: 55 kg
(121 lb)
3. Attach lifting tools (ST 0052) to swing bearing (4)
outer race, lift swing bearing (4) by crane and
remove it.
ST 0052
W507-03-01-001
W3-1-1
UNDERCARRIAGE / Swing Bearing
Installation
Clean the mating surfaces of the track frame and
swing bearing.
Front Side
CAUTION: Swing bearing weight: 55 kg Position for
(121 lb) "S" (Soft Zone) Grease Fitting
Marking Position
IMPORTANT: Failure to align the marks may result
in misalignment of the inner race
soft zone. 25
16
Position for
Grease Fitting
W1LD-03-01-001
3
3. Install mounting bolts (3) (20 used) to the inner
race of the swing bearing and tighten to
specification.
: 19 mm
: 108 N m (11 kgf m 80 lbf ft)
W507-02-03-002
W3-1-2
UNDERCARRIAGE / Travel Device
REMOVE AND INSTALL TRAVEL DEVICE
Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)
Installation 3
W554-03-02-005
NOTE: Refer to "Removal" section for wrench size
and tightening torque.
W3-2-1
UNDERCARRIAGE / Travel Device
1 2
DISASSEMBLE TRAVEL DEVICE 3
29 4
30 5
30
29 6
27 7
28 8
27 9
15 10
18 11
17
26 16
15
25 14
24
23
22
21 13
12
20
19
37 36
W571-03-02-004
55 35
54
53 58 52
51 50 34
49 33
48 32
47 31
46
45
43
44
71 43
42
70 41
40
59 39
57
60 38
61 56
62
63
66 64
67 65
68
50
49 69
52
51 W571-03-02-005
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary Gear 39 - Holder 57 - Choke
(4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-2
UNDERCARRIAGE / Travel Device
Disassemble Travel Device
Read PRECAUTIONS FOR DISASSEMBLING 9. Remove plungers (38) (9 used), holder (39), bar-
AND ASSEMBLING (W1-1-1) carefully before rel holder (40) and pins (41) (3 used) from rotor
disassembling. (42).
1. Remove plugs (63) (2 used), spring guides (61)
(2 used), springs (60) (2 used) and balls (59) (2 CAUTION: Always hold retainer (43) and
used) from body (58). Remove O-rings (62) (2 spring (44) with a press when removing re-
used) from plugs (63) (2 used). taining ring (45). If retaining ring (45) is re-
moved without holding retainer (43) and
2. Remove plugs (49) (2 used), springs (51) (2 spring (44), retainer (43) and spring (44) may
used), Rings (52) (2 used) and spool (69) from fly out potentially causing serious injury.
body (58). Remove O-rings (50) (2 used) from
plugs (49) (2 used). 10. Remove retaining ring (45) from rotor (42), then
remove retainer (43), spring (44) and retainer
3. Remove plugs (68) (2 used), spacer (66), spool (43).
(65) and spring (64) from body (58). Remove O-
rings (67) (2 used) from plugs (68) (2 used). 11. Remove plug (12), O-ring (13), plugs (11) (2
used) and O-rings (10) (2 used) from cover (8).
4. Remove socket bolts (55) (4 used), relief valve : 5 mm, 8 mm
assembly (54), O-rings (70) (2 used) and (71)
from body (58).
: 6 mm 12. Remove stopper ring (9) from cover (8) using a
screwdriver, then remove cover (8) from ring gear
(26).
CAUTION: Valve plate (46) may stick to body
(58). Take care not to drop valve plate (46)
when removing body (58).
W3-2-3
UNDERCARRIAGE / Travel Device
1
2
3
4
29
30 5
30
29 6
7
27
28 8
27
15
18
17
26 16
15
25
24 14
23
22
21
20
19
W571-03-02-004
35
34
33
32
31
W571-03-02-005
W3-2-4
UNDERCARRIAGE / Travel Device
13. Remove O-ring (7) and slide ring (6) from cover
(8).
14. Remove drive gear (5), first stage carrier (3) as-
sembly, retaining ring (4) and sun gear (1) from
ring gear (26).
21. Remove O-ring (29) and seal ring (30) from body
(31).
W3-2-5
UNDERCARRIAGE / Travel Device
ASSEMBLE TRAVEL DEVICE
18 17 15 19 20 21 22 24 25 33 28 34 29 37 36 40 41 47 53 44 48
58
15
16
23
14
55
13 54
12
6
8
10
11
9 7 4 3 2 1 5 26 32 27 39 30 38 42 43 31 56 35 57 45 46
T571-03-05-001
1 - Sun Gear 19 - Retaining Ring (4 Used) 37 - Swash Plate 55 - Socket Bolt (4 Used)
2 - Thrust Collar 20 - Thrust Washer (4 Used) 38 - Plunger (9 Used) 56 - O-Ring
3 - First Stage Carrier 21 - Second Stage Planetary 39 - Holder 57 - Choke
Gear (4 Used)
4- Retaining Ring 22 - Needle Bearing (4 Used) 40 - Barrel Holder 58 - Body
5- Drive Gear 23 - Ring (4 Used) 41 - Pin (3 Used) 59 - Ball (2 Used)
6- Slide Ring 24 - Thrust Washer (4 Used) 42 - Rotor 60 - Spring (2 Used)
7- O-Ring 25 - Retaining Ring 43 - Retainer (2 Used) 61 - Spring Guide (2 Used)
8- Cover 26 - Ring Gear 44 - Spring 62 - O-Ring (2 Used)
9- Stopper Ring 27 - Bearing (2 Used) 45 - Retaining Ring 63 - Plug (2 Used)
10 - O-Ring (2 Used) 28 - Retaining Ring 46 - Valve Plate 64 - Spring
11 - Plug (2 Used) 29 - O-Ring (2 Used) 47 - O-Ring 65 - Spool
12 - Plug 30 - Seal Ring (2 Used) 48 - Bearing 66 - Spacer
13 - O-Ring 31 - Body 49 - Plug (2 Used) 67 - O-Ring (2 Used)
14 - Retaining Ring (3 Used) 32 - Control Piston 50 - O-Ring (2 Used) 68 - Plug (2 Used)
15 - Thrust Washer (6 Used) 33 - Oil Seal 51 - Spring (2 Used) 69 - Spool
16 - Pin (3 Used) 34 - Bearing 52 - Ring (2 Used) 70 - O-Ring (2 Used)
17 - Needle Bearing (3 Used) 35 - Shaft 53 - Socket Bolt (7 Used) 71 - O-Ring
18 - First Stage Planetary Gear 36 - Ball (2 Used) 54 - Relief Valve Assembly
(3 Used)
W3-2-6
UNDERCARRIAGE / Travel Device
69 69
52
49
51
50 68
59
60
61
64 62 63 65 66 67
W571-03-02-001
W3-2-7
UNDERCARRIAGE / Travel Device
19 20 21 22 24 25 33 28 29 30
23
2 26 27 31
T571-03-05-001
W3-2-8
UNDERCARRIAGE / Travel Device
Assemble Travel Device
Read PRECAUTIONS FOR DISASSEMBLING 5. Install rings (23) (4 used), thrust washers (24) (4
AND ASSEMBLING (W1-1-1) carefully before as- used), second stage planetary gears (21) (4
sembling. used), needle bearings (22) (4 used) and thrust
washers (20) (4 used) onto body (31) in this order.
