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Workshop Manual English: Print N. 604.13.254
Workshop Manual English: Print N. 604.13.254
WORKSHOP MANUAL
ENGLISH
Print N. 604.13.254
31102 60413252
Edition: 2/2003
English - Printed in Italy
Printed by Studio ti
0-1
INTRODUCTION
TO THE READER
• This manual has been written for a skilled - For any question or comment, or in case you
technician, in order to give him the information notice a mistake in this manual content,
necessary to repair this machine. please contact:
0-3
INTRODUCTION
AVOID ACCIDENTS
ATTENTION
0-4
INDEX
INDEX
SPECIFICATIONS
MAINTENANCE
Section 11 - Tools
Section 12 - Standard maintenance time schedule
Section 13 - Maintenance standards and test procedures
SYSTEM
DISASSEMBLING
TROUBLESHOOTING
ENGINE
Section 51 - Engine
OPT
0-5
SAFETY PRECAUTIONS
The following is a list of basic precautions that must 8. Use steps and grab handles when mounting or
always be observed. dismounting a machine. Clean any mud or debris
from steps, walkways or work platforms before
1. Read and understand all Warning plates and using. Always face to the machine when using
decal on the machine before Operating, steps, ladders and walkways. When it is not
Maintaining or Repairing this machine. possible to use the designed access system,
provide ladders, scaffolds, or work platforms to
2. Always wear protective glasses and protective perform safe repair operations.
shoes when working around machines. In
particular, wear protective glasses when using 9. To avoid back injury, use a hoist when lifting
hammers, punches or drifts on any part of the components which weigh 20 kg (45 lbs) or more.
machine or attachments. Use welders gloves, Make sure all chains, hooks, slings, etc., are in
hood/goggles, apron and the protective clothing good condition and are the correct capacity. Be
appropriate to the welding job being performed. sure hooks are positioned correctly. Lifting eyes
Do not wear loose fitting or torn clothing. Remove are not to be side loaded during a lifting operation.
all rings from fingers, loose jewelry, confine long
hair and loose clothing before working on this 10. To avoid burns, be alert for hot parts on machines
machinery. which have just been stopped and hot fluids in
lines, tubes and compartments.
3. Disconnect the battery and hang a “Do Not
Operate” tag in the Operators Compartment. 11. Be careful when removing cover plates. Gradually
back off the last two capscrews or nuts located at
31102 60413252
0-6
SAFETY PRECAUTIONS
and plugs on the machine. Hold a rag over the sure that all heat shields, clamps and guards are
cap or plug to prevent being sprayed or splashed installed correctly to avoid excessive heat,
by liquids under pressure. The danger is even vibration or rubbing against other parts during
greater if the machine has just been stopped operation. Shields that protect against oil spray
because fluids can be hot. onto hot exhaust components in event of a line,
tube or seal failure must be installed correctly.
13. Always use the proper tools that are in good
condition and that are suited for the job at hand. 21. Do not operate a machine if any rotating part is
Be sure you understand how to use them before damaged or contacts any other part during
performing any service work. operation. Any high speed rotating component
that has been damaged or altered should be
14. Reinstall all fasteners with the same part number. checked for balance before reusing.
Do not use a lesser quality fastener if
replacements are necessary. 22. Be careful when servicing or separating the
tracks (crawlers). Chips can fly when removing
15. Repairs which require welding should be or installing a track (crawlers) pin. Wear safety
performed only with the benefit of the appropriate glasses and long sleeve protective clothing.
reference information and by personnel Tracks (crawlers) can unroll very quickly when
adequately trained and knowledgeable in welding separated. Keep away from front and rear of
procedures. Determine type of metal being machine. The machine can move unexpectedly
welded and select correct welding procedure when both tracks (crawlers) are disengaged
and electrodes, rods or wire to provide a weld from the sprockets. Block the machine to prevent
metal strength equivalent at least to that of the it from moving.
parent metal. Make sure to disconnect battery
before any welding procedures are attempted.
0-7
SAFETY PRECAUTIONS
NOTE
31102 60413252
0-8
SECTION 1 OUTLINE
TABLE OF CONTENTS
7
1. GENERAL PRECAUTIONS FOR REPAIRS
1-1
specified.
6) If it is hard to remove a part according to the WARNING
procedure, do not try it by force but investigate the Operation of the hydraulic equipment without filling
hydraulic oil or lubricant or without performing air bleeding
cause.
will result in damage to the equipment.
7) Place the removed parts in order and attach tags
to facilitate the reassembling.
8) Note the location and quantity of parts commonly 3) Perform air bleeding of the hydraulic pump and
applied to multiple locations. slewing motor after loosening the upper drain plug,
starting the engine and keep it in low idle condi-
(3) Inspecting parts tion. Complete the air bleeding when seeping of
1) Ensure that the disassembled parts are free from hydraulic oil is recognized, and tightly plug.
seizure, interference and uneven contact. 4) Perform air bleeding of the travel motor and the
2) Measure and record wear condition of parts and hydraulic cylinders by running the engine for more
clearance. than 5 minutes at low speed without load.
3) If the problem is found in a part, repair or replace it
with a new one.
WARNING
(4) Reassembling hydraulic equipment Do not allow the hydraulic cylinder to bottom on the
1) Turn ON the ventilation fan or open windows to stroke end just after the maintenance.
maintain good ventilation prior to starting the
cleaning of parts.
2) Perform rough and finish cleaning before assem- 5) Perform air bleeding of pilot line by performing a
bling. series of digging, slewing and travel.
3) Remove washing oil by air and apply clean hydrau- 6) Check hydraulic oil level after placing the attach-
lic or gear oil for assembling. ment to the oil check position, and replenish oil if
4) Always replace the removed O-rings, backup rings necessary.
and oil seals with new ones by applying grease in
Checking hydraulic oil level
advance.
Level gauge Oil level lines
5) Remove dirt and moisture from and perform (Level located
degreasing on the surface where liquid gasket to between the two
lines shows
be applied. appropriate
amount of oil)
6) Remove rust preventive agent from the new parts
before use.
7) Fit bearings, bushings and oil seals using special
jigs.
1.4 ELECTRICAL EQUIPMENT
8) Assemble the parts utilizing matching marks.
9) Ensure all the parts are completely assembled after
the work. (1) Do not disassemble electrical equipment.
(5) Installing hydraulic equipment (2) Handle it carefully not to drop and give a shock.
1) Ensure hydraulic oil and lubricant are properly
supplied. (3) Turn the key OFF prior to connecting and discon-
2) Perform air bleeding when: necting work.
a. Hydraulic oil changed
b. Parts of suction side piping replaced (4) Disconnect the connector by holding it and press-
c. Hydraulic pump installed ing the lock. Do not pull the wire to apply force to
d. Slewing motor installed the caulking portion.
e. Travel motor installed
f. Hydraulic cylinder installed (5) Connect the connector and ensure it is completely
locked.
1-2
(6) Turn the key OFF prior to touching the terminal of used depending on the working pressure even
starter or generator. the size of fitting and the total length of the hose
is same.
(7) Remove the ground (earth) terminal of battery • Tighten the fitting at the specified torque. En-
when handling tools around the battery or its relay. sure no kink, tension, interference nor oil leak-
age is recognized.
(8) Do not splash water on the electrical equipment
and connectors during machine washing. 1.6 WELDING REPAIR
(1) Refer repair welding to qualified personnel accord-
(9) Check for moisture adhesion inside the waterproof ing to the appropriate procedure.
connector after pulling it out, since it is hard to
remove moisture from the connector. If moisture (2) Disconnect the ground (earth) cable of the battery
adhesion is found, dry it completely before the before starting the repair. Failure to do so will cause
connection. damage to the electrical equipment.
1-3
2. INTERNATIONAL UNIT CONVERSION SYSTEM
(Based on MARKS’ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)
Introduction (4) Derived Units bearing Peculiar Designations
Although this manual uses the gravitational unit [ Table 3-4 ]
system, if you need SI unit, refer to the QUANTITY UNIT SYMBOL FORMULA
following international system of units. Frequency hertz Hz 1/s
Force newton N kg • m/s 2
are related to this manual : Pressure and Stress pascal Pa N/m2
1. Etymology of SI Units Energy, Work joule J N•m
and Quantity
French :Le Systme International d’ Units of heat
English :International System of Units Power watt W J/s
2. Construction of SI Unit System Quantity of coulomb C A•s
electricity
Base units Electric volt V W/A
Table 3-1
potential
Derived units
of base units difference,
Supplemen Voltage, and
SI units tary units Table 3-3
SI unit Table 3-2 Electromotive
system Derived units
force
Derived bearing peculiar Quantity of farad F C/V
units designations static electricity
Table 3-4 and Electric
capacitance
Prefixes of SI Electric ohm ‰ V/A
(n-th power of 10, where n is an integer) resistance
Table 3- 5 Celcius celcius degree °C (t+273.15)K
temperature or degree
Illuminance lux lx l m/m2
(1) Base Units [ Table 3-1 ] Given hereinafter is an excerpt of the units that
QUANTITY UNIT SYMBOL (5) Prefixes of SI [ Table 3-5 ]
Length metre m MULTIPLI-
PREFIX SYMBOL
Mass kilogram kg CATION FACTORS
Time second s giga G 10 9
Electric current ampere A mega M 10 6
Thermodynamic kilo k 10 3
temperature kelvin K
hecto h 10 2
Amount of substance mol mol deca da 10
Luminous intensity candela cd deci d 10-1
centi c 10-2
(2) Supplementary Units [ Table 3-2 ] milli m 10-3
QUANTITY UNIT SYMBOL micro µ 10-6
Plane angle radian rad nano n 10-9
Solid angle steradian sr pico p 10-12
*
1-4
SECTION 2 SPECIFICATIONS
TABLE OF CONTENTS
2-1
2. GENERAL DIMENSION
2-2
3. WEIGHT OF COMPONENTS
Unit : kg (lbs)
Model E135SR E115SR
Item EVOLUTION EVOLUTION
Machine complete 13,700(30,200) 11,900(26,230)
1. Upper frame assy (including the following :) 7,330(16,160) 6,080(13,400)
1.1 Counterweight 3,490(7,690) 2,340(5,160)
Counterweight (Add-on) 600(1,320) ←
1.2 Cab 210(460) ←
1.3 Engine ※ 368(810) 363(800)
1.4 Hydraulic oil tank ※ 91(200) ←
1.5 Fuel tank ※ 53(116) ←
1.6 Slewing motor (including reduction unit) 110(240) ←
1.7 Control valve 122(270) 114(251)
1.8 Boom cylinder ※ 107(235)×2 84(235)×2
1.9 Pin (2pcs. for mounting boom) 37(82) ←
1.10 Pump ※ 95(210) ←
1.11 Radiator ※ 77(170) 65(143)
2. Lower frame assy (including the following :) 4,450(9,810) 4,140(9,130)
2.1 Slewing bearing 149(330) ←
2.2 Travel motor (including reduction unit) 144(320)×2 ←
2.3 Upper roller 8(18)×2 8(18)×2
2.4 Lower roller 27(60)×12 27(60)×12
2.5 Front idler 70(150)×2 ←
2.6 Track tension adjuster 57(125)×2 ←
2.7 Sprocket 36(79)×2 ←
2.8 Swivel joint 30(66) ←
2.9 Track link with 600mm (24in) shoes assy 870(1,920)×2 760(1,670)×2
Track link with 500mm (20in) shoes assy 730(1,610)×2 680(1,500)×2
2.9.1 Track link assy 290(640)×2 270(590)×2
2.10 Dozer blade (OPT) 470(1,040) ←
2.11 Dozer blade cylinder (OPT) ※ 57(125)×2 ←
3. Attachment 1,920(4,230) 1,680(3,700)
3.1 Bucket assy 380(840) 340(750)
3.2 Arm assy (including the following :) 580(1,280) 490(1,080)
3.2.1 Arm 374(820) 300(660)
3.2.2 Bucket cylinder ※ 90(198) 87(190)
3.2.3 Idler link 12(26)×2 ←
3.2.4 Bucket link 43(95) 35(77)
3.2.5 Pin (2pcs. for mounting bucket cylinder /
2pcs. for mounting bucket) 36(79) 24(52)
3.3 Boom assy (Including the following :) 940(2,070) 850(1,870)
3.3.1 Boom 740(1,630) 680(1,500)
3.3.2 Arm cylinder ※ 149(330) 128(280)
3.3.3 Pin (Mounting arm・Mounting arm cylinder) 29(64) 27(59)
4. Lubricant and water (including the following :) 310(680) ←
4.1 Hydraulic oil 138(304) ←
4.2 Engine oil 11(24) ←
4.3 Fuel 139(310) ←
4.4 Water 18(40) ←
NOTE : Numerical values marked ※ indicate the dry weight.
2-3
4. TRANSPORTATION DIMENSION AND WEIGHT
E135SR LC EVOLUTION
● OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
Type 4.6m (15ft-1in) Boom+2.45m (8ft) Arm+
Item 0.50m3(0.65cu・yd) Bucket+600mm (23.6in) Shoes
Width mm(ft-in) 2,590 (8′6″)
Weight kg(lbs) 13,700 (30,200)
2-4
● OVERALL DIMENSIONS OF BOOM
Type
4.6m (15ft-1in) Boom
Item
Length×Height×Width 4.76×1.39×0.57
L×H×W m(ft-in) (15′7″×4′7″×1′10″)
Type
2.45m (8ft) Arm+0.5m3 (0.65cu・yd) Bucket
Item
Length×Height×Width 4.36×0.81×1.00
L×H×W m(ft-in) (14′4″×2′8″×3′3″)
Type
2.45m (8ft) Arm
Item
Length×Height×Width 3.20×0.61×0.37
L×H×W m(ft-in) (10′6″×2′×1′3″)
2-5
● OVERALL DIMENSIONS OF BUCKET
2-6
E115SR EVOLUTION
● OVERALL DIMENSIONS OF A COMPLETE MACHINE ON A TRAILER
Type 4.26m (14ft) Boom+2.2m (7ft-3in) Arm+
Item 0.45m3(0.59cu・yd) Bucket+600mm (23.6in) Shoes
Width mm(ft-in) 2,590 (8′6″)
Weight kg(lbs) 11,900 (26,230)
2-7
● OVERALL DIMENSIONS OF BOOM
Type
4.26m (14ft) Boom
Item
Length×Height×Width 4.42×1.33×0.57
L×H×W m(ft-in) (14′6″×4′4″×1′10″)
Type
2.2m (7ft-3in) Arm+0.45m3 (0.59cu・yd) Bucket
Item
Length×Height×Width 4.07×0.79×0.95
L×H×W m(ft-in) (13′4″×2′7″×3′1″)
Type
2.2m (7ft-3in) Arm
Item
Length×Height×Width 2.93×0.59×0.35
L×H×W m(ft-in) (9′7″×1′11″×1′2″)
2-8
● OVERALL DIMENSIONS OF BUCKET
2-9
E135SR L EVOLUTION DOZER
● OVERALL DIMENSIONS A COMPLETE MACHINE
ITEM E135SR
E135SRLEVOLUTION
EVOLUTION E135SR LC EVOLUTION
(From the center of the arm R1,730mm (5´8˝ )
Length fixing pin to the tip of the blade) R1,630mm (5´4˝ )
Width [600mm (23. 6˝ ) shoe only] 2,590mm (8´6˝ ) 2,590mm (8´6˝ )
Height 570mm (1´10˝ ) 570mm (1´10˝ )
Weight 470kg (1,040 lb) 480kg (1,060 lb)
Set Pressure of Main Relief Valve 2
210kgf/cm (2,990pis) 210kgf/cm2 (2,990pis)
2
Set pressure Of Overload Relief Valve 280kgf/cm2 (3,980pis) 280kgf/cm (3,980pis)
2-10
E115SR EVOLUTION
● OVERALL DIMENSIONS A COMPLETE MACHINE
● DOZER SPECIFICATIONS
2-11
5. SPECIFICATIONS AND PERFORMANCE
E135SR LC EVOLUTION E135SR L EVOLUTION
5.1 SPEED AND CLIMBING CAPABILITY
Model
E135SR EVOLUTION
Item
5.2 ENGINE
2-12
E115SR EVOLUTION
5.5 SPEED AND CLIMBING CAPABILITY
Model
E115SR EVOLUTION
Item
5.6 ENGINE
E115SR EVOLUTION
2-13
6. TYPE OF CRAWLER
E135SR L EVOLUTION
44 links
44 links
Flat shoe
44 links
Triangle shoe
44 links
NOTE :
Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If
you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track
assembly (link, roller, etc.) damage.
2-14
E115SR EVOLUTION
41 links
41 links
Flat shoe
41 links
Triangle shoe
41 links
NOTE :
Use grouser shoes 500mm (20in) or 600mm (24in) on rough ground (areas covered with rocks and gravel). If
you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track
assembly (link, roller, etc.) damage.
2-15
7. TYPE OF BUCKET
E135SR L EVOLUTION E135SR LC EVOLUTION
Hoe bucket Heaped Outer width mm (ft-in) Availability
Struck Number of W or W/O Weight
capacity of face
3 3
m (cu・yd) With side Without side tooth side cutter shovel kg (lbs)
m (cu・yd) cutter cutter
0.20 600 500 280
0.24(0.31) 3 W YES
(0.26) (2′) (1′8″) (620)
0.23 700 600 330
0.31(0.41) 3 W YES
(0.3) (2′4″) (2′) (660)
0.28 800 700 340
0.38(0.50) 4 W YES
(0.37) (2′7″) (2′4″) (750)
0.35 900 800 350
0.45(0.59) 4 W YES
(0.46) (2′11″) (2′7″) (770)
STD 0.38 1,000 900 380
5 W YES
0.50(0.65) (0.50) (3′3″) (2′11″) (840)
0.43 1,100 1,000 400
0.57(0.75) 5 W YES
(0.56) (3′7″) (3′3″) (880)
0.50 1,150 400
0.70(0.92) ── 5 W/O YES
(0.65) (3′9″) (880)
E115SR EVOLUTION
2-16
8. COMBINATIONS OF ATTACHMENT
E135SR L EVOLUTION E135 SR LC EVOLUTION
E115SR EVOLUTION
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage
to the arm and bucket may occur.
2-17
9. ENGINE SPECIFICATION
9.1 SPECIFICATIONS
Rated out put kW (PS) at rpm 62.5 (85) at 2,050 58.8 (80) at 2,050
Maximum kgfym (lbfyft) at rpm
torque 32.4 (235) at 1,600 30.0 (217) at 1,600
2-18
E135SR L EVOLUTION E135SR LC EVOLUTION
9.2 ENGINE CHARACTERISTIC CURVE (ISUZU BB 4BG1T)
Condition to be measured : With fan and generator
Without muffler and air cleaner
-1 (N m) (kgf m)
313–20.0N m /About1600min
-1
(31.9–2.0kgf m /About1600min ) 330
(33)
310
SHAFT TORQUE (31) SHAFT
TORQUE
290
(29)
(PS) (kW) 270
80 (27)
-1
(100) 62.5–1.8kW/2050min
-1
(85–2.5PS/2050min )
SHAFT OUTPUT
(80) 60
SHAFT
(60)
OUTPUT
40
(40)
20
-1
2350–20min
(20)
0
(g/kW h) (g/PS h)
280
(210)
260 (190) FUEL
CONSUMPTION
224.0–7%/kW h /2050min
-1 (170) RATE
240
(150) SFC
220 (130)
FUEL CONSUMPTION RATE
200
1000 1500 2000 2500
-1
ENGINE SPEED (min )
= Fuel consumption rate X kw X Load factor (α) = Fuel consumption rate X PS X Load factor (α)
0.835 X 1000 0.835 X 1000
or
= 224g/kw•h X 62.5kw X α = 164g/PS•h X 85PS X α
0.835 X 1000 0.835 X 1000
=16.7α • /h =16.7α • /h
2-19
E115SR EVOLUTION
9.3 ENGINE CHARACTERISTIC CURVE (ISUZU BB 4BG1T)
Condition to be measured : With fan and generator
Without muffler and air cleaner
-1 (N m) (kgf m)
300–20.0N m /About1600min
-1
(30.6–2.0kgf m /About1600min ) 330
(33)
310
SHAFT TORQUE (31) SHAFT
TORQUE
290
(29)
(PS) (kW)
270
80 (27)
-1
(100) 58.7–1.8kW/2050min
-1
(79.8–2.5PS/2050min )
(80) 60
SHAFT OUTPUT
SHAFT
(60)
OUTPUT
40
(40)
20
-1
2350–20min
(20)
0
(g/kW h) (g/PS h)
280
_1
(210)
224.0–7%/kW h /2050min
260 (190) FUEL
CONSUMPTION
(170) RATE
240
(150) SFC
FUEL CONSUMPTION RATE
220 (130)
200
1000 1500 2000 2500
_
ENGINE SPEED (min 1)
= Fuel consumption rate X kw X Load factor (α) = Fuel consumption rate X PS X Load factor (α)
0.835 X 1000 0.835 X 1000
or
= 224g/kw•h X 58.7kw X α = 164g/PS•h X 79.8PS X α
0.835 X 1000 0.835 X 1000
=15.7α • /h =15.7α • /h
2-20
SECTION 3 ATTACHMENT DIMENSIONS
TABLE OF CONTENTS
3. Bucket..................................................................................................................... 3-7
3.1 Hoe bucket ....................................................................................................................................... 3-7
3.2 Special bucket .................................................................................................................................. 3-9
3.3 Detail dimensional drawing of lug section ...................................................................................... 3-11
3.4 Detail dimensional drawing of boss section ................................................................................... 3-13
d3
B C
C
D
H
G B
d1
F
E
C
B
A
I
J
d4
d2
SECTION BB SECTION CC
E135SR L EV.
No. NAME E115SR EV.
E135SR LC EV.
A Boom length 4,600 (15´1˝ ) 4,260 (13´12˝ )
B Boom foot width 574 (1´10.6˝ ) 574 (1´10.6˝ )
C Boom end inner width 274 (10.8˝ ) 232 (9.13˝ )
D Boom end outer width 386 (1´3.2˝ ) 376 (1´2.8˝ )
E Height of boom cylinder rod pin 961 (3´1.8˝ ) 919 (3´0.2˝ )
F Height of arm cylinder (head side) pin 1,084.5 (3´7˝ ) 1,037.5 (3´5˝ )
G Distance between pins of boss R2,024 (6´8˝ ) R1,960 (6´5˝ )
H Distance between pins of bracket R2,303 (7´7˝ ) R2,129.5 (6´12˝ )
I Arm cylinder (head side) inner width 108 (4.25˝ ) 108 (4.25˝ )
J Outer width of bracket on the arm cylinder (rod side) mounting section 400 (1´3.7˝ ) 400 (1´3.7˝ )
d1 Boom foot pin dia. ∅70 (2.76˝ ) ∅70 (2.76˝ )
d2 Boom cylinder (rod side) pin dia. ∅80 (3.15˝ ) ∅75 (2.95˝ )
d3 Pin dia. of arm end. ∅70 (2.76˝ ) ∅70 (2.76˝ )
d4 Arm cylinder (head side) pin dia. ∅70 (2.76˝ ) ∅70 (2.76˝ )
3-1
1.2 BOOM MAINTENANCE STANDARD
(1) Clearance of pin and bushing
on boom section
C B A
3-2
(2) Clearance in thrust direction on the boom
cylinder installation section A
B A
C
C
D
L3 X L3’ L3
X L4
D
4
※ 3
SECTION DD
SECTION CC
X L2 X L2
X L1
1
2 2
SECTION AA
SECTION BB
Fig. 1-3 Clearance in thrust direction on the boom cylinder installation section
E135SR L EVOLUTION E135SR LC EVOLUTION E115SR EVOLUTION
Table 1-3 Unit : mm (in)
Shim adjusting clearance Length under
Basic size
Sec- (Total of both sides) pin neck
Item Remedy
tion Sym Standard Repairable Service
Size No. Length
-bol value level limit
Boom 574 (22.6) 0.6 (0.02) 1.0 1.5 716
A Boom foot L1 1
Upper frame 581 (22.9) or less (0.04) (0.06) (28.2)
Boom cylinder Boom cylinder 90 (3.54) 0.6~1.0 2.0 2.5 180
B L2 2
(Head side) Upper frame 94 (3.70) (0.02~0.04) (0.08) (0.10) (7.09) Shim
Boom cylinder Boom cylinder L3 80 (3.15)
0.6~2.0 2.5 3.0 ※ 597 adjustment
C
(Rod side) Boom L3’ 400 (15.7) (0.02~0.08) (0.10) (0.12) 3 (23.5)
Arm cylinder Boom cylinder 100 (3.94) 0.6~1.0 2.0 2.5 212
D L4 4
(Head side) Boom 108 (4.25) (0.02~0.04) (0.08) (0.10) (8.35)
However the mark ※ shows the length specified in the figure because it has no neck length.
3-3
2. ARM
2.1 ARM DIMENSIONAL DRAWING
B
G
F
D
H
A A
R
C Ⅰ
B A POINT
D1 D2 B POINT
O
d5
H
D
K
H
J
H
d1 d2
2.95m arm Spec.
SECTION AA P
d3
Q
D4
d4
N
SECTION BB
VEIW Ⅰ
Fig. 2-1 Arm dimensional drawing
3-4
2.2 ARM MAINTENANCE STANDARD
(1) Clearance of pin and bushing E
B D,D’ F
C G
Fig. 2-2 Clearance of pin and bushing on arm section
1) E135SR L EVOLUTION E135SR LC EVOLUTION Table 2-2 (1/2) Unit : mm (in)
3-5
(2) Clearance of arm and cylinder installing
sections in thrust direction
E
D D’
B C F
E
A B G
D D’
F
C
A
G
X3 L3 5 6
X1 L1
X5 L5 X6 L6
1 3
SECTION AA SECTION CC SECTION EE SECTION FF
X2 L2 X4 L4
X4’ L4’ L7
2 4 X7 7
SECTION BB SECTION DD, D’ D’ SECTION GG
Fig. 2-3 Clearance of arm and cylinder installing sections in thrust direction
Remedy
Sec- Basic size (Total of both sides) pin neck
Item
tion E135SR E115SR Standard Repairable Service E135SR E115SR
No. EV. EV. value level limit No. LC EV. EV.
250 216
Arm (9.84) (8.50)
A Arm point L1 251 218 0.6~1.0 1
Bucket (9.88) (8.58) 1.2 ※391 ※351
250 216 (0.02~0.0
Link side (0.05) (15.4) (13.8)
(9.84) (8.50) 4)
B Bucket link L2 252 218 2
Bucket (9.92) (8.58)
244 210
Idler link Arm (9.61) (8.27) 0.5 (0.02) 1.0 2.0
C L3 or less (0.04) (0.08) 3
(Arm connection) Link side
Shim adjustment
― ―
2.44 226
Link
Bucket link
3-6
3. BUCKET
3.1 HOE BUCKET
(1) Hoe bucket dimensional drawing
G
d2
D
A
d1
I I0 B Bushing out dia.
H
C
F
Fig. 3-1 Hoe bucket dimensional drawing
Table 3-1
No. NAME No. NAME
A Distance between pin and bracket G Outer width of bucket bottom
B Distance between bucket pin and tooth end H Bucket outer width of front side
C Inner width of bucket top end I Pitch between teeth
D Inner width of lug I0 Pitch between teeth
E Inner width of bracket d1 Outer width of bushing
F Outer width of side cutter d2 Pin dia.
