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Service Manual

SWE210NB

HUNAN SUNWARD INTELLIGENT MACHINERY CO., LTD.


Foreword

This manual enables maintenance technician to be familiar with products by instructing


proper means to trouble-shooting and service. Make certain fully understand this manual and use
it during every service process for better result.
This manual includes technical information required in service. For easier reference and
understanding, this manual consists of below chapters with several sections contained.

1、safety precautions

This chapter provides safety guidelines during maintenance and service for personnel’s safe
operation.

2、chapter overview

This chapter provides dimensions, technical specifications, and working range information of
complete machine and master parts.

3、structural function and maintenance standard

This chapter illuminates structure and function of individual parts, and provides reference
about trouble shooting, maintenance and service.

4、test and failure diagnosis

This chapter provides instruction for inspection before or after service, and all adjustment
required in maintenance and service.

5、disassembly and assembly

This chapter provides all procedure that should be followed during disassembly and assembly,
and all safety precautions required in operation.

6、others

This chapter provides hydraulic system & electrical drawing, and air conditioning system
drawing (if equipped with air conditioning).

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

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CONTENTS

1. Safety precaution........................................................................................................................................ 1
1.1 Gerneral attention ................................................................................................................................. 1
1.2 Prepareation.......................................................................................................................................... 1
1.3 Attention in working hours ................................................................................................................... 2
2. Summary .................................................................................................................................................... 3
2.1 Dimensional drawing............................................................................................................................ 3
2.1.1 Drawing ............................................................................................................................................. 3
2.1.2 Dimention datas .......................................................................................................................... 3
2.1.3 Working range figure .................................................................................................................. 4
2.1.4 Working range datas ................................................................................................................... 4
2.2 Technical specification ......................................................................................................................... 5
2.3 Weight datas ......................................................................................................................................... 6
2.4 Engine oil, fuel and coolant.................................................................................................................. 7
3. Structure function and maintenance standard............................................................................................. 8
3.1 For mechanical device.......................................................................................................................... 8
3.1.1. Engine parts...................................................................................................................................... 8
3.1.2 Cool system ................................................................................................................................ 9
3.1.3 Power drive system................................................................................................................... 10
3.1.4 End drive (traveling motor reductor) ........................................................................................ 11
3.1.5 Swing bearing ........................................................................................................................... 11
3.1.6 Track frame and tension spring................................................................................................. 12
3.1.7 Guiding wheel........................................................................................................................... 13
3.1.8 Carrier roller ............................................................................................................................. 14
3.1.9 Thrust wheel ............................................................................................................................. 15
3.1.10 Track plate .............................................................................................................................. 16
3.1.11 working device........................................................................................................................ 17
3.2 Function and maintenance standard for hydraulic equipments .......................................................... 18
3.2.1 Hydraulic arrangement plan ..................................................................................................... 18
3.2.2 hydraulic oil tank ...................................................................................................................... 20
3.2.3 Hydraulic pump ........................................................................................................................ 21
3.2.4 Swing motor ............................................................................................................................. 34
3.2.5 Pilot control valve..................................................................................................................... 42
3.2.6 Electromagnetic valve .............................................................................................................. 47
3.2.7 Pilot filter.................................................................................................................................. 48
3.2.8 Travel motor ............................................................................................................................. 48
3.2.9 Multiple way valve ................................................................................................................... 56
3.2.10 Rupture valve.......................................................................................................................... 73
3.3 For electric equipments ...................................................................................................................... 78
3.3.1 Power supply circuit ................................................................................................................. 78
3.3.2 Starting circuit(key switch:START) ................................................................................. 79
3.3.3 Pilot closing circuit(key switch:ON) ................................................................................ 80
3.3.4 Engine closing circuit(key switch:OFF)........................................................................... 81
3.3.5 Wiper and scrubber circuit........................................................................................................ 82
3.3.6 Controller.................................................................................................................................. 83
3.3.7 Engine control........................................................................................................................... 86
3.3.8 ECM system ............................................................................................................................. 87
3.3.9 Multifunction moniter system................................................................................................... 92
4. Test and adjustment and Failure Diagnosis .............................................................................................. 95
4.1 Test and adjustment of mechanical structure device........................................................................... 95
4.1.1 Standard table of engine spare parts ......................................................................................... 95
4.1.2 Standard table of complete machine ......................................................................................... 96
4.2 Test and adjustment of hydraulic device........................................................................................... 105
4.2.1 Test and adjustment of system working pressure.................................................................... 105
4.2.2 Test and adjustment of pilot oil supply pressure..................................................................... 109

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4.2.3 Inspection for main return oil pressure of the system..............................................................111
4.2.4 Inspection for output pressure of the pilot solenoid valve ...................................................... 113
4.2.5 Measuring for output pressure of pilot control valve.............................................................. 115
4.2.6 Measuring for hydraulic drift of working devices .................................................................. 117
4.2.7 Release the residual pressure in hydraulic oil circuits ............................................................ 118
4.2.8 Check for leakage volume ...................................................................................................... 118
4.2.9 Adjusting of main pump ......................................................................................................... 121
4.2.10 Devices exhaust .................................................................................................................... 125
4.3 Fault diagnose................................................................................................................................... 126
4.3.1 Inspection before fault diagnose ............................................................................................. 126
4.3.2 Fault sorts and check methods ................................................................................................ 127
5. Disassembly and assembly ..................................................................................................................... 133
5.1 How to read this manual................................................................................................................... 133
5.2 Instruction during operation ............................................................................................................. 134
5.3 Working device ASSY assemly and disassembly ............................................................................. 137
5.4 Counterweight ASSY assembly and disassembly ............................................................................ 139
5.5 Cab ASSY assembly and disassembly.............................................................................................. 140
5.6 Engine disassemble and assembly.................................................................................................... 142
5.7 Radiator ASSY disassembly and assembly ...................................................................................... 144
5.8 Hydraulic pump ASSY disassembly and assembly .......................................................................... 147
5.9 Hydraulic pump body disassembly and assembly ............................................................................ 150
5.10 Main pump adjustor disassembly and assembly............................................................................. 158
5.11 Rotary motor ASSY disassembly and assembly ............................................................................. 166
5.12 Rotary motor noumenon disassembly and assembly...................................................................... 168
5.12 Handle pilot valve disassembly and assembly................................................................................ 178
5.13 Multiple way valve ASSY disassemble and assemble.................................................................... 185
5.14 Travel motor ASSY disassembly and assembly ............................................................................. 188
5.15 Central rotary joint ASSY disassembly and assembly.................................................................... 190
5.16 Hydraulic tank ASSY. disassembly and assembly.......................................................................... 191
5.17. Carrier roller ASSY disassembly and assembly ............................................................................ 194
5.18. Thrust wheel ASSY disassembly and assembly ............................................................................ 195
5.19. Guiding wheel ASSY. disassembly and assembly ......................................................................... 196
5.20. Tension device disassembly and assembly .................................................................................... 199
5.21 Sproket wheel disassembly and assembly ...................................................................................... 202
5.22. Track shoe ASSY disassembly and assembly................................................................................ 203
5.23. Rotary bearing ASSY disassembly and assembly ......................................................................... 207
5.24. Rotary table ASSY disassembly and assembly.............................................................................. 208
5.25. Air-conditioning ASSY disassembly and assembly....................................................................... 210
6. Figures and others .................................................................................................................................. 213
6.1 Hydraulic system schematic diagram ............................................................................................... 213
6.2 Electrical system drawing................................................................................................................. 214

III
1. Safety precaution

Important safety precaution


For the sake of safety operation, it is particularly important to maintain and check
machine properly.The maintenance and check techniques in this manual or introduced by
SUNWARD are safe and effective operation methods and some of them need to use the special
tools which are designed by SUNWARD.
Sign is used in this manual for safety precautions in case of injuring workers.
Pay attention to these marks. If danger happens or may occur, safety should be considered
first then take the necessary steps according to the circumstances.

1.1 Gerneral attention


Improper operation is quite dangerous. Before repair and maintenance are carried out, it is
essential to read this manual carefully.
1. Before lubrication or repair is carried out, read all the safety notes on labels that are fixed
on the machine.
2. Before any operation, do wear safety shoes and hard hat. Do not wear loose work clothes or
clothes without buttons.
z Wear safety glasses when knocking some parts with a hammer.
z Wear safety glasses when polishing some parts with a grinding wheel.
3. If welding is needed, it should be carried out by trained skilled welder. During welding, wear
special gloves, apron, helmet, hard hat and work clothes that are suitable.
4. When an operation is carried out by two or more workers, the operating procedure should be
agreed upon before the operation. Before any operating procedure begins, you should inform
your partner workers of it. Hang a label reading “repairing” on the control table of control room
before any work.
5. All tools should be kept in good condition and operators are required to learn how to use
them.
6. Put the tools and disassembled parts in an appointed place in the repair shop. Do put the tools
and disassembled parts in a proper place. Keep the work area clean and make sure there are no
dirty things or oil stain on the floor. Smoke in the appointed area only. It is not allowed to
smoke during work hours.
1.2 Prepareation
1. Before you fill oil or carry out any repair, put the machine on a level and hard ground,
underlay the wheels or tracks with pads to prevent the machine from moving.
2. Before operation, lower the push plate, ridger teeth, bucket and other working parts onto the
ground. If some working parts can not be lowered, apply the safety pin or pad to prevent them
from falling down.
3. When disassembly or assembly is needed, use pads, lifting jacks or racks to support the
machine before any operation.

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4. Clean the steps by which you get on and off the machine and the pedals. When you get on or
off the machine, use handrails, steps or gangboards. Do not just jump in or off the machine. If
handrails, steps or gangboards are not available for use, racks should be used in sake of safety.
1.3 Attention in working hours
1. When disassembling the cover of oil filling opening, oil drain plug or hydraulic
measurement plug, release them gradually to prevent the oil from ejecting.
a) When disconnect or disassemble pipes for oil, water or gas supply, release the pressure
in pipeline first.
2. When the engine flames out and the water and oil in the pipeline are hot, be careful to
avoid being scalded.
3. Disconnect battery cable prior to operation. Make sure to disconnect negative terminal first.
4. When lifting heavy loads of parts, use winch or crane to check steel rope, chain and
hook for damage.Be certain to use over rated power crane.Assembling the crane at correct
place.Operating a winch or crane slowly to prevent lifting parts colliding with other objects and
do not work on the parts which is lifted by winch or crane.
5. When removing caps under internal pressure or spring pressure, maintain two bolts on
the other side. With pressure relieved, loosen bolts to remove.
6. Pay attention not to crash or damage cable during parts removal. Failure to do so can cause
electric spark.
7. During pipeline disassembly, prevent any leakage of fuel or oil from pipeline. In case of
any leakage on the floor, wipe it immediately, because fuel or oil on the floor can result in
personnel slip or fire.
8. Do not clean parts with gasoline in normal situation. However a small amount of gasoline is
allowed in an exceptional case.
9. Make sure to position all parts properly, and replace defective parts with new ones.
10. During hose or cable installation, do not let them make contact with other parts.
11. Make sure all high-pressure hose is free of distortion during hose installation. Damaged
pipeline is of highly dangerous. Therefore, pay undivided attention to it during high-pressure
hose installation. In addition, check connecting piece for proper installation.
12. Always operate with specified tightening torque during assembly or disassembly. When
assembling protective parts (e.g. protective guard) or installing other parts with sharp vibration
and high-speed rotation. Make sure they are properly installed.
13. When aligning two holes, do not insert fingers or hands into them so as to prevent finger
from being caught in.
14. Make sure all tools for measuring purpose are properly installed before attempting hydraulic
pressure measurement or other measuring procedures.
15. During track disassembly or assembly, please note that track may disengage out of place
abruptly; make sure the area on both end of the track is clear of persons.

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2. Summary
2.1 Dimensional drawing
2.1.1 Drawing

2.1.2 Dimention datas

Item Unit SWE210NB

A Wheel track mm 3655

B Track total length mm 4450

Platform to ground
C mm 1060
distance

D Platform Swing radius mm 2750

E Upper carriage width mm 2500

F Track gage mm 2040

G Chassis swidth mm 2540

H Track width mm 500

Chassis to ground
I mm 470
distance

J cab height mm 2965

L Transportion length mm 9590

M boom height mm 3045

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2.1.3 Working range figure

2.1.4 Working range datas

Item Unit SWE210NB

A Max. digging height mm 9740

B Max. dumping height mm 6980

C Max. digging depth mm 6690

D 8 feet level digging depth mm 6500

E Max. vertical digging depth mm 6040

F Max. digging radius mm 9950


Max. parking level
G mm 9785
digging distance
H Min. swing radius mm 3530

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2.2 Technical specification

Model SWE210NB

Standard bucket capacity m


3
0.95

Operation weight kg 21

Perf Bucket max.digging force kN 137

orma Arm max.digging force kN 100


nce
Swing speed rpm 12.5
para
mete Traveling speed km/h 5.5/3.2
rs Max.climbing capacity ° 35

Engine model AI-4HK1X


electro, water cool, four strok,
Type
pressurization, intercool
Cylinder numer-diameter X
mm 4—115x125
Pow stroke
er Discharge L 5.193
plant Rated power/rotational kW/rp
122±4/2000
speed m
Max.torque/ rotational Nm/rp
655±60/1500
speed m
Fuel tank capacity L 370

Main pump 2×plunger pump


L/mi
Flow 2×206
n
Working device pressure Mpa 32.4(34.3)

Travel pressure Mpa 32.4


Hydr
aulic Swing pressure Mpa 26

syste Pilot pump 1×gear pump


m L/mi
Flow 30
n
Pilot pressure setting Mpa 3.9
Hydraulic oil tank
L 190
capacity

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2.3 Weight datas
The table can de referred during maintenance or transportion.

Unit:kg

Model SWE210NB

Total machine 21000

Uppercarriage 8084

Undercarriage 8011

Boom 2470

Arm 1195

Bucket 828

Cab 294

Blance weight 4000

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2.4 Engine oil, fuel and coolant

Ambient temperature
-22 -4 14 32 50 68 86 104 Speci Refill
1220F fied capac
capac ity
-30 -20 -10 0 10 20 30 40 it
500C

SAE 30

SAE 10W

Engine oil pan SAE 10W-30

Engine
oi SAE 15W-40

SAE 5W-30

Swing reductor
API-GL-4 85W-90
API-GL-5 80W-90
Travel reductor

32#wear hydraulic oil

Hydraulic Hydrau 46# wear hydraulic oil


system lic oil

68# wear hydraulic oil

GB252 premium 0#

GB252 premium -10#


Engine Diesel
GB252 premium -20#light
diesel

GB252 premium -35#light diesel

Swing
mechanism
grease chamber Grease NLGI No.2
Oil cup

Cool system Coolan add proper anti-freezing fluid


t

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3. Structure function and maintenance standard
3.1 For mechanical device
3.1.1. Engine parts

1. Fan blade Technical specification:


2. Engine installation bracket Front shock pad: 750602000073(2 pieces)
3. Rear shock pad Rear shock pad: 750602000077(2 pieces)
4. Engine installation front bracket Muffler: 750205000046(1 piece)
5. Front shock pad
6. Muffler

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3.1.2 Cool system

1.Engine exhalent siphon Technical specification:


2.Engine water inlet pipe Affix water tank: 750203000086(1 piece)
3.Affix water tank Radiator: 730701000044 (1 piece)
4.Radiator
5.Air director cover
6.Condenser
7.Oil cooler

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3.1.3 Power drive system

SWE210NB

Guiding wheel 750105000035

Centre swing joint 739802000019

Main pump 730302000082

Traveling motor 730250000119

Hydraulic pump 730201000127

Engine 750201000121

Electromagnetic
730305000085
valve group
Swing motor 730250000241

Swing bearing 750550000053

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3.1.4 End drive (traveling motor reductor)

1. Chain wheel: 817-MA-B3000

2. Traveling motor: MAG-170VP-3800G-1

3.1.5 Swing bearing

1.Outer race of swing bearing


2.Steel ball
3.Inner race of swing bearing

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3.1.6 Track frame and tension spring

1.Track frame

2.Carrier roller:80X-MH-C3000 Number:2 in one side

3.Thrust wheel:80X-MH-A1000 Number: 9 in one side

4.Track assy:190MH-49360 Track plate number: 49 in one side

5.Track cover sheet

6.Driving wheel

7.Traveling mortor

8.Tension spring

9.Guiding wheel

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3.1.7 Guiding wheel

Unit:mm
satandard
NO. Checking item measures
Standard dimension Repayment limit

1 Total width 159 -

2 Flange width 84 -

Track bearing Repair or


3 surface outer φ500 φ488 replace
diameter
Flange outer
4 φ538 -
diameter

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3.1.8 Carrier roller

Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit
Flange outer
1 φ145 -
diameter
Track bearing
2 surface outer φ120 φ106
diameter
Repair or
3 Total width 170 - replace
Track bearing
4 43 -
surface width

5 Flange width 14 -

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3.1.9 Thrust wheel

Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit
Flange outer
1 φ188 -
diameter
Track bearing
2 surface outer φ156 φ144
diameter
Repair or
3 Total width 230 - replace
Track bearing
4 174 -
surface width
Inner side
5 85 -
width

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3.1.10 Track plate

Unit:mm
Standard
NO. Checking item Measures
Standard dimention Repair limit

1 Hight 25 15
Repair or
Thickness replace
2 35 -

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3.1.11 working device

1.Bucket 5.Arm
2.Connecting rod 6.Arm cylinder
3.Rocker arm 7.Boom
4.Bucket oil cylinder 8.Boom cylind

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3.2 Function and maintenance standard for hydraulic equipments
3.2.1 Hydraulic arrangement plan

1: Tee joint shutoff valve 10: Auxiliary pedal valve


2: Hydraulic tank 11: Travel pedal valve
3: Right side counterbalance 12: Central swing joint
valve (4.5Mpa) 13: Oil collecting block
4: Main pump 14: Right handle valve
5: Right travel motor 15: Left handle valve
6: Pilot filter 16: Swing motor
7: Multiple way valve 17: Oil return block
8: Pilot solenoid valve 18: Right trave motor
9: Left side counterbalance valve (2.5Mpa)

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19:Arm cylinder 20:Right boom cylinder 21:Left boom cylinder
22:Bucket cylinder 23:Shutoff valve- right side 24:Shut off valve- left side

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3.2.2 hydraulic oil tank

1:Pressure signal

2:Drain plug

3:Air filter

4:Liquid level gage

5:Tank body

6:Oil suction filter gauze

7:Oil return filter gauze

8:By-pass check valve

9:Magnetic filter core

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Technical parameters
oil tank oil return filter core oil suction filter core
oil tank
190L flow 750L/min flow 1000L/min
capacity
oil tank filtering
155L rated pressure 1.6MPa 100μ
capacity accuracy
filtering
10μ
accuracy
By-pass valve
opening 0.3MPa
pressure

3.2.3 Hydraulic pump


Summary
K3V112DT-1x7R-9ND9-9V

The pump includes two variable cam-type plunger pumps、pilot oil source、one
electromagnetic proportional valve and two main pump adjusters.

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1:Front main pump
2:Back main pump
3:Pilot oil source
4:Electromagnetic proportional valve
5:Adjuster
A1:Output port-front pump pressure oil
A2:Output port-back pump pressure oil
B1:Port-main pump suction oil
Dr:Drain oil port
Pi1:Feedback port-front pump negative flow
Pi2:Feedback port-back pump negative flow
Psv:Input port-electromagnetic proportional valve
a1:Pressure test port-front pump vent
a2:Pressure test port-back pump vent
a3:Pressure test port-pilot oil source vent
A3:Pressure oil output port-pilot oil source
B3:Pump suction port-pilot oil source

Function (front pump & back pump)


z Convert the engine rev motion which transferred to the pump spindle and torque to hydraulic
energy. Export pressure oil according to the amount of load.
z It is possible to change the output quantity of pressure oil through changing the angle of
sloping cam plate.
Structure (front pump & back pump)
z (see JPG0002):two variable cam-type plunger pumps are connected by spline joint (114),
transfer motor revolution to the drive axle of the front F(111)and drive the two pumps. Oil
suction and output ports are placed at the valve block (312)-the connecting place of the two
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pumps. Front pump and back pump use the same suction port. Take the two pumps for example
because the sameness of the two pumps construction and motion theories. This pump is mainly
consists of rotary mechanisim for pump rotary motion, tilted plate mechanism for adjusting
output flow and valve cover mechanism for doing oil suction and output motions alternately.
z Rotary mechanism:consists of drive axle F(111),oil tank body(141),
Plunger (151), slipper (152), pressure plate (153), spherical cylinder (156), shim (158) and oil
tank spring (157). The end sides of drive axle are supported by roller bearing (123) and needle
bearing (124). Install piston shoe on piston, form sphero joint and reduce the pushing force.
There is a shell part on piston shoe (211) to adjust the balance of oil pressure. For the servive
mechanism of piston shoe to move smoothly on supporting plate, oil pressure spring would press
piston shoe on supporting plate by pressure plate and spherical cylinder liner. And oil tank body
also is pressed on the valve plate (313) by oil tank spring.
z Sloping cam plate mechanism:consists of sloping cam plate(212), piston shoe(211),sloping
cam plate supporter(251), tilting cylinder liner(214), tilting pin(531) and servo-oil tank(532).
Sloping cam plate is supported on the supporting platform which formed a cylindraceous part at
the opposite side of piston shoe moving face. Adjuster controls the oil pressure and makes the
service piston move side-to-side under the direction of oil pressure cavity,Then the tilting angle
(α)can be changed in the presence of the ball part of tilting pin and the shaking of sloping cam
plate.
z Valve cover mechanisim:Consists of valve block (312), valve plate (313) and valve plate
pin (885). The valve plate with two legena holes is placed on the valve block and supplying and
recovering oil for cylinder. The oil switched by valve plate is connected with exterior piping by
valve block.
Working process (front pump & back pump)

1.Working process of pump


i Tank body(141)and axle(1)rotate together(see JPG0003),slipper(152)slips on level A . Sloping
cam plate(212)moves around column face B ,so the angle changed between the central line X of
sloping cam plate(212)and the axis of tank bady(141). (This angle α is called sloping cam plate
obliquity).
ii The central line X of sloping cam plate(212)remains the obliquity α. Level A does cam
movement relatively with slipper(152). So plunger(151)does axial motion in tank body(141),and
procucts the capacity difference E and F in tank body(141). Capacity differenc F-E results in
pump oil suction and oil drain.
That is, drain oil as tank body (141)rotating and the capacity of tank cavity E reduced. On the
other hand, tank cavity F increased and would suck oil in this position.
iii As the central line X of sloping cam plate(212)in line with the axial ine direction of tank
body(141)(sloping cam plate obliquity=0) , the capacity difference E and F in tank
body(141)turns to be zero,pump would not suck and drain oil.(It will not form the position Z
(obliquity =0) actually).

