onais HYDRAULIC SYSTEM 61 STRUCTURE AND FUNCTION Hydraulic piping (031E-18, D31P-18A, D37E, P-2) Hydraulic controt (031E-18, D31P-18A, 0376, P-2) Hydraulic circuit system (031€-18,031P-18A, 0376, P-2) . Hydraulic circuit diagram (031E-18, D31P-18A, 0376, P-2) Hydraulic piping (D31P, PL, PLL-18) Hydraulic control (031P, PL, PLL-18) Hydraulic circuit system (031P, PL, PLL-18) Hydraulic circuit diagram (031P, PL, PLL-18) Hydraulic piping (0318, 0-18) Hydraulic control (0318, Q-18) Hydraulic circuit system (0318, 0-18) Hydraulic circuit diagram (0315, 0-18) Hydraulic tank and filter Hydraulic pump Hydraulic control vaive (031-18, 031P-184, D37E, P-2) Hydraulic control vaive (031P, PL, PLL-18) Hydraulic control valve (0318, 0-18) Hydraulic lever operation (031E, P, PL, PLL-18, 031P-18A, D37E, P-2) Hydraulic lever operation 0318, 0-18) Hydraulic cylinder {031E-18, D31P-18A, D37E, P-2) Hydraulic cylinder (031P, PL, PLL-18) Hydraulic eviinder (0315, Q-18) .HYDRAULIC PIPING D31E-18, D31P-18A, D37E, P-2 OUTLINE ‘+The oil in hydraulic tank (1) is sucked up by hy- raulic pump (2) installed to the engine, and is it to hydraulic control vaive (3) ‘The hydraulic control valve sets the pressur the circuit to 175 kg/em?. It switches the flow of cil to lift cylinder (4), angle cylinder (5), or tit cylinder (6) to operate the blade according to the ‘movement of the work equipment control lever. If the hydraulic control valve is at the "HOLD" po- sition, the oil enters hydraulic fiter (7) installed to the hydraulic tank and returns to the hydraulic tank. 61-2 onaie Hyarauti tank Hyeraut pump ee Hyraut contol vave e Blade It evinder Blade angle eyinder Blade tit eyinder Hydrate fter i 2 3 4. 5. 6. 7, The hydraulic fiter is @ cartridge type with 2 filtering precision of 10, and a maximum fi ing rate of 100&/min, and the normal pressure set to 1.5 kg/cm’,on1aie HYDRAULIC CONTROL D31E-18, D31P-18A, D37E, P-2 1 2. 3. 4 ‘Work equipment control lever (For blade itt anc 4) ‘ock lever Hydraulic control valveHYDRAULIC CIRCUIT SYSTEM 031E-18, 031P-18A, D37E, P-2 & POWER ANGLE AND TILTDOZER + Engine running, hydraulic control lever in “HOLD”. 18 = a tl] Aft baer 1B SF i 10- 1 3 4 = tS a Woes — Te ell f F : ee bt} | F wf a phealtslaoe5 ly y El | Ty =e a il 5 16: ——] —f 16 é i | 7d aie =e FS re 1 '@D CTT) Frrar903eHYDRAULIC CIRCUIT DIAGRAM 0s1E-18, 031P-18A, D37E, p-2 POWER ANGLE AND TILTDOZER * Engine running, hydraulic control lever in “HOLD”, —————— TTT pen Love aie 2 AHIEAI EL xe & 1s AGH x De ie LE * AEUIESE ssc oy racing se preset] Po pressure wkgen Caw Tokar 2 iM iis ‘tne a 2950 [ D57E2 Seri No, 2501 and up 1 ‘D37P2 Seria No. 2001 and vP 9552 /min Engine at 2800 rpm saree 1, Hydraulic tank 9. Blade tt cylinder 2. Hydraulic pump 10. Check valve 3. Main reliet valve 11, Blade lft valve spool 4. Check valve 12. Suction valve for blade lower 5. Blade angle valve spoot 18. Blade lift cylinder 6. Blade angle cylinder 14. Hydraulic fitter 7. Check valve 18. Air bleeding valve 8. Blade tit valve spoo! 16. Suction safety valve 61-5HYDRAULIC PIPING D31P, PL, PLL-18 OUTLINE ‘+ The oil in hydraulic tank (1) is sucked up by by- draulic pump (2) installed to the engine, and is sent to hydraulic control valve (3) ‘The hydraulic control valve sets the pressure in the circuit to 178 kg/emt. It switches the flow of oil to lift cylinder (4), or tilt cylinder (6) to operate the blade according to the movement of the ‘work equipment control lever. 1 the hydraulic eantrol valva ia at tha “HOLD” po- sition, the oil enters hydraulic filter (6) installed tank and returns to the hydraulic Hydraulic tank Hydraulic pump Iroulio control valve Blade it cylinder 5. Blade tt cylinder Hydraulic filter 1 2. 4 5. 6 ‘The hydraulic fitter is a cartridge type with a filtering precision of 10, and a maximum fitter- ing rate of 100%/min, and the normal pressure is setto 1.5 kg/em. ‘The total capacity of the hydraulic tank is 49 liters, with the amount of oil inside the tank set 10.33 litres. o1aieHYDRAULIC CONTROL D31P, PL, PLL-18 Bivlto 1. Work equipment control lever or 3. Hydraulic control valve 61-7HYDRAULIC CIRCUIT SYSTEM s1P, PL, PLL-18 ‘* Engine running, hydraulic contro! lever in “HOLD”. 6 Fiiaie035 61-8HYDRAULIC CIRCUIT DIAGRAM sip, pL, PLL-18 ‘Engine running, hydraulic control lever in “HOLD”. 10 a 6 A i : RH. tilt AP 2 3 M 1. Hydraulic tank 7. Check valve 2. Hydraulic pump 8. Blade lft valve spool 3. Main relief valve 9. Suction valve for blade lower 4. Chack valve 10. Blade lift cylinder 5. Blade tit vaive spool 11. Hydraulic fiter 6. Blade ttt cylinder 61-9HYDRAULIC PIPING D31s, 0-18 ‘OUTLINE +The oil in hydraulic tank (1) is sucked up by hy- d,> 4, >; ‘+ When the cylinder is operated, the oil fils charn- bers A, B, and D. However. the surface pressure {d,) of chamber B is larger than the surface pressure (d,) of cham- ber A, so valve (3) is pushed against the body seat and the passage between chambers A and Cis closed, White the hydraulic pressure in chamber A is smaller than the tension of spring (4), poppet (1), is pushed into the seat of valve (3). + When the cylinder is being operated, or when it is at HOLD, and a large shock is applied to the cylinder, momentarily high pressure is formed i chambers A, B, and D. ‘When this hydraulic pressure becomes larger than the tension of spring (4), poppet (1) moves to the right, and the passage between chambers ‘A and C is opened. The hydraulic pressure in chamber A is relieved to chamber C and the hy- dy, valve (2) ia not actuated, Poppet Valve body Valve 4. Safety valve spring 5. Piston 6. Suction valve spring 61-23FLOW OF OIL. WHEN SUCTION VALVE IS ACTUATED + When negative pressure is formed in the cylinder Circuit, the hydraulic pressure in chambers A and 3 B also becomes negative pressure. When this heppens, the hydraulic pressure in chamber € becomes relatively higher. ‘Therefore, the hydraulic pressure in chamber © becomes the surface pressure dy — d, and acts ‘on vaive (3). At the point where this surface pres- = sure becomes greater than the tension of spring (6), valve (3) moves to the right, the passage be- tween chambers C and A is opened and the cil in ruiateoss the tank drain circuit is supplied to the cylinder Circuit to prevent negative pressure = ornare 61-24HYDRAULIC LEVER OPERATION 031€,p, PL, PLL-18, D31P-18A, D37E, P-2 POWER ANGLE AND TILTDOZER BLADE LIFT AND TILT CONTROL LEVER IN “LOWER” ‘* The diagram shows the D31E-18, D31P-18A and D37E, P-2, but the explanation of the operation for the D31P, PL, PLL-18 is the same. 8 5 a é 2 1 1. Hydraulic tank 7. Check vane 13, Blade lit oyinder 2: Hydraulic pump 8. Blade tit valve spool 14. Hydraute iter 3. Mainrebit valve 9 Blade sit eyinder 18, Ai bleeding valve 4. Check valve 10. Check valve 16. Suction safety valve 5. Blade angle valve spool 11. Blade ft valve spoo! 6. Blade angle cyinder 12. Suction valve fr blade lower & 61-26 ®onaie POWER ANGLE AND TILTDOZER BLADE LIFT AND TILT CONTROL LEVER IN “LOWER” 3 T — Ss = 2 13. = \——_6———_ 11 pee IT oe ma AHEM X i 10 Ps ph ‘ x t to a ral | Ina on " AUT XI 6 aw. [eh 6 H 4 5 tH Anae| | [Ra Angle Pts: Xb 23 ir 2 7 os saaxe so1eimin b me Ope see, CORT Goa ta Bot oar] 1 Barra Sra An tons wot [Bete s00 on rroveouen rowor on nen the Blade contol lever is moved to the When tis happens ifthe it yingeris extended "LOWER" positon Ift spol (11) moves to the tuddenty because of the weight of the Bld ane there wil be a shortage of ol rom the pump and when thi happens, the pump por P and ft repstve.preeeure wil form atthe eyindor Sader bottom port Ay an the tank por and fetom end itteyinder heed port, ae connected ‘Therefore, suction valve (12) opens, end ol a + The’ pransanzed of fom the. pump_pesses tucked in rom the dain cuit te prevent nega through angle spect (S) and tit spoo! (snd tie prsaure trom forming Inthe ckcult atthe pusnet open check vai (0) then gows Tron tyncer boom end the It spool and enters the bottom end of iit + When the Ifteyinder reaches the end of is evlnder 3, stroke, the hyeroule pressure in the cult ees + When the hydraulic pressure inthe circuit rise, to the set pron the If eyinder extended and the bode is tmainreet valve) Towered ‘At the same time, the oil atthe lift cylinder head is pushed out by the cylinder piston, returns 10 the lift spool ands drained to the hydraulic tank.Bs POWER ANGLE AND TILTDOZER BLADE LIFT AND TILT CONTROL LEVER IN “LEFT TILT” % The diagram shows the D31E-18, D31P-18A and D37E, P-2, but the explanation of the operation for the D31P, PL, PLL-18 is the same. 8 onais, Frraten4o 1. Hydraulic tank 7. Check valve 13, Blade lft cylinder 2. Hydraulic pump 8. Blade tit valve spool 14, Hydraulic Fiter 3. Mein rei valve 8. Blade tit cytinger 1b. Air bieeaing valve 4. Check valve 10. Check valve 16. Suction safety valve 5. Blade angle valve spool 11. Blade lift valve spool 6. Blade angle cylinder 12. Suction valve for blade lower 61-28 ®nate POWER ANGLE AND TILTDOZER BLADE LIFT AND TILT CONTROL LEVER IN “LEFT TILT” Float _Lower f x} i 280 sgt 18 ot! | | ao are Wel X 250 jem? Set pressure b= 175 glen" 1¢ FLOW OF OIL When the blade control lever is moved to the “LEFT TILT” position, tit spool (8) moves to the Fight. ‘When this happens, the pump port P and tit cylinder bottom port A; and the tank port T and tittoylinder head port B, are connected. The pressurized oll from the pump passes through angle spool (5) and pusher open check valve (7), It then goes from the tit spool and ‘enters the bottom end of tilt cylinder (9). 