1. Install oil seal (33) into body (31). Secure them with retaining rings (19) (4 used),
then install thrust collar (2).
2. Install O-ring (29) onto seal ring (30), then install
them into the body (31).
26
Screw Clamp
31
W571-03-02-006
W3-2-9
UNDERCARRIAGE / Travel Device
18 17 15
15
16
14
13
12
6
8
10
11
9 7 4 3 1 5 26
T571-03-05-001
W3-2-10
UNDERCARRIAGE / Travel Device
6. Install pins (16) (3 used) onto first stage carrier
(3). Install sun gear (1) and secure it with retain-
ing ring (4).
9. Install O-ring (7) onto ring gear (26). Add 0.6 litter
(0.159 US gal) of lubrication oil into ring gear (26).
10. Install the assembly of cover (8) and slide ring (6)
onto ring gear (26), then secure them using stop-
per ring (9).
11. Install plug (11), O-ring (10), plug (12) and O-ring
(13) onto cover (8).
: 5 mm
: 12 to 13 N m
(1.2 to 1.3 kgf m, 8.9 to 9.6 lbf ft)
: 8 mm
: 46 to 51 N m
(4.7 to 5.2 kgf m, 34 to 38 lbf ft)
W3-2-11
UNDERCARRIAGE / Travel Device
34 37 36 40 41 47 53 44 43 48
58
71
55
54
70
32 39 38 43 42 31 56 35 57 45 46
T571-03-05-001
W3-2-12
UNDERCARRIAGE / Travel Device
IMPORTANT: Do not remove bearing (34) on shaft
(35) assembly unless replacing it.
17. Install rotor (42) assembly into body (31). Add 0.2
litter (0.053 US gal) of hydraulic oil into body (31).
19. Install body (58) onto body (31), and tighten using
socket bolts (53) (7 used).
: 10 mm
: 51 to 65 N m
(5.2 to 6.6 kgf m, 38 to 48 lbf ft)
W3-2-13
UNDERCARRIAGE / Travel Device
69 58 69
52
49
51
50 68
59
60
61
64 63 62 65 66 67
W571-03-02-001
W3-2-14
UNDERCARRIAGE / Travel Device
21. Install O-rings (67) (2 used) onto plugs (68) (2
used). Install spring (64), spool (65) and spacer
(66) into body (58), then install plugs (68) (2
used).
: 8 mm
: 46 to 51 N m
(4.7 to 5.2 kgf m, 34 to 38 lbf ft)
W3-2-15
UNDERCARRIAGE / Travel Device
MAINTENANCE STANDARDS
Sprocket
C B
D
A
W1SE-03-02-001 W105-03-07-040
Unit: mm
Dimension Standard Allowable Limit Remedy
A 47.6 (42.6)
B 73.1 70.6
Cladding by
C 96.05 93.55 welding and
finishing
C PCD92.35 -
D 135.0 -
NOTE: The value in the parenthesis is the refer-
ence value.
W3-2-16
UNDERCARRIAGE / Center Joint
REMOVE AND INSTALL CENTER JOINT
Removal
W554-03-03-002
W571-03-03-001
W3-3-1
UNDERCARRIAGE / Center Joint
Installation
1
6
CAUTION: Center joint weight: 19 kg (42 lb)
1. Install center joint (1) onto the frame with bolts (6)
(4 used).
: 17 mm
: 49 N m (5 kgf m, 36 lbf ft)
W571-03-03-001
1
W507-03-03-004
4
3. Install undercover (5) onto the frame with bolts (4)
(3 used).
: 19 mm 5
: 88 N m (9 kgf m, 65 lbf ft)
4. Install lock plate (2) onto the frame with bolts (3)
(2 used).
: 19 mm W554-03-03-002
1
: 88 N m (9 kgf m, 65 lbf ft)
2
3
5. Connect all body side hoses to center joint (1).
: 19 mm
: 29.5 N m (3 kgf m, 22 lbf ft)
: 22 mm
: 39 N m (4 kgf m, 29 lbf ft) W1LD-03-03-001
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft)
W3-3-2
UNDERCARRIAGE / Center Joint
(Blank)
W3-3-3
UNDERCARRIAGE / Center Joint
DISASSEMBLE CENTER JOINT
11
10
12 13
W555-03-03-001
1- Bolt (4 Used) 5 - Thrust Washer 8 - O-Ring 11 - Spindle
2- Cover 6 - Body 9 - Backup Ring 12 - Plug (4 Used)
3- Retaining Ring 7 - Oil Seal (7 Used) 10 - Dust Seal 13 - Plug (3 Used)
4- O-ring
W3-3-4
UNDERCARRIAGE / Center Joint
Disassemble Center Joint IMPORTANT: For easy removal, two pins can be
Read PRECAUTIONS FOR DISASSEMBLING used to pry out oil seals (7). Take
AND ASSEMBLING (W1-1-1) carefully before care not to damage the seal groove
disassembling. with the pins.
ST 1995
6. Remove oil seals (7) (7 used) from body (6).
1
7. Remove dust seal (10), backup ring (9) and O-
ring (8) from body (6).
6
W506-03-03-002
W3-3-5
UNDERCARRIAGE / Center Joint
ASSEMBLE CENTER JOINT
5 2
4
6
8
9
10
11
W555-03-03-002
12 13
W3-3-6
UNDERCARRIAGE / Center Joint
Assemble Center Joint
Read PRECAUTIONS FOR DISASSEMBLING
AND ASSEMBLING (W1-1-1) carefully before as-
sembling.