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111:Drive axle
123:Roller bearing
124:Needle bearing
141:Oil tank body
151:Plunger
152:Slipper
153:Pressure plate
156:Spherical cylinder
157:Oil tank spring

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158:Shim
211:Piston shoe
212:Sloping cam plate
214.Tilting cylinder liner
251:Sloping cam plate support table
312:Valve block
313:Valve plate
531:Tilting pin
532:Servo-oil tan

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Maintenance standard (front pump and back pump)
When the wear extents of every parts of pump exceed the following standard, change or
adjust it again. While apparent damage happens it must be replaced.

standard dimension /
recommend replacing value
Name and inspection Item Disposal
pump type
K3V112 K3V140
gap value in piston and oil tank replace piston or
0.039~0.067 0.043~0.070
(D-d) oil tank
gap part looseness of piston and replace piston and
0~0.3 0~0.3
piston shoe(δ) coupling parts
replace piston and
thickness of piston shoe( t ) 4.7~4.9 5.0~5.4
coupling parts
replace oil tank
free height of oil tank spring(L) 40.3~41.1 47.1~47.9
spring
replace pressure
assembly height of pressure plate 11.0~12.0 12.5~13.5
plate and spherical
and spherical liner(H-h) liner

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Function (adjuster)
Use adjuster to realize the adjusting and controlling output power and flow of main pump
automatically.
Structure (adjuster)
Main pump adjuster(see JPG0006):Front and back pump adjusters are also consist of
plunger units 1,plunger units,servo-valve core unit 3, connecting rod(612、613), feedback
rod(611),shell and end cover. They are the parts that make up the flow and power adjusting units
of main pump.Pin shaft(548 ) connects feedback rod(611)with servo-piston on main pump.The
whole adjuster is connected to the body of main pump by four hexagon socket screws(438).
Working procedure (adjuster)
The adjuster of main pump could adjust the flow and power automatically and prevent
engine from overloading operations.
1. Flow control
The obliquity (output flow) could be controlled randomly by changing leading pressure Pi.
The working way of adjuster: Control negative flow (negative sense control) as leading pressure
Pi increasing and output flow Q decreasing. This unit could give leading pressure instruction in
line with the necessary operation flow.Piston pump only output essential flow. Therefore power
will not be exhausted in vain.
z Motion illustration
See as the following figure (JPG0004). The output flow of piston pump could be controlled
randomly as the changing of leading pressure Pi.

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z Motion of flow reduction
As leading pressure Pi increased, leading piston (643) moves right. As the pressure of guide
spring(646)and oil pressure resting at the equilibrium position, the pin(875)fixed on connecting
rod 2(613)is embedded in the groove part [A part]of leading piston.Therefore, as the moving of
leading piston, connecting rod 2 pivots on point B[fixed by pivot plug(614),pin(875)]. Because
of the pin (897)fixed on feedback connectiong rod (611)lies in the big hole part [C part]of
connecting rod 2, pin (897)would move right as connecting rod 2 rotating. The (D) part of
feedback connecting rod tables the pin (548) fixed on tilted pin (531)(tilted pin shakes tilted
plate ). So when pin(897)moves,feedback connecting rod pivots on point D. Short pipe would
move right because feedback connection rod connects pin (874) with short pipe (652).As moving
procedure, output pressure P1 is led to the port of servo-piston through pipe C1. While output
pressure P1 is led to the small port of servo-piston and makes it move right to reduce obliquity as
area difference. When servo-piston moves right, point D will also move right. Offsetting
spring(654)on short pipe produces a pull force that will make short pipe move left and that
makes pin(897)pressed to the big hole part[C patr] of connecting rod 2. As the moving of point
D, feedback connecting rod pivot on point C and short pipe moves left. These moving make
sleeve aperture (651) and short pipe aperture (652) close slowly, and servo-piston would stop as
it closed completely.
z Motion of increasing flow
When leading pressure Pi decreased, the pressure of guide spring (646) makes leading
piston (643) move left. Connecting rod 2(613)pivots on point B. Pin (897) is pushed to the big
hole[C part] of connecting rod 2 by offsetting spring (654) through short pipe (652), pin (874)
and feedback connecting rod (611). As the moving of connecting rod 2, feedback connecting rod
2 pivots on point D and short pipe moves left.
As short pipe moving, pipe C would open to oil tank, the pressure on big port of
servo-piston would reduce. Output pressure P1 on small port would act on servo-piston and
make it move left and flow increased. Point D also moves left as servo-piston moving. Feedback
connecting rod pivots on point C. Short pipe moves right. This moving repeated until the
aperture of sleeve and short pipe closed and would stop at the closed place.

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2. Power control
The increasing of output pressure P1 and P2 of piston pumps makes the obliquity (output
flow) reduces automatically and controls output torque under fixed value (input power remains if
rev remains). Operate according to the summation of load pressure on two piston pumps of the
double piston pumps in series and take full power way. Therefore, under the power control status,
make the obliquitis (output flow) the same by controlling the adjusters of every piston pumps. In
spite of how variable the two piston pumps loads are, this mechanism could prevent the
overloading operations of engine automatically.
The motiong of power control is the same as flow control. The following are simple
illustration. (Refer to flow control about the details of every units motion).
z Motion instruction
Increase load pressure (see fig JPG0005) and decrease obliquity of piston pump to prevent
engine overloading. As the adjuster adopts the synchronous power control way, so control the
obliquities of the two piston pumps (extrusion capacity) to make them the equivalent. See as the
following formula.

Tin=P1*q/2π+ P2*q/2π= (P1+P2)*q/2π


z Prevent overloading motion
When the output pressure P1 and P2 of two sides piston pumps increased,P1 and P2 would
act on the compensation piston(621),push compensation rod (623)to the right until the elasticity
and oil pressure of exterior spring(625) and interior spring(626) reach the equilibrium position
and stop moving. The motion of compensation rod is conveied to connecting rod 1 through pin
(875). Connecting 1 pivots on pin (875)[point E] which is fixed on pump case(601). There is a
prominent pin (897) fixed on feedback connecting rod (611) on the big hole [F part] of
connecting 1. As rotating of connecting rod 1, feedback connecting rod 1 pivot on point D, short
pipe (652) moves right and output flow Q reduced to get negative flow control.
As short pipe moving, output pressure P1 is led to the big port of servo-piston through pipe
Cℓ,servo-piston moves right, output flow of piston pump is reduced to prevent motor
overloading. The motion of servo-piston conveies to feedback connecting rod through point D.
Feedback rod pivots on point F, short pipe moves left and keeps moving until the port with
sleeve(651) closed and then it would stop.
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z Flow resetting motion
When the output pressure P1 and P2 of two sides piston pumps decreased, compensation
rod(623) is pushed back by spring(625,626). Connecting rod 1 pivots on point E. As it moving,
feedback connecting pivots on point D and short pipe moves left. Pipe Cℓ would open to oil tank,
servo-piston moves left and its pressure on big port decreased, output flow of piston pump
increased.The motin of servo-piston would convey to short pipe by feedback units and keep
moving until the port of short pipe and sleeve closed.
3. Priority mechanism of instruction
According above stated,tilting instruction of flow and power control are conveyed to
feedback connecting rod and short pipe through the big port [part C & F ]of connecting rod 1 and
2. Part C & F adopt the structure of prominent pin (φ4), therefore, only lesser connecting rod can
get to pin (897) while the holeφ8 of connecting rod with big tilt instruction would not get to pin
(897). The little tilt instruction of flow control and power control would be adopted first.

30
601.Pump shell 626.Internal spring 651.Sleeve
611.Feedback rod 627.Telescopic link (C) 652.Slide valve
612.Connecting rod (1) 628.Regulating screw (C) 653.Spring
613.Connecting rod (2) 629.Cover (C) 654.Offsetting spring
614.Bearing pin 630.Locknut 655.Regulating spring
615.Regulating pole 631.Sleeve PF
621.Compensation piston 641.Guide housing
622.Piston cover 643.Guide piston
623.Compensation rod 644.Spring (Q)
624.Spring (C) 645.Spring (Q)
625.External spring 646.Guide spring

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Function (pilot oil source)
Provide stable pressure oil for pilot control of multiple way valve, unlocking of swing
motor, high and low speed control of traveling and electronic proportional valve of main pump,
ect. The maximum pressure in pilot oil circuit is set by the relief valve in pilot oil source.
Structure (pilot oil source)
Pilot oil source (see figure JPG0007) :consists of two meshed gears(354、353),two drive
shafts (354、353) standing on shell, relief valve module and shell (351). Spline end of power
input shaft (353) connects with spline hole on main shaft end (113) of back pump. Bolt (435)
connects shel l (351) of pilot oil source to supporting plateform (251) of sloping cam plate on
main pump.

353.Gear
354.Gear
351.Shell
435.Hexagon socket screw

32
Function (electromagnetic proportional decompression)
It can set the output power of main pump momently. When coil of electronic proportional
valve gets a current value from host machine controller, the output port of proportional
decompression valve would export a corresponding pressure value. The force acts directly on
plunger rod (621) of adjuster to counteract parts of the spring force and reaches the output power
of main pump which has been set.
Structure (electromagnetic proportional decompression)
Electromagnetic proportional valve(see figure JPG0008):It is a screw thread plug-in valve
and is installed in valve plate (313) of main pump. It consists of valve pocket (312), valve core
(311), offsetting spring (324) and electromagnetic coil (801).

311.Valve core
312.Valve pocket
324.Offsetting spring
801.Proportional electromagnetic coil

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3.2.4 Swing motor
Summary
M5X180CHB-12A-1PA/265-149
It consists of valve units, motor and swing reductor.

1. valve units PG:Unlocking pressure oil import


2. swing motor SH:Unlocking pilot opening
3. swing reductor L:Gear oil detecting and blow vent
A、B:Main oil opening IP:Gear oil filling opening
M:Replenishing opening DP:Gear oil drain opening
PA、PB:Main oil pressure detecting opening AN:Bearing vent opening
DR:Oil drain opening GN;Butter smear opening

Function (motor noumenon)


Convert the oil flow and pressure which provided by hydraulic pump to torque and rev, and
then convey them to swing redactor so as to drive the running of uppercarriage. Swing stop brake
fits for wet multichip brake. Releasing pressure by brake is input by pilot pump only as the
operating of working device and swing mechanism. The other operating besides swing and
working devices or during the engine nonoperating, Brake releasing pressure returns to hydraulic
tank, so brake works automatically by spring.

34
Structure (motor noumenon)
Motor noumenon consists of sloping cam plate, rotor, plunger, port plate,shell, output shaft
and swing stop brake (consists of spring, brake piston, sheet steel, friction disk and swing stop
brake switch ), ect.

121:Plunger 702:Brake piston


124:Sloping cam plate 743:Sheet steel
111:Rotor 742:Friction disk
131:Port plate 031:Swing stop brake switch
301:Shell 161:Drive shaft
712:Spring

Working procedure (motor noumenon)


1. power and rev output
After high pressure oil flowing into rotor through input hole (a)of port plate(1)(see figure
JPG0153),the produced hydraulic pressure works on plunger and produces force F on axial
direction. Force F produces upright force F1 and axis right angle force F2 separately on sloping
cam plate (3) through slipper(2). Force F2 conveys to rotor (4) through plunger and produces
turning pair around output shafts. There are nine plungers arranged equidistantly in rotor.
Plunger communicates with input hole of high pressure oil and conveys swing torque to output
shafts in turn. When change oil in and out direction in reverse, the swing direction of power shaft
would turn reverse.

35
2. brake releasing
1) When swing or working device joy stick operating, swing stop brake release valve rod in
signal pilot pressure control valve moves and pilot hydraulic oil flows into oil port SH through
pilot pump.
2) Valve rod is pushed right by pilot pressure which flows into oil port SH. Pilot pressure in oil
port PG comes into brake piston room through valve rod and the upper and the under cavities in
brake piston room are broken, brake piston moves up and motor releases brake.
3. brake works
1) When swing and joy stick of working devices release, swing stop brake release valve rod in
signal pilot pressure control valve returns to free position, pilot pressure flows into oil port
SH would be decreased.
2) Valve rod returns back. Pilot pressure from oil port PG is blocked up and time-delay valve
opened.
3) Hydraulic oil in brake piston room returns to swing motor shell through time-delay valve.
4) Spring force 1 acts on sheet steel and friction disk. Sheet steeel and friction disk mesh with
rotor outer diameter and shell inner diameter by brake piston. So rotor outer diameter is
supported by friction force. When engine stops working, there is no pilot pressure into oil
port SH and makes brake to work automatically.
4. brake delay
1) When the order of releasing brake for hole SH disappears, valve rod moves left under the act
of spring and cuts off hole PG and PR.
2) Oil in hole PR flow into hole D through orifice in time-delay valve. Brake has certain stroke
volume (V:cm3). Assume the flow through orifice is Q, then the delay time from releasing
status of brake piston to contact friction disk and sheet steel is : t=V/S.

36
Maintenance and service standard (motor noumenon)
1. Replace standard for friction parts
When friction extent of every friction parts over the standards in the following figure, it
should be replaced or adjusted again. While there are evident damages in appearance, it should
not refer to the following standards and should be replaced in advance.
replacement
standard
item recommended remedy
dimension(mm)
value(mm)
fit
replace plunger or
clearance-plunger 0.027 0.052
rotor
& rotor(D-d)
hinge
replace plunger and
clearance-plunger 0 0.3
slipper units
&slipper sphere(δ)
replace plunger and
slipper thickness(t) 5.5 5.3
slipper units

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2. Refacing standard for swing engagement face
As the degrees of roughness of every parts’ swing engagement faces over the following
standards, it should be refaced or replaced.

parts description standard degree of roughness need to be refaced degree of roughness

slipper 0.8 一 Z(Ra:0.2) (grind) 3 一 Z(Ra;0.8)

sloping cam plate 0.4 一 Z(Ra=0.1) (grind) 3 一 Z(Ra=0.8)

rotor 1.6 一 Z(Ra:0.4) (grind) 12.5 一 Z(Ra:3.2)

port plate O.8 一 Z(Ra=0.2) (grind) 6.3 一 Z(Ra=1.6)

Sructure (valve units)


Valve unit consists of compensation valve, relief valve and anti-reverse-rotation valve, etc.

351: Compensator valve 051: Overflow valve

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Function (valve units)
Compensator valve:Prevent motor sucking air or cavitation erosion due to oil unable to
supply in time during the process of braking.
Overflow valve:When swing operation starts or stops, oil pressure in swing oil way
increased. Relief valve could prevent oil way pressure from going up above the setting pressure.
Anti-reverse-rotation valve:When swing stops, it reduces revolution shaking owing to
inertia of revolving body, recoil strength and rigidity of mechanical system and compressibility
of hydraulic oil, ect. And it could prevent the load things in bucket from coming out and reduce
cycle time efficiently. (Good locating performance and fast moving for the next operation).

Working procedure (valve units)


1. Compensator valve
During swing stops, swing motor is pushed by the inertia force from swing platform of
upper carriage. Motor pushed by inertia force runs faster than pushed by output pressure oil from
pump. So cavity would be produced in oil way. To prevent cavity, when pressure in swing oil
way is much little than pressure in return oil way (oil port M), check valve would open and
hydraulic oil enter into oil way from hydraulic tank to eliminate the status of lacking oil.

2. Overflow valve
Low-pressure overflow operation(shock absorption function):
1) Pressure of oil port HP (swing oil way) enter oil cavity C through thr orifice of lift valve.
2) Pressure oil in oil cavity C enter oil cavity A and B separately through oil way A and B.
3) Pressure area in oil cavity B is bigger than that in oil cavity A, so piston moves left.
4) Piston moves continuously and pressure difference presents in lift valve. When pressure

39
difference over spring force, lift valve leaves its position and makes pressure oil enter into oil
port LP.
5) When piston moves total excursion, pressure difference of lift valve disappears and makes
lift valve back to its position.
High-pressure overflow operation(prevent over loading):
1) After piston moves total excursion, spring is compressed to increase the pressure in oil way
to the setting pressure.
2) If the pressure in oil port HP increased above the setting pressure of spring, lift valve leaves
its positon and makes pressure oil flow into oil port LP through oil port HP.
3) When pressure in oil port HP decreased to the setting pressure, lift valve returns to its
position because of the spring force.

3. Anti-reverse-rotation valve

See figure JPG0159 , figure 1 shows the connection between neutral condition of
anti-reverse-rotation valve and hydraulic circuit. Assume that there was brake pressure at the
side of port A and is in brake state. When port A is pressed, the pressure flows into room n
through way 1, port above the shaft of valve base 313 and way m of plunger 311. When pressure
P exceeds the setting value of pring 321, plunger 311 leads spring 321 moving left. Valve base
313 is pushed by plunger 311 and leads spring 322(week elasticity) moving left. [as figure 2].
When inertia load stops moving, brake pressure decreases. When P <PS, plunger 311 moves
right and returns under the act of spring 321. Valve base 313 also moves right under the act of
spring 322. But there is antihunt action produced by orifice g in room P, therefore, comparing
with plunger return, the return time of valve base lags. Part t on valve base becomes open status,
through the procedure of 1一t—r—k,it forms the way which consists connect port A with port
B,ie, two sides of the port of hydraulic motor. Work as the above principle, when the pressure in
port A and port B are as the same, using close pressure of port A to prevent reversal of hydraulic
motor.

40
Function (swing reduction device)
Planetary gear train in reductor could reduce the output speed of motor noumenona and
increase torque.

Structure (swing reduction device)

41
231: Primary planet carrier 204: Second central gear
211: Primary central gear 230: Second planet carrier
210: Primary planet pinion 201: Gear shaft
202: Gear ring 102: Shell
203: Second planet pinion

Working procedure (swing reduction device)


Swing reduction device is two-class reduct planetary gear style. Gear ring(202)is formed as
a whole on the surface of shell(102). Because shell (102) is fixed on the upper swing platform,
gear ring (202) could not turn. Swing motor shaft (161) conveys torque and rev to primary
central gear (211). Then, conveys to second central gear (204) through primary planet pinion
(231) and planet carrier (231). Second central gear (204) conveys to gear shaft through second
planet pinion (203) and planet carrier (230). Gear shaft meshes with inner gear which fixed on
swing bearing of undercarriage to turn upper swing platform running.

3.2.5 Pilot control valve


Summary
Generally, there are two types of pilot control valve configured with every machine. One is
left and right handle valve used to control swing/ working devices. The other is two-gang pedal
valve for controlling travel. One-gang pedal valve for auxiliary control may be configured
according to the demands. Although there is difference between external and inner structure,
their working theories are the same with one oil input port P and one oil return port T.

1. Handle pilot control valve TH40K1344(left side)、TH40K1345(right side)

oil port oil port


control motion control motion
No. No.
bucket platform swing
1 1
inward-retract left
arm epicyclic
right 2 boom down right 2
motion
handle handle
bucket epicyclic platform swing
valve 3 valve 3
motion right
arm
4 boom up 4
inward-retract

42
2. Travel control pilot valve PVD8P5021A

oil port No. control motion

1 forward-right travel
travel backward-right
2
two-gang travel
pedal valve 3 forward-left travel
4 backward-left travel

43
3. Auxiliary pedal valve RCV8C1109

44
Structure (right handle pilot control valve)

302: Cam 201: Valve rod


212: Push rod 101: Shell
216: Spring guide sleeve 111: Interface plate
241: Balance spring PP: Working cavity
221: Release spring T: Oil return cavity
P: Feeding cavity

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Working procedure (right handle pilot control valve)
The theory and working procedure of pilot control valve are similar. Only working
procedure of right handle control valve are described here.

Free position(output graph:A~B)


1. In free position, valve rod (201) blocks up input oil cavity PP (from pilot pump). Working
cavity communicates with oil reture cavity (hydraulic tank).So, the oil pressure of output oil port
(to control valve) is the same as the pressure of oil port T.
2. When joystick tilts slightly, cam (201) tilts, push rod (212) moves down. Then push rod (212)
compresses release spring (221) along spring guide sleeve (214). Their oil pressures are the same
because of the communication of working cavity and oil return cavity.
3. It is always in this status as the communication of working cavity and oil input cavity.
During proportional decompression(output graph:C~D)
1. When joystick tilts again and makes push rod (212) move down further, working cavity
communicates with oil input cavity and makes pressure export.
2. Oil pressure of output oil port acts on the bottom of valve rod (201) and pushes valve rod (201)
up.
3. However, after the push-up force acts on the bottom of valve rod (201) conquers the elasticity
of balance spring (241), balance spring (241) would not compress, valve rod would not lift and
the oil pressure of output oil port would increase.
4. Because of the increasing of oil pressure, the force on push-up valve rod (201) increases. After
the force conquers the elasticity of balance spring (241), balance spring (241) is compressed to
make valve rod (201) move up.
5. When valve rod (201) moves up, the opening between input oil cavity and working oil cavity
closes up so the pressure oil in output oil port would no more increase.
6. When valve rod (201) moves down, valve opens up, and oil pressue in working cavity
increases, the pressure acts on the bottom of valve rod increasing and repeat the motion
procedures from step 2 to step 5. In this way pressure oil and spool operating stroke can be
exported proportionally.

46
Total excursion(output graph:E~F)
1. When joystick is in total excusion, push rod (212) moves down till the push rod (212) of pilot
valve comes into contact with shell (111).
2. Therefore, the oil pressure of output oil port and oil port P are the same.

3.2.6 Electromagnetic valve


ST0661-AA00

1: Accumulator FP: from pilot oil source


2: Pilot oil way lock solenoid valve FT: to hydraulic oil tank
3: Spare solenoid valve F1: to pressure increasing port of two-stage relief
4: Pressure increasing solenoid valve relief valve (boosting)
5: Two-speed travel solenoid valve F2: to central swing joint (two-speedcontrol)
F3: to pilot oil collecting block

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Technical parameters
rated pressure 3.5MPa accumulator air pressure 1.5MPa

rated flow 30L/min accumulator capacity 0.46L

magnetic coil DC24V

3.2.7 Pilot filter

EF-097B

1. Cover Technical parameter


2. Filter core Rated pressure: 14Mpa
3. Shell Rated flow: 22L/min
Filtering precision: 20μ

3.2.8 Travel motor


Summary
MAG-170VP-3800G-1
Travel device consists of valve unit, motor noumenon and travel speed brake.Travel motor
is variable cam-type plunger motor which is fit with stop and release brake (wet negative
pressure multiple-disk brake). Travel motor is driven by pressure oil of pump and transmits
rotary force to travel speed brake. Travel speed brake is third planet pinion. It converts rotary
power from travel motor to low speed high torque power so as to drive sprocket and track. Valve
unit is used to protect motor overloading, two-speed switch, maintain the steady speed of motor,
reduce hydraulic shock of motro and prevent producing gas cavity.

