Service Manual

SWE210

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)

I
 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 Regulated dimensional drawing.......................................................................................... 3
2.1.1 Drawing................................................................................................................... 3
2.1.2 Dimension datas ...................................................................................................... 3
2.1.3 Working range diagram ........................................................................................... 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 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 .......................................................................................................... 31
3.2.5 Pilot control valve ................................................................................................. 39
3.2.6 Electromagnetic valve ........................................................................................... 44
3.2.7 Pilot filter............................................................................................................... 46
3.2.8 Travel motor .......................................................................................................... 46
3.2.9 Multiple way valve................................................................................................ 55
3.3 For electric equipments..................................................................................................... 70
3.3.1 Multifunction monitor system............................................................................... 72
3.3.2 Engine control ....................................................................................................... 76
3.3.3 System operation ................................................................................................... 76
3.3.4 Spare parts of the system....................................................................................... 78
4. Test and adjustment and Failure Diagnosis ....................................................................................... 81
4.1 Test and adjustment of mechanical structure device......................................................... 81
4.1.1 Standard table of engine spare parts...................................................................... 81
4.1.2 Standard table of complete machine ..................................................................... 82
4.2 Test and adjustment of hydraulic device........................................................................... 91
4.2.1 Test and adjustment of system working pressure .................................................. 91
4.2.2 Test and adjustment of pilot oil supply pressure ................................................... 94
4.2.3 Inspection for main return oil pressure of the system ........................................... 95
II
 4.2.4 Inspection for output pressure of the pilot solenoid valve .................................... 96
4.2.5 Measuring for output pressure of pilot control valve ............................................ 98
4.2.6 Measuring for hydraulic drift of working devices ................................................ 99
4.2.7 Release the residual pressure in hydraulic oil circuits ........................................ 100
4.2.8 Check for leakage volume................................................................................... 100
4.2.9 Adjusting of main pump ...................................................................................... 102
4.2.10 Devices exhaust................................................................................................. 106
4.3 Fault diagnose ................................................................................................................. 107
4.3.1 Inspection before fault diagnose ......................................................................... 107
4.3.2 Fault sorts and check methods ............................................................................ 108
5. Disassembly and assembly ................................................................................................................. 114
5.1 How to read this manual ................................................................................................. 114
5.2 Instruction during operation............................................................................................ 114
5.3 Working device ASSY assemly and disassembly ........................................................... 118
5.4 Counterweight ASSY assembly and disassembly........................................................... 119
5.5 Cab ASSY assembly and disassembly............................................................................ 120
5.6 Engine disassemble and assembly .................................................................................. 121
5.7 Radiator ASSY disassembly and assembly..................................................................... 122
5.8 Hydraulic pump ASSY disassembly and assembly ........................................................ 124
5.9 Hydraulic pump body disassembly and assembly .......................................................... 126
5.10 Main pump adjustor disassembly and assembly........................................................... 132
5.11 Rotary motor ASSY disassembly and assembly ........................................................... 138
5.12 Handle pilot valve disassembly and assembly.............................................................. 145
5.13 Multiple way valve ASSY disassemble and assemble.................................................. 150
5.14 Travel motor ASSY disassembly and assembly............................................................ 151
5.15 Central rotary joint ASSY disassembly and assembly.................................................. 152
5.16 Hydraulic tank ASSY. disassembly and assembly........................................................ 153
5.17 Carrier roller ASSY disassembly and assembly ........................................................... 155
5.18 Thrust wheel ASSY. disassembly and assembly........................................................... 156
5.19 Guiding wheel ASSY. disassembly and assembly ........................................................ 156
5.20 Tension device disassembly and assembly ................................................................... 158
5.21 Sproket wheel disassembly and assembly .................................................................... 160
5.22 Track shoe ASSY disassembly and assembly............................................................... 160
5.23 Rotary bearing ASSY. disassembly and assembly........................................................ 163
5.24 Rotary table ASSY. disassembly and assembly ............................................................ 164
5.25 Air-conditioning ASSY disassembly and assembly...................................................... 165
6. Figures and others................................................................................................................................. 167
6.1 Hydraulic system schematic diagram ............................................................................. 167
6.2 Electrical system drawing............................................................................................... 168

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.parameters in this manual are all for standard layout of excavator
except special instruction.

1.1 Gerneral attention them.

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.
5. Hang a label reading “repairing” on the
control table of control room before any
work.
6. All tools should be kept in good condition
and operators are required to learn how to use
1
7. 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.
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. 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
1.3 Attention in working hours
distortion during hose installation. Damaged
1. When disassembling the cover of oil pipeline is of highly dangerous. Therefore,
filling opening, oil drain plug or hydraulic pay undivided attention to it during
measurement plug, release them gradually to high-pressure hose installation. In addition,
prevent the oil from ejecting. check connecting piece for proper installation.
a) When disconnect or disassemble 12. Always operate with specified tightening
pipes for oil, water or gas supply, release the torque during assembly or disassembly.
pressure in pipeline first. When assembling protective parts (e.g.
2. When the engine flames out and the protective guard) or installing other parts with
water and oil in the pipeline are hot, be sharp vibration and high-speed rotation. Make
careful to avoid being scalded. sure they are properly installed.
3. Disconnect battery cable prior to 13. When aligning two holes, do not
operation. Make sure to disconnect negative insert fingers or hands into them so as to
terminal first. prevent finger from being caught in.
4. When lifting heavy loads of parts, 14. Make sure all tools for measuring purpose
use winch or crane to check steel rope, chain are properly installed before attempting
and hook for damage.Be certain to use over hydraulic pressure measurement or other
rated power crane.Assembling the crane at measuring procedures.
correct place.Operating a winch or crane During track disassembly or assembly,
slowly to prevent lifting parts colliding with please note that track may disengage out of
other objects and do not work on the parts place abruptly; make sure the area on both
which is lifted by winch or crane. end of the track is clear of persons.
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.

2
2. Summary
2.1 Regulated dimensional drawing
2.1.1 Drawing

2.1.2 Dimension datas

Item Unit SWE210

A Wheel track mm 3465
B Track total length mm 4220
Platform to ground
C mm 1060
distance
Platform Swing
D mm 2750
radius
Upper carriage
E mm 2710
width
F Track gage mm 2200
G Chassis width mm 2800
H Track width mm 600
Chassis to ground
I mm 470
distance
J Cab height mm 2965
L Transportion length mm 9590
M boom height mm 3045

3
2.1.3 Working range diagram

2.1.4 Working range datas

Item Unit SWE210

A Max. digging height mm 9740
B Max. dumping height mm 6980
C Max. digging depth mm 6690
8 feet level digging
D mm 6500
depth
Max. vertical digging
E mm 6040
depth
F Max. digging radius mm 9950
Max. parking level
G mm 9785
digging distance
H Min. swing radius mm 3530

4
2.2 Technical specification

Model SWE210

Standard bucket capacity m3 0.95

Operation weight kg 21.3
Bucket
max.digging kN 137
force
Arm max.digging
kN 100
force
Performan
ce Swing speed rpm 12.5
parameters Traveling speed km/h 5.5/3.2
Max.climbing
° 35
capacity
Max.tractive
kN 185
ability
Engine model 6BG1TRP-03
electro, water cool, four strok, pressurization,
Type
intercool
Cylinder
numer-diameter X mm 6—105ｘ125
stroke
Power
Discharge L 6.494
plant
Rated
kW/rp
power/rotational 110/2100
m
speed
Max.torque/ Nm/rp
511～629/1600
rotational speed m
Fuel tank capacity L 370
Main pump 2×plunger pump
Flow L/min 2×206
Working device
Mpa 32.4(34.3)
pressure
Hydraulic system

Travel pressure Mpa 32.4

Swing pressure Mpa 26
Pilot pump 1×gear pump
Flow L/min 30
Pilot pressure
Mpa 3.9
setting
Hydraulic oil tank
L 250
capacity

5
2.3 Weight datas

The table can be referred during maintenance or transportion.

Unit: kg
Model SWE210
Total machine 21300
Uppercarriage 8040
Undercarriage 8280
Boom 2870
Arm 1225
Bucket 885
Cab 280
Blance weight 3900

6
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

7
3. Structure function and maintenance standard
3.1 For mechanical device
3.1.1. Engine parts

2
3
4

5
6

1. Fan blade Technical specification:

2. Engine installation bracket Front shock pad: 750201010200(2)
3. Front shock pad Rear shock pad: 750201010202(2)
4. Muffler Muffler: 750205000059(1)
5. Rear shock pad
6. Muffler bracket

8
3.1.2 Cool system
SWE210

1. Engine exhalent siphon Technical specification

2. Engine water inlet pipe Affix water tank: 750203000086(1)
3. Affix water tank Radiator: 818812050100(1)
4. Radiator
5. Air director cover
6. Condenser
7. Oil cooler

9
3.1.3 Power drive system

SWE210
Guiding wheel 750105000035
Centre swing joint 739802000019
Main pump 730302000151
Traveling motor 730250000119
Hydraulic pump 730201000127
Engine 750201000116
Electromagnetic
730305000085
valve group
Swing motor 730250000241
Swing bearing 750550000053

10
3.1.4 End drive (traveling motor reductor)

1. Chain wheel: 306060000064

2. Traveling motor: 730250000119(MAG-170VP-3800G-1)
3.1.5 Swing bearing

1. Outer race of swing bearing

2. Steel ball
3. Inner race of swing bearing

11
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: 8 in one side
4. Track assy: 8190-MH-473603 Track plate number: 47 in one side
5. Track cover sheet
6. Chain wheel
7. Travel motor
8. Tension spring
9. Guiding wheel

12
3.1.7 Guiding wheel

Unit: mm
Standard
Checking
NO. Standard Repayment Measures
item
dimension 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

13
3.1.8 Carrier roller

Unit: mm
Standard
NO. Checking item Standard Repair Measures
dimension 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 －

14
3.1.9 Thrust wheel

Unit: mm
Standard
NO. Checking item Standard Repair Measures
dimension 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

15
3.1.10 Track plate

Unit: mm
Standard
NO. Checking item Standard Repair Measures
dimension limit
1 Hight 25 15 Repair or
2 Thickness 35 － replace

16
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 cylinder

17
3.2 For hydraulic equipments
3.2.1 Hydraulic arrangement plan
1: Tee joint shutoff valve
2: Hydraulic tank
3: Right side
counterbalance valve
(4.5Mpa)
4: Main pump
5: Right travel motor
6: Pilot filter
7: Multiple way valve
8: Pilot solenoid valve
9: Left side counterbalance
valve (2.5Mpa)
10: Auxiliary pedal valve
11: Travel pedal valve
18
12: Central swing joint
13: Oil collecting block
14: Right handle valve
15: Left handle valve
16: Swing motor
17: Oil return block
18: Right travel motor
19: Arm cylinder 21: Left boom cylinder 23: Shutoff valve- right side
20: Right boom cylinder 22: Bucket cylinder 24: Shut off valve- left side

19
3.2.2 Hydraulic oil tank

1: Pressure signal 4: liquid level gage 7: Oil return filter gauze

2: Drain plug 5: Tank body 8: By-pass check valve
3: Air filter 6: Oil suction filter gauze 9: Magnetic filter core

Technical parameters

oil tank oil return filter core oil suction filter core
oil tank
240L flow 750L/min flow 1000L/min
capacity
oil tank filtering
185L rated pressure 1.6MPa 100μ
capacity accuracy
filtering
10μ
accuracy
By-pass valve
opening 0.3MPa
pressure

20
3.2.3 Hydraulic pump
Summary
K3V112DT-1X7R-9ND9-6V
The pump includes two variable cam-type plunger pumps、pilot oil source、one
electromagnetic proportional valve and two main pump adjusters.