W3-3-7
UNDERCARRIAGE / Center Joint
Blank
W3-3-8
UNDERCARRIAGE / Track Adjuster
REMOVE AND INSTALL TRACK ADJUSTER
Removal
2
Installation W507-03-04-001
W507-03-04-001
3 3
W507-03-04-003
W507-03-04-002
W3-4-1
UNDERCARRIAGE / Track Adjuster
DISASSEMBLE TRACK ADJUSTER
1 2
3
5
6
7
10
16
15 13
12
11
14
W1LD-03-04-001
W3-4-2
UNDERCARRIAGE / Track Adjuster
Disassemble Track Adjuster
Be sure to read Precautions for Disassembly and CAUTION: Track adjuster weight:
Assembly thoroughly on page W1-1-1 before 14 kg (31 lb)
starting any repair work. 3. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and put the track adjuster
on cradle of special tool.
CAUTION: Special tool weight: 161 kg
(350 lb)
Track Adjuster
W 105-03-04-009
Nut
CAUTION: Plate (ST 4140) weight: 36 kg
(79 lb)
4. Install plate (ST 4140) onto special tool (ST 4943)
so that plate (ST 4140) overlies the track adjuster.
Cradle
Remove valve (11) from rod (8).
Oil Jack
Plate
(ST 4140)
Base
W 105-03-04-006
Track
Adjuster
Oil Jack
W 105-03-04-007
W 105-03-04-013
W3-4-3
UNDERCARRIAGE / Track Adjuster
15 13
12
11
14
W1LD-03-04-001
W3-4-4
UNDERCARRIAGE / Track Adjuster
6. Tighten the nuts onto plate (ST 4140) to secure
the track adjuster. CAUTION: Plate (ST 4140) weight:
Operate the oil jack to compress the track 36 kg (79 lb)
adjuster approximately 10 mm (0.4 in) until a When removing the nut and plate (ST 4140),
clearance is observed between washer (14) and be sure to remove it after loosening the oil
nut (12). jack. Not loosening the oil jack poses a
: 46 mm danger of washer (14) and spring (15) flying
off under the reaction of the spring.
8. Lower the oil jack to release the spring force.
Loosen the nuts to remove plate (ST 4140).
Remove washer (14) from rod (8).
Nut
Plate (ST4140)
Plate
(ST 4140)
14
W 105-03-04-012
15
Eyebolt
15
W 105-03-04-014
W 105-03-04-017
W3-4-5
UNDERCARRIAGE / Track Adjuster
1 2
3
5
6
7
10
16
W1LD-03-04-001
W3-4-6
UNDERCARRIAGE / Track Adjuster
11. Remove spacer (16) from rod (8).
15. Remove rod (8) and O-ring (10) from cylinder (9).
W3-4-7
UNDERCARRIAGE / Track Adjuster
ASSEMBLE TRACK ADJUSTER
4 5 6 7 9 10 14
1 3
12 13 8 11
W1LD-03-04-002
A 15 B 16
W3-4-8
UNDERCARRIAGE / Track Adjuster
Assemble Track Adjuster
CAUTION: Spring assembly weight:
13 kg (28.5 lb)
Be sure to read Precautions for Disassembly and 6. Install spring (15) onto cylinder (9). Install eyebolt
Assembly thoroughly on page W1-1-1 before (M14, pitch 1.5) to the cylinder. Lift the spring
starting any repair work. assembly by crane. Then set them on special tool
(ST 4943).
1. Install O-ring (10) and rod (8) into cylinder (9). Eyebolt
9
IMPORTANT: Install U-ring (6) with the lip facing
retaining ring (7).
Apply the hydraulic oil to wear ring
(5) and the U-ring (6).
2. Install wear ring (5), U-ring (6) and retaining ring
(7) onto piston rod (4). ST 4943
Plate
(ST 4140)
Nut
ST 4943
W 105-03-04-012
W3-4-9
UNDERCARRIAGE / Track Adjuster
12 13 8 11
W1LD-03-04-002
15
W3-4-10
UNDERCARRIAGE / Track Adjuster
9. Operate the oil jack to compress spring (15) until
the specified length (223 mm) (8.8 in) is obtained. CAUTION: Track adjuster weight:
14 kg (30 lb)
12. Attach the wire rope to the track adjuster. Lift the
track adjuster by crane and remove them from the
special tool.
15
Track Adjuster
Oil Jack
Special Tool
W 105-03-04-026
10. Install nut (12) and valve (11) to rod (8). Install
plug (13) to the nut. W105-03-04-009
: 46 mm
: 5 mm
: 14.5 N m (1.5 kgf m, 10.5 lbf ft) CAUTION: Special tool (ST 4944) weight:
: 19 mm 64 kg (141 lb)
: 88 N m (9 kgf m, 65 lbf ft) IMPORTANT: If only the track adjuster is to be
transported, be sure to use special
12 8 13 tool (ST 4944) to avoid personal
injury.
: 30 mm
Track Adjuster
W 105-03-04-014
W105-03-04-011
W3-4-11
UNDERCARRIAGE / Track Adjuster
(Blank)
W3-4-12
UNDERCARRIAGE / Front Idler
REMOVE AND INSTALL FRONT IDLER
Removal
1. Remove the idler assembly from the track frame. Idler Assembly
Remove the front idler and yoke assembly from Track Frame
the track frame using a crowbar.
W562-03-05-001
Installation
Track
Frame
W507-03-04-003
W3-5-1
UNDERCARRIAGE / Front Idler
DISASSEMBLE AND ASSEMBLE FRONT
IDLER
4 5
6 7
2
8
1
9 W1LD-03-05-001
W3-5-2
UNDERCARRIAGE / Front Idler
Disassemble Front Idler Assemble Front Idler
Be sure to read Precautions for Disassembly and Be sure to read Precautions for Disassembly and
Assembly thoroughly on page W1-1-1 before Assembly thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
1. Remove bolts (8) (4 used) to remove plate (7) 1. Install bushings (4) (2 used) into idler (3) with a
from yoke (6) (2 used). press.
: 19 mm
2. Install axle (1) into idler (3).
2. Remove spring pin (9) (2 used) from yoke (6) (2
used). 3. Install O-ring (5) (2 used) onto axle (1).
8 mm
IMPORTANT: For handling of floating seal (2), re-
IMPORTANT: For handling of floating seal (2), re- fer to the section Floating Seal Pre-
fer to the section Floating Seal Pre- cautions on page W1-1-4.
cautions on page W1-1-4. 4. Install floating seal (2) (2 used) and yoke (6) (2
3. Remove yoke (6) (2 used) and floating seals (2) used) into idler (3).
(2 used) from idler (3).
5. Tap spring pin (9) (2 used) into yoke (6) (2 used).
4. Remove O-ring (5) (2 used) from axle (1).
6. Secure plate (7) to yoke (6) (2 used) with bolts (8)
5. Remove axle (1) from idler (3). (4 used).
: 19 mm
IMPORTANT: Do not remove bushings (4) (2 used) : 88 N m (9 kgf m, 65 lbf ft)
unless necessary.