(2) Hoe bucket dimensional table
1) E135SR L EVOLUTION E135SR LC EVOLUTION Table 3-2 (1/2) Unit : mm (ft-in)
3-7
2) E115SR EVOLUTION Table 3-2 (2/2) Unit : mm (ft-in)
3-8
3.2 SPECIAL BUCKET
(1) Special bucket dimensional drawing
C
1) Bucket with ejector
B’ E
H
d1
I0 I0
A
d2
d2
B
J G
d2
D
A
d1
I I0
B
H C
F
3-9
Table 3-3
No. NAME
A Distance between pin and bracket
B Distance between bucket pin and tooth end
B’ Distance between bucket pin and bucket end
C Inner width of bucket top end
D Inner width of lug
E Inner width of bracket
F Outer width of side cutter
G Outer width of bucket bottom
H Bucket inner width of front side
I Pitch between teeth
I0 Pitch between teeth
J Finishing plate depth
d1 Pin dia.
d2 Pin dia.
3-10
3.3 DETAIL DIMENSIONAL DRAWING OF LUG SECTION
B
∅J
∅A
BOSS (E135SR EV.)
A M BOSS (E115SR EV.)
3-G
∅D
∅F
∅E
SHIM t=1 Insert No.13 pin until the _ BOSS (E135SR EV.)
surface becomes level. SECTION_AA BOSS (E115SR EV.)
DETAIL__
Fig. 3-4_Dimension of lug section
Capacity
Type of
Pin hole dia.
Boss width.
Boss width.
of bucket
Screw dia.
Hole dia.
bucket
m3 (cu yd)
A B D E F G H J M N
_STD_
0.50 (0.65)
0.24 (0.31)
0.31 (0.41)
∅65 22 ∅80 ∅10 ∅146 22 ∅138 36 115
Hoe bucket M14
0.38 (0.50) (2.56˝ ) (0.866˝ ) (3.15˝ ) (0.394˝ ) (5.75˝ ) (0.866˝ ) (5.43˝ ) (1.42˝ ) (4.53˝ )
0.45 (0.59)
0.57 (0.75)
0.70 (0.92)
Dismantle ∅65 22 ∅80 ∅10 ∅146 22 ∅138 36 115
0.50 (0.65) M14
Spec. bucket (2.56˝ ) (0.866˝ ) (3.15˝ ) (0.394˝ ) (5.75˝ ) (0.866˝ ) (5.43˝ ) (1.42˝ ) (4.53˝ )
Bucket with ∅80
0.21 (0.27)
ejector (3.15˝ )
Slope 1800_900
∅80 115
finishing (5´11˝ _35.4˝ )
(3.15˝ ) (4.53˝ )
bucket 0.52 (0.68)
3-11
2) E115SR EVOLUTION Table 3-5 (2-2) Unit : mm (ft-in)
Boss width.
Boss width.
Type of
Screw dia.
of bucket
Hole dia.
bucket
m3 (cuyyd)
A B D E F G H J M N
〔STD〕
0.45 (0.59)
0.17 (0.22)
∅60 22 ∅75 ∅10 ∅140 22 ∅128 28 107
Hoe bucket 0.23 (0.30) M14
(2.36˝ ) (0.866˝ ) (2.95˝ ) (0.394˝ ) (5.51˝ ) (0.866˝ ) (5.04˝ ) (1.10˝ ) (4.21˝ )
0.30 (0.39)
0.37 (0.48)
0.51 (0.67)
Bucket with ∅75 ∅128
0.21 (0.27)
ejector (2.95˝ ) (5.04˝ )
Slope 1600×900
∅10 107
finishing (5´3˝ ×35.4˝ ) M14
bucket (0.394˝ ) (4.21˝ )
0.40 (0.52)
3-12
3.4 DETAIL DIMENSIONAL DRAWING OF BOSS SECTION
∅G H 5
∅A ∅B ∅C ∅D
30°
15
DETAIL Ⅰ
E
0.50 (0.65˝ )
0.24 (0.31˝ )
0.31 (0.41˝ )
Hoe bucket ∅101.6 ∅69 ∅94.5±0.2 ∅99.5 19 34 ∅15 13 2.5
0.38 (0.50˝ )
(4.00˝) (2.72˝) (3.70˝±0.0079˝) (3.92˝) (0.748˝) (1.34˝) (0.591˝) (0.512˝) (0.0984˝)
0.45 (0.59˝ )
0.57 (0.75˝ )
0.70 (0.92˝ )
Dismantle
Spec. 0.50 (0.65˝ )
bucket
Bucket with
0.21 (0.27˝ )
ejector 15 30
Slope 1800×900 ↑ ↑ ↑ ↑ ↑ ↑ ↑
(0.591˝) (1.18˝)
finishing (5´11˝×35. 4˝ )
bucket 0.52 (0.68˝ )
Loader
0.52 (0.68˝ )
bucket
〔STD〕
0.45 (0.59˝ )
∅95 ∅64 ∅88.5±0.2 ∅93.5 30 45 ∅15 13 2.5
0.17 (0.22˝ )
E115SR EVOLUTION
Hoe bucket 0.23 (0.30˝ ) (3.74˝) (2.56˝) (3.48˝±0.0079˝) (3.68˝) (1.18˝) (1.77˝) (0.591˝) (0.512˝) (0.0984˝)
0.30 (0.39˝ )
0.37 (0.48˝ )
0.51 (0.67˝ )
Bucket with 25 40
0.21 (0.27˝ )
ejector ↑ ↑ ↑ ↑ ↑ ↑ ↑
(0.984˝) (1.57˝)
Slope 1600×900
finishing (5´3˝ ×35.4˝ )
bucket 0.40 (0.52˝ )
3-13
4. DOZER
4.1 DOZER DIMENSIONAL DRAWING
G E
d2 d1 F
A D
B
G E
C
d2 d1
↑ VIEW Ⅰ
Ⅰ
Unit : mm (ft-in)
Table 4-1 E135SR L EV. E115SR EV.
E135SR LC EV.
No. NAME DIMENSION DIMENSION
A Blade width 2,590 (8´6˝ ) ←
B Blade height 590 (23.2˝ ) ←
C Distance from dozer attaching pin center to R1,729 (5´8˝ ) R1,633 (5´4˝ )
cutting edge end
D Inner width of dozer attaching bracket 672 (26.5˝ ) ←
E Width of dozer attaching bracket 128 (5.04˝ ) ←
Distance from dozer attaching pin center to
F R881 (34.7˝ ) ←
attaching pin on dozer cylinder head side
G Attaching bracket inner width on dozer cylinder 92 (3.62˝ ) ←
head side
d1 Dozer attaching pin dia. ∅60 (2.36˝ ) ←
d2 Attaching pin dia. on dozer cylinder head side ∅60 (2.36˝ ) ←
3-14
4.2 DOZER MAINTENANCE STANDARD
A T=Tightening torque : kgfym (lbfyft)
T=6.7±0.7
(48±5.1)
M12×120
B DOZER CYLINDER C T=11.7±1.2
A (85±8.7)
}
L3 3
M12×120 M12×120
T=11.7±1.2 T=11.7±1.2
(85±8.7) (85±8.7)
3-15
NOTE
3-16
SECTION 11 TOOLS
TABLE OF CONTENTS
Table 1-1 Tightening torque for coarse thread metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8 T 7T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
0.45±0.05 0.38±0.04 0.98±0.1 0.83±0.08 1.77±0.18 1.5±0.15
M 6 P=1 (3.3±0.4 ) (2.7±0.3) (7.1±0.7) (6.0±0.6) (13±1) (11±1)
1.09±0.11 0.92±0.09 2.4±0.2 2.0±0.2 4.3±0.4 3.6±0.4
M 8 P=1.25 (7.9±0.8) (6.7±0.7) (17±1) (14±1) (32±3) (26±3)
2.2±0.2 1.83±0.18 4.7±0.5 4.0±0.4 8.5±0.9 7.2±0.7
M10 P=1.5 (16±1) (13±1) (34±4) (29±3) (61±7) (52±5)
3.7±0.4 3.2±0.3 8.1±0.8 6.8±0.7 14.6±1.5 12.3±1.2
M12 P=1.75 (27±3) (23±2) (59±6) (49±5) (110±11) (89±9)
5.9±0.6 5.0±0.5 12.8±1.3 10.8±1.1 23±2 19.5±1.9
M14 P=2 (43±4) (36±4) (93±9) (78±8) (170±14) (140±14)
9.0±0.9 7.6±0.7 19.5±2.0 16.4±1.6 35±4 29±3
M16 P=2 (65±7) (55±5) (140±14) (120±12) (250±29) (210±22)
12.4±1.2 10.5±1.0 27±3 23±2 49±5 41±4
M18 P=2.5 (90±9) (76±7) (200±22) (170±14) (350±36) (300±29)
17.5±1.7 14.7±1.4 38±4 32±3 68±7 57±6
M20 P=2.5 (130±12) (110±10) (270±29) (230±22) (490±51) (410±43)
23±2 19.6±2.0 51±5 43±4 92±9 77±8
M22 P=2.5 (170±14) (140±14) (370±36) (310±29) (670±65) (560±58)
30±3 24±3 65±7 53±5 118±12 96±10
M24 P=3 (220±22) (170±22) (470±51) (380±36) (850±87) (690±72)
44±4 36±4 96±10 78±8 173±17 140±14
M27 P=3 (320±29) (260±29) (690±72) (560±58) (1300±120) (1000±100)
60±6 50±5 131±13 110±11 235±24 198±20
M30 P=3.5 (430±43) (360±36) (950±94) (800±80) (1700±170) (1400±140)
81±8 68±7 176±18 148±15 317±32 266±27
M33 P=3.5 (590±58) (490±51) (1300±130) (1100±110) (2300±230) (1900±200)
105±10 88±9 227±23 190±19 409±41 343±34
M36 P=4 (760±72) (640±65) (1600±170) (1400±140) (3000±300) (2500±250)
Table 1-2 Tightening torques for fine threads metric screws (not plated) unit : kgfym (lbfyft)
Strength
grade 4.8 T 7T 10.9 T
Size Use No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
1.15±0.11 0.97±0.1 2.5±0.2 2.1±0.2 4.5±0.4 3.8±0.4
M 8 P=1 (8.3±0.8) (7.0±0.7) (18±1) (15±1) (33±3) (27±3)
2.3±0.2 1.91±0.19 4.9±0.5 4.2±0.4 8.9±0.9 7.5±0.7
M10 P=1.25 (17±1) (14±1) (35±4) (30±3) (64±7) (54±5)
4.0±0.4 3.4±0.3 8.7±0.9 7.3±0.7 15.7±1.6 13.2±1.3
M12 P=1.25 (29±3) (25±2) (63±7) (53±5) (110±12) (95±9)
9.4±0.9 7.9±0.8 20±2 17.2±1.7 37±4 31±3
M16 P=1.5 (68±7) (57±6) (140±14) (120±12) (270±29) (220±22)
19±1.9 15.8±1.6 41±4 34±3 74±7 62±6
M20 P=1.5 (140±14) (110±12) (300±29) (250±22) (540±51) (450±43)
32±3 27±3 70±7 58±6 126±12 105±10
M24 P=2 (230±22) (200±22) (510±51) (420±43) (910±87) (760±72)
65±6 54±5 142±14 118±12 255±26 212±21
M30 P=2 (470±43) (390±36) (1000±100) (850±87) (1800±190) (1500±150)
87±9 72±7 190±19 158±16 341±34 284±28
M33 P=2 (630±65) (520±51) (1400±140) (1100±120) (2500±250) (2100±200)
109±11 91±9 238±23 198±20 428±43 357±36
M36 P=3 (790±80) (660±65) (1700±170) (1400±140) (3100±310) (2600±260)
11-1
2. SCREW SIZE
B
B
11-2
3. TIGHTENING TORQUES FOR NUTS AND SLEEVES
Table 3 indicates standard tightening torques sleeves in flareless joint may develop oil leaks
applicable to cases where no particular note is through pipe connections.
given. Always tighten nuts and sleeves to proper
Overtightening or understanding of nuts and torques.
Table 3-1
Working pressure Tube size Opposing Tightening torque
Manufacturer´s name OD×thickness
kgf / cm2 (psi) mm (in) flats (HEX) kgfym (lbfyft)
10×1.5 19 5±1
(0.394×0.059) (36±7)
15×2.0 27 12±1.2
(0.591×0.079) (87±9)
300 18×2.5 15±1.5
Nippon A.M.C. 32
(4270) (0.709×0.098) (108±11)
22×3.0 36 22±2.2
(0.866×0.118) (159±16)
28×4.0 41 28±2.8
(1.10×0.157) (200±20)
300 35×5.0 45±4.5
Ihara Koatu 55
(4270) (1.38×0.197) (330±33)
Table 3-2
SLEEVE NUT
B
∅d ∅d
Opposing
Tube size Tube size
flats (HEX)
∅d ∅d B
6 6 14
8 8 17
10 10 19
12 12 22
15 15 27
18 18 32
22 22 36
28 28 41
32 32 50
35 35 55
38 38 60
11-3
4. PLUG
(1) Plug for hydraulic pipe joint
Table 4-1
1) Cap nut
Applicable Opposing flat
pipe T screw
O. D : A H1 H
6 M12×1.5 14 14
8 M14×1.5 17 17
10 M16×1.5 17 19
12 M18×1.5 19 22
15 M22×1.5 24 27
18 M26×1.5 27 32
H1 T screw H 22 M30×1.5 32 36
28 M36×1.5 38 41
Table 4-2
2) Plug
Applicable
pipe
O. D : A
6
8
10
12
15
18
Flareless
joint body Nut 22
28
11-4
(2) Plug for hydraulic equipment
1) PF screw
B Table 4-4
O ring PF Norminal
screw B mm O ring
PF 1/4 19 1B P11
PF 3/8 22 1B P14
PF 1/2 27 1B P18
PF 3/4 36 1B P24
PF screw PF 1 41 1B P29
2) PT screw
Table 4-5
PT B mm
B screw
PT screw
PT 1/8 5
PT 1/4 6
PT 3/8 8
PT 1/2 10
PT 3/4 14
PT 1 17
PT 1 1/4 22
PT 1 1/2 22
Table 4-7
PF E mm F mm
screw
PF 1/4 14 19
PF PF 3/8 17 22
screw
PF 1/2 23 27
Opposing Opposing PF 3/4 27 36
flat F flat E PF 1 36 41
PF 1 1/4 40 50
11-5
(4) Plug for ORS joints
Male
O RING
Table 4-8
Applicable
Opposing Norminal
Screw size A hose
O.D flats(HEX) O ring
A
A 1-14UNS ∅21.7 27 1B A16
A
1 3/16-12UN ∅27.2 36 1B A18
1 7/16-12UN ∅34.0 41 1B A21
A 1-14UNS ∅21.7 32
1 3/16-12UN ∅27.2 36
1 7/16-12UN ∅34.0 41
11-6
5. SPECIAL SPANNER FOR TUBE
Table 5-1
Applicable tube diameter HEX
Drawing of a special spanner mm (in)
mm (in) mm
70 (2.76)
8(0.315)
15 16
27 (0.630) PART-No. 22(0.866)
(0.591)
HEX27 40(1.57)
□
+0.3
(
12.7 -0.1 0.500 -0.004
+0.012
)
70 (2.76)
42(1.65)
18 19
32 (0.748) PART-No. 22(0.866)
(0.709)
22(0.866)
HEX32 □ 12.7 +0.3 ( +0.012
-0.1 0.500 -0.004 )
70 (2.76)
40(1.57)
22 19
30 PART-No. 22(0.866)
(0.748)
(0.866)
22(0.866)
HEX30 □ 12.7 +0.3 (
-0.1 0.500 -0.004
+0.012
)
48 (1.89) 70 (2.76)
11.5 (0.453)
22
36 23
(0.906) PART-No. 22(0.866)
(0.866)
28 31
46 (1.22) PART-No. 35(1.38)
(1.10)
HEX46 □
+0.5
(
19.05 -0.1 0.750 +0.020
-0.004 )
109 (4.29)
80 (3.15)
32 50 33 PART-No.
PART-No. 35(1.38)
(1.26) (1.30)
Table 6-1
Swing
Spanner
3 motor
Nominal S : 32
A,B port
PF3/4 O ring
For
slinging
Eye bolt the swing
5 M10×18
motor
&
M10 Flare hose
11-8
Table 6-2
tube dia. 22 )
(Nominal
Reference nut Flare hose
6 Reference
Eye bolt
Nut M8×18
Additional
threading for
M8 Eye bolt
M8 Eye bolt
M8×18
Plug Additional
Nominal threading
1-14UNS
7 Flare hose
Eye bolt
M8 Eye bolt
M8×18
Plug Additional
threading
Nominal
1 3/16-12UN
8 Flare hose
Eye bolt
M8
Plug
PF1/2 Additional M8×20 For slinging the
10
threading for
swivel joint
M8 Eye bolt
O RING
PF1/2
11-9
7. APPLICATION OF SCREW LOCKING COMPOUND AND SEALING
COMPOUND
(1) For general
Table 7-1
Manufacturer
Service Features
Loctite Three-bond
(Manufacture ; Loctite)
(Manufacture ; Three-bond)
Showa-Shell Shell Alvania EP2 New Molyknock Grease 2 Swing bearing grease
petroleum bath
11-10
8. SUCTION STOPPER
8.1 COMPONENTS
4 O ring
8.2 DIMENSION
50
(1.97″)
Fig. 8-1 Components of suction stopper
∅113 (4.45″)
2
M8 NUT
∅8(0.315″)
M8 ∅100 +0.5
0
(3.94″+0.0197
0 )
∅108
(4.25″)
ROD COVER
11-11
9. COUNTERWEIGHT LIFTING JIG
(1) Use two eye bolts M36 or commercial
equivalent for the standard counterweight
lifting gear.
M36
M20
11-12
10. BOOM FOOT PIN PULLING TOOLS
AA
1
M24
M24
Boom foot
2 Hammer
pin pulling
11-13
11. UPPER FRAME LIFTING JIG
SECTION AA
Q'ty : 2set
Material : POK400(SS41)
Fig. 11-1 Upper frame lifting jig
11-14
12. ENGINE MOUNTING
Note) Hold the oil pan
section of engine.
Retainer plate
Stand
Hydraulic jack
Base
Fig. 13-1 Track spring set jig
11-15
NOTE
11-16
SECTION 12 STANDARD MAINTENANCE TIME SCHEDULE
TABLE OF CONTENTS
2. Standard working time table for the maintenance of engine ................................. 12-9
34402 60413254
1. STANDARD MAINTENANCE TIME SCHEDULE FOR EXCAVATOR
(1) Standard maintenance time schedule (2) Classification of working code
1) Units of working time : 6 minutes=0.1 hour
No. Group Remarks
2) Calculating method of standard maintenance
01 Attachment Indicates installing,
time : 02 Cab & Guard
03 Swing frame removing, replacement
Maintenance time=working time×
04 Travel system and overhaul.
the number of workers
06 Electric Indicates the installing,
(working time=Maintenance time÷ equipments removing and
the number of workers) replacement of single
3) When more than one operation is going on : items.
Add each standard service time. 09 E/G relation Indicates overhaul of the
single engine.
A pure time (readily started) is given except (Materials prepared by
covers easily removed by hand. Assy works manufacturer )
include the following works marked with
black dot •. (3) Conditions for standard service time of the
4)O/H : Basically the installing and removing engine
operations are included. 1) Tools designated by E/G maker are used
5) Abbreviations in the table. 2) Genuine parts are changed
A/C ; Air conditioner F hose ; Flexible hose 3) Correct working procedures are observed.
ASSY ; Assembly O/H ; Over haul • The time required for works specified
ATT ; Attachment SOL ; Solenoid in this Chapter shows the total time
BRG ; Bearing SW ; Switch for maintenance.
C/V ; Control valve V ; Valve
Cyl ; Cylinder
E/G ; Engine
Unit : Hour
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
12-1
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
12-2
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
12-3
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
12-4
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
12-5
E115SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
71 Swing bearing ASSY Detach/attach 1 pc. After removing upper flame 0.6 ←
72 Swing bearing mounting bolt Detach/attach 1 pc. 0.4 ←
73 Swing bearing slinging Detach/attach 1 pc. 0.2 ←
80 Dozer relation
81 Dozer ASSY Detach/attach 1 pc. 0.6 ―
82 ● Dozer cylinder piping Detach/attach 1 pc. 0.2 ―
83 ● Dozer cylinder slinging Detach/attach 1 0.2 ―
84 Dozer slinging Detach/attach 1 pc. 0.2 ―
85 Dozer Cylinder O/H 1 2.0 ―
Controller
0 6equipments
Electric
12-6
E115SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
Diode
D-1 Diode Replace 1 0.2 ←
D-2 Diode Replace 1 0.2 ←
D-3 Diode Replace 1 0.2 ←
D-4 Diode Replace 1 0.2 ←
D-5 Diode Replace 1 0.2 ←
Electric equipments
Include C1 controller removing and
E-1 Fuse box Replace 1 installing. 0.3 ←
E-2 Alternator Replace 1 1.0 ←
E-3 Hour meter Replace 1 0.2 ←
E-5 Horn Replace 1 0.2 ←
E-6 Cigar lighter Replace 1 0.2 ←
E-7 Tuner AM & FM(OPT) Replace 1 0.2 ←
E-7 Tuner AM(OPT) Replace 1 0.2 ←
E-8 Speaker left (OPT) Replace 1 0.2 ←
E-9 Speaker right(OPT) Replace 1 0.2 ←
E-10 Receiver dryer Replace 1 Include gas sealing. 0.3 ←
Include counter weight removing and
E-11 Air compressor Replace 1 installing. 0.5 ←
Light
L-1 Boom work light left Replace 1 Bulb 0.2 ←
06 Electric equipments
12-7
E135SR EV.
E115SR EV.
Work to be
Group Location done Unit Remark
Sensor
SE-1 Pressure sensor (low pressure ; bucket digging) Replace 1 0.2 ←
SE-2 Pressure sensor (low pressure ; bucket dump) Replace 1 0.2 ←
SE-3 Pressure sensor (low pressure ; boom up) Replace 1 0.2 ←
SE-4 Pressure sensor (low pressure ; boom down) Replace 1 0.2 ←
SE-5 Pressure sensor (low pressure ; swing) Replace 1 0.2 ←
SE-7 Pressure sensor (low pressure ; arm in) Replace 1 0.2 ←
SE-8 Pressure sensor (low pressure ; arm out) Replace 1 0.2 ←
Include removing and installing guard on
SE-9 Pressure sensor (low pressure ; travel right) Replace 1 cab lower side. 0.4 ←
Include removing and installing guard on
SE-10 Pressure sensor (low pressure ; travel left) Replace 1 cab lower side. 0.4 ←
SE-13 Engine speed sensor Replace 1 Include guard removing and installing. 0.5 ←
SE-14 Engine water temperature sensor Replace 1 0.2 ←
SE-15 Fuel sensor Replace 1 Include guard removing and installing. 0.3 ←
SE-16 Accel potentio Replace 1
06 Electric equipments
0.2 ←
SE-22 P1 pump pressure sensor Replace 1 0.2 ←
SE-23 P2 pump pressure sensor Replace 1 0.2 ←
Solenoid
Include proportional valve removing and
SV-1 Swing parking SOL Replace 1 installing. 2.0 ←
Include proportional valve removing and
SV-3 2-speed travel SOL Replace 1 installing. 2.0 ←
Include proportional valve removing and
SV-4 Lever lock SOL Replace 1 installing. 2.0 ←
Switch
SW-1 Key switch Replace 1 0.2 ←
SW-3 2-speed travel switch Replace 1 0.2 ←
SW-4 Swing parking release switch Replace 1 0.2 ←
SW-5 KPSS release switch Replace 1 0.2 ←
SW-6 Engine water temperature switch Replace 1 0.2 ←
SW-7 Engine oil pressure switch Replace 1 0.2 ←
SW-8 Clogged air filter switch Replace 1 0.1 ←
SW-10 Horn switch Replace 1 0.2 ←
SW-11 Lever lock switch Replace 1 0.3 ←
SW-12 Heater switch (OPT) Replace 1 0.2 ←
SW-13 Air conditioner switch Replace 1 0.2 ←
SW-16 Auto accel release switch Replace 1 0.2 ←
SW-21 Work light switch Replace 1 0.2 ←
12-8
2. STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF
ENGINE
Introduction 2. Special equipments not listed in this table
This standard working time table provides time may be used for operation.
required for maintenance (if the work is carefully
carried out) under the following condition : If such operations are performed, fill out reasons
○Tools designated by us are used. in the Claim Application Sheet in detail and
○Genuine parts are prepared. submit it to us.
○Correct working procedures are observed. (Note 1) Unit of maintenance time
○The engine is mounted correctly to the The maintenance time is given in
machine. 6 minutes=0.1 hour in the decimal system.
1. The working hours given in this table can not (Note 2) Applicable models :
be applied because of special machine BB-4BG1T; E135SR LC EVOLUTION
construction. E115SR EVOLUTION
Engine cushion rubber (both sides) Replace 0.4 Tappet Replace 5.4
Replace 0.1 Detach &
Drain plug Tappet chamber cover attach 0.4
Detach &
Engine assy attach 21.6 Valve rocker stand Replace 0.4
Detach &
• Incl. overhaul of engine and cylinder body Timing gear casing cover attach 1.2
Sealing plug Replace 0.2 • Incl. replacement of gear
Replace Detach &
Cylinder block drain cock assy 0.1 Cam shaft attach 11.6
Detach &
Piston & conn rod (2 cycle) attach 11.8 • Incl. replacement of bearing and tappet
Incl. replacing parts (4 cycle) 11.4 Intake, exhaust system
Crank shaft rear oil seal Replace 0.2 Air intake hose Replace 0.3
Detach &
Crank shaft pulley attach 0.8 Manifold fastening bolts Retighten 0.3
Detach &
• Incl. replacement of front oil seal Inlet manifold attach 1.1
Retighten Detach &
Oil pan 0.3 Exhaust manifold attach 0.7
Detach & Detach &
Oil pan attach 0.9 Throttle valve assy attach 0.8
• Incl. overhaul of oil pump • Incl. overhaul of throttle valve
Detach &
Crank casing & oil pan attach 2.5 Intake shutter spring Replace 0.1
Incl. overhaul of oil pump and replacement Detach &
of other parts Intake shutter attach 0.5
Oil pan level gauge guide tube Replace 0.1 • Incl. overhaul of intake shutter
Detach &
Cylinder head Turbo charger assy (If equipped) attach 1.8
Valve clearance Adjust 0.5 • Incl. overhaul of turbo charger
Detach & Detach &
Cylinder head cover attach 0.5 Turbo charger oil pipe (1 pc.) attach 0.1
Detach &
• Incl. retightening cylinder head Turbo charger oil pipe (2 pcs.) attach 0.2
Detach & Detach &
• Cylinder head assy attach 9.6 Inlet pipe assy attach 0.2
Detach &
• Overhaul of cylinder head, replacement of valve guide, etc. Exhaust pipe adapt assy attach
Lubricating system
Detach &
Oil filter element cover attach 0.5
• Incl. replacement of relief valve
Oil filter element (cartridge) Replace 0.2
Detach &
Oil filter assy attach 0.6
12-9
Work Mainte- Work Mainte-
to be nance to be nance
Location of work done time Location of work done time
• Incl. overhaul of oil filter Fuel pipe (Filter → injection) Replace 0.4
Detach &
Oil filter oil pipe attach 0.3 Fuel return pipe Replace 0.4
Detach &
Oil cooler assy (incl. replacement of one hose) attach 0.7 Fuel hose Replace 0.2
Detach &
Oil cooler assy (2 hoses) attach 0.9 Cooling system
Oil cooler water hose Replace 0.1 Fan belt Adjust 0.1
Oil relief valve Replace 0.2 Fan belt Replace 0.1
Detach &
Fuel system Cooling fan attach 0.3
Detach &
Injection time Adjust 0.3 Water pump assy attach 1.2
Detach &
Injection pump assy attach 3.8 • Incl. overthaul of pump
Detach &
• Incl. replacement of governor, feed pump, etc. Water pipe and hose attach 1.0
Injection pump overflow valve Replace 0.3 • Incl. replacement of pipe and packings
Detach &
Injection pump diaphragm Replace 0.3 Thermostat attach 0.6
Detach &
Fuel feed pump assy attach 1.2 • Incl. performance test
Incl. overhaul of pump and replacement of
check valve Electrical equipments of engine
Detach & Detach &
Feed pump strainer attach 0.3 Starter assy attach 0.8
• Incl. cleaning strainer Generator pulley Replace 0.6
Detach & Detach &
Injection pipe (2 pcs.) attach 0.1 Generator assy attach 1.3
Injection pipe (4 pcs.) 0.2 Generator drive belt Replace 0.1
Injection pipe clip Replace 0.1 Voltage regulator Adjust 0.5
Nozzle leakoff pipe Replace 0.3 Voltage regulator Replace 0.1
Primimg pump Replace 0.4 Glow plug (2 pcs.) Replace 0.3
Injection pump Vent air 0.1 Glow plug (4 pcs.) Replace 0.4
Fuel cut solenoid Replace 0.1 Glow plug relay Replace 0.1
Detach &
Nozzle holder assy (1 pc.) attach 0.7 Switch, unit, relay
Detach &
• Incl. replacement of nozzel (2 pcs.) attach 1.2 Ignition & starter switch Replace 0.2
Detach &
• Incl. replacement of nozzel (4 pcs.) attach 1.7 Oil pressure unit Replace 0.1
Fuel filter (cartridge) Replace 0.1 Oil pressure switch Replace 0.1
Detach &
Fuel filter element attach 0.2 Thermo unit Replace 0.2
Detach &
Fuel filter assy attach 0.6 Control resistor Replace 0.2
Detach & Detach &
Fuel filter overflow valve attach 0.4 Auto stop motor assy attach 0.2
Fuel pump (feed pump → filter) Replace 0.4
12-10
SECTION 13 MAINTENANCE STANDARD
AND TEST PROCEDURE
TABLE OF CONTENTS
1. How to use the maintenance standard and cautions to be exercised ................... 13-1
13-1
2. PERFORMANCE INSPECTION STANDARD TABLE
Table 1 (1/2)
Note; the mode is already S mode when power is thrown.