2 MESA) sacs sen eymin 1 Cracking erestre To gem! 7! 4 (Engine at 2.360 rpm) | Bin sovaine arta | 95.5¢/min : ‘When the hydraulic pressure in the circuit ris the tlt cylinder is extended and the biade is tted to the left. At the same time, the oil at the tit cylinder head is pushed out by the cylinder piston, returns to the tlt spool and is drained to the hydraulic tank. ‘When the tit cylinder reaches the end of its etroko, the hydraulic proceure in the circuit rises to the set pressure and the oil is relieved from ‘main relief valve (3) 61-29 @POWER ANGLE AND TILTDOZER BLADE ANGLE CONTROL LEVER IN “LEFT ANGLE” 1. Hydraulic tank 2. Hydraulic pump 3. Main relief valve 4. Check valve 5. Blade angle valve spool 6. Blade angle cylinder 61-30 ® 7. Check valve 8. Blade tit valve spool 9. Blade tt cylinder 10. Check valve 11. Blade lift valve spool 12. Suction valve for blade lower uu Friatoost- 13. Blade lift cylinder 14, Hydraulic filter 16. Air bleeding valve 16. Suction safety valve ornate,POWER ANGLE AND TILTDOZER BLADE ANGLE CONTROL LEVER IN “LEFT ANGLE” 13 : wie || Jan re =X : jem! é <3 eure th ne tes f= sc ee Enaaltt ae ‘ a dy ls MAE) gare sein BO ws rcey Ld] (EE Seri No 250) and up (03762 Seral No. 2001 and eE8e min Engine at 2.500 rpm J FLOW OF OIL ‘+ When the blade control lever is moved to the The oil pushes back the piston of the left angle “LEFT ANGLE” position, angle spool (6) moves cylinder to retract the left angle cylinder and tothe right. angle the blade to the left. When this happens, the pump port P and right ‘At ine same time, tne ol at the left angle cylinder angle cylinder bottom port A; and the tank port bottom returns to the angle spool and is drained T and left angle cylinder bottom port B, are to the hydraulic tank. connected. ‘+ When the right angle cylinder reaches the end of +The pressurized oil from the pump pushes open its stroke, the hydraulic pressure in the circuit check valve (4). t then goes from the angle spool rises to the set pressure and the oil is relieved ‘and enters the bottom end of right angle cylinder ‘from main relief valve (3) ©). ‘+ Priming valve (16) is installed for adjusting if the ‘+ When the hydraulic pressure in the circuit rs left and right angle cylinders do not reach the the right angle cylinder is extended fend of thaie strokes at tha game time. {At the same time, the oil at the right angle cylin- {der head is pushed out by the cylinder piston and {9008 to the head end of left angle cylinder (6). 61-31 @HYDRAULIC LEVER OPERATION 031s,0-18 BUCKET CONTROL LEVER IN “LOWER” & 3S 1. Hydraulic tank 8. Bucket dump cylinder 2. Hydraulic pump 9. Check valve 3. Main elif valve 10. Bucket lft valve spool 4. Check vab 111. Suction valve for bucket lower 5. Bucket dump valve spoo! 12. Bucket it cylinder 6. Safety valve for bucket dump 13. Hydraulic filter 7. Safety valve for bucket tt 61-32o1taig 3 Set pressure J Po'tgrem f—7 175 igen ‘+ When the bucket control lever is moved to the “LOWER” position, lft spool (10) moves to the right When this happens, the pump port P and litt cylinder head port A, and the tank port T and lift cylinder bottom port B, are connected. ‘+ The pressurized oil from the pump passes through dump spool (5) and pushes open check value (@). It than goes from the lift spool and enters the head end of lft cylinder (12). + When the hydraulic pressure in the circuit rises, the lift cylinder is retracted and the lift arm and bucket are lowered. ‘At the seme tine, the oll at the lft cylinder bottom is pushed out by the cylinder piston, re- ‘tums to the lift spool and is drained to the hy- ) When this happens, ifthe lit cyinderis retracted suddenly because of the weight of the load, or lift arm and bucket, there will be a shortage of oil from the pump and negative pressure will form at the cylinder head end. Therefore, suction valve (11) opens, and oil is sucked in from the drain circuit to prevent nega- tive pressure from forming in the circuit at the cylinder hoad end, When the lift cylinder reaches the end of its stroke, the hydraulic pressure in the circuit rises to the set pressure and the oil is relieved from main relief valve (3). 61-33BUCKET CONTROL LEVER IN “DUMP” e 2 @ df ws aot _4 i" 7 oot : a & pa as - é : F 11318085 1. Hydraulic tank 8. Bucket dump cylinder 2. Hydraute pump 98. Check valve 3. Main elie valve 10, Bucket it valve spoo! 2. Chookalve 11, Suction vove for bucket lower 5. Bucket dump valve sp001 12, Bucketitoyinder 6. Safety vave for bucket dump 18, Hydraulic ter 7 Safety valve for bucket tit 61-34& nai 12 2 TET XE 9 = 7 L}- 4 las. set sraire: xy a ne) vos Bat. se > FEE Y portscrt 3 IPs Stacking sa geet | mer Le 115 igiem™ - 8 FLOW oF on ‘When the bucket control lever is moved to the “DUMP” position, dump spool (5) moves to the Fight. When this happens, the pump port P and dump cylinder bottom port A; and the tank port T and ‘dump cylinder head port B, are connected ‘The pressurized oil from the pump pushes open ccheck valve (4), It then goes from the dump ‘spool and enters the bottom end of dump cylin- der (8). When the hydraulic pressure in the circuit rises, the dump cylinder is extended and the bucket is tipped forward, [At the same time, the oil at the dump cylinder head is pushed out by the cylinder piston, returns to the dump spool and is drained to the hydraulic tank. When this happens, if the dump cylinder is ex- tended suddenly because of the weight of the load or bucket, there will be @ shortage of oil from the pump and negative pressure will form at the cylinder bottom end. ‘501.038: 90,1 imi (Engina at 2380 "pm 1 ) ‘Therefore, the suction function of safety valve (6) is actuated, and cil is sucked in from the drain circuit to prevent negative pressure from forming in the circuit atthe cylinder bottom end. If external force is applied to the dump cylinder ‘and the pressure in the circuit exceeds 100 kg/em®, safety valve (6) acts to relieve the cil, so the pressure in the circuit does not rise any further. ‘+ Therefore, even if the dump cylinder reaches the tend of its stroke when the bucket is dumped, the hydraulic pressure in the circuit does not rise to the set pressure of main reli valve (3) + However, the set pressure of safety valve (7) in the bucket tit circuit is 195 kg/em!, so when the bucket is tilted if the dump cylinder reaches the fond of its stroke, the hydraulic pressure inthe ci cuit rises to the set pressure of main relief valve (3) (178 kg/cm*) and the oll is relieved from the ‘main reli valve. 61-35HYDRAULIC CYLINDER 031-18, 031P-18A, D37E, P-2 1. BLADE LIFT CYLINDER 2. BLADE TILT CYLINDER 61-36 onaie‘<3, BLADE ANGLE CYLINDER ornare 1, Peton rod ouTUNE 2: Cynder head + Each hydrauic cylinder has » reciprocal motion 3. Cylinder piston. The dimensions end stokes are es 4. Piston Shown below. 2. Piston nut 6. Bushi sim 7. Wearing nen [ tien] Aroeat 8. Pistonring Ocae drar 9. Bushing _of piston rod 40 40 “0 10. Bushing Cynder bore | 0 Piston woke ee Mes eee 1300 | mia | tno Win dete a between ne 408 ne With eros Wi across rina " 61-37,HYDRAULIC CYLINDER 0s1P, pL, PLt-18 : 1. BLADE LIFT CYLINDER @ Em I 1 2 3 5 £ ie) / / [ | 9 8 7 6 2 3 61-38orate, OUTLINE + Each hydraulic cylinder has @ reciprocal motion piston. The dimensions and strokes are as shown below. Uren or ‘Guise damater Stpatonrea 4 “0 Cvlnder bore Piston stroke 250 120 Tax ditance Between pine 1,360 790 ‘Win. distance between pe With scree fais 6 a Piston rod. Cylinder head Cylinder Piston Piston nut Wear ring Seeaxogpens 61-39HYDRAULIC CYLINDER 0s1s, 0-18 1. BUCKET LIFT CYLINDER 2. BUCKET DUMP CYLINDER En 61-40 5114i OUTLINE + Each hydraulic cylinder has a reciprocal motion piston. The dimensions and strokes are as ‘shown below. tutteyt ump evt ‘Guisise diameter Stpictonred 50 45 Cyl bore 109 Piston stoke 950 595 between poe 10 1.880 ‘Min diane between ns 1.080 1288 ‘Wn across fats ot piston nt 50 Piston rod Cylinder head Cylinder Piston Piston nut Bushing Wear ring Piston ring Bushing Buching 61-41011418 br PP b HYDRAULIC SYSTEM e 62, TESTING AND ADJUSTING Standard for testing and adjusting 62.2 Testing and adjusting too! lst 25 Measuring and adjusting oil pressure 26 Measuring oil temperatur 7 Bleeding air from angle cylinder circuit oe ‘Troubleshooting 29 When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety pins and block the tracks. When working in groupe, use agreed 10d porsone noar the machine. ‘When checking the water level in the radiator, wait for the water to cool, Do not remove the radiator cap while the water is hot. Boiling water may spurt out 'e careful not to get caught in rotating parts. Bleeding air from hydraulic cylinder. ‘After replacing or installing hydraulic cylinders or hydraulic piping, bleed the air from the hydraulic ¢ dors as follows: 1. Start the engine and run at idling for about § minutes. 