Professional Documents
Culture Documents
CX36B
Compact Hydraulic Excavator
CX31B - PIN PW14-46519 - and higher
CX36B - PIN PX15-21105 - and higher
SERVICE MANUAL
MAINTENANCE SPECIFICATIONS
SHOP CX31B
MANUAL model CX36B
INDEX
1 SPECIFICATIONS SECTION
SYSTEM
2 MAINTENANCE SECTION
3 SYSTEM SECTION
4 DISASSEMBLY SECTION
DISASSEMBLING
5 TROUBLESHOOTING
6 ENGINE SECTION
7 PROCEDURE E / G TROUBLESHOOTING
OF INSTALLING
OPTIONS SECTION OPT.
(1) Most accidents, which occur during operation, are (6) Continue studying the manual until all Safety, Oper-
due to neglect of precautionary measures and safe- ation and Maintenance procedures are completely
ty rules. Sufficient care should be taken to avoid understood by all persons working with the ma-
these accidents. Erroneous operation, lubrication chine.
or maintenance services are very dangerous and
may cause injury or death of personnel. Therefore
all precautionary measures, NOTES, DANGERS,
WARNINGS and CAUTIONS contained in the man-
ual and on the machine should be read and under-
stood by all personnel before starting any work with
or on the machine.
(2) Operation, inspection, and maintenance should be
carefully carried out, and safety must be given the
first priority. Messages of safety are indicated with
marks. The safety information contained in the
manual is intended only to supplement safety
codes, insurance requirements, local laws, rules
and regulations.
(3) Messages of safety appear in the manual and on
the machine : All messages of safety are identified
by either word of "DANGER", "WARNING" and
"CAUTION".
1) DANGER- Indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury and is represented as
follows:
0-2
SAFETY PRECAUTIONS stands, capable of supporting the machine, before
performing any disassembly.
0-3
(13)Always use the proper tools that are in good condi- (21)Do not operate a machine if any rotating part is
tion and that are suited for the job at hand. Be sure damaged or contacts any other part during opera-
you understand how to use them before performing tion. Any high speed rotating component that has
any service work. been damaged or altered should be checked for
(14)Reinstall all fasteners with the same part number. balance before reusing.
Do not use a lesser quality fastener if replacements (22)Be careful when servicing or separating the tracks
are necessary. (crawlers). Chips can fly when removing or install-
(15)Repairs which require welding should be per- ing a track (crawlers) pin. Wear safety glasses and
formed only with the benefit of the appropriate ref- long sleeve protective clothing. Tracks (crawlers)
erence information and by personnel adequately can unroll very quickly when separated. Keep away
trained and knowledgeable in welding procedures. from front and rear of machine. The machine can
Determine type of metal being welded and select move unexpectedly when both tracks (crawlers)
correct welding procedure and electrodes, rods or are disengaged from the sprockets. Block the ma-
wire to provide a weld metal strength equivalent at chine to prevent it from moving.
least to that of the parent metal. Make sure to dis-
connect battery before any welding procedures are
attempted.
(16)Do not damage wiring during removal operations.
Reinstall the wiring so it is not damaged nor will be
damaged in operation of the machine by contacting
sharp corners, or by rubbing against some object or
hot surface. Do not connect wiring to a line contain-
ing fluid.
(17)Be sure all protective devices including guards and
shields are properly installed and functioning cor-
rectly before starting a repair. If a guard or shield
must be removed to perform the repair work, use
extra caution and replace the guard or shield after
repair is completed.
(18)The maintenance and repair work while holding the
bucket raised is dangerous due to the possibility of
a falling attachment. Don’t fail to lower the attach-
ment and place the bucket to the ground before
starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic
lines, tubes and hoses can cause fires. Do not bend
or strike high pressure lines or install ones which
have been bent or damaged. Inspect lines, tubes
and hoses carefully. Do not check for leaks with
your hands. Very small (pinhole) leaks can result in
a high velocity oil stream that will be invisible close
to the hose. This oil can penetrate the skin and
cause personal injury. Use card-board or paper to
locate pinhole leaks.
(20)Tighten connections to the correct torque. Make
sure that all heat shields, clamps and guards are in-
stalled correctly to avoid excessive heat, vibration
or rubbing against other parts during operation.
Shields that protect against oil spray onto hot ex-
haust components in event of a line, tube or seal
failure must be installed correctly.
0-4
CASE-NA INDEX CX31B
CX36B
Book Code No. Index
Distribution Year–Month
Title
No. 33 1
MAINTENANCE SPECIFICATIONS
S5PA0105E01
2010-03
OUTLINE 1
S5PW0232E02
2010-06
SPECIFICATIONS 2
S5PW0332E02
ATTACHMENT DIMENSIONS 3 2
2010-06 42 34
S5PW1131E02
TOOLS 11
2010-06
S5PW1231E02 STANDARD MAINTENANCE
2010-06 TIME TABLE
12
S5PW1332E02 MAINTENANCE STANDARD
13
2010-06 AND TEST PROCEDURE
43 11 3
_ 51
S5PW2232E02
2010-06
HYDRAULIC SYSTEM 22
S5PW2332E02
SYSTEM
2010-06
ELECTRIC SYSTEM 23
44 12
S5PW2432E02
2010-06
COMPONENTS SYSTEM 24
_
13
S5PA3105E01 GENERAL DISASSEMBLY
DISASSEMBLING
S5PW4231E02
2010-06
HYDRAULIC SYSTEM 42
S5PW4331E02
2010-06
ELECTRICAL SYSTEM 43 31 23
S5PW4431E02
ENGINE 44
2010-06
S5PW5131E02
ENGINE 51
2010-06
_
32 24
_
PW14-46519~
PX15-21105~ APPLICABLE MACHINES
0-5
NOTE: This Manual may be revised due to the improvement of
products, modification of specifications, etc. There may
This manual contains information necessary for the
be cases where the system on the actual machine may
maintenance and repair of hydraulic excavators. It is
differ with the manual - this may be due to variation of
categorized into seven chapters: Specification, Mainte-
specifications by countries. Contact your local distribu-
nance, System, Disassembly, Troubleshooting, Engine
tor if you need clarification.
and Installation Procedures for Optional Attachment.
0-6
1. OUTLINE
1. OUTLINE
TABLE OF CONTENTS
1-1
1. OUTLINE
1-2
1. OUTLINE
(4) Recording
Record the following items for communication and prevention of recurring malfunction.
WARNING
(1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.
(2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary
meeting before starting work.
(3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine.
(4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of
emergency.
(5) Choose a hard, level and safe place, and place the attachment on the ground securely.
(6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine.
(7) Use proper tools, and replace or repair defective tools.