1: Front main pump Pi2: Feedback port-back pump negative

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

21
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 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)，
22
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.
z 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
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).

23
 111: Drive axle 158: Shim
123: Roller bearing 211: Piston shoe
124: Needle bearing 212: Sloping cam plate
141: Oil tank body 214: Tilting cylinder liner
151: Plunger 251: Sloping cam plate support table
152: Slipper 312: Valve block
153: Pressure plate 313: Valve plate
156: Spherical cylinder 531: Tilting pin
157: Oil tank spring 532: Servo-oil cylinder

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: K3V112DT

gap value in piston and oil replace piston

0.039～0.067
tank (D-d) or oil tank
replace piston
gap part looseness of piston
0～0.3 and coupling
and piston shoe (δ)
parts
replace piston
thickness of piston sho ( t ) 4.7～4.9 and coupling
parts
free height of oil tank spring replace oil
40.3～41.1
(L) cylinderspring.
replace
assembly height of pressure 11.0～12.0 pressure plate
plate and spherical liner (H-h) and spherical
bush

24
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.
25
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.

‹ 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,
26
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.
‹ 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.
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
‹ 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
27
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.
‹ 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.
601. Pump shell 624. Spring (C) 643. Guide piston
611. Feedback rod 625. External spring 644. Spring (Q)
612. Connecting rod (1) 626. Internal spring 645. Adjusting ring (Q)
613. Connecting rod (2) 627. Telescopic link (C) 646. Guide spring
614. Bearing pin 628. Regulating screw (C) 651. Sleeve
615. Regulating pole 629. Cover (C) 652. Slide valve
621. Compensation piston 630. Locknut 653. Spring
622. Piston cover 631. Sleeve PF 654. Resetting spring
623. Compensation rod 641. Guide housing 655. Regulating spring

28
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

29
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

30
3.2.4 Swing motor
Summary
M5X130CHB-10A-122-RG11D20M1
It consists of valve units, motor and swing reductor.

1. valve units PG: Unlocking pressure oil import

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

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.

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.

31
 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.

32
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.

33
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
clearance-plunger replace plunger and
0 0.3
&slipper slipper units
sphere(δ)
slipper replace plunger and
5.5 5.3
thickness(t) slipper units

34
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 need to be refaced degree of
standard degree of roughness
description roughness

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

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

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.

35
 351: Compensator valve
051: Overflow valve

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 etc. 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 time, 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 state 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.
36
 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
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.
37
Function (swing reduction device)
Planetary gear train in reductor could reduce the output speed of motor noumenona and
increase torque.
Structure (swing reduction device)

38
 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 PV48K1363(left side), PV48K1364(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

39
2. Travel control pilot valve PVD8P5021A

oil
port control motion
No.
forward-right
1
travel
travel backward-right
2
two-gang travel
pedal forward-left
3
valve travel
backward-left
4
travel

40
41
3. Auxiliary pedal valve RCV8C1109

42
Structure (right handle pilot control valve)

302: Cam 101: Shell

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

43
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. 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.
3.2.6 Electromagnetic valve
ST0661-AA00
44
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.
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.
1: Accumulator
2: Pilot oil way lock solenoid valve
3: Spare solenoid valve
4: Pressure increasing solenoid valve
5: Two-speed travel solenoid valve
FP: from pilot oil source
FT: to hydraulic oil tank
F1: to pressure increasing port of two-stage
relief valve (boosting)
F2: to central swing joint
(two-speedcontrol)
F3: to pilot oil collecting block

Technical parameters

accumulator
rated pressure 3.5MPa 1.5MPa
air pressure
accumulator
rated flow 30L/min 0.46L
capacity
magnetic coil DC24V

45
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.

46
 1: Valve unit Pm2: pressure testing port (P2) of main
2: Motor noumenon oil pressure
3: Travel speed brake PS: Two-speed control port
p1: main oil port Tin: hydraulic oil filling opening
P2: main oil port FILL: gear oil refill opening
Pm1: pressure testing port (P1) of main LEVEL: detecting port of gear oil
oil pressure DRAIR: gear oil drain

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).

47
 1－1: Shell of motor 15: Second central pinion
3: Angular contact ball bearing 17: Primary planet carrier
4: Reduction case 20: Needle bearing
6: Bracket 21: Primary planet pinion
11: Needle bearing 25: Gear shaft
12: Second planet pinion 27: Gear case end cover
14: Screw

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
(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
48
(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

49
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)

50
Working procedure
1. Working procedure of motor
When operate travel joystick, pressure oil from control valve are converted to oil port (P2).
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)
51
moves to the minimum tilt angle direction, motor capacity turns to mini.and machine comes to
travel in high speed.

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
52
 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
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.

53
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.

54
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.

55
1: Check valve (arm valve kit 1)
2: By-pass shutoff valve
3: Check valve (boom valve kit 1)
4: Flow control (rotary valvel kit)
5: Check valve (auxiliary valve kit)
6: Check valve (left travel valve kit)
7: Check valve
8: Negtive flow valve (p2)
9: Arm valve kit 2
10: Locking relief valve (small cavity of
arm)
11: Boom valve kit 1
12: Jockey valve (boom)
13: Bucket valve kit
14: Blocking relief valve (small cavity of
bucket)
15: Flow control valve (bucket valve kit)
16: Right travel valve kit
17: Straight travel pilot valve
18: Straight travel valve kit
19: Check valve
20: Main relief valve
21: Flow control valve (arm valve kit)
22: Blocking relief valve (big cavity of
56
arm)
23: Negtive flow valve (P1)
24: Oil return throttle valve (arm valve
kit)
25: Arm valve kit 1
26: Jockey valve (arm)
27: Boom valve kit 2
28: Blocking relief valve (big cavity of
boom)
29: Flow control valve (rotary valve kit)
30: Rotary valve kit
31: Shutoff valve (auxiliary valve kit)
32: Auxiliary valve kit
33: Left travel valve kit
34: Check valve
35: Blocking relief valve (small cavity of
boom)
36: Blocking relief valve (big cavity of
bucket)
37: Shutoff valve (auxiliary valve kit)
38: Check valve (arm valve kit 2)
39: Check valve (boom valve kit 2)
40: Check valve (right travel valve kit)
57
58
PA: Signal port of travel pressure
PC3: From oil port Pi1
Pbu: To hydraulic oil tank
pcc: To oil port DR5
PH: From solenoid valve (high and low
pressure)
Pi1: From oil port Pa4
Pi2: Flow control valve pilot port (bucket
valve kit)
PS1: To main pump (negtive flow
feedback of back pump)
PS2: To main pump (negtive flow
feedback of front pump)
DR6: To oil port DR4
DR4: To oil return block
DR5: To oil return block
DR3: To hydraulic oil tank
T1: To radiator (main oil return)
T2: To hydraulic oil tank (main oil
return)
P1: From main pump (back pump)
P2: From main pump (front pump)
prs1: To swing motor (deblocking signal)
pa1: From travel control valve (left side
travel)
pb1: From travel control valve (left side
travel)
pa6: From travel contrl valve (right side
travel
pb6: From travel control valve (right side
travel)
pa2: From auxiliary control valve
pb2: From auxiliary control valve
59
pa3: From left handle control valve
(rotary)
pb3: From left handle control valve
(rotary)
pa4: To oil port Pi1
Pb4: To oil return block
Pa5: From left handle control valve (arm
epicycloid)
Pb5: From left handle control valve (arm
digging)
pa7: From right handle control valve
(bucket epicycloid)
pb7: From right handle control valve
(bucket digging)
pb8: From right handle control valve
(boom down)
Pa8: From right handle control valve
(boom up)
Pb9: To shuttle valve of oil port Pi2
A1: To left side travel motor
B1: To left side travel motor
A2: To auxiliary
B2: To auxiliary
A3: To rotary motor
B3: To rotary motor
A5: To arm oil cavity (small cavity)
B5: To arm oil cavity (big cavity)
A6: To right side travel motor
B6: To right side travel motor
A7: To bucket oil tank (small cavity)
B7: To bucket oil tank (big cavity)
A8: To boom oi tank (big cavity)
B8: To boom oi tank (small cavity)
Function
Multiple way valvel is mainly used for distributing oil pressure and flow in oil circuit and
controlling flow direction, etc.
Structure

60
61
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.
z Jockey valve: when joystick is in middle
position, boom and arm would descend
automatically because of internal leakage 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
62
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.

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
valve increase.

63
64
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.

65
66
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.

67
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.

68
6. Oil returning and regeneration pressure in the small cavity to shut off check
Regeneration functions of every valve kits are valve and stop the regeneration operation.
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

69
3.3 For electric equipments
(1) Control function

70
(2) Machine control system figure
(3) Control function of engine and pump

71
 Operator can turn the operation mode switch on the panel of monitor to mode H, S or L, and
select the proper engine rev and pump torque according to the operation mode. Controller
inspection fuel control engine rev. control throttle controls the absorption power of the electric
engine and the pumps to make the pumps absorb all the torque on every output points of the
engine.

3.3.1 Multifunction monitor system

Monitor panel:
(1) Summary
There are monitoring display function, working mode selection and electric parts switch on the
monitor panel.
There is CPU inside which can dispose, display and output data.
The display units are composed of LCD and the switch is plane type style.
(2) Input and output signals
72
 CN1 CN2.
stitc signal name input/output stitc signal name input/outpu
h h t
CAN
1 ground lead input 1 communicatio input
n shield
RS232
communicatio communica
2 communicatio 2 CAN1_L
n tion
n TxD
RS232
communicatio communica
3 communicatio 3 CAN1_H
n tion
n RxD
RS232
communicatio communica
4 communicatio 4 CAN0_L
n tion
n CTS
RS232
communicatio communica
5 communicatio 5 CAN0_H
n tion
n RTS
GROUND
6 power supply input 6 input
FOR CAN
7 GROUND input
power supply
8 input
for CAN
input of key
9 input
switch
10 power supply input

Monitoring and control of monitor

73
 1－current date and time selection
2－alarm flashing symbol 9－system parameter setting
3－working mode 10－mode switch
4－travel high/low speed 11－controller I/O port parameter
5－auto-idle speed switch
6－coolant temperature 12－fault diagnosis switch
7－fuel level 13－buzz off
8－system maintenance information

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

74
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.