2. Run the engine a low idling, and raise and lower the work equipment 4 — § times. + Stop the piston rod about 100 mm from the end of the stroke. Never operate it to the relief position. 2 Rum the engine at full thratta and repeat the above pracedure, Then run the engine at low idling and ‘operate the piston rod to the end of the stroke to relieve the circuit.STANDARD FOR TESTING AND ADJUSTING Chatten contin =) ae Wa AAse en | o-= tae routines “Nant a wna on [wn Lowen a-a | eon Bucher oe LOWER ~ FLOAT. orm oan name eon | em noun ae sn sonotewriaey LOWER ~RDAT aone0 | 20-00 Engine sipped FLOAT = N 15-45, 15-45 4 yeaiiecot emer: Engine ow ina win. 155 | win 158 suf anacreowe iramaconnder et comet sas | es= 3 Checker Conditions rit Hyaraul Blade Blade tit Rie blade from ground to 300 mn, From tis postion measure hydreulc t"h" of te beds ‘Starttomansure immediately after sting in positon Mascara the amount of hydra it forthe next 15 minutes. Machine on lev! ground Conta ever n HOLD position Engine stopped | Hydraulic oitemperaure: 45 ~ 55°C Unit 100 vate 100 50 Bucket it arm (0315, 0-18) Bucket (0315, 0-18) From this postion, mesure hycrauke rit of te bucket hinge pin and extension ump cyinder ofthe senna on eve grouns Control teverin HOLD positon Engine stopped yereuc ol temperature: 45 — 55°C 30 100 100ee ee owe |e tee |e : ae my a (Be a eal ANGLE 20 7 «_ nuemainangeacs oon | ao LH. angle fully — FH, angle fully, noes ™ \\fpr 1 ot =) : 4 Menten 0 } cleeseraaaas a g * Hydraulic oil temperature: 40~ 60°C | TAT os 7 2 ‘Ground = rai fly tow so | ae Bite + Machine on level ground us a a : teat «Reta tam 62-4 = 5TESTING AND ADJUSTING TOOL LIST No. ‘Check item Too! Part No. Remarks 1 | Oittemperature Thermiatorkit | 799-101-6000 | 0 — 1,000°c cure Pressure gauge’ 2 | oilpres Hydraulic tester | 799-101-5000 | F650 480 00 kgiem* 1:60 — 2,000 7m 3. | Engine speed Muttitachometer | 799-203-8000 | Digitalaisplay 60 — 19,989 rom ‘Commercially = 4 | Operating force Push-pull scale Ee Commercialy 5 | Stroke, hydraulic dritt | Scale Sa = nt opwal ‘Commercially = 6 |Workequipmentspeed | Stopwatch ace 7 | Pump performance Flowmeter kit | 790-303-1001 = oa bailMEASURING AND ADJUSTING OIL PRESSURE AL Stop the machine on level ground and lower the work equipment to the ground. “AS Loosen the oil filler cap slowly to release the remaining ol pressure in the hydraulic tank 1, Measuring main relief pressure 1) Remove plug (1). 2) Install hydraulic tester A (400 kg/em?) 3). Start engine, operate work equipment con- trol lever, and measure main ralief pressure with eylinder at stroke end, 3 2. Adjusting main relief pressure % If the main relief pressure is not within the standard range, adjust as follows. 1) Remove cap (1), loosen locknut (2), and turn adjustment screw (3) to adjust % To INCREASE pressure, turn CLOCK- WISE. To DECREASE pressure, turn COUN- TERCLOCKWISE, Une turn oF the agjustment screw ad Justs by 248 kg/emé. i 62-6ornate, MEASURING OIL TEMPERATURE A. stop thems work equip ‘on level ground, lower the the ground. BL Loosen the ot titer cap slowly to release the remaining ol pessurein the hydraulic tank. Measuring hydraulic oll temperature 1) Remove oil filer cap. 2). Using thermistor A, measure temperature of oilin hydraulic tankBLEEDING AIR FROM ANGLE CYLINDER CIRCUIT (POWER ANGLE AND TILTDOZER) “A when loosening the plug, remember that it is stil under hydraulic pressure. "oprah tt sow oa peated ‘slowly, oli will spurt out. 1. Loosen the hydraulic tank cap. 2. Raise the blade approx. 400 — 500 mm from ‘the ground. % Raise the angle cylinder to horizontal or higher. Run the engine at low idling Operate LEFT TILT and RIGHT TILT to the end of the cylinder stroke 10 times in turn to fill the ttt cylinder circuit with o 5. Angle the blade to the maximum left angle (re- tract the left angle cylinder) 6. Loosen air bleed valve (1) two turns, air blood plug (2) of the left angle cylin tums. 7. Operate the RIGHT TILT (retract tit cylinder) con- tinuously and when no more bubbles come out with the oil from plug (2), tighten plug (2) 8. Angle the blade to the maximum right angle (re- tract the right angle cylinder) 9. Loosen air bleed valve (3) of the right angle cylin- der three turns. 10. Operate the RIGHT TILT (retract tit cylinder) con- ‘tinuously and when no more bubbles come out ith the ol from plug (3), tighten plug (3) 11. Tighten air bleed valve (1) SRD Vane: 2.5 +0.5 kgm 12, After bleeding the alr, check the hydraulle tank cillevel, then tighten the hydraulic tank cap, nd loosen, three= 6 TROUBLESHOOTING D31E,P,PL-18, D31P-18A, D37E,P-2 1 Blade lacks lifting power and lifting speed is slow co 62-10 Blade does not rise, the front of machine cannot be raised off ground, 2 when lowering the blade ........... 62-11 3, Hydraulic drift of blade lft cylinder is excessive . = 62-12 4. Blade moves unsteadily when leveling the ground. (Control lever at HOLD) 62-13 5. Blade lowers under the following conditions : 62-13 6. Blade lacks tilting power, blade tilting speed is slow. The machine cannot be reised off ground by blade tilting power. ......... 62-14 7. Blade tilt cylinder does not move (Tilting is impossible) cee veceeess 6215: 8. Hydraulic drift of blade tlt cylinder is excessive 62-16 9. Blade lacks angling power, blade analina speed is slow (For power angle and titdozer) .... 62-17 10. Blade angle cylinder does not move (Angling is impossible) (For power angle and tiltdozer)..... vs 6218 11. Blade returns straightly or moves unsteady when loading by angling (Control lever at HOLD) (For power angle and titdozer) 62-19 D318,0-18 12, Lift arm lacks lifting power and lifting speed is slow .... coeeeeeeeees 62:20 13. Lift arm does not rise, the front of machine cannot be raised off around when lowering the bucket .. : : vos 62-21 14. Hydraulic drift of bucket itt cylinder is excessive ... es 62-22 18. Bucket lacks tit back power and bucket tit speed is slow 62.23 16. Bucket dump cylinder does not move (Bucket tlt back is impossible) 62-24 17. Bucket dump cylinder does not move (Dumping is impossible), ‘machine cannot be raised off ground by the dump cylinder corer 62.25 18. Bucket dump speed is slow — — 62-26 19. Hydraulic drift of bucket dump cylinder is excessive vices 62-27 20. Bucket moves up and down along ground and lift arm moves tunsteadily when leveling the ground, (Control lever at HOLD) ......2..2+e+cesessessesses 62-28 21, Lift arm lowers under the following conditions 62.28 22. Bucket moves unsteady when veing the ground with machine traveling in reverse, (Control lever at HOLD) aio - 62-28 23. Bucket dumps 5 ice 2s) 24. Liftarm cannot be raised when bucket dumps fully soeeevese 62:28 25. Operating force of work equipment control lever is heavy coors 62.29 62-91. Blade lacks litting power and lifting speed is slow Check before troubleshooting ee + "ise quant in hyrauti tank normal? + rete travel of hydraulic conta ver nd valve spool normal? Check he rouble Weeniaienee apse age owe soo | coe See BPs] SES" |] Soe | SO vo] roan remy § Tiaras ani einyp oe Woe & 1 | ache titing the blade fully, 2 [ Retinaeeocan een ° SS 3 5 eee 3° fo : 1 3 vwowewner "The following symbols reused to indicate the scion Trossienooring | robe gten ae aca of ue ene Flow mete kit eee aes 62-10 oS 2. Blade does not rise, the front of machine cannot be raised off ground when lowering the blade. ‘Ask the operator the following questions + Didn't the blade move off cuddenly? Seizure and damage to various units. + In this time, was an unusual noise produced? (where did it emanate from?) — Damage to various units. + Was tne blade lifting speed slower than any speed has been obtained so far. —- Wear of parts or flattening of spring, Check before troubleshooting + soll quantity in hydraulic tank normal? + Are the travels of hydraulic control lever and control valve spot normal? varauhe * | remoneand the engine matea, MBO yarouli retire doesnot rat eoine fall ore 2 | Inblade RAISE and LOWER crew ep of ° 7 | Hyareunepresure doesnot ie at engine fll rote en tng ble fly Oe 2 | fetes rors nme rote ai 5 | owing ag opet convo ta to RAISE, evn eS © | Thee eaten pe dachowe rom mearaieoume foo "The folowing symbols ae used to indicate he Beton robe taken when cout of are inom Xe Replace 2 Repair low mater kit Pe san & Rast 62-113. Hydraulic drift of blade lift cylinder is exces: ‘Ask the operator the following questions & * Did the hydraulic drift of ft cylinder suddenly become lage? — Logged dirt in valve or damaged parts. + Did the hydraulic drift of tt ovlinder ‘radualy become large? — Wom parts Chock before troubleshooting + If the rod of control elver is disconnected {rom the control valve spool, is the hydraulic rift of lift cylinder normal? — Bend of rod or seizure of rod bushing, onl te cy TOC a x io,| protien wmway [2] S remeay [ 2) S x 1 ifthe eng trom lift evinder hea is blocked! ° 011418, 2 | Caper and ower svetion valves are interchanged Q aie blade to maximum, remove botom pp 3. | Hitevindersun engine a om ting ena operate Cantal ee to RAISE, comer cut am i] 4 | 01 doesnot come out a iam 3 ° Ths foloning symbols re wae to indicate the action tobe taken when a cause of failure located. X Reploce ‘A: Repair A Aajut : Clee 62-124, Blade moves unsteadily when leveling the ground. (Control lever at HOLD) cs + Check hydraulic drift of blade litt eyinder. Itis above the standard value Go 10 “3. Hydraulic drift of blade tft cylinder Is excessive”, Forming a vacuum in cylinder Itis within the standard value Itis corrected by raising the machine with blade lift cylinder and lowering the machine slowly. + Butifitis frequent Suction valve defective, 5. Blade lowers under the following conditions 1). Blade lowers momentarily when control lever is changed from HOLD position to RAISE position, 2) Blade lowers gradually when contro! lever is at RAISE position with engine stopped, Remedy ex Cause: Check valve for blade control valve defective ornare6. Blade lacks tilting power, blade tilting speed is slow. The mact ground by blade tilting power. Check before troubleshooting + [soil quantity in hydraulic tank normal? + Are the travels of control lever and contro! valve spoot normal? (Chock the trouble le eh hyeoulie pressure peasare 2 opine fl peed when ain he blade fui? “At engine tow iling pod? Noes [ coos eae | coos troubie } tame | [Troube rooting || tntabte | | Zoonng | | Machine Brimetaoe| | itcaum | | Sy mesene| | corece fio.| Probiens ened iraule presure is normal at engine fll hove 2 | when blade ful re ° a | fh sing ose of ice svar epi a a tow ling and opera a edt tt eyinder (For power angie sha titSoze Tit lads ro maximum Fgh, remove head piping from 5 | tserise un crginy esr inn ont epee a Conia ove! to RIGHT TILT. Oi comer out fom Mass nao tt evlinger Ror rag tinaores) 6 | Discharge of nyeralie pump isto smal, ‘Toubienooting | HYertule ter “ols Flow meter kit 62-14 © “The following symbols rewind w indiave the ation robe taken when a cause of aie iocatd, XE Replace A: Repair A: Adjust : Ciean < 57. Blade tilt cylinder does not move (Tilting is impossible) ‘Ask the operator the following questions + Didn't the tilt cylinder move off suddenly? = Seizure and damage to various units. ‘+ Inthis time, was an unusual noise produced? (where did it emanate from?) — Wear of parts of flattening of spring. + Was the blade titing speed slower than any speed has been obtained 80 far. Check betore troubleshooting + soil quantity in hydraulic tank normal? + Are the travels of hydraulic control lever and. ‘control valve spool normal? i puma] contol vave /eyinser fof fefep syerau- J vyerouie Tin ] Fone] ree unwiy [8] x leh x S 1 [ecrmsmmesema esr” To 2 [iisoategaremaes seater T Yolo fo] oO 2 | Seceatsarase agen irareane twee T To | 0 shenratina bide ful 5 | tower to sde when does petit. Grinder des not ° “Tare is most no cicharge from hyarale pum 6 | nen neers on, 212 Trowbiemooting | Hvereue rete tobe taken when «cous of fale located toot | Flow meter it polaeaaa &: Repair A Acjust, © Clean 62-15 o8. Hydraulic drift of blade tilt cylinder is excessive. ‘Ask the operator the following questions *+ Did the hydraulic drift of tilt cylinder sudden- ly become large? — Damaged parts, + Did the hydraulic drift of tt cylinder gradual ly become large? — Worn parts, Check before troubleshooting + If the rod of control lever is disconnected ‘from the control valve spool, is the hydraulic drift of tilt cylinder normal? — Bend of rod cr seizure of rod bushing, Contirmation of trouble + Check for the amount of hydraulic drift compared with “standard value table” ‘when ting Tit blade ro maximam lf, remove hand piping om 1 eacctee! Ie LEETIEY. Oh wien toy end c indo uivevinde. (Fer power gi a titsoze) Tit bios to maximum Fgh, remove head pipig ror 2 | tlveviinee run engine a low ilng snd operate a ‘convo lever to MIGHT TILT, Oi comes aut fam ead end oft evindee oe stright tae) 3 | 1 doesnot come out a items 1 and. oo “The fllowine wnbol re waa ta indice she Aine {tobe taken hen» cause o failure i tcated X= Replace ‘A: Repair A: Aaj, ©: Clean 62-16 onaie,9. Blade lacks angling power, blade angling speed is slow. (For power angle and tiltdozer) Check before troubleshooting + Iscilquantity in hydraulic tank normal? + Are the trevels of control lever and control valve spool normal? Check the trouble at engine fall sped when lifting te Blage fully? No aood Good [At engine low iling weed? veges] ens mom] es fey | sxae” [fame [Tae ++ This table indicates when the right angling is im- possible. When the left angling is impossible, use the tables after replacing RIGHT to LEFT. frank to puma) Conve! [aue] a], fale No. Probleme emer fof [x [8] x/ x] x + | Reseale emus gor norrn areas anmone | Ta]o ‘Hvarauic pressures normal at engine full vane 2 | then raising bine fly ° 2 | Unuwal noise i heard fom hyaraulic pum. ° See porn eae Bao | lating and operate conta ever to RIGHT ANGLE ° Oil comes oot trom bottom end of ght gle evi 5 | Disenarge of hvac pump isto smal o lo angina ed ssi when operating the gana! but hvauie preture Yoo Nah i Tana wnr [The folowing symbols are used to indicts the action ‘Trowwiesnooung | Here tobe taken when caus of fale located, emer X: Replace 4: Reoair 1 Adjust ©: Che 62-17 ©10. Blade angle cylinder does not move (Angling is impossible) (For power angle and tiltdozer) ‘Ask the operator the following questions * Birt the ines move off suddeny? — jure and damage ta various unit «+ inthis time, war ov unuausl noise produced? (where did it emanate from?) —- Damage to various units. + Was the blade angling speed slower than any speed has been obtained wo far? Check before troubleshooting + soil quantity in hydraulic tank normal? + Are the travels of control lever and contro! valve spoo! normal? % This table indicates when the right angling is. impossible. When the left angling is impossi- ble, use the table after replacing RIGHT to LEFT. [ome Consol sass] 7 | Nositcomes out wien th pressure takeot plus emoved, ona the engine canes 2 | inbtednanging crouse engine al the 3 | Hyaraute presure does nor ize at engine full throttle wen rasng ble fly. ‘Remove benim ping am right angie cylin, run «5. | sraeatiom ating ana operate come! over te RIGHT ANGLE. Cylinder doesnot move, but ol Comer out rom bottom endo nant angi eyes, «5 | enuinest low iding and operate control lever to UEET ANGLE: Cynder docs not move, but on comes out ror bottarn snd of et ong inde. There is slmost no azeharge from hydra pump shen thee one rewiesnaonng | Heater 62-18 “The following symbols reused to indies the aeton X Replace ‘A: Repair 1 Aaj i cheen S ontaie,11, Blade returns straightly or moves unsteadily when loading by angling (Control lever at = HOLD) (For power angle and tittdozer) Check before troubleshooting + soil quantity in hydrautie tank normal? + Are the travels of control lever and control vvalve spool normal?’ ornate Ter Bago maxim rahi sae, rae bora 1 | laiiopand operate contrat lever @ RIGHT ANGLE. | O {Gi'comes out om bottom ena. ht ante evi. ‘Se blade 1 ax langle renova ‘Bling ond operate contfal ever to LEPT ANGLE, ° Gi'zamas out rom bottom end fff anal ever, 2 | ot comes outa items 1 and 2 olo Towuevener "Tae folowing symbols ore vied to indicate the acton Trowbletooung | NYS tobe taken when a cause of fale tant Plow mater tie pa raeaee 2: Reosir A Adjute Ci Gieen 62-19 ©12. Lift arm lacks lifting power and litting sj Check before troubleshooting * Is oilquantity in hydraulic tank normal? + Are the travels of hydraulic control lever and control valve spool normal? CCheck the trouble th Sopne fal gpd when iting the Bad ay? No good | Gove ogous | Goo trowie | emain [frou 1 yn thes” |] oonng || Machine i Soe” | [Brine toe a we] rooms reo Jo [8 /xJale]e] x 7 | visite esa atom sengine for moe 2 thon ting Bone he Buck aly sca cal) 5 3 Hyco peer ic normat engine ul rote 2 | wenn bank te bucket Ta ie 2 | nue note hear rom hvac pu ° 1g | Homi ayinaer, run engine tow ing and onal everte False Oi comer ut rom ° | buena of maul pump too sal 2 |o © | ag nego en omg te Si 8 Fie fonowingsynbow ar ied onda ion “eowtetooting | Mrsaue e oe taken wens enuf ales leat, oe %: Repace esonais 13. Lift arm does not rise, the front of machine cannot be raised off ground when lowering the bucket. ‘Ask the operator the following questions ‘+ Didn't the lift arm move off suddenly? — Seizure and damage to various units. ‘+ Inthis time, was an unusual noise produced? (when did it emanate from?) — Damage to ‘various units. /as the lift arm lifting speed slower than ‘any speed has be of parts or flattening of spring, Check before troubleshooting + Isoilquantity in hydraulic tank normal? + Are the travels of hydraulic control lever and control valve spool normal? ‘Check the trouble + Relief oll pressure obtained so far — Wear rere cons uk sss] ee ent | Saemecee nae ene 2 [insemmmeeranarcaee're | [ol o [o [0 3 | sahen titing back the bucket Fully. foals : Sa ole even fedpana ton cic anya 7 | tesiainon redux tonnramicrore To] oweneoung | varie te [The Tatowing wmbols are used wo indica tho action to be taken nena cau of faire ocated. XC: Replace ‘4: Reps A Agus G: Gieen 62-2114. Hydraulic a ‘Ask the operator the following questions + Did the hydraulic drift of lit cylinder sudden- ly become large? — Logged dirt in valve or damaged parts. *+ Did the hydraulic drtt of itt cylinder gradual ly become large? — Wear parts. Check before woubleshooting + IF the rod of control lever is disconnected from the control valve spool, is the hydraulic drift of lift cylinder normal?’ — Bend of rod or seizure of rod bushing Probleme Femedy of bucket lift cylinder is excessive, ‘Rave iit arm to maximum, remove head ppina om Ti@evlindee un angne a ow ing sid opens contol lee’ ta RAISE. Ol come out Wom heed Seal iftevinder (0 08s not come ou at tem 1 ° Hyaraulie rife of it eyinderbocomes normal when Upper an loner suction vals are iterangade 62-22 Ti folowing symbole are ied to vacate the acon tobe taken when a cause of are located X: Replace ‘: Repair A Aajurt C: Clean = 315. Bucket lacks tilt back power and bucket tilt speed is slow. Check before troubleshooting *+ Is oilquantity in hydraulic tank normal? + Are the travels of control lever and control valve spool normal? Check the trouble No goes Gove A engine lowing p86? ‘vo 9000 | Gone ‘no 9000 | coos Trovbie ee |e No.| Probleme Remedy 3 Tiyareue presar lom a engine fll rome Tyaraue prosure normal at engine fll hvore Sima thenrasing the it rfl 23 | Unusat noise i nara from nydautie ume, ° 4 | Gouate convo! ivne 10 TILT em Sotiam endo! dump eying 5 | buena ot auc pumo i woo sna ° fo 6 | cing one of a nora ° Gackt ington a dow nia oun 7 | the contro! lever, but hydraulic pressure is t00 high. I ha Totoning nba wa und to cts ewe ‘Troublesnooting | VGCUNE tester ‘to be taken when a cause of failure is located, =e XC hence nese lowe mene A A: Adjust C: Clean 62-23 o16. Bucket dump cylinder does not move (Bucket tilt back is impossible) ‘Ask the operator the following questions ‘+ Didn't the bucket move off suddenly? — Sei 3nd damage to various uri + In this time, was an unusual noise produced? (where did it emanate from?) — Damage to various units. + Was the bucket titing speed slower than teny speed hes been obteined so fer. —- Wee of parts of flattening of spring, ‘Check before troubleshooting * soll quantity in hydraulic tank normal? * Are the travels of hydraulic control lever and. control vaive spool normal? — 7 ° No.] Problems remedy | & i = awn /8]] 8] 8] x g 5 1 | removed, and the engine is cranked. 9 7 Tha temeesonsovinnoamstamem | Tofo]o| 7 [eracmenemraeenemnromm | Tofo « [Seca ere ef 6 Cylinder does not move, but cil comes out from oI 7 [tessa tomas . wane vener [The Tolowing ambos are used to iaieae the action Trowbleroonng be taken when a cause of fare i ocated footed | eee Xe Repiace ‘A: Repsie 1: Agius, : Cinan17. Bucket dump cylinder does not move (Dumping is impossible), machine cannot be raised off ‘ground by the dump cylinder. Check before troubleshooting = Iscil quantity in hydraulic tank normal? + Are the travels of hydraulic control lever and control valve spool normal? [rome] Conor | Conor vive Naive / “oevinaer Problems vernedy c fe /a c/a = = flee] 1 | removed, andthe sine romase POMBE | O onaie 2 | Hyseatepresre i tow at engine full owe shen ing back the ache aly. "18, Bucket lacks it back power and bucket ti eed i om” 2 | erhen iting back the bucket fully. 4 | tonto re bocket dumm eveune "70 (at baie | Hvaraue presure of book rae {oo high at engine a © | Eylmaer does not move, but on comes out fom’ ° hea end ot cump cylinder, 62-25 ®18. Bucket dump speed low. Check before troubleshooting oS * Is oll quantity in hydraulic tank normal? «re the travels of canto! lver and control valve spool normal? Check the trouble Ieee nyorauie pressure obtained the sting pressure {tengin fal speed hon long he Base aly? uo good Good [At engine low iting speed? ‘No 9008 | Good o00a | Gove trouble. |} tromain |[ trouble: || suenine shooting |] ables” |} anooting | | Machine Bytmerwbie| | cause” || by the abe 7 @ rotons ale 5 We, amen fee /x/ele/e] x : Hydraulic pressure is low at engine full throttle ° 1 | When raising the fe arm fal pee | yee rues act tern Toe 2 | when raising the ift arm fully one, 2. | Uno roe end rom hare pum ° | BamapGiadren negroes {nd operate con iver t9 DUN. Ol comes out ° Ie Sue seer | Bueno mrcape to a ° fo | Resins soot arm proper ° cia pom so an parting he conch 7 | Never, but hycreute pressure higher, a Teowiemooung | Hvsaute ne tobetainanan seve ol rele, eae | eee X: Ropioce ‘A: Repair A dus : Clee 62-2619. Hydraulic drift of bucket dump cylinder is excessive. Ws questions. the operator the foll Did the hydraulic drift of dump cylinder sud- rge? — Logged dirt in v Ask: denly become of damaged parts. + Did the hydraulic drift of dump cylinder grad- ually become large? — Worn parts. F is disconnected Ccheck before troubleshooting +t the rod of contra from the contra valve spool is the hydraulic ditt of dump oyinder normal? — Bend oF ‘odor seizure of rod bushing é/ | s th] } F A f/f] 2 eile] Ff] 2 o/5/ é [sect 2 rotiems fr ee B oml me wony f fe T x 3 Tilt back bucket to maximum, remeve bottom fy) es er cores gee aa ° Ssewemtmnasuiaast argent) Theo du no come ot ait 1 ofo 2 Hyareulie dit of aumpevlinger becomes normal tobe taken when» cau of fale located X Fepiace A: Adjust 62-27 D20, Bucket moves up and down along ground and lift arm moves unsteadily when leveling the ‘ground. (Control lever at HOLD) @ Problems and cause + Check the hydraulic drift of bucket lft cylinder: Itis above the standard value Go to “14. Hydraulic drift of bucket lift cylinder is {tis within the standard value ———— Forming en vacuum in eylinder, itis corected by raising the machine wit it arm (bucket ft cylinder and lowering the machine slow\y 4% Butifitis frequent Suction valve defective. 21. Lift arm lowers under the following conditions. 1) _Liftarm lowers momentarily when control lever is changed from HOLD position to RAISE position, 2) Lift arm lowers gradually when control lever is at RAISE position with engine stopped. Cause: Check valve for bucket lift control valve defective tad 22. Bucket moves unsteadily when leveling the ground with machine tra\ (Control lever at HOLD) ing in reverse. Problems and cause + Check Itis above the standard value. Problems as “19. Hydraulic drift of bucket dump cylinder is large” 6 Itis within the standard value Forming an vacuum in cylind Itis corrected corrected by raising the machine with bucket dump cylinder and lowering the machine slowly, 4% Butifitis frequent Suction valve of bucket dump circuit defective. 23. Bucket dumps 1). Bucket dumps momentarily when control lever is chanaed from HOLD position to TILT BACK position. 2) Bucket dumps gredually when control lever is at TILT BACK position with engine stopped. couse: Check ate for bucket up contol ae dtetie Remedy 24. Lift arm cannot be raised when bucket dumps fully. ‘Cause: Safety valve in dump circuit defective mer cx28. Operating force of work equipment control lever is hi Check the trouble Confirm the trouble in according with the follow- ing table, 7 ge erie waenepea a oer a pressure 3 The following symbol are used to indicate the acon to be taken wien a cau of fares located X: Replace 4: Repair A Adiuet, 1: Cinen 62.29HYDRAULIC SYSTEM 63 DISASSEMBLY AND ASSEMBLY onaie HYDRAULIC PLUMP Removal and installation HYDRAULIC CONTROL LALVE Removal and installation Disassembly (031E-18,D31P-18, 0376, P-2) Assembly (031-18, D31P-18, D376, P-2) Disassembly (031P, PL-18) ‘Assembly (031P,PL-18) Disassembly (0315, 0-18) ‘Assembly (0318, 0-18) BLADE LIFT CYLINDER Removal and instalation BLADE TILT CYLINDER Removal and instal tion BLADE ANGLE CYLINDER Removal and installation Bucket litt eyiinder Removal and installation BUCKET DUMP CYLINDER Removal and Installation HYDRAULIC CYLINDER Disassembly .. Assembly 63- 2 63-2 63-2 63-6 63-8 63-10 63-12 63-14 63-16 63.16 63.18 63-18 63-18 63-20 63-20REMOVAL OF HYDRAULIC PUMP ASSEMBLY “AX Loosen the ol filer cap slowly to release the pressure inside the hydraulic tank. 1. Remove drain plug and drain oil from hydraulic tank, wley Hydraulic tank: Approx. 