(8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.
1-3
1. OUTLINE
1-4
1. OUTLINE
Level gauge
Oil level lines (Level
located between the
two lines shows
appropriate amount
of oil)
Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will
result in damage to the equipment.
Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.
1-5
1. OUTLINE
1-6
1. OUTLINE
(1) O-ring
• Ensure O-rings have elasticity and are not damaged before use.
• Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply
to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to
corrosive fluid, even if the size is same.
• Fit the O-rings without distortion and bend.
• Always handle floating seals as a pair.
1-7
1. OUTLINE
1-8
1. OUTLINE
1-9
1. OUTLINE
1-10
2. SPECIFICATIONS
2. SPECIFICATIONS
TABLE OF CONTENTS
2-1
2. SPECIFICATIONS
2-2
2. SPECIFICATIONS
ARM CYLINDER
LIGHT
BOOM
BOOM CYLINDER 2
BUCKET
CYLINDER CANOPY
OPERATING LEVER
ARM
DOZER OPERATING LEVER
HYDRAULIC TANK
LINK
CONTROL VALVE
BUCKET
TRAVEL LEVER MONITOR PANEL
(GAUGE CLUSTER)
RADIATOR
AIR CLEANER
SWING CYLINDER
RESERVOIR TANK
DOZER CYLINDER
MUFFLER
BATTERY ENGINE
FUEL TANK
DOZER
2-3
2. SPECIFICATIONS
{7.28"}
185
660 {2'2.0"} 660 {2'2.0"}
1550 {5'1.0"}
R775
{2'6.5"}
{2.0"}
50
{3.3"}
85
4470 {14'8.0"}
1840 {6'0.44"}
1380 {4'6.3"}
1550 {5'1.0"}
775 {2'6.5"}
2570 {8'5.2"}
{1'10.4"}
570
345 {13.6"}
R775
{2'6.5"}
{2.0"}
50
{3.3"}
85
4470 {14'8.0"}
1840 {6'0.44"}
1380 {4'6.3"}
1550 {5'1.0"}
775 {2'6.5"}
{1'10.4"} 2570 {8'5.2"}
570
345 {13.6"}
2-4
2. SPECIFICATIONS
160{6.3"}
660 {2'2.0"} 660 {2'2.0"}
1700 {5'6.9"}
R850
{2'9.5"}
{2.0"}
50
2
{2.4"}
60
4710 {15'5.4"}
1910 {6'3.2"}
1550 {5'1.0"} 1460 {4'9.5"}
850 {2'9.5"}
2570 {8'5.2"}
{13.6"}
330 {13.0"}
345
{1'10.4"}
570
1600 {5'3.0"}
300 1700 {5'6.9"}
{11.8"} 1400 {4'7.1"} 2150 {7'0.6"}
1700 {5'6.9"} 2680 {8'9.5"}
R850
{2'9.5"}
{2.0"}
50
{2.4"}
60
4710 {15'5.4"}
1910 {6'3.2"}
1460 {4'9.5"}
1550 {5'1.0"} 850 {2'9.5"}
2610 {8'6.8"}
330 {13.0"}
{13.6"}
345
{1'10.4"}
570
1600 {5'3.0"}
300 1700 {5'6.9"}
{11.8"} 1400 {4'7.1"} 2150 {7'0.6"}
1700 {5'6.9"} 2680 {8'9.5"}
2-5
2. SPECIFICATIONS
ENGINE
HYDRAULIC COMPONENTS
2-6
2. SPECIFICATIONS
WEIGHT
Attachment
(Boom+STD Arm+STD Bucket)
kg (lb) 400 (880) 460 (1020) 2
Oil & Water kg (lb) 80 (175) <--
2-7
2. SPECIFICATIONS
CX31B
MODEL RUBBER SHOE IRON SHOE
CANOPY CAB CANOPY CAB
COMPLETE MACHINE 3,200 (7050) 3,340 (7360) 3,310 (7300) 3,450 (7600)
UPPER FRAME ASSEMBLY 1,600 (3530) 1,740 (3840) 1,600 (3530) 1,740 (3840)
(ASSY OF FOLLOWINGS)
UPPER FRAME 348 (767) <-- <-- <--
CANOPY / CAB 85 (187) 220 (485) 85 (187) 220 (485)
ENGINE 155 (340) <-- <-- <--
HYDRAULIC PUMP 28 (60) <-- <-- <--
RADIATOR 3 (7) <-- <-- <--
HYDRAULIC TANK 42 (93) <-- <-- <--
FUEL TANK 4 (9) <-- <-- <--
SWING BRACKET 82 (181) <-- <-- <--
SWING CYLINDER 37 (82) <-- <-- <--
SLEWING MOTOR 38 (84) <-- <-- <--
CONTROL VALVE 25 (55) <-- <-- <--
COUNTERWEIGHT 370 (815) <-- <-- <--
GUARD - BONNET 92 (203) <-- <-- <--
BOOM CYLINDER 35 (77) <-- <-- <--
LOWER FRAME ASSEMBLY 1,120 (2470) <-- 1,230 (2710) <--
(ASSY OF FOLLOWINGS)
LOWER FRAME 350 (771) <-- <-- <--
SLEWING BEARING 42 (93) <-- <-- <--
TRAVEL MOTOR 42X2 (93X2) <-- <-- <--
LOWER ROLLER 6X 8 (13X 8) <-- <-- <--
FRONT IDLER 22X2 (49X2) <-- <-- <--
IDLER ADJUSTER 16X2 (35X2) <-- <-- <--
SPROCKET 9X2 (20X2) <-- <-- <--
RUBBER CRAWLER SHOE 141X2 (311X2) <-- - -
300mm (11.8") IRON SHOE - - 190X2 (420X2) <--
SWIVEL JOINT 22 (49) <-- <-- <--
DOZER 140 (310) <-- <-- <--
DOZER CYLINDER 27 (60) <-- <-- <--
ATTACHMENT ASSEMBLY 400 (880) <-- <-- <--
(ASSY OF FOLLOWINGS)
BOOM ASSEMBLY 220 (485) <-- <-- <--
BOOM 130 (286) <-- <-- <--
ARM CYLINDER 30 (66) <-- <-- <--
ARM ASSEMBLY 120 (265) <-- <-- <--
ARM 70 (155) <-- <-- <--
BUCKET CYLINDER 20 (44) <-- <-- <--
BUCKET LINK 10 (22) <-- <-- <--
IDLER LINK 4X2 (9X2) <-- <-- <--
BUCKET ASSEMBLY (STD) 81 (180) <-- <-- <--
FLUIDS 80 (176) <-- <-- <--
HYDRAULIC OIL 42 (93) <-- <-- <--
FUEL 32 (70) <-- <-- <--
COOLANT 4 (9) <-- <-- <--
2-8
2. SPECIFICATIONS
Unit ; kg (lb)
CX36B
MODEL RUBBER SHOE IRON SHOE
CANOPY CAB CANOPY CAB
COMPLETE MACHINE 3,580 (7890) 3,720 (8200) 3,700 (8160) 3,840 (8470)
UPPER FRAME ASSEMBLY 1,900 (4190) 2,040 (4500) 1,900 (4190) 2,040 (4500)
(ASSY OF FOLLOWINGS)
UPPER FRAME 348 (767) <-- <-- <-- 2
CANOPY / CAB 85 (187) 220 (485) 85 (187) 220 (485)
ENGINE 155 (340) <-- <-- <--
HYDRAULIC PUMP 28 (60) <-- <-- <--
RADIATOR 3 (7) <-- <-- <--
HYDRAULIC TANK 42 (93) <-- <-- <--
FUEL TANK 4 (9) <-- <-- <--
SWING BRACKET 82 (181) <-- <-- <--