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.

75
3.3.2 Engine control

1. Accumulator relay 6. Start motor

2. Accumulator 7. Controller
3. Start switch 8. Injection pump
4. Knob of fuel control 9. Throttle control electric engine
5. Adapting device

Summary
Engine is started and stoped by start switch (3). Controller(7) receives the signal from fuel
control knob(4) and transmits driving signal to throttle control electric engine(9)to control the
governor arm position of injection pump(8)and engine rev.(The figure needs to be replaced).

3.3.3 System operation

(1) Start the engine
After start switch turns to “start” position，the start signal transfered to start motor and make
it run to start the engine. Engine will run in low idle speed for a while, controller sends signals
and adjusts the engine rev to the setting rev set by fuel control knob.

76
(2) Engine rev control
Controller will send signals to throttle control electric engine to run it to the target position.
The position of throttle control electric engine is inspected by potentiometer and feedback the
results to the controller. It can therefore monitor the operation state of throttle control electric
engine.

(3) Shut off the engine

If start switch turns to “stop” position, throttle control electric engine runs to the least injection
position, extinction electric engine cuts off the oil circuits of the engine.

77
3.3.4 Spare parts of the system

1. knob; 2.dial; 3.spring; 4.ball; 5.potentiometer

3.3.4.1 Fuel control knob

Fuel control knob is fitted on the control box. Potentiometer is fitted under the knob. Turn
the knob and potentiometer shaft will tun as well. Then the resistance in variohm will change,
controller converts resistance signals to voltage signals.

78
3.3.4.2 Governor motor

Controller sends control signals to drive the throttle electric engine and control the governor
arm of injection pump.The potentiometer for feedback is fitted to monitor and control working
states of electric engine.The running of electric engine will be transmitted to the potentiometer
by gears.

3.3.4.3 Governor and pump controller

79
 input
stitch signal name input/output stitch signal name /outp
ut
power supply of power supply of
1 input 28 input
controller controller
power supply of
2 input 29 CAN input
controller
GND for alarm for coolant
3 input 39 input
imitation high temperature
travel pressure
4 throttle dial input 40 input
switch valve
feedback about engine oil
5 input 41 input
throttle position pressure switch
6 fuel level input 42 air filter alarm input
cooling water touch stress
7 input 43 input
temperature application
GND for automatic idle
8 input 44 input
imitation speed
travel in high and
9 engine rev input 45 input
low speed switch
11 GND input 46 spare input
12 CANL communication 47 GND input
outpu
13 CANH communication 48 torque control
t
outpu
14 GND input 49 engine throttle
t
control electric
power supply engine outpu
16 output 50
output t
GND for secondary relief outpu
21 input 51
imitation valve(power) t
travel in high and
pressure sensor outpu
22 input 52 low speed control
of pump 1 t
valve
pressure sensor of outpu
23 input 53 travel alarm
pump 2 t
GND for outpu
26 input 54 buzzer
imitation t
electric engine
power supply of power supply for outpu
27 input 55
controller controlling t
throttle

80
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 SWE210

engine ISUZU AA-6BG1TRP-03

standard
measure work value of service limit
item unit
condition new value
machine
high idle speed 2350 2350±50
engine rev low idle speed rpm 950 950±50

rated rev 2100 2100±50

valve intake valve 0.4 —
clearance(normal mm
temperature) blast gate 0.4 —
the minimum
engine oil
compression difference value
temperature: 40-60℃ MPa 3.04
pressure between
engine rev: 250rmp
cylinders: 1.0
in high idle speed
in low idle speed
engine oil pressure kPa 290-590
(water temperature: in
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

81
4.1.2 Standard table of complete machine
suitable machine model SWE210
un standar allowabl
class item measure working condition
it d value e value
·engine water temperature: within
working range
second-class ·hydraulic oil temperature: within
2050 2050±50
overflow working range
·engine runs in high idle speed
·arm in overflow state
·engine water temperature: within
second-class working range
rp
engine rev overlow ＋ ·hydraulic oil temperature: within
m
touch power working range 2050 2050±50
enhancemen ·engine running in high idle speed
t · 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
arm control
valve
bucket
valve core control m
10 10±0.5
stroke valve m
rotary
control
valve
travel
control
valve
boom
control 75 75±10
valve
arm control
75 75±10
valve
bucket ·engine misses
control ·at the handle center of joystick 75 75±10
joystick
valve ·measure the max. value to the m
stroke
rotary stroke terminal m
control (except joystick is in the middle 75 75±10
valve position)
travel
control 180 180±20
valve
joystick
max.10 max.15
clearance
82
suitable machine model SWE210
un standar allowabl
class item measure working condition
it d value e value
boom
7
joystick
arm joystick ·hydraulic oil temperature: within 7
bucket working range
7
joystick ·engine running in high idle speed
joystick
rotary ·at the handle center of joystick
operating N 7
joystick ·at the top of pedal
force
Tra joystic ·measure the max. value to the
stroke terminal 15
vel k
joy
stic pedal 105
k
·hydraulic oil temperature: within
working range
·engine running in high idle speed
unloading
·work mode: H 3 3±0.5
pressure
·hydraulic pump output pressure
with all the joysticks in the
middle position
boom ·hydraulic oil temperature: within
arm working range
bucket ·engine running in high idle speed
rotary ·work mode: H
hydraulic
·hydraulic pump output pressure 32±0.5
pressure 32(34)
when all measure oil circuits (34±0.5)
releasing
travel M
·value in bracket:hydraulic oil
Pa
pressure of touch type switch in
ON mode
·hydraulic oil temperature: within
pressure of working range
control oil ·engine running in high idle speed 3.5±0.5
3.5
circuit ·output pressure of pressure-relief
supply valve with all the joysticks at the
middle position

83
suitable machine model SWE210
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

84
suitable machine model SWE210
cla standard allowabl
item measure working condition unit
ss value e value
rotary
hydraulic drift

·hydraulic oil temperature ： within

working range mm 0 0
·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
leakage working range
·engine running in high idle speed
·rotary lock switch：ON L/min 24.5
·leakage rate after rotary overflow for 1
minute

85
suitable machine model SWE210

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

86
suitable machine model SWE210
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

87
suitable machine model SWE210
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
ng ·hydraulic oil temperature ： within seco
boom
de working range nds
vic ·engine running in high idle speed fall 2.5 2.5±0.5
e ·work mode：H
·required time from lift stroke end to
bucket contact ground

88
suitable machine model SWE210
standa
cla allowabl
item measure working condition unit rd
ss 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
wo
·required time from unload stroke
rki
end to digging stroke end
ng
seco
de
nds
vic dig 3.1 3.1±0.5
e

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

89
suitable machine model SWE210
standard allowabl
class item measure working condition unit
value e value

travel
com
deviation
poun
amount for
d
working
oper ·hydraulic oil temperature：within working Mm
device and 300 ≤
ation range
travel
perf ·engine running in high idle speed
synchro
orm ·work mode：H
operation
ance
• travel speed：low
• flat ground
• travel deviation amount(X)for measuring
of traveling 20m after traveling 10m
hydr
aulic
pum hydraulic
p pump flow
perf
orm
ance

90
4.2 Test and adjustment of hydraulic device The flow distribution to every actuator by
front and back main pumps when act
4.2.1 Test and adjustment of system
separately:
working pressure

Instruments actuato oil relief

act
r supply valve
ma specificati qt front
No. name
rk on y. pump、
boom up
shock back
cylind
resista pump
74040200 er
S1 nce 0－60MPa 1 front
0057 down
pressur pump
e table front
pressur epicyclic pump、
73050500 e SMA3-50 motion back
S2 1 arm
0005 testing 00 pump
hose cylind
front two-stag
pressur er
inward-retra pump、 e main
73010100 e VKA3/06 relief
S3 1 ct back
0358 testing SA3C valve
pump
joint
epicyclic front
End direct bucket
motion pump
73010100 connection cylind
S3 joint 1 inward-retra front
0080 GEO08LR er
ct pump
OMDA3C
right
front
travel travel
★The working pressure (output pressure of pump
motor
hydraulic pump) of every actuator is
left
displayed on the monitor of the cab. back
travel travel
★Before measuring, the hydraulic oil pump
motor
temperature should be increased to 50～55º
own
Celsius. rotary back
rotary relief
motor pump
valve
Measurement
1. Combination of pumps, hydraulic
2. Preparation work for measuring
components and valves
Lower the working device to the ground
Please refer to the contents of main
and stop the engine, release pressure in pipes
pump and multiple way valve and hydraulic
by operating joystick and pressure in oil tank
schematic diagram in chapter 3.2 for
by loosening the cover of pouring orifice.
hydraulic device functions and maintenance
1) Dismantle the pressure sensor(1) which
standards so as to understand the structure and
connects with oio port a1(or a2)，then
test point of main pump and multiple way
valve and system flow distribution. connects joint S3, and connects piezometric
91
joint to the other end of S3. Connect
manometer S1 with piezometric hose S2 to
S3.
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) Start engine and keep it running until the
increasing of hydraulic oil pressure meets the
working range.
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.

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) Start engine and turn it to model H.
2) Measure hydraulic oil pressure when
3) Measure hydraulic oil pressure when
engine runs in high idle speed and the
engine runs in high idle speed.
cylinder is in overflow state.
★ Display hydraulic oil pressure when main
★ Display hydraulic oil pressure of main
relief valve overflows.If press the touch
relief valve when it is in overflow state.
compression switch on handle, oil pressure
★ If press the touch compression switch on
will transform to high overflow pressure. If
handle, oil pressure will transform to high
92
release the pressure, it will transform to low ★Please connect the pilot hose when measure
overflow pressure. pressure.
★It also need to adjust if adjust high pressure
Adjusting setting value which will influence low
1. Adjusting for overflow pressure pressure setting value
(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.
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. 3. Adjusting for rotary overflow pressure
★ If the screw turns to the left, pressure will ★If the rotary overflow pressure is in
decrease. abnormal state, adjust it according to the
3) Check the pressure after adjusting. Perform following steps:
measuring work according to the above steps. ★overflow valve (1) or (2) of rotary motor
★ Please connect the pilot hose when ★adjust the pressure (1) of right rotary
measure pressure. ★adjust the pressure (2) of left rotary.