E135SR L EVOLUTION E135SR LC EVOLUTION Unless otherwise specified, measure it on H mode.
Measuring Position Measuring
Inspection Item Standard
Hi Lo Unit Adjusting
Position Size Port value Point condition
50 +5 -5
Hydraulic oil temperature Tank surface (122) (41) (23) ℃ ― Atmospheric temp.
50℃~-10℃
75 +15 -15 (°F)
Water temperature Radiator surface (167) (59) (5)
― (122°
F~14° F)
FULL throttle
Measuring
+5
& (5000) (+70)
0 MR1
ATT P1,P2 a1,2 Boom up
Main relief
230 +5
Ex. & Doz. P4 a4 (3300) (+70)
0 MR4,5 Dozer up
210 +5
Extra P4 a4 (3000) (+70)
0 MR5 Extra ope.
210 +5
Dozer P4 a4 (3000) (+70)
0 MR4 Dozer up
H 385 -35 OR3 Boom up
Boom a1 (5500)
0
(-500)
R OR4 Boom down
H 385 -35 OR1 Bucket digging
Bucket a1 (5500)
0
(-500)
R OR2 Bucket dump
Forward kgf/cm2 ―
High pressure circuit
RH a1 ― ― ― (Psi) Simultaneous
Travel
RH and LH
Forward ― (without port relief)
LH a2
Port relief valve pressure
PF1/4 ― ― ―
Reverse ―
LH 285 +35 +5 OR5 Swing LH
Swing a2 (4100) (+500) (+70)
RH OR6 Swing RH
H 385 -35 OR7 Arm in
Arm a2 (5500)
0
(-500)
R OR8 Arm out
H 280 -70 OR9 Dozer down
Dozer a4 (4000)
0
(-1000)
R OR10 Dozer up
H 250 +10 OR12 Nibbler close
N&B a2 (3600) (+150)
0
R OR11 Nibbler open
H 230 -20 OR13 Extra ope.
Extra a4 (3300)
0
(-300)
R OR14 Extra ope.
Extra H OR9,13 Ex. & Doz. ope
230 -20
& a4 (3300)
0
(-300)
Dozer R OR10,14 Ex. & Doz. ope
13-2
Table 1 (2/2)
E135SR L EVOLUTION E135SR LC EVOLUTION
Gauge cluster
valve
Multi display
700 +5 -5 FULL
350 +5 -5 NEUTRAL
Proportional
Travel Adjustment
straight valve C 22 532 +5 -5 mA FULL
not required
Drain press By switch
700 +5 -5 operation
C-2
Performance of mm (in)
Swing parking brake 1 / 5 Gradient 0 ←
Tip of the bucket tooth 90
ATT amount of Boom cylinder 3 mm/5min
←
drift Arm cylinder 4 (At no load)
Dozer cylinder 3
30~50
Amount of horizontal play at the bucket tooth (1.18~1.97) mm (in) ←
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation
numbers in advance. ⑧ ④
①Bucket digging ②Bucket dumping ③Boom up
④Boom down ⑤Swing left ⑥Swing right ⑤ ⑥ ① ②
⑦Arm in ⑧Arm out
⑦ ③
LH RH
CONTROL LEVER
13-3
Table 2 (1/2)
Note; the mode is already S mode when power is thrown.
E115SR EVOLUTION Unless otherwise specified, measure it on H mode.
Measuring Position Standard
Inspection Item Hi Lo Unit Adjusting Measuring
Position Size Port value Point condition
Hydraulic oil in Sampling
Cleanliness of hydraulic oil NAS 8 +1 -1 Class ―
tank
50 +5 -5 Ambient temp.
Hydraulic oil temperature Tank surface (122) (41) (23) ℃ ―
75
50℃~-10℃
Water temperature Radiator surface
+15 -15 (°
F) ― (122°
F~14° F)
(167) (59) (5)
Lo idle Selector switch on LOW throttle
Engine speed
+5
& (5000) (+70)
0 MR1
ATT P1,P2 a1,2 Boom up
Main relief
210 +5
Extra P5 a5 (3000) (+70)
0 MR5 Dozer up
230 +5
Ex.&Dozer P4 a4 (3300) (+70)
0 MR4 Extra ope.
210 +5
Dozer P4 a4 (3000) (+70)
0 MR4 Dozer up
H 365 -35 OR3 Boom up
Boom a1 (5200)
0
(-500)
R OR4 Boom down
H 365 -35 OR1 Bucket digging
Bucket a1 (5200)
0
(-500)
R OR2 Bucket dump
Forward kgf/cm2 ―
RH PF1/4 a1 ― ― ― (Psi) Simultaneous
High pressure circuit
Travel
Main pump
13-4
E115SR EVOLUTION Table 2 (2/2)
Measuring Posision Standard Adjusting Measuring
Inspection Item Hi Lo Unit
Position Screen code value Point condition
Operating
Arm variable 665 +5 -5
Gauge cluster
Proportional valve
valve
Multi display
700 +5 -5 FULL
350 +5 -5 NEUTRAL
Travel Adjustment
straight valve C 22 532 +5 -5 mA FULL
not required
Drain press By switch
700 +5 -5 operation
C-2
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation
numbers in advance. ⑧ ④
①Bucket digging ②Bucket dumping ③Boom up
④Boom down ⑤Swing left ⑥Swing right ⑤ ⑥ ① ②
⑦Arm in ⑧Arm out
⑦ ③
LH RH
CONTROL LEVER
13-5
3. MEASUREMENT OF ENGINE SPEED
E/G water temp. gauge Screen select switch
3.1 MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine
Start engine to raise the coolant temperature
of engine to 40℃ to 80℃. (104° F to 176°
F)
The E/G coolant temperature gauge is used to
measure. The range in white color shows the
temperature of approx. 40℃ to 100℃ (104° F
to 212°F), so confirm that the measured value
indicates the temperature within the range of
OK 2250RPM
white color.
a2(a1)
Fig. 4 Gauge port on main pump
a3
4.2 PLACE TO INSTALL PRESSURE GAUGE
Preparation
Start the engine before working, and relieve the
oil pressure of hydraulic system by operating the
switches on gauge cluster. Then stop the engine.
13-7
4.3 PRESSURE ADJUSTMENT POSITION
(1) Main control valve
BUCKET DUMPING
OVERLOAD RELIEF
OR2
ARM IN OVERLOAD
BOOM UP RELIEF
OVERLOAD RELIEF OR7
OR3
NIBBLER CLOSE
OVERLOAD RELIEF
OR12
Fig. 6-1 View from the top of the machine
NIBBLER OPEN
OVERLOAD RELIEF
OR11
ARM OUT
OVERLOAD RELIEF
OR8
BOOM DOWN
OVERLOAD RELIEF
OR4
BUCKET DIGGING
OVERLOAD RELIEF
OR1
13-8
(2) Dozer or Extra control valve
MAIN RELIEF VALVE
OVERLOAD
MR4 or 5
RELIEF
T P OR9 or 13
B1 A1
OVERLOAD
RELIEF
OR10 or 14
13-9
4.4 PROCEDURE FOR ADJUSTING RELIEF
VALVE
(1) Pilot relief valve
Adjust it with adjust screw (611).
: 6mm
Table 3
611
Pressure change
No. of turns of adjust screw kgf/cm2(psi)
1 turn Approx. 21 (300)
Fig. 10 Pilot relief valve
(2) Main relief valve
(Travel section, ATT common section)
Loosen lock nut (7) and adjust it with adjust 7
screw (6).
6
: 19mm
: 4mm
Table 4
Pressure change
No. of turns of adjust screw kgf/cm2(psi) Fig. 11 Main relief valve
(Travel section, ATT common section)
1 turn Approx. 180 (2600)
Table 5
Pressure change
No. of turns of adjust screw kgf/cm2(psi) Fig. 12 Port relief valve
(Boom, bucket, arm sections)
1 turn Approx. 180 (2600)
13-10
5. MEASURING TRAVEL PERFORMANCES
5.1 TRAVEL SPEED
(1) Purposes
Measure the travel sprocket revolution and
confirm the performances between the
hydraulic pump and the travel motor of the
travel drive system.
(2) Conditions
Operating oil temperature ; 45~55℃(113~131°
45~55℃ F)
Crawler on the right and left sides are Fig. 15 One side lifted position
tensioned evenly.
(3) Preparation
Install the reflection panel with a magnet to REFLECTION
the travel motor cover. PANEL
Swing the swing frame through 90°as shown
in Fig.15 and make the crawler on one side
take off the ground, using the attachment.
(4) Measurement
Engine revolution ; Hi idle
2-speed travel switch ; 1-speed and 2-speed Fig. 16 Adhering position of reflection panel
Measuring points ; Right and left
Method, example 1 ; Sprocket E115SR EV.
revolution E135SR L EV.
Table 6-2 Unit : min-1
Measure revolution with a stroboscope.
Measurement Standard Reference value Service
Method, example 2 ; item value for remedy limit
Measure the revolutions per minute H1 34.5~31.1 26.9~24.3 22.0~
visually.
H2 57.9~52.3 45.2~40.8 36.9~
E115SR EV.
Sprocket S2 52.2~47.2 40.7~36.8 33.3~
revolution E135SR LC EV.
Table 6-1 Unit : min-1
13-12
6. MEASURING SWING PERFORMANCES
6.1 SWING SPEED
(1) Purpose
Measure the swing time and confirm the
performances between the hydraulic pump
and the swing motor of the swing drive
system.
(2) Conditions
Hydraulic oil temperature ;4 45~55℃(113~131° F) Fig. 23 Swing speed measuring position
Plain, level, and solid ground (at the max. reach)
Engine ;Hi idle
(3) Preparation
Bucket unloaded, arm cylinder min.
retraction (Max. reach), arm cylinder min.
extension (Min. reach)
(4) Measurement
Swing the machine by bringing the swing
lever to its full stroke. Measure the time
required to make two turns after one turn of
preliminary run and calculate the time
required for one turn. Fig. 24 Swing speed measuring position
(at the min. reach)
6.2 PERFORMANCE OF SWING BRAKE
Swing speed Table 10 Unit : sec / rev
(1) Purpose
Measuring Reference value Service
Confirm the braking torque performances by position
Standard value
for remedy limit
the swing relief valve.
E135SR LC EV. 4.8~5.8 6.1~7.4 8.0~
(2) Conditions
Hydraulic oil temperature ;45~55°C
45~55℃(113~131° F) E115SR EV. 4.8~5.8 6.1~7.4 8.0~
Plain, level and solid ground
Engine ;Hi idle
(3) Preparation
1) A height of 1.5m (5ft) at which the bottom of
the bucket matches the tip of the tooth on
condition that the bucket is empty, the arm
1.5m (5ft)
cylinder is most retracted and the bucket is
used for digging.
2) Put a mark (matching mark) on the outer Fig. 25 Swing brake performance measuring position
circumference of the swing bearing of the Measuring the length of the arc over the
upper frame side and of the track frame side. outer circumference of swing race
Erect two poles (flags ) at the front and back Matching marks
of the extended line of the matching mark. on swing race B
(4) Measurement
1) When operating in regular swing speed, by
shifting lever to neutral position at pole
position the swing operation stops.
2) Calculate the swing drift angle by the
following equation, after the upper swing
body stops, using the amount of deflection Matching marks on track frame
(m) of the matching marks on the swing race
and the length (m) of the circumference of the Fig. 26 Measuring position of swing brake performances
swing race : Swing brake
performance Table 11 Unit : degree
Amount of deflection of Measuring Reference value Service
Swing drift matching marks [m (ft-in)] Standard value
position for remedy limit
angle (°)= ×360°
Circumferential length of E135SR LC EV. 75°or less 85° 95°
swing race [m (ft-in)]
E115SR EV. 65°or less 75° 85°
13-13
6.3 PERFORMANCE OF SWING PARKING BRAKE
(1) Purpose
To confirm the mechanical performances of
the swing parking brake that is fitted to the
inside of the swing motor.
(2) Conditions
On a slope with 1/5 (Approx. 12deg.) gradient 1/5
Stop the machine at right angles with the
slope at the height of 1.5m (5ft) at which the YN-B74
bottom of the bucket matches the tip of the Fig. 27 Swing parking brake
performance measuring position
tooth on condition that the bucket is empty,
the arm cylinder is most retracted and the
Measuring the length of the arc over the
bucket is operated for digging. outer circumference of swing race
(3) Preparation Matching marks
Put the angle meter on the shoe plate and on swing race C
make sure that the angle is more than 12°.
Put a matching mark over the outer
circumference of the swing bearing on the
upper frame side and on the track frame side.
(4) Measurement
When five minutes has passed after the Matching marks on track frame
engine stops, measure the length of the Fig. 28 Measuring position
movement of the matching marks. of swing brake performances
13-14
7. MEASURING ATTACHMENT OPERATING PERFORMANCES
7.1 OPERATING TIME OF CYLINDERS
(1) Purpose
Measure the operating time of the boom, arm
② ①
and bucket and confirm the performances
(1ft)
between the hydraulic pump and the cylinder 30cm
of the attachment drive system. Fig. 30 Measuring position for bucket digging
(2) Condition and dump
45~55℃(113~131°
Hydraulic oil temperature ;45~55°C F)
Engine ;Hi idle
Operating time excluding the cushion stroke
(3) Preparation
Plain ground with the bucket empty ③
(4) Measurement 1 ; Boom up and down ④
With the boom operating lever at full stroke,
measure the required operating time of the Fig. 31 Measuring position for boom up
and down motions
bucket between the ground surface and its
highest position. ⑧
(3) Preparation
1) Install a dial indicator to the magnetic base 90~110°
and fix it to the lower frame.
2) Direct the upper swing body and the lower (1ft)
frame toward the travel direction, bring the 30cm
probe of the dial indicator in contact with the
bottom surface of the outer race on the swing Fig. 35 Measuring position Ⅰ
body side and set the reading at zero.
Axial play of
swing bearing Table 16 Unit : mm (in)
Measuring Reference value
position Standard value for remedy Service limit
13-16
9.
MECHATRO CONTROLLER“A”ADJUSTMENT
9.1 ENGINE CONTROL INPUT/OUTPUT
SWITCH PANEL
H.S.FC MODE SELECT SWITCH C-1 MECHATRO CONTROLLER
GAUGE CLUSTER
MULTI DISPLAY
MODE SELECT SW.
GOVERNOR
MOTOR
ENGINE
SCREEN
SELECT SW.
BUZZER PUMP
STOP SW. ACCEL DIAL STARTER SW.
Fig. 38 E/G SPEED SENSOR
9.2 ENGINE CONTROL INSTALLATION
E/G
EMERGENCY STOP KNOB
OPERATOR SEAT
TIGHTENING TORQUE
4.0±0.4 kgfym
(29±2.9 lbfyft)
Apply Loctite ♯262
or equivalent. TIGHTENING TORQUE 1.1±0.1 kgfym(8.0±0.72 lbfyft)
Fasten it with the Apply Loctite ♯262 or equivalent.
TIGHTENING TORQUE
mounting plate for the 2.0±0.2 kgfym
engine lifting hook (14±1.4 lbfyft)
Apply Loctite ♯242
GOVERNOR LEVER or equivalent.
TIGHTENING TORQUE A GOVERNOR MOTOR
1.0±0.1 kgfym
(7.2±0.72 lbfyft)
E/G A TIGHTENING
EMERGENCY TORQUE
STOP CABLE 6.6±0.7 kgfym
(48±5.1 lbfyft)
Apply Loctite
♯242 or equivalent.
SECTION AA
(ADJUST BOLT)
Fasten it with harness
against the frame clip.
VIEWⅠ
Fig. 39
13-17
9.3 E/G CONTROL EQUIPMENT REDUCTION GEAR SECTION
(1) Governor motor and C-1 controller OIL SEAL
MOTOR SECTION
1) By operating accel dial, the input voltage OUTPUT SHAFT
change is sensed by CN11-32 pins of C-1
controller.
2) The C-1 controller computes the input
voltage, and outputs command to governor CAM
motor (M-2), and incline governor lever of
LIMIT
engine to the swing angle corresponding to SWITCH
accel dial set value.
3) The limit switch in governor motor is set to a
angle from motor rotation OFF to ON
position (Starting point).
Fig. 40
(2) Rotation sensor
1) Installing place Opposing flat 19 SIGNAL(Yellow)
M16×1.5 Opposing flat 17
Engine flywheel housing
GAUGE CLUSTER
(3) Work mode selector switch
If the work mode switch [MODE] is pressed,
a signal is transmitted to the C-1 controller.
SCREEN
The controller changes the work modes in the SELECTSW.
order of S→H→FC each time the work mode
switch is pressed. A selected mode is
BUZZER STOP SW.
indicated at the uppermost part of the gage
cluster. MODE SELECT SW.
13-18
9.5 “A”
A” ADJUSTMENT OF MECHATRO
CONTROL
GROMMET
(1) When adjustment of mechatro control is
required; Case “A”adjustment
Replace mechatronic controller. ○
Replace governor motor. ○
CPU ROM DATA FAILURE
on display. ○
CPU ROM DATA FAILURE and C-1 MECHATRO CONTROLLER
CPU MECHATRO SET ERROR ○
are shown by turns. Fig. 43
(2) Preparation
1) Warm up engine.
2) Turn A/C switch OFF.
3) Turn starter switch OFF to stop engine.
4) Pull up the safety lock lever and pull up the
MULTI DISPLAY
left control box upwards.
5) Pull operator seat forward fully and incline
seat back forward.
6) Remove resin cover on the rear side, then
SCREEN SELECT
mechatro controller appears. (Remove 5 atta- SWITCH
ching bolts from resin cover with driver ◯,+).
Note : Check to be sure that the engine
emergency stop lever knob is fully
pressed down. If mechatro controller is
adjusted in the condition where the knob Fig. 44
is pulled out, the engine speed can not be
set properly.
Table 18 (1/2)
(3) Adjustment Procedure Multi display Movement of governor motor
① Remove grommet on upper surface of
FULL
mechatro controller, and switch internal STOP
adjustment JP switch from RUN to TEST
.
LEVER
In normal
RUN position LEVER
During
TEST adjustment
GOVERNOR
MOTOR
13-19
Table 18 (2/2)
Procedure Multi display on Movement of governor motor
gauge cluster
③ Keep the buzzer stop switch pressed and
when it is let free after 5 to 10 seconds, STEP 1 A
S
STEP 1 is displayed on the multi display.
CPU START
Then let your hand free and wait till the
display changes to STEP 2.
13-20
(4) After completion of adjustment
1) Turn starter switch OFF to stop engine.
2) Return the inner adjust switch to RUN from TEST, attach the grommet, push the screen select
switch on the gauge cluster one time, and get an engine rpm indication.
3) The auto accel release switch located on the right-hand console is a seesaw hold type switch. If it is
pressed on the rear side(bland side) of the machine, the auto accel is released, and the engine is
brough to HIGH IDLE after started up.
4) Make sure that if the work mode on the switch panel is changed, the mode display on the gauge
cluster changes and the engine rpm on the multi display changes.
5) Set accel dial to low idling position, and changes connector after engine stops, and starts engine
after switching to auto accel.
6) Set accel dial to high idling, and check engine speed when running in auto accel position.
7) Get "MONITOR SYSTEM OK" by pushing the screen select switch on the gauge cluster two times.
8) Attach resin cover as it was, and slide operator seat backward to move the seatback backward.
Then, check connector of speaker for disconnection.
9) Turn the left control box forward, bring down the safety lock lever, and start the engine again. Then
make sure that the actual engine revolution under the service diagnosis No.2 matches the measured
value on the diesel revolution meter. This completes the operation.
AUTO ACCEL
RELEASE SW.
13-21
NOTE
13-22
SECTION 21 MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
21-1
1.2 BOOM RAISE CONFLUX 1.3 SWING CUT VALVE CONTROL
21-2
1.4 ARM IN RECIRCULATION & SEQUENCE CONFLUX (1) Recirculation cut control
2
1) If load increases and the load pressure of the pump rises above 160kgf/cm (2280psi) during arm in
operation, the output voltage of the high pressure sensor (SE-23) is put into the mechatro controller.
The mechatro controller processes pilot signals and puts out a command current that cuts off the
variable recirculation, to the variable recirculation proportional valve.
2) The variable recirculation proportional valve puts out secondary pilot pressure according a command
current of the mechatro controller, brings back the variable recirculation valve to the recirculation cut
position and blocks the recirculation passage.
(2) Sequence conflux control
2
1) If load increases and the load pressure rises above 220kgf/cm (3130psi) during arm in operation, the
mechatro controller processes a pilot signal and puts out a command current to the travel straight
proportional valve and the P1 bypass cut proportional valve according to the secondary operating pilot
pressure.
2) The travel straight proportional valve and the P1 bypass cut proportional valve put out the secondary
pilot pressure according to a command current of the mechatro controller and switches the travel straight
valve and the P1 bypass cut valve.
3) When the travel straight valve is changed over, the parallel passage on the P1 side connects with the
parallel passage on the P2 side.
When the P1 bypass cut valve and the P2 bypass cut valve are changed over, the oil discharged by the
P1 pump is combined with that by the P2 pump by arm operation.
Note: If sequence conflux control operates during slope finishing work, the oil is combined in the parallel
passage. The operability is deteriorated as the oil for the bucket operation is combined together. If a
signal is put into the low pressure sensor on the bucket dump side, the sequence conflux control does
not operate.
(3) Recirculation control
1) Start arm in operation simultaneously, and arm operation pilot secondary pressure switches arm spool,
and is input into low pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro
controller processes the pilot signal and puts out a command current according to the input voltage to
the P2 pump proportional valve, the P2 bypass cut proportional valve and the variable recirculation
proportional valve.
3) Each proportional valve puts out secondary pilot pressure according to a command current from the
mechatro controller and switches the discharge rate of the P2 pump. At the same time it switches the P2
bypass cut valve and the variable recirculation valve of the control valve.
4) The pure hydraulic command switches the arm main spool. Then a command from the mechatro
controller switches the P2 pump, the P2 bypass cut valve and the variable recirculation valve. This
21-3
1.5 ARM IN ANTI- CAVITATION CONTROL 1.6 ARM OUT CONFLUX
21-4
1.7 TRAVEL STRAIGHT TRAVEL STRAIGHT
1) Start ATTs work operations (boom, arm, bucket, swing) in travel operation (right and left), and the pilot
pressure switches respective spools, and is input into respective low pressure sensors.
Note: Boom raise operation is explained here.
2) If mechatro controller receives the input satisfying the following combination shown in Table, the
controller determines it as travel straight, and the travel straight signal turns on.
3) After the travel straight signal has turned on, the signal is input to respective proportional valve
corresponding to the following commands.
21-5
1.8 SWING PRIORITY CONTROL (1) Swing priority control at Arm in (The forced recirculation position)
1) If swing operation is performed during arm in (or arm in is performed during swing), the secondary pilot
pressure for arm operation switches arm spool and swing spool. Respective pressure is simultaneously
put into each low-pressure sensor (SE-7, SE-5).
2) The output voltage of the low pressure sensor is put into the mechatro controller.
The mechatro controller processes pilot signals. The command currents according to the input voltage
are put out to the ,P1 pump proportional valve(PSV-P1), P2 pump proportional valve (PSV-P2), travel
straight proportional valve (PSV-C), P1 bypass cut proportional valve (PSV-D), P2 bypass cut
proportional valve (PSV-B) and the arm variable recirculation valve (PSV-A).
3) Each proportional valve puts out a secondary pilot pressure according to a command current from the
mechatro controller and switches the delivery rate of the P1&P2 pumps. At the same time, the pressure
moves the P1&P2 bypass cut spool to full stroke position, and switches the arm variable recirculation
valve to the forced recirculation position.
4) If arm in and swing operations are performed simultaneously, the secondary pilot pressure moves sub-
spool of arm spool and consequently passage in arm cylinder head is restricted. The arm variable
recirculation spool is shifted to forced recirculation position, the return oil from rod side is recirculated at
head side while restricton. The operation pressure of arm cylinder is risen by restriction of arm cylinder
circuit.
5) Delivery oil of P2 pump flows into swing and arm sections of P2 side, but it flows preferentially into swing
side because the operation pressure of arm cylinder is higher than swing side pressure.
6) On the other hand, as travel straight spool is shifted to travel straight position and P1 bypass cut spool is
switched, delivery oil of P1 pump flows into parallel circuit of P2 side and confluxes with swing circuit, and
swing priority is available.
7) By this operation the operating pressure of arm cylinder is risen, delivery oil of P2 pump preferentially
flows into swing side which pressure is lower than arm.
Arm working speed keeps minimum loss because recirculation oil is used to arm cylinder, and as P1
pump delivery oil confluxes with swing circuit, swing priority control is more available.
8) If arm in and swing operation are performed, energized signal from mechatro controller to swing parking
brake solenoid valve (SV-1) is cut, and swing parking brake is released.
21-6
1.9 PRESSURE DRAINING (RELEASING) CONTROL (1) Pressure draining (releasing) control
1) If display select switch and buzzer stop switch of gauge cluster are kept pressed for more than five
seconds, the mechatro controller judges it as Pressure Releasing Control.
2) If the mechatro controller judges it pressure releasing control, the mechatro controller performs the
following regardless of input signals (From operation pilot valve, accel potentiometer, etc.):
a. Puts out a minimum tilting angle command to the pump proportional valve.
b. Puts out a command current for pressure releasing control revolution to the governor motor.
c. Puts out a command current for the pressure position switch to the travel straight proportional valve.
d. Puts out a standby command current to the P1 bypass cut valve and the P2 bypass cut proportional
valve.