SWING CYLINDER 37 (82) <-- <-- <--
SLEWING MOTOR 38 (84) <-- <-- <--
CONTROL VALVE 25 (55) <-- <-- <--
COUNTERWEIGHT 665 (1470) <-- <-- <--
GUARD - BONNET 92 (203) <-- <-- <--
BOOM CYLINDER 35 (77) <-- <-- <--
LOWER FRAME ASSEMBLY 1,140 (2520) <-- 1,260 (2780) <--
(ASSY OF FOLLOWINGS)
LOWER FRAME 370 (815) <-- <-- <--
SLEWING BEARING 42 (93) <-- <-- <--
TRAVEL MOTOR 42X2 (93X2) <-- <-- <--
LOWER ROLLER 6X8 (13X8) <-- <-- <--
FRONT IDLER 22X2 (49X2) <-- <-- <--
IDLER ADJUSTER 16X2 (35X2) <-- <-- <--
SPROCKET 9X2 (20X2) <-- <-- <--
RUBBER CRAWLER SHOE 141X2 (311X2) <-- - -
300mm (11.8") IRON SHOE - - 190X2 (420X2) <--
SWIVEL JOINT 22 (49) <-- <-- <--
DOZER 150 (330) <-- <-- <--
DOZER CYLINDER 27 (60) <-- <-- <--
2-9
2. SPECIFICATIONS
2.5 TRANSPORTATION
2-10
2. SPECIFICATIONS
2
H
3. ARM
2-11
2. SPECIFICATIONS
2-12
2. SPECIFICATIONS
Rubber shoe
CX31B 300 (11.8") 1,550 (5’1.0") 88 27 (3.9) 28 (4.1)
2
2-13
2. SPECIFICATIONS
Standard
size
600 530
CX36B 0.11 (0.144) 4 89 (196)
(1’11.6") (1’8.9")
2-14
2. SPECIFICATIONS
2.8.1 SPECIFICATIONS
2-15
2. SPECIFICATIONS
N.m (lbf.ft)
120 (89)
[T]
100 (74)
SHAFT TORQUE
(PS) kW
T
80 (59)
(34) 25 60 (44)
40 (30)
(27) 20
POWER OUTPUT
kW
(20) 15
g/kWh (g/psh)
[F]
260 (191)
220 (162)
200 (147)
1000 1500 2000 2500
F kWh
Fuel consumption volume = XPX
X 1000 kW
245
= X 21.2 X
0.835 X 1000
3.73 ~ 4.35 L / h (load factor : (0.60 ~ 0.70))
= 6.22
2-16
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3
TABLE OF CONTENTS
3-1
3. ATTACHMENT DIMENSIONS
3-2
3. ATTACHMENT DIMENSIONS
3.1 BOOM
DIMENSIONS [mm(ft-in)]
No. NAME
CX31B CX36B
A Boom length 2300 (7'6.55") 2500 (8'2.43")
B Distance between pins of boss R1217.5 (3'11.93") R1210 (3'11.64")
C Distance between pins of bracket R1130.5 (3'8.51") R1157 (3'9.55")
D Height of boom cylinder rod pin 420.5 (1'4.56") 385.5 (1'3.18")
E Height of arm cylinder (head side) pin 764 (2'6.08") 708 (2'3.87")
F Boom foot width 178 (7.01") <--
G Inner width of bracket for boom cylinder (rod side) mounting 61 (2.40") <--
H Boom end inner width 150 (5.91") <--
J Boom end outer width 235 (9.25") <--
K Inner width of bracket for arm cylinder (head side) 61 (2.40") <--
d1 Boom foot pin dia. 45 dia. (1.77") <--
[Bushing outer dia.] [55 dia. (2.17")]
d2 Boom cylinder (rod side) pin dia. 45 dia. (1.77") <--
d3 Pin dia. of arm end 45 dia. (1.77") <--
d4 Arm cylinder (head side) pin dia. 45 dia. (1.77") <--
3-3
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Standard dimensions Clearance
Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabi Remedy
Pin dia. on bushing value for
on pin dia. value lity limit
bore dia. repair
–0.02 +0.10 0.07-
–0.05 +0.05 0.15
A Boom foot PX02B01299P1
(-0.0008) (+0.0039) (0.0028-
(-0.0020) (+0.0020) 0.0059)
–0.02 +0.12 0.08-
Boom
–0.08 +0.06 0.20
B cylinder PX02B01263P1 Replace
(-0.0008) (+0.0047) (0.0031- 0.7 1.0
(Head side) bushing
(1.7717) (-0.0031) (+0.0024) 0.0079) (0.028) (0.039)
or pin
Boom
C cylinder –0.02 +0.13 0.09-
(Rod side) –0.05 +0.07 0.23
PW02B01306P1
Arm (-0.0008) (+0.0051) (0.0035-
D cylinder (-0.0020) (+0.0028) 0.0091)
(Head side)
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
3-4
3. ATTACHMENT DIMENSIONS
3-5
3. ATTACHMENT DIMENSIONS
PL2
L2 X
3-6
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Standard Clearance X adjusted with shim
Pin length
dimensions (total of both sides)
Sec. Item Standard Remedy
Standard Serviceabili
No. Dimensions value for No. Dimensions
value ty limit
repair
178
Boom
0.2-0.6
(7.008 ) 297
A-A Boom foot L1 (0.008- PL1
(11.69)
Swing 178 0.024)
bracket
(7.008 )
Boom 60
cylinder 0.1-0.5 3
Boom cylinder (2.362 ) 178
B-B L2 (0.004- PL2
(Head side) (7.01)
Swing 61 0.020)
bracket Adjusted
(2.402 ) 1.0 1.5
with
(0.039) (0.059)
Boom 60 shim
cylinder 0.5-0.9
Boom cylinder (2.362 ) 151
C-C L3 (0.020- PL3
(Rod side) (5.94)
61 0.035)
Boom
(2.402 )
Arm 60
cylinder 0.1-0.5
Arm cylinder (2.165 ) 151
D-D L4 (0.004- PL4
(Head side) (5.94)
61 0.020)
Boom
(2.205 )
3-7
3. ATTACHMENT DIMENSIONS
3.2 ARM
3-8
3. ATTACHMENT DIMENSIONS
Dimensions [mm(ft-in)]
No. Name
CX31B CX36B
A Arm length 1180(3'10.46") 1320(4'3.97")
B Distance between pins of boss and bracket R304.5(11.99") R314(1'0.36")
C Distance between pins of boss and bracket R1036(3'4.79") R1036(3'4.79")
D Distance between pins of boss and boss R190(7.48") R190(7.48")
E Height between pins of boss and bracket 332(1'1.07") 332(1'1.07")
F Height between pins of boss and bracket 180(7.09") 149.5(5.89")
G Height between pins of boss and center 8(0.31") 8(0.31")
H Boss width 140(5.51") 140(5.51")