2. Adjusting for overflow pressure

(two-level pressure setting value) 1) Unscrew latch nut (1) and adjust pressure
1) Break pilot hose. according to turning adjust screw (2).
2) Unscrew latch nut (5) and adjust pressure ★If the screw turns to the right, pressure
hrough turning keeper (6). will increase.
★If the screw turns to the right, pressure will ★If the screw turns to the left, pressure will
increase. decrease.
★If the screw turns to the left, pressure will
decrease.
3) Check the pressure after adjusting. Perform
measuring work according to the above steps.
93
 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) 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 2) Connect piezometric joint S3 to

m piezometric point (a3). Connect piezometric
specificati qt hose (S2) with manometer (S1) to (S3).
ar No. name
on y. 3) Start engine and keep it running until the
k
shock increasing of hydraulic oil pressure meets the
resista working range.
74040200
S1 nce 0－6MPa 1
0034
pressur
e table
pressur
73050500 e SMA3-50
S2 1
0005 testing 00
hose
pressur
73010100 e VKA3/06
S3 1
0358 testing SA3C
joint
4) The measured oil pressure is pilot
End direct
overflow pressure when engine runs in high
73010100 connection
S4 joint 1 idle speed and all the joysticks are in middle
0080 GEO08LR
position.
OMDA3C
★Before measuring, the hydraulic oil Adjusting
temperature should be increased to 50～55º ★If the measured pilot overflow pressure
Celsius. cannot match the setting pressure, please
Measuring adjust the pressure of pilot overflow (1)
Lower the working device to the ground according to the following steps:
and stop the engine, release pressure in pipes
94
 q
m
specificati t
ar No. name
on y
k
.
pressur
S 7305050000 e SMA3-50
1
2 05 testing 00
hose
pressur
S 7301010003 e VKA3/06
1
1) Unscrew nut (312) and adjust screw 3 58 testing SA3C
(311). joint
★If the screw turns to the right, pressure will End direct
Transit
increase. S 7301010000 connection
ion 1
★If the screw turns to the left, pressure will 4 80 GEO08LR
joint
decrease. OMDA3C
★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.
2) Check the pressure after adjusting. Perform 1) Dismantle the oil plug (1) of piezometric
measuring work according to the above steps. point (TR).
★Use latch nut for locking after adjusting.

4.2.3 Inspection for main return oil

pressure of the system
Instruments
q
m
specificati t
ar No. name
on y
k
.
shock
resista 2) Connect piezometric joint S3 to
S 7404020000
nce 0－6MPa 1 piezometric point (a3). Connect piezometric
1 34
pressur hose (S2) with manometer (S1) to (S3).
e tab 3) Start engine and keep it running until
the increasing of hydraulic oil pressure meets
the working range.
95
4) Read the max. value of being displayed ma specifica qt
No. name
by manometer when working device is rk tion y.
running. pressur
★If the volume of system return oil is max., 73010100 e EMA3/G
S3 1
the pressure of return oil will be the max. 0170 testing 1/8
★The return oil volume will be the max. if joint
there are no other actions except operating the tramsit
control valve to lower the boom, make the S4 ion tee 1
arm and bucket do epicyclic motion. joint
tramsit
S5 ion tee 1
joint

★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.
2) Dismantle all the measuring tools after Measuring
completing measure work and make sure the Lower the working device to the ground
machine’s normal condition. 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:
4.2.4 Inspection for output pressure of the
pilot solenoid valve mark outgoing direction
inlet oil port of pilot
Instrument 1
oil collecting block
ma specifica qt pressure increasing
No. name
rk tion y. 2 port of two-stage
shock overflow valve
resista two speed control port
74040200 0－ 3
S1 nce 1 of travel motor
0034 6MPa
pressur
e tab 1. Break the hoses of solenoid valve to
pressur measure out its output pressure.
73050500 e
S2 6M 1
0004 testing
hose

96
 Pilot latch solenoid valve
state function
security lock OFF
lock
unlock ON
lever

Pressure increasing solenoid valve

state function
2. Connect transition joint on the output oil pilot latch solenoid
port joint. Connect oil port(1) with (S4), valve ON
(2)and(3)with(S5)，and fit with piezometiric ON
press the pressure
joint (S3). Connect piezometric hose (S2) button
with manometer (S1) to (S3). reset the pressure
3. Start engine and keep it running until the OFF
button
increasing of hydraulic oil pressure meets the
working range. Two-speed solenoid valve
state function
pilot latch solenoid
valve ON
ON
close the
two-speed switch
break the
OFF
two-speed switch

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.
97
4.2.5 Measuring for output pressure of mar measuring oil mar measuring oil
pilot control valve k circuit k circuit
left
Instruments boom
1 travel(forward 6
(descend)
ma specifica qt )
No. name platform
rk tion y. arm(epicyclic
shock 2 rotary(to the 7
motion)
resistan right)
74040200 0－ platform
S1 ce 1
0034 6MPa 3 arm(digging) 8 rotary(to the
manom
eter left)
pressur right left
73050500 e 4 travel(forward 9 travel(backw
S2 6M 1 ) ard)
0004 testing
hose bucket(diggin
5 10 boom(lift)
pressur g)
73010100 e EMA3/
S3 1
0170 testing G1/8
joint
Transiti
S4 1
on joint

★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.

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
98
increasing of hydraulic oil pressure meets the
working range.

2) Operate pilot valve to make the main

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 ★If the pressure in accumulator descend;
full-stroke 2.6MPa
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.
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.
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.

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. 2) Operate arm joystick to move the arm to
★Fill the bucket with sand or apply rated the side of digging.
load on the bucket. • Increasing of the fall speed indicates there
are leakage fault in oil tank.
99
• No change indicates there are faults in oil tank.
control valve. Do not break the hose in the big cavity
★ The start switch of the engine is in ON of oil tank.
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.
3) Start the engine and apply overflow
1. Stop the engine and unscrew the pouring
pressure on the big cavity of oil cylinder
orifice gradually to release the pressure in oil
when the engine runs in high idle speed.
tank.
4) Remain this state for 30 seconds and then
2. Operate the joystick for several times.
measure the leakage volume of one minute.
★Operate joystick when engine start switch
5) After measuring, insure the machine
is in ON position.
return to the normal state.
★Pressure stored in accumulator wll be
released when joystick is operated for 2-3
2. Measuring for the leakage volume of
times.
arm oil cylinder
3. Start the engine, runs it at low idle speed
for 10 second to store pressure in accumulator,
1) Start the engine and keep it running until
and then stop engine.
hydraulic temperature rises to the working
4. Repeat step 2 and step 3 for several
range and extend the pistion rod of arm
times.
cylinder to the end of the stroke.
Release the residual pressure in pipes.
4.2.8 Check for leakage volume
Refer to the last part “Release the residual
1. Measuring for the leakage volume of pressure in hydraulic oil circuits”.
boom oil cylinder 2) Break the hose (1) in the small cavity of
oil cylinder.
1) Start the engine and keep it running until Be careful not to break the hoses at the
hydraulic temperature rises to the working bottom of the oil cylinder.
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
100
 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
3) Start the engine and apply overflow
tank，and plug its oil port.
pressure on the big cavith of oil tank when the
engine runs in high idle speed. 2) Put working device on flat ground and
4) Remain this state for 30 seconds and then make the bucket against ground.
measure the leakage volume of one minute. 3) Start the engine. Measure leakage volume
5) After measuring, insure the machine when engine runs in high idle speed and apply
return to the normal state. rotary overflow pressure.
★Travel motor remains still.
3. Measuring for the leakage volume of ★Keep the state of step 3)for 30 seconds，
bucket oil cylinder measure the leakage volume of one minute.
1) Start the engine and keep it running until ★After the first measuring, turn the up rotary
hydraulic temperature rises to the working platform of 180 º, and measure again with the
range and extend the pistion rod of bucket same method.
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.

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.
Put pin ① between sprocket and track
frame to stop travel.
101
 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

3) Break hose (1) of drain oil port of travel max. flow, min.flow, power and flow control
motor, fit with choke plug on the end of the character.(Refer to table 1 and table.2 for
hose. adjust volume)
4) Start the engine. Measure leakage volume
when engine runs in high idle speed and apply 1. Adjusting of the max. flow
rotary overflow pressure. Release hexagon nut (1)，tighten(or release)
When doing this measuring, a faulty fix screw (2)for adjusting. There are no
operation of the joystick will cause a serious changes of the other control characters except
accident, so insure every signal and make for the max. flow.
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.

2. Adjusting of the min. flow

Release hexagon nut(1)，tighten (or release)

102
fix screw (2) for adjusting.No changes of the will change as well. So turn adjusting screw
other control characters. Notice that if (3) inversely.
tightened too much, it may need increasing
power in overflow state.

2) Adjusting of internal spring

Release hex nut(2)，tighten(or release adjust
3. vdjusting of input power screw(3)for adjusting. When tighten the
★ Adjustor uses the sync full power control adjust screw, see as the following fig., the
way. When adjust the setting volume of the flow and input power will increase when
power, make the same change for the adjust tightening.
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

103
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.

104
 adjusting for the adjusting for the
adjusting for the character
max. flow min. flow of flow control
variabl
e in
adjust adjust start
adjus adjust variab
rev the the pressur variabl
ter variable the le in
(r/min screw screw- e e in
mod in screw-i disch
) -in in control dischar
el discharge n depth arge
depth depth led by ge
(ℓ/min-1) (turning (ℓ/mi
(turni (turni dischar (ℓ/min)
) n)
ng) ng) ge
(kgf/c
m²)
KR3
G-2 2100 +/4 6 +1/4 3 +1/4 1.5 14
NO9

Table 1

adjust input power

adjusting for internal spring adjusting for external spring
compe
rev nsate
adjuster variable adjust
(r/mi adjust the variable and variable
model in the
n) screw-in in input control in input
discharg screw-in A
depth torque( start torque
e depth
(turning) N.M) pressur (N.M)
(ℓ/min) (turning)
e
(MPa)
KR3G-2 1.
2100 +1/4 10 42 +1/4 1.6 43
NO9 8

105
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
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.

106
4.3 Fault diagnose
4.3.1 Inspection before fault diagnose
N
o 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 pull-off. tighten or replace
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 and tighten or replace
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 are replace
wet, water penetration or oil immersion.

107
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
Turn the start switch to ON position, if
the input end (1, 2)of the relay is
fault in the relay of
normal, then use multimeter to check if
extinction motor
the output contact(3, 5)of the security
relay is closed, or it may be destroyed.
Turn the start switch to ON position,
check if the extinction motor B, P1
fault in extinction
terminal voltage(24V)and P2 terminal
motor
voltage(0V)is normal ， or it may be
destroyed.
Turn the start switch to ON position,
check if the B 、 C terminal
fault in the start
voltage(24V)of the start motor is
motorof the engine
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.