6. When replacing bushing (4) (2 used), build-up
weld at 4 places in its inner diameter with welding
rod, shrink bushing (4) to pull it out.
90
90
W105-03-05-012
W3-5-3
UNDERCARRIAGE / Front Idler
MAINTENANCE STANDARD
C D F
A
B
W503-03-05-001
Unit: mm (in)
A 53 (2.1)
B 92 (3.6)
E 10 (0.4)
F 344 (13.5)
W3-5-4
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL UPPER ROLLER
Removal
1
1 2
IMPORTANT: Clean off gravel or mud packed
between the sprockets and tracks
before loosening valve (1).
Its enough to turn valve (1) by only
one turn. Do not loosen it over one
turn.
Grease Outlet
W1F1-03-07-001
6 Wooden Blocks 5 7
3. Loosen bolt (7) and remove upper roller (5). 3
: 22 mm
W507-03-06-003
W3-6-1
UNDERCARRIAGE / Upper and Lower Roller
Installation
1. Install upper roller (5) onto track frame (3) with
6 Wooden Blocks 5 7
bolt (7). 3
: 22 mm
: 137 N m (14 kgf m, 101 lbf ft)
4
3. Lower oil jack (4) to lower the track (6).
Remove oil jack (4).
W507-03-06-003
Roller W507-03-06-005
Rubber Cralwer
M503-05-050 90 110º
W3-6-2
UNDERCARRIAGE / Upper and Lower Roller
REMOVE AND INSTALL LOWER ROLLER
Removal
1. Raise the one side track off the ground using the
90 110º
front attachment. Then place a block under track
frame to support the machine.
M570-07-001
3
4
W507-03-06-005
W3-6-3
UNDERCARRIAGE / Upper and Lower Roller
Installation
1 2
CAUTION: Securely support the raised ma-
chine with wooden blocks.
1. Install lower roller (3) to the underside of the track 3
frame, aligning the bolt holes. 4
: 27 mm
: 450 N m (46 kgf m, 330 lbf ft)
W507-03-06-005
Roller
A Grease Outlet
W1F1-03-07-001
Rubber Crawler
M503-05-050
90 110º
M570-07-001
W3-6-4
UNDERCARRIAGE / Upper and Lower Roller
(Blank)
W3-6-5
UNDERCARRIAGE / Upper and Lower Roller
DISASSENBLE AND ASEMBLE LOWER
ROLLER
1 2 3 4 5 6 7
10
W577-03-06-001
W3-6-6
UNDERCARRIAGE / Upper and Lower Roller
Disassemble Lower Roller Assemble Lower Roller
Be sure to read Precautions for Disassembly and Be sure to read Precautions for Disassembly and
Assembly thoroughly on page W1-1-1 before Assembly thoroughly on page W1-1-1 before
starting any repair work. starting any repair work.
1. Remove plug (8) from collar (6) to drain engine oil IMPORTANT: For handling of floating seal (1) and
from the roller. (5), refer to the section Precautions
: 4 mm for Floating Seal Handling on page
W1-1-4.
IMPORTANT: Axle (4) and collar (10) unable to be 1. Install floating seal (1) to roller (2) and collar (10).
disassembled. In case the axle must Press axle (4) with collar (10) into roller (2).
be replaced, replace axle (4) assem-
bly. 2. Install floating seal (5) to roller (2) and collar (6).
2. Remove stopper ring (9) from collar (6). Push out NOTE: When disassembling, O-ring (7) may be
axle (4) assembly from the collar (6) side in roller damaged. Replace it with the new one.
(2) with a press.
3. Install O-ring (7) to axle (4).
IMPORTANT: For handling of floating seal (1) and Aligning the grooves on axle (4) and collar (6) for
(5), refer to the section Precautions stopper ring (9), install collar (6) and stopper ring
for Floating Seal Handling on page (9) onto axle (4).
W1-1-4.
IMPORTANT: Apply LOCTITE #503 onto plug (8).
3. Remove collar (6) from roller (2). Remove floating 4. Refill engine oil (SAE #30, API class CD) (45 cm3
seal (1) and (5) from both sides of roller (2). (0.047 US qt)) through the plug hole on collar (6).
Install plug (8) to the collar.
4. Remove O-ring (7) from axle (4). : 4 mm
: 9.8 N m (1 kgf m, 7.2 lbf ft)
IMPORTANT: Do not remove bushings (3) (2 used)
from roller (2). In case the bushing
must be replaced, replace the roller
(2) assembly.
W3-6-7
UNDERCARRIAGE / Upper and Lower Roller
MAINTENANCE STANDARDS
Upper Roller
W566-03-06-001
Unit: mm
W3-6-8
UNDERCARRIAGE / Upper and Lower Roller
Lower Roller
C D E
B
W577-03-06-001
Unit: mm (in)
Standard Allowable Limit Remedy
A 53 (2.09) -
B 142 (5.59) -
Build-up weld
C 39 (1.54) - and finishing or
D 95 (3.74) - replace
E 122 (4.80) -
Unit: mm (in)
Axle and Bushing
Lubrication Oil
Engine Oil Grade: API Class CD, SAE30
3
Oil Capacity: 45 cm (0.048 US qt)
W3-6-9
UNDERCARRIAGE / Upper and Lower Roller
(Blank)
W3-6-10
UNDERCARRIAGE / Track
REMOVE AND INSTALL RUBBER CRAWLER
Removal
1 2
M570-07-001
1
2. Slowly loosen track adjuster valve (1) to allow
grease to escape.
: 19 mm
W 190-03-06-001
Rotate Direction
W3-7-1
UNDERCARRIAGE / Track
Installation
Joint
Joint M102-07-070
M102-07-075
W3-7-2
UNDERCARRIAGE / Track
MAINTENANCE STANDARD
5 W190-03-07-002
Lower Roller
Lug Wear
1. If the lug height (A) is less than 5 mm, replace the Rubber Track
rubber crawler as an assembly.
Lug W190-03-07-003
5
W190-03-07-004
W3-7-3
UNDERCARRIAGE / Track
Rubber Crawler and Steel Cord Cutting
1. When either of the two rows of the steel cord (5)
has cut, replace rubber crawler as an assembly.