J Boss width 150(5.91") 150(5.91") 3
K Bracket inner width 56(2.20") 56(2.20")
L Bracket inner width 61(2.40") 61(2.40")
M Idler link dimension 310(1'0.20") 310(1'0.20")
N Bucket link dimension 285(11.22") 285(11.22")
D1 I.D. of boss 50 dia.(1.97") 50 dia.(1.97")
D2 I.D. of boss 50 dia.(1.97") 50 dia.(1.97")
D3 I.D. of boss 55 dia.(2.17") 55 dia.(2.17")
d1 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d2 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d3 Pin dia. 45 dia.(1.77") 45 dia.(1.77")
d4 Pin dia. 40 dia.(1.57") 40 dia.(1.57")
d5 Pin dia. 45 dia.(1.77") 45 dia.(1.77")
3-9
3. ATTACHMENT DIMENSIONS
3-10
3. ATTACHMENT DIMENSIONS
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
3-11
3. ATTACHMENT DIMENSIONS
3-12
3. ATTACHMENT DIMENSIONS
55
Rod side
Less
Bucket link (2.165 ) 1.0 1.5
L4 than 0.5
(Rod side) (0.039) (0.059)
56 (0.020)
Link side
204.5
D-D (2.205 ) PL5
(8.05)
140 Adjusted
Bucket link 0.1-0.5 with
Bucket link
L5 (5.512 ) (0.004- — shim
(Idler link side)
— 0.020)
Idler link
(—)
55
Head side
0.5-0.9
Bucket cylinder (2.165 ) 153
E-E L6 (0.020- PL6
(Head side) (6.02)
56 0.035)
Arm
(2.205 )
150
Arm
Less
(5.906 ) 1.0 1.5 234.5
F-F Arm foot L7 than 0.5 PL7
(0.039) (0.059) (9.23)
150 (0.020)
Boom
(5.906)
60
Rod side
0.5-0.9
Arm cylinder (2.362 ) 151
G-G L8 (0.020- PL8
(Rod side) (5.94)
61 0.035)
Arm
(2.402 )
Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.
3-13
3. ATTACHMENT DIMENSIONS
55
Rod side
Less
Bucket link (2.165 ) 1.0 1.5
L4 than 0.5
(Rod side) (0.039) (0.059)
56 (0.020)
Link side
204.5
D-D (2.205 ) PL5
(8.05)
140 Adjusted
Bucket link 0.1-0.5 with
Bucket link
L5 (5.512 ) (0.004- — shim
(Idler link side)
— 0.020)
Idler link
(—)
55
Head side
0.5-0.9
Bucket cylinder (2.165 ) 157
E-E L6 (0.020- PL6
(Head side) (6.18)
56 0.035)
Arm
(2.205 )
150
Arm
Less
(5.906 ) 1.0 1.5 234.5
F-F Arm foot L7 than 0.5 PL7
(0.039) (0.059) (9.23)
150 (0.020)
Boom
(5.906)
60
Rod side
0.5-0.9
Arm cylinder (2.362 ) 160
G-G L8 (0.020- PL8
(Rod side) (6.30)
61 0.035)
Arm
(2.402 )
Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.
3-14
3. ATTACHMENT DIMENSIONS
3.3 BUCKET
3-15
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Plate outer dia. Boss thickness Pin bore dia. Lug plate thickness
Portion
øA B øC D
ø85 26 ø40 14
Dimensions
(3.35) (1.02) (0.551)
(1.578 )
Unit : mm (in)
Portion øA øB øC øD E F øG
65 43 60 63 12 24 11
Dimensions
(2.56) (1.69) (2.36) (2.48) (0.472) (0.945) (0.433)
3-16
3. ATTACHMENT DIMENSIONS
3.4 DOZER
Dimensions [mm(ft-in)]
No. NAME
CX31B CX36B
A Blade width 1550 (5'1.02") 1700 (5'6.93")
B Blade height 346 (1'1.62") 345 (1'1.58")
C Distance from dozer attaching pin center to cutting edge end R1187 (3'10.73") R1232 (4'0.50")
D Inner width of dozer attaching bracket 500 (1'7.69") <--
E Width of dozer attaching bracket 60 (2.36") <--
F Distance from dozer attaching pin center to attaching pin on R608 (1'11.94") R626 (2'0.65")
dozer cylinder head side
G Attaching bracket inner width on dozer cylinder head side 62 (2.44") <--
H Horizontal distance from dozer attaching pin center to edge end 1144 (3'9.04") 1192 (3'10.93")
J Vertical distance from dozer attaching pin center to edge end 315 (1'0.40") 310 (1'0.20")
d1 Dozer attaching pin dia. 40 dia.(1.57") <--
d2 Attaching pin dia. on dozer cylinder head side 45 dia.(1.77") <--
3-17
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Standard dimension Clearance
Tolerance Tolerance Standard
Pos. Item Pin part No. Standard Serviceabi Remedy
Pin dia. on pin dia. on bushing value for
value lity limit
bore dia. repair
Dozer blade
A cylinder –0.06 +0.20 0.11-
(Head side) ø45 –0.11 +0.05 0.31
PH12B01009P1
Dozer blade (1.772) (-0.0024) (+0.0079) (0.0043-
Replace
B cylinder (-0.0043) (+0.0020) 0.0122) 0.7 1.0
bushing
(Rod side) (0.028) (0.039)
or pin
–0.06 +0.22 0.18-
Dozer blade ø40 –0.09 +0.12 0.31
C PW51B01028P1
foot (1.575) (-0.0024) (+0.0087) (0.0071-
(-0.0035) (+0.0047) 0.0122)
3-18
3. ATTACHMENT DIMENSIONS
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
(2) Clearance in thrust direction on the dozer and cylinder installation section
Unit : mm (in)
Standard dimensions Pin length
Pos. Item Clearance X Remedy
No. Dimensions No. Dimensions
(total of both sides)
Head side
60 3
Dozer blade
(2.362 ) 137
A cylinder L1 PL1
(5.39)
(Head side) 62
Dozer blade
(2.441 )
When
60 0.6-2.0
Rod side clearance X
Dozer blade (0.023-0.079)
(2.362 ) exceeds 3.5 137
B cylinder L2 After shim PL2
mm, adjust it (5.39)
(Rod side) Lower 62 adjustment
with shim.