48
1: Valve unit PS:Two-speed control port
2:Motor noumenon Tin: hydraulic oil filling opening
3:Travel speed brake FILL: gear oil refill opening
p1: main oil port LEVEL: detecting port of gear oil
P2: main oil port DRAIR: gear oil drain
Pm1: pressure testing port (P1) of main oil
Pm2: pressure testing port (P2) of main oil pressure

Function (travel speed brake)


Reduce the rev and increase torque of hydraulic motor by travel speed brake to meet the
requirement of travel speed and tractive force.
Structure (travel speed brake)
Travel speed brake consists of two-stage planetary gear train, reduction case (4), gear case
end cover (27) and gear shaft (25). Gear shaft (25) connects with output shaft of motor
noumenon through splines. Planet pinion meshes with reduction case (4) which is supported on
the shell (1-1) of motor noumenon by angular contact ball bearing (3).

49
1-1:Shell of motor 14:Screw
3: Angular contact ball bearing 15:Second central pinion
4: Reduction case 17:Primary planet carrier
6: Bracket 20:Needle bearing
11:Needle bearing 25:Gear shaft
12:Second planet pinion 27:Gear case end cover

Working procedure (travel speed brake)


Power and rev transmit to reducer through gear shaft (25). Then transmit through primary
planet pinion (21) →primary planet carrier (17) →second central pinion (15) →second planet
pinion (12) →to reduction case (6) with gear ring. Motor shell (1-1) is connected by bolts to
down carriage. Sprocket meshed with track is fastened on reduction case (4) by bolts. So, power
is transmitted to track

Function (motor noumenon)


Convert fluid pressure and flow to torque and rev then export them to run the machine.

Structure (motor noumenon)


Travel motor is cam-type double-discharge axial piston motor. It consists of port plate

50
(1-21), sloping cam plate (1-5), rotor (1-4-1), plunger (1-4-2), shaft (1-3) and brake plunger
(1-15) etc. Shaft (1-3) connects with rotor (1-4-1),plunger (1-4-2) inserts in rotor. Port plate
(1—21) clings to rotor but would not rotate with it. Slipper and rotor are pressed on sloping cam
plate under the act of spring (1-4-7).

1-3:Shaft 1-1: Shell


1-4-3:Slipper 1-7: Adjusting piston
1-4-2:Plunger 1-20:Balance spring
1-21:Port plate 1-15: Brake plunger
1-4-1:Rotor 1-14: Friction disk
1-5:Sloping cam plate 1-13: Steel disk
1-4-7:Spring 1-18: Brake spring

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Function (valve unit)
z Balance valve:When machine travels downgrades, it would get out of control as its weight
make the machine itself move faster than motor. This is very dangerous. However, balance
valve can prevent it.
z Buffer overflow valve:When machine stop short, start-up or travel reverse, it could release
the instant high pressure produced by motor so as to prevent the damage of motor and
pipeline.
z Two-speed control valve:Switch motor discharge to control high and low speed of motor.

Structure (valve unit)

Working procedure
1. Working procedure of motor
When operate travel joystick, pressure oil from control valve are converted to oil port (P2).
52
Pressure oil push away the check valve (1-2-2-2) in balance valve core (1-2-2-1) and flow into
oil cavity (M2) through motor,flow into the plunger cavity in rotor (1-4-1) through port plate
(1-21) so as to give rotary applied torque. Meanwhile, return oil from plunger cavity flow out
through oil cavity (M1). But motor oil output cavity (M1) is shut off by check valve (1-2-2-2)
and balance valve core (1-2-2-1). So the pressure of oil feeding side increased. Then the pressure
oil flow from orifice (G1) into balance valve oil cavity (S1).Balance valve core push right when
the pressure in oil cavity (S1) is higher than the converse pressure of balance valve core.
Therefore, oil cavity(M1)connects with oil port(P1),that is, motor oil return side opened and
motor begins to run.

2. High and low speed control


Switch high and low speed by moving adjusting piston (1-7) and changing tilt angle of
sloping cam plate (1-5).
1) From high to low speed of motor
When motor is in high speed, the high pressure oil from oil cavity M1 or M2 acts on
adjusting pistion (1-7) and makes these plates at minimum angles through the opening in valve
pod (1-2-9). If travel model is currently on low speed shift and MC (main controller) doesn’t
send signals to pilot two-speed solenoid valve, the oil cavity (K) connects with it would be cut
off. So valve rod (1-2-9) may return to its original place through spring (1-2-10). The oil canals
in piston cavity (F) and oil cavity M1 or M2 are cut off while drain oil canal of piston cavity (F)
and shell is opened. Sloping cam plate (1-5) turns right to increase its angle. Meanwhile, the oil
in piston cavity (F) flows back to oil tank through damping hole and oil drain return circuit.
When sloping cam plate (1-5) turns at maximum angle, motor displacememt turns maximum and
motor speed turns to low speed.
2) From low to high speed of motor
When solenoid valve is excited, pilot pressure oil from main pump flows into oilcavity (K)
through oil port (PS). Two-speed control valve core (1-2-9) moves left. Main pressure oil from
(M2) or (M1) flow into oil cavity(V),which connects with adjusting piston cavity (F). So
adjusting piston (1-7) is pushed to the left side by oil pressure. Then sloping cam plate (1-5)
moves to the minimum tilt angle direction, motor capacity turns to mini.and machine comes to
travel in high speed.

53
3. Stop and release brake
Stop and release brake is a kind of wet multi-disc brake. Brake is negative pressure style
and it would declutch only as hydraulic oil released by brake flows into the piston chamber of
brake. Stop and release brake decluches automatically. Friction disk (1-14) and sheet steel (1-13)
bond with rotor (1-4-1) and shell (1-1) separately.
1) Travel start
Suppose feed oil from (P2) and when operate travel joystick, pressure oil from pump flow
into oil port (P2) to make balance valve core (1-2-2-1) move right. Oil cavity (E) connects with
high pressure oil in (P2) and flow into brake piston cavity (F) through oil canal (L). Pressure oil
absorbs spring force of spring (1-18) and push brake piston (1-15) to the left. Then sheet steel
(1-13) separates from friction disk (1-14) and release braking.
2) Travel stop
Suppose feed oil from P2 and when travel joystick is placed at middle position, motor stop
oil feeding and pressure of P1 disappears. Meanwhile, balance valve core (1-2-2-1) return to
54
middle position under the act of spring force. The oil canal from oil port (P2) to oil cavity (E) is
cut off. Brake piston (1-15) moves right under the act of brake spring (1-18) until sheet steel
(1-13) contacts with friction disk (1-14) and so produce brake torque. Then oil in oil cavity (F)
flows back to oil tank from motor shell through orifice in brake piston. Oil return orifice in brake
piston (1-15) is for producing brake lag effect and stop and release brake would brake after
motor stop by hydraulic brake.

4. Working procedure of balance valve

Suppose feed oil from(P2)and return oil from (P1),when machine travel on falling gradient,
travel speed may over motor speed as the weight of the machine. And motor would be in
load-free running. Then the pressure of motor inlet oil port would decrease, and also do the
pressure in oil cavity (S1). Balance valve core (1-2-2-1) would move left under the act of spring
when the pressure in oil cavity (S1) decreases under the switch pressure of balance valve core,
which produces throttle effect to motor oil return canal and forms oil return backpressure to
avoid losing control of machine. The higher of machine’s falling speed, the higher of the back
pressure to control travel speed by supplied flow of pump so as to ensure smooth travel.

55
5. Working procedure of buffer overflow valve

Suppose feed oil from (P2) and return oil from (P1),when joystick back to middle position,
the pressure of motor oil inlet port (P2) decreases, and so the pressure of cavity S1. Balance
valve core (1-2-2-1) returns to the left side under the act of spring force and oil canal of motor oil
return side (M1) is closed. Under this circumstance, motor still run under the effect of inertia
force. Pressure of oil return side (M1) increase and would act on valve core (1-2-7-2) through
port (P) of buffer relief valve. Valve core (1-2-7-2) would open immediately when the pressure
is above the setting pressure of spring (1-2-7-5). Then high pressure oil is released from port (T)
to motor low pressure side (M2). Meanwhile, oil in M1 flow into spring cavity through damping
hole (X) and flow out from hole (Y) to act on the left end side of plunger (1-2-7-9) so as to make
plunger move right.When plunger moves to the left end, pressure of spring cavity increase.
When the force acts on the left end side of valvel core is above the right side force, valve core
(1-2-7—2) would be shut off. As there is a period for plunger (1-2-7-5) to move from left end to
right end, pressure increased instantly is avoided and also as hydraulic buffer. And the valve can
act as the same when motor just start.

3.2.9 Multiple way valve


Summary
KVMG-270-XB
Multiple way valve is integral type and consists of main overflow valve, blocking relief
valve, flow control valve, check valve, jockey valve, by-pass shutoff valve, straight travel valve
kit and 9-kit main control valve kit, etc.

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1:Check valve (arm valve kit 1) 22:Blocking relief valve (big cavity of arm)
2: By-pass shutoff valve 23:Negtive flow valve (P1)
3: Check valve (boom valve kit 1) 24: Oil return throttle valve (arm valve kit)
4: Flow control (rotary valvel kit) 25: Arm valve kit 1
5: Check valve (auxiliary valve kit) 26:Jockey valve (arm)
6: Check valve (left travel valve kit) 27:Boom valve kit 2
7: Check valve 28:Blocking relief valve (big cavity of boom)
8: Negtive flow valve (p2) 29:Flow control valve (rotary valve kit)

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9: Arm valve kit 2 30:Rotary valve kit
10:Locking relief valve (small cavity of arm) 31:Shutoff valve (auxiliary valve kit)
11:Boom valve kit 1 32:Auxiliary valve kit
12:Jockey valve (boom) 33:Left travel valve kit
13:Bucket valve kit 34:Check valve
14:Blocking relief valve (small cavity of bucket) 35:Blocking relief valve (small cavity of
15:Flow control valve (bucket valve kit) boom)
16:Right travel valve kit 36:Blocking relief valve (big cavity of
17:Straight travel pilot valve bucket)
18:Straight travel valve kit 37:Shutoff valve (auxiliary valve kit)
19:Check valve 38:Check valve (arm valve kit 2)
20:Main relief valve 39:Check valve (boom valve kit 2)
21:Flow control valve (arm valve kit) 40:Check valve (right travel valve kit)

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PA:Signal port of travel pressure pa3:From left handle control valve (rotary)
PC3:From oil port Pi1 pb3:From left handle control valve (rotary)
Pbu:To hydraulic oil tank pa4:To oil port Pi1
pcc:To oil port DR5 Pb4:To oil return block
PH:From solenoid valve (high and low Pa5:From left handle control valve (arm
pressure) epicycloid)
Pi1: From oil port Pa4 Pb5:From left handle control valve (arm
Pi2: Flow control valve pilot port (bucket digging)
valve kit) pa7:From right handle control valve (bucket
PS1:To main pump (negtive flow feedback of epicycloid)
back pump) pb7:From right handle control valve (bucket
PS2:To main pump (negtive flow feedback of digging)
front pump) pb8:From right handle control valve (boom
DR6:To oil port DR4 down)
DR4:To oil return block Pa8:From right handle control valve (boom
DR5:To oil return block up)
DR3:To hydraulic oil tank Pb9:To shuttle valve of oil port Pi2
T1:To radiator (main oil return) A1:To left side travel motor
T2:To hydraulic oil tank (main oil return) B1: To left side travel motor
P1:From main pump (back pump) A2: To auxiliary
P2:From main pump (front pump) B2:To auxiliary
prs1: To swing motor (deblocking signal) A3:To rotary motor
pa1:From travel control valve (left side B3:To rotary motor
travel) A5:To arm oil cavity (small cavity)
pb1:From travel control valve (left side B5:To arm oil cavity (big cavity)
travel) A6:To right side travel motor
pa6:From travel contrl valve (right side travel B6:To right side travel motor
pb6:From travel control valve (right side A7:To bucket oil tank (small cavity)
travel) B7:To bucket oil tank (big cavity)
pa2:From auxiliary control valve A8:To boom oi tank (big cavity)
pb2:From auxiliary control valve B8:To boom oi tank (small cavity)

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Function
Multiple way valvel is mainly used for distributing oil pressure and flow in oil circuit and
controlling flow direction, etc.
Structure

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Function
z Main oil circuit:arm valve kit 1(25) and arm valve kit 2 (9) act together to control arm oil
tank together and make a confluence of (P1) and (P2). Arm valve kit 1 (25) has the function of
oil returning and regeneration as arm oil tank extends. Boom valve kit 1(11) and boom valve kit
2 (27) take control together of boom oil tank to make a confluence of (P1) and (P2) as boom
lifting. Boom valve kit 1 (11) has the function of oil returning and regeneration as boom oil tank
goes down. Bucket valve kit (13) also has the function of oil returning and regeneration as
bucket oil tank extends.
z Pilot oil circuit:Each oil circuit connects with control valve directly takes control of the
stroke of main valve cores. Interior pilot oil circuit gets control of jockey valve and travel
straight valve, and exports the signal of rotary deblocking and travel pressure. Pilot oil circuit
connects with pressure increasing solenoid valve is for controlling the boosting of system.

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z Jockey valve : when joystick is in middle position, boom and arm would descend
automatically because of internal drainage of main valve core.
z Oil returning and regeneration:when boom descends , arm retracts and bucket digs, the
corresponding control valve kits have the function of oil returning and regeneration, which is for
increasing oil tank speed, preventing break-off of oil tank and tightening machine controllability.
z Travel straight valve:when travel motor runs together with other performers, travel motor
and other performers are fed oil separately to avoid travel action being interfered by other
actions.
z Main relief valve:when performer(except ratary motor)runs, main relief valve would
prevent overloading of system pressure and retain the pressure in the range of set value.
z Blocking relief valve:the oil circuits of boom , arm and bucket are fit with overload relief
valve. When performer moved by exterior load, blocking relief valve controls the oil circuit’s
pressure of performer to avoid abnormal increasing. And when the pressure decreases,
overloading relief valve complement hydraulic oil to prevent producing gas cavity.
z By-pass shutoff valve:get control of oil supply volumn by opening and closing the oil return
circuit of middle position.
z Flow control valve:It is assembled on arm, bucket and oil return circuit. And it would take
precedence over other performers to restrict the flow of oil circuit when in compound operation.
Match the actions of every performer by controlling oil inlet circuits of every valve kis.
Working procedure
1. Travel straight
1) When execute travel and other compound operations, machine travel straightly through
travel straight valve. The following is the figure of oil circuit when travel and bucket running at
the same time. When operate joystick to make bucket do epicyclic motion and left and right
motors travel together, the pilot signal oil of bucket from(Pa7) and the pilot signal oil(Pb1、Pb6)
from left and right travel act together to reverse travel straight valve core.
2) When travel straight valve core is moved, the pressure oil of pump (P1) supplies to left and
right travel motor at the meantime and the pressure oil from pump (P2) supplies to bucket, which
makes separate oil supply for travel and bucket to avoid getting the different speed between the
left and right travel motors because of the changing of bucket load. When other actions
compound travel action, these functions come into effect through travel straight valve.

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2. Main relief valve
1. The pressure in oil port HP (main oil circuit) is applied to pilot lift valve through orifice A of
main lift valve and orifice B of valve base.
2. When the pressure in oil port HP rises above the setting pressure of spring B,pilot lift valve
moves from its base to make pressure oil flow to oil port LP(oil return) through the oil canal and
clearance around sleeve.
3. Meanwhile, the pressure difference between oil port HP and spring cavity would rises because
of orifice A.
4. If the pressure difference rises above the setting pressure of spring A, main lift valve would
move from its place to make the pressure oil in oil port HP flow to oil port LP.
5. So, pressure in main oil circuit decreases.
6. When main oil circuit pressure decreases under the stated pressure, main lift valve would be
retracted by spring A.

Increasing operation of setting pressure


1. Controller MC gives signals to pressure increasing solenoid valve, solenoid valve closes, pilot
pressure conveies to oil port PH and piston compresses spring B.
2. Then, the force of spring B increases.
3. So, the pressure for pilot lifts valve moving increases to make the setting pressure of relief
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valve increase.

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3. Blocking relief valve
Relief operation:
1. The pressure in oil port HP (oil circuit of performer) applies to pilot lift valve through orifice
on piston.
2. When the pressure in oil port HP rises above the setting pressure of spring B,pilot lift valve
moves from its base to make pressure oil flow to oil port LP (hydraulic oil tank) through the
channel A and clearance around sleeve.
3. Meanwhile, the pressure difference between oil port HP and spring cavity would rises because
of orifice.
4. If the pressure difference rises above the setting pressure of spring A, main lift valve would
move from its place to make the pressure oil in oil port HP flow to oil port LP.
5. So, pressure in main oil circuit decreases.
6. When main oil circuit pressure decreases under the stated pressure, main lift valve would be
retracted by spring A.

Compensation operation:
1. When the pressure in oil port HP (oil circuit of performer) decreses under the the pressure in
oil port LP (hydraulic oil tank),sleeve would move right.
2. Then, hydraulic oil flows from oil port LP to oil port HP to avoid producing cavity.
3. When the pressure in oil port HP rises above the stated pressure, sleeve would be shut off by
spring C.

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4. Flow control valve
The functions of every flow control valves are shown as the following
flow control
compound operation
valve
arm boom lifting and arm
bucket bucket and boom lifting or digging with arm
rotary boom lifting and rotary

Take rotary flow control valve as example and state as below:

When operate rotary isolately:


1) The pressure oil from pump (P1) acts on check valve core and absorbs the force of spring 1
to lower check valve core.
2) So, the pressure oil from (p1) flows to rotary main valve core.
Boom lifting and rotary
1. The pilot pressure oil for lifting boom flows into the pilot port (Pi1)of rotary flow control
valve and acts on plunger 1. So plunger 1 drives plunger 2 to move up and stands on spring base.
2. When the pressure oil from (P1) acts on check valve core 1, it can not be opened as the other
side of check valve core 1 is standed. But interior throttle valve core can be opened if it can
conquer the force of spring 1. Then oil in rotary motor is throttled.
3. The load of boom lifting is higher than that of rotary. But there is throttle effect when oil into
rotary, which makes pressure oil distributed properly to boom oil tank and rotary so as to match
actions.

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5. Jockey valve
Retain operation
1. When joystick is on free position(valve kit place of free position),switch valve in jockey
valve would not move.
2. So, the pressure on the bottom of boom oil tank (the rod side of arm oil tank) transmitted to
the check valve (the side of spring) in jockey valve through switch valve.
3. So, check valve closes to stop oil returning to oil tank and decreases the shift of oil tank.

Relief operation
1. When arm retracts or boom descends, pilot pressure oil from pilot valve pushes the plunger of
jockey valve to move switch valve.
2. Then, the oil in spring chamber of check valve flows back to hydraulic oil tank through switch
valve.
3. So, check valve opens to let return oil flow from the bottom of boom oil tank (rod side of arm
oil tank) to main valve kit.

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6. Oil returning and regeneration
Regeneration functions of every valve kits are similar. Let’s take regenerative valve of
bucket as example:
1) When bucket digging, the return oil of the small cavity flow into part (a) of bucket kits and
act on check valve.
2) If the pressure in the big cavity of oil tank is lower than that in small cavity, check valve will
open.
3) Then, the return oil in small cavity will flow into the big cavith together with the outlet oil of
the pump to increase the speed of oil tank.
4) If the total excursion of oil tank moves or digging load increases, the oil circuit pressure in
the big cavity will increase above the pressure in the small cavity to shut off check valve and
stop the regeneration operation.

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3.2.10 Rupture valve
1. Summary
The purpose of equipment of maintainng valve on working device is to prevent oil cylinder
to be out of control when main pipeline connected to load device occurs rupture.

AL: balance pipeline


L: oil leakage
VSt: pilot control
Z: connect with oil cylinder
st: from main contrl valve kit

2 Installation position

Rupture valve is installed in protected oil circuit located between load device and
corresponding main control valve kit, and it is connected to load device by flange. Rupture
valves are equipped in two places of the whole machine, the one locates in boom cylinder large
cavity port, and another locates in arm cylinder small cavity port.

Function
When pilot hand lever (5) has no action, main control valve kit (2) locates in middle
position, and port Vst has no pressure, rupture valve is on no leakage and close state, and
cylinder cavity connected with it will be choked, the cylinder position is on maintaining state.
When oil in main oil circuit enters port St, oil can enter cylinder cavity freely through
by-pass check valve to move the cylinder. When cylinder need inverse action, oil in cylinder
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need to retrun to oil tank through rupture valve Z port; the control pressure from pilot hand lever
(5) enters Vst port and acts on adjusting slide valve in rupture valve,and conquer pressure spring
and open the valve, and then load device begins smooth falling action. When pilot pressure rises
again, the throttle of whole slide vale is fully opened and attains highest falling speed. During the
falling process, if pipeline rupture occurs, rupture valve will adjust the highest falling speed to
setting value to prevent from exceeding the regulated highest falling speed. When control lever
turns back to middle position, load device will be prevented from further falling because slide
valve is in balance due to load pressure. So adjusting slide valve will not be closed when oil
retuen pressure acts on it.
Secondary overflow valve is connected to port Z, when pressure of cylinder cavity
connected to the port attains to setting value, Secondary overflow valve will open the passway to
Vs port, and adjusting slide valve is opened, and pressure is unloaded from port Z to port St.
AL ports of rupture valve located on both sides of boom cylinder are connected hy rubber
hose, which can eliminate pressure difference of two cylinders.

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1. Main pump
2. Main control valve kit
3. Working device relief valve
4. Pilot control lever

4. Disassembly and assembly of rupture valve

Before disassembly and assembly of rupture valve, please fall working device to the ground,
and flame out the engine, and release residual pressure of the system.
★ Label the detached hoses for fear mistakes in assembly. In the same time, seal evey pipe port,
and save the seal parts properly.
Disassembly
A. Arm rupture valve

①. Detach pilot pipe (1) and oil discharge pipe (2).

②. Detach main oil circuit hose (3) and pipe clamp (4)

③. Detach fixed screw (5) finally

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B. Boom rupture valve
Detach oil leakage pipe (1), pilot pipe (2), balance pipe (3), steel pipe fixed screw (4),
rupture valve fixed screw (5) in turn.

Assemly
1) Assemble according to inverse sequence of disassembly.
★. Pay attention to connecting port label in rupture valve

★. Hose can not be contacted with rupture valve, or else hose will be damaged due to
overheated.
★. Flange mounting surface can not be damaged when assembly

★ : Screw torques of some parts in rupture valve is as shown in following figure.