33. 2, Remove engine side cover. 3. Disconnect pump tubes (1) and (2). (See P1) 4, Remove mounting bolts, and remove hydraulic Pump assembly (3). (See P1) INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 11. Fit O-ring and install hydraulic pump assembly (4). (SeeP1) 2. Fit O-ring and connect pump tubes (1) and (2), (See Pt) 3. Install engine side cover. 4, Tighten drain plug and add hydraulic oll through oil filer to the spacified level §P_ Hydraulic tank: Approx. 33% Run the engine to circulate the ol through the system then check the ol lvel again, REMOVAL OF MAIN RELIEF VALVE ASSEMBLY 1. Remove cover (1). (SeeP2) 2. Remove main relief valve assembly (2) (See P3) INSTALLATION OF MAIN RELIEF VALVE ASSEMBLY 1. Fit O-ring and install main relief valve assembly (2). (SeeP3) ZA Velveassembly: 7 = 1 kgm SED Locknut: 8.5 + 1.5 kgm 2. Install cover (1). (See P2) 63-2 ® REMOVAL OF HYDRAULIC CONTROL VALVE ASSEMBLY Lower the work equipment completely to ‘the ground and atop the engine. Operete the Control levers several times to release the re- ‘maining pressure in the hydraulic piping. 41. Remove floor plate and cover (1), (See P2) 2. Disconnect control rods (2). (See PA) 3. Disconnect tube (3), and remove tube (4). 4. Disconnect tubes (6) and 6). (See P6) 5. Remove hydraulic control valve assembly (7) together with bracket (8). (See P6) INSTALLATION OF HYDRAULIC CONTROL VALVE ASSEMBLY + When connecting the piping, clean all dit and dust from the sleeve nut and nipple contact surface. 1. Install hydraulic control valve assembly (7) together with bracket (8). (See P6) 2. Connect tubes (6) and (6). (See P6) 3. Install tube (4) and connect tube (3) (See PS) FE) Sleeve nut Width across fats 24 mm) 8+ 2kgm Z=E Sleeve nut Width across flats 32 mm) 23 = 3kgm EI Sleeve nut (Width across flats 41 mm) = 3 kgm 4. Connect control rods (2). (See P4) Install cover (1) and floor plate, (See P2) ontaie,oraisDISASSEMBLY OF HYDRAULIC CONTROL & VALVE ASSEMBLY ANGLE CONTROL VALVE ASSEMBLY (See F1) (POWER ANGLE, TILTDOZER) 18. The procedure for disassembly of the angle D31E-18, D31P-18A, D37E, P-2 control valve assembly (35) is the same as the procedure for dissssembly of the tit control LIFT CONTROL VALVE ASSEMBLY valve assembly. (See F1) 19. Remove main relief valve assembly (3). 1. Remove case (1) together with detent (2), plate {@), and snap ring (4), 20. Remove suction safety valve assembly (37). 2. Remove ball (5) FINE DISASSEMBLY OF MAIN RELIEF 3. Loosen plug (6). VALVE ASSEMBLY Loosen the plua while the spool is stil in- (See F3) serted in the body. 21. Remove cap (38) 4. Pullout lft spool (7) from body @). 22, Loosen locknut (39), then remove adjustment 5. Remove plug (9), then remove ball (10) and ‘screw (40). spring (11). * To make the set dimension when assembl- ing the same as when disassembling, check Remove plug (6), then remove retainer (12), the set dimension of the adjustment screw spring (13) and spacer (14) (40) and end face of the holder (42) before removing the nut. 7. Remove plates (15). 2 23, Loosen locknut (41), then remove holder (42) = 8. Remove plate (16) and collar (17). 5 8. Remove plug (18), then remove spring (19) and ‘check valve (20), 10. Remove suction valve assembly (21) TILT CONTROL VALVE ASSEMBLY (See F1) 11. Remove case (22). 12. Loosen bolts (23) * Loosen the bolts while the spool is still in- serted in the body, 13. Pull out ut spool (24) rom body (25). 14, Remove bolt {23} from tit spool, then remove. collar (26), retainer (27) and spring (28). 15. Remove plate (29). 16. Remove plate (30) and collar (31). 17. Remove plug (92). then remove spring (33) and check valve (34), 24, Remove poppet (43), spacer (44), spring (48) and retainer (46) from holder (42). 25, Remove seat (47) from slee 48} 26, Remove plug (49), then remave valve (50) and spring (51) from sleeve (48) + If there is any abnormality in the velve or sleeve, replace the whole valve assembly. These parts are not availabe individually. LIFT SUCTION VALVE ASSEMBLY (See Fa) 21, Remove screw (52) 28. Remove spring (53) and ball (54) from sleeve (68) % If there is any abnormality in these parts replace the whole assembly. These parts are not available individually. SUCTION SAFETY VALVE ASSEMBLY + Do not disassemble the suction safety valve as- sembly because a test stand is required to ad- just the set pressure if the valve has been dis- assembled.F2 atvtLo a 5 i 2 e a 5 a . =“Qo0 j !ASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY {POWER ANGLE, TILTDOZER) D31E-18, D31P-18A, D37E, P-2 Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with en- ine oil before installing LIFT SUCTION VALVE ASSEMBLY (See F4) 1, Assemble ball (58) and spring (83) In sh 68. 2. Tighten with screw (52). FINE ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (See F3) 3. Assemble spring (51) and valve (60) in sleeve (48), an instal plug (4) 4. Fit Oving and bakewup ring, then assemble seat (arin leave (48), 8. Assemble retainer (46, spring (48), spacer (44) and poppet (4) in hoer (42) 6. Fit Oring and assemble holder (42) in sleeve (48), then tighten locknut HD Holder: 4 £ 1 kgm SE Lockout: 7 1 kgm 2. Screw adjustment screw (0) in hor (42) 8. Adjust set dimension of adjustment screw (40) fandand face of holder (42) t0 came cimansion a5 when disassembling, then tighten nut (38), Make the final agustment ater instaing to the machine, and adjust so that the set Drossure is 175 189 kg/cm? +» For datais of me adjustment proceaure, 8 62 TESTING AND ADJUSTING. 8. Fit O-ring and install cap (28) ZED Cap; 35 +05 kgm ANGLE CONTROL VALVE ASSEMBLY (See F1) 10. The procedure for assembly of the angle con- trol valve assembly (36) is the same as the procedure for assembly of the tt contol valve assembly 11, Fit O-ring and install suction safety valve as- sembly(37. G=HE Suction safety valve assembly 5.25 + 0.75 kgm. 12, Fit O-ring and install main relief valve assembly (36). FED Main relief valve assembly: 8521.5 kam + When installing the main relief valve assem- bly, fix with grease (G2-LI) so that the back up ring does not protrude from the outside circumference of the sleeve. 63-6 © TILT CONTROL VALVE ASSEMBLY (See F1) 1. Assemble spring (33) and check valve (34) in body (25}, then ft O-ring and install plug (32) SRD Plug: 11+ 1.5 kgm 14 Press fit dust seal to plate (30), then fit O-ring and inctall collar (31) and plato (30). 15. Fit dust seal to body (25), then fit Oxing and install plate (29). 16. Assemble retainer (27), spring (28) and coll (26) to tit spool (24), then tighten bolt (23) tem porarly 4% Tighten the bolt fully after installing the p00! in the body. ‘Assemble tit spool (24) in body (25). ‘Tighten bott (23). FREI Bolt: 35 £05 kgm 19, Install case (22) LIFT CONTROL VALVE ASSEMBLY (See F1) 20. Fit O-ring and install suction valve assembly 0. =D Suction valve assembly: 5.5 + 0.5 kgm 21. Assemble check valve (20) and spring (19) in body (8), then fit O-ring and install plug (18) SBI Plug: 11-415 kgm 22. Fit U-packing to body (8), press fit dust seal to plate (16), then fit O-ring and install collar (17) ‘and plate (16) 23. Press fit Urpacking, then fit Oving and inst plate (15). 24, Assemble spacer (14), retainer (12) and spring (13) to lift spool (7), then install plug (6) tem- % Tighten the plug fully after installing the ‘spool in the body. 25, Assemble spring (11) and ball (10) to plug (6), then install plug (9). SRD Plug: 0.75 + 0.25 kgm 26, Assemble lift spool (7) in body (8). 27. Tighten plug (6). FEED Plug: 1.5 + 05 kgm 28. Insta bell (5). 29. Assemble detent (2), plate (3), and snap ring (4) to case (1) then install to body. @F2 2 Aa g Re fea) “8 8) ID “—g £3 arte222 isrie23 sr3Fta220 airito 63-7DISASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY (STRAIGHT TILTDOZER) D31P, PL, PLL-18 LIFT CONTROL VALVE ASSEMBLY (See F1) 1. Remove case (1) together with detent (2), plate (3), and snap ring (4). 2, Remove ball (5) 13 Loosen plug (11) * Loosen the plug while the spool is stl in- sertad in the body 4. Pull out lft spool (6) from body (7). 5. Remove plug (8), then remove ball (9) and spr- ing (10) 6. Remove plug (11), then remove retainer (12), spring (13} and spacer (14). 7. Remove plates (15). 