108
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
nothing ohm，or the rotary transducer wire group
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 extinction motor fault terminal A on extinction motor, the
extinct 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
Check the automatic idle switch. Its
automatic idle switch resistance should above 1M if it is at
fault OFF position, and under 1M if it is at
ON position.
Use multimeter to measure the resistance
wire group break of the two wires, its normal value should
below 1 ohm.
rev doesn’t reach the If the engine rev is above 1500 /m，the
4 setting value automatic idle will work.
the pressure value of If the pressure of the main pump is under
automatic the main pump is
4M Pa，the automatic idle will work.
idle function excessive
do not work 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.

109
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-up work.
6 of the When start the machine, the automatic
engine do cooling water
warming-up of the engine will not work
not work temperature of the
if the cooling water temperature is above
engine is high
25°C.
touch step-up switch Use multimeter to check the touch
fault press-up button on handle.
Use multimeter to check if the wire
wire group fault
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
Check if the resistance of the cooling
the alarm engine cooling water temperature sensor changes along
light for temperature sensor of with the temperature change. The higher
cooling the engine fault 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.
Check if it is tight sealed around the
Others (i.e. inlet scoop
engine inlet scoop. If it false air, the
of the engine false air,
cooling effect will be bad and the cooling
etc.)
temperature rises.

110
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.
Use multimeter to check if the end wire
wire break of fuel level
group of the fuel level sensor is open
sensor fault
circuit.
The charging alarm light turns red when
machine won’t start
the machine doesn’t work.
After the engine start, measure if there is
charging the generator doesn’t output voltage at the output end of the
10 alarm light work generator. If the generator belt is slip or
turns red break, or the generator fault.
Measure if there is open circuit or ground
charge loop group fault 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 clogging all the time. If the air filter is clogging,
air filter
sensor fault the sensor will be closed constantly, or
clogging
the sensor may be damaged.
11 alarm light
sensor wire group Measure if the wire group of the sensor
is red
connect ground connects ground.
The engine oil alarm light will turn red
machine won’t start
in this state.
Measure the engine oil level is a little
engine oil pressure is
alarm light lower after a few minutes of the engine
low
12 for engine stop.
oil engine oil pressure
Engine oil sensor fault
pressure sensor fault
turns red sensor wire group Measure if the sensor wire group
connect ground connects grouond.
Turn the throttle knob and measure if its
resistance value changes in the range of
throttle knob fault 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 Measure if the throttle knob and the wire
the throttle wire group break group of throttle motor have been broken
knob or connected ground.
The resistance value of the throttle
feedback signal wire of
feedback potentiometer changes in the
the throttle open circuit
range of 10K ohm.

111
No. fault sorts fault diagnosis(probable processing method
cause)
Supply the throttle motor with
throttle motor fault DC12V power. The motor may be
damaged if it doesn’t work.
When the machine is in the state of
machine is under the automatic idle, the rev will have no
rev doesn’t change
automatic idle state 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
ratio electromagnet
is about 17.5 ohm, otherwise the
fault
the working device ratio electromagnet may be
14
speed is too low destroyed.
Measure the wire group of the ratio
wire group of ratio
electromagnet if it is broken or
electromagnet break
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
throttle knob open
indicator light on there 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
open circuit of the
sensor indicator there are open circuit fault in the
18 water temperature
light on diagnose water temperature sensor and wire
sensor fault
interface turns red group.
fuel level sensor Use multimeter to measure if
open circuit or short
indicatior light on there 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.

112
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 Use multimeter to measure if
potentiometer throttle actuator fault or there are opencircuit or ground
22 indicator light on open circuit or short circuit connection fault in the throttle
the diagnose in feedback wire 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 Replace power fuse and check
the power fuse of the monitor
if there is ground connection
melt
fault.
open circuit or groud Use multimeter to measure if
no voice of the connection in the wire there are open circuit or short
24
travel alarm group of the travel alarm circuit in the travel alarm, or
fault it may be destroyed.
wire group open circuit or
25 wiper doesn’t work
ground connection fault

113
5. Disassembly and assembly Assembly
z This section “assembly” includes
5.1 How to read this manual
procedure, precaution and know-how.
Installation and removal of assy. z All the sighs and marks are explained and
Removal of parts listed as follow:
z Section “removal” includes procedure 1) This mark is used to provide
and instruction. instruction and attention to operating
z All the warning signs and marks which procedure.
have been used in the section “removal” are
listed as follow: 2) Important security attentions.
★ This mark is used to provide 3) : Fill lubricant when
instructions and attentions to operating assembling.
procedure. 4) : Lift weight.
Important security attentions.
5) : Bolt torque.
★ : Lift weight. 5.2 Instruction during operation
Installation of parts
z Install parts in reverse order unless The following items should be followed when
otherwise noted. attempt any disassembling or assembling
z All marks and signs used in section procedure (removal or installation).
“installation” is as follow: 1. Instructions during disassembling:
z Dispose properly if engine coolant
★ This mark is used to provide
contains antifreeze.
instruction and attention to operating
z Always cap or plug hoses when hoses or
procedure.
steel pipes are removed to prevent them from
★ Important security attentions. entry of dirt, dust and debris.
z Provide a proper container to catch the oil
★ : Fill lubricant when
discharged
assembling.
z Confirm matching marks which indiceates
★ : Lift weight. installation position, provide mating marks to
★ : Bolt torque. avoid re-assembling mistake, prior to
Assembly and disassembly of assy. disassembling.
Disassembly z Do not pull conducting wire to avoid
z Section ”disassembly” includes loose from contact point. When
procedure and instruction. disconnecting conduct wire, Hold connector
z All the warning signs and marks which to avoid excessive force applied to wire.
have been use in this section “disassembly” z Attach marks on the wire or hose to make
are listed as follow. certain their positions. It helps to avoid
★ This mark is used to provide mistake during re-assembling.
instruction and attention to operating z Calculate and inspect the number and
procedure. thickness of washers, and keep them at safe
place.
★ Important security attentions.
z Make certain to use proper lifting
★ : Lift weight. device with sufficient strength and reliability,
114
when lifting components. fasten them evenly to prevent that one side’s
z Evenly fasten screw in proper sequence flange is over fastened.
when lifting bolt was used to remove any 3. The fasten torques of main bolts\ nuts are
components. as following table. (N.m)
z When disassembling any devices, clean
the surrounding area and cover them to Scre tightening torque
prevent dust or dirt from entering into them. w oppo Target
2. Instructions during the process of diam site using limit
value
assembly eter side(
z Replace and fasten all the nuts (cannula (mm mm) N•m N•m
nuts) and bolts with specified torque value. )
z No distortion or interference is allowed 6 10 13.2 11.8 - 14.7
during hose installation.
8 13 31 27 - 34
z Replace all bolt, nut, bushing, o-ring,
cotter pin, and locking plate with new ones. 10 17 66 59 - 74
z Bent cotter pin and fix locking plate 12 19 11 98 - 123
securely.
14 22 177 157 - 196
z When applying bonding compound,
Clean components and remove all oil and 16 24 279 245 - 309
grease. And then apply 2 or 3 drops to all 18 27 382 343 - 425
parts with thread.
20 30 549 490 - 608
z When applying sealant, clean surface and
remove all oil and grease. If no dirt and 22 32 745 662 - 829
damages are recognized, evenly wipe sealant 24 36 927 824 - 1030
to it. 27 41 1320 1180 - 1470
z Remove or repair all part’s damage, dent,
30 46 1720 1520 - 1910
burrs and rust.
z Grease all rotary components or sliding 33 50 2210 1960 - 2450
components. 36 55 2750 2450 - 3040
z Apply anti-friction composites to the part
39 60 3280 2890 - 3630
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
metamorphic. Make sure to completely fasten
it and align it with the lifting hook.
z When fastening counter flange, always

115
 Tighten torque is as following table. (N.m) 4. Recommended grease brand name
tighten bucket、arm and boom、
torque rotary gear, swing
screw thread bearing etc
standard across target use —20 to 40°C(—4 to
width value limit 104F)
(mm) N•m N•m BP Energrease
BP
35 - Ls—EP2
9/16-18UNF 19 44
63 Caltex Multifax EP2
54 -
11/16-16UN 22 74 Esso Beacon EP2
93
Daphne Coronex
84 - Apollo
13/16-16UN 27 103 Grease EP2
132
Mobil Mobilux EP2
128
1-14UNS 32 157 - 2# extreme pressure
Fuchs
lithium grease
186
Shell Alvania EP
177 Shell
Grease 2
13/16-12UN 36 216 -
245 lithium grease with
Remark extreme high load
176 capacity
1-7/16-12UN-2B 41 215 -
234

★ 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.

116
5. Random auxiliary tools for general serial name and
product No.
purpose No. specification
serial name and Wooden
product No. 15 740210000017 handle ball
No. specification
Straight hammer 2P
screwdriver Adjustable
1 740121000030 bending bar
200X8X1.2 16 740119000098
GB10639 300X36
Cross GB4440
screwcriver Wire cutter
2 740121000011 17 740103000004
150 200MM
GB1064-89 Nipper pliers
18 740131000004
Cross 200
screwcriver Adjustable
3 740121000014 bending bar
200 19 740131000022
GB1064-89 300X36
Inner hexagon GB4440
4 740104000019 spanner S3 ★ After the cylinder, main pump and other
GB5356-85 hydraulic devices are disassembled and
nner hexagon repaired then re-assembled; bleed the air for
5 740104000004 spanner S5 the first time use. The operation procedures
GB5356-85
are as follow:
Inner hexagon
6 740104000005 spanner S6 (1) Start the engine and run it with low idle
GB5356-85 speed.
Inner hexagon (2) Operate working device controller to
7 740104000006 spanner S8 operate hydraulic cylinder 4-5 times, stop the
GB5356-85 cylinder at a position 100 mm away from the
Inner hexagon
8 740104000007 spanner S10 stroke end.
GB5356-85 (3) Operate hydraulic cylinder 3-4 times to its
Inner hexagon stroke end.
9 740104000008 spanner S12 (4) Make the engine run with normal speed,
GB5356-85 afterwards.
Inner hexagon
10 740104000009 spanner S14
GB5356-85 ★When using the machine for the first time
Inner hexagon after long-term storage or repair, follow the
11 740104000010 spanner S17 same procedure.
GB5356-85
Common box
6. Instruction after operation
spanner
12 740105000201 z In the event that engine coolant is drained,
new14 pieces
unit tighten drain valve, refill coolant to specified
Box spanner level. Run the engine to cycle coolant in
13 740106000037 new 6 pieces system then check the fluid level.
unit z In the event that hydraulic device has been
Double ended
14 740115000044 spanner new 6 disassembled then re-assembled, refill oil to
pieces unit the specified level. Run the engine to cycle oil

117
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

Special tools

No. product No. name spec.