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5. Adjutment of rupture valve
Rupture valve do not need adjustment in normal state, when it need adjustment, do it
according to following content.
Rupture valve will be heated to oil temperature in operation.
1) Adjust rupture valve open point
a). Loosen lock screw (1).
b). Rupture opening pressure:
Increase: tighten screw (2) clockwise.
Decrease: loosen screw (2) counter clockwise.

c). screw lock nut (1)

2) Secondary relief valve adjustment


a). Loosen lock nut (1)
b). Attain to needed working pressure by adjusting bolt (2).
c) .tighten lock nut (1)

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3.3 For electric equipments
Electric system contains following section:
3.3.1 Power supply circuit
3.3.2 Starting circuit
3.3.3 Pilot closing circuit
3.3.4 Engine stop circuit
3.3.5 Wiper and scrubber circuit
3.3.6 Controller
3.3.7 Engine control
3.3.8 ECM system
3.3.9 Multifunction monitor system

3.3.1 Power supply circuit


Accumulator grounding terminalis connected to carriage frame. When key switch is at close
state, accumulator current of positive terminal flow is shown as following figure.

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3.3.2 Starting circuit(key switch:START)
1) When the key switch is turned to START position, terminal 30 in switch is connected to
terminal 15 and 17.
2) When current from terminal 15 delivers a input signal to GPS and controller, GPS will
output a current signal to activate accumulator relay, accumulator current will be sent to starter
terminal B and start relay terminal B through accumulator relay.
3) Current from the teminal 17 delivers GPS an input signal, and GPS output a current signal to
ECM and start relay terminal S.
4) So start relay response, current flow from start relay terminal C to starter terminal C.
5) Magnetic coil in starter become live to make tips response, and starter runs.
6) When EMC get the electric signal from GPS, it will output an electric signal to make the
main relay to response. Current from fuse F1 flow to B terminal of start cut relay coil and coil of
fuel pump relay through main relay tips, and fuel pump relay
responses to make the fuel pump work.
7) After the engine runs, EMC make C terminal of start relay
get grounding, start cut relay responses, which make start relay
terminal G to be broken from ground connection, at this time,
even if the key switch is turned to start position, start can not
have any actions. This is the anti-restart function in starting
circuit.

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3.3.3 Pilot closing circuit(key switch:ON)
1) When pliot closing stick is put to free position, current of fuse F10 flow to GPS, after it
received the signal, it output a current signal to turn on pilot cut-off electromagnetic valve, and
pressure oil from pilot pump will be provided to pilot valve.
2) When pilot closing stick(as figure 1 show) is
turned to free position, terminal b of pilot switch has
no current, and GPS can not receive current signal
from terminal 17, so it can not output current to
terminal S of start relay, and start relay will not
response. So although the key switch is turned to
START position, starter will not rotate. This fuction
can avoid unexcepted hydraulic action when starting.

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3.3.4 Engine closing circuit(key switch:OFF)
1) When key switch is turned from ON position to OFF position, signal current will stop from
flowing from terminal 15 to GPS.
2) Output signal current of GPS stop to flow to ECM
3) ECM stops spraying of oil ejector, the engine will stop.
4) When engine stops, ECM will close main relay

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3.3.5 Wiper and scrubber circuit
1) Wiper OFF step
Wiper has no action in this step. Tips 1 and 2 are connected, and 4
and 5 are connected of the two pairs of tips in switch. Because tios 4
are suspended, so circuit is on off-state.
2) Wiper interval step
Wiper will act in 5-seconds interval, Tips 1 and 2 are connected, and 5
and 6 are connected of the two pairs of tips in switch. Current flow
direction is 6-5-2-1,and then from tip 1 to interval signal output
terminal 4 of wiper controller.
3) Wiper continuous action step
Wiper act continuously in this step, tips 2 and 3 are connected, and 5
and 6 are connected of the two pairs of tips in switch. Current flow
direction is 6-5-2-3,and then from tip 3 to continuous signal
output terminal 14 of wiper controller, and then wiper motor act
continuously under wiper controller controlling.
4) Scrubber operation
Scrubber switch is auto-reseting wane type switch, scrubber circuit is
cut-off when switch is not pressed; when it is pressed, and tips 2 and 3 are connected, current
flows into scrub input signal terminal 1 of scrubber controller.

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3.3.6 Controller
The controller is equipped on every control device in this machine, to display situation of
whole machine on monitor in cab, the controllers are connected by CAN.
‹ CONTROLLER: Main controller
‹ ECM: Engine control module
‹ GPS: globle locating system
‹ MONITOR: monitor

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CAN (controller local net)
Controller, monitor, GPS, controller and ECM are connected by concentration line, and
transfer signal and datas to each other. CAN concentration line includes two lines: CAN high
line and CAN low line. Every controller judge level of CAN concentration line by pressure
difference between CAN high line and CAN low line. Every controller arranges the level of
concentration line, and sends signal and datas to other controller.
CONTROLLER: main controller
It is used to control the operation of whole machine. Signals of control knobs from engine,
all kinds of sensors and switches will be sent to main controller and be processed in logic circuit.
Main controller sends signal corresponding to target engine rotational speed to ECM (engine
control module) by CAN communication, to control engine.

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Ports definition of main controller:
signal
stitch Input/output stitch signal description Input/output
description
controller
1 power Input 31 CANH1.2 communication
supply
controller
controller power
2 power Input 34 output
supply
supply
Analogue
3 Input 38 Electric signal Input
GND
4 throttle dial Input 39 Pressure switch S1 Input
oil level Travel
5 Input 40 Input
sensor pressyreswitch
power
11 supply Input 41 Pressure switch S2 Input
GND.
12 CANL1.1 communication 42 Air filter alarming Input
touch stress
13 CANH1.1 communication 43 Input
application
power
14 supply Input 44 auto idle speed Input
GND.
current travel high/low
16 Input 45 Input
output speed switch
18 RS232-R1 communication 46 spare
19 signal GND communication 47 power GND Input
controller
proportional
20 battery Input 48 Output
solenoid valve
power
Pump 1
proportional
22 pressure output 49 Output
solenoid valve PV1
sensor
Pump 2
proportional
23 pressure Input 50 Output
solenoid valve PV2
sensor
Pump 3
secondary overflow
24 pressure Input 51 Output
valve(reinforcement)
sensor
controller
travel high/low
27 power Input 52 Output
speed control valve
supply
Pressure
28 Input 53 travel alarm system Output
switch S3
30 CANL1.2 communication 54 buzzer Output

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ECM: engine control module
1) fuel ejecting control
ECM inspect engine working situation and control fuel ejecting according to sensors and
signals from main controller.
2) Engine starting control
ECM control connecting time of current of preheating plug and improve the starting of
engine.
3) EGR(exhaust gas recycle)control
ECM ensures the gas quantity according to engine rotational speed, fuel flow, collant
temperature, atmospheric pressure and input air temperature. ECM turns on the EGR valve and
makes exhaust gas to be recycled. Quantity of exhaust gas is equivalent to air input quantity in
air-in manifold. Some EGR exhaust gas is mixed with input air to lower burning temperature and
to lower the producing of NOx in EGR exhaust gas.
4) Fuel eljecting modifying
EMC adjusts fuel ejecting according to atm pressure sensor signal.
5) Engine stop control
When you press emergency cut-off switch, ECM will stop fuel ejecting of oil ejector and
close engine.

3.3.7 Engine control


Engine is stopped and started by key switch in special situation, you can stop engine by
emergency cut-off switch. Controller sends signals corresponding to target engine rotational
speed to ECM using CAN communication, according to turning angle of engine control knob.
ECM control engine rotational speed according to CAN communication.
1) Engine control knob
Engine control knob is installed on control box. Potentiometer is installed under the knob,
when you turn thr knob, potentiometer shaft rotates, and the resistance of variable resistor will
change, and then will be change into voltage
signal to transfer into controller.
1. Knob
2. Dial plate
3. Spring
4. Ball
5. Potentiometer
2) Starting engine
When starting switch is turned on
START position, the signal is sent to GPS and
ECM to control starting motor rotating.
3) Control of engine rotational speed
Controller sends signals corresponding to target engine rotational speed to ECM using CAN
communication, according to position of engine control knob. ECM control engine rotational
speed according to CAN communication.

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4) Close engine
When key switch is turned to OFF position, ECM can not receiveindication signals sent
from GPS, and then ECM stop the oil ejection and stop the engine. When you encounter
emergency, or you can not stop the engine even if you turned the key switch to OFF position,
you can press emergency cut-off button, and engine stop terminal V47 will receive current signal
from GPS, and then ECM will stop the engine.

3.3.8 ECM system


Summarization:ECM(engine control module)will receive signals from sensors and main
controller. ECM processes and drive two-sport valve, oil suction control valve and ECM motor
to control high pressure fuel feed pump, oil ejection pump and EGR valve.
z Oil ejecting control
z Engine starting control
z EGR control
z Oil ejecting mass control
z Engine stop control
z High pressure oil feed pump is drived by engine and produces high pressure fuel.
z Common rail distributes high pressure fuel produced by high pressure fuel feed pump
to oil ejectors of engine cylinders.
z Oil ejector will eject high pressure fuel from commom rail.

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Oil ejection control
ECM inspects engine running situation and controls oil ejection mass, ejecting pressure, and
ejecting timing and rate according to signals of sensors and main controller.
Two-sport control
z oil ejecting mass control
z oil ejecting timing control
z oil ejecting rate control
z oil suction control valve control
z oil ejecting pressure
Oil ejecting mass control
Fuction: Control optimum oil ejecting mass
1) ECM inspects engine rev. according to signals from crank rev. sensor and crank shaft angle
sensor.
2) MC calculates target engine rev. according to engine control knob and signals of sensors and
switches, and it sends signals to ECM by CAN communication.
3) ECM controls oil ejecting mass according to engine rev. and signals from main controller
trough open/close two-sport valve in oil ejector.

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Oil ejecting pressure control

Function: control fuel ejecting pressure according to fuel pressure in common rail.
1) ECM calculates fuel ejecting massaccording to engine rev. and signals from main controller
through CAN communication.
2) Common rail pressure sensor sends signals to ECM according to pressure in common rail.
3) ECM calculates optimum fuel pressure according to engine rev., oil ejecting mass and
signals from common rail pressure. ECM drives oil suction control valve in high pressure oil
feed pump and provides optimum fuel mass to common rail.
4) Fuel is provided to oil ejector from common rail according to fuel pressure, which controls
fuel ejecting pressure.

Oil ejecting timing control


Fuction: calculates optimum oil ejecting timing
1) ECM calculates fuel ejecting timing according to engine rev. and fuel ejecting mass.
2) ECM open/close two-sport valve in oil ejector according to fuel ejecting timing.

Oil ejecting rate control

Function: improve burning condition in engine air cylinder.


1) Oil ejector ejects a liitle fuel (pilot ejecting) and fires up.
2) Then ejector ejects fuel (main ejecting). ECM controls fuel ejecting timng though open/close
two-sport valve in oil ejector.

Fuel ejecting
1) Nozzle in oil ejector is always pressurized.
2) When magnetic coil is switched on in two-sport valve, high pressure fuel in control cavity
returns back to fuel tank though orifice 1
3) Then hydraulic pitson moves upward, nozzle is open, and ejecting starts.
4) When magnetic coil in two-sport valve is cut-off, the valve will be closed, and oil circuit to
fuel tank is also closed, pressure oil from common rail flows to control cavity through orifice 2.
5) So when high pressure oil flows to control cavity, hydraulic pitson moves downwards due to
pressure difference, and ejecting stops.

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Engine start control
Function: control current connect time of preheat plug and improve engine starting according to
coolant temperature.
1) Sensor sends signals to ECM according to coolant temperature.
2) ECM connects GND circuit of preheat plug relay according to signals and control current
connect time of preheat plug.

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EGR (exshaust gas recycle) control
Function: make some air to recycle in air-in manifold and mix with inlet air. So burning
temperature falls and controls NOx.
z EGR air control
1) ECM ensures EGR air according to engine rev., fuel flow, coolant temperature, and atm
pressure and air-in temperature.
2) ECM drives EGR motor, open EGR valve and send the EGR air into air-in manifold
according to engine condition, to make EGR air and inlet air mixed together.
3) ECM ensures EGR valve open extent by EGR motor position.
z EGR cooling system
Some exhaust air is cooled by EGR cooler; the cooled exhaust air is mixed together with air-in,
which lowers burning temperature and descends producing of NOx. In EGR exhaust air.
z Check valve
It prevents fresh air to enter into EGR, and prevent EGR exhaust gas flow in inverse direction.
Thus, EGR air current flows in one direction and air increases.

Fuel ejecting mass modification


1) Atm pressure sensor sends signals to ECM according to atmospheric condition.
2) ECM calculates atm pressure according to signals, and controls two-sport valve in oil ejector
and modifies fuel ejecting mass.

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Engine stop control
1) When engine stop switch is at stop position, ECM can not receive ON situation instructive
signals sent from GPS.
2) ECM stops ejecting of oil ejector and stops engine.
3) Close ECM after ECM main relay is closed.

3.3.9 Multifunction moniter system

1-current date and time 8-system maintenance information


2-alarm flashing symbol selection
3-working mode 9-system parameter setting
4-travel high/low speed 10-mode switch
5-auto-idle speed 11-controller I/O port parameter
6-coolant temperature switch
7-fuel level 12-fault diagnosis switch
13-buzz of

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A. coolant temperature alarm monitor
Coolant temperature alarm monitor (1) displays ( ) when it’s functioning properly. If the
coolant temperature is high, and exceeds alarm limit, the alarm monitor symbol will become
( ) and a alarm symbol ( ) will flash in the same time. On this occasion, if the engine is still
running at high revs, the controller will regulate work speed according to current coolant
temperature. The revs will slow down; work equipment speed will decrease until coolant
temperature returns to normal state.
B. engine oil pressure alarm monitor
Engine oil pressure alarm monitor displays as , if engine lubricating oil pressure is normal. In
case of low lubricating oil pressure and reaching limits, the alarm symbol will change to , an

alarm symbol will flash simultaneously. In this case, stop the engine, check engine
lubricating system. With the failure identified and restored, the engine is allowed to start again.

Note: when starting switch is set to ON position, engine oil pressure alarm monitor displays
red. With engine started, the red disappears. This is a normal sign.

C. fuel level monitor


If fuel level is normal, fuel level alarm monitorwill display as . If fuel level is running low
and exceeds alarm limits, alarm monitoring symbol will change to while a flashing symbol

will emerge. After getting this alarm information, operator needs to check fuel tank as soon
as possible and refill.
D. air filter clogging alarm monitor
Air filter clogging alarm monitor (1) displays as if it works normally. In case of clogging,

the alarm symbol will change to , an alarm symbol will flash as well. When getting this
information, the operator needs to check, clean up or replace the air filter.
E、charging alarm monitor
Charging alarm monitor (5) displays as if the battery voltage is normal. In case of
abnormality (engine fails to charge), alarm monitor will change to and an alarm

symbol will flash as well. The moment getting this information, stop the engine, check
charging circuit and engine function.

Note: when starting switch is set to ON position, charging alarm monitor will display in
red, after starting the engine, the red light disappears. It’s normal.

93
Abnormal Check
Symbol Display Item
Display
coolant coolant level and cooling duct
temperature
engine oil shut off engine and check engine oil
pressure level
check oil tank ASAP, and refill fuel
fuel level
in time
check, clear up or replace air filter
air filter clogging
ASAP
check charging circuit and engine
charging alarm
working state

Working mode selection


z Select working mode by pressing symbol 10-“mode”. There are 3 working modes available,
i.e. mode “H”, “S” and “L”. Select proper mode according to different work condition. The
symbol 3 will display accordingly, the machine will operate at different speed.
Mode L:
Apply for light load, e.g. smoothing job etc.
Mode S:
Apply for medium load work condition with high economical requirement.
Mode H:
Apply for heavy load work condition demanding a certain degree of work speed.
z When the starting switch is set to “ON”, the position 3 located on the upper right corner of
the monitoring system display the mode which was set prior to last shut-down. Select desired
mode by pressing symbol 10. The mode shifting sequence is shown in the fig.

94
4. Test and adjustment and Failure Diagnosis
4.1 Test and adjustment of mechanical structure device
4.1.1 Standard table of engine spare parts

suitable machine model SWE210NB

engine AI-4HK1X

standard value
service limit
item measure work condition unit of new
value
machine

high idle speed 2200 2200±50

engine rev low idle speed rpm 950 950±50

rated rev 2000 2000±50

valve intake valve 0.4 —


clearance(normal mm
temperature) blast gate 0.4 —

engine oil temperature: the minimum


compression difference
40-60℃ MPa 3.04
pressure value between
engine rev:250rmp
cylinders: 1.0
in high idle speed
engine oil in low idle speed
pressure (water temperature:in kPa 290-590

the working range)


full speed range
engine oil
(inside the oil sump ℃ 80
temperature
tank
before the top
injection timing °(degree) 9±1 9±1
dead-center

belt tightening mm 5~8 5~8


the side-play amount
belt tightening of pressed with about
air condition 58.8N by finger. mm 5~8 5~8
compressor

95
4.1.2 Standard table of complete machine

suitable machine model SWE210NB


cla standard allowable
item measure working condition unit
ss value value
·engine water temperature : within
working range
·hydraulic oil temperature : within
second-class
working range 2000 2000±50
overflow

·engine runs in high idle speed


·arm in overflow state
en ·engine water temperature : within
gin working range
second-class rpm
e ·hydraulic oil temperature : within
overlow +
rev working range 2000 2000±50
touch power
·engine running in high idle speed
enhancement
· arm overflow+touch step-up switch is
on
rev in ·engine runs in high idle speed
automatic ·automatic slow-down switch is on
1100 1100±50
slow-down ·all the joysticks are in the middle
operation position
boom control
valve
val
arm control
ve
valve
cor
bucket control
e mm 10 10±0.5
valve
str
rotary control
ok
valve
e
travel control
valve
joy boom control
·engine misses 75 75±10
sti valve
·at the handle center of joystick
ck arm control
·measure the max. value to the stroke 75 75±10
str valve mm
terminal
ok
bucket control (except joystick is in the middle
e 75 75±10
valve position)

96
suitable machine model SWE210NB
cla standard allowable
item measure working condition unit
ss value value
joy rotary control engine misses
75 75±10
sti valve ·at the handle center of joystick
ck travel control ·measure the max. value to the stroke
180 180±20
str valve terminal
ok joystick (except joystick is in the middle
max.10 max.15
e clearance position)
joy boom joystick 7
·hydraulic oil temperature : within
sti arm joystick 7
working range
ck bucket
·engine running in high idle speed 7
op joystick
·at the handle center of joystick N
era rotary joystick 7
·at the top of pedal
tin Trav joystic 15
·measure the max. value to the stroke
g el k
terminal
for joyst 105
pedal
ce ick
·hydraulic oil temperature : within
working range
unloading ·engine running in high idle speed
3 3±0.5
pressure ·work mode:H
·hydraulic pump output pressure with all
the joysticks in the middle position
boom ·hydraulic oil temperature : within
hy arm working range
dra bucket ·engine running in high idle speed
uli rotary ·work mode:H 32±0.5
c 32(34)
·hydraulic pump output pressure when (34±0.5)
pre
all measure oil circuits releasing
ssu travel
·value in bracket:hydraulic oil pressure MPa
re
of touch type switch in ON mode
·hydraulic oil temperature : within
working range
pressure of
·engine running in high idle speed 3.5±0.5
control oil 3.5
·output pressure of pressure-relief valve
circuit supply
with all the joysticks at the middle
position

97
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value

rotary brake
·hydraulic oil temperature : within degree 72.4 100
angle
working range
·engine running in high idle speed
·work mode:H
·rotary stops after running one circle

rot required time ·hydraulic oil temperature : within


second 2.4 max.3.0
ary for rotary start working range
·engine running in high idle speed
·work mode:H
·required time for turning at an angle of
90º from the beginning

required time
·hydraulic oil temperature : within second 24.6±2.5 max.30
for rotary
working range
·engine running in high idle speed
·initial rotary after one circle,required
time for measuring rotary 5 circles

98
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value
rotary mm 0 0
hydraulic drift

·hydraulic oil temperature : within


working range
·engine misses
rot ·remain upper carriage side-turning at an
ary angle of 90º on 15°sloping ground
·make an alignment mark on inner circle
and outer circle of rotary bearing
·measur staggered amount of alignment
mark after 5 minutes
rotary motor ·hydraulic oil temperature : within L/min 24.5
leakage working range
·engine running in high idle speed
·rotary lock switch:ON
·leakage rate after rotary overflow for 1
minute

99
suitable machine model SWE210NB

cla standard allowabl


item measure working condition unit
ss value e value

H
13.1 13.1±1

travel speed ·hydraulic oil temperature:within second


working range
·engine running in high idle speed
L 21.2 21.2±1
·work mode:H
·flat ground
· required time for measuring of
traveling 20m after traveling 10m

tra
vel

·hydraulic oil temperature : within


working range
·engine running in high idle speed
travel ·work mode:H
Mm 200 ≤
deviation ·travel speed:low
·hard and flat ground
· required time for measuring of
traveling 20m(X) after traveling 10m

100
suitable machine model SWE210NB
cla standard allowabl
item measure working condition unit
ss value e value

travel
Mm 0 0
hydraulic drift ·hydraulic oil temperature : within
working range
tra ·engine misses
vel ·sproket faces the up grade position and
park the machine on 12º slope
·5 minutes sliding space
·hydraulic oil temperature: in working
range
travel motor ·engine runs at high idle speed
L/min
leakage ·travel when rag wheel is locked
·oil leakage after trvelling 1 minute in
overflow state

101
suitable machine model SWE210NB
standa
cla allowabl
item measure working condition unit rd
ss e value
value
complet
e
working
device(t
200 ≤
ooth
point
fall
extent)
boom oil
hy cylinder
dra (retracti ·hydraulic oil temperature:within working 20 ≤
uli ve range
mm
c extent) ·flat ground
dri arm oil ·in measuring state as the above fig
ft cylinder ·engine misses
wo
(extende ·the joystick is in the middle position 20 ≤
rki
d ·measure falling amount every 5 minutes
ng
degree) and make a conclusion refer to the result in
de
bucket 15 minutes
vic
e oil
cyinder
20 ≤
(retracti
ve
degree)

lift 3.1 3.1±0.5


wo
rki
fall 2.5 2.5±0.5
ng ·hydraulic oil temperature : within seco
boom
de working range nds
vic ·engine running in high idle speed
e ·work mode:H
·required time from lift stroke end to
bucket contact ground

102
suitable machine model SWE210NB
standa
clas allowabl
item measure working condition unit rd
s e value
value

dig 3.3 3.3±0.5

arm ·hydraulic oil temperature : within


working range unlo
2.6 2.6±0.5
·engine running in high idle speed ad
·work mode:H
·required time from unload stroke
wor
end to digging stroke end
king
seco
devi
nds
ce dig 3.1 3.1±0.5

bucket
·hydraulic oil temperature : within unlo
working range 2.3 2.3±0.5
ad
·engine running in high idle speed
·work mode:H
·required time from unload stroke
end to digging stroke

103
suitable machine model SWE210NB
cl
standard allowabl
as item measure working condition unit
value e value
s
co
m
po
un
d travel deviation
op amount for
er working device
ati and travel ·hydraulic oil temperature:within working Mm 300 ≤
on synchro range
pe operation ·engine running in high idle speed
rf ·work mode:H
or • travel speed:low
m • flat ground
an • travel deviation amount(X)for measuring
ce of traveling 20m after traveling 10m
hy
dr
au
lic
pu
m hydraulic pump
p flow
pe
rf
or
m
an
ce

104
4.2 Test and adjustment of hydraulic device
4.2.1 Test and adjustment of system working pressure
Instruments

mark No. name specification Qty.