5
W190-03-07-005
W190-03-07-006
W3-7-4
SECTION 4
FRONT ATTACHMENT
CONTENTS
Group 1 Front Attachment
Remove and Install Front Attachment...... W4-1-1
Maintenance Standards........................... W4-1-6
Group 2 Cylinder
Remove and Install Cylinders .................. W4-2-1
Disassemble Boom Cylinder.................... W4-2-8
Assemble Boom Cylinder ...................... W4-2-12
Disassemble Arm Cylinder .................... W4-2-16
Assemble Arm Cylinder ......................... W4-2-20
Disassemble Bucket Cylinder ................ W4-2-26
Assemble Bucket Cylinder..................... W4-2-30
Disassemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-34
Assemble Boom Swing Cylinder
and Blade Cylinder .............................. W4-2-38
Maintenance Standards......................... W4-2-44
1LDW-4-1
Blank
1LDW-4-2
FRONT ATTACHMENT / Front Attachment
REMOVE AND INSTALL FRONT ATTACH-
MENT
Removal
IMPORTANT: Bleed air from the hydraulic oil tank
before any work. (Refer to W1-3-1)
1. Park the machine on a solid level surface. Fully
retract the bucket and arm cylinder and lower the
bucket onto the ground. Lay wooden block under
the arm tip.
: 19 mm
W554-02-03-007
W4-1-1
FRONT ATTACHMENT / Front Attachment
7. Loosen bolt (7) (2 used) to remove cover (6).
: 13 mm
W1LD-04-01-001
W1LD-04-01-004
W4-1-2
FRONT ATTACHMENT / Front Attachment
11. Remove boom foot pin (9).
9 W527-04-01-004
W1LD-04-01-005
W4-1-3
FRONT ATTACHMENT / Front Attachment
Installation
W1LD-04-01-005
W1LD-04-01-001
W4-1-4
FRONT ATTACHMENT / Front Attachment
W4-1-5
FRONT ATTACHMENT / Front Attachment
MAINTENANCE STANDARDS
Pin Bushing
M N
H A
C
B
E D P
I K Q
J
O
G
H
W571-04-01-004
W533-04-01-002
Unit: mm (in)
W4-1-6
FRONT ATTACHMENT / Front Attachment
Unit: mm (in)
W4-1-7
FRONT ATTACHMENT / Front Attachment
Side Cutter
D
A
W505-04-01-001
Unit: mm (in)
Point
B C
W554-04-01-003
Unit: mm (in)
W4-1-8
FRONT ATTACHMENT / Cylinder
REMOVE AND INSTALL CYLINDER
Link W527-04-02-002
10
W571-04-02-003
W4-2-1
FRONT ATTACHMENT / Cylinder
Install Bucket Cylinder
5
4. Insert stopper pin (6) into link and pin (7) to install
ring (4). W507-04-02-004
4
IMPORTANT: After installation, bleed air from the
hydraulic system by moving the
bucket cylinder full stroke several
times.
Link
W527-04-02-002
Link
W4-2-2
FRONT ATTACHMENT / Cylinder
Remove Arm Cylinder
4 5 1
1. Insert a wooden block (3) between arm cylinder
(1) and boom (2).
W571-04-02-006
8 7 W527-04-02-008
W4-2-3
FRONT ATTACHMENT / Cylinder
Install Arm Cylinder
: 27 mm
: 64 N m (6.5 kgf m, 47 lbf ft) 1
6
W527-04-02-006
3 2
W571-04-02-004
W4-2-4
FRONT ATTACHMENT / Cylinder
Remove Boom Cylinder
Wire
7
9
8 W1LD-04-02-002
W4-2-5
FRONT ATTACHMENT / Cylinder
Install Boom Cylinder
W1LD-04-02-001
times.
W4-2-6
FRONT ATTACHMENT / Cylinder
(Blank)
W4-2-7
FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM CYLINDER
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
27 Clevis Part
W1LD-04-02-003
1- Piston Rod 8- Backup Ring 15 - Cushion Ring 22 - Steel Ball
2- Wiper Ring 9- U-Ring 16 - Spacer 23 - Set Screw
3- Cylinder Head 10 - Connector 17 - Stopper 24 - Seal Ring
4- O-Ring 11 - Stopper 18 - Cushion Bearing 25 - O-Ring
5- Backup Ring 12 - Retainer 19 - Shim 26 - Slide Ring
6- O-Ring 13 - Backup Ring 20 - Slide Ring 27 - Cylinder Tube
7- Bushing 14 - O-Ring 21 - Piston
W4-2-8
FRONT ATTACHMENT / Cylinder
Disassemble Boom Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (27).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 105 mm (4.13 in)
disassembling.
Start the following procedures after disconnecting
Hook Wrench
the lines.
1 3
IMPORTANT: Do not reuse slide rings (20) and (26).
W506-04-02-003
When disassembling boom cylinder,
replace them with new ones.
7. Clamp piston (21) and hold it horizontally in a vice
to remove slide ring (20) and (26) from piston
(21).
W4-2-9
FRONT ATTACHMENT / Cylinder
25
24
21
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
W1LD-04-02-003
W4-2-10
FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (21 IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
8. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 14. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove O-ring (25) in the same procedure. head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (7) with a lathe,
scrape off thinned bushing (7) from
21 cylinder head (3) with a special tool
24, 25 (copper spatula).
W506-04-02-007
12. Remove wiper ring (2), U-ring (9) and backup ring
(8) from the inside of cylinder head (3).
13. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outside of cylinder head (3).
W4-2-11
FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM CYLINDER
3 4 7 5 6 13 14 27 18 19 21 20 26 23 22
W571-04-02-009
2 8 9 10 11 12 15 16 17 1 25 24
W4-2-12
FRONT ATTACHMENT / Cylinder
Assemble Boom Cylinder IMPORTANT: Take care of the mounting direction
Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).
3
ST 8048
Flush the
surface
3
W577-04-02-007
2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7275). the outside of cylinder head (3).
W506-04-02-010
W4-2-13
FRONT ATTACHMENT / Cylinder
3 27 18 19 21 20 26 23 22
W571-04-02-009
1 25 24
W4-2-14
FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that o-ring (25) is not IMPORTANT: When the work of installing set
twisted after installing it. screw (23) is finished, crimp it at two
7. Install o-ring (25) to piston (21), and then install places with a punch in order to
seal ring (24) with special tool (ST 2594, ST2335) prevent it from loosening.
and (ST 2590, ST 2334). 12. Install steel ball (22) into piston (21) and then
install set screw (23) on it.
ST 2594(ZX40U)
ST 2335(ZX50U) : 4 mm
: 16.5 N m (1.7 kgf m, 12 lbf ft)
24
ST 2590(ZX40U) IMPORTANT: Take care not to let slide rings (20)
ST 2334(ZX50U) and (26) drop from piston (21) when
25 inserting the piston rod (1) assembly.