3) A command current from the mechatro controller causes the following to occur:
a. The pump proportional valve puts out a secondary pilot pressure to the pump to minimize the tilting
angle of the pump.
b. The governor motor controls the engine revolution to a pressure releasing control revolution.
c. The travel straight proportional valve puts out a secondary pilot pressure to switch the travel straight
valve to the pressure releasing position.
d. The P1 bypass cut valve and the P2 bypass cut proportional valve put out a secondary pilot pressure
to hold the P1 bypass cut valve and the P2 bypass cut valve in their standby position.
4) The mechatro controller senses the output voltage of the high pressure sensor of the main pump, judges
it as pump pressure and displays “DRAINING HYD. PRESS” or “FAIL DRAIN HYD. PRESS” on the
gauge cluster.
5) Since the travel straight valve is in the pressure releasing position, the oil discharged by each pump is
unloaded to the tank passage.
If the operating levers are operated and the spools switched, the pressure remaining in the actuators may
be discharged.
21-7
(1) Positive control
1.10 PUMP CONTROL (POSITIVE CONTROL & P_Q CONTROL) 1) If any operation performed, the secondary pilot pressure switches the spools and is put into the low
pressure sensors.
2) The output voltage of the low pressure sensor is put into the mechatro controller which processes pilot
signals and puts out command current to the proportional valve of each pump according to the input
voltage.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
from the mechatro controller, switches the tilting angle of the pump and controls the discharge rate of the
pump.
4) This causes the delivery rate according to a lever stroke to be supplied to the actuator, thus an operating
speed according to a lever stroke is achieved.
(2) P-Q control
1) The output voltage of the high pressure sensor attached to each pump piping is put into the mechatro
controller, which processes pilot signals and computes command current according to input voltage (load
pressure).
2) The lower of the command current computed by positive control and the command value (1) computed by
P-Q control is selected and put out to the proportional valve of each pump as a command current.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current
of the mechatro controller, switches the tilting angle of the pump and controls the discharge rate of the
hydraulic pressure.
4) This increases the load of the actuator, enabling the engine to keep running even if the pump is highly
loaded.
21-8
1.11 STANDBY FLOW CONSTANT CONTROL (1) Standby flow constant control
1) An engine rotation command put out of the accel potentiometer is put into the mechatro controller.
2) The mechatro controller processes pilot signals and puts out a command current to the proportional valve of
each pump so as to make the delivery rate of the pump constant when the engine speed is below an
intermediate rpm between the FC mode and the Decel revolutions.
3) The proportional valve of each pump puts out a secondary pilot pressure according to a command current of
the mechatro controller, changes the tilting angle of the pump till the engine speed arrives at an intermediate
rpm between the FC mode and the Decel revolutions.
4) If the engine speed increases an intermediate rpm between the FC mode and the Decel revolutions, command
current from the mechatro controller become constant, with the result that the delivery rate of each pump rises
linearly as the engine speed increases.
5) The result is that the motion of the lever at the start of each operation becomes the same as that when a
standby flow is available. Also, if the engine revolution is increased, the operating feeling according to each
revolution is available.
21-9
1.12 FC MODE CONTROL (1) FC mode control
1) If the FC mode is selected by the switch on the gauge cluster, FC mode signal is put into the mechatro
controller.
2) Upon receipt of the FC mode signal, the mechatro controller; a. Judges it as FC mode, and
b. Puts out a FC mode rpm command to the governor motor.
3) The governor motor controls the engine speed to a level that matches a command current from the
mechatro controller. During operation it puts out, to each proportional valve, a command current in the FC
mode according to the input voltage from the low pressure sensor.
(2) Peculiar control of proportional valve at FC mode
1) If arm in action is performed at FC mode, the secondary pilot pressure for arm in operation switches the
arm spool and is put into the lower pressure sensor.
2) The output voltage of the low pressure sensor is put into the mechatro controller. The mechatro controller
processes pilot signals and puts out command current according to the input voltage to the P2 pump
proportional valve and the P2 bypass cut proportional valve.
3) In that case, a peculiar control command current at the FC mode is put out to the variable recirculation
proportional valve. (the recirculation ratio higher than normal recirculation operation)
4) This combines the speed drop of the ATTs as the engine speed decreases with the fine arm operation at
the FC mode, in order to improve the delicate controllability of the entire working.
21-10
1.13 RELIEF CUTOFF CONTROL (1) Relief cutoff control
1) When the conflux and single flow selector switch is turned on and the optional operation is carried out at
full power with the engine speed was at constant speed or higher, the voltage output by the high
pressure sensor and required to input into the mechatro controller is equivalent to the relief pressure, and
if the condition is continuously maintained for a certain length of time, the mechatro controller decides the
condition as relief cutoff.
2) After the condition is decided as relief cutoff by the mechatro controller, the command value is output to
the pump proportional valve on the side where the relief pressure is detected in order to reduce the
delivery rate.
3) The proportional valve of the pump on the side on which relief valve is detected puts out a secondary
pilot pressure according to a command current from the mechatro controller, decreases the delivery rate
of the pump and decreases the absorbed torque of the pump.
4) This decreases the unwanted torque consumption, prevents the heat balance from deteriorating and
improves the fuel efficiency.
5) However, in case other operation pilot (operation pilot from the main actuator) is put in, the relief cutoff is
not performed.
This relief cutoff control contains a learning function. In case the relief pressure falls with time, the system
reads pressure changes over the past 10 hours of operation, detects the relief pressure and renews it, even if
the relief pressure falls with time or the optional relief pressure differs from the main relief pressure.
21-11
This page is blank for editing convenience
21-12
2. MECHATRO CONTROLLER
The functions displayed on the multidisplay are classified roughly into the following 7 types.
1. CPU error displayDisplay the error of the mechatro controller, etc. (28 items)
2.1 SUMMARY OF MECHATRO CONTROLLER 2. Self-diagnosis displayDisplays the failure of the I/O system of the mechatro controller such as the low and high
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster. However, the pressure sensors, governor motor, proportional valve, solenoid valve,
mechatro display and the cumulative engine oil lubrication time may be changed over if the screen select switch is etc.
pressed.
3. Service diagnosis displayDisplays the information output by the mechatro controller such as the pressure sensor
detection, proportional valve, solenoid valve, etc.
RIGHT HAND (22 items)
OPERATOR 4. Trouble history display Stores and displays the contents of the troubles detected through the mechatro self diagnosis.
CONTROL LEVER 5. Mechatro A adjustment displayDisplays it by procedure during the mechatro A adjustment.
6. E/G oil supply cumulative (integrated) time Displays the E/G oil supply cumulative time and E/G speed (rpm) list.
CIGARETTE LIGHTER
7. Warning displays When the machine is normal after self-diagnosis ( ) but the actual operation fails, the occurence of
PLUG any of the following items is indicated every time.
(Opt.switch)
DOZER LEVER
(SK115SRDZ SPEC.)
ACCEL DIAL
STARTER SWITCH
Control
Buzzer stop switch contains the following functions.
(Buzzer alarm)
➀ Stops the warning sounding Selector valve (SOL)
➁ Display item rollbacked in service diagnosis operation Governor motor
➂ Display item rollbacked in trouble history operation
➃ Time display rollbacked when correcting E/G oil supply Battery relay
SCREEN SELECT MULTI DISPLAY LCD
SWITCH cumulative time
21-13
(3) Self diagnosis Connector
No. Contents Display of monitor No. Wire No. Wire color
Indication item -Pin No.
Connector Arm variable recirculation CN15-10 757 BrG
No. 19
No. Contents Display of monitor Wire No. Wire color propo-valve fail CN15-11 758 YV
-Pin No.
Mechatro controller Pump P1 CN15-17 760 VR
1 20 pressure sensor fail CN15-18 759 BrG
fail
Pump P2 CN15-19 764 VW
2 ROM data CN14-25 600 R 21
pressure sensor fail CN15-20 763 GY
When the E/G Travel two-speed
speed is not in 22 solenoid valve fail CN15-21 702 LgB
3 Mechatro set error the range from
300rpm~3000rpm
CN11-3 902 WV Swing parking
Boom raising 23 CN15-22 700 VR
4 CN11-2 502 LgY solenoid valve fail
pressure sensor fail CN11-1 952 BR
CN15-1 851 G
CN11-4 903 OB Governor motor CN15-2 852 B
5 Boom lowering 24 current fail
CN11-5 503 LO CN15-15 853 R
pressure sensor fail CN11-6 953 BrW W
CN15-16 854
CN11-9 904 OL Governor motor
6 Arm in
CN11-8 504 PW 25 starting point indexing CN11-34 560 V
pressure sensor fail CN11-7 954 BrY fail
CN11-10 905 OW CN11-33 930 WR
Arm out
7
pressure sensor fail
CN11-11 505 PL 26 Accel potentio meter CN11-32 530 P
CN11-12 955 Gr fail CN11-31 970 BW
CN11-15 900 RB Gauge cluster→Mechatro
8 Bucket digging CN14-26 601 W
CN11-14 500 LgR 27 controller communication
pressure sensor fail CN11-13 950 BrR failure CN14-27 602 B
CN11-16 901 RL
9 Bucket dump
CN11-17 501 LgW 28 Battery relay fail CN15-24 805 WG
pressure sensor fail CN11-18 951 BL
CN11-21 906 YB
10 Swing right CN11-20 506 V
pressure sensor fail CN11-19 956 GrL
Travel right CN11-27 908 YL
12 CN11-26 508 VY
pressure sensor fail CN11-25 958 BY
Travel left CN11-28 909 YR
13 CN11-29 509 Sb
pressure sensor fail CN11-30 959 BG
Pump P1 CN12-3 941 YL
14 CN12-2 514 VY
pressure sensor fail CN12-1 964 BrB
Pump P2 CN12-4 915 YR
15 CN12-5 515 Sb
pressure sensor fail CN12-6 965 BrL
P1 bypass cut CN15-4 755 BP
16
propo-valve fail CN15-5 756 PW
21-14
2.3 SERVICE DIAGNOSIS No. DISPLAY REMARKS No. DISPLAY REMARKS
No.12 No.22
The result of the service diagnosis at the present time is displayed in 22 categories depending on the PRESS. SENSOR PROPO-VALVE
data output by the mechatro controller. B-7 SWING (R) Sensor voltage / D-3 S-TRAVEL Command current /
12 3.5V 38k Pressure converted value 22 COMP. 600mA 45k Pressure converted value
How to display B-8 SWING (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
1) Turn the starter key switch on, keeping the buzzer stop switch depressed, and place the attachment 3.5V 38k Pressure converted value Pressure converted value
to the travel position while operating in the low idling condition after the engine starts. No.13 No.23
2) The mechatro controller P/NO and the program version in the 1st item are displayed. PRESS. SENSOR PROPO-VALVE
B-9 TRAVEL (R) Sensor voltage / D-6 A-RECIRCULAT Command current /
13 3.5V 39k Pressure converted value 23 COMP. 600mA 45k Pressure converted value
E115SR EVOLUTION E135SR LC EVOLUTION GAUGE CLUSTER B-10 TRAVEL (L) Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 39k Pressure converted value Pressure converted value
No.1 No.1
MAIN CONTROLLER P/No. No.14 No.24
MAIN CONTROLLER P/No.
PRESS. SENSOR PROPO-VALVE
PROGRAM VERSION PROGRAM VERSION C-1 PUMP P1 Sensor voltage / E-1 P1 PUMP Command current /
VER 5.40 Screen select switch Buzzer stop switch 14 3.5V 350k Pressure converted value 24 COMP. 600mA 45k Pressure converted value
VER 5.30
Advances the screen Returns the screen C-2 PUMP P2 Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 350k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.15 No.25
3) By pressing screen select switch, goes to No.2,No.3… in order. PRESS. SENSOR PROPO-VALVE
4) By pressing the buzzer stop switch, returns from No.13, No.12… in order. B-16 P1 OPT. Sensor voltage / E-2 P2 PUMP Command current /
15 3.5V 36k Pressure converted value 25 COMP. 600mA 45k Pressure converted value
5) Turn the starter switch off, and the display also goes off. B-17 P2 OPT. Sensor voltage / MEAS. 600mA 45k Feedback current /
3.5V 36k Pressure converted value POWER SHIFT 100mA Pressure converted value
No.20 No.39
PROPO-VALVE MECHATRO ADJT.
No. DISPLAY REMARKS No. DISPLAY REMARKS D-1 P1 BYPASS Command current / CONT. SW TEST RUN/TEST indication
No.1 No.6 20 COMP. 600mA 45k Pressure converted value 39 CONT. VOL 100% Inner trimmer
Service diagnosis
MAIN display
CONT.P/No. SK115SR or SOL. VALVE MEAS. 600mA 45k Feedback current / PROG. SW OFF ON/OFF indication
YV22E00008F1 SK135SR F-3 1/2-TRAVEL Pressure converted value
1 YY22E00022F1 P/No. indication 6 COMP. OFF ON/OFF indication
PROGRAM VER Version indication MEAS. OFF ON/OFF indication No.21 No.40
VER 5.30 SWITCH OFF ON/OFF indication PROPO-VALVE RELEASE SW
D-2 P2 BYPASS Command current / KPSS TEST ON/OFF indication
No.2 No.8 21 COMP. 600mA 45k Pressure converted value 40 SWING BRAKE OFF ON/OFF indication
E/G SET 2310 No load set rpm RELAY MEAS. 600mA 45k Feedback current /
MEAS 2310 Actual rpm I-2 BAT. RELAY Pressure converted value
2 E/G PRS. LIVE LIVE/DEAD indication 8 COMP. OFF ON/OFF indication
KPSS SW H H / S / FC indication MEAS. OFF ON/OFF indication
KEY SWITCH OFF ON/OFF indication
No.3 No.9
H-1 PRESS. SENSOR Note:
ACCEL VOLT. 4.2V Potentio voltage B-1 BOOM RAISE Sensor voltage /
3 POS. 100% Voltage position 9 3.5V 35k Pressure converted value Service diagnosis and trouble history can be displyed with the screen select switch and the buzzer stop
MOTOR STEP 440 No of motor steps B-2 BOOM LOWER Sensor voltage / switch. Note that the displays do not come out in some cases if the switches are pressed too quickly.
POS. 100% Step position 3.5V 35k Pressure converted value
(This is not a fault.) Give one second or more before pressing next switch.
No.4 No.10
GOVERNOR MOTOR PRESS. SENSOR
G-1 COIL A 1.0A A phase current B-3 ARM OUT Sensor voltage /
4 G-1 COIL B 1.0A B phase current 10 3.5V 36k Pressure converted value
G-2 LIMIT OFF ON/OFF indication B-4 ARM IN Sensor voltage /
3.5V 36k Pressure converted value
No.5 No.11
SOL. VALVE PRESS. SENSOR
F-2 SWING-BRAKE B-5 BUCKET DIG Sensor voltage /
5 COMP. OFF ON/OFF indication 11 3.5V 37k Pressure converted value
MEAS. OFF ON/OFF indication B-6 BUCKET DUNP Sensor voltage /
RELEASE SW OFF ON/OFF indication 3.5V 37k Pressure converted value
21-15
2.4 TROUBLE HISTORY DIAGNOSIS 4) To scroll the page, use the work mode select 2.5 HOW TO CORRECT THE E/G OIL SUPPLY CUMULATIVE TIME
The error item detected by the self-diagnosis is switch and the buzzer stop switch. (1) LCD display
stored in the mechatro controller as a history and z Press the work mode select switch, page up.
LCD display Operating procedure Buzzer sound
is displayed on the multidisplay. z Press the buzzer stop switch, page down.
Note :
(1) How to display All the error items are stored by hour meter, when
1) Turn the starter switch on. the hour meter is differed, press the work mode
O K 1515 RPM
2) Press the buzzer stop switch 5 times in select switch and the buzzer stop switch, and
sequence for 10 seconds. displays all items and make sure that they are Normal
(Example) right. 256Hr. have passed None
display after E/G oil was
CONTENTS DISPLAY
5) Turn the starter switch off, and the display is
No errors NO ERROR Supplementary explanation :
disappeared.
00025H If the screen change switch is pressed, the above three
Error detected in the B-1 BOOM RAISE (2) How to cancel the contents of the trouble screen may be changed over.
past D-1 P1 BYPASS CUT history
F-3 TRAVEL 1.2-SPEED 1) Display the trouble history mode.
2) Press the work mode select switch and the
3) Transmits the error data (one or many) and buzzer stop switch for 10 seconds or more
hour meter to the gauge cluster. concurrently.
z Hour meter and 3 error data are displayed 3) When the deletion is completed, the “NO
on the screen. ERROR” is displayed.
z If three error data or more exist, display the 4) Turn the starter switch off.
data three by three in order for every 5 (2) How to correct
seconds. Proce-
Note :
dure
Operating procedure Display on multidisplay
All the stored items are erased. (Normal)
It is impossible to erase data partially. MONITOR
A Turn the starter switch “ON”. is displayed.
SYSTEM OK
E/G speed is displayed
Press the gauge cluster screen change switch Press once
B MONITOR
2250RPM
once, and the E/G speed (rpm) is displayed. SYSTEM OK
(3) Contents of the trouble history
Symbol Display Symbol Display Press once more, and the engine oil supply E/G speed is displayed 100Hr AFT
C Press once more
cumulative time screen is displayed. 2250RPM E/G OIL CH
A-1 ROM DATA FAILURE D-1 P1 BYPASS CUT
A Controller relation
A-2 MECHATRO SET ERROR Proportional valve D-2 P2 BYPASS CUT
D D-3 TRAVEL PRIORITY Press the screen change switch for 3 to 10
(Control valve)
B-1 BOOM RAISING D-6 ARM VALEABLE D seconds and release the hand, it returns to 100Hr AFT MONITOR
100Hr AFT
B-2 BOOM LOWERING RECULATION E/G OIL CH SYSTEM OK E/G OIL CH
Portional valve E-1 the correction mode.
B-3 ARM OUT E
PUMP P1 PORPO- VALV
B-4 ARM IN (Hydraulic pump) E-2 PUMP P2 PORPO- VALV
Press the work mode selector switch “H”, and 100Hr AFT Cumulative time 101Hr AFT
Low pressure B-5 BUCKET DIGGING F-2 SWING PARKING E
B F Solenoid valve the cumulative time increases. (once 1Hr) E/G OIL CH increases E/G OIL CH
sensor B-6 BUCKET DUMP F-3 TRAVEL 1,2-SPEED
B-7 SWING RIGHT G-1 STEP MOTOR
CURRENT-NG Press the buzzer stop switch, the cumulative 100Hr AFT The cumulative 99Hr AFT
B-8 SWING LEFT G E/G Accessory G-2 STEP MOTOR S/PT. F
ERROR time decreases. (once 1Hr) E/G OIL CH time decreases E/G OIL CH
B-9 TRAVEL RIGHT
B-10 TRAVEL LEFT G-3 E/G REV. SENSOR
H Potentio relation H-1 ACCELERATR Press the gauge cluster screen change switch (Normal)
High pressure POTENTIO
C-1 PUMP P1 once the correcting time is stored, and exits 99Hr AFT Complete the MONITOR
C sensor I-1 RECEIVE ERROR G
(Hydraulic pump)
C-2 PUMP P1 I from the correction mode and OK symbol is E/G OIL CH correction SYSTEM OK
I-2 BAT. RELAY
MONITOR SYSTEM OK displayed to complete the correction.
Note :
Press the screen change switch once after the procedure D, and the condition is stored and the correction is
completed.
21-16
2.6 MECHATRO CONTROL EQUIPMENT
(1) C-1 Mechatro controller Connec- Pin Port In/out Connec- Pin Port In/out
Specification Signal level No. name Specification put Signal level
10 2 1 6 2 1 4 2 18 2 1 tor No. No. name put tor No.
1) General view Engine coolant high temp. LS 1 D7
1 B8 IN GND / OPEN
16 High/Normal
Engine oil pressure low LS 2 D7´
26 2 B9 Without/With IN GND / OPEN
3 D8
Air filter clogged LS
34 3 B10 Clogged/Normal IN GND / OPEN 4 D8´
4 B11 Double single select SW. opt IN GND / OPEN 5 D9
WINDOW
27 22 18 16 12 28 22 5 B12 Over load SW. (KCME) IN GND / OPEN 6 D9´
FOR CN11 CN12 CN13 CN14 7 D10
6 B13 JIB pressure SW. (KCME OPT) IN GND / OPEN
ADJUST
13 2 18 2 1 11 2 1 7 B14 Extra pressure SW. (KCME OPT) IN GND / OPEN 8 D10´
CN16
Fuel level thermistor 9 D11
ROM REWRITE COUPLER 8 B15 Low/Normal IN 670Ω/1140Ω
10 D11´
9 B16
11 D12
10 B17
12 D12´
11 B18 Connector for flat control IN 13 H1
26 14 16 9 22 12 12 C1
CN15 CN16 CN17 ADJUSTMENT SWITCH 14 H1´
13 C2 Wiper interlock SW. OUT GND / OPEN 15 B26
CN14
Connec- Pin Port In/out 14 C3 16 C22
tor No. No. name Specification put Signal level 15 C4 Washer motor relay Out/Stop OUT GND / OPEN
1 C15
1 G 16 C5 Front working light relay ON/OFF OUT GND / OPEN
2 C16
2 A12 P1 pump pressure sensor IN 0.5~4.5V 17 C6
2) List of connectors 3 C17 Swing flasher & working light unit OUT GND / OPEN
3 +5V 18 +5V
4 C18 Swing flasher & working light unit OUT GND / OPEN
Connec- Pin Port In/out 4 +5V
tor No. No. name Specification put Signal level 19 B19
5 C19 IT controller source
5 A13 P2 pump pressure sensor IN 0.5~4.5V 20 C7
1 G 6 C20
6 G 21 C8
2 A1 Boom raise pressure sensor IN 0.5~4.5V 7 C21
7 G 22 C9
3 +5V Opt. P1 side pressure 8 B20 Auto accel release switch ON/OFF IN GND / OPEN
8 A14 sensor IN 0.5~4.5V 23 C10
4 +5V 9 B21
Boom lower pressure 9 +5V 24 G
5 A2 sensor IN 0.5~4.5V 10 B22 (Swing flasher select switch) IN GND / OPEN
10 +5V 25 TXD1 IN/OUT
6 G 11 B23 Lock lever SW. IN +24V / OPEN
11 A15 26 RXD1 Gauge cluster IN/OUT CN17
7 G 12 B24
CN12 12 G 27 G
8 A3 Arm in pressure senor IN 0.5~4.5V 13 B25
13 A16 Alternator voltage IN 0~36V 28 SHG Shield earth
9 +5V 14 TXD2 OUT
1 F1 IT controller
10 +5V 14 A17 15 RXD2 IN
Accel motor A phase
11 A4 Arm out pressure sensor IN 0.5~4.5V 15 B2 Key switch(ON) ON/OFF IN +24V / OPEN 2 F1´ 16 G
12 G 16 B3 Key switch(GLOW) ON/OFF IN +24V / OPEN 3 SHG Shield earth 17 SHG
13 G 17 B4 Travel 1.2 speed switch ON/OFF IN GND / OPEN 4 D1 P1 bypass cut OUT 0~800mA 18 +5V
Bucket digging pressure Swing parking release switch 5 D1´ proportional valve C OUT 0~800mA
14 A5 sensor IN 0.5~4.5V 18 B5 Release/Normal IN 17Ω/ OPEN 19 A23
6 D2 P2 bypass cut OUT 0~800mA 20 A24
15 +5V KPSS rerease switch
19 B6 Release/Normal IN ~12V / 12V~ 7 D2´ proportional valve A OUT 0~800mA
16 +5V 21 A25
Bucket extend pressure 20 E1 IN 3.0~20Vp-p 8 D3 Travel straight OUT 0~800mA
17 A6 sensor IN 0.5~4.5V Engine revolution sensor 22 G
CN11 21 E1´ 9 D3´ proportional valve B OUT 0~800mA
18 G 1 DL IN/OUT
22 SHG Shield earth 10 D4 Arm variable recirculation OUT 0~800mA
19 G proportional valve D
2 TXD3 IN/OUT
1 G 11 D4´ OUT 0~800mA CN18 Handy checker
20 A7 Swing pressure sensor IN 0.5~4.5V Opt. P2 side pressure 3 RXD3 IN/OUT
2 A18 sensor IN 0.5~4.5V 12 +24V
21 +5V Power supply + 24V 4 G
3 +5V 13 +24V
22 +5V
4 +5V CN15 14 +24V Battery back up
23 A8
5 A19 15 F2
24 G Accel motor B phase
25 G
6 G 16 F2´
Travel right pressure 7 G 17 D5 P1 pump proportional OUT 0~800mA
26 A9 sensor IN 0.5~4.5V
8 A20 18 D5´ valve E OUT 0~800mA
27 +5V CN13
9 +5V 19 D6 P2 pump proportional OUT 0~800mA
28 +5V
10 +5V 20 D6´ valve F OUT 0~800mA
29 A10 Travel left pressure sensor IN 0.5~4.5V
11 A21 Travel 1,2-speed selector valve
OUT +24V / OPEN
30 G 21 C11 2 speed/1 speed
12 G Swing parking selector valve
31 G 22 C12 OUT +24V / OPEN
13 G ◯,P /Release
32 A11 Accel potentio IN 0~5.0V
14 A22 23 C13
33 +5V 24 C14 Battery relay Operation/Stop OUT +24V / OPEN
Accel motor starting point detection 15 +5V
34 B1 LS starting Point/Reguler
IN GND / OPEN 25 G
16 B7 Power supply (earth)
26 G
21-17
(2) Gauge cluster (symbol C-2) (3) Governor motor(Symbol M-2)
1) General view NAME PLATE
Gauge and
Display lamp
21-18
SECTION 22 HYDRAULIC SYSTEM
TABLE OF CONTENTS
34402 60413254
1. SUMMARY
The hydraulic circuits are built up with the following functions and features in order to achieve easy
operability, safety, mass volume handling and low fuel consumption.
Table 1
Perfor-
mance Device Function Features
Travel straight Travel straight at combined operation.
2 speed travel changeover 2 speed changeover of travel speed.
Auto parking brake Automatic braking when parking.
Travel
Pump
22-1
2. HYDRAULIC CIRCUITS AND COMPONENTS
2.1 EU STD (1/2)
Standard spec. E135SR EVOLUTION
No. NAME MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3V63DTP100R
2 CONTROL VALVE (MAIN) KMX13YB
3 SWING MOTOR UNIT M2X63CHB-13A
4 TRAVEL MOTOR UNIT GM18VL2
5 LH
BOOM CYLINDER CA100X1038B38F
6 RH
7 ARM CYLINDER CA115X1135B38F
8 BUCKET CYLINDER CA95X885B38F
9 SWIVEL JOINT
10 PILOT VALVE (ATT) PV48K1008
11 PILOT VALVE (TRAVEL) 07291-00000
13 INLINE FILTER YTD9257
14 SUCTION STRAINER Y-501000
15 SOLENOID VALVE ASSY 7KWE5G
16 RETURN FILTER Y-418900
17 BY-PASS VALVE Y-169200
19 BREATHER ASSY Y-466000
20 BOOST CHECK VALVE Y-443600
21 BY-PASS CHECK VALVE Y-479600
22 SLOW RETURN VALVE 07579-00000
23 SLOW RETURN VALVE 07580-00000
24 CONTROL VALVE (Ex.&N&B) KADV22Y/S10102
Standard spec. E115SR EVOLUTION
No. NAME MODEL No.