frame
(2.441 )
60±0.3
Dozer blade
(2.362±0.012)
Dozer blade 127
C L3 PL3
foot Lower 62 (5.00)
frame
(2.441 )
3-19
3. ATTACHMENT DIMENSIONS
3.5 SWING
E
H
d3
B A G
d2
C
F1
d4
F
F2 J
d1
3-20
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Standard dimension Clearance
Tolerance Standard
Pos. Item Pin part No. Tolerance Standard Serviceabi Remedy
Pin dia. on bushing value for
on pin dia. value lity limit
bore dia. repair
Swing
A cylinder PX02B01241P1 +0.20 0.07-
(Rod side) ø45 +0.05 0.25
Swing (1.772) (+0.0079) (0.0028-
–0.02
B cylinder PW02B01271P1 (+0.0020) 0.0098) Replace
–0.05 0.7 1.0
(Head side) bushing
(-0.0008) (0.028) (0.039)
Swing or pin
(-0.0020) +0.07 0.04-
C center PX02B01239P1
ø65 +0.02 0.12
(Upper side)
(2.559) (+0.0028) (0.0016-
Swing center
D PX02B01275P1 (+0.0008) 0.0047)
(Lower side)
-The tolerance for bushing inside diameter means the dimension after fitting of it into place.
-The part number for pins may be changed owing to improvement, use them only for reference.
3-21
3. ATTACHMENT DIMENSIONS
(2) Clearance in thrust direction on swing bracket and cylinder installation section
Clearance in thrust direction on swing portion
3-22
3. ATTACHMENT DIMENSIONS
Unit : mm (in)
Standard Clearance X adjusted with shim
Pin length
Dimension (total of both sides)
Sec. Item Standard Remedy
Standard Serviceability
No. Dimensions value for No. Dimensions
value limit
repair
65
Cylinder
Swing 0.5-0.9
(2.559 ) 1.5 123
A-A cylinder L1 (0.020- — PL1
(0.059) (4.84)
(Rod side) 67 0.035)
Bracket
Adjusted
(2.638 )
with
65 shim
Swing
Cylinder
0.1-0.5 3
(2.559 ) 1.0 128
B-B cylinder L2 (0.004- — PL2
(0.039) (5.04)
(Head side) Upper 67 0.020)
frame
(2.638 )
71±0.5
Upper
Swing (2.795
frame
center ±0.020) Replace 153.5
C-C L3 — PL3
(Upper 75.7±1 washer (6.04)
side) Bracket (2.98
±0.039)
71.5±0.5
Upper
Swing (2.815
frame 0.5-0.9 Adjusted
center ±0.020) 1.5 134
D-D L4 (0.020- — with PL4
(Lower 73.5±1 (0.059) (5.28)
0.035) shim
side) Bracket (2.894
±0.039)
3-23
3. ATTACHMENT DIMENSIONS
3-24
11. TOOLS
11. TOOLS
11
TABLE OF CONTENTS
11-1
11. TOOLS
11-2
11. TOOLS
The following Torque Specifications are provided for use when actual torque value of a fastener is not known.
Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the
periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new
machine, the check and retightening of them must be carried out at first 50 hours operation. For the replacement of
them, make sure to use the same size of manufacturer's genuine parts.
Refer to the table below for the tightening and retightening of capscrews.
• The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening
torque for such capscrews, consult with an authorized our distributor. Over-tightening may cause damages on
the parts to be fixed.
• In case that the tightening torque is specified in the manual, use such torque values regardless to the table
below.
• Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is
provided for smaller size of capscrews, M 5 or less.
11
Make certain to tighten all capscrews and nuts to proper torque values.
11-3
11. TOOLS
11-4
11. TOOLS
11.2.1 CAPSCREW
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M6 10 M24 36
M8 13 M30 46
M10 17 M36 55 B
M12 19 M42 65
M16 24 M48 75
M20 30
11
Nominal B mm Nominal B mm
screw size screw size d
Tool size Tool size
(d) (d)
M6 5 M20 17
M8 6 M24 19
M10 8 M30 22 B
M12 10 M36 27
M14 12 M42 32
M16 14 M48 36
(M18) 14
11-5
11. TOOLS
11-6
11. TOOLS
11
11.4.2 PART NO.
SLEEVE NUT
B
d
d
11-7
11. TOOLS
11.5 PLUGS
No.
O. D : A H1 H
6 ZF83H06000 M12 X 1.5 14 14
8 ZF83H08000 M14 X 1.5 17 17
10 ZF83H10000 M16 X 1.5 17 19
12 ZF83H12000 M18 X 1.5 19 22
H1 T screw H 15 ZF83H15000 M22 X 1.5 24 27
18 ZF83H18000 M26 X 1.5 27 32
22 ZF83H22000 M30 X 1.5 32 36
28 ZF83H28000 M36 X 1.5 38 41
Applicable
tube Plug parts No.