S1 740402000057 shock resistance pressure table 0-60MPa 1

S2 730505000005 pressure testing hose SMA3-5000 1

VKA3/06SA
S3 730101000358 pressure testing joint 1
3C
End direct
connectionG
S3 730101000080 joint 1
E008LROM
DA3C

★The working pressure (output pressure of hydraulic pump) of every actuator is displayed on
the monitor of the cab.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measurement
1. Combination of pumps, hydraulic components and valves
Please refer to the contents of main pump and multiple way valve and hydraulic schematic
diagram in chapter 3.2 for hydraulic device functions and maintenance standards so as to
understand the structure and test point of main pump and multiple way valve and system flow
distribution.
The flow distribution to every actuators by front and back main pumps when act separately:

actuator act oil supply relief valve


up front pump、back pump
boom cylinder
down front pump
epicyclic motion front pump、back pump
arm cylinder
inward-retract front pump、back pump two-stage
epicyclic motion front pump main relief
bucket
valve
cylinder inward-retract front pump
right travel
travel front pump
motor
left travel
travel back pump
motor
own relief
rotary motor rotary back pump
valve
105
2. Preparation work for measuring

Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the pressure sensor(1) which connects with oio port a1(or a2),then connects joint
S3, and connects piezometric joint to the other end of S3. Connect manometer S1 with
piezometric hose S2 to S3.

2) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.

3. measuring for unload pressure


1) Start engine and adjust it to model H.
2) Read the scales displayed on manometer.
★ Engine runs in high idle speed.
★ All the joysticks are in the middle position.
4. Measuring for overflow pressure of working device
1) Start engine and turn it to model H. Move the measured cylinder to the end of stroke.
2) Measure hydraulic oil pressure when engine runs in high idle speed and the cylinder is in
overflow state.
★ Display hydraulic oil pressure of main relief valve when it is in overflow state.

106
★ If press the touch compression switch on handle, oil pressure will transform to high overflow
pressure. If release the pressure, it will transform to low overflow pressure.

5. Measuring for rotary overflow pressure


1) Start engine and turn it to model H. Put working device on flat ground and make the bucket
against ground.

2) Measure hydraulic oil pressure when engine runs in high idle speed and rotary oil circuit
overflows.
★Display hydraulic oil pressure when the safety valve of rotary motor overflows.
★The overflow pressure of rotary motor islower than the main overflow pressure.
6. Measuring for overflow pressure of travel oil circuits
1) Latch travel. Put pin (1) between the sprocket wheel and track bracket to insure latch travel.

2) Start engine and turn it to model H.


3) Measure hydraulic oil pressure when engine runs in high idle speed.
★ Display hydraulic oil pressure when main relief valve overflows.If press the touch
compression switch on handle, oil pressure will transform to high overflow pressure. If release
the pressure, it will transform to low overflow pressure.

Adjusting
1. Adjusting for overflow pressure (one-level pressure setting value)
★ If the one-level overflow pressure of working device or travel is abnormal, or the two-level
overflow setting pressure is adjusted, the one-level overflow pressure should also be adjusted.
107
1) Break hose.
2) Unscrew latch nut (7) and adjust pressure through turning keeper (8).
★ If the screw turns to the right, pressure will increase.
★ If the screw turns to the left, pressure will decrease.
3) Check the pressure after adjusting. Perform measuring work according to the above steps.
★ Please connect the pilot hose when measure pressure.

2. Adjusting for overflow pressure (two-level pressure setting value)


1) Break pilot hose.
2) Unscrew latch nut (5) and adjust pressure hrough turning keeper (6).
★If the screw turns to the right, pressure will increase.
★If the screw turns to the left, pressure will decrease.
3) Check the pressure after adjusting. Perform measuring work according to the above steps.
★Please connect the pilot hose when measure pressure.
★It also need to adjust if adjust high pressure setting value which will influence low pressure
setting value.

3. Adjusting for rotary overflow pressure


★If the rotary overflow pressure is in abnormal state, adjust it according to the following steps:
★overflow valve (1) or (2) of rotary motor
★adjust the pressure (1) of right rotary
★adjust the pressure (2) of left rotary

108
1) Unscrew latch nut (1) and adjust pressure according to turning adjust screw (2).
★If the screw turns to the right, pressure will increase.
★If the screw turns to the left, pressure will decrease.

2) Check the pressure after adjusting. Perform measuring work according to the above steps.
★Use latch nut for locking after adjusting.

4.2.2 Test and adjustment of pilot oil supply pressure

Instruments

specificatio
mark No. name qty.
n
shock
resistance
S1 740402000034 0-6MPa 1
pressure
table
pressure
S2 730505000005 testing SMA3-5000 1
hose
pressure
VKA3/06S
S3 730101000358 testing 1
A3C
joint
End direct
connection
S4 730101000080 joint 1
GE008LRO
MDA3C
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.

109
Measuring

Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the oil plug (1) of piezometric point (a3).

2) Connect piezometric joint S3 to piezometric point (a3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.

4) The measured oil pressure is pilot overflow pressure when engine runs in high idle speed
and all the joysticks are in middle position.

Adjusting
★If the measured pilot overflow pressure cannot match the setting pressure, please adjust the
pressure of pilot overflow (1) according to the following steps:

110
1) Unscrew nut (312) and adjust screw (311).
★If the screw turns to the right, pressure will increase.
★If the screw turns to the left, pressure will decrease.

2) Check the pressure after adjusting. Perform measuring work according to the above steps.
★Use latch nut for locking after adjusting.

4.2.3 Inspection for main return oil pressure of the system

Instruments

mark No. name specification qty.

S1 740402000034 shock resistance pressure tab 0-6MPa 1

S2 730505000005 pressure testing hose SMA3-5000 1

VKA3/06SA3
S3 730101000358 pressure testing joint 1
C
End direct
connection
S4 730101000080 Transition joint 1
GEO08LROM
DA3C
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.

111
Measuring

Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
1) Dismantle the oil plug (1) of piezometric point (TR).

2) Connect piezometric joint S3 to piezometric point (a3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3) Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.
4) Read the max. value of being displayed by manometer when working device is running.
★If the volume of system return oil is max., the pressure of return oil will be the max.
★The return oil volume will be the max. if there are no other actions except operating the
control valve to lower the boom, make the arm and bucket do epicyclic motion.

5) Dismantle all the measuring tools after completing measure work and make sure the
machine’s normal condition.

112
4.2.4 Inspection for output pressure of the pilot solenoid valve

Instruments

mark No. name specification qty.


S1 740402000034 shock resistance pressure tab 0-6MPa 1

S2 730505000004 pressure testing hose 6M 1

S3 730101000170 pressure testing joint EMA3/G1/8 1

S4 tramsition tee joint 1

S5 tramsition tee joint 1

★Measure the output pressure of solenoid valve after insuring the initial pressure of control oil
circuit is normal.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measuring

Lower the working device to the ground and stop the engine, release pressure in pipes by
operating joystick and pressure in oil tank by loosening the cover of pouring orifice.
★outgoing direction for output oil port of solenoid valve:

mark outgoing direction

1 inlet oil port of pilot oil collecting block

2 pressure increasing port of two-stage overflow valve

3 two speed control port of travel motor

1. Break the hoses of solenoid valve to measure out its output pressure.

2. Connect transition joint on the output oil port joint. Connect oil port(1) with (S4),
113
(2)and(3)with(S5),and fit with piezometiric joint (S3). Connect piezometric hose (S2) with
manometer (S1) to (S3).
3. Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.

4. Run the machine with model H, then operate the pilot control valve or cut off the solenoid
valve for measuring pressure.
★If every outlet pressure data shows as the following fig, it is regarded as normal.
solenoid output
valve pressure
OFF
0
(erasement)
★Please refer to the “function state fig”for every solenoid valve about how to open or close
them.
Pilot latch solenoid valve

state function
security lock OFF
lock
unlock ON
lever

Pressure increasing solenoid valve

state function
pilot latch solenoid
valve ON
ON
press the pressure
button
reset the pressure
OFF
button

114
Two-speed solenoid valve

state function
pilot latch solenoid
valve ON
ON
close the
two-speed switch
break the
OFF
two-speed switch

4.2.5 Measuring for output pressure of pilot control valve

Instruments

mark No. name specification qty.


shock resistance
S1 740402000034 0-6MPa 1
manometer
pressure testing
S2 730505000004 6M 1
hose
pressure testing
S3 730101000170 EMA3/G1/8 1
joint
S4 Transition joint 1

★Measure the output pressure of solenoid valve after insuring the initial pressure of control oil
circuit is normal.
★Before measuring, the hydraulic oil temperature should be increased to 50~55º Celsius.
Measuring
1. Break the pilot hoses on multiple way valve according to the following table to measure its
pressure.
mark measuring oil circuit mark measuring oil circuit
boom
1 left travel(forward) 6
(descend)
arm(epicyclic
2 platform rotary(to the right) 7
motion)
platform rotary(to the
3 arm(digging) 8
left)
4 right travel(forward) 9 left travel(backward)
5 bucket(digging) 10 boom(lift)

115
2. Connect transition joint (S4) on the pilot oil port, and thread piezometric joint (S3). Connect
piezometric hose (S2) with manometer (S1) to (S3).
3. Start engine and keep it running until the increasing of hydraulic oil pressure meets the
working range.

4. Run the machine with model H, and then measure the output pressure for joystick when it is
in free state or full-stroke state.
★If outlet pressure shows as the following fig, it is regarded as normal.
joystick output pressure
free state 0
full-stroke 2.6MPa

116
5. Dismantle all the measuring tools and make sure that the machine is in normal state.

4.2.6 Measuring for hydraulic drift of working devices


★If the data for hydraulic drift of working device (oilcylinder) is over the data in normal value
table, check it according to the following steps, which can test preliminary that if it is caused by
the leakage of oil tank or control valve.

1. Check for boom and bucket oil tank


1) When measure hydraulic drift, place the state of working device as showed in the following
fig and stop the engine.
★Fill the bucket with sand or apply rated load on the bucket.

2) Operate pilot valve to make the main valve core of the boom move to its lift position or
make the main valve core of the bucket move to its epicyclic motion position.
• Increasing of the fall speed indicates there are leakage fault in oil tank.
• No change indicates there are faults in control valve.
★The start switch of the engine is in ON position,press security handle and operate joystick.
★If the pressure in accumulator descend; keep the engine running about 10 seconds for
recharging.

2. Check for arm oil tank


1) Operate arm oil tank to move the arm to the 100mm position before the end of digging
stroke and stop the engine.

117
2) Operate arm joystick to move the arm to the side of digging.
• Increasing of the fall speed indicates there are leakage fault in oil tank.
• No change indicates there are faults in control valve.
★ The start switch of the engine is in ON position,press security handle and operate joystick.
★ If the pressure in accumulator descend, keep the engine running about 10 seconds for
recharging.

4.2.7 Release the residual pressure in hydraulic oil circuits

When break the pipes of hydraulic system, the residual pressure should be released according
to the following methods.
1. Stop the engine and unscrew the pouring orifice gradually to release the pressure in oil tank.
2. Operate the joystick for several times.
★Operate joystick when engine start switch is in ON position.
★Pressure stored in accumulator wll be released when joystick is operated for 2-3 times.
3. Start the engine, runs it at low idle speed for 10 second to store pressure in accumulator, and
then stop engine.
4. Repeat step 2 and step 3 for several times.

4.2.8 Check for leakage volume


1. Measuring for the leakage volume of boom oil cylinder
1) Start the engine and keep it running until hydraulic temperature rises to the working range
and extend the pistion rod of boom cylinder to the end of the stroke.
Release the residual pressure in pipes. Refer to the last part “Release the residual pressure in
hydraulic oil circuits”.
2) Break the hose (1) in the small cavity of oil tank.
Do not break the hose in the big cavity of oil tank.

118
3) Start the engine and apply overflow pressure on the big cavity of oil cylinder when the
engine runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.

2. Measuring for the leakage volume of arm oil cylinder


1) Start the engine and keep it running until hydraulic temperature rises to the working range
and extend the pistion rod of arm cylinder to the end of the stroke.

Release the residual pressure in pipes. Refer to the last part “Release the residual pressure in
hydraulic oil circuits”.
2) Break the hose (1) in the small cavity of oil cylinder.

Be careful not to break the hoses at the bottom of the oil cylinder.

3) Start the engine and apply overflow pressure on the big cavith of oil tank when the engine
runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.
3. Measuring for the leakage volume of bucket oil cylinder
1) Start the engine and keep it running until hydraulic temperature rises to the working range
and extend the pistion rod of bucket cylinder to the end of the stroke.

Release the residual pressure in pipes. Refer to the last part “Release the residual pressure in
hydraulic oil circuits”.
2) Break the hose (1) in the small cavity of oil cylinder.

Do not break the hose in the big cavity of oil cylinder.

119
3) Start the engine and apply overflow pressure on the big cavith of oil tank when the engine
runs in high idle speed.
4) Remain this state for 30 seconds and then measure the leakage volume of one minute.
5) After measuring, insure the machine return to the normal state.
4. Measuring for the leakage volume of rotary motor
1) Break hose (1) which connects with oil tank,and plug its oil port.
2) Put working device on flat ground and make the bucket against ground.
3) Start the engine. Measure leakage volume when engine runs in high idle speed and apply
rotary overflow pressure.
★Travel motor remains still.
★Keep the state of step 3)for 30 seconds,measure the leakage volume of one minute.
★After the first measuring, turn the up rotary platform of 180 º, and measure again with the
same method.

4) After measuring, insure the machine returns to the normal state.

5. Measuring for the leakage volume of travel motor


1) Dismantle the cover of travel motor.
2) Lock travel.
120
Put pin ① between sprocket and track frame to stop travel.

3) Break hose (1) of drain oil port of travel motor, fit with choke plug on the end of the hose.
4) Start the engine. Measure leakage volume when engine runs in high idle speed and apply
rotary overflow pressure.

When doing this measuring, a faulty operation of the joystick will cause a serious accident, so
insure every signal and make correct confirmation.
★Remain step 4) for 30 seconds,measure the leakage volume for one minute.
★ Run the motor slightly to change the position of oil distributing plate and rotor. And then
repeat the above steps to measure several times.
5) After measuring, insure the machine returns to the normal state.

4.2.9 Adjusting of main pump

It is forbidden to do the following recovery operation to the pumps in normal station, unless
the power and displacement of the main pump are different from the setting data caused by
dismantlement or service to the main pump.
★Adjust the screw on adjustor can adjust the max. flow, min.flow, power and flow control
character.(Refer to fig. 1 and fig.2 for adjust volume)
1. Adjusting of the max. flow
Release hexagon nut (1),tighten(or release) fix screw (2)for adjusting. There are no changes
of the other control characters except for the max. flow.

121
2. Adjusting of the min. flow
Release hexagon nut(1),tighten (or release) fix screw (2) for adjusting.No changes of the
other control characters. Notice that if tightened too much, it may need increasing power in
overflow state.

122
3. Adjusting of input power
★ Adjustor uses the sync full power control way. When adjust the setting volume of the power,
make the same change for the adjust screws of front and back pumps. The changed value of the
pressure is the value when the pressure of the two pumps increased simultaneously.
1) Adjusting of external spring
Release hex nut(1),tighten(or release adjust screw(4)for adjusting. When tighten the adjust
screw, see as (JPG0328). Control the line gragh move to the right and increase the inlet power.
After turning adjust screw(4)for N times,the setting value of internal spring will change as well.
So turn adjusting screw (3) inversely.

2) Adjusting of internal spring


Release hex nut(2),tighten(or release adjust screw(3)for adjusting. When tighten the adjust
screw, see as the following fig., the flow and input power will increase when tightening.

123
4. Adjusting of charaters of the flow control
Release hex nut(2),tighten(or release adjust screw(1)for adjusting. When tighten the fix
screw, see as (JPG0035). Control the line graph move to the right when tightening.

adjusting for the adjusting for the


adjusting for the character of
max. flow min. flow flow control
adjus adjust variable
adjus adjust variab
t the the in start variable
ter rev variable the le in
screw screw- pressure in
mod (r/min) in screw-i disch
-in in controlle dischar
el discharge n depth arge
depth depth d by ge
(ℓ/min-1) (turning (ℓ/mi
(turni (turni discharge (ℓ/min)
) n)
ng) ng) (kgf/cm²)
KR3
G-2 2100 +/4 6 +1/4 3 +1/4 1.5 14
NO9

124
adjust input power
adjusting for internal spring adjusting for external spring
compensate
adjuster rev adjust adjust and variabl
variable
model (r/min) the variable in the contro e in
in
screw-in input screw-in l start input A
discharge
depth torque(N.M) depth pressu torque
(ℓ/min)
(turning) (turning) re (N.M)
(MPa)
KR3G-2
2100 +1/4 10 42 +1/4 1.6 43 1.8
NO9

4.2.10 Devices exhaust


Item Steps for exhaust
replace hydraulic oil engine start hydraulic pump exhaust oil tank
exhaust rotary motor exhaust travel motor
clean filter core
exhaust starting operation
replace reflux filter core engine start starting operation
repair or replace hydraulic
engine start hydraulic pump exhaust oil tank
pump
exhaust starting operation
dismantle oil suction pipe
repair or replace control
engine start oil tank exhaust starting operation
valve
replace oil tank
engine start hydraulic pump exhaust oil tank
dismantle the pipeline of
exhaust starting operation
oil tank
replace rotary motor
engine start rotary motor exhaust starting
dismantle the pipeline of
operation
rotary motor
replace travel motor
engine start travel motor exhaust starting
dismantle the pipeline of
operation
travel motor

1. Hydraulic pump exhaust


1) Start the engine and keep it running with low idle speed for 5 minutes.
2) No operation with all joysticks.
2. Hydraulic oil cylinder exhaust
125
1) Start the engine and keep it running with low idle speed for 5 minutes.
2) When the engine runs with low idle speed, lift and lower the boom for 4-5 times.
★ Be careful not to apply overflow pressure. Stop piston rod at a distance of 100mm before the
end of the stroke. Repeat the above step 2), engine will run with high idle speed.
3) Apply overflow pressure when it gets to the end of the piston rod and the engine runs with low
idle speed.
4) Exhaust from the arm oil tank and bucket oil tank according to the above steps 2) to 4).
★ Because of the replacement for oil cylinder, we suggest exhaust from the new oil cylinder
before fitting working devices. Especially the boom cylinder, after working device is installed;
arm can not be extended to falling side stroke end.
3. Rotary motor exhaust
1) Start the engine and keep it running with low idle speed.
2) Exaust from the motor by turning the up rotary platform slowly.
4. Travel motor exhaust
1) Start the engine and keep it running with low idle speed.
2) Operate the travel joystick to make the machine travel slowly.

4.3 Fault diagnose


4.3.1 Inspection before fault diagnose
No.
Inspection item Disposal ways

1 Check the voltage of accumulator when replace


stop the machine.
2 Check the electrolyte level of the maintenance-free battery,
accumulator. replace directly
3 Check if the fuses in disaster box melt or replace
not.
4 Check if the wires are scorched or tighten or replace
pull-off. Check if there are loose of the
plugs.
5 Check if there are loose or corrosion of tighten or replace
AC-generator terminal and wires.
6 Check whether the start motor terminal tighten or replace
and wires are loose or corroded.
7 Check whether the accumulator terminal tighten or replace
and wires are loose or corrupt.
8 Check the wire group and plugs if there replace
are wet, water penetration or oil
immersion.

126
4.3.2 Fault sorts and check methods
No. fault sorts fault processing method
diagnosis(probable
cause)
1. Measure the voltage of the
accumulator by multimeter. The normal
insufficiency of the voltage should be over 24V;
accumulator’s 2. Observe the electric check hole
electricity (maintenance-free battery is green under
the normal state, it will turn black if the
electric is insufficient).
Keep the start switch of the engine in
fault in the start switch OFF state,OFF position is over 1M
of the engine ohm. Keep it in start state, which is
under 1 ohm.
Put the start switch light on start
position, if the input end (S, E)of the
fault in security relay relay is normal, then use multimeter to
check if the output (B, C)of the security
engine can
1 relay is closed, or it may be destroyed.
not start
fault in the relay of Turn the start switch to ON position, if
extinction motor the input end (1, 2)of the relay is normal,
then use multimeter to check if the
output contact(3, 5)of the security relay
is closed, or it may be destroyed.
fault in extinction Turn the start switch to ON position,
motor check if the extinction motor B, P1
terminal voltage(24V)and P2 terminal
voltage(0V)is normal , or it may be
destroyed.
fault in the start Turn the start switch to ON position,
motorof the engine check if the B 、 C terminal
voltage(24V)of the start motor is
normal, or the start motor is break or
damaged.
Keep the engine running when fault
rev displays
diagnose.Use multimeter to measure the
abnormal or fault in rotary
2 voltage of the two ends of the
diplays transducer
transducer. The normal voltage should
nothing
be over 5V, or it may be destroyed.