1 PUMP ASSY (WITH GEAR PUMP) K3V63DTP100R
2 CONTROL VALVE (MAIN) KMX13YC
3 SWING MOTOR UNIT M2X63CHB-13A
4 TRAVEL MOTOR UNIT GM18VL2
5 LH
BOOM CYLINDER CA95X995B36F
6 RH
7 ARM CYLINDER CA110X1075B36F
8 BUCKET CYLINDER CA95X885B38F
9 SWIVEL JOINT
10 PILOT VALVE (ATT) PV48K1008
11 PILOT VALVE (TRAVEL) 07291-00000
13 INLINE FILTER YTD9257
14 SUCTION STRAINER Y-501000
15 SOLENOID VALVE ASSY 7KWE5G
16 RETURN FILTER Y-418900
17 BY-PASS VALVE Y-169200
19 BREATHER ASSY AB0210, GA001B
20 BOOST CHECK VALVE Y-443600
21 BY-PASS CHECK VALVE Y-479600
22 SLOW RETURN VALVE 07579-00000
23 SLOW RETURN VALVE 07580-00000
24 CONTROL VALVE (Ex.&N&B) KADV22Y / S10102
22-2
HYDRAULIC CIRCUITS AND COMPONENT MODEL
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-3
2.2 DOZER SPEC.
E115SR EVOLUTION
Applicable machines; same as STD E135SR EVOLUTION
Dozer spec.
No. NAME MODEL NO.
50 HYD PUMP ASSY SGP1A25F2H9
51 SWIVEL ASSY
52 DOZER CYL. (LH) CA110X220B21G
53 DOZER CYL. (RH) CA110X220B21G
54 CONTROL VALVE KVS-65-1
M
B4
51
FG
A4
PUMP
50
HYD. TANK
BLADE 54 DOWN
UP
VALVE
A1 B1
BLADE(RH)
53
22-4
2.3 BOOM & ARM SAFETY SPEC.
E115SR EVOLUTION
NOTES : 1. This hydraulic circuit is used to BOOM&ARM SAFETY SPEC. E135SR EVOLUTION
add to following circuit. No. NAME MODEL NO.
REMARKS 60 HOLDING VALVE KHCV20P010
E135SR EVOLUTION 61 HOLDING VALVE KHCV20P010
E115SR EVOLUTION E115SR EVOLUTION
BOOM SAFETY SPEC. E135SR EVOLUTION
No. NAME MODEL NO.
60 HOLDING VALVE KHCV20P010
61 HOLDING VALVE KHCV20P010
M
PUMP
HYD. TANK
BOOM(LH)
R
A B1
DR
61
PL C B
385 kgf/cm2
(5480psi)
PLc2 P
Drd PL C B
OUT PBa
PBb DOWN Pisc
Drc BOOM ARM
PAb UP IN PAa
Bb DOWN
PLc 1
DR
A B1
60
IN Aa
P
BOOM(RH) R
Ab UP ARM H
OUT Ba A B1
DR
60
PL C B
385 kgf/cm2
(5500psi)
22-5
2.4 EXTRA SPEC.
E115SR EVOLUTION
NOTES : 1. This hydraulic circuit is used to EXTRA SPEC. E135SR EVOLUTION
add to following circuit. No. NAME MODEL NO.
REMARKS 50 HYD PUMP ASSY SGP1A25F2H9
E115SR EVOLUTION 81 PILOT VALVE 16041-0000
E135SR EVOLUTION 82 CONTROL VALVE KVS-65-1
2. This symbol means attachable
port coupler for pressure detector.
PUMP ASSY
50
HYD. TANK
NOTES 2
SOL/V BLOCK
T
SAFETY
LOCK
4 LEVER
P1
22-6
E115SR EVOLUTION
2.5 N & B SPEC. Applicable machines; same as STD NOTES : 1. This hydraulic circuit is used to add E135SR EVOLUTION
N & B spec.
to following circuit. No. NAME MODEL NO.
REMARKS 70 PILOT VALVE 16030-00000
E115SR EVOLUTION STD 71 SELECTOR VALVE
E135SR EVOLUTION STD 72 STOP VALVE
74 RETURN FILTER Y-487100
2. BRAND MARK OF VALVE, SELECTOR (ITEM 71) 75 CONTROL VALVE
KADV22/S10102
N : NIBBLER
B : BREAKER
3. FOR USING OF NIBBLER CONFLUENCE/SINGLE FLOW OR BREAKER, CHOOSED CONDITION AND AN ORDER
CHOOSED CONDITION AN ORDER OF OUTPUT FOR PROPOTIONAL SOLENOID VALVE
CONFLUENCE/SINGLE FLOW BRAND MARK OF
P1 PUMP P2 PUMP TRAVEL STRAIGHT P1 NEUTRAL CUT P2 NEUTRAL CUT
CHANGEOVER SWITCH SELECTOR VALVE (ITEM 51)
CONFLUENCE FLOW OF NIBBLER CONFLUENCE "ON" N
SINGLE FLOW OF NIBBLER CONFLUENCE "OFF" N
M BREAKER CONFLUENCE "OFF" B
PUMP
B C1 C2 A
B P SE-11
BREAKER
ROD
LCo2 N&B PBo2
HEAD
PAo2
75 250 kgf/cm2
(3550psi)
Bo2
Ao2
Po
22-7
P1
3. COLOR CODING STANDARD FOR HYDRAULIC CIRCUITS 4. NEUTRAL CIRCUIT
This section describes the following. diameter of it and increases the tilting angle
Blue ................... Feed, drain circuit, less than 1) Safety lock lever and pilot circuit (α). The servo piston and the sleeve are linked
4.5kgf/cm2 (64psi) 2) Pump control together by the feedback lever (611). A pin is
Green ................. Return, make up circuit, 3) P-Q curve control action of pumps provided at point A of the feedback lever. Since
4.5~6kgf/cm2 (64~85psi) the feedback lever runs on the fulcrum, the
Purple ................ Secondary pilot pressure, 4.1 SAFETY LOCK LEVER AND PILOT CIRCUIT servo piston and the sleeve (651) move in the
6~50kgf/cm2 (85~710psi) Purpose: opposite directions and stop where the spool-
Red ..................... Primary pilot pressure, To protect attachment from unexpected sleeve opening is closed.
35~50kgf/cm2 (500~710psi) operation for safety, however, dozer is outside 2) Flow reducing action
Orange ............... Main pump drive pressure, of adaptation. If the command current I of the mechatro
50~350kgf/cm2 (710~4980psi) Principle: controller decreases, the secondary pressure
Blue tone ........... At valve selection Cut pressure source of pilot valve for of the solenoid proportional valve decreases.
Red valve ........... When proportional valve operation. This causes the pilot spring (646) to move the
(reducing) is operating Operation: spool (652) to the left. If the spool is shifted,
Red solenoid ...... In active and exciting After engine starts, push down the safty lock the discharge pressure P1 is admitted to the
Displaying the flow circuit and standby circuit lever (red), and the limit switch (SW-11) is larger diameter chamber of the servo piston
when operating. turned on, the pilot operation circuit is by way of the spool.
Regarding the electrical symbols in this manual, changed to standby condition. The discharge pressure P1 is there at the
refer to the electric circuit diagram. smaller diameter of the servo piston at all
4.2 PUMP CONTROL times, but because of the difference in the area
Type: causes the servo piston to move to the right and
Variable displacement pump of electric flow to decrease the tilting angle. If the servo piston
control type. moves to the right the same way as above, the
Principle: sleeve moves to the left by the feedback lever,
Controls the tilting angle of the pump till the opening of the spool-sleeve is closed.
(delivery rate) by changing the command
current I to the solenoid proportional 4.3 P-Q CURVE CONTROL ACTION OF PUMPS
reducing valve. Type:
Operation: Electrically flow controlled variable-
1) Flow increase function (for example; P1 displacement pump
pump): Principle:
This is a positive control type that increases Outputs of the high pressure sensor for the
the command current I of the mechatro pump are converted to P-Q curve control values
controller. If the attachment other than the by the mechatronic controller to give commands
dozer is operated, the secondary pilot to the pump’s solenoid proportional valve.
operating pressure is put in each low Operation:
pressure sensor. The output voltage of the The high-pressure sensor of the pump
low pressure sensor is put into the mechatro converts the discharge pressure of the pump
controller. The mechatro controller to voltage outputs.
processes pilot signals and put out a current The mechatronic controller converts the
command according to the input voltage. If voltage outputs from the high-pressure
the secondary pressure of the solenoid sensor to command current as it makes P-Q
proportional valve increases, the spool (652) curve control.
is pushed to the right via the pilot piston In the meantime, the mechatronic controller
(643) and stops where it balances the action selects the lower of the command current and
of the pilot spring (646). the positive control command current from
The larger diameter of the servo piston (532) the low-pressure sensor and sends out a
opens to the tank port, moves to the left by current command to each proportional valve
the discharge pressure P1 of the of the pump.
22-8
SE-22 SE-23 D2 P D1
1 P P
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-9
NEUTRAL CIRCUIT; SAFETY LOCK LEVER ON
5. TRAVEL CIRCUIT
This section describes the following. pressure.
1) Travel forward pilot simultaneous operation Provided if the main circuit pressure exceeds
circuit 290 kgf/cm2, the self pressure pushes back
2) 2 speed travel solenoid command circuit and the 2 speed select piston to select 1st speed.
auto 1-speed return function
3) Travel main circuit 5.3 TRAVEL MAIN CIRCUIT
4) Travel motor function Operation:
If the travel spool is changed by the travel
5.1 TRAVEL FORWARD PILOT SIMULTANEOUS pilot action, the oil discharged from port A1,
OPERATION CIRCUIT A2 of the main pump enters ports B, A of the
Purpose: travel motor by way of the BL-, Br port of C/V
Light operating force and shockless operation and the C, D ports of the swivel joint (8) and
Operation: performs the following functions in the travel
1) If the travel lever with damping mechanism motor.
is operated for travel right, left and forward
motions, the secondary pilot proportional 5.4 TRAVEL MOTOR FUNCTION
pressure comes out of the 2,4 ports of P/V Function:
(11). The higher of the pressures is selected, 1) Prevents overrunning of travel motor on
comes out of the 5, 6 ports and acts upon the downhill slope.
low pressure sensors (SE9), (SE10). 2) Hydraulic motor cavitation protective check
2) Pilot proportional secondary pressure flows valve.
into PBL, PBr ports of control valve, acts on 3) Shockless relief valve and anticavitation
travel spool, and switches main circuit. valve when stopping it with the force of
3) The output voltage of the low pressure sensor inertia.
is put into the mechatro controller. The 4) High/Low 2 step change mechanism and auto
mechatro controller processes signals and 1st speed return at high load.
puts out a flow increase current to the P1 5) Travel parking brake.
pump proportional valve (PSV-1) and the P2
pump proportional valve (PSV-2).
22-10
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-11
TRAVEL CIRCUIT; TRAVEL 2nd SPEED OPERATION
6. BUCKET CIRCUIT
This section describes the following. 6.3 CONSTANT FLOW CONTROL FOR STANDBY
1) Bucket digging pilot circuit Principle:
2) Auto accel operation At pressures below the intermediate
3) Constant flow control for standby revolution between the decel and the FC
4) Bucket digging main circuit mode, a command current is put out so as to
make the delivery rate of the pump constant.
6.1 BUCKET DIGGING PILOT CIRCUIT Operation:
Operation: Even if the engine revolution of the accel
1) If bucket digging action is performed, the potentiometer is set in Lo rpm, the pump
secondary proportional pilot pressure comes delivers a discharge rate equal to the
out of port ① of the right pilot valve (10), intermediate revolution between the above
enters port PBc of C/V (2) and acts upon the decel and the FC mode. For this reason, the
low pressure sensor (SE-1). At the same time, actuator operates faster than the moving of
the pressure changes the bucket spool. the operating lever when load is light.
2) The output voltage of the low pressure sensor
is put into the mechatro controller. The 6.4 BUCKET DIGGING MAIN CIRCUIT
controller processes signals and puts out a Operation:
command current for pump flow increase to With pilot operation, the pressure oil
the solenoid proportional valve (PSV-1) on switches bucket spool, and is fed into bucket
the P1 pump. The relation between the low cylinder H side through C/V (2) BC port. And
pressure sensor and the pump flow increase the return oil from cylinder R side flows into
is the same as above; the explanation of it is tank circuit while being restricted by bucket
deleted hereafter. spool through C/V (2) AC port.
22-12
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
Dra ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-13
BUCKET CIRCUIT ; BUCKET DIGGING OPERATION
7. BOOM CIRCUIT
This section describes the boom raise conflux 3) Then the oil passes through boom spool,
operation. opens lock valve of boom lock valve, and is led
1) Boom up pilot circuit into H side of boom cylinder through C/V (2)
2) Boom up 2 pumps conflux main circuit in C/V Ab port.
4) The return oil from boom cylinder R side
7.1 BOOM UP PILOT CIRCUIT flows into tank circuit through boom spool
Operation: from C/V (2) Bb port.
1) If the boom up action is performed, the
secondary pilot proportional pressure from
the right pilot valve (10) comes out of port ③
and acts upon the low pressure sensor (SE3).
At the same time, the pressure acts upon the
PAb port and the PB1 port of C/V (2).
2) The voltage output by low pressure sensor is
processed by mechatro controller and outputs
command current to P2 bypass cut valve
(PSV-B) and solenoid valve outputs
proportional secondary pressure and the
pressure acts on C/V (2) PCa port.
3) Then, the secondary pressure fed into C/V (2)
PAb port switches boom conflux spool. And
the solenoid proportional secondary pressure
fed into PCa port switches P2 bypass cut
valve.
22-14
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-15
BOOM CIRCUIT; BOOM UP OPERATION, CONFLUX FUNCTION
This section describes boom down operation. 7.5 FIXED RECIRCULATION FUNCTION OF
1) Boom down pilot circuit. BOOM DOWN MAIN CIRCUIT
2) Prevention of natural fall by lock valve and Purpose:
actuation at lowering. Prevention of cavitation during boom
3) Fixed recirculation function of boom down lowering motion.
main circuit. Principle:
The oil returning from the boom cylinder
7.3 BOOM DOWN PILOT CIRCUIT head (H) is recirculated to the rod (R).
Operation: Operation:
1) Start boom down operation, and the pilot When the oil is supplied to the boom cylinder
proportionl secondary pressure is output rod (R) side during boom down operation,
through port (4) of pilot valve, and acts on the boom moves faster than it should do in
low pressure sensor (SE4), at the same time some cases by the self weight of the
branches into two circuits, then scts C/V(2) attachment. On that occasion, the circuit
PBb and PLC1 ports. pressure on the rod (R) side is on the negative
2) The voltage output by low pressure sensor side. The oil supplied to the boom cylinder
(SE4) is input into mechatro controller. rod (R) flows into the A1 port of the P1 pump
3) Then, the proportionl secondary pressure fed and the P1 port of C/V. The oil then passes
into C/V(2) PBb port switches boom spool. through the boom spool and goes out of the
And the proportional secondary pressure Bb port. On that occasion, the oil returning
flown into C/V (2) PLC1 port releases boom from the head (H) goes through the
lock valve. recirculation path in the boom spool, pushes
the check valve (C) in the spool open, is
7.4 PREVENTION OF NATURAL FALL BY LOCK recirculated to the Bb port and is supplied to
VALVE AND BOOM DOWN the rod (R). When the (R) pressure is larger
Purpose: than the (H) pressure, the check valve (C)
Prevention of natural fall when the lever is closes. Thereupon, the recirculation is
neutral. stopped.
Principle:
The oil is prevented from returning to the
boom spool by the poppet seat of the boom
lock valve.
Operation:
During the boom lowering, the boom spool
shifts by secondary proportional pressure of
PLC1 port to change the selector valve of the
lock valve located at the end of the spool.
Then the poppet spring chamber of the lock
valve connects with the drain line (drc), with
the result that the lock valve poppet is moved
to an open state. When the boom spool is
neutral, the drain line on the lock valve
poppet spring chamber side is closed. since
the poppet is closed, the oil returning to the
boom spool from the boom cylinder head (h) is
held. this prevents oil leaks from the boom
spool, thereby preventing the boom cylinder
from making a natural fall.
22-16
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-17
BOOM CIRCUIT; BOOM DOWN OPERATION
8. SWING CIRCUIT
This section describes the following operations. 3) The swing parking solenoid (SV-1) is excited
1) Swing left pilot circuit five seconds after the pressure of the swing
2) Swing auto parking brake low pressure sensor (SE-5) disappears. In the
3) Swing main circuit case of arm in, the swing parking solenoid
4) Swing motor function (SV-1) is excited to operate the mechanical
brake the moment the pressure of the low
8.1 SWING LEFT PILOT CIRCUIT pressure sensor (SE-7) for arm in disappears.
Operation:
1) If the swing left action is performed, the 8.3 SWING MAIN CIRCUIT
secondary pilot proportional pressure goes out of Operation:
port ⑤ of left pilot valve (10) and acts upon the The delivery oil through A2 port of P2 pump
low pressure sensor (SE-5). At the same time, flows into P2 port of the C/V (2) and is branched
the pressure acts upon the PAS port of C/V (2). into the bypass circuit and parallel circuit, but
2) The low pressure sensor output voltage the bypass circuit is closed with the movement
enters in the mechatro controller, and after of the swing spool, the pressure opens load
signal processing the mechatro controller check valve (LCS) through the parallel circuit
outputs the command current to P2 bypass flows into B port of the swing motor through AS
cut solenoid proportional valve (PSV-B), and port of the C/V (2) and rotates the swing motor
the proportionl valve secondary pressure is counterclockwise. However, when starting
discharged from this the solenoid valve and swing operation, the oil flows out in the tank
acts on PCa port of the C/V (2). circuit through P2 bypass cut valve from the
3) Then, the secondary pressure entered into bleed off passage of the swing spool. The P2
PAS port of the C/V (2) switches the slewing bypass cut valve closes in late and
spool. And the solenoid proportionl valve consequently the swing hunting due to the
secondary pressure entered in PCa port control of the swing flow rate is prevented.
switches the P2 bypass cut spool.
8.4 SWING MOTOR FUNCTION
8.2 SWING AUTO PARKING BRAKE 1) Anticavitation circuit when reducing swing
Purpose: speed.
Swing lock and parking brake in neutral 2) Shockless relief to protect it from reverse
position rotation.
Principle:
Release mechanical brake only when required
to operate swing and arm in
Operation:
1) The swing parking function operates usually
when the key switch is ON condition and the
mechanical brake spring is actuated.
2) If the swing parking solenoid is de-excited, the
mechanical brake is released only when the
secondary operating pressure that is built up
during swing action or arm in action acts upon
either of the low pressure sensors (SE-5.7).
22-18
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-19
SWING CIRCUIT; SWING LEFT OPERATION
9. ARM CIRCUIT
This section describes the following operations. 9.2 ARM IN, LIGHT-DUTY VARIABLE NORMAL
1) Arm in, light-duty operating pilot circuit RECIRCULATION MAIN CIRCUIT
2) Arm in, light-duty variable normal Operation:
recirculation main circuit 1) The oil returning from the arm cylinder (R)
opens the arm lock valve and flows into the
9.1 ARM IN, LIGHT-DUTY OPERATING PILOT arm variable recirculate spool through the
CIRCUIT arm spool.
Purpose: 2) Since the passage to the tank is throttled by
Speed-up and Anticavitation when the arm is the arm variable recirculation spool, the oil
at light duty. returning from the arm cylinder (R) flows
Principle: into the load check valve CAr.
The oil returning from the arm cylinder rod 3) Since the R side pressure of the cylinder is
(R) is recirculated variably to the head of C/V. higher than the H side pressure of it when
Operation: working load is light, the pressure pushes the
1) If arm in is performed, the secondary pilot load check valve CAr open and is recirculated
proportional pressure is generated from to the H side so as to speed up the light-duty
port⑦ of left pilot valve (10) and acts upon digging operation.
the low pressure sensor (SE-7). At the same 4) If the FC mode is selected, the command
time, the pressurized oil is branched to two current to the arm variable recirculation
circuits acts upon the PAa port and the PLC2 solenoid proportional valve decreases. This
port of C/V (2), changes the arm spool, and reduces the secondary pressure of the
releases the arm lock valve. solenoid proportional valve. The result is that
2) The output voltage of the low pressure sensor the arm variable recirculation valve is turned
is put into the mechatro controller and to the normal recirculation, thereby causing
processes pilot signals. It is then put out to the arm variable recirculation function to
the P2 pump proportional valve (PSV-2), the prevent cavitation.
proportional valve (PSV-B) of the P2 bypass
cut valve and the arm variable recirculation
proportional valve (PSV-A).
3) The pressure from the P2 pump proportional
valve (PSV-2) and the P2 bypass cut
proportional valve (PSV-B) is created in
proportion to the pilot operating pressure
and acts upon the P2 pump and the PCa port
of the bypass cut valve of C/V (2). In the
case of the arm variable recirculation
proportional valve, the secondary pressure of
the solenoid proportional valve is controlled
so it is put out in reversely proportional to
the pilot operating pressure. Therefore, in the
light-duty arm digging, the secondary
pressure of the solenoid proportional valve
decreases which changes from forcible
recirculation to normal recirculation.
22-20
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-21
ARM CIRCUIT; ARM IN LIGHT LOAD OPERATION, VARIABLE RECIRCULATION FUNCTION
This section describer the following operations. 3) Then, the confluxed oil is fed into arm
3) Arm in, heavy duty operating pilot circuit cylinder H side through C/V (2) Aa port from
(recirculation cut) arm spool.
4) Arm in, heavy-duty sequence conflux main 4) In addition, the return oil from arm cylinder
circuit R side flows into arm lock valve through Ba
port, but since the arm lock valve CRa is
9.3 ARM IN, HEAVY DUTY OPERATING PILOT open, it flows into arm spool.
CIRCUIT 5) Then, the oil passes though orifices on arm
Operation: spool and returns into tank while restricting.
1) If the arm is at heavy duty (more than 160
kgf/cm2) of the pump pressure during arm in
operation, the current of the arm variable
recirculation solenoid proportional valve is
reduced to a minimum, and the arm variable
recirculation function is cut off.
2) The moment the command current for the
arm variable recycle solenoid proportional
valve is minimized, the travel straight
solenoid proportional valve(PSV-C) and the
P1 bypass cut solenoid proportional
valve(PSV-D) are energized. The secondary
pressures of those solenoid valves act upon
the PTb port and the PCb port of the C/V(2)
and changes over the travel straight valve
and the P1 bypass cut valve. This makes up
an arm sequence conflux flow configuration.
3) The action of the left pilot valve in an arm in
motion is the same as in a light-duty
operation.
22-22
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-23
ARM CIRCUIT; ARM IN HEAVY LOAD OPERATION, CONFLUX FUNCTION
This section describes the following operations. 9.7 NATURAL DROP PROTECTION WITH ARM
5) Arm out pilot circuit LOCK VALVE
6) Arm out 2 pumps conflux main circuit Purpose:
7) Natural drop protection with arm lock valve To prevent the arm from falling naturally by
the weight of the arm & bucket.
9.5 ARM OUT PILOT CIRCUIT Principle:
Operation: Complete seat of the return circuit against
1) If arm out operation is performed, the the arm spool of the arm cylinder R side
secondary proportional pilot pressure comes circuit.
out of port ⑧ of the left pilot valve (10) and Operation:
acts upon the low pressure sensor (SE-8). At 1) If the secondary pressure for arm operation
the same time, the pressure is branched to disappears and the arm cylinder stops, the
two circuits and acts upon the PA1, PBa pressure on the rod (R) side passes through
ports of C/V (2). the selector of the lock valve from the Ba port
2) Then, the pilot secondary pressure fed into of C/V, acts the back pressure on the lock
C/V (2) PBa port switches arm spool and fed valve and seats the lock valve.
into PAL port switches arm conflux valve. 2) Since the oil flow from the lock valve to the
3) The output voltage of the low pressure sensor arm spool is blocked completely, the arm is
(SE-8) puts in the mechatro controller which prevented from falling naturally due to oil
processes signals. The controller puts out a leaks through the arm spool.
current command to the P1 bypass cut
solenoid proportional valve (PSV-D). The
secondary pressure comes out of the solenoid
valve, acts upon the PCb port of C/V (2) and
switches the spool of P1 bypass cut valve.
22-24
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-25
ARM CIRCUIT; ARM OUT OPERATION, CONFLUX FUNCTION
10. COMBINED CIRCUIT 4) Next, the travel motion is performed by the
oil discharged by the P2 pump.
(WITH MULTIPLE C/V CIRCUIT)
5) Before entering the travel valve, the oil
This section describles only the difference in discharged by the P2 pump is branched off
combined operation. into the P1 and P2 bypass lines. The oil then
1) Boom up/travel, pilot circuit passes through the right and left travel
2) Boom up/travel, main circit spools and is supplied to the travel motor via
the Br and BL ports of the C/V (2).
10.1 BOOM UP/TRAVEL, PILOT CIRCUIT 6) However, part of the oil gets through by way
Opreation: of the notched throttle in the travel straight
<Points which are differed from the independent valve spool. The throttled passage controls
operation> the speed of the attachments such as travel
1) With signal processing of mechatro controller, and boom motions.
the controller outputs command current to
travel straight valve (PSV-C) and P2 bypass
cut valve (PSV-B) and this solenoid valve
outputs secondary pressure, then acts on C/V
(2) PTb and PCa ports.
2) Next, the PTb port pressure changes the
travel straight valve by one step. The
solenoid proportional secondary pressure
which flows into the PCa port of C/V (2)
changes over the P2 bypass cut valve.
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-27
COMBINED OPERATION; BOOM UP / TRAVEL FORWARD, 1st-SPEED
This section describes difference in combined And swing pilot pressure is led from "Pisc"
operation. port to sub-spool in arm spool, the pressure of
3) Swing/Arm in, pilot circuit arm cylinder head (H) rises higher by
4) Swing/Arm in, swing priority main circuit restricting opening of arm spool circuit
according to swing pilot pressure, as a result
10.3 SWING/ARM IN, PILOT CIRCUIT the oil P2 pump flows preferentially into
Opreation: swing circuit.
1) When swing and arm in operations are This is so-called swing priority control.
concurrently carried out, with signal
processing of mechatro controller, the
controller outputs commands current to
travel straight valve (PSV-C) & P1 bypass cut
valve (PSV-D) & P2 bypass cut valve (PSV-
B) and this solenoid valve outputs secondary
pressure, then acts on C/V (2) PTb & PCb &
Pca ports.
(These operations are the same as that of the
combined respective independent operation.)
2) The arm variable recirculation valve
operates, the same as usual, but the spool
moves toward the forcible recirculation side
according to the pilot pressure for the arm in
action.
22-28
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-29
COMBINED OPERATION; SWING / ARM IN LIGHT LOAD, SWING PRIORITY FUNCTION
11. PRESSURE DRAINING
(RELEASING) CIRCUIT
This section describes the following operations. right and left four to five times to their full
1) Pressure drain (releasing) pilot circuit stroke, pressure may be relieved. If the pump
2) Pressure drain (releasing) main circuit pressure is determined to be more than 5
kgf/cm2 by the output value of the high
11.1PRESSURE RELEASE PILOT CIRCUIT pressure sensor or the high pressure sensors
Purpose: (SE-22,23) are broken, the buzzer sounds
To release the main circuit pressure for continuously. In that case, the buzzer is not
piping repair work. stopped unless the engine key is turned to
Principle: OFF. Repeat the pressure releasing
When press screen change switch of gauge procedure once again.
cluster and buzzer stop switch at the same Operation:
time for more than 5 seconds, mechatro If the travel straight valve is turned to the
controller recognizes this is pressure release pressure release position, the oil discharged
control and out puts the following command. by each pump is unloaded to the tank
1) Puts out the minimum tilting command value passage. If the spools are switched by pilot
to the pump proportional valve (PSV-1, PSV- operation, the remaining pressure from the
2). actuators may be relieved to the tank circuit,
2) Puts out a pressure release control revolution i.e. the main circuit pressure may be
command value to the governor motor. released.