O. D : A
A
6 ZF83P06000
8 ZF83P08000
10 ZF83P10000
12 ZF83P12000
Sleeve Nut
Type 15 ZF83P15000
joint body 18 ZF83P18000
22 ZF83P22000
28 ZF83P28000
(3) Nut
Applicable
D Screw tube Nut parts No. D screw Opposing flats
A
O. D : A
6 ZF93N06000 M12 X 1.5 14
8 ZF93N08000 M14 X 1.5 17
10 ZF93N10000 M16 X 1.5 19
12 ZF93N12000 M18 X 1.5 22
15 ZF93N15000 M22 X 1.5 27
18 ZF93N18000 M26 X 1.5 32
22 ZF93N22000 M30 X 1.5 36
28 ZF93N28000 M36 X 1.5 41
32 ZF93N32000 M42 X 1.5 50
35 ZF93N35000 M45 X 1.5 55
38 ZF93N38000 M48 X 1.5 60
11-8
11. TOOLS
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring
PF1/4 ZE72X04000 19 ZD12P01100 1B P11
PF3/8 ZE72X06000 22 ZD12P01400 1B P14
PF1/2 ZE72X08000 27 ZD12P01800 1B P18
PF3/4 ZE72X12000 36 ZD12P02400 1B P24
PF screw PF1 ZE72X16000 41 ZD12P02900 1B P29
(2) PT screw
B
11
PT screw
PT screw Plug parts No. B mm
PT1/8 ZE82T02000 5
PT1/4 ZE82T04000 6
PT3/8 ZE82T06000 8
PT1/2 ZE82T08000 10
PT3/4 ZE82T12000 14
PT1 ZE82T16000 17
PT1 1/4 ZE82T20000 22
PT1 1/2 ZE82T24000 22
PF screw
PF3/8 2444Z2728D2 17
PF1/2 2444Z2728D3 22
PF3/4 2444Z2728D4 27
Opposing flats B PF1 2444Z2728D5 36
screw
PF3/8 2444Z2729D2 17 22
PF1/2 2444Z2729D3 23 27
PF3/4 2444Z2729D4 27 36
Opposing PF1 2444Z2729D5 36 41
Opposing
flats F PF1 1/4 2444Z2729D6 40 50
flats E
11-9
11. TOOLS
70(2.76)
(0.630) (0.866)
15 (0.591) 2421T160 27 (0.315)
70(2.76)
42(1.65)
12.7 (0.500 )
22(0.866)
70(2.76)
48(1.89) 11.5(0.453)
12.7 (0.500 )
109(4.29)
60(2.36)
14.5(0.571)
12.7 (0.500 )
11-10
11. TOOLS
11
11-11
11. TOOLS
Manufacturer
Service Features
Loctite Three-Bond
#242 1360K Low strength
Screw locking
#262 1374 Middle strength
compound
#271 1305 High strength
Sealing compound #515 1215 Sealing
11-12
11. TOOLS
11
11-13
11. TOOLS
5 40(2)-100
Q'ty : 2 sets (0.20") (1.58"(0.079")-3.94")
2-
Material : Mild steel
5")
20
0.9
Unit : mm (in)
(0
.7
24(
9"
)
(1.97")
50
300 (11.8")
100
(3.94") ") 15
R 1. 58
40( (0.59")
5 40(4)-120
(0.20") {1.58"(0.16")-4.72"}
470 (18.5")
536 (21.1")
12 (0.47") 12 167
420 (16.5")
(0.47") (6.58")
50
(1.97")
5
(0.20")
R3 8")
(1
0
.1
C2 .98"
(1.97")
(0
5 )
50
R2 9")
(0
0
.3 0
.7
(0.63")
)
C1
9"
16
(0
11-14
12. STANDARD MAINTENANCE TIME TABLE
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR 12-4
12
12-1
12. STANDARD MAINTENANCE TIME TABLE
12-2
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
(1) Working Conditions
1. Technicians : One more technicians who are qualified by Manufacturer are needed. The technicians need five of
more years of experience, and they have to complete the training in the operation of this machine.
2. Facilities : General jigs, tools, apparatus, testers to be provided.
The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection
instruments necessary for specific self inspection activities.
3. Place : The workshop should have a level surface where work can be performed with access to a lift crane.
12-3
12. STANDARD MAINTENANCE TIME TABLE
01 Attachment(1/2)
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Bucket portion Refer to 32.1.2
01 Bucket ASSY Rem./Inst. 1 pc. Include adjustment 0.4
02 -Bucket removing / installing position Preparation 1 pc. 0.1
03 -Bucket installing pin Rem./Inst. 1 pc. Include stopper pin. 0.1
04 -Bucket drive pin - ditto - 1 pc. 0.1
05 -Bucket sling and transfer Preparation 1 pc. 0.1
06 Bucket (Single) O/H 1 pc. Not include removal / inst. 0.6
07 -Bushing Replace 1 pc. 0.5
10 Arm portion Refer to 32.1.3
11 Arm ASSY Rem./Inst. 1 pc. 0.8
12 -Bucket cylinder removing / installing Preparation 1 pc. 0.2
position and piping
13 -Bucket cylinder rod pin Rem./Inst. 1 pc. Include stopper pin. 0.1
14 -Bucket cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
15 -Bucket cylinder assy - ditto - 1 pc. 0.1
16 -Arm cylinder rod pin - ditto - 1 pc. Include stopper pin. 0.1
17 -Boom top pin - ditto - 1 pc. 0.1
18 -Arm sling and transfer - ditto - 1 pc. 0.1
12-4
12. STANDARD MAINTENANCE TIME TABLE
01 Attachment(2/2)
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
20 Boom portion Refer to 32.1.4
21 Boom ASSY Rem./Inst. 1 pc. 1.0
22 -Boom removing / installing position Preparation 1 pc. 0.1
23 -Boom cylinder temporary slinging - ditto - 1 pc. Include stopper pin. 0.1
24 -Boom cylinder rod pin Rem./Inst. 1 pc. 0.1
25 -Boom cylinder piping - ditto - 1 pc. 0.1
26 -Arm & Bucket piping - ditto - 1 pc. 0.2
27 -Boom assy temporary slinging Rem./Inst. 1 pc. Include stopper pin. 0.1
28 -Boom foot pin - ditto - 1 pc. 0.1
29 -Boom assy slinging - ditto - 1 pc. 0.1
30 Arm cylinder removing / installing - ditto - 1 pc. 0.3
31 -Arm cylinder piping - ditto - 1 pc. 0.1
32 -Arm cylinder head pin - ditto - 1 pc. Include stopper pin. 0.1
33 -Arm cylinder slinging - ditto - 1 pc. 0.1
40 Boom cylinder removing / installing - ditto - 1 pc. 0.3
41 -Boom cylinder piping - ditto - 1 pc. 0.1
42 -Boom cylinder head pin - ditto - 1 pc. 0.1
43 -Boom cylinder slinging - ditto - 1 pc. 0.1
50 Bucket cylinder O/H 1 pc. 2.5 12
51 -Pin bushing Replace 1 set Include seal. 1.0
60 Arm cylinder O/H 1 pc. 2.5
61 -Pin bushing Replace 1 set Include seal. 1.0
70 Boom cylinder O/H 1 pc. 2.5
71 -Pin bushing Replace 1 set Include seal. 1.0
80 Swing portion Refer to 32.1.5
81 Swing bracket assy Rem./Inst. 1 pc. After removing boom. 0.4
82 -Swing cylinder rod pin - ditto - 1 pc. 0.1
83 -Swing bracket slinging - ditto - 1 pc. 0.1