127
No. fault sorts fault processing method
diagnosis(probable
cause)
Turn the start switch to OFF position,
rev displays
use multimeter to measure the resistance
abnormal or break in rotary
2 of the two wires, which shoud be under 1
diplays transducer harness
ohm,or the rotary transducer wire group
nothing
may be break.
Break the connector of start switch and
turn it to OFF position. Use multimeter
to measure if the resistance of the
terminal BR and B are normal (above
start switch fault 1M ohm). If they are normal, it shows
there is short circuit and check the start
circuit please. If the resistance is under1
ohm, it shows the start switch is
short-circuited.
Keep the start switch at ON position.Use
engine multimeter to measure the voltage of
3 cannot terminal A on extinction motor, the
extinct extinction motor fault normal voltage is 24V, or the extinction
motor may be break.
Keep the start switch at ON position.Use
multimeter to measure the voltage of the
output end (3) on extinction relay, the
normal value is 4V. Keep the start switch
extinction relay fault at OFF position, use multimeter to
measure the voltage of the output end
(3), the norma value is 0V, or the relay
may be damaged.
wire group break
automatic idle switch Check the automatic idle switch. Its
fault resistance should above 1M if it is at
OFF position, and under 1M if it is at
ON position.
wire group break Use multimeter to measure the resistance
of the two wires, its normal value should
automatic below 1 ohm.
4 idle function rev doesn’t reach the If the engine rev is above 1500 /m,the
do not work setting value automatic idle will work.
the pressure value of If the pressure of the main pump is under
the main pump is 4M Pa,the automatic idle will work.
excessive
Start the machine, if the cooling
temperature is under 25 degrees
the machine is in
centigrade,the machine will come into
warming-up process
warming-up state automatically and the
automatic idle function will not work.

128
No. fault sorts fault processing method
diagnosis(probable
cause)
When the machine is running, the engine
will retard automatically if the cooling
the cooling temperature
automatic temperature of the engine is above
of the engine is low
retard of the 100°C.If it is under 100°C, the automatic
5
engine do retard will not work.
not work If the engine rev is under 1800/m, the
engine rev is low automatic retard of the engine will not
work in the machine’s running state.
If the engine rev is above 1200/m,its
automatic engine rev is high automatic warming-up function will not
warming-u work.
6 p of the cooling water When start the machine, the automatic
engine do temperature of the warming-up of the engine will not work
not work engine is high if the cooling water temperature is above
25°C.
touch step-up switch Use multimeter to check the touch
fault press-up button on handle.
wire group fault Use multimeter to check if the wire
groups are break or not.
touch
If the engine rev is under 1600/m,the
step-up of engine rev is low
7 touch press-up function will not work.
the engine
do not work working mode of the Only the engine is on mode S or H, the
engine is not correct touch press-up function will work.
pressure increasing Use multimeter to check the pressure
solenoid valve is increasing solenoid valve
damaged
cooling water Check the cooling temperature of the
temperature of the engine is higher than the normal value
engine is higher
engine cooling Check if the resistance of the cooling
the alarm temperature sensor of water temperature sensor changes along
light for the engine fault with the temperature change. The higher
cooling of the temperature, the less of the
8 temperature resistance.
of the wire group of Use multimeter to check if the wire
monitor temperature sensor group of temperature sensor connect
turns red connect ground ground.
Others (i.e. inlet scoop Check if it is tight sealed around the
of the engine false air, engine inlet scoop. If it false air, the
etc.) cooling effect will be bad and the cooling
temperature rises.

129
No. fault sorts fault processing method
diagnosis(probable
cause)
fuel level is low The actural fuel level is a little low
Use multimeter to check if the resistance
range of the fuel sensor is 10 ohm~180
ohm,the range value will not change
fuel alarm fuel level sensor fault
9 light turns with the fuel level change. If the
red resistance is too high or too low, the
sensor may be damaged.
wire break of fuel level Use multimeter to check if the end wire
sensor fault group of the fuel level sensor is open
circuit.
machine won’t start The charging alarm light turns red when
the machine doesn’t work.
the generator doesn’t After the engine start, measure if there is
charging work output voltage at the output end of the
10 alarm light generator. If the generator belt is slip or
turns red break, or the generator fault.
charge loop group fault Measure if there is open circuit or ground
connection fault in the wire group of
charging return circuit.
air filter clogging clogging in the air filter
In normal condition the air filter is open
air filter air filter clogging all the time. If the air filter is clogging,
11 clogging sensor fault the sensor will be closed constantly, or
alarm light the sensor may be damaged.
is red sensor wire group Measure if the wire group of the sensor
connect ground connects ground.
The engine oil alarm light will turn red in
machine won’t start
this state.
alarm light Measure the engine oil level is a little
engine oil pressure is
for engine lower after a few minutes of the engine
low
12 oil stop.
pressure engine oil pressure Engine oil sensor fault
turns red sensor fault
sensor wire group Measure if the sensor wire group
connect ground connects grouond.
throttle knob fault Turn the throttle knob and measure if its
resistance value changes in the range of
5K ohm. If therer is no change or the
rev doesn’t value is too high, the throttle knob is
change by damaged.
13 adjusting wire group break Measure if the throttle knob and the wire
the throttle group of throttle motor have been broken
knob or connected ground.
feedback signal wire of The resistance value of the throttle
the throttle open circuit feedback potentiometer changes in the
range of 10K ohm.

130
No. fault sorts fault diagnosis(probable processing method
cause)
throttle motor fault Supply the throttle motor with
DC12V power. The motor may be
damaged if it doesn’t work.
machine is under the When the machine is in the state of
automatic idle state automatic idle, the rev will have no
rev doesn’t change
change by adjusting the throttle
13 by adjusting the
knob.
throttle knob
The machine is in low idle state
when it has just started for a few
machine is start just
seconds, and the rev will have no
now
change by adjusting throttle knob at
this time.
Measure the ratio electromagnet in
halt mode, its normal resistance is
ratio electromagnet
about 17.5 ohm, otherwise the
fault
the working device ratio electromagnet may be
14
speed is too low destroyed.
wire group of ratio Measure the wire group of the ratio
electromagnet break electromagnet if it is broken or
connected ground.
Measure if the CAN bus is broken
or connected ground. Measure
monitor displays bus CAN break or short when to connect the negative of the
15
abnormal(displayed circuit accumulator after breaking it for
data is 255) several seconds. Observe if the data
showed on the monitor recover.
proportional valve
Use multimeter to measure if there
of the main valve proportional valve open
are open circuit or ground
16 indicator light on circuit or short circuit
connection fault in the proportional
the monitor turns fault
valve and wire group
red
throttle
potentiometer Use multimeter to measure if there
throttle knob open
indicator light on are open circuit or ground
17 circuit or short circuit
the diagnose connection fault in the throttle
fault
interface of the knob and wire group
monitor turns red
water temperature Use multimeter to measure if there
open circuit of the
sensor indicator are open circuit fault in the water
18 water temperature
light on diagnose temperature sensor and wire
sensor fault
interface turns red group.
fuel level sensor Use multimeter to measure if there
open circuit or short
indicatior light on are opencircuit or ground
19 circuit of the fuel level
the diagnose connection fault in fuel level
sensor fault
interface turns red sensor and wire group.

131
No. fault sorts fault diagnosis(probable processing method
cause)
main pump
Use multimeter to measure if
pressure P1
open circuit or short circuit there are opencircuit or ground
sensor indicator
20 fault in pressure sensor P1 of connection fault in the
light on the
the main pump pressure sensor P1 of the main
diagnose
pump and wire group.
interface turns red
main pump Use multimeter to measure if
pressure P2 sensor open circuit or short circuit there are opencircuit or ground
21 indicator light on fault in pressure sensor P2 of connection fault in the
the diagnose
the main pump pressure sensor P2 of the main
interface turns red pump and wire group.
throttle feedback throttle actuator fault or open Use multimeter to measure if
potentiometer circuit or short circuit in there are opencircuit or ground
22 indicator light on feedback wire connection fault in the throttle
the diagnose feedback potentiometer and
interface turns red wire group.
monitor fault
open circuit in the power Check the return circuit of the
no display on the wire group of the monitor power.
23
monitor the power fuse of the monitor Replace power fuse and check
melt if there is ground connection
fault.
no voice of the open circuit or groud Use multimeter to measure if
travel alarm connection in the wire there are open circuit or short
24
group of the travel alarm circuit in the travel alarm, or
fault it may be destroyed.
25 wiper doesn’t work wire group open circuit or
ground connection fault

132
5. Disassembly and assembly
5.1 How to read this manual
Installation and removal
Removal of parts
z Section “removal” includes procedure and instruction.
z All the warning signs and marks which have been used in the section “removal” are listed as
follow:
★ This mark is used to provide instructions and attentions to operating procedure.

★ Important security attentions.

★ :Lift weight.
Installation of parts
z Install parts in reverse order unless otherwise noted.
z All marks and signs used in section “installation” is as follow:
★ This mark is used to provide instruction and attention to operating procedure.

★ Important security attentions.


★ :Fill lubricant when assembling.

★ :Lift weight.
★ :Bolt torque.

Assembly and disassembly


Disassembly
z Section ”disassembly” includes procedure and instruction.
z All the warning signs and marks which have been use in this section “disassembly” are
listed as follow.
★ This mark is used to provide instruction and attention to operating procedure.

★ Important security attentions.

★ :Lift weight.
Assembly
z This section “assembly” includes procedure, precaution and know-how.
z All the sighs and marks are explained and listed as follow:
★ This mark is used to provide instruction and attention to operating procedure.

★ Important security attentions.


★ :Fill lubricant when assembling.

★ :Lift weight.

★ :Bolt torque.
133
5.2 Instruction during operation
The following items should be followed when attempt any disassembling or assembling
procedure (removal or installation).
1. Instructions during disassembling
z Dispose properly if engine coolant contains antifreeze.
z Always cap or plug hoses when hoses or steel pipes are removed to prevent them from entry
of dirt, dust and debris.
z Provide a proper container to catch the oil discharged
z Confirm matching marks which indiceates installation position, provide mating marks to
avoid re-assembling mistake, prior to disassembling.
z Do not pull conducting wire to avoid loose from contact point. When disconnecting
conduct wire, Hold connector to avoid excessive force applied to wire.
z Attach marks on the wire or hose to make certain their positions. It helps to avoid mistake
during re-assembling.
z Calculate and inspect the number and thickness of washers, and keep them at safe place.

z Make certain to use proper lifting device with sufficient strength and reliability, when
lifting components.
z Evenly fasten screw in proper sequence when lifting bolt was used to remove any
components.
z When disassembling any devices, clean the surrounding area and cover them to prevent dust
or dirt from entering into them.
2. Instructions during the process of assembly
z Replace and fasten all the nuts (cannula nuts) and bolts with specified torque value.
z No distortion or interference is allowed during hose installation.
z Replace all bolt, nut, bushing, o-ring, cotter pin, and locking plate with new ones.
z Bent cotter pin and fix locking plate securely.
z When applying bonding compound, Clean components and remove all oil and grease. And
then apply 2 or 3 drops to all parts with thread.
z When applying sealant, clean surface and remove all oil and grease. If no dirt and damages
are recognized, evenly wipe sealant to it.
z Remove or repair all part’s damage, dent, burrs and rust.
z Grease all rotary components or sliding components.
z Apply anti-friction composites to the part surface, when press- fitting.
z Make certain snap rings have been securely located in the groove after assembling snap
rings.
z Make wire connector free of oil, dirt and water; connect securely when connecting wire with
wire connector.

z When using eye bolt, inspect it to make certain the bolt free of distortion and
134
metamorphic. Make sure to completely fasten it and align it with the lifting hook.
When fastening counter flange, always fasten them evenly to prevent that one side’s flange is
over fastened.
3.The fasten torques of main bolts\ nuts are as following table. (N.m)
tightening torque
Screw diameter opposite
Target value using limit
(mm) side(mm)
N•m N•m
6 10 13.2 11.8 - 14.7
8 13 31 27 - 34
10 17 66 59 - 74
12 19 11 98 - 123
14 22 177 157 - 196
16 24 279 245 - 309
18 27 382 343 - 425
20 30 549 490 - 608
22 32 745 662 - 829
24 36 927 824 - 1030
27 41 1320 1180 - 1470
30 46 1720 1520 - 1910
33 50 2210 1960 - 2450
36 55 2750 2450 - 3040
39 60 3280 2890 - 3630

Tighten torque is as following table. (N.m)

tighten torque
screw thread standard across width target value use limit
(mm) N•m N•m
9/16-18UNF 19 44 35 - 63
11/16-16UN 22 74 54 - 93
13/16-16UN 27 103 84 - 132
1-14UNS 32 157 128 - 186
13/16-12UN 36 216 177 - 245
1-7/16-12UN-2B 41 215 176 - 234

135
★ The torque of control valve and motor should be reduced by 10% according to “bolt/ nut
fasten torque fig”. Fasten the circumferential uniform bolt in diagonal cross line. Wipe the glue
1277 when assembling.

4.Recommended grease brand name


bucket、arm and boom、rotary gear, swing bearing etc
—20 to 40°C(—4 to 104 F)
BP BP Energrease Ls—EP2
Caltex Multifax EP2
Esso Beacon EP2
Apollo Daphne Coronex Grease EP2
Mobil Mobilux EP2
Fuchs 2# extreme pressure lithium grease
Shell Shell Alvania EP Grease 2
Remark lithium grease with extreme high load capacity

5. Random auxiliary tools for general purpose

serial No. product No. name and specification


1 818899160000 Valuable tool box
2 740119000009 Engine oil filter spanner
3 740105000164 Common box spanner 13 pieces unit
4 740103000003 Adjustable bending bar 250X28 GB4440
5 740131000004 Wire cutter 200MM
6 740210000006 Ball hammer 2P
7 740106000033 Box spanner 6 pieces unit
8 740121000011 Cross screwcriver 150 GB1064-89
Straight screwdriver 250X10X1.6
9 740121000016
GB10639
10 740104000005 Inner hexagon spanner S6 GB5356-85
11 740104000006 Inner hexagon spanner S8 GB5356-85
12 740104000007 Inner hexagon spanner S10 GB5356-85
13 740115000002 Double ended spanner 13-16
14 740115000003 Double ended spanner 17-19

★ After the cylinder, main pump and other hydraulic devices are disassembled and
repaired then re-assembled; bleed the air for the first time use. The operation procedures
are as follow:
136
(1) Start the engine and run it with low idle speed.
(2) Operate working device controller to operate hydraulic cylinder 4-5 times, stop
the cylinder at a position 100 mm away from the stroke end.
(3) Operate hydraulic cylinder 3-4 times to its stroke end.
(4) Make the engine run with normal speed, afterwards.
★When using the machine for the first time after long-term storage or repair, follow the
same procedure.

6. Instruction after operation


z In the event that engine coolant is drained, tighten drain valve, refill coolant to specified level.
Run the engine to cycle coolant in system then check the fluid level.
z In the event that hydraulic device has been disassembled then re-assembled, refill oil to the
specified level. Run the engine to cycle oil in the system. Then check oil level.
z If repair and disassembly to pipelines or hydraulic devices are made, bleed the air after
re-assembling components.
z Apply grease with specified volume to relevant parts of working device.

5.3 Working device ASSY assemly and disassembly

(1) Special tools

No. product No. name spec.


1 740105000164 Common box spanner

2 740104000007 Inner hexagon spanner S10 GB5356-85


80-300N.m
3 740119000011 torque spanner
12.5mm
(2) Disassembly
Extend arm and bucket totally. Lower the working device to the ground and put the securing rod
at the lached position.
★ Release the residual pressure in hydraulice circuits. Refer to the part “Release the residual
pressure in hydraulic circuits” in chapter “measure and adjust”.
1. Break butter hose (1).
2. Lift boom oil tank ASSY (4) and disassemble lock bolt (3).

137
3.Disassemble plate(3),then the pin.
★ Check the shims number and thickness and put them at safety place.
4.Start the engine and retract piston rod.
★ Fix piston rod with cable and lower the oil tank on the platform or place a bearing under the
oil tank to support it.
★ Disassemble the other side of the boom oil tank with the same way.Two pieces of the oil tank
hose (5). Seal the port and make necessary labels.

★ Choke the hose to prevent oil discharging and fix it on the other side of the valve.
6. Dismantle the connector (7) on the lamp.
7. Life the working device and dismantle pressure plate(8),then the pin(9).

★ Don’t forget to check the shims number and every parts with shims.

138
8. Lift the working device ASSY and decompose it.

Working device ASSY :5000 kg

(1) Assembly
• Assemble in reverse order of dissemble.

:See 5.2 for recommended lubricant brand.

:Apply according to the torque fig.5.2.

Wipe butter on the inner surface of the bushing when assemble the pins and align the pin
holes. Do not put fingers into the holes.
★ Exhaust from oil tank. Refer to exhaust from the parts in chapter “testing and adjustment”.
★ Fill the oil to specified level through the oil port. Run the engine to cycle the oil in the system
and then chek the oil level.

5.4 Counterweight ASSY assembly and disassembly


No. product No. name spec.
1 740105000164 Common box spanner

3 740119000074 Torque spanner 0-3000

(1) Disassembly
1. Disassemble the engine cover (1). Refer to “engine assembly and disassembly”.
2. Disassemble counterweight rubber choke plugs (2). Fit with handling bolts and lift them.

3. Dismantle 4 construction bolts (3)


★ Check the shims number and thickness and put them at safety place.

139
4. Lift counterweight slowly and horizontally.
★ Be careful not to touch the engine, radiator and cooler.

Counterweight ASSY :4500 kg


(2) Assembly
• Assemble in reverse order of disassemble.
★ Screw thread glue:thread lock glue 1277.
:Apply as the torque fig.5.2.
★ Counterweight assembly and adjustment
Lift the counterweight to the proper place on the platform. Move counterweight slowly. Fit with
construction bolts and adjust the clearance between the bolts and platform and coves.

5.5 Cab ASSY assembly and disassembly


(1) Special tools
No. product No. name spec.
1 740105000164 Common box spanner
80-300N.m
7 740119000011 torque spanner
12.5mm
150
8 740121000011 Plastic handle cross screwdriver
GB1064-89
250X10X1.6
9 740121000016 Plastic handle straight screwdriver
GB10639

(2) Disassembly
Disassemble the cable from the negative terminal of the accumulator.
1.Disassemble rubber floor mat in the cabin.

2.Disassemble part (1). Disassemble the electric joints between every electric parts and electric
mounting plate (2) and make necessary mark.. Disassemble the bellows between evaporator and
duct, new tuyere and evaporator. Disassemble the hose of window scrubber.

140
3.Disassemble lock drag bar (3).

4.Disassemble the 6 bolts (4) which connect the cabin and the worktable.

5. Lift cab ASSY for disassembling.

Cab ASSY :240 kg

★ Be careful not to touch the worktable and platform.


(3) Assembly
• Assemble in reverse order of disassemble.

141
5.6 Engine disassemble and assembly

(1) Special tools

No. product No. name spec.

1 740105000164 Common box spanner

80-300N.m
7 740119000011 Torque spanner
12.5mm
8 740121000011 plastic handle cross screwdriver 150 GB1064-89

(2) Disassembly

★ Lower the working device to the ground and stop the engine. Disassemble the cable
from the negative (–) terminal of accumulator. Gradually loosen the oil ejector lid of the
hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting.
1.Dismantle release plug to discharge hydraulic oil from hydraulic oil tank and pipelines.

Hydraulic oil in hydraulic oil tank:about 240L

2.Release the engine coolant.

Engine coolant:about 23L

3.Lift engine cover (1) and dismantle coupling bolt and stand bar (2). Support the engine cover
with proper batten and lift device.

4.Dismantle intercooled air duct(3), cooler water inlet pipe(4), intercooled escape pipe(6),
supercharger air duct(7), intercooled escape pipe(9), cooler drain pipe(10), rubber ring(5)and
drag bar(8),make the necessary marks and seal the pipe orifice.

142
5. Dismantle engine oil pipeline, compressor pipeline and electric joint. Make the necessary
mark and seal the pipe orifice.
6.Dismantle compressor ASSY.
7.Dismantle all the oil pipelines of hydraulic pumps, electric joints(refer to “hydraulic pump
ASSY disassembly and assembly”)and its cover parts and baffles.
8.Dismantle exhaust muffler and its discharge pipe.
9.Dismantle all the construction bolts of the engine.

★ Check there are no connecting wires or pipelines.

10. Lift engine and hydraulic pump ASSY.

Engine and hydraulic pump ASSY :700 kg

(3) Assembly
• Assemble in reverse order of disassemble.
★ Refer to section “check and adjust” of part” belt tension of air-conditioning compressor” in
chapter“measuring and adjustment”.
★ Screw thread glue:thread lock glue 1277.

★ :Apply according to the torque fig.5.2.


★ Refill the engine coolant to specified level through the water feeding port.
Engine coolant:about 23L
143
★ Refill the hydraulic oil to specified level through the oil port.
Hydraulic oil:about 240L
★ Start the engine to cycle the water so as to release any gas bubble, then check the water level.
★ Start the engine to cycle the oil in hydraulic system, then check the oil level and liquid level.
★ Exhaust air and consult the content in section “exhaust air from the parts”in chapter “testing
and adjusting”.

5.7 Radiator ASSY disassembly and assembly

(1) Special tools

No. product No. name spec.

Common box
1 740105000164
spanner
2 740119000011 Torque spanner 80-300N.m 12.5mm
Plastic handle
3 740121000011 cross screwdriver GB1064-89
150
Inner hexagon
4 740104000007 S10 GB5356-85
spanner
(2) Disassembly

★ Lower the working device to the ground and stop the engine. Disassemble the cable
from the negative (–) terminal of accumulator. Gradually loosen the oil ejector lid of the
hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting.
1.Dismantle release plug to discharge hydraulic oil from hydraulic oil tank and pipelines.

Hydraulic oil:about 240L

2.Release the engine coolant.

Engine coolant:about 23L


3. Open the engine cover. Dismantle intercooled air duct (3), cooler water inlet pipe(4),
intercooled escape pipe(6), supercharger air duct(7), intercooled escape pipe(9), cooler drain
pipe(10), rubber ring(5)and drag bar(8),make the necessary marks and seal the pipe orifice.

144
4.Dismantle hydraulic oil pipes joint (11), cover plate(12)and auxiliary water tank hose(13),seal
the orifice.

5.Dismantle hydraulic oil pipes joint (14) and seal the orifice.

6.Dismantle air-conditioning cooler (15) and seal the orifice.


145
7.Using two lifting hook to lift radiator ASSY.
8.Dismantle four radiator construction bolts.

9. Lift radiator ASSY :155 kg


(3) Assembly
• Assemble in reverse order of disassemble.
★ Screw thread glue:thread lock glue 1277.

★ :Apply according to the torque fig.5.2.


★ To preserve heat balance, the sponge plate must be fitted at the original place.
★ Adjust the clearance between the air deflector hooks of the radiator and the engine to insure
the uniform of the clearance.
★ Refill the engine coolant to specified level through the water feeding port. Start the engine to
cycle the water so as to release any gas bubble, and then check the water level.
Engine coolant:about 23L
★ Refill the hydraulic oil to specified level through the oil port.
Hydraulic oil:about 240L
★ Start the engine to cycle the oil in hydraulic system, then check the oil level.
★ Exhaust air and consult the content in section “exhaust air from the parts”in chapter “testing
and adjusting”.

146
5.8 Hydraulic pump ASSY disassembly and assembly

Tools

No. product No. name spec.