(electric system).
3) Travel straight solenoid proportional valve
(PSV-C) outputs the command valve to
change the pressure release position to the
travel straight valve.
4) Puts out a standby command value to the P1,
P2 bypass cut proportional valves. (a
command that does not put out the secondary
pressure of the P1, P2 bypass proportional
valves).
Operation:
1) The pump proportional valve minimizes the
delivery rates of the P1, P2 pumps.
2) The secondary pilot pressure for the travel
straight valve pressure release position
selection comes out of the travel straight
proportional valve (PSV-C), flows into the
PTb port of C/V (2) and switches the travel
straight valve to its pressure release position.
22-30
SE-22 SE-23 D2 P D1
1 P P
PB PA
A3
M D1
TRAVEL RIGHT TRAVEL LEFT
P D2
B1 a5
4,80 B DE F A C
4,80
PUMP ASSY
※4 Dr3 13 9 B A
B3
19
16,17 TOWER BLOCK
2
4.5kgf/cm
2
2
(64psi) 2.0kgf/cm P
(28psi) 20 SE-1
14 MAIN CONTROL VALVE 21
P2 P1 T P
CMR1 SE-8 23
PL1 ※1 CMR2
HYD. TANK FOR. PBL
PTb TRAVEL
TRAVEL LEFT REV. PAL
STRAIGHT
REV. AL
22
CT2 CP2 FOR. BL
LCs
Drb
BUCKET DUMP
RIGHT PBS 1
BOOM DOWN
BUCKET DIG.
PBr FOR. PBs2 P
SWING RH
SWING LH
CT1 SWING
BOOM UP
TRAVEL Pss SE-5
ARM OUT
PAr REV. RIGHT LEFT PAS
ARM IN
Br FOR. LEFT AS
Ar REV. CP1 RIGHT BS
ATT. ③④ ② ① ⑦⑧ ⑥ ⑤
Dra LCc BOOM PB1 PILOT
PBc DIG. CONFLUX VALVE
BUCKET
PAc DUMP
P SE-2 Bc DIG. SE-7
Ac DUMP
CCb P 10
※2 ※2
PLc2
Drd P T P T 10
LCb OUT PBa
PBb DOWN
Drc BOOM Pisc
PAb UP LCa ARM
IN PAa
P
SE-3 ATT. T P
Bb DOWN IN Aa H PILOT
PLc1 VALVE
CRb CRa
P
※2
CAr ARM R 7 11
SE-4
Ab UP ※2 ※2 OUT Ba
2 5 1 4 6 3
※2 TRAVEL R. FOR.
P P
ARM SE-9 SE-10
CONFLUX TRAVEL R. REV.
PCb Pis TRAVEL L. FOR.
P1 SOL/V BLOCK
P1 P2 VARIABLE
22 TRAVEL L. REV.
BYPASS T BYPASS CUT CCa PCa
CUT D BYPASS RECIRCULATION
SAFETY PA1 CUT
LOCK (T)
TRAVEL 4 LEVER (P4)
STRAIGHT C
PBo2 LCo2 PAo2
TRAVEL Relief set pressure
P2
BYPASS 3 1,2SPEED E115SR EVOLUTION E135SR EVOLUTION
CUT B 24 ※2 ※2 ※1
2
330kgf/cm (4700psi) ※1 350kgf/cm (4970psi)
2
Bo2
Ao2
BOOM(LH) R 5 ※2
2
365kgf/cm (5190psi) ※2 385kgf/cm (5480psi)
2
H
VARIABLE Po 2 2
RECIRCULATION A ※3 265kgf/cm (3770psi) ※3 285kgf/cm (4060psi)
2 2
SWING ※4 51kgf/cm (725psi) ※4 51kgf/cm (725psi)
1 PARKING BRAKE H
P1 BOOM(RH) R 6
15 R 8
H
BUCKET 22-31
PRESSURE DRAIN (RELEASING) CIRCUIT
12. HYDRAULIC LINES
12.1 HYDRAULIC LINES LIST (1/2)
DIVISION
22-32
12.1 HYD. LINES LIST (2/2)
DIVISION
22-33
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
(1-1) STD 10 HOSE; PF1/4 L=2200 1 Swing P/B prim. press. 27 CLIP 1
PUMP CONTROL LINES
(1-2) For DOZER 11 HOSE; PF1/4 L=2650 1 Travel straight changeover 28 SOCKET BOLT 8 M6×25
1 INLINE FILTER 1 ← 12 HOSE; PF1/4 L=3250 1 P2 bypass cut changeover 29 WASHER 8 M6
2 CONNECTOR 3 ← PF3/8 13 HOSE; PF1/4 L=3150 1 Arm variable recirculation 30 CAPSCREW 2 M10×20
3 TEE 1 ← PF1/4 14 HOSE; PF1/4 L=3200 1 P1 bypass cut changeover 31 WASHER 2 M10
4 ELBOW 2 ← PF3/8 15 HOSE; PF3/8 L=550 1 Safety lock changeover 32 GROMMET 1
5 ELBOW 1 ← PF3/4 16 HOSE; PF3/8 L=3000 1 SOL. block prim. press. 33 CLIP 1
6 ELBOW 1 ← PF3/4 17 HOSE; PF3/8 L=3400 1 Drain 35 TUBE 1 L=1200
8 ELBOW 1 ← PF1/4 with filter 18 TUBE 1 L=600
9 CONNECTOR 1 ← PF1/4-PF3/8 19 CLIP 2 (4) T. BLOCK CONTROL Terminal block control lines
10 HOSE; PF1/4 L=400 1 ← P2 Pump SOL. prim. press. 20 CAPSCREW 2 M10×70 1 BRACKET 1
11 HOSE; PF3/8 L=1000 1 ← Pilot pump delively 21 WASHER 2 M10 2 TERMINAL BLOCK 1
12 HOSE; PF1/4 L=900 1 ← P1 Pump SOL. prim. press. 22 RUBBER 1 L=700 3 PRESS. SENSOR 2
13 HOSE; PF3/4 L=480 1 ← Suction 23 CLIP 3 4 ELBOW 5 PF3/8
14 TEE 2 ← PF3/8 24 CLIP 3 5 PLUG 1 PF1/4
15 CAPSCREW 3 ← M10×20 25 GUIDE 1 6 ELBOW 1 PF3/8
16 WASHER 3 5 M10 26 RUBBER 1 L=125 9 HOSE; PF3/8 L=700 1 ⑥ Swing left, ⑧ Arm out
17 CONNECTOR 1 ← PF1/4 L=23 with filter 28 TUBE 1 L=1200 10 HOSE; PF3/8 L=800 1 ① Bucket digging
18 PLUG 2 ← PF1/4 29 CLIP 1 11 CAPSCREW 2 M8×25
19 ELBOW 1 ← PF1/4-PF3/8 12 WASHER 4 M8
20 ELBOW 1 ← PF3/8 (3) ATT REMOTE CONTROL ATT remote control lines 13 NUT 2 M8
21 HOSE; PF3/8 L=700 1 ← Drain 1 PILOT VALVE 2 14 CAPSCREW 2 M12×25
22 HOSE GUARD - 1 L=600 2 CONNECTOR 2 PF1/4 with filter 15 WASHER 2 M12
24 TUBE 1 ← L=790 3 BOOT 2 16 CHECK VALVE 1
25 CLIP 1 ← 4 CONNECTOR 10 PF3/8
26 PLUG 1 ← PF1/4 5 ELBOW 1 PF3/8 (5-1) STD
P-T BLOCK CONTROL
28 TUBE 1 ← L=1000 6 HOSE; PF3/8 L=1400 1 Drain (5-2) EXTRA & N & B
29 CLIP 2 ← 7 HOSE; PF3/8 L=1950 1 Drain 1 P-T BLOCK 1 ←
30 CONNECTOR 1 ← PF3/8 L=23 8 HOSE; PF1/4 L=1450 1 Prim. press. for P/V 2 CONNECTOR 1 ← PF3/8
31 TUBE 1 ← L=300 9 HOSE; PF1/4 L=2000 1 Prim. press. for P/T 3 ELBOW 3 ← PF3/8
32 TEE 1 ← PF3/8 10 HOSE; L=4300 GRAY 1 ⑤ Swing left 4 ELBOW 3 ← PF1/4
33 ELBOW - 2 PF1 11 HOSE; L=4050 RED 1 ⑥ Swing right 5 CAPSCREW 2 ← M8×40
34 HOSE ; PF1 L=760 - 1 Suction 12 HOSE; L=4200 BLUE 1 ⑦ Arm in 6 WASHER 2 ← M8
35 SOCKET BOLT - 2 M10×30 13 HOSE; L=4050 GREEN 1 ⑧ Arm out 7 TEE - 1 PF3/8
36 TUBE 1 ← L=600 14 HOSE; L=3800 RED 1 ① Bucket digging 8 CONNECTOR - 2 PF1/4
37 ELBOW 1 ← PF3/8 15 HOSE; L=3800 BLUE 1 ② Bucket dump 9 PLUG 1 - PF3/8
16 HOSE; L=3400 GREEN 1 ③ Boom up & boom conflux 10 ELBOW 1 ← PF3/8
(2) SOL. VALVE CONTROL SOL.valve control lines 17 HOSE; L=3400 GRAY 1 ④ Boom down 11 ELBOW - 2 PF3/8-PF1/4
1 CAPSCREW 1 M10×20 18 HOSE; L=2600 1 Drain 12 CONNECTOR 1 ← PF1/4 L=23
2 SOLENOID VALVE 1 19 HOSE; L=470 2 13 PLUG 1 - PF1/4
3 CONNECTOR 1 PF1/4 20 CLIP 4 14 ELBOW - 1 PF3/8
4 CONNECTOR 1 PF3/8 L=23 with filter 21 RUBBER 1 L=220 15 TEE - 1 PF1/4
5 ELBOW 7 PF1/4 22 RUBBER 1 L=520 16 CONNECTOR 1 ← PF3/8
6 ELBOW 2 PF3/8 23 RUBBER 1 L=300
7 ELBOW 1 PF3/8 24 RUBBER 1 L=390
8 WASHER 1 M10 25 GROMMET 1
9 HOSE; PF1/4 L=1600 1 Travel 2 speed changeover 26 CLIP 2
22-34
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
(6-1) STD (7) TRAVEL CONTROL Travel control lines (9) Ex.&N&B REMOTE Ex.&N&B remote contr:lines
(6-2) N&B 1 PILOT VALVE 1 1 HOSE; PF1/4 L=3200 1 B ; N/B close
(6-3) With BOOM SAFETY 2 PRESSURE SENSOR 2 2 HOSE; PF1/4 L=2900 1 A ; N/B open
MAIN C/V CONTROL
(6-4) N & B with BOOM SAFETY 3 CONNECTOR 1 PF3/8 3 HOSE; PF1/4 L=400 2 P/V prim. press.
(6-5) With BOOM – ARM SAFETY 4 WASHER 4 M10 4 HOSE; PF1/4 L=500 1 Drain
(6-6) N & B with BOOM – ARM SAFETY 5 CONNECTOR 1 PF1/4 with filter 5 NUT 2 M8
2 CONNECTOR 2 ← ← ← 3 3 PF3/8 6 ELBOW 4 PF3/8 6 PIN 2
3 CONNECTOR 4 ← ← ← ← ← PF1/4 L=23 7 HOSE; PF1/4 L=400 1 Prime. press. for P/V 7 WASHER 6 M8
4 CONNECTOR 2 ← ← ← ← ← PF3/8 L=23 8 HOSE; PF3/8 L=450 1 Drain 8 SOCKET BOLT 4 M10×20
□,1 RH Reverse, □,3 LH
5 CONNECTOR 1 ← ← ← ← ← PF1/4-PF3/8 L=23 9 HOSE; PF3/8 L=3000 2 9 LOCK WASHER 4 M10
Reverse
6 CONNECTOR 3 ← ← ← ← ← PF3/8 L=46 10 SOCET BOLT 4 M10×30 10 CAPSCREW 4 M10×25
□,2 RH Forward, □,4 LH
7 CONNECTOR 1 ← ← ← ← ← PF3/8 ∅0.8 throtring 11 HOSE; PF3/8 L=2600 2 11 WASHER 8 M10
Forward
8 CONNECTOR 2 ← 3 3 3 3 PF1/4-PF3/8 12 CLIP 1 12 CONNECTOR 2 PF1/4 L=23
9 ELBOW 4 ← ← ← ← ← PF1/4 13 TUBE 1 L=400 13 ELBOW 7 PF1/4
10 ELBOW 9 ← 8 8 8 8 PF3/8 14 ELBOW 2 PF1/4 with filter
11 ELBOW 7 8 6 7 6 7 PF1/4-PF3/8 (8-1) BOOM SAFETY 15 PILOT VALVE 1
H/V CONTROL LINES
12 TEE 1 ← ← ← ← ← PF1/4 (8-2) BOOM ARM SAFETY 16 CONNECTOR 1 PF1/4
13 TEE 1 ← ← ← ← ← PF1/4 1 BRACKET 1 ← 17 CAPSCREW 4 M8×20
14 PRESSURE SENSOR 5 ←← ← ←← 2 CONNECTOR 1 2 PF3/8 18 LOCK ASSY 1 RH.
15 ELBOW 1 ← ← ← ← ← PF3/8 3 ELBOW 1 ← PF3/8 19 PEDAL 2
16 TEE 7 ← 8 8 9 ← PF3/8 4 ELBOW - 1 PF3/8 20 RUBBER 2
17 CONNECTOR 1 ← ← ← ← ← PF3/8 L=28 5 ELBOW 1 ← PF1/2 21 LOCK ASSY 1 LH.
18 HOSE; PF1/4 L=650 1 ← ← ← ← ← Drain 6 PLUG 5 2 PF3/8 22 PRESSURE SENSOR 1
19 HOSE; PF1/4 L=450 1 ← ← ← ← ← Drain 7 BLOCK 1 ← 23 PLUG 1 PF1/4
20 HOSE; PF1/4 L=500 1 ← ← ← ← ← Drain 8 TUBE 1 ← L=1800 24 ELBOW 1 PF1/4
21 ELBOW 2 ← ← ← ← ← PF1/4 9 TUBE - 1 L=400 25 HOSE; PF1/4 L=2100 1 A ; Extra.
22 TUBE 2 ← ← ← ← ← L=600 10 TUBE 1 ← L=1900 26 HOSE; PF1/4 L=420 1 Drain
23 TUBE 1 2 1 2 1 2 PF1/4-PF3/8 11 HOSE; PF1/2 L=1700 1 ← Drain 27 HOSE; PF1/4 L=2500 1 B ; Extra.
24 CONNECTOR 1 ← ← ← ← ← PF3/8 ∅1.2 throtring 12 HOSE; PF1/2 L=2000 1 ← Drain 28 PILOT VALVE 1
25 HOSE; PF1/4 L=400 2 ← ← ← ← ← Arm conflux com. 13 HOSE; PF3/8 L=2000 1 ← Boom down command
RAb; Boom up,
26 HOSE; PF1/4 L=760 2 ←← ← ←← PLC1 ; Boom rock changeover 14 HOSE; PF3/8 L=1750 1 ← Boom down command
27 ELBOW 3 ← ← ← ← ← PF1/4 15 HOSE; PF3/8 L=2300 - 1 Arm in command
28 TEE - - 1 1 1 1 PF3/8 16 HOSE; PF3/8 L=680 - 1 Arm in command
29 CONNECTOR 2 ← ← ← ← ← PF1/4 17 HOSE; PF1/2 L=660 - 1 Drain
30 TUBE 3 ← ← ← ← ← L=650 18 CAPSCREW 2 ← M8×20
31 TUBE 1 ← ← ← ← ← L=650 19 TUBE - 1 L=600
32 TUBE 1 ← ← ← ← ← L=350 20 TUBE - 1 L=600
33 CHECK VALVE 2 ←← ← ←← 21 WASHER 2 ← M8
34 TEE 2 ← ← ← ← ← 2-PF1/4-PF3/8 22 WASHER 2 ← M10
35 HOSE; PF3/8 L=760 1 ← ← ← ← ← Swing press. SW. com. 23 TUBE 1 ← L=1500
37 HOSE; PF1/4 L=700 1 ← ← ← ← ← Arm rock changeover 24 CAPSCREW 2 ← M10×25
38 CONNECTOR - - 1 1 1 1 PF1/2-PF3/8 25 TUBE 1 - L=400
40 TEE 2 ← ← ← ← ← PF1/4 26 CLIP 1 ←
41 HOSE; PF1/4 L=650 1 ← ← ← ← ← Drain 27 CLIP 1 ←
30 ELBOW 2 ← PF1/2-PF3/8
31 ELBOW - 1 PF1/2-PF3/8
22-35
ITEM PART NAME Q’TY REMARKS. ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
(11-1) STD 27 HOSE 1 ← 1-14UNS L=1680 25 O RING 1 ← 1A G45
PUMP HYD. LINES
(11-2) DOZER 28 HOSE 1 ← 1-14UNS L=1200 26 U BOLT 1 ←
1 TUBE 1 - Suction 29 HOSE 1 ← 1-14UNS L=1120 27 WASHER 4 ← M8
2 O RING 1 ← 30 HOSE 1 ← 1-14UNS L=1600 28 NUT 5 ← M8
3 RUBBER 2 ← L=200 31 TUBE 2 ← ∅21.7 L=16.5 29 TUBE 1 ← L=1000
4 HOSE 1 ← Suction 32 HOSE 2 ← 1-14UNS L=1950 30 CLIP 5 ←
5 HOSE 1 ← 1-3/16-12UN L=900 33 RUBBER 1 ← L=95 31 CONNECTOR 1 ← PF1/2-PF3/4 L=70
6 HOSE 1 ← 1-3/16-12UN L=1050 34 O RING 19 ← 1B A16 32 RUBBER 2 ←
7 O RING 2 ← 35 O RING 1 ← 1B A18 33 CAPSCREW 1 ← M8×50
8 O RING 2 ← 1B P26 36 CLAMP 2 ← ∅21.7 34 BUSHING 5 ←
9 ELBOW 1 ← 1-3/16-12UN, PF3/4 37 GROMMET 1 ← 35 SPACER 1 ←
10 CONNECTOR 1 ← 1-3/16-12UN, PF3/4 38 CAPSCREW 4 ← M10×25 36 RUBBER 1 ← L=200
11 HALF CLAMP 4 ← 39 CAPSCREW 2 ← M10×45 37 CLIP 1 ←
12 CAPSCREW 8 ← M10×35 40 CAPSCREW 3 ← M12×45
13 SOCKET BOLT 4 ← M12×30 41 CAPSCREW 1 2 M12×90 (14) Add. UPPER HYD. LINES DOZER
14 LOCK WASHER 8 ← M10 44 RUBBER 1 ← L=125 1 ELBOW 2 PF1/2-∅18
15 LOCK WASHER 4 ← M12 45 BRACKET 1 - 2 TEE 1 2-PF1/2 PF1/4
16 CLIP 4 ← 46 CLAMP 1 - 3 ELBOW 1 PF1/2
17 PRESSURE SENSOR 2 ← 47 TUBE 1 ← 4 HOSE 1 ∅18 L=1300
18 TUBE - 1 Suction 49 PLUG 1 ← PF3/8 5 HOSE 1 ∅18 L=1200
6 HOSE 1 PF1/2 L=680
(12-1) KCME (13-1) STD 7 O RING 2 1B P18
UPPER HYD. LINES RETURN HYD. LINES
(12-2) KCME EXTRA & N & B (13-2) For DOZER 8 PLUG 1 PF1/4
1 BRACKET - 1 1 TUBE 1 ← 9 CONNECTOR 1 PF1/2 L=32
2 BUSHING 1 ← 2-∅26.5 2 TUBE 1 ← 10 HOSE GUARD 1 L=600
3 BUSHING 1 ← ∅26.5-∅30.4 3 PLUG 1 - PF3/4
4 CLAMP - 1 4 CONNECTOR 1 ← PF3/4 L=140 (15) Add. RETURN HYD. LINES DOZER
7 SUPPORT 1 ← 5 CONNECTOR 2 ← PF1 1 CONNECTOR 1 PF1/2-PF3/4
8 SUPPORT 1 ← 6 ELBOW 1 ← PF1/2 2 ELBOW 1 PF3/4
9 CONNECTOR 7 ← 1-14UNS, PF3/4 7 ELBOW 2 ← PF3/4 3 HOSE 1 PF3/4 L=450
10 CONNECTOR 1 ← 1-3/16-12UN, PF3/4 8 ELBOW 2 ← PF1 4 HOSE GUARD 1 L=600
11 CONNECTOR 4 ← 1-14UNS, PF3/4 9 TUBE 1 ← L=1600
12 CLIP 3 ← 10 HOSE 1 ← PF3/4 L=1600 (16-1) EXTRA & N & B
Add. UPPER HYD. LINES
13 ELBOW 1 ← 1-14UNS, PF1/2 11 HOSE 1 ← PF1 L=3600 (16-2) EXTRA & N & B & DOZER
14 ELBOW 1 ← 1-14UNS, PF1/2 12 HOSE 1 ← PF1 L=1600 1 HOSE 1 ← PF1/2 L=2150
15 RUBBER 1 ← L=100 13 COUPLING 2 ← ∅42.7 2 HOSE 1 ← PF1/2 L=2100
16 HOSE 1 ← 1-14UNS L=1070 14 CHECK VALVE 1 ← 3 HOSE 1 ← PF1/2 L=600
17 TUBE 1 ← 15 CHECK VALVE 1 ← 4 TUBE 1 - L=1100
18 HOSE 1 ← 1-14UNS L=920 16 CONNECTOR 1 ← PF3/8 L=68 5 TUBE - 1 L=1300
19 HOSE 1 ← 1 3/16-12UN L=2930 17 ELBOW 1 ← PF1/2 6 HOSE 1 - PF1/2 L=1200
20 HOSE 1 ← 1-14UNS L=2970 18 TEE 1 ← PF3/8, 2-PF1/2 7 CONNECTOR 1 ← PF1/2 L=41
21 HOSE 1 ← 1-14UNS L=2620 19 TEE 1 ← PF1/2 8 HOSE 1 ← PF1/2 L=520
22 HOSE 1 ← 1-14UNS L=2570 20 HOSE 1 ← PF1/2 L=1200 9 CLIP 2 ←
23 WASHER 6 ← M10 21 HOSE 1 ← PF1/2 L=700 10 BUSHING 1 ← 2-∅23.5
24 WASHER 5 ← M12 22 HOSE 1 ← PF1/2 L=1850 11 CONNECTOR 1 ← PF1/2
25 GROMMET 1 ← 2-∅29 23 WASHER 4 ← M10 12 CONNECTOR 1 ← PF1/2 L=32
26 CLIP 2 ← 24 CAPSCREW 4 ← M10×75 13 CAPSCREW 4 ← M12×30
22-36
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS. ITEM PART NAME Q’TY REMARKS
14 HOSE - 1 PF1/2 L=1400 5 TUBE ※ 1 ← 26 TUBE 1 ←
15 ELBOW 4 ← PF1/2 6 TUBE ※ 1 ← 27 TUBE 1 ←
16 BRACKET 1 ← 2-PF1/2 7 TUBE ※ 1 ← 28 TUBE 1 ←
17 WASHER 6 ← M12 8 TUBE ※ 1 ← 29 TUBE 1 ←
18 CONNECTOR 2 3 PF1/2 9 TUBE ※ 1 ← 30 HOSE 4 ←
19 ELBOW 1 ← PF1/2 10 TUBE ※ 1 ← 31 TEE 2 ←
20 TEE 1 ← 2-PF1/2 PF1/4 11 TUBE ※ 1 ← 32 CLAMP 4 ←
21 PLUG 1 ← PF1/4 12 TUBE ※ 1 ← 33 CAPSCREW 2 ← M8×80
22 BRACKET 1 ← 13 HOSE ※ 2 (←) L=1750 (L=2000) 34 NUT 2 ← M8
23 SELECTOR VALVE 1 ← 14 HOSE GUARD 2 ← L=300
24 BUSHING 1 ← ∅26.5-∅0.5 15 CLIP 12 14 (19-1) S/J hyd. lines
SWIVEL HYD. LINES
25 CONNECTOR 1 ← PF1-PF3/4 16 CONNECTOR 4 ← (19-2) S/J hyd. lines
26 CONNECTOR 1 ← 1-14UNS-PF3/4 17 CONNECTOR 2 ← 1 CONNECTOR 4 ← PF1-∅22
27 CONNECTOR 1 ← 1-14UNS-PF3/4 18 CLAMP 2 ← 2 CONNECTOR 2 ← PF1/4
28 ELBOW 1 ← PF1 19 CLAMP 2 ← 3 TEE 1 ← PF1/2-∅18
29 ELBOW 1 ← 1-14UNS-PF3/4 20 SPACER 4 ← 4 O RING 4 ← 1B P29
30 ELBOW 1 ← 1 3/16-12UN-PF3/4 21 CAPSCREW 4 ← M8×40 5 O RING 1 3 1B P18
31 O RING 3 ← 1-14UNS 22 LOCK WASHER 4 ← M8 6 CONNECTOR - 2 PF1/2
32 O RING 1 ← 1 3/16-12UNS 23 WASHER 4 ← M8
33 HOSE 1 ← 1-14UNS L=3060 (20) TRAVEL HYD. LINES Travel hyd. lines
35 HOSE 1 ← 1 3/16-12UN L=1950 (18-3) DOZER E115SR EV. 1 CONNECTOR 4 PF3/4
LOWER HYD. LINES
36 HOSE 1 ← PF1 L=850 (18-4) DOZER E155SR EV. 2 CONNECTOR 2 PF1/2
37 CAPSCREW 4 ← M8×25 1 TUBE ※ 1 ← 3 CONNECTOR 2 PF1/4
38 WASHER 4 ← M8 2 TUBE ※ 1 ← 4 O RING 4 1B P24
41 BUSHING 1 ← 3 TUBE ※ 1 ← 5 O RING 2 1B P18
42 CLIP 1 ← 4 TUBE ※ 1 ←
43 CAPSCREW 1 ← M12×20 5 TUBE ※ 1 ← (21-1) E115SR EVOLUTION
BOOM HYD. LINES
44 LABEL 1 ← 6 TUBE ※ 1 ← (21-2) E135SR EVOLUTION
45 HOSE 1 ← 1-14UN L=1540 7 TUBE ※ 1 ← 1 TUBE ※ 1 ← ∅27.2×3.2
46 CONNECTOR 1 ← PF1 8 TUBE ※ 1 ← 2 TUBE ※ 1 ← ∅21.7×2.8
49 CAPSCREW 1 ← M12×35 9 TUBE ※ 1 ← 3 TUBE ※ 1 ← ∅21.7×2.8
10 TUBE ※ 1 ← 4 TUBE ※ 1 ← ∅21.7×2.8
(17-1) STD 11 TUBE ※ 1 ← 5 CLAMP 4 ←
SWIVEL HYD. LINES
(17-2) DOZER 12 TUBE ※ 1 ← 6 CLAMP 2 ←
1 ELBOW 2 ← PF1 1-14UNS 13 HOSE ※ 2 (←) L=1880 (L=2000) 7 CLAMP 2 ←
2 ELBOW 2 ← PF1 1-14UNS 14 HOSE 2 ← L=300 8 CAPSCREW 1 ← M10×40
3 CONNECTOR 1 ← PF1/2 L=130 15 CLIP 12 14 9 CAPSCREW 5 ← M10×45
4 O RING 4 ← 1-14UNS 16 CONNECTOR 4 ← 10 CAPSCREW 2 ← M12×45
5 ELBOW - 2 PF1/2-∅18 17 CONNECTOR 2 ← 11 LOCK WASHER 6 ← M10
6 O RING - 2 1B P18 18 CLAMP 2 ← 12 LOCK WASHER 2 ← M12
19 CLAMP 2 ← 13 O RING 6 ← 1B A16
(18-1) STD E115SR EVOLUTION 20 SPACER 4 ← 14 O RING 2 ← 1B A18
LOWER HYD. LINES
(18-2) STD E155SR EVOLUTION 21 CAPSCREW 4 ← M8×40
1 TUBE ※ 1 ← 22 LOCK WASHER 6 8 M8
2 TUBE ※ 1 ← 23 WASHER 4 ← M8
3 TUBE ※ 1 ← 24 TUBE 1 ←
4 TUBE ※ 1 ← 25 TUBE 1 ←
NOTE ; The parts with mark ※ are having different part numbers. 22-37
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
(21-3) EXTRA & N & B E115SR EV. (22-1) STD E115SR EVOLUTION 8 CAPSCREW 16 ← M10×30
Add. BOOM HYD. LINES ARM HYD. LINES
(21-4) EXTRA & N & B E135SR EV. (22-2) STD E115SR EVOLUTION 9 LOCK WASHER 2 ← M10
1 TUBE ※ 1 ← ∅27.2×t3.2 1 HOSE ※ 2 (←) L=1050 (L=1100) 10 CONNECTOR 2 ←
2 TUBE ※ 1 ← ∅21.7×t2.8 11 GREASE NIPPLE 2 ←
3 TUBE ※ 1 ← ∅27.2×t3.2 (22-3) EXTRA &N&B E115SR EV. 12 O RING 4 ← 1B A16
Add. ARM HYD. LINES
4 TUBE ※ 1 ← ∅21.7×t2.8 (22-4) EXTRA &N&B E115SR EV. 13 O RING 4 ← 1B P26
5 TUBE ※ 1 ← ∅18×t2.5 1 TUBE ※ 1 ←
6 TUBE ※ 1 ← ∅18×t2.5 2 TUBE ※ 1 ← (23-3) With HOLD.VALVE E115SR EV.
H/V BOOM CYL. HYD.