8. Remove plate (16) and collar (17) 8, Remove plug (18), then remove spring (19) and check valve (20) 10, Remove suction valve assembly (21) TILT CONTROL VALVE ASSEMBLY (See F1) 11, Remove case (22) 12, Loosen woi(29). + Loosen the bolts while the spool is stil in- serted in the body. 13, Pull out tilt spool (27) from body (28). 14, Remove bolt (23) from tilt spool, then remove collar (24), retainer (25) and spring (26), 15. Remove plate (28). 16. Remove plate (30) and collar (31) 17, Remove plug (32), then remove spring (33) and chock valve (3), Remove main relief valve assembly (35). 63-8 ® FINE DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (See F3) 419, Remove cap (37). 20. Loosen locknut (38), then remove adjustment screw (38). % To make the set dimension when assembl- ing the same as when disassembling, check the set dimension of the adjustment screw (39) and end face of holder (41) before removing the nut 21. Loosen locknut (40), then remove holder (41) 22. Remove poppet (42), spacer (43), spring (44) and retainer (45) from holder (41) 23. Remove seat (47) from sleeve (46), 24, Remove plug (48), then remove valve (49) and spring (50) from sleeve (46). % If there is any abnormality in the valve or sleeve, replace the whole assembly. These parts are not available individually. LIFT SUCTION VALVE ASSEMBLY (See Fa) 25. Remove screw (51) 26. Remove spring (52) and ball (53) from sleeve (64, 4 If thace ig any abnormality in these parts, replace the whole valve assembly. These parts are not available individually.orate, Ft F2 igere224 Ae 8 E WY aFr6226 J u—s »—" — —@ o os 8 od «8 So oS ° nar 0226 artez27ASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY (STRAIGHT TILTDOZER) D31P, PL, PLL-18 # Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oll be- fore instalin. LIFT SUCTION VALVE ASSEMBLY (See Fa) 41. Ascomblo ball (53) and epring (62) in eloove (64) 2. Tighten with screw (51). FINE ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (See F3) 3. Assemble spring (50) and valve (49) in sleeve (46}, and install plug (48). 4 Fit O-ing and back-up ring, then assemble seat (47) in sleeve (48), 5. Assemble retainer (46), spring (44), spacer (43) and poppet (42) in holder (41). 6. Fit O-ring and assemble holder (41) in sleeve (46), then tighten locknut (40). GRE Holder: 4 1 kgm SRE Locknut: 741 kgm 7. Serew adjuctment serow (38) in holder (41). 8. Adjust set dimension of adjustment screw (39) ‘and end face of holder (41) to same dimension as when disassembling, then tighten nut (38) Make the tna agjustment aner instaling t0 the machine, and adjust so that the set pressure is 175 ~ 183 kg/em?. + For details of the adjustment procedure, see 62 TESTING AND ADJUSTING. 8. Fit Oxing and install cap (37). FD Cap: 35.405 kgm 10. Fit O-ring sind intel ain 5). 3 Main relief valve assembly: 85 21.5 kgm * When installing the main relief vaive assem- bly, fix with grease (G2-LI) so that the back- up ring does not protrude from the outside circumference of the sleeve. lief valve assembly TILT CONTROL VALVE ASSEMBLY (See F1) 11. Assemble spring (33) and check valve (34) in body (28), then fit O-ing and install plug (32). SRD Plug: 11 + 1.5 kgm 12. Press fit dust seal to plate (20), then fit O-ring ‘and install collar (31) and plate (3). 12. Fit dust seal to body (28), then fit O-ring and stall plate (23). 14, Assemble retainer (25), spring (26) and collar (24) to tit spool (27), then tighten bolt (23) tem porary * Tighten the bolt fully after installing the ‘spool in the body. 1, Assemble tit spool (27) in body (28) 16. Tighten bolt (23) GRE Bolt: 35+ 0.5 kgm 17. Install case (22. LIFT CONTROL VALVE ASSEMBLY (See F1) 18. Fit Oxing and install suction valve assembly 0, ZED Suction volve aocombly: 6.5 4 0.6 kam 19. Assemble check valve (20) and spring (19) in body (7), then fit O-ring and instal plug (18). Sw Plug: 11+ 1.5 kgm 20. Fit Upacking to body (7), press fit dust seal to plate (16), then fit O-ring and install collar (17) ‘and plate (16) 21. Press fit Uspacking, then fit Oxing and install plate (15). 22. Assemble spacer (14), retainer (12) and spring (13) 10 Me spout (0), dren install plug (11) ter porary + Tighten the plug fully after installing the spool in the body. 23. Assemble spring (10) and ball (9) to plug (11), then install plug (8). GE Plug: 0.75 + 0.25 kgm 24, Azcembie lift 9p00! (6 in body (7). 3. Tighten plug (11), SD Plug: 1.505 kgm 26. Install ball (5). 27, Assemble detent (2), plate (3), and snap ring (4) 10.case (1), then instal to body.= F2 sFrez2s ery srarien9 oF oy “—s ° ° ° aFt6290 arte 63-11 ©DISASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY D315, 0-18 LIFT CONTROL VALVE ASSEMBLY (See Ft) 41. Romove case (1) together with detent (2), plate 2, Remove ball (5) {3 Loosen plug (11) % Loosen the plug while the spool is stil in- sorted in the body. 4, Pull out lit spool (6) from body (7). '5, Remove plug (8), then remove ball (9) and spr- ing (10) 6 Remove plug (11). then remove retainer (121, spring (13) and spacer (14). 7. Remove plate (15), 18, Remove plate (16) and collar (17). 98, Remove plug (18), then remove spring (18) and ‘check valve (20) 10, Hemove suction vaive assembly (21) DUMP CONTROL VALVE ASSEMBLY (See F1) 11, Remove case (22) 12. Loosen bolt (23), * Loosen the bolts while the spool is stl in 13, Pull out dump spool (27) from body (28) 14, Remove bolt (23) from dump spoo (27), then remove collar (24), retoiner (25) and apring (26) 15. Remove plate (29) 16. Remove plate (90) and collar (31) 17, Remove plug (32), then remove spring (33) and check valve (34), 18, Remove main reliet valve assembly (35). 19, Remove dump and tilt back suction safety valve assemblies (36) FINE DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (See F3) 20, Remove cap (37) 21. Loosen lock screw (99) + To make the sot dimension when assembl- ing the same as when disassembling, check the set dimension of the adjustment screw (89) end end face of holder (41) before removing the nut (3A), then remove adjustment 22. Loosen locknut (40), then remove holder (41) 23. Remove poppet (42), spacer (43), spring (44) ‘and retainer (48) from holder (41). 24, Remove seat (47) from sl ve (46) 25, Remove plug (48), then remove valve (49) and ‘spring (60) from sleeve (46) + If there is any abnormality in the valve or sleeve, replace the whole assembly. These parte are not avalable individually LIFT SUCTION VALVE ASSEMBLY (See Fa) 26. Remove screw (51) 2. Remove spring (52) and ball (63) from sleeve (64 + If there is any abnormality in these parts, replace the whole valve assembly. These parts are not available individually. DUMP AND TILT BACK SUCTION SAFETY VALVE ASSEMBLY (See F2-C, D) % Do not disassemble the suction safety valve as sembly because a test stand is required to ad- juet the eot preccure if the valve has besn dis- assembled. be &F2 * A srte233 F3 varrez04 syaFte236 ea aiyiio .o 63-13ASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY 31S, 0-18 Clean all parts, and check for dirt or damage Coat the sliding surfaces of all parts with en- gine oil before insaling LIFT SUCTION VALVE ASSEMBLY (See F4) 1. Assemble ball (53) and spring (52) in sleeve (64) 2. Tighten with screw (61) FINE ASSEMBLY OF MAIN RELIEF VALVE ‘ASSEMBLY (See F3) 3. Assemble spring (50) and valve (49) in sleeve (46), and instal plug (8. 4. Fit Oring ana back-up ring, then assemble seat (ann soove (48) 5. Assemble retaines (I, spring (4, spacer (43) and poppet (42 in holder). 6. Fit Orring and assemble holder (41) in sleeve (48), then tighten locenut (0). SH Holder: 4 £1 kam S35 Locknut: 71 kom 2. Screw adjustment screw (9) in holder (4) 8. Adjust set dimension of acjustment screw (39) and end face of holder (4) to same dimension 235 when isassembiing, then tighten nu (38). + Make the final adjustment ater instaling to the machine, and adat so. that the sat pressure i175 ~ 183 kglem? 1+ For deta of the adjustment procedure, see 62 TESTING AND ADJUSTING 9. Fit Ong and instal cap (37), SS Cap: 35 +05kam 10. Fit O-ring and install dump and tit back suction safety valve assembly (28) 32 Dump and tit back suction safety valve 11. Fit Oxing and instal main relief valve assembly (35. 3 Main clot valve assembly 85+ 1.5kam + When instaling the main reli valve assem biy, fie with grease (G2) so that the back- up ring does not protrude from the outside circumference of the sleeve DUMP CONTROL VALVE ASSEMBLY (See F1) 12. Assemble spring (33) and check valve (34) in ‘body (28), then fit O-ring and install plug (32). SHED Plug: 1141.5 kgm 13, Press ft cust seal to plate (30), then Mh Oving and install collar (31) and plate (20) 14. Fit dust seal to body (28), then fit O-ing and install plate (29) 15. Assemble retainer (25), spring (26) and collar (24) t0 dump spool (27), then tighten bolt (23) temporar % Tighten the bolt fully after installing the ‘spool in the body. 16, Assemble dump spool (271 in body (28) 17. Tighten bolt (23). FSD Bolt: 35 4.0.5 kgm 18, Install case (22). LIFT CONTROL VALVE ASSEMBLY (See F1) 18. Fit Oring and install suction valve assembly (an, ZzE Suction valve assombly: 6 05 kgm 20. Assemble check valve (20) and spring (19) in body (7), then ft Oring and install plug (1) SD Plug: 1141.5kgm 21. Fit Urpecking to body (7), press fit dust seal to plate (16), then fit O-ring and install collar (17) and plate (16). 