In addition, care should be taken not
to damage the piston rod assembly
21
and insert the piston rod assembly
straightly. Apply the hydraulic oil to
the packing parts.
W566-04-02-010 13. Lay cylinder tube (27) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
IMPORTANT: Adjust seal ring (24). If not adjusting, tube.
piston (21) can not be installed to
cylinder tube (27). IMPORTANT: Apply the hydraulic oil to the
8. Adjust seal ring (24) with special tool (ST 2598, packing parts.
ST 2336). 14. Tighten cylinder head (3) to cylinder tube (27)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 105 mm
: 360 N m (37 kgf m, 265 lbf ft)
24
Hook Wrench
ST 2598(ZX40U)
ST 2336(ZX50U)
W566-04-02-011
W4-2-15
FRONT ATTACHMENT / Cylinder
DISASSEMBLE ARM CYLINDER
1 30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
31
W1LD-04-02-006
1- Piston Rod 9- U-Ring 17 - Stopper 25 - O-Ring
2- Wiper Ring 10 - Connector 18 - Cushion Bearing 26 - Slide Ring
3- Cylinder Head 11 - Stopper 19 - Backup Ring 27 - Cushion Seal
4- O-Ring 12 - Retainer 20 - Slide Ring 28 - Retaining Ring
5- Backup Ring 13 - Backup Ring 21 - Piston 29 - Cushion Bearing
6- O-Ring 14 - O-Ring 22 - Steel Ball 30 - Stopper
7- Bushing 15 - Cushion Ring 23 - Set Screw 31 - Cylinder Tube
8- Backup Ring 16 - Spacer 24 - Seal Ring
W4-2-16
FRONT ATTACHMENT / Cylinder
Disassemble Arm Cylinder
Read PRECAUTIONS FOR DISASEMBLING IMPORTANT: Set screw (23) was crimped with a
AND ASEMBLING (W1-1-1) carefully before punch in two places after it was
disassembling. tightened. Before loosening set
Start the following procedures after disconnecting screw, cut away the crimped
the lines. portions.
4. Secure piston rod (1) horizontally and remove set
screw (23) and steel ball (22) from piston (21).
CAUTION: Arm cylinder weight: : 4 mm
41 kg (90 lb) (ZX40U)
42 kg (93 lb) (ZX50U) 5. Remove piston (21), backup ring (19) and cushin
IMPORTANT: When draining off hydraulic oil from bearing (18) from piston rod (1).
the cylinder, piston rod (1) shall be : 60 mm
moved slowly in order to prevent the
oil from splashing.
6. Remove retaining ring (28) from piston rod (1).
1. Clamp the cylinder tube (31) pin at its mounting
portion (clevis part) in a vise and secure it
horizontally to drain off hydraulic oil from the 7. Slide cushion bearing (29) toward piston rod (1)
cylinder. screw thread to remove stoppers (30).
IMPORTANT: The detent is provided on cylinder 8. Remove cushion bearing (29) and cushion seal
tube (29) to form an integral part. (27) from piston rod (1).
Take care not to damage the cylinder
tube and cylinder head (30) when 9. Wrap piston rod (1) screw thread with protective
bending and extending the detent. tape to protect wiper ring (2) of cylinder head (3)
2. Pull piston rod (1) approx. 200 mm (7.9 in) out to and then remove cylinder head (3) from piston
install a protective cover on the piston rod and rod (1).
then extend the detent at cylinder head (3).
IMPORTANT: Do not reuse slide rings (20) and (26).
Detent
When disassembling boom cylinder,
replace them with new ones.
10. Clamp piston (21) and hold it horizontally in a vice
to remove slide ring (20) and (26) from piston
(21).
1 3
W506-04-02-003
31
1
W506-04-02-004
W4-2-17
FRONT ATTACHMENT / Cylinder
25
24
21
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
W1LD-04-02-006
W4-2-18
FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (21) IMPORTANT: Do not reuse bushing (7).
when removing seals. Replace it with new one when
11. Insert a screwdriver into the clearance between disassembling the cylinder.
piston (21) and seal ring (24). Raise seal ring (24) 17. Remove bushing (7) from the inside of cylinder
with screwdriver. Cut off seal ring (24) with cutting head (3) with a special tool.
pliers to remove seal ring (24) from piston (21). NOTE: As bushing (7) is installed into cylinder
Remove o-ring (25) in the same procedure. head (3) with a press, it can not be
removed with a hammer. After cutting off
the inner surface of bushing (7) with a lathe,
scrape off thinned bushing (7) from
21 cylinder head (3) with a special tool
24 25 (copper spatula).
W506-04-02-007
15. Remove wiper ring (2), U-ring (9) and backup ring
(8) from the inside of cylinder head (3).
16. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outside of cylinder head (3).
W4-2-19
FRONT ATTACHMENT / Cylinder
ASSEMBLE ARM CYLINDER
3 4 5 6 15 16 17 31 18 19 20 26 23 22
28 27
2 7 8 9 10 11 12 13 14 1 21 25 24 29 30 W1LD-04-02-007
W4-2-20
FRONT ATTACHMENT / Cylinder
Assemble Arm Cylinder IMPORTANT: Take care of the mounting direction
Read PRECAUTIONS FOR DISASSEMBLING of U-ring (9).
AND ASSEMBLING (W1-1-1) carefully before 2. Install backup ring (8) and U-ring (9) to cylinder
assembling. head (3).
3
CAUTION: Arm cylinder weight:
41 kg (90 lb) (ZX40U) 9
42 kg (93 lb) (ZX50U)
IMPORTANT: Apply hydraulic oil to the inner side
of cylinder head (3).
Press bushing (7) until the end of
bushing (7) is flush with the end
surface of cylinder head (3).
If not flushing, backup ring (8) will
be damaged when installing backup
ring (8). W1LD-04-02-004
ST 8047
Flush the
surface
3
W577-04-02-007
2
W506-04-02-012
1. Press bushing (7) into cylinder head (3) with 4. Install O-ring (4), backup ring (5) and O-ring (6) to
special tool (ST 7325). the outside of cylinder head (3).
W506-04-02-010
W4-2-21
FRONT ATTACHMENT / Cylinder
3 31 18 19 20 26 23 22
28 27
1 21 25 24 29 30 W1LD-04-02-007
W4-2-22
FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (25) is not IMPORTANT: Take care not to install cushion
twisted after installing it. bearing (18) in wrong direction.
7. Install O-ring (25) to piston (21), and then install 13. Install cushion bearing (18), backup ring (19) and
seal ring (24) with special tool (ST 2625) and (ST piston (21) assembly to piston rod (1).