7 TUBE ※ 1 ← ∅18×t2.5 3 TUBE ※ 1 ← (23-4) With HOLD.VALVE E135SR EV.
8 TUBE ※ 1 ← ∅18×t2.5 4 TUBE ※ 1 ← 1 TUBE 1 ←
9 CONNECTOR 2 ← ∅18-∅18 5 TUBE ※ 1 ← 2 TUBE 1 ←
10 CONNECTOR 2 ← ∅18-PF1/2 6 TUBE ※ 1 ← 3 TUBE 2 ←
11 O RING 1 ← 1B A16 7 HOSE ※ 2 (←) L=1200 (L=1300) 4 HOSE 4 ← L=740
12 O RING 4 ← 1B A18 8 HOSE ※ 2 (←) L=1050 (L=1250) 5 HOSE 1 ← L=1250
13 O RING 1 ← 1B A21 9 STOP VALVE 2 ← 6 HOSE 1 ← PF3/8 L=1400
14 PLUG 2 ← PF1 10 CONNECTOR 2 ← 1 3/16-12UN-PF3/4 7 HOSE 1 ← PF1/2 L=1400
15 CLAMP 2 ← 11 TEE 2 ← 3-M26×P1.5 8 HOLDING VALVE ※ 1 ←
16 CLAMP 3 ← 12 PLUG 2 ← M26×P1.5 9 HOLDING VALVE ※ 1 ←
17 CLAMP 3 ← 13 PLUG 2 ← 10 CONNECTOR 1 ← 2-PF3/8
18 CLAMP 1 ← 14 NUT 2 ← 11 CONNECTOR 2 ← 2-PF3/8
19 CLAMP 4 ← 15 CLAMP 1 ← 12 CONNECTOR 2 ← PF1/2-1-14UNS
20 CLAMP 4 ← 16 CLAMP 2 ← 13 CONNECTOR 2 ← PT1/4-PF1/4
21 CLAMP 1 ← 17 BRACKET 2 ← 14 CONNECTOR ※ 1 ← PF1/2-PF3/8
22 CAPSCREW 10 ← M10×45 18 O RING 4 ← 1B A18 15 ELBOW 1 ← 2-PF3/8
23 CAPSCREW 1 ← M12×50 19 CAPSCREW 8 ← M8×25 16 ELBOW 1 ← 2-PF3/8
24 CAPSCREW 3 ← M12×55 20 CAPSCREW 1 ← M10×45 17 ELBOW 2 ← PF3/4-1-14UNS
25 LOCK WASHER 10 ← M10 21 CAPSCREW 2 ← M10×55 18 ELBOW 1 ← PF1/2-PF3/8
26 LOCK WASHER 4 ← M12 22 CAPSCREW 4 ← M12×45 19 ELBOW 1 ← 2-PF1/2
23 WASHER 8 ← M8 20 TEE 1 ← 3-PF3/8
(21-5) ARM SAFETY E115SR EV. 24 WASHER 4 ← 21 TEE 1 ← 3-PF1/2
Add. BOOM HYD. LINES
(21-6) ARM SAFETY E135SR EV. 25 LOCK WASHER 3 ← M10 22 GREASE NIPPLE 2 ← PT1/8
1 HOSE ※ 1 ← PF1/2 L=3900 26 LOCK WASHER 4 ← M12 23 CLAMP 2 ←
2 HOSE ※ 1 ← PF3/8 L=3800 24 CAPSCREW 2 ← M10×45
3 HOSE GUARD 1 ← L=500 (22-5) CONNECTOR ASSY EXTRA & N & B 25 CAPSCREW 8 ← M10×30
4 BRACKET 1 ← 1 CONNECTOR 1 26 CAPSCREW 8 ← M10×60
5 CONNECTOR 2 ← PF1/2-PF3/8 2 PLUG 1 27 LOCK WASHER 2 ← M10
6 CONNECTOR 2 ← 2-PF3/8 3 O RING 1 1B P24 28 O RING 8 ← 1B A16
7 CAPSCREW 2 ← M10×20 29 O RING 4 ← 1B P26
8 CAPSCREW 1 ← M10×16 (23-1) STD E115SR EVOLUTION 30 CLIP 10 ←
BOOM CYL. HYD. LINES
9 LOCK WASHER 2 ← M10 (23-2) STD E135SR EVOLUTION
10 WASHER 1 ← M10 1 TUBE 1 ←
11 CLIP 1 ← 2 TUBE 1 ←
12 CLIP 20 ← 3 TUBE 1 ←
4 TUBE 1 ←
5 HOSE 4 ← L=740
6 CLAMP 2 ←
7 CAPSCREW 2 ← M10×45
22-38 NOTE ; The parts with mark ※ are having different part numbers.
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
(23-5) STD E115SR EV. (23-9) E115SR EVOLUTION
ARM CYL. HYD. LINES BUCKET CYL. HYD.
(23-6) STD E135SR EV. (23-10) E135SR EVOLUTION
1 TUBE 1 ← 1 TUBE ※ 1 ←
2 HOSE ※ 1 (←) L=870 (L=870) 2 TUBE ※ 1 ←
3 HOSE ※ 1 (←) L=830 (L=800) 3 CLAMP 1 ←
4 CLAMP 1 ← 4 CAPSCREW 1 ← M10×50
5 HALF CLAMP 2 ← 5 SOCKET BOLT 4 8 M10×30
6 CONNECTOR 1 ← 6 O RING 2 ← 1B A16
7 SOCKET BOLT 4 ← M10×30 7 O RING 2 ← 1B P26
8 CAPSCREW 1 ← M10×45 8 GREASE NIPPLE 1 ←
9 SOCKET BOLT 4 ← M10×35 9 GREASE NIPPLE 1 ←
10 GREASE NIPPLE 1 ← 10 LOCK WASHER 1 ← M10
11 O RING 1 ← 1B A16 11 SOCKET SCREW 4 - M10×35
12 O RING 2 ← 1B P26
13 LOCK WASHER 1 ← M10 (23-11) DOZER CYL. HYD. Dozer cylinder hyd. lines
14 LOCK WASHER 4 ← M10 1 CONNECTOR 4 PF1/2
2 O RING 4 1B P18
(23-7) With HOLD.VALVE E115SR EV.
H/V ARM CYL. HYD.
(23-8) With HOLD.VALVE E135SR EV.
1 TUBE ※ 1 ←
2 HOSE ※ 1 (←) L=870 (L=870)
3 HOSE ※ 1 (←) L=830 (L=800)
4 HOLDING VALVE 1 ←
5 CONNECTOR 1 ← 2-PF3/8
6 CONNECTOR 1 ← 2-PF3/8
7 CONNECTOR 1 ← PT1/4-PF1/4
8 ELBOW 1 ← PF1/2-PF3/8
9 ELBOW 1 ← PF3/4-1-14UNS
10 PLUG 1 ← PF1/2
11 GREASE NIPPEL 1 ← PT1/8
12 CLAMP 1 ←
13 HALF CLAMP 2 ←
14 CAPSCREW 1 ← M10×45
15 SOCKET SCREW 4 ← M10×35
16 SOCKET SCREW 4 ← M10×60
17 LOCK WASHER 1 ← M10
18 LOCK WASHER 4 ← M10
19 O RING 2 ← 1B A16
20 O RING 2 ← 1B P26
21 CLIP 20 ←
NOTE ; The parts with mark ※ are having different part numbers. 22-39
PILOT PIPNG
(1-1) Pump control lines STD
(1-2) Pump control lines For DOZER
22-40
(2) SOL. valve control lines
22-41
(3) ATT remote control lines
22-42
(4) Terminal block control lines (5-1) P-T block control lines STD
(5-2) P-T block control lines EXTRA & N & B
22-43
22-44
(6) Main C/V control lines (2/2)
22-45
(7) Travel control lines
22-46
(8-1) Holding valve control lines BOOM SAFETY
(8-2) Holding valve control lines BOOM・ARM SAFETY
22-47
(9) Extra & N & B remote control lines
22-48
(11-1) Pump hyd. lines STD
(11-2) Pump hyd. lines DOZER
22-49
(12-1) Upper hyd. lines (1/2)
(12-2) Upper hyd. lines (1/2) EXTRA & N & B
22-50
(12-1) Upper hyd. lines (2/2)
(12-2) Upper hyd. lines (2/2) EXTRA & N & B
22-51
(13-1) Return hyd. lines (1/2) STD
(13-2) Return hyd. lines (1/2) For DOZER
22-52
(13-1) Return hyd. lines (2/2) STD
(13-2) Return hyd. lines (2/2) DOZER
22-53
(14) Add upper hyd. lines DOZER (15) Add return hyd. lines DOZER
22-54
(16-1) Add upper hyd. lines (1/2) EXTRA & N & B
(16-2) Add upper hyd. lines (1/2) EXTRA & N & B & DOZER
22-55
(16-1) Add upper hyd. lines (2/2) EXTRA & N & B
(16-2) Add upper hyd. lines (2/2) EXTRA & N & B & DOZER
22-56
(17-1) Swivel hyd. lines STD (17-2) Swivel hyd. lines DOZER
22-57
(18-1) Lower hyd. lines STD, E115SR EVOLUTION
(18-2) Lower hyd. lines STD, E135SR EVOLUTION
22-58
(18-3) Lower hyd. lines DOZER, E115SR EVOLUTION
(18-4) Lower hyd. lines DOZER, E135SR EVOLUTION
22-59
(21-1) Boom (4.25M) hyd. lines E115SR EVOLUTION
(21-2) Boom (4.6M) hyd. lines E155SR EVOLUTION
22-60
(21-3) Add boom hyd. line; EXTRA & N & B, E115SR EVOLUTION
(21-4) Add boom hyd. lines EXTRA & N & B, E135SR EVOLUTION
22-61
(21-5) Add boom hyd. lines; ARM SAFETY E115SR EVOLUTION
ARM SAFETY E135SR EVOLUTION
22-62
(22-1) Arm hyd. lines STD, E115SR EVOLUTION (22-3) Add arm hyd. lines EXTRA & N & B STD, E115SR EVOLUTION
(22-4) Add arm hyd. lines EXTRA & N & B STD, E135SR EVOLUTION
22-63
(22-5) Add connector assy EXTRA & N & B (23-1) Boom cylinder hyd. lines STD E115SR EVOLUTION
(23-2) Boom cylinder hyd. lines STD E135SR EVOLUTION
22-64
(23-3) Boom cylinder hyd. lines With HOLDING VALVE E115SR EVOLUTION (23-7) Arm cylinder hyd. lines With HOLDING VALVE SK115SR-1E
(23-4) Boom cylinder hyd. lines With HOLDING VALVE E135SR EVOLUTION (23-8) Arm cylinder hyd. lines With HOLDING VALVE SK135SR(LC)-1E
22-65
NOTE
22-66
SECTION 23 ELECTRICAL SYSTEM
TABLE OF CONTENTS
MOTOR
SOLENOID
C-2 M-4 Washer motor (tank assy) SV-6 Clockwise sol
C-2 Gauge cluster (EU Spec.) M-9 Fuel pump SV-7 Counter-clockwise sol.
M-11 Fuel supply pump SV-9 Nibbler open sol.
C-4 Air conditioner controller (A/C Acc.) SV-10 Nibbler close sol.
R-1 Battery relay
D-1 Diode R-3 Glow relay PSV-A Arm variable recirculation proportional valve
PROPORTIONAL VALVE
D-2 Diode R-4 Safety relay PSV-B P2 bypass cut proportional valve
D-3 Diode R-5 Wiper motor relay PSV-C Travel straight proportional valve
DIODE
SOLENOID
D-4 Diode R-6 Washer motor relay PSV-D P1 bypass cut proportional valve
D-5 Diode R-7 Horn relay PSV-P1 P1 pump proportional valve
D-6,7,8,9 R-8 Work light relay PSV-P2 P2 pump proportional valve
R-10 Cab work light relay 1
E-1 Fuse box RELAY R-11 Cab work light relay 2
E-1 Alternator (E115SR EV.) R-18 Travel alarm relay
E-2 Alternator (E135SR EV.) R-19 Flasher relay
E-3 Hour meter R-20 Timer relay SW-1 Key switch
E-4 Horn (Low) R-22 Clockwise relay
E-5 Horn (High) R-23 Counter-clockwise relay SW-3 2-speed travel switch
ELECTRIC FITTINGS
E-6 Cigarette lighter R-24 Nibbler open relay SW-4 Swing parking release switch
E-7 Tuner AM & FM R-25 Nibbler colse relay SW-5 KPSS release switch
E-8 Speaker (Left) SW-6 E/G water temperature switch [105℃(221°F)]
E-9 Speaker (Right) SE-1 Pressure sensor (low pressure) bucket digging SW-7 E/G oil pressure switch
E-10 Receiver drier (A/C Accessory) SE-2 Pressure sensor (low pressure) bucket dump SW-8 Air filter clogging switch
E-11 A/C compressor (A/C Accessory) SE-3 Pressure sensor (low pressure) boom up SW-10 Horn switch left
E-14 Resistor (P1, P2 pump proportional valve) SE-4 Pressure sensor (low pressure) boom down SW-11 Lever lock switch (Limit SW.)
E-15 Travel alarm SE-5 Pressure sensor (low pressure) swing SW-13 Air conditioner switch (Panel assy)
E-16 DC-DC converter SW-16 Auto accel release switch (Desel)
E-17 Power socket 12V SE-7 Pressure sensor (low pressure) arm in SW-17 Swing flasher select switch
E-25 Battery (95E41R) SE-8 Pressure sensor (low pressure) arm out SW-20 Horn switch right
SWITCH
SE-9 Pressure sensor (low pressure) travel right SW-21 Work light switch
L-1 Boom work light left SE-10 Pressure sensor (low pressure) travel left SW-22 Single/Conflux flow select switch
L-2 Work light right SE-11 Pressure sensor (low pressure); P2 option SW-23 Wiper inter lock switch
SENSOR
L-3 Room light (Cab) SE-11 Pressure sensor (low pressure); N&B (Opt.) SW-30 Rotary light switch
L-4,5,78 Cab work light (front) SE-12 Pressure sensor (low pressure); Offset left opt. SW-32 Overload display switch
LIGHT
L-8 Engine room light SE-12 Pressure sensor (low pressure); Offset right opt. SW-37 Hydraulic oil temp. switch
L-9 Boom work light (RL) SE-13 E/G speed sensor SW-38 Warm-up switch
L-10 Cab work light (Re) SE-14 E/G water temperature sensor SW-39 Overload pressure switch
L-11,1 Swing flasher (right, left) SE-15 Fuel sensor SW-42 Engine room light switch
2
L-15 Rotary light SE-16 Accel potentiometer SW-43 Jib press switch: option
SE-20 Pressure sensor (low pressure); P1 option SW-44 Extra press switch: option
SE-20 Pressure sensor (low pressure); Jib extend / contract opt. SW-46 Clockwise sw.
SE-22 Pressure sensor (high pressure); P1 pump SW-47 Counter-lockwise sw.
SE-23 Pressure sensor (high pressure); P2 pump SW-48 Nibbler open sw.
SE-26 Pressure sensor (low); Revolution R/L Opt. SW-49 Nibbler close sw.
23-4
3. HARNESS
3.1 HARNESS LIST
DEVICION DWG. No. HARNESS REMARK
23-5
3.2 HARNESS CONNECTION DRAWING
23-8
3.4.3-8 INSTRUMENT PANEL HARNESS
INSTALL TERMINAL
TERMINAL CORRUGATE TERMINAL BOLT DOUBLE- 60-8L
NUT
60-8 60sq TUBE BA710 WOUND TAPING
60sq
INSTALL
TERMINAL VIEW Ⅰ
WHITE TAPING CORRUGATE CAP BC816
YAZAKI : 7034-1283
CAP
TAPING 1PAF-58Y
A Ⅰ
YAZAKI : 7034-1283
AVX5sq
TERMINAL Fig. 12
LA310
Fig. 9
TERMINAL TERMINAL
60-8 BC818
CAP AV60B CAP
YAZAKI : 7034-1283 BTC-135-R (RED)
Fig. 10
Fig. 11
23-17
3.7.23 MAIN HARNESS
E115SR EVOLUTION
CLIP
CLIP TERMINAL AND
STARTER CABLE
CONNECTOR WITH
RUBBER CAB
TO BATTERY RELAY
VIEW__
MAIN HARNESS
DETAIL OF STARTER MOTOR
GND (E/G ACCESSORY)
TIGHTEN GND.CABLE CONNECTOR OF ENGINE SPEED SENSOR
STARTER MOTOR (M-1) TIGHTENING TORQUE :
8.5kgfym {61 lbfyft}
DIS-
AIR HEATER E/G WATER HIGH CHARGE
E/G WATER
NOT TO PASS TEMP SW. (SW-6)
B OVER HEAD
UNDER SUPPLIED
C NUT
COVER. WITH E/G.
E/G COOLANT THERMO VIEW__
SENSOR (SE-14)
E/G COOLANT THERMO ALTERNATOR (E-2)
SENSOR (SE-14)
TIGHTEN ITEM CLIP AND HARNESS
GND TERMINAL OF ITEM 1. WASHER
TIGHTENING TORQUE :
5.1kgfym {37 lbfyft}
E/G SUB HARNESS DETAIL D
TIGHTENING TORQUE :
0.5_0.7kgfym {3.6_5.1 lbfyft}
TIGHTENING
D TORQUE :
AIR HEATER 0.2_0.5kgfym FIX HARNESS AT
{1.4_3.6 lbfyft} WHITE TAPING
POSITION
WIRING HARNESS OUT CLIP
OF TOUCH ENGINE
CLIP
BY USING EXISTING FIX CONNECTOR CLIP
CAPSCREW TIGHTEN WITH BRACKET FIX THE HARNESS
LIFTING LUG FOR AS DRAWING
MAIN HARNESS
ENGINE AND CLIP
TOGETHER.
DETAIL OF ALTERNATOR
DETAIL B DETAIL C
Fig. 15 (1/2)_Engine harness assy
23-20
BY USING EXISTING CAPSCREW
3.8 ENGINE HARNESS ASSY TIGHTEN LIFTING LUG FOR
E/G SUB HARNESS
ENGINE AND CLIP TOGETHER.
ENGINE HARNESS ASSY E135SR EV.
TIGHTENING TORQUE :
CONNECTOR (GRAY) 6.6kgfym {48 lbfyft}
ITEM PART NAME Q’TY REMARKS
STARTER TERMINAL
1 HARNESS 1 E/G sub
E135SR EVOLUTION
CLIP
CLIP TERMINAL AND STARTER CABLE
CONNECTOR WITH VIEW__
RUBBER CAB
TO BATTERY RELAY
GLOW
E/G WATER HIGH
SUCTION
TEMP. LIMIT SW. (SW-7)
UNDER
E/G WATER
AIR CONPRESSOR CLUTCH VIEW__ SUPPLIED
TEMP SW. (SW-6) A NUT
B WITH E/G.
E/G COOLANT THERMO
SENSOR (SE-14) TIGHTEN EARTH
NOT TO PASS OVER
ALTERNATOR (E-2) TERMINAL TO
HEAD COVER.
COMPRESSOR HARNESS
BRACKET
WASHER
FIX HARNESS AT
C E/G SUB HARNESS WHITE TAPING
POSITION
GLOW
CLIP
23-21
3.8.1A E/G SUB HARNESS
E115SR EVOLUTION
23-22
3.9 FLOOR HARNESS ASSY
E115SR EV.
FLOOR HARNESS ASSY
E135SR LC EV.
ITEM PART NAME Q’TY REMARKS
1 HARNESS 1 Under floor
3 CABLE 1 Earth
23-23
3.9.1 UNDER FLOOR HARNESS
23-24
3.10 CAB HARNESS ASSY
E115SR EV.
CAB HARNESS ASSY
E135SR EV.
ITEM PART NAME Q’TY REMARKS
3 HARNESS 1 Cab front
5 HARNESS 1 Install RH
10 HARNESS 1 Install LH
CAB INSTALL
E115SR EV.
CAB INSTALL
E135SR LC EV.
CONNECT WITH
ITEM NAME Q’TY REMARKS HARNESS.
4 WASHER TANK ASSY 1
CONNECT WITH
4-1 ELECK MOTOR ASSY 1 INSTRUMENT
PANEL HARNESS
2PAM
189
CONNECT TO TUNER
CLIP
HARNESS 2-37 4PAM-HM
CURL
CODE
2-8
4PAF
CAB 4
GLASS MARK
Fig. 25 Cab install F1 : MANUAL WINDOW
Fig. 24 Cab assy
23-29
3.11.2-37 WIPER HARNESS 3.11.61 CURL CODE HARNESS 3.11.64 CAB WIPER MOTOR HARNESS
Fig. 26 Fig. 27
Fig. 28
3.11.65 ANTENNA 3.11.189 ROOM LAMP HARNESS WINDOW WASHER TANK & MOTOR
Fig. 29 Antenna
Fig. 31
23-30
3.12 BATTERY INSTALL & BATTERY 3.13 LIGHT INSTALL
E115SR EV. 3.13.2 DECK LIGHT INSTALL
BATTERY INSTALL E115SR EV.
E135SR LC EV.
DECK LIGHT INSTALL
ITEM PART NAME Q’TY REMARKS E135SR LC EV.
2 CAPSCREW 2 1 LIGHT 1
BATTERY
BRACKET
23-31
3.13.2 CAB LIGHT INSTALL
23-33
3.15 FUEL PUMP ASSY 3.15.2 FUEL PUMP ASSY
E115SR EV. E115SR EV.
FUEL PUMP ASSY E135SR LC EV. FUEL PUMP ASSY E135SR LC EV.
ITEM PART NAME Q’TY REMARKS ITEM PART NAME Q’TY REMARKS
2 FUEL PUMP ASSY 1 10 ELEC MOTOR 1
22 FUSE 1
TABLE OF CONTENTS
34402 60413254
Part I: HYDRAULIC EQUIPMENT
1. HYDRAULIC PUMP・REGULATOR
1.1 SUMMARY
(1) Outside view and hydraulic port
4 a3 PSV1 5 a5,Dr3
A3
A4,B4 3 No. NAME
1 MAIN PUMP ASSY
B3 2 REGULATOR ASSY
Dr1
3 GEAR PUMP ASSY(FOR PILOT)
GEAR PUMP ASSY FOR DOZER
4 (ONLY E115SR EV.)
5 PTO GEAR CASE ASSY
SOLENOID PROPORTIONAL
6 REDUCING VALVE
PSV2 a4
6 a3 6
a4 2
2 A3
a5
Dr3
B3
Dr1 A1 A2 B1 PH2 a2 A2
Standard spec.
Solenoid Solenoid
proportional proportional
reducing valve reducing valve
Regulator
Regulator
Main pump
Dozer spec.
Solenoid Solenoid
proportional proportional
reducing valve reducing valve
Regulator
Regulator
Main pump
24-2
(3) Specification
E115SR EVOLUTION
E135SR LC EVOLUTION Table 1-2
24-3
1.2 HYDRAULIC PUMP
1.2.1 CONSTRUCTION
(1) Main pump
535 789 732 212 156 532 214 531,548 534 702 792 954 124 124 901 116 711 312 719 151 152 113 252
953
808
251
886
406
261 717
406
111 123
824
774
127
710
262
401
490
271 211 153 462,728 157 313 466,725 885 886 314 141 468,728
24-4
(2) Gear pump(for pilot)
433
434 A
351
435
312
353
311
732
SECTION AA
309 310 307 308 355 434 850 466 725 728 467
Table 1-4
24-5
(3) PTO gear case
GEAR PUMP
326 118 125 825 (for pilot) 728 468
117
126
128
435
886
827
115
826
Table 1-5
24-6
(4) Gear pump for dozer or extra
55 54 51 6 3 53 52
4 1 7 5 50 2
Specification
Gear pump for dozer
Item
Model SGP1A25F2H9-L389
Displacement capacity cm3/rev 24.9
Working pressure kgf/cm2(psi) 210 (3,000)
Max. flow /min(gal/min) 51 (13)
Relief set pressure kgf/cm2(psi) 210 (3,000)
Table 1-6
No. NAME Q’TY No. NAME Q’TY
1 FRONT COVER 1 50 GASKET(SHAPED LIKE LETTER 3) 2
2 REAR COVER 1 51 GASKET 2
3 BODY 1 52 SOCKET BOLT 4
4 DRIVE GEAR 1 53 WASHER 4
5 DRIVEN GEAR 1 54 OIL SEAL 1
6 SIDE PLATE 2 55 SNAP RING 1
7 BUSHING 4
24-7
1.2.2 OPERATION
The pump assy is equipped with two pumps
arranged on the same axis that are connected
with gear (116) and distribute the rotating power REGULATOR
to the gear trains on a different axis. Thus the
engine rotation is transmitted to front shaft (111)
that drives the two pumps and, at the same time,
drives the pilot gear pump and the dozer gear
116
pump(option) arranged on a different axis.
The pump assy consists largely of the rotary
111
group, the main part of the pump that makes
rotary on; the swash plate group that changes the
delivery rate; the valve block group that selects
between oil suction and delivery ; and the PTO
group that transmits the drive power to the gear GEAR PUMP
pump. PTO FOR DOZER
(OR EXTRA)
GEAR
(1) Rotary group GEAR PUMP CASE
(FOR PILOT)
The rotary group consists of shaft (111),
cylinder block (141), piston (151), shoe (152),
plate (153), spherical bushing (156), and
cylinder spring (157).