84 -Swing center pin - ditto - 1 pc. 0.1
85 Swing cylinder removing / installing - ditto - 1 pc. After removing swing 0.3
86 -Swing cylinder hose Rem./Inst. 2 pcs. bracket. 0.2
87 -Swing cylinder head pin - ditto - 1 pc. 0.1
88 Swing cylinder O/H 1 pc. 2.5
89 -Pin bushing Replace 1 pc. 1.0
Other necessary works Rem./Inst. 1 set Include seal. 0.1
Panel assy (3)
90 Dozer portion Refer to 32.1.6
91 Dozer ASSY Rem./Inst. 1 pc. 0.6
92 -Dozer cylinder hose - ditto - 2 pcs. 0.2
93 -Dozer cylinder rod pin - ditto - 1 pc. 0.1
94 -Dozer installing pin - ditto - 2 pcs. 0.2
95 Dozer cylinder O/H 1 pc. 2.5
96 -Pin bushing Replace 1 set Include seal. 1.0
12-5
12. STANDARD MAINTENANCE TIME TABLE
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Canopy portion Refer to 33.1.1
01 Canopy assy Rem./Inst. 1 pc. 0.2
02 -Hand rail - ditto - 1 pc. 0.1
10 Cab portion Refer to 33.1.1
11 Cab assy Rem./Inst. 1 pc. 0.4
12 -Harness - ditto - 1 pc. 0.1
20 Bonnet & Guard Refer to 33.1.2
21 Cover assy (1) Rem./Inst. 1pc. 0.1
22 Bonnet assy (2) - ditto - 1pc. 0.1
23 Cover assy (3) - ditto - 1pc. 0.1
24 Cover assy (4) - ditto - 1pc. 0.1
25 Cover assy (5) Rem./Inst. 1pc. 0.1
30 Control stand portion Refer to 33.1.15
31 Control stand ASSY Rem./Inst. 1 pc. 1.0
32 -Air cleaner - ditto - 1 pc. 0.1
33 -E / G control cable - ditto - 1 pc. 0.2
34 -Deceleration motor (OPT) - ditto - 1 pc. 0.1
35 -Filler neck - ditto - 1 pc. 0.1
36 -Fuel air bleed hose - ditto - 1 pc. 0.1
37 -Harness - ditto - 1 set 0.3
12-6
12. STANDARD MAINTENANCE TIME TABLE
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Control portion
01 E / G control cable Rem./Inst. 1 pc. 0.2
12-7
12. STANDARD MAINTENANCE TIME TABLE
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
50 Hydraulic oil tank portion Refer to 33.1.11
51 Hydraulic oil tank ASSY Rem./Inst. 1 pc. After removing fuel tank ; 1.6
52 -Return filter Replace 1 pc. Include pressure releasing 0.2
& replacing O-ring
53 -Hydraulic oil - ditto - 1 pc. 0.2
54 -Suction hose Rem./Inst. 1 pc. 0.2
55 -Strainer Replace 1 pc. Include replacing O-ring 0.1
56 -Pilot return hose Rem./Inst. 1 pc. 0.1
57 -Swivel drain hose - ditto - 1 pc. 0.1
58 -SOL. valve return hose - ditto - 1 pc. 0.1
59 -Slewing, C / V return hose - ditto - 2 pcs. 0.2
60 -Tank fixing bolt - ditto - 4 pcs. 0.2
Other necessary works - ditto - 1 pc. Covers 0.2
- ditto - 1 pc. Control valve 1.6
- ditto - 1 pc. Solenoid valve 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
70 Pump portion Refer to 33.1.6
71 Pump ASSY Rem./Inst. 1 pc. After removing 1.2
counterweight
72 -Hydraulic oil Replace 1 pc. Include pressure releasing 0.2
73 -Pilot delivery oil hose Rem./Inst. 1 pc. 0.1
74 -Suction hose - ditto - 1 pc. 0.2
75 -Suction tube (pump side) - ditto - 1 pc. 0.2
76 -Main pump delivery hose - ditto - 3 pcs. 0.2
77 -Pump fixing bolt - ditto - 2 pcs. 0.2
78 Pump ASSY O/H 1 pc. 3.0
Other necessary works Feed 1 pc. Hyd. oil in pump 0.1
Preparation 1 pc. Hyd. oil tank pressurizing 0.1
80 Radiator portion Refer to 33.1.17
81 Radiator ASSY Rem./Inst. 1 pc. 1.2
82 -Coolant (LLC) Replace 1 pc. 0.2
83 --Coolant density Measuring 1 pc. (0.2)
84 -Reserve tank hose Rem./Inst. 1 pc. 0.1
85 -Radiator hose - ditto - 2 pcs. 0.2
86 -Cooler hose - ditto - 2 pcs. 0.2
87 -Radiator fixing bolt - ditto - 3 pcs. 0.1
88 -Radiator lifting or slinging - ditto - 1 pc. 0.1
Other necessary works - ditto - 1 pc. Counterweight 0.4
- ditto - 1 set Covers 0.2
- ditto - 1 pc. Duct 0.1
12-8
12. STANDARD MAINTENANCE TIME TABLE
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
90 Engine (E / G) Installing portion Refer to 33.1.18
91 Engine ASSY Rem./Inst. 1 pc. 1.0
92 -Fuel hose - ditto - 4 pcs. For injection pump - 2 pcs. 0.2
& For feed pump - 2 pcs.
93 -Harness, connector and cable Rem./Inst. 1 set 0.3
94 -Engine fixing nut - ditto - 1 pc. 0.2
95 -Engine slinging - ditto - 1 set 0.2
Other necessary works - ditto - 1 set Covers 0.2
- ditto - 1 pc. Canopy 0.2
- ditto - 1 set Control stand 1.0
- ditto - 1 pc. Counterweight 0.4
- ditto - 1 pc. Air cleaner 0.2
11 Air cleaner ASSY - ditto - 1 pc. Muffler 0.4
12 •Hose (1) - ditto - 1 pc. Pump 1.2
13 •Hose (2) - ditto - 1 pc. Radiator 1.0
14 •Element - ditto - 1 pc. Battery negative terminal 0.1
100 Control valve portion Refer to 33.1.7
101 Control valve ASSY Rem./Inst. 1 pc. 1.6 12
102 -Piping connector, hose - ditto - 1 set Include attaching hose's 1.0
tag and plug
104 -Fixing bolt - ditto - 1 set 0.1
105 Control valve ASSY O/H 1 pc. 3.0
Other necessary works Rem./Inst. 1 set Covers 0.1
- ditto - 1 set Hoses 0.2
110 Slewing motor portion Refer to 33.1.20
111 Slewing motor ASSY Rem./Inst. 1 pc. 1.0
112 -Piping connector, hose - ditto - 7 pcs. Include attaching hose's 0.5
tag and plug
113 -Fixing bolt - ditto - 1 pc. 0.3
114 Slewing motor ASSY O/H 1 pc. 3.0
Other necessary works Rem./Inst. 1 set Floor plate, Covers 0.2
Feed 1 pc. Hyd. oil in motor 0.1
120 Swivel joint portion Refer to 33.1.21
121 Swivel joint ASSY Rem./Inst. 1 pc. After removing slewing 2.5
motor
122 -Under cover - ditto - 1 pc. 0.1
123 -Piping connector, hose - ditto - 1 set Include attaching hose's 1.5
tag and plug
124 -Stopper - ditto - 1 pc. 0.1
125 -Fixing bolt - ditto - 1 set 0.2
126 Swivel joint ASSY O/H 1 pc. 2.0
Other necessary works Preparation 1 pc. Removal / Inst. position. 0.1
(Secure working space.)