2623). : 60 mm
: 1270 N m (130 kgf m, 940 lbf ft)
ST 2625
ST 2627
W566-04-02-011
W4-2-23
FRONT ATTACHMENT / Cylinder
3 31
W1LD-04-02-007
W4-2-24
FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the
packing parts.
16. Tighten cylinder head (3) to cylinder tube (31)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 95 mm
: 330 N m (34 kgf m, 245 lbf ft)
Hool Wrench
31
W506-04-02-019
W4-2-25
FRONT ATTACHMENT / Cylinder
DISASEMBLE BUCKET CYLINDER
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
17
W1LD-04-02-005
W4-2-26
FRONT ATTACHMENT / Cylinder
Disassemble Bucket Cylinder 3. Loosen cylinder head (3) with a hook wrench and
pull piston rod (1) (with protective cover on it) out
Read PRECAUTIONS FOR DISASSEMBLING of cylinder tube (17).
AND ASSEMBLING (W1-1-1) carefully before Cylinder head (3) diameter: 85 mm (3.35 in)
disassembling. Hook Wrench
Start the following procedures after disconnecting
the lines.
W4-2-27
FRONT ATTACHMENT / Cylinder
15
14
11
9
8
7
6
5
4
3
2
W1LD-04-02-005
W4-2-28
FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.
11
14, 15
W506-04-02-007
10. Remove O-ring (4), backup ring (5) and O-ring (6)
from the outer side of cylinder head (3).
W4-2-29
FRONT ATTACHMENT / Cylinder
ASSEMBLE BUCKET CYLINDER
3 4 5 6 17 10 16 13 12
W571-04-02-011
2 7 8 9 1 11 14 15
W4-2-30
FRONT ATTACHMENT / Cylinder
Assemble Bucket Cylinder 3. Install wiper ring (2) to cylinder head (3) with
Read PRECAUTIONS FOR DISASSEMBLING special tool (ST 8045, ST 8046).
AND ASSEMBLING (W1-1-1) carefully before
assembling.
ST 8045 (ZX40U)
CAUTION: Bucket cylinder weight: ST 8046 (ZX50U)
ST 7277 (ZX40U)
ST 7276 (ZX50U)
2
9
W506-04-02-012
3
4. Install O-ring (4), backup ring (5) and O-ring (6) to
the outside of cylinder head (3).
8
11
W566-04-02-010
W1LD-04-02-004
W4-2-31
FRONT ATTACHMENT / Cylinder
3 17 10 16 13 12
W571-04-02-011
1 11 14
W4-2-32
FRONT ATTACHMENT / Cylinder
IMPORTANT: Adjust seal ring (14). If not adjusted, IMPORTANT: Take care not to let slide rings (10)
piston (11) can not be installed to and (16) drop from piston (11) when
cylinder tube (17). inserting the piston rod (1) assembly.
6. Adjust seal ring (14) with special tool (ST 2626, In addition, care should be taken not
ST 2600). to damage the piston rod assembly
straightly. Apply the hydraulic oil to
the packing parts.
11. Lay cylinder tube (17) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
14 tube.
ST 2626 (ZX40U)
ST 2600 (ZX50U) IMPORTANT: Apply the hydraulic oil to the
packing parts.
12. Tighten cylinder head (3) to cylinder tube (17)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 85 mm (ZX40U)
W566-04-02-011
90 mm (ZX50U)
: 320 N m (32.5 kgf m, 235 lbf ft)
IMPORTANT: When installing slide ring (10) and (ZX40U ZX50U)
(16), do not align their split portion.
7. Install slide rings (10) and (16) to piston (11). Hook Wrench
W4-2-33
FRONT ATTACHMENT / Cylinder
DISASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
Clevis Part
17
W1LD-04-02-008
1- Piston Rod 6- U-Ring 10 - Slide Ring 14 - Seal Ring
2- Wiper Ring 7- O-Ring 11 - Piston 15 - O-Ring
3- Cylinder Head 8- Backup Ring 12 - Steel Ball 16 - Slide Ring
4- Bushing 9- O-Ring 13 - Set Screw 17 - Cylinder Tube
5- Backup Ring
W4-2-34
FRONT ATTACHMENT / Cylinder
Disassemble Boom Swing Cylinder and Blade 3. Loosen cylinder head (3) with a hook wrench and
Cylinder pull piston rod (1) (with protective cover on it) out
of cylinder tube (17).
Read PRECAUTIONS FOR DISASSEMBLING Cylinder head (3) diameter: 115 mm (4.53 in)
AND ASSEMBLING (W1-1-1) carefully before (Boom swing cylinder, Blade cylinder)
disassembling. Hook Wrench
Start the following procedures after disconnecting
the lines.
W4-2-35
FRONT ATTACHMENT / Cylinder
15
14
11
9
8
7
6
5
4
3
2
W1LD-04-02-008
W4-2-36
FRONT ATTACHMENT / Cylinder
IMPORTANT: Take care not to damage piston (11)
when removing seals.
8. Insert a screwdriver into the clearance between
piston (11) and seal ring (14). Raise seal ring (14)
with screwdriver. Cut off seal ring (14) with cutting
pliers to remove seal ring (14) from piston (11).
Remove O-ring (15) in the same procedure.
11
14, 15
W506-04-02-007
10. Remove O-ring (7), backup ring (8) and O-ring (9)
from the outer side of cylinder head (3).
W4-2-37
FRONT ATTACHMENT / Cylinder
ASSEMBLE BOOM SWING CYLINDER
AND BLADE CYLINDER
3 7 8 9 17 11 10 16 13 12
W1LD-04-02-009
2 7 5 6 1 14 15
W4-2-38
FRONT ATTACHMENT / Cylinder
Assemble Boom Swing Cylinder and Blade IMPORTANT: Take care of the mounting direction
Cylinder of U-ring (6).
Read PRECAUTIONS FOR DISASSEMBLING 2. Install backup ring (5) and U-ring (6) to cylinder
AND ASSEMBLING (W1-1-1) carefully before head (3).
assembling. 3
ST 8047
ST 8048
3
W577-04-02-007
4
3
W506-04-02-010
W4-2-39
FRONT ATTACHMENT / Cylinder
3 17 11 10 16 13 12
W1LD-04-02-009
1 14 15
W4-2-40
FRONT ATTACHMENT / Cylinder
IMPORTANT: Make sure that O-ring (15) is not 8. Wrap the piston rod (1) screw thread with
twisted after installing it. protective tape and then install the cylinder head
5. Install O-ring (15) to piston (11), and then install (3) assembly to the piston rod while rotating the
seal ring (14) with special tool. former one.