Comm
7401050001 on box 2. Then detach the pin.
1
64 spanne ★ Check the shims number and thickness and
r put them at safety place.
Inner 3. Start the engine and retract piston rod.
hexag S10 ★ Fix piston rod with steel cable and lower
7401040000
2 on GB5356-8 the oil tank on the platform or place a bearing
07
spanne 5 under the oil tank to support it.
r ★ Disassemble the other side of the boom oil
torque tank with the same way.Two pieces of the oil
7401190000 80-300N.m
3 spanne tank hose (5). Seal the port and make
11 12.5mm
r necessary labels.

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. Lift boom assy.(3)and detach lock bolts(1)
★ Choke the hose to prevent oil discharging
and nut (2).
and fix it on the other side of the valve.

4. Dismantle the connector (7) on the lamp.

5.Lift the working device and dismantle
pressure plate(8)，then the pin(9).

118
 5.4 Counterweight ASSY assembly and
disassembly

Tools

N
product No. name spec.
o.
Comm
7401050001 on box
1
64 spanne
★ Don’t forget to check the shims number r
and every parts with shims. Torque
7401190000
3 spanne 0-3000
74
r
6. Lift the working device ASSY. and
decompose it.
Disassembly
Working device ASSY : 4900 kg 1. Disassemble the engine cover (1). Refer to
Assembly “engine assembly and disassembly”.
Assemble in reverse order of dissemble. 2. Disassemble counterweight rubber choke
: See 5.2 for recommended lubricant plugs (2). Fit with handling bolts and lift
brand. them.
: 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.
3. Dismantle 4 construction bolts (3)
★ Check the shims number and thickness and
put them at safety place.

119
4. Lift counterweight slowly and electric mounting plate (2) and make
horizontally. necessary mark.. Disassemble the bellows
★ Be careful not to touch the engine, radiator between evaporator and duct, new tuyere and
and cooler. evaporator. Disassemble the hose of window
scrubber.
Counterweight ASSY : 4000 kg
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
covers.
3. Disassemble lock drag bar (3).

5.5 Cab ASSY assembly and disassembly

Special tools

No. product No. name spec.

Commo
740105000
1 n box
164
spanner
740119000 torque 80-300N.m
7
011 spanner 12.5mm
Plastic 4. Disassemble the 6 bolts (4) which connect
handle 150 the cabin and the worktable.
740121000
8 cross GB1064-8
011
screwdr 9
iver
Plastic
handle
740121000 250X10X1.
9 straight
016 6 GB10639
screwdr
iver
Disassembly
Disassemble the cable from the negative
terminal of the accumulator.
5. Lift cab ASSY for disassembling.
1. Disassemble rubber floor mat in the cabin.
2. Disassemble part (1). Disassemble the Cab ASSY. : 200 kg
electric joints between every electric parts and
★ Be careful not to touch the
120
worktable and platform.
Assembly
• Assemble in reverse order of disassemble.

5.6 Engine disassemble and assembly

Special tools

N
product
o name spec.
No. 4. Dismantle intercooled air duct(3), cooler
.
Commo water inlet pipe(4), intercooled escape pipe(6),
74010500 supercharger air duct(7), intercooled escape
1 n box
0164 pipe(9), cooler drain pipe(10), rubber
spanner
74011900 Torque 80-300N.m ring(5)and drag bar(8)，make the necessary
7 marks and seal the pipe orifice.
0011 spanner 12.5mm
plastic
handle
74012100
8 cross GB1064-89
0011
screwdri
ver 150

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 5. Dismantle engine oil pipeline, compressor
240L pipeline and electric joint. Make the necessary
2. Release the engine coolant. mark and seal the pipe orifice.
Engine coolant: about 23L 6. Dismantle compressor ASSY.
3. Lift engine cover (1) and dismantle 7. Dismantle all the oil pipelines of hydraulic
coupling bolt and stand bar (2). Support the pumps, electric joints(refer to “hydraulic
engine cover with proper batten and lift pump ASSY disassembly and assembly”)and
device. its cover parts and baffles.

121
8. Dismantle exhaust muffler and its 5.7 Radiator ASSY disassembly and
discharge pipe. assembly
9. Dismantle all the construction bolts of the
engine. Special tools
★ Check there are no connecting wires or
pipelines. No. product No. name spec.
Com
10. Lift engine and hydraulic pump
mon
ASSY. 7401050001
1 box
Engine and hydraulic pump ASSY : 64
spann
700 kg er
Torqu
Assembly 7401190000 e 80-300N.m
• Assemble in reverse order of disassemble. 2
11 spann 12.5mm
★ Refer to section “check and adjust” of er
part” belt tension of air-conditioning Plastic
compressor” in chapter“measuring and handle
adjustment”. 7401210000 cross
★ Screw thread glue: thread lock glue 1277. 3 GB1064-89
11 screw
★ : Apply according to the torque driver
fig.5.2. 150
★ Refill the engine coolant to specified level Inner
through the water feeding port. hexag
7401040000 S10
Engine coolant: about 23L 4 on
07 GB5356-85
★ Refill the hydraulic oil to specified level spann
through the oil port. er
Hydraulic oil: about 240L
★ Start the engine to cycle the water so as to Disassembly
release any gas bubble, then check the water
level. ★ Lower the working device to the
★ Start the engine to cycle the oil in ground and stop the engine. Disassemble the
hydraulic system, then check the oil level and cable from the negative (–) terminal of
liquid level. accumulator. Gradually loosen the oil ejector
★ Exhaust air and consult the content in lid of the hydraulic oil tank to release the
section “exhaust air from the parts”in chapter inner pressure.
“testing and adjusting”. ★ 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
122
3. Open the engine cover. Dismantle
intercooled air duct (3), cooler water inlet
pipe (4), rubber ring (5), intercooled escape
pipe (6), supercharger air duct (7), drag bar
(8), intercooled escape pipe (9), cooler drain
pipe (10), make the necessary marks and seal
the pipe orifice.

6. Dismantle air-conditioning cooler (15) and

seal the orifice.

7. Using two lifting hook to lift radiator

ASSY.
8. Dismantle four radiator construction bolts.

4. Dismantle hydraulic oil pipes joint (11),

cover plate(12)and auxiliary water tank
hose(13)，seal the orifice.

9. Lift radiator ASSY. : 155 kg

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

123
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”.
5.8 Hydraulic pump ASSY disassembly and
assembly
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)

Tools

No. product No. name spec.

S8
1 740104000006 GB535
6-85
inner
hexgon
spanner
2 740104000007 inner S10
hexgon GB535
spanner 6-85 3. Dismantle the following 7 hoses and 3
inner connectors:
hexgon (1) Negative flux feedback pipe of the front
spanner
3 740104000009 pump
S14
GB535 (2) Two pressure sensor connector
6-85
double (3) Oil drain pipe of the main pump
4 740115000003 17-19
end (4) Two main oil pipes
5 740115000032 solid 16-18 (5) Pilot oil supply output pipe
spanner
(6) Connector of the proportional solenoid
torque 80-300
6 740119000011 N.m vave
spanner 12.5mm
(7) Negative flux feedback pipe of the back
open SH15D
7 740119010059 end pump
of ×17
the (8) Oil inlet of the proportional solenoid vave
8 740119010060 torque SH15D (9) Suction pipe of the pilot oil supply
spanner ×19

124
 6.Lift the hydraulic pump, and then
disassemble the connecting bolt between the
engine and the hydraulic pump.
hydraulic pump ASSY. :156 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”.

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

main pump.

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

125
5.9 Hydraulic pump body disassembly and parts when dismantle pumps.
assembly ★The numbers in () after the parts name are
serial NO. of the parts in fig.(JPG0066).
Tools
1． Choose the place for disassembly.
No
product No. name spec. ★ Choose a neat and clean place.
.
★To prevent collision of the parts, lay rubber
S4
74010400000 plate or working cloth on the worktable.
1 GB5356-
3 2. Use cleaning oil to wipe off the debris and
85
rusty spot on the surface of the pump.
S5
74010400000 3. Open the oil-embolus cover (468) on the
2 GB5356-
4 pump body and extract the oil in the pump.
85
inner 4. Dismantle hexagon bolts (412,413) and the
S6
74010400000 hexagon adjustor.
3 GB5356-
5 spanner ★Please refer to the chapter of adjustor
85
disassembly.
S8
74010400000
4 GB5356-
6
85
S17
74010400001
5 GB5356-
0
85
74010600000
6 17-19
5
74010600000
7 24-27
3 Box
74010600001 spanner
8 27-30 5. Unscrew the hexagon bolt (401) which is
91
74010600002 fixed on the shoe plate (251) of the swash
9 32-36 plate, pump body (271) and valve body (312).
0
Cross 75X5 ★If there are connecting pieces at the back of
74012100001 the pump, dismantle the connecting pieces
10 screwdriv GB1064-
0 before doing the next step.
er 89
Adjustabl 6. Put the fitting surface of the pump and the
200X24 adjustor downwards and place it on the
11 74010300000 e bending
GB4440 worktable flatly. Dismantle pump body (217)
bar
and valve body (312). Lay rubber plate to
74013100002 Nipper
12 160 avoid damaging the fitting surface.
3 pliers

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
126
 9. Disassemble hexagon bolt (408) and the
7. Align pump body (271) and drive shaft,
back cover plate (263).
take out cylinder body (111), piston (151),
10. Slightly knock the flange tray of the
pressure plate (153), spheric bushing (156)
support table for tilt plate (251) on the side of
and oil tank spring. Be careful not to destroy
the pump to disconnect the pump body and
the slip surfaces of the oil tank, spheric
shoe plate.
bushing, and guide track and piston shoe.

11. Take out piston shoe (211) and tilted plate

8. Dismantle inner hexagon bolt (406) and
(212) from pump body (271).
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.

12. Slightly knock the shaft end face of the

drive shafts (111,113) with plastic hammer.
127
Pull out the drive shaft from the tilt plate Assembly
support table. 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 of disassemble.

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.
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.
★ 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.

128
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.
★Knock the outer circle of the bearing
slightly with rubber hammer, and then use
copper bar to knock it fully in.
129
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.
 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.

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.

9. Assemble oil drain pinhole (467) and

complete the whole operation steps.

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).