1 740104000006 S8 GB5356-85
inner hexgon spanner
2 740104000007 inner hexgon
S10 GB5356-85
spanner
inner hexgon spanner
3 740104000009
S14 GB5356-85
4 740115000003 double end 17-19
5 740115000032 solid spanner 16-18
6 740119000011 torque spanner 80-300N.m 12.5mm
7 740119010059 open end of SH15D×17
the torque
8 740119010060 SH15D×19
spanner
Disassembly

Disassemble the cable from the negative (–) terminal of accumulator before starting the
engine. Lower the working device to the ground and stop the engine. Gradually loosen the oil
ejector lid of the hydraulic oil tank to release the inner pressure.
★ Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1.Discharge the hydraulic oil from the oil tank. If there is no special oil drain device to use, twist
off the discharge plug at the bottom of the oil tank.

hydraulic oil:about 185L

2.Disassemble cover (1)

3.Dismantle the following 7 hoses and 3 connectors:


(1) Negative flux feedback pipe of the front pump

147
(2) Two pressure sensor connector
(3) Oil drain pipe of the main pump
(4) Two main oil pipes
(5) Pilot oil supply output pipe
(6) Connector of the proportional solenoid vave
(7) Negative flux feedback pipe of the back pump
(8) Oil inlet of the proportional solenoid vave
(9) Suction pipe of the pilot oil supply

4.Dismantle oil suction steel pipe (1) of the main pump.

5.Dismantle dummy plate (1) and (2).

148
6.Lift the hydraulic pump, and then disassemble the connecting bolt between the engine and the
hydraulic pump.

hydraulic pump ASSY:120 kg.


Assembly
• Assemble in reverse order of disassemble.

★ :Apply according to the torque fig.5-1 and 5-2.


★Before connecting the oil suction steel pipe to the inlet port of the main pump, loosen the
anchor ear on the hoses to adjust the position of the steel pipe
★After assembling, fill oil to the hydraulic oil tank. Start the engine to cycle the oil in the
system and check the oil level.
★Exhaust air and consult the content in section “exhaust air from the parts”in chapter “testing
and adjusting”.

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5.9 Hydraulic pump body disassembly and assembly

Tools

No. product No. name spec.


1 740104000003 S4 GB5356-85
2 740104000004 S5 GB5356-85
inner hexagon spanner
3 740104000005 S6 GB5356-85
4 740104000006 S8 GB5356-85
5 740104000010 S17 GB5356-85
6 740106000005 17-19
7 740106000003 24-27
Box spanner
8 7401060000191 27-30
9 740106000020 32-36
10 740121000010 Cross screwdriver 75X5 GB1064-89
11 74010300000 Adjustable bending bar 200X24 GB4440
12 740131000023 Nipper pliers 160
Disassembly
★When disassemble pumps, please read the content of pumps disassembly and assembly
carefully first, and then do as the following requirements. Do not intermix the pumps parts when
dismantle pumps.
★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0066).
1. Choose the place for disassembly.

★ Choose a neat and clean place.


★To prevent collision of the parts, lay rubber plate or working cloth on the worktable.
2.Use cleaning oil to wipe off the debris and rusty spot on the surface of the pump.

3.Open the oil-embolus cover (468) on the pump body and extract the oil in the pump.

4.Dismantle hexagon bolts (412,413) and the adjustor.


★Please refer to the chapter of adjustor disassembly.

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5. Unscrew the hexagon bolt (401) which is fixed on the shoe plate (251) of the swash plate,
pump body (271) and valve body (312).
★If there are connecting pieces at the back of the pump, dismantle the connecting pieces before
doing the next step.
6.Put the fitting surface of the pump and the adjustor downwards and place it on the worktable
flatly. Dismantle pump body (217) and valve body (312).
Lay rubber plate to avoid damaging the fitting surface.

7. Align pump body (271) and drive shaft, take out cylinder body (111), piston (151), pressure
plate (153), spheric bushing (156) and oil tank spring. Be careful not to destroy the slip surfaces
of the oil tank, spheric bushing, and guide track and piston shoe.

8. Dismantle inner hexagon bolt (406) and sealing cover (F) (261).
★Assemble pulling bolts in the pulling holes of the sealing cover (F) can take out the cover plate
easily.
★There is oil seal packingring on the sealing cover (F). Don’t damage oil seal packingring as
assembling and disassembling.

151
9. Disassemble hexagon bolt (408) and the back cover plate (263).
10.Slightly knock the flange tray of the support table for tilt plate (251) on the side of the pump
to disconnect the pump body and shoe plate.

11.Take out piston shoe (211) and tilted plate (212) from pump body (271).

12.Slightly knock the shaft end face of the drive shafts (111,113) with plastic hammer. Pull out
the drive shaft from the tilt plate support table.

152
13. Take valve bodies (313,314) from the valve body (312) .they will be pulled off when
operating step 6.

14.Take out hold down plates (L) (534), (S) (535), auxiliary piston (532) and tilt pin (531) from
pump body (271) if necessary. And take out needle bearing (124) and spline connect shaft (114)
from valve body (312). When dismantle the tilt pin, use clamp to prevent damaging the head of
the tilt pin.
★There is hard gum on the match surface between the tilt pin and auxiliary piston. Please avoid
damaging the piston.
★Do not pull out the needle bearing.
★Do not loosen valve body and the hexagon nuts on the tilt plate support table, otherwise the
setting flow will change.
Assembly
Fastening torque table
parts No. dimension torque N.M
401 M20 430
406 M8 29
466 G1/4 36
468 G3/4 170
490 NPTF1/16 8.8
531、532 24X2 330
806 M16 130
808 M20 240

Assemble in reverse order ofdisassemble.Fastening torque of the bolts are as the above table.
Please note following item:
★ Repair the damaged parts and prepare the new ones.
★ Clean all the parts using cleaning oil and assemble them after air scavenging.
★ Assemble the movable parts and bearings after wiping action oil for them.

153
★ Replace in principle the sealing parts, i.e. O-ring and oil seal, etc.
★Screw up construction bolts and pins with spanner as per the specified torque.
★Don’t intermix the front pump parts with the back pump parts.
1.Using hammer to knock the tilt plate support table (251) slightly into pump body (271) and fit
it.
★Assemble the auxiliary piston, tilt pin and hold down plates (L) (S) on pump body before
taking them out.
★When tightening the auxiliary piston and tilt pin, please use clamp to avoid damaging the head
of the tilt pin and feedback pin, wipe hard gum (medium intensity) on the bolt.

2.Place the fitting surface of the pump body and the adjustor downwards. Embed the bushing
into the tilt plate of tilt pin (531). Assemble the tilt plate (212) into the tilt plate support table
(251).
★Ensure the tilt plate turns well by using your fingertips.
★Wipe lubricant oil on tilt plate, tilt plate support table and drive parts for assembling drive
shaft.

3. Assemble the drive shaft with bearing (123), shaft flapper (127) and baffle ring (824) into tilt
plate support table (251).
★It is forbidden to knock the drive shaft with hammer.
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★Knock the outer circle of the bearing slightly with rubber hammer, and then use copper bar to
knock it fully in.

4.Put the seal cover (F)(261)into pump body (271)and fix it with inner hexagon bolt(406).
★Wipe a thick lubricant oil on the oil seal of the seal cover (F).
★ Be careful not to damage the oil seal.
★Assemble the back cover (263) and seal cover (262) of the pumps in series as per the same
steps.

5.Assemble the auxiliary piston cylinder body〔oil tank(141), auxiliary pistons(151,152),


pressure plate(153), spheric bushing(156), washer(158)and oil tank spring(157). Align the
spheric bushing with oil tank spline and put them into the pump body.

155
6.Align the valve block (313) with pin and then fit it into the valve body (312).
★ Please don’t make wrong assembly for inlet and outlet directions of the valve block.

7.Assemble valve body (312) on shell (271) and fix it with hexagon bolt (401).
★The operation will be easier to assemble the back pump body first.
★Please don’t fit wrong direction for the valve body. The outlet position (from inlet axes
direction): left side (the position of the adjustor: upwards).

8.The feedback pin of tilt pin is in the feedback pin of adjustor. Assemble the adjustor and fix it
with inner hexagon bolt(412,413).
★Do not make wrong assembling for the front and the back adjustors.

9.Assemble oil drain pinhole (467) and complete the whole operation steps.

156
157
5.10 Main pump adjustor disassembly and assembly

Tools

No. product No. name spec.


1 740104000003 S4 GB5356-85
inner hexagon spanner
2 740104000004 S5 GB5356-85
3 740104000005 S6 GB5356-85
4 740121000010 cross screwdriver 75X5 GB1064-89
5 740103000004 Adjust bending bar 300X36 GB4440
6 740131000023 Nipper pliers 160
Disassembly
★The disassembly and assembly work for the adjustor is a little complex as its parts are both
precise and mini. So it is suggested to replace adjustor ASSY without special circumstances
when maintenance. If it is necessary to disassemble, please read the following dismantle gists
before disassembling it.
★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0083). Please see
this chapter.
1.Choose a place for disassembling.

2.Use cleaning oil to wipe off the debris and rusty spot on the surface of the adjustor.

3.Take out hexagon bolts(312,413)and adjustor noumenon from pump body.


★ Be careful not to lose O-rings.

4.Dismantle inner hexagon bolt (438) and cover(C) (629).

★Cover(C)is fit with adjusting screws(C)(CI),(628 、 925), adjusting wheel(C)(627), lock


nut(630), hexagon nut(801)and adjusting screw(924). Don’t screw off these screws and nuts.
Otherwise the setting pressure and flow will change.

158
5.Dismantle cover(C)(629)and take out outer circle spring(625), inner circle spring(626) and
spring seat( C)(624). Pull out adjusting ring (Q) (645), guide spring (646) and spring seat (644).
★Using bolt M4 can take out adjusting ring (Q) (645) easily.

6.Please dismantle hexagon bolt (436 438) and guide cover (641). Then take out set spring (655)
from guide part.

7.Dismantle check ring(814),spring seat(653), retracting spring(654)and sleeving(651).


★Sleeving (651) is fit with clamping ring (836).
★When take out check ring (814), retracting spring (654) may be ejected. Be careful not to lose
it.

159
8.Take out lock check ring (858), support latch (614) and adjust latch (615).
★Using bolt M6 can take out support latch (614) and adjust latch(615).

9.Take out lever (2) (613), and don’t pull out pin(875).
★Using nipper can simplify operation process.

10.Pull out pin (874) and take out feedback rod block (611).
★Using thick copper bar to push out pin (874) (its diameter is φ4) from the top down without
touching lever (1) (612).
160
11.Take out rod block (612). Do not pull out pin (875).

12.Pull out guide piston shell (643) and sliding shoe (652).

13.Pull out piston shell (622), compensation plug (621) and compensation rod (623). The
disassembly work for adjustor is completed.
Assembly
Fastening torque figure
parts NO. dimension torque N.M
412、413 M8 29
436、438 M6 12
496 NPTF1/16 8.8
630 M30X1.5 160
801 M8 16
802 M10 19

Assemble in reverse order of disassemble. Please note the followings:


★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0086).
★ Repair the damaged parts and prepare the new ones.
★ Clean all the parts using cleaning oil and assemble them at a clean place after air scavenging.
★Screw up construction bolts and pins as per the specified torque.
★ Assemble the movable parts after wiping action oil for them.
★ Replace in principle the sealing parts, i.e. O-ring, etc.

161
1.Assemble compensation plug (623)into the compensation hole of the shell(601).

2.Insert the rod block (1) (612) which has been fit with pins into the compensation plug groove.
Assemble the rod block on the pin.
3.Assemble bushing (652) and sliding shoe (651) into the sleeving hole.
★Ensure the bushing and sliding shoe can move smoothly in the adjustor shell.
★ Pay attention to the direction of the bushing.

4.Assemble feedback rod block(611).Align the pin (874)with the pin hole of feedback rod block
and insert it.
★Insert the pin to the feedback rod block beforehand will be convenient for operation.
★ Pay attention not to fit wrong direction of the feedback rod block.

5.Assemble the guide shaft (643) into the inside hole of the shell.
★Ensure the guide shaft can move smoothly.
6.Insert the pin of press-in rod block (2)(613)into the guide piston groove and assemble rod
block (2).

7.Press the pin of support latch (614) into the pin hole of rod block (2), assemble support latch
and locating ring (858).
162
8.Insert adjusting pin (651) and assemble location ring.
★ Be careful not to fit wrong positions for the support latch hole and the adjusting latch hole.
★Meanwhile, confirm if the action distance for feedback lever block is too long, and if there is
jamming problem.
9.Assemble retracting spring (654) and spring seat (653)into sleeving hole, then assemble check
ring(814).

10.Assemble setting spring (655) into sleeving hole, compensation piston (621), piston shell
(622) and guide cover (641) into compensation hole. Tighten and fix it with inner hexagon
bolts (436) (438).

11.Assemble spring seat (644), guide spring (646) and adjusting wheel (Q) (645) in spring seat.
Assemble spring seat (624), inner spring (626) and outer spring (625) in compensation hole.
★ Caution not to fit wrong direction of spring seat.

163
12.Assemble the cover (C) (629) which is fit with adjusting bolt(628)(925), adjusting
wheel(C)(627), latch nut(603), hexagon nut(801)and adjusting bolt(924). Tighten and fix the
cover with inner hexagon bolt (438). Assembly is completed.

164
165
5.11 Rotary motor ASSY disassembly and assembly

Tools

No. product No. name spec.


common box
1 740105000164
spanner
740104000006 inner hexagon S8 GB、
2
spanner 5356-85
single-ended
3 740115000035 41
spanner
4 740115000023 32-34
Double-ended
5 740115000003 17-19
spanner
6 740115000032 16-18
80-300N.m
7 740119000011 torque spanner
12.5mm
8 740119010065 open end of torque SH22D×32

9 740119010067 spanner SH22D×41


75X5GB
10 740121000010 Cross screwdriver
1064-89

Disassembly
Release the residual pressure in hydraulice circuits. Refer to the part “Release the residual
pressure in hydraulic circuits” in chapter “measure and adjust”. Lower the working device to the
ground and stop the engine. Open the oil ejector cover on hydraulic oil tank to release the
residual pressure and turn the security lock rod to the lock position.
★Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1.Dismantle the following 7 hoses:
(1) Oil feed hose
(2) Two main oil hoses
(3) Oil drain hose
(4) Two unlocking hoses

166
2. Dismantle gear oil dranin hose (1) and 14 motor construction bolt (2).

3.Lift rotary motor. (1) is lift bolt.

multiple way valve weight:230kg


Lift screw thread hole:M10X1.5
Assembly
• Assemble in reverse order of disassemble.
★ :Apply as per torque fig. 5-1、5-2.
★ Refill the hydraulic oil to specified level through the oil port. Start the engine to cycle the oil
in hydraulic system and then check the oil level.

★ Exhaust air and consult the content in section “exhaust air from the parts”in chapter “testing
and adjusting”.

167
5.12 Rotary motor noumenon disassembly and assembly

Tools

No. product No. name spec.


1 740104000004 S5 GB5356-85

2 740104000005 S6 GB5356-85

3 740104000006 inner hexagon S8 GB5356-85

4 740104000009 spanner S14 GB5356-85

5 740104000010 S17 GB5356-85

6 740104000014 S24 GB5356-85

7 740121000010 cross screwdriver 75X5GB1064-89


80-300N.m
8 740119000011 torque spanner
12.5mm

Disassembly
★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0152、JPG0155).
Please read the content of part “rotary motor” in chapter “function and structure”.
★As the parts are precise, so be careful to dismantle them to prevent damage. When repair it, be
careful to avoid the dust get into it and damaging the O-rings and sealing plate.
1. Tie the motor down with steel cable and use crane to lift it, wash clean and dry it with
compressed air.
2. Drain working oil in the motor noumenon from outlet.
3. Put the shaft end of drive shaft (101) downwards and fix it on the worktable which is easy to
disassemble. Make combining mark at the combining site of motor noumenon (301) and valve
body (303).

168
★ Lay rubber plate or cloth when you ismantle platform to avoid damaging the parts.
4. Screw off relief valve (051) and dismantle it from valve body (303).

★ When screw off the relief valve, O-ring will be damaged. So it must be replaced.
5. Dismantle ROMH oil drain plug(469)from valve body(303),and then take out spring (355)
and plunger (351).

★ Be careful not to damage the plunger valve seat.


6. Screw off inner hexagon bolt (401),dismantle valve body (303) from motor body (301).
Then take out valve plate (131) from valve body (303).

★As the elastic force of the brake spring (712),valve bocy (303) will eject from motor body
(301).
7. Dismantle brake plunger from brake spring (712).

169
8. Pull out brake plunger (702) from motor body (301) with disassembly tools.

★Hook the claw end of dismantle tool in the groove of the brake plunger and lift it upright.
9. Place the motor in level again.Pull out oil tank (111) from drive shaft (101), and then the
plunger (121), pressure plate (123), (121), (123), pressure spring and brake shoe plate (124).

★ Be careful not to damage the rotary mesh face between the oil tank and the brake shoe plate.
If the shoe plate can not be taken out, dismantle it in the operation of item 12.
10. Take out friction plate (742) and separator metal plate (743) from motor body (301).

170
11. Take out drive shaft (101) and brake shoe plate (124).

★When take out drive shaft, oil seal may be destroyed by splines. So use plastic tape to wind
around the splines before take it out.
Apply the following steps according to the actual situations:
Push out the inner loop of column rolling bearing with punch.

★It can also use hammer and steel bar to beat the inner loop. Be careful to beat it with uniform
force to avoid damaging. The dismantled bearing can not be used again.
1) Slightly beat the outer ring of the column rolling bearing from the side of the oil seal (491)
with hammer and steel bar and take it out gradually from motor body (301).
★The dismantled bearing can not be used again.
2) Using slip hammer bearing detacher to take out column rolling bearing (444) from valve
body (303).

171
★The dismantled bearing can not be used again.

Assembly
Fastening torque figure
parts NO. dimension torque N.M
(031-1) G1/4 0.9
033 M6 12
051 M33X1.5 177
151 G1/4 26
171 M8 29
400 M22X1.5 69
401 M20 430
469 M36X1.5 539
984 G1/2 2.7
985 G1 5.6

Assemble in reverse order of disassemble.


★ Clean all the parts using cleaning oil and assemble them after air scavenging.
★Before assembling, wipe working oil on rotary meshing part and bearing.
★ Replace in principle the sealing parts, i.e. O-ring and oil seal, etc.
★Screw up fixed bolts and oil drain spout plug with torque spanner as per table.1.

1. Place motor body (301) on proper plateform and one side of valve body (303) upwards.
2. Using hot pressure matched way to assemble the inner loop of column rolling bearing (443)
in drive shaft (101).
★ Pay attention to the direction of the locating pin on column rolling bearing.
3. Assemble oil seal (491) into motor body (301).

172
4. Pay attention to the direction of oil seal. Wipe thin grease on oil seal port; knock it
uniformly to avoid damaging the peripheral parts. Knock it slightly and assemble the rolling
bearing (443) into motor body (301) with hammer and steel bar.

5. Assemble drive shaft into motor body (301).

★ Be careful not to damage oil seal port when assembling. Wind the shaft splines with plastic
tape.
Place motor body (301) in level and insert brake shoe plate (124).

173
★ Screw the bigger side of chamfering into motor body. To prevent breaking off from
combining site, wipe thin grease on the surface.

6. Connect pressure plate (123) with its spring, then assemble it on the plunger unit (12l,122).

7. Assemble the plunger unit (12l,122) which are placed on plate (123) into oil tank (111),
together with the spline of driving shaft (101).

174
8. Reset motor body (301),put one side of the oil seal downward. Assemble 4 metal plates
(743) of separator and 3 friction plates (742) into motor body (301) in order.

9. Fit O-ring (706) (707) into motor body (301).

★Wipe thin grease on O-ring to avoid breaking the brake plunger when fit it in.
10. Assemble brake plunger (702) into motor body (301).

175
11. Assemble brake spring (712)) into brake plunger (702).

12. Assemble the external ring of column rolling bearing (444) into valve body (303) gradually
by tapping it with hammer and steel bar at the same time.

★Apply this step only after disassembling column rolling bearing (444).
★Evenly tap the periphery of external ring until it is completely fit into the holding latch groove
of valve body.

13. Assemble valve plate (131) into valve body (303),then assemble O-ring.

176
★ Wipe thin grease on the connecting face of valve plate to prevent it to be breaking off.

14. Assemble valve body (303) into motor body (301),then screw it up with inner hexagon bolt.

★Pay attention to the installation base of valve body, avoid falling down of brake spring. Screw
up the bolt evenly.

15. Assemble plunger (351) and spring (355) into valve body (303),and then assemble ROMH
oil drain spout plug (469) which fit with O-ring (488) into valve body (303).

★Check if the plunger can run smoothly.


16. Assemble relief valve (051) into valve body (303).

177
5.12 Handle pilot valve disassembly and assembly

Tools

No. product No. name spec.


inner
1 740104000005 hexagon S6 GB5356-85
spanner
2 740115000024 double solid 22-24

3 740115000025 spanner 27-30


Cross 75X5GB1064-8
4 740121000010
screwdriver 9
Disassembly
★The numbers in () after the parts name are serial NO. of the parts in fig.(JPG0152、JPG0155).
Please read the content of part “pilot control valve” in chapter “function and structure”.
★As the parts are precise, so be careful to avoid parts collision and falling down.
★ Do not consider the parts are very tight so to beat it at will or distort it for release, or burr or
damage will occur for the parts, which will cause hard assembly, oil leakage and poor
performance.
★ Place the parts at random under the state or on the process of disassembly, humidity or
garbage will cause rust of the parts. Pay attention for rust and dust protection if the operation has
to be stopped.
1. Clean valve body with kerosene
★ Plug up every oil ports with pins.
2. Fasten the valve on pliers with copper plate (or lead plate).

3. Disassemble the lower end of rubber sheathing (501) from valve shell (101) and take it out
from the top of the valve shell.

★If there is a switch; take down wire (456) beforehand through the hole of valve shell.
4. Screw off lock nut (315) and adjust nut (312)by spanner and take down the whole handle
body.

178
5. Place spanner on the surface between adjust nut (312) and cam (302), unscrew adjust nut,
take down the nut and cam, screw off the joint to the left direction by clamp.

★If return spring (221) is tight, plate (151), bushing (211) and push rod (212) will float up when
screw off the joint.
6. Take down washer (300) and plate (151).

7. If return spring (221) is weak, spring guide sleeve (211) will still stay in valve shell as the
block act of O-ring. Using screwdriver to take it out.

★Because of the act of return spring (221), the pin may fly off when pull it out.
179
8. Because of the act of return spring (221), the pin may fly off when pull it out.