Boom swing cylinder and blade cylinder:
ST 2597, ST 2593 9. Install piston (11) assembly to piston rod (1).
: 60 mm
ST 2597
: 1960 N m (200 kgf m, 1450 lbf ft)
W566-04-02-010
IMPORTANT: Take care not to let slide rings (10)
and (16) drop from piston (11) when
inserting the piston rod (1) assembly.
IMPORTANT: Adjust seal ring (14). If not adjusted,
In addition, care should be taken not
piston (11) can not be installed to
to damage the piston rod assembly
cylinder tube (17).
and insert the piston rod assembly
6. Adjust seal ring (14) with special tool.
straightly. Apply the hydraulic oil to
Boom swing cylinder and blade cylinder: ST 2601
the packing parts.
11. Lay cylinder tube (17) horizontally in a vise, and
insert the piston rod (1) assembly into the cylinder
tube.
14
ST 2601
W566-04-02-011
W4-2-41
FRONT ATTACHMENT / Cylinder
3 17
W1LD-04-02-009
W4-2-42
FRONT ATTACHMENT / Cylinder
IMPORTANT: Apply the hydraulic oil to the
packing parts.
12. Tighten cylinder head (3) to cylinder tube (17)
with a hook wrench. Bend the detent to prevent it
from loosening.
Cylinder head (3) diameter: 115 mm
: 390 N m (40 kgf m, 290 lbf ft)
Hook Wrench
17
W506-04-02-019
W4-2-43
FRONT ATTACHMENT / Cylinder
MAINTENANCE STANDARD
A Dial Gauge
Cylinder Rod
W105-04-02-094 W166-04-02-022
ZX40U unit: mm (in)
1m
Recommended Size After
Cylinder Name V Block
Re-manufacturing (A)
+0.023 (2.1 0.0009 unit: mm (in)
Boom 55 ) Bend Run out Remedy
-0.043 7 0.0017
+0.023 (1.9 0.0009 Allowable limit 0.5 (0.020) 1.0 (0.039) Repair
Arm 50 ) Allowable limit 1.0 (0.039) 2.0 (0.079) Replace
-0.043 7 0.0017
+0.023 (1.5 0.0009
Bucket 40 )
-0.043 8 0.0017
+0.023 (1.9 0.0009
Boom Swing 50 )
-0.043 7 0.0017
+0.023 (2.1 0.0009
Blade 55 )
-0.043 7 0.0017
W4-2-44
SECTION 5
ENGINE
CONTENTS
SECTION 1 General Information SECTION 5 Fuel System
GENERAL REPAIR INSTRUCTION................... 2 FUEL CIRCULATION SYSTEM DIAGRAM ......88
NOTES ON THE FORMAT GOVERNOR ....................................................89
OF THIS MANUAL ........................................... 2 NOZZLE HOLDER ASSEMBLY .......................97
APPEARANCE .................................................. 5
MAIN DATA AND SPECIFICATIONS ................. 6 SECTION 6 Troubleshooting
TIGHTENING TORQUE SPECIFICATIONS....... 7
ANGULAR NUT AND BOLT SECTION 7 Special Tool
TIGHTENING METHOD .................................. 9
TIGHTENING TORQUE ON SECTION 8 Service Standard
MAJOR COMPONENTS ................................ 11
GASKET LOCATION ....................................... 17 SECTION 9 Conversion Table
MAINTENANCE............................................... 20 LENGTH ........................................................109
RECOMENDED LUBRICATION OIL................ 25 AREA ............................................................. 111
VOLUME........................................................ 111
SECTION 2 Engine MASS ............................................................ 113
DISASSEMBLY................................................ 28 PRESSURE ................................................... 114
INSPECTION AND REPAIR ............................ 41 TORQUE ....................................................... 115
REASSEMBLY................................................. 55 TEMPERATURE ............................................ 116
1LDW-5-1
Blank
1LDW-5-2
Many thanks for your purchase.
Happy every day.
QIWEN YE
file:///C|/Users/yeqiwen/Documents/QIWEN-YE-END.txt[2015/1/2 21:20:52]
Attach to Vol. No. : T1LDE-00
Connector
Engine 1
Main YAZAKI
YAZAKI
Starter
YAZAKI
Fuel Pump
YAZAKI
Shermo SW.
Shermo Sensor
QOS Sensor
QOS Sensor YAZAKI
Glow Glow Plug Alternator
Starter YAZAKI
Shermo SW.
Shermo SW.
Attach to Vol. No. : T1LDE-00
CAUTION: Parts numbers on the drawing are provided only for reference purpose.
ZAXIS 40U,50U FLOOR HARNESS
Fuse Box
To order parts on the drawing, be sure to consult the Parts Catalog.
Connector
Starter Relay1 Starter Relay2
YAZAKI Glow Timer
YAZAKI YAZAKI
YAZAKI
Install a Puller
Key SW.
SUMITOMO Harness
Auxiliary
Satellite Terminal
YAZAKI
AUX
Gauge Panel
Power
Heater
YAZAKI
Relay a
Relay a Power
Alarm Power
MITSUBISHI
Bypass a Relay b
Bypass a Relay b Horn SW
Bypass a
Bypass a
Relay a
Relay a Gauge Panel
Lock SW. (R)
Relay b
Relay b
Auxilialy Bypass b
Bypass b
Bypass b
Horn SW
Water Proof
Horn SW.
Water Proof
Lock SW. (L)
Alarm Alarm
Main1
Auxilialy
Power YAZAKI
Open Engine2 Engine1 Main2
MITSUBISHI SUMITOMO
Fuse Box Open YAZAKI
SUMITOMO
Open Open
Open
Open
Attach to Vol. No. : T1LDE-00
CAUTION: Refer to the performance standard table in the Technical
ZAXIS 40U,50U HYDRAULIC CIRCUIT DIAGRAM Manual for the set pressure of each relief valve.
Blade Cylinder
Backet Cylinder
Arm Cylinder
Swing Cylinder
Boom Cylinder
Center Joint
Swing Boom Arm Bucket Boom Swing Auxiliary Travel(R) Travel(L) Blade
Cont rol Valve
Pilot Valve (Travel)
Pilot Filter
Mesh 2-Unit Solenoid Valve
Revolution Sensing Valve Pump
Pilot Shut-Off
CONNECTOR TERMINAL LOCATION Sol. Valve Travel Mode SW.
(Drawing are shown in face view of the connector)
Water Proof Water Proof
A Float
Connector
Floor 1 Travel
Changeover
YAZAKI Sol. Valve
Groud
Horn YAZAKI
Travel Mode SW. Work Light
Ground Water Proof
Ground