130
131
5.10 Main pump adjustor disassembly and
assembly

Tools

No product
name spec.
. No.
S4
740104000
1 GB5356-8
003
5
inner 4. Dismantle inner hexagon bolt (438) and
S5
740104000 hexagon cover(C) (629).
2 GB5356-8
004 spanner ★Cover(C)is fit with adjusting
5
S6 screws(C)(CI),(628、925), adjusting
740104000
3 GB5356-8 wheel(C)(627), lock nut(630), hexagon
005
5 nut(801)and adjusting screw(924). Don’t
cross 75X5 screw off these screws and nuts. Otherwise
740121000 the setting pressure and flow will change.
4 screwdrive GB1064-8
010
r 9
Adjust
740103000 300X36
5 bending
004 GB4440
bar
740131000 Nipper
6 160
023 pliers

Disassembly
★The disassembly and assembly work for the
adjustor is a little complex as its parts are both
5. Dismantle cover(C)(629)and take out outer
precise and mini. So it is suggested to replace
circle spring(625), inner circle spring(626)
adjustor ASSY without special circumstances
and spring seat( C)(624). Pull out adjusting
when maintenance. If it is necessary to
ring (Q) (645), guide spring (646) and spring
disassemble, please read the following
seat (644).
dismantle gists before disassembling it.
★Using bolt M4 can take out adjusting ring
★The numbers in () after the parts name are
(Q) (645) easily.
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.

132
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 9. Take out lever (2) (613), and don’t pull out
miss it. pin (875).
★Using nipper can simplify operation
process.

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).
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).

133

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.
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.
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

Assembly 4. Assemble feedback rod block (611).Align

Fastening torque figure the pin (874) with the pin hole of feedback
parts NO. dimension torque N.M rod block and insert it.
412、413 M8 29 ★Insert the pin to the feedback rod block
436、438 M6 12 beforehand will be convenient for operation.
496 NPTF1/16 8.8 ★ Pay attention not to fit wrong direction of
630 M30X1.5 160 the feedback rod block
801 M8 16 5. Assemble the guide shaft (643) into the
802 M10 19 inside hole of the shell.
Assemble in reverse order of disassemble. ★Ensure the guide shaft can move smoothly.
Please note the followings: 6. Insert the pin of press-in rod block
★ The numbers in () after the parts name are (2)(613)into the guide piston groove and
serial NO. of the parts in fig.(JPG0086). assemble rod block (2).
★ Repair the damaged parts and prepare the
new ones.
★ Clean all the parts using cleaning oil and
134
 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).

7. Press the pin of support latch (614) into the

pin hole of rod block (2), assemble support
latch and locating ring (858).

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
8. Insert adjusting pin (651) and assemble hole.
location ring. ★ Caution not to fit wrong direction of spring
★ Be careful not to fit wrong positions for seat.
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).

12. Assemble the cover (C) (629) which is fit

with adjusting bolt (628) (925), adjusting

135
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.

136
137
5.11 Rotary motor ASSY disassembly and elements.
assembly 1. Dismantle the following 7 hoses:
(1) Oil feed hose
Tools (2) Two main oil hoses
No product (3) Oil drain hose
name spec. (4) Two unlocking hoses
. No.
74010500 common
1
0164 box spanner
74010400 inner
S8 GB、
2 0006 hexagon
5356-85
spanner
74011500 single-ende
3 41
0035 d spanner
74011500
4 32-34
0023
74011500 Double-end
5 17-19
0003 ed spanner 2. Dismantle gear oil dranin hose (1) and 14
74011500 motor construction bolt (2).
6 16-18
0032
80-300N.
74011900 torque
7 m
0011 spanner
12.5mm
74011901 SH22D×
8 open end of
0065 32
torque
74011901 SH22D×
9 spanner
0067 41
74012100 Cross 75X5GB
10
0010 screwdriver 1064-89
3. Lift rotary motor. (1) is lift bolt.
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 Multiple way valve weight: 220kg
the pipe orifice and preserve all the sealing Lift screw thread hole: M10X1.5
138
Assembly ★As the parts are precise, so be careful to
• Assemble in reverse order of disassemble. dismantle them to prevent damage. When
★ : Apply as per torque fig. 5-1、5-2. repair it, be careful to avoid the dust get into it
★ Refill the hydraulic oil to specified level and damaging the O-rings and sealing plate.
through the oil port. Start the engine to cycle 1. Tie the motor down with steel cable and
the oil in hydraulic system and then check the use crane to lift it, wash clean and dry it with
oil level. compressed air.
★ Exhaust air and consult the content in 2. Drain working oil in the motor noumenon
section “exhaust air from the parts”in chapter from outlet.
“testing and adjusting”. 3. Put the shaft end of drive shaft (101)
downwards and fix it on the worktable which
Tools is easy to disassemble. Make combining mark
at the combining site of motor noumenon
No product nam
spec. (301) and valve body (303).
. No. e
74010400 S5
1
0004 GB5356-85
74010400 S6
2
0005 inne GB5356-85
74010400 r S8
3
0006 hexa GB5356-85
74010400 gon S14
4
0009 span GB5356-85
74010400 ner S17
5
0010 GB5356-85 ★ Lay rubber plate or cloth when you
74010400 S24 ismantle platform to avoid damaging the
6
0014 GB5356-85 parts.
cros 4. Screw off relief valve (051) and dismantle
s it from valve body (303).
74012100 75X5GB106
7 scre
0010 4-89
wdri
ver
torq
74011900 ue 80-300N.m
8
0011 span 12.5mm
ner

Disassembly
★The numbers in () after the parts name are
serial NO. of the parts in fig.(JPG0152、 ★ When screw off the relief valve, O-ring
JPG0155). Please read the content of part will be damaged. So it must be replaced.
“rotary motor” in chapter “function and 5. Dismantle ROMH oil drain plug(469)from
structure”. valve body(303)，and then take out spring
139
(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).
140
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).
 (491) with hammer and steel bar and take it
out gradually from motor body (301).
★The dismantled bearing can not be used
again.
3) Using slip hammer bearing detacher to
take out column rolling bearing (444) from
valve body (303).

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

plate (124).

★The dismantled bearing can not be used

again.

Assembly
★When take out drive shaft, oil seal may be Fastening torque figure
destroyed by splines. So use plastic tape to parts NO. dimension torque N.M
wind around the splines before take it out. (031-1) G1/4 0.9
Apply the following steps according to 033 M6 12
the actual situations: 051 M33X1.5 177
1) Push out the inner loop of column rolling 151 G1/4 26
bearing with punch. 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.
★It can also use hammer and steel bar to beat ★Before assembling, wipe working oil on
the inner loop. Be careful to beat it with rotary meshing part and bearing.
uniform force to avoid damaging. The ★ Replace in principle the sealing parts, i.e.
dismantled bearing can not be used again. O-ring and oil seal, etc.
2) Slightly beat the outer ring of the column ★Screw up fixed bolts and oil drain spout
rolling bearing from the side of the oil seal plug with torque spanner as per table.1.

141
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). ★ 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).

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.
★ 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).

5. Assemble drive shaft into motor body

(301).

7. Assemble the plunger unit (12l，122) which

142
are placed on plate (123) into oil tank (111),
together with the spline of driving shaft (101).

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

(301).

8. Reset motor body (301)，put one side of the ★Wipe thin grease on O-ring to avoid
oil seal downward. Assemble 4 metal plates breaking the brake plunger when fit it in.
(743) of separator and 3 friction plates (742) 10. Assemble brake plunger (702) into motor
into motor body (301) in order. body (301).

11. Assemble brake spring (712)) into brake

plunger (702).

143
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.
144
★ 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 poor performance.
body (303). ★ 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
5.12 Handle pilot valve disassembly and take it out from the top of the valve shell.
assembly

Tools

No. product No. name spec.

inner
hexag S6
7401040000
1 on GB5356-8
05
spann 5
er
7401150000 double ★If there is a switch; take down wire (456)
2 22-24
24 solid beforehand through the hole of valve shell.
7401150000 spann 4. Screw off lock nut (315) and adjust nut
3 27-30
25 er (312) by spanner and take down the whole
Cross handle body.
7401210000 75X5GB10
4 screw
10 64-89
driver

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
5. Place spanner on the surface between
avoid parts collision and falling down.
adjust nut (312) and cam (302), unscrew
★ Do not consider the parts are very tight so
adjust nut, take down the nut and cam, screw
to beat it at will or distort it for release, or
off the joint to the left direction by clamp.
burr or damage will occur for the parts, which
will cause hard assembly, oil leakage and

145
 ★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.
8. Because of the act of return spring (221),
the pin may fly off when pull it out.
146
★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 (121) to tighten intake plate on shell body
sleeve (216), spring (241) and washer 2(217). (101). Screw up the inner hexagon bolt (125)
Pull out push rod (212) from bushing (211) with specified torque.
and take down O-ring (214).

★Pay attention the holding position of spring

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.
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.

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
4. Place the bottom of valve rod uprightly on
level worktable, press spring guide sleeve,
Assemble in reverse order of disassemble. insert two washers 1(215) into spring guide
1. Assemble bearing bush (131) and O-ring sleeve. Assemble spring (221) and
(122) into pump shell (101). pressure-relief valve module into shell body.

2. Use inner hexagon bolt (125) and lock ring

147
★ 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).
8. Assemble cam (302) into joint.

★Wipe butter on the surface of pressure bar.

★Screw in cam until it contacts with all the
6. Assemble bushing module into pump.
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.

★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.
★ 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.

148
11. Assemble rubber jacket (501) and lock 14. Assemble the bottom of corrugated pipe
nut (315). Thus, assembly for handle module on shell body. Fill in rust preventive from
has completed. each oil port and plug it with choke plug.

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.

149
5.13 Multiple way valve ASSY disassemble
and assemble

Tools

N product
name spec.
o. No.
S8
740104000 inner
1 GB5356-
006 hexagon
85
Common 2． Dismantle the spacing plate (1) of the
740105000
2 box engine.
164
spanner
740115000 single-end
3 41
035 ed spanner
740115000
4 32-34
023
Double
740115000
5 –ended 17-19
003
spanner
740115000
6 16-18
032
80-300N.
740119000 torque
7 m 3． Dismantle oil return steel pipes and the
011 spanner
12.5mm following hoses:
740119010 SH15D×1 a) To bucket cylinder hose
8 open head
059 7 b) To rotary motor main hose
of torque
740119010 SH22D×4 c) Right oil return steel pipe
9 spanner
067 1 d) Rotary motor feed pipe
e) To arm cylinder hose
Disassembly f) Left oil return steel pipe
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
4． Dismantle pipe clip (1) and left/ right
upper cover (1)of the multiple way valve.
travel hoses (2).