1 pc. Canopy removal / inst. 0.2
(for easy working)
1 pc. Floor plate cover (2) 0.1
removal / inst.
12-9
12. STANDARD MAINTENANCE TIME TABLE
03 Upper structure(4/4)
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
130 Upper frame portion Refer to 33.1.22
131 Upper frame ASSY Rem./Inst. 1 pc. 1.0
132 -Fixing bolt - ditto - 1 set Apply sealant 0.3
133 -Upper frame slinging - ditto - 1 pc. 0.3
134 -Cleaning Cleaning 1 pc. 0.2
Other necessary works Rem./Inst. 1 pc. Canopy 0.2
- ditto - 1 pc. Guard (Cover, support) 1.5
- ditto - 1 pc. Counterweight 0.4
Drain / Feed 1 pc. Hydraulic oil 0.2
Rem./Inst. 1 set Swivel joint hose 0.5
- ditto - 1 set Boom, Swing bracket 1.5
12-10
12. STANDARD MAINTENANCE TIME TABLE
04 Under carriage
WORK TO UNIT:
No. EQUIPMENT PORTION UNIT REMARKS
BE DONE HOUR
00 Travel portion Refer to 34.1.2
01 Rubber crawler Rem./Inst. One side 0.6
02 -Rubber shoe removing / inst. position. Preparation One side 0.1
03 -Tension adjusting Adjusting One side 0.2
04 -Crawler shoe Rem./Inst. One side 0.2
10 Upper roller portion Refer to 34.1.3
11 Upper roller ASSY Rem./Inst. 1 pc. After removing crawler 0.2
12 Upper roller O/H 1 pc. shoe 1.0
20 Lower roller portion Refer to 34.1.4
21 Lower roller ASSY Rem./Inst. 1 pc. 0.2
22 Lower roller O/H 1 pc. 1.0
30 Front idler & Idler adjuster portion Refer to 34.1.5 & 34.1.6
31 Idler & Idler adjuster ASSY Rem./Inst. One side After removing crawler 0.5
32 Idler & Idler adjuster ASSY O/H One side shoe 0.1
33 Idler ASSY O/H One side 1.0
34 Idler adjuster ASSY - ditto - One side 0.5
12
40 Sprocket portion Refer to 34.1.7
41 Sprocket Replace One side After removing crawler 0.5
shoe
50 Travel motor portion Refer to 34.1.8
51 Travel motor ASSY Rem./Inst. One side After removing crawler 1.0
52 -Motor cover - ditto - One side shoe 0.1
53 -Hydraulic connector, hose - ditto - One side 0.6
Include attaching hose's
54 -Motor fixing bolt - ditto - One side tag and plug 0.3
55 -Motor slinging - ditto - One side 0.1
56 Travel motor O/H One side 3.0
57 Travel reduction unit - ditto - One side 3.0
Other necessary works Feed One side Hyd. oil in motor 0.1
60 Slewing bearing portion Refer to 34.1.9
61 Slewing bearing ASSY Rem./Inst. 1 pc. After removing upper 0.6
62 -Slewing bearing fixing bolt - ditto - 1 pc. frame 0.3
63 -Slewing bearing Cleaning 1 pc. 0.1
64 -Slewing bearing slinging Rem./Inst. 1 pc. Decreasing / 0.2
Replenishment
12-11
12. STANDARD MAINTENANCE TIME TABLE
12-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-2
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(1) Application
1. For New Machine;
This manual is to be used to compare actual performance and functions of the machine with performance
standards.
2. At Specific Self-Inspection (as per LOCAL RULES);
The maintenance standards are criteria to determine time needed for reconditioning, adjustment and
replacement.
3. At Deterioration of Performance;
This manual provides the criteria for safe and economical judgment on whether the deterioriation of
performance on the machine is caused by a fault or normal
4. For Replacement of Major Components;
This manual is the standard to determine the time for replacement to maintain the performance of major
components such as pump, etc
(2) Terminology
1. Standard Values :
These are the standard values to assemble and regulate a new machine. Where special notes are not given,
these values are based on the machine with standard structure (machine with standard attachments and
shoes).
2. Standard Values for Repair :
These are of the values at which the reconditioning is required.
In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and
components over the standard values.
3. Serviceability Limit :
This is of the service limit for each part and component at which reconditioning is impossible and the part must 13
be replaced with a new one.
All the parts and components which are estimated to exceed the serviceability limit up to the next periodic
inspection and maintenance, should be also be replaced.
Operating the machine with parts and components that have exceeded the serviceability limit is unsafe and
could result in equipment failuer and down time.
13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-4
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Arm • Swing •
Travel (RH) • P2 MPa 23.0 (3340 ) — 23.0 (3340 ) —
Service (psi)
Dozer • *1 Slew P3 20.0 (2900 ) — 20.0 (2900 ) —
Pilot relief valve
Pilot Line — 3.5 (508 ) — 3.5 (508 ) —
pressure
Head 13
*2 Port (Over load) relief
Head
Arm 25.5 (3700 ) — 25.5 (3700 ) —
Rod MPa
Bucket Head (psi) 25.5 (3700 ) — 25.5 (3700 ) —
*1. The pressure for slew is controlled by the relief valve attached to the slew motor.
*2. Reference value for checking of pressure
(tighten up the adjusting nut of main relief valve. Refer to item 13.4.2.1)
13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-6
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-7
13. MAINTENANCE STANDARD AND TEST PROCEDURE
However, if the proper high idling speed is not obtainable, consult it with the engine manufacturer.
13-8
13. MAINTENANCE STANDARD AND TEST PROCEDURE
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with
the instrument for analysis. If the measured value is over the standard value, replace the return filter and/or change
the hydraulic oil.
13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13-10
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