22. Press fit Upacking, then fit Orring and install plate (15). 22, Assemble spacer (14), retainer (12) and spring (13) to lift spool (6), then install plug (11) tom- poreriy. % Tighten the plug fully after installing the spol inthe body. 24, Assemble spring (10) an Wal () «9 ploy CN, then install plug (8). SHED Plug: 0.75 + 0.25 kgm 25, Assemble lit spool (6) in body (7) 26, Tighten plug (1). SD Plug: 15405 kom 27. Inatall ball (6). 28. Assemble detent (2), plate (3), and snap ring (4) to case (1), then install to bod ontaieF2 sraF1027, £3 4 8 8 —8 ——s ° ° ° rare 13818209 FH 3Fr6296 atyito 63-15,REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY D31E-18, D31P-18A, D37E, P-2 “AS Lower the work equipment completely to ‘the ground and stop the engine. Operate the Control levers several times to release the re- ‘maining pressure in the hydraulic piping, Disconnect hoses (1). (See P1) 2. Sling lift cylinder assembly (2) and pull out pins (3) and (4). (See P1,P2) 3. Liftoff lift cylinder assembly (2) (See P2). (is) Lifteylinder assembly: 30 kg INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY D31E-18, D31P-18, D37E, P-2 1. Raise it cylinder assembly (2), align with mount, ‘then knock in pins (3) and (4), (See P1, P2) 2. Connect hoses (1). (See P1) After bleeding air, check the oil level of hydraulic tank. REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY D31P, PL-18 1. Pullout pin (1). (See P3) 2. Start engine and retract rod, then disconnect hoses (2) (See P3) “a + Stop the engine, operate the control levers several times to release the remaining pres- sure in the hydraulic piping. ‘$ Littorr art cytinaer assembly (3). (566 #4) (is) Lifteylinder assembly: 35 ko INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY D31P,PL-18 Raise lft cylinder assembly (3) and set in mount- ing position, then install. (See P4) 2. Connect hoses (2), run engine and extend rod, ‘then align with mount. (See P3) 3. Knock in pin (1). (See P3) * After bleeding air, check the oil level of hydraulic ‘tank, 63-16 @ REMOVAL OF BLADE TILT CYLINDER ASSEMBLY D31E-18, D31P-18A, D37E, P-2 AS Lower the work equipment completely to ‘* the ground and stop the engine. Operate the control levers several times to release the re- ‘maining pressure in the hydraulic piping. 1. Disconnect hoses (1) and pull out pin (2) of oylin« der bottom end, (See PS) 2. Pull out pin (3) and remove tilt cylinder assembly (4). (See P6) INSTALLATION OF BLADE TILT CYLINDER ASSEMBLY D31E-18, D31P-18A, D37E, P-2 Align tit cylinder assembly (4) with mount, then knock in pin (). (See P6) 2. Knock in pin (2) of cylinder bottom end, then ‘connect hoses (1). (See PS) * After bleeding air, check the oil level of hydraulic tank REMOVAL OF BLADE TILT CYLINDER ASSEMBLY D31P,PL-18 1. Remove cover (1), then and (3). (See P7, P8) 2. Remove cap (4) and pullout pin (5). (See PB) 3. Remove il cylinder essembly (0). (See PB) INSTALLATION OF BLADE TILT CYLINDER ASSEMBLY D31P, PL-18 1. Align tilt cylinder assembly (6) with mount, then knock in pin (6). (See P8) 2. Install cap (4) and connect noses (2) and (3) (See P8) 3. Install cover (1). (See P7) ding air, check the oil level of hydraulico11aisREMOVAL OF BLADE ANGLE CYLINDER ASSEMBLY D31E-18, D31P-18A, D37E, P-2 1. Jack up machine and insert blocks (height: approx. 150 mm, then lower work equipment _assembiy to ground. 2. Remove cover. (SeeP1) 3. Insert block (height: approx. 100 mm) under the cylinder assembly, then pull out pin (2). (See P2) 4, Start engine and retract rod, then disconnect hotes (3). (Gee P3) “AS Stop the engine, operate the control levers several times to release the remaining pres- sure in the hydraulic piping, 5. Pullout pin (4), thon lift off angle oylind biy (5). (See P4) as Cae] Angle cylinder: 26 kg INSTALLATION OF BLADE ANGLE CYLINDER ASSEMBLY D31E-18, D31P-18A, D37E, P-2 1. Align angle cylinder assembly (5) with mount, then knock in pin 4). (See P4) 2. Connect hoses (3), eun angina and extend rod, then align with mount. (Gee P3) Knock in pin 2). (See P2) Install cover (1). (See P1) ‘After bleeding air, check the oillevel of hydraulic tank, REMOVAL OF BUCKET LIFT CYLINDER ASSEMBLY D318,0-18 tae 1. Place stand (D) (height: approx. 800 mm) under the crass bar of lift arm securely. (See PS) 2. Sling litt cylinder assembly, then pull out pin (1) (See PS) 3. Start engine hoses (2). “A Stop the engine, Operate the control levers several times to release the remaining pres- sure in the hydraulic piping. 4. Pullout pin (3), then liftoff lift cylind (4). Ge0P6) CEE tern 4569 assembly 63-18 ® INSTALLATION OF BUCKET LIFT CYLINDER ASSEMBLY D31s,a-18 1. Raise lft cylinder assembly (4) and align with ‘mount, then knock in pin (3). (See P6) 2. Connect hoses (2), run engine and extend rod, then align with mount. (See P6) 3. Knock in pin (1). (See PS) % After bleeding air, check the oil level of hydraulic tank. REMOVAL OF BUCKET DUMP CYLINDER ASSEMBLY D31s,a-18 Lower work equipment assembly to ground securely. 1. Sling dump cylinder assembly, then pull out pin (1). (SeeP7) 2. Start engine and retract rod, then disconnect ‘hoses (2). (See P8) “Af Stop the engine, operate the control lovers ‘+ several times to release the remaining pres- ‘sure in the hydraulic piping. 3. Pull out pin (3), then it off dump cylinder assem- bly (4) (See P8) Dump cylinder: 36 kg INSTALLATION OF BUCKET DUMP CYLINDER ASSEMBLY 0318, 0-18 1. Raise dump cylinder assembly (4) and align with ‘mount, then knock in pin (3). (See P8) 2. Connect hoses (2), run engine and extend rods, and align with mount. (See PB) 3. Knock in pin (1), (SeeP7) S nai,sivitoDISASSEMBLY OF HYDRAULIC CYLINDER & 1, Assembly of cylinder head assembly ASSEMBLY 1) Using push tool, press fit bushing (11). (See Ps ‘Special tools: ‘* Be careful not to deform the bushing when PartNo. PartName | Oy 2) Assemble rod packing (10). (See P5) j7B0-802-10025| Stand u 3) Using push tool, press fit dust seal (9). (See 8 | 790-390-100 | Wrench 1 Pa) 7003021270 | soamioamr tt 4) install snap ring (8). (See 4) 2. Assembly of piston assembly 1. Set cylinder assembly (1) in tool A, then using 1) Using tool D. expand piston ring (7) and tool B, loosen cylinder head assembly 2). Se assemble to piston assembly. (See PS, P3) Pi) 2) Assemble cylinder head assembly to rod (3). 2, Remove piston rod assembly (3) from cylinder 3) Using tool E and Et, instal piston ring {0 assembly (1). (See P2) piston assembly (5), then assemble wear 3. Using tool, ramovn nut 2), then remove piston fing (). (See 7,3) assembly (5) and cylinder head assembly (2) 4) Assemble retainer and install piston assem- from piston rod (See P2) by torod, then assemble nut. (See P2) 44. Remove wear ring (6) and piston rng (7) from piston assembly (8). (See P3) 3. Using too tighten nut (4). (S202) 5. Disassembly of cylinder head assembly 1) Remove snap ting (8), then remove dust sea! a= Piston nut htSeePs) 2), Remove rd packing (10). (S00 P5) tee] aan 83) Pull eut bushing (11) trom cylinder hesd aril | Stille | me (Seors) were | a Ey » & ASSEMBLY OF HYDRAULIC = SIE feast rosea te CYLINDER ASSEMBLY 4. Set cylinder assembly (1) in tool A, then using Special tools too! B, tighten cylinder head assembly (2). (See Pt) PartNo, Part Nam y — = eee} jorey Cylinder head: | 790-502-1002 | Stand 7 B | 790-330-1100 | Wrench 1 Tose mm exept ot Joueerun} tet © | 790-302-1270 | Socket(GOmm) | 1 ose On BD | 700 720 1000 | Expand. 1 ae aa 0 100 80 £ | 796-720-1640 | Ring Yervintroon | «0 =00|60=80 £, | 07281-00908 | clamp 1 F | 796-720-1680 | Ring Sesvinsron:| G | 796-720-1660 | Ring “xevnsedse:| 4 G, | 07281-01159 | clamp 1 * Clean all parts, and check for dirt or damage. Be careful not to damage the rod packing, dust sale oF O-rings when installingS Ps Prisisies 63-21 ®HYDRAULIC SYSTEM e 64 MAINTENANCE STANDARD onan Hydraulic control valve (3-spoo! valve) (D31E-18, DS1P-18A, D37E, P-2) os. 2 Hydraulic control valve (031P, PL, PLL-18) 64. 4 Hydraulic control valve (0318, 0-18) 64. 6 Hydraulic cylinder (031E, P, PL-18, D31P-18A, D37E, P-2) 64. 8 Hydraulic cylinder (0318, 0-18) 64-10 64-11 Hydraulic pump.HYDRAULIC CONTROL VALVE (3-SPOOL) D31E-18, D31P-18A, D37E, P-2 GD 3540.54m 8 = Tel hsm 85 = 15kam 5 Sp 141.500, 5 ‘ 1 % - GD 1.540.54m gm 55 20.54m a w sectonA~A 4 4 4 Ss sttem 7 pars S557 21m Sectond 0. Secton8—8 Sectonc—<¢ Section -E @ ona