150
 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． Dismantle hose(1)of P1 and P2 ， to 5.14 Travel motor ASSY disassembly and

operation valve, pilot hose (2) of solenoid assembly
valve, to negative flow feedback pipe(3)of
Special tools
main pump and to oil return hose (4) of
hydraulic cylinder. No
product No. name spec.
.
74010500016 socket
1
4 wrench
74011500002
2 41-46
6 double
74011500000 end
3 24-27
7 solid
74011500000 wrench
4 17-19
3
74011900001 torque 80-300N.m
5
6． Dismantle the steel pipes around multiple 1 wrench 12.5mm
way valve from the top down, and dismantle 74011901006
6 open SH19D×27
the mounting screw of main valve and under 3
end of
carriage, fit with lifting ring (1) and lift it with 74011901005
7 torque SH15D×17
lifting equipment. 9
spanne
SH22DX4
8 74011901007 r
6

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
multiple way valve weight: 195kg avoid making mistakes when refitting and
Lifting tap hole: M10X1.5
151
seal the pipe orifice.
1.Dismantle sprocket wheel(1)，refer to
chapter “dismantle sprocket wheel”in this
manual.
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
2. Dismantle cover (1). No
product No. name spec.
.
inner S8
74010400000
1 hexago GB5356-8
6
n 5
74010500016 socket
2
4 wrench
74011500002
4 double 32-34
3
end
74011500000
5 wrench 17-19
3
3. Dismantle 4 travel motor hoses (1) and 18
torque 80-300N.m
mounting bolts, then lift. 6 740119000011
wrench 12.5mm
open
74011901005 end of
7 SH15D×17
9 torque
spanner

Disassembly
Release the residual pressure in hydraulic
circuit. Refer to the relevant contents in
chapter “testing and adjustment”.

travel motor weight: 320 kg ★Conserve well dismantled hoses, pipe

Lifting tap hole: M10X1.5 orifices need to be sealed and sealing
M12X1.5 elements.

152
1. Dismantle the following 6 hoses: 5.16 Hydraulic tank ASSY. disassembly
(1) Oil drain pipe and assembly
(2) Right side travel pipe
(3) Double speed pipe Special tools
(4) Left side travel pipe No
(5)Dismantle catch bolt (5) and 4 product No. name spec.
.
mounting bolts (6). S8
7401040000
1 inner GB5356-
06
hexago 85
n S6
7401040000
2 wrench GB5356-
05
85
7401050001 socket
3
64 wrench
7401150000
4 27-30
25 double
7401150000 end
5 17-19
2. Dismantle the 6 hoses connect central 03 solid
rotary joint with travel motor: 7401150000 wrench
6 32-34
3. Lift it with lifting equipment 23
central rotary joint ASSY: 40 kg 80-300N.
7401190000 torque
7 m
11 wrench
Assembly 12.5mm
Assemble in reverse order of disassemble. 7401190100 SH15D×1
8 open
59 7
★ : Apply as torque fig.5-1、5-2. end of
7401190100 SH19D×2
★ Feed oil to specified level. Start engine, 9 torque
63 7
cycle the oil in system and check the oil level. spanne
7401190100 SH22D×3
★Exhaust air from travel motor refers to 10 r
65 2
“exhaust air of the parts”in chapter “testing
and adjustment” of this manual.
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.

153
 Hydraulic oil: about 185L
2. Dismantle engine cover (1) and brace rod
(2).

6. Dismantle oil return steel pipe (1).

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

7. Dismantle oil water separator(5), diesel

filter(3), engine oil filter(4)，main pump oil
drain hose(2)and spacing plate(1).
4. Dismantle 5 oil return hoses (2), oil return
steel pipe (1) and engine spacing plate (3).

8. Dismantle closed plate at the bottom of oil

tank firstly, and then take apart the inlet hose
5. Dismantle covering part (1) and cover (2). (1) connects with the oil tank.

154
 5.17 Carrier roller ASSY disassembly and
assembly

Special tools

No. product No. name spec.

socket
74010500016
1 wrenc
4
h
9. Lift it with lifting equipment after torque 80-300N.
74011900001
disconnecting the mounting bolts of the 4 2 wrenc m
1
hydraulic oil tanks. h 12.5mm

(1) Assembly

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.
★ 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.
155
★ : Apply as per the torque fig.in 5.2. and guiding wheel (4).

5.18 Thrust wheel ASSY. disassembly and

assembly
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.

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
5.19 Guiding wheel ASSY. disassembly and reverse side of the guiding wheel (4), shaft (5)
assembly and bearing ASS (7).

(1) Special tools

No. product No. name spec.

ball
74021000000
1 hamm 6
6
e2P
imitati
on
5. Dismantle locating pin (8) for easily taking
75040100000 impor
2 down bearing (7) from shaft (5).
6 t
6. Dismantle lining (9) and (10) from guiding
grease
wheel (4).
gun

(2) Disassembly
1. Dismantle locating pin (1) and bearing (2).
2. Dismantle floating seal (3) from bearing (2)
156

(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
157
in range of 5-7 mm.
4. Assemble shaft (5) and bearing (7) ASSY.
on guiding wheel(4).
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.

5.20 Tension device disassembly and

assembly

(1) Special tool

No. product No. name spec.

socket
74010500016
1 wrenc
4
h
torque 80-300N.
74011900001
2 wrenc m
1
h 12.5mm
compr 2. Disassemble tension spring ASSY
3
essor
1) Place tension spring ASSY (1) on
range
4 tool J1. As the tension spring is in big
spacer
assembly load, assemble it correctly to avoid
tensio
danger.
5 n
★ Assembly load of spring: 108.8 KN
device
oil
6 cylind
er
7 pump
guide
8
bolt

(2) Disassembly
1. Dismantle piton ASSY (2) from tension 2) Apply hydraulic pressure slowly to
spring ASSY (1). 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.
158
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.
159
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.
5.21 Sproket wheel disassembly and 5.22 Track shoe ASSY disassembly and
assembly assembly

(1) Special tools (1) Special tools

No product No product
name spec. name spec.
. No. . No.
socket socket
740105000 740105000
1 wrenc 1 wrenc
164 164
h h
torque 750-2000 torque 750-2000
740119000 740119000
2 wrenc N.m 2 wrenc N.m
012 012
h 25mm h 25mm
track
(2) Disassembly press
3
1. Disassemble track shoe ASSY. See “track machi
shoe ASSY disassembly”. ne
2. Rotate working device to 90°，jack up the
chassis with working device and place pad (2) Track shoe ASSY disassembly and tensity
between track frame and track shoe. (steel)
1. Park the machine at the position as the king
3. Dismantle and lift sprocket wheel (1). pin is between idler and carrier roller and on
Sprocket wheel : 40 kg 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) Assembly
• Assemble in reverse order of disassemble.
★ screw thread glue: 1277
★ : Apply as the torque fig. in 5.2.

2． Pull out king pin (2) with tool M.

160
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).

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

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 ★ Before assemble dust seal, wipe butter
assemble track shoe. lubricant Multifak EP2 on the contact surface
★ If track shoe nut is assembled reverse, the with lining.
corner of nut and the surface of connecting ★ If you have road gasket (rubber-type track
rod seat will interfere each other and raise the shoe gasket), replace the track shoe gasket
nut and make it loose. when you find the rubber has worn or broken.
Otherwise, track shoe bolt will be damaged

161
and dismantlement will turn to be difficult.
(3) 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.
5. Pull out main pin (3) with tool M and pin.
(4) 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.

6. Take away tool M，move the machine

forward and pull out pin(2).
7. Disassemble dust seal and spread track
shoe ASSY (4) when move machine forward.

162
★ Press main pin with tool M. The protrude
distance is the nether size a. Main pin
protrudes distance a: 2.5±1 mm

3. Lift rotary bearing ASSY. (2).

★ 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. ★ Rotary bearing ASSY : 315 kg

(3) Assembly
socket
74010500016 • Assemble in reverse order of disassemble.
1 wrenc
4 ★ screw thread glue: 1277
h
★ : Apply as the torque fig. in 5.2.
torque 750-200
74011900001 ★ Put the marking sides of inner race soft
2 wrenc 0N.m
2 area and outer race soft area to the right, and
h 25mm
assemble them on track frame.
imitati
on
75040100000 impor
3
6 t
grease
gun

(2) Disassembly
1. Disassemle rotary table ASSY. See “rotary
ASSY disassembly”.
2. Dismantle the 36 mounting bolts (1) to ★ Rotary bearing : See
disassemble rotary bearing ASSY. recommended grease lubricant brand in 5.2.

163
5.24 Rotary table ASSY. disassembly and central rotary joint as per “central rotary joint
assembly disassembly and assembly”, make necessary
labels and seal the pipe orifice.
(1) Special tools
3. Dismantle 36 rotary table mounting
bolts and rotary table ASSY (16) and lift it
No. product No. name spec.
away.
socket
74010500016
1 wrenc
4
h
torque 750-2000
74011900001
2 wrenc N.m
2
h 25mm
inner
hexag S10
74010400000
on GB5356-
7
wrenc 85
★ Lift the upper carriage ASSY slowly and
h
parallel. Pay attention not to hit the central
rotary joint ASSY.
(2) Disassembly
★ Upper carriage ASSY : 7500Kg
Extend arm and bucket completely, (3) Assembly
lower working device to the ground and turn • Assemble in reverse order of disassemble.
the securing rod to the lock position. ★ screw thread glue: 1277
1. Dismantle 4 hoses (1) of boom cylinder.
★ : Apply as the torque fig. in 5.2.
★ Plug hoses to avoid oil flowing out.
★ 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.
★ Exhaust air
Exhaust air from travel motor. See the content
of “exhaust air of the parts” of chapter“testing
and adjustment”in this manual.

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

164
5.25 Air-conditioning ASSY disassembly 5. Disconnect the electric joints on electric
and assembly mounting plate (2), make necessary marks
and then dismantle electric mounting plate
(1) Special tools (2).
No. product No. name 6. Dismantle the corrugated pipes between
evaporator and the ducts of inner adorn parts,
740105000
3 socket wrench new ducts and evaporator. Dismantle hoses of
164
window scrubber.
740131000
5 wire pliers 200MM
004
plastic handle
740121000
8 Phillips driver 150
011
GB1064-89
plastic handle
740121000 screwdriver
9
016 250X10X1.6
GB10639

(2) Disassembly
7. Dismantle the two hoses (5) from drying
Firstly disassemble the cable of negative
bottle to evaporator and from compressor to
terminal (-) of accumulator.
evaporator, make necessary mark and seal
1. Drain cooling water.
pipe orifice. Dismantle electric joint (6) of
Cooling water: about 23L
evaporator and make marks.
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.

8. Dismantle the two water pipes (7) between

evaporator and engine. Dismantle fixed bolt
(8) of evaporator.

165
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.
★ 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.

166
6. Figures and others
6.1 Hydraulic system schematic diagram

167
6.2 Electrical system drawing

168