★Please record the positions between pressure-relief valve module and valve shell beforehand.
9. Use inner hexagon spanner to screw off inner hexagon nut (125) and take it out. Take down
interface plate (111), O-ring (122) and bearing bush (131) from valve shell.

10. When disassembling pressure-relief valve, take down valve rod (201) and place it upright on
level worktable, lower spring seat (216), using the head of little screwdriver to take down the
two half-round washers 1 (215).

★ Do not lower spring seat over 6mm.


★ Pay attention not to scratch the surface of slide valve.

11. Disconnect valve rod (201), spring guide sleeve (216), spring (241) and washer 2(217). Pull
out push rod (212) from bushing (211) and take down O-ring (214).

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12. Cleaning and rust prevention for parts.
★First clean the contaminative part in oil will scotch the surface. So soak the parts completely
until dirt and grease out.
★If use compress air to dry parts, dirt and moisture in air will damage parts or cause rust, so this
procedure will not be applied.
Assembly
Fastening torque figure
Parts No. Dimension Torque N.M
125 M8 29.4
301 M14 47.1
302、312 M14 68.6
315 M14 49

Assemble in reverse order of disassemble.


1. Assemble bearing bush (131) and O-ring (122) into pump shell (101).

2. Use inner hexagon bolt (125) and lock ring (121) to tighten intake plate on shell body (101).
Screw up the inner hexagon bolt (125) with specified torque.

181
★Pay attention the holding position of spring pin (126) can be inserted by the hole of shell body.
3. Insert washer 2(217),spring(241)and spring guide sleeve(216)into valve rod(201)in turn.

4. Place the bottom of valve rod uprightly on level worktable, press spring guide sleeve, insert
two washers 1(215) into spring guide sleeve. Assemble spring (221) and pressure-relief valve
module into shell body.

★Lean the wedge part of washer (215) against the top of slip valve to assemble them;pay
attention not to overlap the washers.
★Pay attention not to press spring guide sleeve over 6mm.
★Assemble as the position before being disassembled.
5. Fit O-ring (214), lock ring (213) and push rod (212) on bushing (211).

182
★ Wipe butter on the surface of pressure bar.
6. Assemble bushing module into pump.

★Use plate (151) to fit in four bushing modules together and fix them temporarily with a joint.
7. Use clamp to fix joint (301) on shell body with specified torque.

8. Assemble cam (302) into joint.

★Screw in cam until it contacts with all the four pressure bars. Do not screw in too much.
9. Assemble adjust nut (312), place spanner on cam (302) to fix it, then tighten adjust nut with
specified torque.

183
★ Caution not to change the position of circular flat-plate when tightening.
10. Use little bolt 3(431) to fix handle lever together with specified torque.

11. Assemble rubber jacket (501) and lock nut (315). Thus, assembly for handle module has
completed.

12. Decide the direction of handle, use spanner to fix adjust nut(311,312)and use lock nut (315)
to fix handle with specified torque.

13. Wipe lubricant on the rotating parts of the joint and the contact surface of cam and push rod.

184
14. Assemble the bottom of corrugated pipe on shell body. Fill in rust preventive from each oil
port and plug it with choke plug.

5.13 Multiple way valve ASSY disassemble and assemble

Tools

No. product No. name spec.


inner S8
1 740104000006
hexagon GB5356-85
Common
2 740105000164
box spanner
single-ended
3 740115000035 41
spanner
4 740115000023 32-34
Double
5 740115000003 –ended 17-19
spanner
6 740115000032 16-18
torque 80-300N.m
7 740119000011
spanner 12.5mm
8 740119010059 open head SH15D×17
of torque
9 740119010067 spanner SH22D×41

185
Disassembly
Before operation, disassemble the cable from the negative terminal of the accumulator. Lower
the working device to the ground and stop the engine, release pressure in oil tank by loosening
the cover of pouring orifice.

★ Stick identification tags on each pipe to avoid making mistakes when refitting. Seal the pipe
orifice and preserve all the sealing elements.
1. Open engine cover and disassemble the upper cover (1) of the multiple way valve.

2. Dismantle the spacing plate (1) of the engine.

3. Dismantle oil return steel pipes and the following hoses:


a) To bucket cylinder hose
b) To rotary motor main hose
c) Right oil return steel pipe
d) Rotary motor feed pipe
e) To arm cylinder hose
f) Left oil return steel pipe

186
4.Dismantle pipe clip (1) and left/ right travel hoses (2).

5.Dismantle hose(1)of P1 and P2,to operation valve, pilot hose (2) of solenoid valve, to
negative flow feedback pipe(3)of main pump and to oil return hose (4) of hydraulic cylinder.

6.Dismantle the steel pipes around multiple way valve from the top down, and dismantle the
mounting screw of main valve and under carriage, fit with lifting ring (1) and lift it with lifting
equipment.

187
multiple way valve weight:195kg
Lifting tap hole:M10X1.5

Assembly
Assemble in reverse order of disassemble.
★ :Apply as torque fig.5-1、5-2.
★After assembly, feed oil for the hydraulic cylinder to start engine , cycle the oil in system,
exhaust air and check the oil level.
★Air exhaust refers to “exhaust air of the parts”in chapter “testing and adjustment” of this
manual.

5.14 Travel motor ASSY disassembly and assembly

Special tools

No. product No. name spec.


socket
1 740105000164
wrench
2 740115000026 double 41-46
end
3 740115000007 24-27
solid
4 740115000003 wrench 17-19
torque 80-300N.m
5 740119000011
wrench 12.5mm
6 740119010063 open SH19D×27
end of
7 740119010059 SH15D×17
torque
8 74011901007 spanner SH22DX46

188
Disassembly

Before operation, disassemble the cable from the negative terminal of the accumulator. Lower
the working device to the ground and stop the engine, release pressure in oil tank by loosening
the cover of pouring orifice on hydraulic cylinder.
★ Stick identification tags on each pipe to avoid making mistakes when refitting and seal the
pipe orifice.
1.Dismantle sprocket wheel(1),refer to chapter “dismantle sprocket wheel”in this manual.

2. Dismantle cover (1).

3. Dismantle 4 travel motor hoses (1) and 18 mounting bolts, then lift.

travel motor weight:320 kg


Lifting tap hole:M10X1.5
M12X1.5
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Assembly

Assemble in reverse order of disassemble.

★ :Apply as torque fig.5-1、5-2.

★After assembly, feed oil for the hydraulic cylinder to start engine , cycle the oil in system,
exhaust air and check the oil level.

★Air exhaust refers to “exhaust air of the parts”in chapter “testing and adjustment” of this
manual.

5.15 Central rotary joint ASSY disassembly and assembly

Special tools

No. product No. name spec.


S8
1 740104000006 inner hexagon
GB5356-85
2 740105000164 socket wrench

4 740115000023 double end 32-34

5 740115000003 wrench 17-19


80-300N.m
6 740119000011 torque wrench
12.5mm
open end of
7 740119010059 SH15D×17
torque spanner

Disassembly

Release the residual pressure in hydraulic circuit. Refer to the relevant contents in chapter
“testing and adjustment”.
★Conserve well dismantled hoses, pipe orifices need to be sealed and sealing elements.
1.Dismantle the following 6 hoses:
(1) Oil drain pipe
(2) Right side travel pipe
(3) Double speed pipe
(4) Left side travel pipe
Dismantle catch bolt (5) and 4 mounting bolts (6).

190
2.Dismantle the 6 hoses connect central rotary joint with travel motor:
3.Lift it with lifting equipment

central rotary joint ASSY:40 kg

Assembly
Assemble in reverse order of disassemble.
★ :Apply as torque fig.5-1、5-2.
★ Feed oil to specified level. Start engine, cycle the oil in system and check the oil level.
★Exhaust air from travel motor refers to “exhaust air of the parts”in chapter “testing and
adjustment” of this manual.

5.16 Hydraulic tank ASSY. disassembly and assembly

Special tools

No. product No. name spec.


1 740104000006 S8 GB5356-85
inner hexagon wrench
2 740104000005 S6 GB5356-85

3 740105000164 socket wrench

4 740115000025 27-30

5 740115000003 double end solid wrench 17-19

6 740115000023 32-34

7 740119000011 torque wrench 80-300N.m 12.5mm

8 740119010059 SH15D×17

9 740119010063 open end of torque spanner SH19D×27

10 740119010065 SH22D×32
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Disassembly
Release pressure in oil tank by loosening the cover of pouring orifice on hydraulic cylinder.
★ Stick identification tags on each pipe to avoid making mistakes when refitting and seal the
pipe orifice.
1.Discharge hydraulic oil in cylinder. If there is no special oil drain device, twist-off the drain
plug at the bottom of oil tank to discharge hydraulic oil.

Hydraulic oil:about 185L

2.Dismantle engine cover (1) and brace rod (2).

3. Dismantle the cover of control valve (3).

4. Dismantle 5 oil return hoses (2), oil return steel pipe (1) and engine spacing plate (3).

5. Dismantle covering part (1) and cover (2).

192
6. Dismantle oil return steel pipe (1).

7. Dismantle oil water separator(5), diesel filter(3), engine oil filter(4),main pump oil drain
hose(2)and spacing plate(1).

8.Dismantle closed plate at the bottom of oil tank firstly, and then take apart the inlet hose (1)
connects with the oil tank.

193
9. Lift it with lifting equipment after disconnecting the mounting bolts of the 4 hydraulic oil
tanks.

Hydraulic oil tank ASSY:130 kg


Assembly
Assemble in reverse order of disassemble.
★ Refill oil (hydraulic oil tank)
★ Refill oil to specified level through pouring orifice, run the engine to cycle oil in system then
check the oil level.

★ Exhaust air from travel motor refers to “exhaust air of the parts”in chapter “testing and
adjustment” of this manual.

5.17. Carrier roller ASSY disassembly and assembly

(1) Special tools

No. product No. name spec.

1 740105000164 socket wrench

2 740119000011 torque wrench 80-300N.m 12.5mm

3 750401000006 imitation import grease gun

194
(2) Assembly

★ Use special tools to test the leakage air capacity from the seal by applying the standard
pressure on pouring orifice.
★ Check that the meter hand will not move down within 10 seconds when applied pressure is
lower than standard pressure.
Standard pressure:0.1 Mpa (1 kg/cm2)

★ Feed oil into carrier wheel ASSY.


:See the recommended grease lubricant brand in 5.2.
★ :Apply as per the torque fig.in 5.2.

5.18. Thrust wheel ASSY disassembly and assembly


(1) Special tools
★ Before assembling floating seal, clean the butter completely on the surface of the o-ring
floating seal (dashes area in fig.) and do not make dust attach on floating seal.
★ After assembling floating seal, check the gradient of the seal should be less than 1mm, and the
seal bulging qty.a should be preserved in range of 7-11 mm.
★ :Apply as per the torque fig.in 5.2.

195
5.19. Guiding wheel ASSY. disassembly and assembly
(1) Special tools

No. product No. name spec.

1 740210000006 ball hamme2P 6


imitation import
2 750401000006
grease gun

(2) Disassembly
1.Dismantle locating pin (1) and bearing (2).
2.Dismantle floating seal (3) from bearing (2) and guiding wheel (4)

.
3.Dismantle guiding wheel (4) from shaft (5) and bearing ASSY. (7).
★ There is 80 cc oil in guiding wheel, so the oil should be drained in disassembly stage.
4.Disasseble floating seal (6) from the reverse side of the guiding wheel (4), shaft (5) and
bearing ASS (7).

5.Dismantle locating pin (8) for easily taking down bearing (7) from shaft (5).
6.Dismantle lining (9) and (10) from guiding wheel (4).

196
(3) Assembly

1.Assemble lining (9) and (10) into guiding wheel (4).


2.Assemble O-ring and fit bearing (7) on shaft (5) by using locating pin (8).

3.Assemble floating seal (6) on guiding wheel (4), shaft (5) and bearing (7) ASSY.
★ Floating seal
Before assembling floating seal, clean the butter completely on the surface of the o-ring floating
seal (dashes area in fig.) and do not make dust attach on floating seal.
★ After assembling floating seal, check the gradient of the seal should be less than 1mm, and the
seal bulging qty.a should be preserved in range of 5-7 mm.

4.Assemble shaft (5) and bearing (7)ASSY on guiding wheel(4).

197
5.Assemble floating seal (3) on guiding wheel (4) and bearing (2).

★ Wipe oil is on the surface of floating seal. Pay attention not to make any dirt or dust attach on
it.
★ Clean all the butter and oil from O-ring and the contact surface of floating seal.
6.Assemble O-ring, and then fit bearing (2) with locating pin (1).
7.Feed oil and screw on screw plug.
:See recommended grease lubricant brand in 5.2.
★ :Apply as the torque fig. in 5.2.

198
5.20. Tension device disassembly and assembly

(1) Special tool

No. product No. name spec.

1 socket wrench socket wrench

2 torque wrench torque wrench 80-300N.m 12.5mm

3 compressor compressor
4 range spacer range spacer
5 tension device tension device

6 oil tank oil cylinder

7 pump pump

8 guide bolt guide bolt

(2) Disassembly
1.Dismantle piton ASSY (2) from tension spring ASSY (1).

2.Disassemble tension spring ASSY

1) Place tension spring ASSY (1) on tool J1. As the tension spring is in big assembly load,

199
assemble it correctly to avoid danger.
★ Assembly load of spring:108.8 KN.

2) Apply hydraulic pressure slowly to compress spring, disassemble jam plate (3) and then
the nut (4).
★ Compress spring until the nut begins to loose.
★Release hydraulic pressure and spring tension slowly.
★ Free length of spring:558 mm
3) Disassemble york piece (6), spring seat (7) and dust seal (8) from spring(5).
3.Disassembly for plunger ASSY
1) Disassemble lock blade (10) from plunger (9), then dismantle valve (11).
2)Dismantle snap ring(12),then dismantle U-ring(13)and ring(14).

1.Plunger ASSY assembly


1)Assemble ring(14)and U-ring(13)on plunger(9),and fix it with snap ring(12).
2) Screw up valve (11) temporary and fix it with lock blade (10).
2.Tension spring ASSY assembly
1) Assemble dust seal (8) spring seat (7) with tool J2.

200
2)Assemble spring seat(7)and york piece(6)on spring(5),and place it on tool J1.
Sliding part of oil tank: :See recommended grease lubricant brand in 5.2.
3) Apply hydraulic pressure slowly to compress spring. Tighten nut (4) until spring mounting
length gets to size “a”, then fix it with lock blade (3).

★Spring mounting length a:437 mm

4) Dismantle tension spring ASSY (1) from tool J1.


3.Assemble plunger ASSY (2) on tension spring ASSY (1).
Sliding part of wear ring: :See recommended grease lubricant brand in 5.2.
★ Assemble piston ASSY, make valve mounting position outside.
Feed 300 cc butter in oil tank.
:See recommended grease lubricant brand in 5.2.
Exhaust air and check if butter overflow from butter hole.

201
5.21 Sproket wheel disassembly and assembly

(1) Special tools

No. product No. name spec.

socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
(2) Disassembly
1.Disassemble track shoe ASSY. See “track shoe ASSY disassembly”.

2.Rotate working device to 90°,jack up the chassis with working device and place pad between
track frame and track shoe.

3. Dismantle and lift sprocket wheel (1). Sprocket wheel :40 kg

(3) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue: 1277
★ :Apply as the torque fig. in 5.2.

202
5.22. Track shoe ASSY disassembly and assembly

(1) Special tools

No. product No. name spec.

1 740105000164 socket wrench


750-2000N.m
2 740119000012 torque wrench
25mm
track press
3
machine

(2) Track shoe ASSY disassembly and tensity (steel)


1.Park the machine at the position as the king pin is between idler and carrier roller and on
which can spread track ASSY.

2. Lower working device, screw off nozzle tip (1) to release internal butter and decrease
track tensity.
★ Adjust oil tank is in extremely high pressure. Do not screw off nozzle tip over one circle. If
oil can not flow out, move the machine fore and after.

3. Pull out king pin (2) with tool M.

4.Dismantle tool M,move the machine forward to make temporary pin ② lie in front of idler
and place pad ①on it.

5.Dismantle temporary pin ② and dust seal, then move the machine backward to spread track
(3).
203
(3) Assembly
• Assemble in reverse order of disassemble.
★ See the content “track shoe tensity checking and adjustment” of chapter “checking and
adjustment” in this manual.
• Assembly program for the bolts and nuts of track shoe.
1) Turn the side R of track shoe nut (1) to the surface of connecting rod seat, and make the two
seat surfaces contact closely when assemble track shoe.
★ If track shoe nut is assembled reverse, the corner of nut and the surface of connecting rod seat
will interfere each other and raise the nut and make it loose.

2) Tighten track shoe bolt after checking the close contact of mating surface.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Press main pin with tool M. The protrude distance is the nether size a.
Main pin protrude distance a:2.5±1 mm

204
★ Before assemble dust seal, wipe butter lubricant Multifak EP2 on the contact surface with
lining.
★ If you have road gasket (rubber-type track shoe gasket), replace the track shoe gasket when
you find the rubber has worn or broken.
Otherwise, track shoe bolt will be damaged and dismantlement will turn to be difficult.
(4) Road gasket disassembly and spread
1.Stop the machine and make main pin stay over idler, so track shoe ASSY can spread forward
and backward.

2. Lower working device and screw off lubricator (1) to loose track..
★Adjust oil tank is in extremely high pressure. Do not try to screw off lubricator (1) over one
circle. If the inner butter seeps out little, move the machine fore and after.

3.Dismantle road gasket (2).


4.Withstand track shoe ASSY with stopper ➀.

5.Pull out main pin (3) with tool M and pin ➁.

6.Take away tool M,move the machine forward and pull out pin(2).

205
7.Disassemble dust seal and spread track shoe ASSY (4) when move machine forward.

(5) Road gasket assembly


• Assemble in reverse order of disassemble.
★ See the content “track shoe tensity checking and adjustment” of chapter “checking and
adjustment” in this manual.
• Assembly program for the bolts and nuts of track shoe.
1) Turn the side R of track shoe nut (1)to the surface of connecting rod seat, and make the two
seat surfaces contact closely when assemble track shoe.
★ If track shoe nut is assembled reverse, the corner of nut and the surface of connecting rod seat
will interfere each other and raise the nut and make it loose.
2) Tighten track shoe bolts.
★ Tighten track shoe bolt after checking the close contact of mating surface.
★ :Apply as the torque fig. in 5.2.

★ Press main pin with tool M. The protrude distance is the nether size a. Main pin protrude
distance a:2.5±1 mm

206
★ Before assemble dust seal, wipe butter lubricant Multifak EP2 on the contact surface with
lining.

5.23. Rotary bearing ASSY disassembly and assembly

(1) Special tools

No. product No. name spec.

socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
imitation
3 750401000006 import grease
gun
(2) Disassembly
1.Disassemle rotary table ASSY. See “rotary ASSY disassembly”.

2.Dismantle the 36 mounting bolts(1)to disassemble rotary bearing ASSY.

3. Lift rotary bearing ASSY. (2).

207
★ Rotary bearing ASSY :315 kg
(3) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Put the marking sides of inner race soft area and outer race soft area to the right, and assemble
them on track frame.

★ Rotary bearing :See recommended grease lubricant brand in 5.2.

5.24. Rotary table ASSY disassembly and assembly

(1) Special tools

No. product No. name spec.

socket
1 740105000164
wrench
torque 750-2000N.m
2 740119000012
wrench 25mm
inner
S10
3 740104000007 hexagon
GB5356-85
wrench

208
(2) Disassembly

Extend arm and bucket completely, lower working device to the ground and turn the
securing rod to the lock position.
1.Dismantle 4 hoses (1) of boom cylinder.
★ Plug hoses to avoid oil flowing out.

2.Disassemble parts as per “working device disassembly and assembly”, “counterweight ASSY
disassembly and assembly”and “hydraulic cylinder disassembly and assembly”. Dismantle the
upper hoses of central rotary joint as per “central rotary joint disassembly and assembly”, make
necessary labels and seal the pipe orifice.

3. Dismantle 36 rotary table mounting bolts and rotary table ASSY (16) and lift it away.

★ Lift the upper carriage ASSY slowly and parallel. Pay attention not to hit the central rotary
joint ASSY.

★ Upper carriage ASSY : 8000Kg


(3) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Refill hydraulic oil
Refill hydraulic oil to specified level throuth pouring orifice, start the engine and make the oil
cycle in hydraulic system, then check the oil level.

209
★ Exhaust air
Exhaust air from travel motor. See the content of “exhaust air of the parts” of chapter“testing
and adjustment”in this manual.

5.25. Air-conditioning ASSY disassembly and assembly

(1) Special tools

No. product No. name


3 740105000164 socket wrench
5 740131000004 wire pliers 200MM
plastic handle Phillips
8 740121000011
driver 150 GB1064-89
plastic handle screwdriver
9 740121000016
250X10X1.6 GB10639

(2) Disassembly
Firstly disassemble the cable of negative terminal (-) of accumulator.
1. Drain cooling water.
Cooling water:about 23L
2. Use special device to drain cooling medium from air-conditioning. Dismantle two hoses,
make necessary marks and seal the pipe orifice.
3. Disassemble drying bottle(3), condenser(4)pipelines,make necessary marks and seal the
pipe orifice.

4. Dismantle base pad.


5. Disconnect the electric joints on electric mounting plate (2), make necessary marks and then
dismantle electric mounting plate (2).
6. Dismantle the corrugated pipes between evaporator and the ducts of inner adorn parts, new
ducts and evaporator. Dismantle hoses of window scrubber.

210
7. Dismantle the two hoses (5) from drying bottle to evaporator and from compressor to
evaporator, make necessary mark and seal pipe orifice. Dismantle electric joint (6) of evaporator
and make marks.

8. Dismantle the two water pipes (7) between evaporator and engine. Dismantle fixed bolt (8)
of evaporator.

(3)Assembly
• Assemble in reverse order of disassemble.
★ When assemble the hoses in the loop of air-condition, pay attention not to make dirt, dust and
water into the hoses.
★ Assemble air-condition hoses only after checking O-ring lies behind the interconnecting
pieces.
★ Check if there is damage on O-ring.
★ Wipe compressor oil (ND-OIL8)on the screw thread of connectiong parts of refrigerant line,
and tighten the pipeline with double end wrench.
211
★ Use special device to feed the cooling medium into air-condition loop.
★ screw thread glue:1277
★ :Apply as the torque fig. in 5.2.
★ Refill coolant to specifiec level through feed water port. Engine coolant:about 23L
★ Start the engine to cycle water to release all the air bubble, then recheck.

212
6. Figures and others
6.1 Hydraulic system schematic diagram

213
6.2 Electrical system drawing

214