The shaft is supported by bearings (123) and Fig. 1-6 (1/2) Construction of hydraulic pump
(124) at its both ends. The shoe, which is
caulked to the piston, forms a spherical joint
and relieves it of thrust force that is
generated by load pressure.
Further, the piston is provided with a pocket
so it moves lightly on shoe plate (211), taking
hydraulic balance.
The sub group of the piston-shoe is pressed
against the shoe plate by the cylinder spring,
via the retainer plate and the spherical
bushing, so that it moves smoothly over the
shoe plate. The cylinder block (141) is also
pressed against valve plate (314) by the
action of cylinder spring (157). 313
124
312
111
116
314124
141
157
151 156
・ 153
152
211
24-8
(2) Swash plate group 532
The swash plate group consists of swash
plate (212), shoe plate (211),swash plate
support (251), tilting bushing (214), tilting 531 214
pin (531),and servo piston (532). The swash 211
plate is the cylindrical part that is formed on 212
the opposite side of the shoe sliding surface
and is supported by the swash plate
support. 251
The hydraulic force controlled by the
regulator flows into the hydraulic chamber
that is provided on both sides of the servo
piston. This moves the servo piston to the
right and left. The result is that the swash
plate swings on the swash plate support via
the spherical part of the tilting pin and
changes the tilting angle(α). Fig. 1-7 Swash plate group
24-9
1.3 REGULATOR Table1-7
1.3.1 CONSTRUCTION
No. NAME Q’TY
643 A 801
466 924
・
755
407
724
A
631 887
24-10
1.3.2 OPERATION
(1) Summary
Regulator KR36-0E01 for the inline axial
piston pump K3V series is of electric flow
control type that regulates the tilting angle
(delivery rate) of the pump as the command
currentⅠto the solenoid proportional
reducing valve is varied.
This regulator is of positive flow control type
that increases the delivery flow Q as the
command current I increases.
If an electric current is put in by this control
according to the flow needed for the
operation, the pump delivers at a flow rate
that is only required by the pump,
consequently holding down unwanted power
consumption.
(2) Positive control.
As shown in the figure on the right, the
regulator regulates the delivery rate of the
pump by command current I.
DELIVERY RATE Q
1) Flow increasing action
As the command current I rises, the
secondary pressure of solenoid proportional
reducing valve (079) increases. This causes
spool (652) to move via pilot piston (643) and
stops where the hydraulic pressure pushing
the spool rightwards balances with the action COMMAND CURRENT Ⅰ
of pilot spring (646).
If the spool (652) moves, port C opens to the
Fig.1-11 Positive flow control
tank port. This causes the pressure of the
large diameter part of servo piston (532) to go
away. This causes the servo piston (532) to
the left by delivery pressure P1 of the small
diameter part, resulting in an increase in the
tilting angle α.
643 652 651 611 624 627 646 801 924
532
808
808
954 953
A
24-11
Feedback lever (611) is linked with the servo
piston and sleeve (651). As the servo piston
moves to the left, the feedback lever rotates
on point A which causes the sleeve to the
right. As the servo piston moves to the right,
the feedback lever rotates on point A to move SOLENOID PROPORTIONAL
the sleeve to the right. The result is that the REDUCING VALVE REGULATOR
opening of the spool sleeve begins to close
gradually and the servo piston settles down
when the opening of the spool sleeve closes
completely.
646
(2) Flow decrease function
As the command current Ⅰ decreases, the 652
secondary pressure of the solenoid
proportional valve decreases. This causes the
spool to move to the left.
When the spool (652) has moved, delivery MAIN
pressure P1 reaches port C via spool and is PUMP
admitted to the large diameter chamber of
643
the servo piston. Delivery pressure P1 is
admitted to the small diameter part of the
servo piston at all times. The servo piston 651
moves rightward by areal difference to C PORT 532 POINT 611
A
decrease tilting angle (α). As the servo
piston moves to the right, the feedback lever Fig. 1-13 Regulator hydraulic circuit
rotates on point A to move the sleeve to the
left. The sleeve keeps moving till the opening
of the spool sleeve closes and settles down
when the spool sleeve closes completely.
24-12
1.3.3 ADJUSTING REGULATOR
The maximum flow, minimum flow and flow
control characteristics of the regulator may be
controlled by the adjust screw of the regulator.
(Amounts of adjustment are shown in table 1-8.)
24-13
(3) Adjusting the flow control characteristics
For adjustment, loosen hex nut (801) and
tighten (loosen) the set screw (924). If the set
screw is tightened, the control curve moves
DELIVERY RATE Q
rightwards, as shown in Fig.1-16.
COMMAND CURRENT Ⅰ
1.3.4 CAUSES OF FAULT RESULTING FROM Fig. 1-16 Flow control characteristics
REGULATOR
(1) Engine is overloaded
Load each of the pumps and check which of
the pumps, front or rear is faulty. In case
both are faulty, check the following ① and ②:
If only one of the pumps is faulty, start with
③.
① Check that the command current Ⅰ of the
solenoid proportional reducing valve is
normal.
24-14
1.4 CONTROL CURVE OF PUMP E115SR EVOLUTION
(1) At H mode
(2) At S mode
24-15
(3) At FC mode
24-16
E135SR LC EVOLUTION
(1) At H mode
(2) At S mode
24-17
(3) At FC mode
24-18
2. PILOT VALVE (ATT)
2.1 OUTLINE
(1) Outside view (2) Specification
SINGLE SINGLE
Table 2-1
OPERATION OPERATION
ANGLE ANGLE Item Specification
(PORT 2,4) (PORT 1,3)
The adjust nut Model PV48K1008
(opposing flats: 22):
Operating torque Refer to the table below
Fix adjust nut
(opposing flats: 22) Max. primary pressure 50kgf/cm2 (710psi)
when the lever is installed by
means of spanner or the like.
Primary pressure 50kgf/cm2 (710psi)
Then tighten the mating lock Rated flow 20 /min (5.3gal/min)
nut to 4.2±0.3kgfym
(30±2.2 lbfyft). Weight Approx. 2kg (4 lbs)
5-PF3/8
T=5±0.5
PF1/4
T=3±0.2
Hydraulic simbol
Fig. 2-1
24-19
2.2 CONSTRUCTION, FUNCTION AND OPERATION
(1) Cross section view
312
501
302
Rotating sliding
part, apply
grease.
213 301 Beware of the
assembly
direction
151 212
Apply grease
246 to top
218-2
211
214
218-1
216-2 216-1
241-1
241-2
201-2 201-1
011-2 011-1
131
217 122
Secondary
pressure 101
adjusting shim 121 Not to
Designed value 126 be reused
t=0.4 (0.016˝ ), PORT 2,4 PORT 1,3 125
1 pc. 111
Fig. 2-2 Pilot valve (ATT)
Apply Loctite #277 to areas marked ☆.
Tightening torque Tightening torque
kgfym (lbfyft) No. NAME Q’TY kgfym (lbfyft) No. NAME Q’TY
101 CASING 1 216-1 SPRING SEAT 1 2
111 PORT PLATE 1 216-2 SPRING SEAT 1 2
121 SEAL WASHER 2 217 WASHER 2 (SHIM) 4
122 O RING 1 218-1 SPRING SEAT 2 2
2.1 (15) 125 SOCKET BOLT; M8×35 2 218-2 SPRING SEAT 2 2
126 SPRING PIN 1 011-1 SPRING 2
131 BUSHING 1 011-2 SPRING 2
151 PLATE 1 241-1 SPRING 2
201-1 SPOOL 2 241-2 SPRING 2
201-2 SPOOL 2 246 SPRING 4
211 PLUG 4 4.8 (35) 301 JOINT; M14 1
212 PUSH ROD 4 302 CIRCULAR PLATE 1
213 SEAL 4 7 (51) ☆ 312 ADJUST NUT; M14 1
214 O RING; 1B P20 4 501 BOOTS 1
24-20
(2) Construction
The pilot valve is constructed as shown in the
cross-sectional view (Fig.2-2). The casing has
a vertical shaft hole in which a reducing
valve is assembled.
The reducing valve consists of spool (201),
spring (241) (for secondary pressure setting),
spring (011) (for return), spring seat (216),
and washer (217). The spring (241) (for
secondary pressure setting) is so set as to
achieve the secondary pressure conversion
5~10kgf/cm2 (71~140psi) (varies with the
model.). The spool (201) is pressed against
push rod (212) by spring (011) (for return).
If push rod (212) is pushed down by tilting
the control part of the handle, the spring seat
(216) falls at the same time and changes a set
pressure of spring (241) (for secondary
pressure setting).
The casing (101) and the port plate (111) are
provided with an oil inlet (primary pressure)
port P and an outlet (tank) port T. They are
further provided with ports 1, 2, 3, 4 from
which secondary pressure is discharged.
(3) Function
1) Basic functions 2) Main functions
The pilot valve controls the stroke and the The function of spool (201) is to receive the
direction of the control valve spool. This is supply pressure of the hydraulic pump by
achieved by applying the output pressure of port P and admit the hydraulic pressure at
the pilot valve to the end of the control valve port P to output ports (1, 2, 3, 4) or admit the
spool. hydraulic pressure at the output ports to port
In order to satisfy the functions, the pilot T. Spring (241) (for secondary pressure
valve is constructed with the following setting) acts upon spool (201) and determines
elements : the output pressure.
① Inlet port (P) to which the oil of the Push rod (212) that changes the deflection of
hydraulic pump is supplied. spring (241) (for secondary pressure setting)
② Multiple output ports (1, 2, 3, 4) that is inserted in plug (211) so as to enable
exert the supply pressure from the input smooth movement.
port upon the end of the spool of the Spring (011) (for return) acts upon casing
control valve. (101) and spring seat (216) and brings push
③ Tank port (T) to control the above rod (212) toward zero displacement
mentioned output pressure. regardless of output pressure, in order to
④ Spool that connects the output port with positively bring spool (201) back to neutral.
the inlet port or the tank port. The spring also acts as a reactive force that
⑤ The mechanical means including springs gives the operator a proper operating feeling.
that act upon the above- mentioned
spool, in order to control the output
pressure.
24-21
(4) Function
Now, let us explain the function of the pilot
valve, using the hydraulic diagram (the
figure on the right) and the functional
explanation drawing (Fig.2-3 to 2-5).
1 3
P T
Lever in neutral
216
241
011
201
PORT(2,4)
24-22
2) When the pilot lever is tilted (See Fig. 2-4 )
When the lever is tilted and the push rod
(212) strokes, the spool (201) spring seat
(216) moves down-ward to make the port P to
connect with the port 2, 4, with the result
that the oil of the pilot pump flows to the port 212
2 ,4 to produce a pressure.
216
201
PORT(2,4)
3) Handle held (See Fig.2-5.) Fig. 2-4 When the lever is tilted
When the pressure at ports (2,4) rises to a
level equivalent to the action of spring (241)
that is set by tilting the handle, the hydraulic
pressure balances the spring action. When
the pressure of ports (2,4) rises above a set
value, ports (2,4) and the P port close while
ports (2,4) and the T port open. When the
pressure at ports (2,4) falls below a set value,
ports (2,4) and the P port open while ports
(2,4) and the T port close. Thus the secondary
pressure is kept constant.
241
T PORT
P PORT
PORT (2,4)
Fig. 2-5 When the handle is held
(When the secondary pressure is higher than a set value)
4) Operation in the area where the tilting angle the bottom of the bore of the push rod
of the handle is large. (varies with the model) contacts the spring if the handle is turned
If the handle is inclined beyond a certain beyond a certain angle. This causes the
angle on certain models, the top end of the secondary pressure gradient to change by the
spool contacts the bottom of the bore of the spring action. Thereafter, the bottom of the
push rod. This keeps the output pressure bore of the push rod contacts the top end of
connected with the P port pressure. the spring seat, keeping the output pressure
Furthermore, on a model in which a spring connected with the P port.
seat and a spring are built in the push rod,
24-23
3. PILOT VALVE (TRAVEL)
3.1 OUTLINE
(1) Outside view
Tightening
Port torque Port 4-∅11
size kgfym (lbfyft) name Function
Through
1 LH travel forward port
2 LH travel reverse port
7.5±0.5
PF3/8 3 RH travel forward port
(54±3.6)
4 RH travel reverse port
T Tank port
5 Travel pressure sensor
6 port
3.7±0.2
PF1/4 P Travel pressure sensor
(27±1.4) Fig. 3-1 Out side view of travel pilot valve
port
Pilot primary pressure port
(3) Performance characteristics
(2) Specification
Item Specification
Type 07291-00000
Primary pressure 50kgf/cm2 (710psi)
Secondary pressure 5.5~24kgf/cm2 (78~340psi)
Rated flow 10 /min (2.6gal/min)
Weight Approx. 11kg (24 lbs)
24-24
3.2 CONSTRUCTION AND OPERATION
Z
33 2 36 33
13 12 28 RORT5
36 14
PORT
5
42
19
37 26 25
1,3 30
20
34 25
22 15
20 21 42
20
39 PORT
PORT66
32 17
44,16 33 36 33
40
6 7 SECTION AA
18 8
24 25,42
41
27
4 10,11 35
9 31 5 29
38
4-M10
T=4.3±0.4(31±29)
SECTION BB
24,41 VIEW Z Fig. 3-2 Construction of travel pilot valve
Apply Loctite #262 to areas marked ☆.
Tightening Tightening
torque No. NAME Q’TY torque No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
1 ORIFICE(SHIM) 4 22 SPRING 4
☆1.5(11) 2 SEAT 2 1.0(7.2) 24 PLUG: PF1/8 3
3 ORIFICE(SHIM) 4 2.5(18) 25 PLUG: PF1/4 3
4 SPOOL 4 6.0(43) 26 SOCKET BOLT: M10×60 2
5 BODY 1 0.5(3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5(11) 28 SETSCREW : M8 4
7 SPRING 4 29 WASHER 4
8 SPRING 4 30 WASHER 2
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN: ∅5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING: 1A P5 4
17 GUIDE 4 39 O RING: 1A P24 4
18 SLEEVE 4 40 O RING: 1A P26 4
19 HOLDER 4 41 O RING: 1B P8 3
20 RING 12 42 O RING: 1B P11 3
21 ORIFICE(SHIM) 4 44 PISTON ASSY 4
24-25
3.3 OPERATION
(1) Construction z If the cam operates during travel operation, the oil
The valve consists of the following parts in in the damper chamber is kept from flowing back
terms of hydraulic function: by the check valve. Thus the oil flows to part (E)
only from the orifice. Damper action operates by
A: Damper section
the resistance that is built up as the oil passes
B: Reducing valve section
through the orifice.
C: Shuttle section Let us explain the profile of the piston (See Fig. 3-4).
(2) Operation The upper part of the piston has a diameter of
1) Damper section 12mm (0.472in), while the lower part of it has a
z If the primary pressure is supplied by P, it is diameter of 11mm (0.433in). This results in an
flowed to the damper chamber by way of areal difference, with the result that the piston is
circuits (D) and (E). constantly subject to a vertical force.
The pressure is then filled up in the damper For this reason, the orifice rises by the pressure
caused by the areal difference between the
chamber via the orifice and the check valve.
operating part of the cam and the piston on the
In that case, the air present in the damper
opposite side i.e. the piston follows the cam.
chamber is pushed out to the T port from That is to say, constant damper action
circuits (F) and (G), in order to prevent the operates wherever the cam is located.
damper characteristics from fluctuating by Since the larger diameter of the piston, the cover,
air mixture. the 11mm diameter part of the piston and the
guide are manufactured with minimal clearance,
only a little leakage occurs. Consequently, the
CAM
damper performance is not affected at all.
(F)
PISTON (G)
COVER
(E) CHECK
VALVE
GUIDE
ORIFICE
DAMPER
SPRING FOR CHAMBER
T
SECONDARY (D)
PRESSURE
T
(I)
SPOOL P P
(H)
∅12
(0.472˝ )
∅11
(0.433˝ )
RETURN
SPRING
T T
(I)
(J)
P P
(J)
(H)
SECONDARY Fig. 3-4
PRESSURE PORT
24-27
3) Shuttle section
z If pressure is built up at port 1 or 3, the ball
is pressed against the seat by the pressure.
The pressure goes through from port 1 to port
5 (or from port 3 to port 6).
Only a little leakage occurs from port 2 or 4
as the ball is sealed metallically by the seat.
If pressure occurs at port 2 or 4, the ball is
pressed against the body by the pressure. The
result is that the pressure connects with port
5 from port 2 (with port 6 from port 4).
Only a little leakage occurs at port 1 or 3 as
the ball is sealed metallically against the
body.
PORT 5
PORT 2 PORT 1
SEAT BALL
BODY
PORT 4 PORT 3
PORT 6
24-28
4. CONTROL VALVE Table 4-1
2-M10-20/27 (FOR LIFTING) Tightening
Port torque Port
4-M10 SCREW DEPTH 13 size name Description
4.1 SPECIFICATION kgfym (lbfyft)
(1) General view and hydraulic ports P1 Pump P1 port
P2 Pump P2 port
Ab Boom up port
Bb Boom down port
Ac Bucket dump port
Bc Bucket digging port
Ar Travel right port (forward)
15.3~18.4 Br Travel right port (reverse)
PF3/4 (110~133) AL Travel left port (forward)
BL Travel left port (reverse)
Aa Arm in port
Ba Arm out port
As Swing port (right)
Bs Swing port (left)
Ao2 Option 2 port (A)
Bo2 Option 2 port (B)
10~12.2 (P3) Option port
PF1/2 (72~89) (P4) Option port
MAIN C/V PAa Arm in pilot port
3-M10-20/27 (FOR LIFTING) P1(P2) T PBa Arm out pilot port
PAb Boom up pilot port
PBb Boom down pilot port
TRAVEL TRAVEL PAc Bucket dump pilot port
PTb TRAVEL PAL PBL
STRAIGHT TRAVEL LEFT LEFT PBc Bucket digging pilot port
STRAIGHT PBs2
Dra,Drb PAr Travel right pilot port (forward)
TRAVEL SWING PBs PBr Travel right pilot port (reverse)
PBr PAr SWING PAs
LEFT TRAVEL PAL Travel left pilot port (forward)
Pss
BUCKET RIGHT BOOM PBL Travel left pilot port (reverse)
PB1 7.0~8.0
PBc PAc BUCKET
BOOM CONFLUX PF3/8 PAs Swing left pilot port
B PLc2 (51~58)
CONFLUX ARM PBs1 Swing right pilot port
BOOM PAa PBs2 Swing right pilot port
PBb PAb Drd
BOOM ARM Pis Arm recirculation port
ARM PA1 Arm conflux pilot port
P1 CUT Pis RECIRCU- P2
PCa PB1 Boom conflux pilot port
ARM LATION CUT
PA1 PCb P1 CUT ARM PTb Travel straight pilot port
CONFLUX
RECIRCULATION
PCa P2 bypass pilot port
PAo2 PBo2 PCb P1 bypass pilot port
PAo2 Option 2 pilot port (A)
(P4) PBo2 Option 2 pilot port (B)
(P3)
Dra Drain port
Drb Drain port
A OPTION C/V Drc Drain port
3.5~3.9 Drd Drain port
PF1/4 (25~28) Pss Swing low pressure sensor port
Pisc Swing priority pilt port
PLc1 Boom lock valve release pilot port
ARM PLc2 Arm lock valve release pilot port
CONFLUX 3-M10-18/22 (FOR LIFTING) 5~6.6
CUT
M10 T Tank port
(CUT) (36~48)
(2) Machine specification
BOOM ARM Table 4-2
Item E115SR EVOLUTION E135SR EVOLUTION
BUCKET BOOM CONFLUX
Main C/V
TRAVEL RIGHT
Model KMX13YC/B33016 KM13YC/B33006
SWING
Max. flow /min (gal/min) 118 (31)×2 118 (31)×2
TRAVEL Max. pressure kgf/cm (psi)
2 385 (5470) 385 (5470)
STRAIGHT TRAVEL LEFT
Main relief valve set pressure kgf/cm2 (psi) 330 (4690) at 60 /min (16gal/min) 350 (4980)at 60 /min (16gal/min)
Port relief valve set pressure kgf/cm2 (psi) 365 (5120) at 30 /min (7.9gal/min) 385 (5470) at 30 /min (7.9gal/min)
24-29
4.2 CONSTRUCTION 155 164 101
T
B A
273
PBL PAL
H H PAs
’
TRAVEL TRAVEL
STRAIGHT PBs1 PBs2
C LEFT C
Pss
TRAVEL
RIGHT SWING PB1
D D
BOOM
BUCKET PAa
CONFLUX PBa
E E
BOOM ARM
PCa Pis
F F
ARM
RECIRCULATION
CUT
G (ARM G
CONFLUX) PBo2 PAo2
(CUT)
OPTION 2
H H 162
B
SECTION A-A
A
166 156 102
974 973
P2 P1
973
(974) PTb
162 973
562 562
PBr PAr
552 552
973
CT1 CT2 PAc
PBc
522 522
PBb
515 512 973 PAb
162 168 158
(973)
SECTION J-J PA1 PCb
973 973
SECTION H’-H’
162 164 155 162
SECTION B-B
Fig. 4-2 (1/3) Construction of control valve
24-30
201 166 156 201
156 166 201
201
333 333 333
332 333
332 PAc 332
PAL 332
337
337 337
326 338
328 326
325 327
602 325
332 325 329 332
262 332 332
157 262
262 262 512
167 162 162 Ac CCB
601 AL 512 (ROD SIDE)
522
513 522 512 552
LCc 562
522 CP2
CMR1
522
552 552 552
552
562 562 Bc 562
BL 562
562 CMR2
163 162 (HEAD
552 SIDE)
24-31
204 204 Table 4-3 Apply Locktite #262 to areas marked ☆.
333 333
Tightening torque Q'TY Tightening torque Q'TY
332 (CUT) (ARM RECIRCULATION)
332
PCb Pis kgfym (lbfyft) No. NAME kgfym (lbfyft) No. NAME
337 KCME KAI KCME KAI
337
326 PAL 101 CASING A 1 ← 322 SPRING (TRAVEL STRAIGHT OUTER) ― 1
326
325 102 CASING B 1 ← 323 SPRING (TRAVEL STRAIGHT INNER) ― 1
325
332 11.2~13.3 (81~96) 155 PLUG; PF1/2 2 ← 324 SPRING (ARM,SWING INNER) 2 ←
332
262 262 7~8 (51~58) 156 PLUG; PF3/8 3 ← 325 SPRING (TRAVEL, CUT, ARM CONFLUX, 8 ―
602 3.5~4.0 (25~29) 157 PLUG; PF1/4 1 ← BOOM CONFLUX,TRAVEL STRAIGHT OUTER)
512
309
562 1.3~1.7 (9.6~13) 158 PLUG; PF1/8 1 ← 325 SPRING (TRAVEL, CUT, ARM CONFLUX, ― 7
Ab
552 162 O RING; 1B G30 17 ← BOOM CONFLUX)
CAa
(HEAD SIDE)
163 O RING; 1B P15 3 ← 326 SPRING (CUT, ARM CONFLUX, 6 ―
308 164 O RING; 1B P18 2 ← BOOM CONFLUX, TRAVEL STRAIGHT INNER)
310
512
166 O RING; 1B P14 3 ← 326 SPRING (CUT,ARM CONFLUX, BOOM CONFLUX) ― 5
522 162
167 O RING; 1B P11 1 ← 327 SPRING (TRAVEL INNER) 2 ←
552 CCa (ROD SIDE)
Ba 309 168 O RING; 1B P8 1 ← 328 SPRING (BOOM,BUCKET INNER) 2 ←
562
262 201 SPRING COVER 7 ← 329 SPRING (ARM,BOOM, BUCKET,SWING OUTER) 4 ←
262
332 202 SPRING COVER 1 ← 332 SPRING SEAT 24 ←
332
325 204 SPRING COVER 4 ← ☆1.6~1.8 (12~13) 333 SPACER BOLT ; M8 12 ←
325
326 326 206 SPOOL COVER 8 ← 337 STOPPER (OTHER THAN TRAVEL) 10 ―
602 211 LOCK VALVE SELECTOR SUB ASSY 2 ← 337 STOPPER ― 9
337 337 214 PLATE 2 ← (OTHER THAN TRAVEL,TRAVEL STRAIGHT)
332 332 262 O RING 12 ← 338 STOPPER (TRAVEL) 2 ←
333 PA1 PCa 333 265 O RING; 1B G35 8 ← 339 STOPPER (TRAVEL STRAIGHT) ― 1
204 (ARM CONFLUX) (CUT) 204 10~12.2 (72~89) 271 SOCKET BOLT M12×25 8 ← 512 POPPET D=20 11 ←
SECTION G-G 2.6~3.5 (18~25) 273 SOCKET BOLT M8×25 40 ← 513 POPPET (CMR1, CMR2) 2 ←
301 BOOM SPOOL ASSY 1 ← 514 POPPET (LOCK VALVE) 2 ←
PAo2
302 ARM SPOOL ASSY 1 ← 522 SPRING 13 ←
272 303 SWING SPOOL 1 ← 524 SPRING (LOCK VALVE POPPET) 2 ←
304 BUCKET SPOOL 1 ← 13.3~15.2 (96~110) 552 PLUG M22 14 ←
271
305 BOOM CONFLUX SPOOL 1 ← 13.3~15.2 (96~110) 556 PLUG M22 2 ←
306 TRAVEL SPOOL 2 ← 562 O RING; 1B P20 16 ←
307 TRAVEL STRAIGHT SPOOL 1 ← 7~8 (51~58) 601 RELIEF VALVE (MAIN) 1 ←
308 ARM CONFLUX SPOOL 1 ← 7~8 (51~58) 602 RELIEF VALVE (PORT) 6 ←
309 BYPASS CUT SPOOL 2 ← 14.3~18.4 (103~133) 973 SOCKET BOLT M14×110 7 ←
Ao2
310 ARM RECIRCULATION SPOOL ASSY 1 ← 14.3~18.4 (103~133) 974 SOCKET BOLT M14×75 1 ←
214 213
Bo2
PBo2
271 272
SECTION H-H
24-32
(2) Main relief valve (601) (3) Port relief valve (602)
301 564 563 521 124 561 611 621 661 612
512 541 521 123 124 125 561 562 121 122 611 621 103 163 661 612 651 671 123 125 562
Fig. 4-6
Tightening
torque No. NAME Q'TY
kgfym (lbfyft) Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
302 SPOOL 1 kgfym (lbfyft) kgfym (lbfyft)
312 SUB SPOOL 1 301 SPOOL 1 330 SPRING B2 1
313 PISTON 1 315 PLUNGER 1 1 340 SPRING B3 1
329 SPRING 1 316 PLUNGER 2 1 5~6 (36~44) 352 PLUG 1 M16 1
5~6 (36~44) 357 PLUG (1) 1 317 PLUNGER 3 1 5~6 (36~44) 353 PLUG 2 M16 1
5~6 (36~44) 358 PLUG (2) 1 320 SPRING B1 1
24-33
(6) Control valve for option (213) (7) Lock valve selector sub assy (211)
S202 A
PAo S334 PAo PAo
S337
S333
S323
S603 L101
S324
991 L541
S271
S161
S337 992 L162
TA TA’ S261 S512 L163
S101 Ao S522 Ao
TA’
S161 S301 S561
Po’
Po Po’ S551
C L171
B B L511
S161
TB’ Bo
Bo L512
TB TB’
L161
L201
S262
Po’
Tightening Tightening
torque No. NAME Q'TY torque No. NAME Q'TY
kgfym (lbfyft) kgfym (lbfyft)
L101 CASING 1 7~8 (51~58) L201 PLUG (M27; HEX 22) 1
Po L161 O RING 1 L511 SPOOL 1
SECTION B-B L162 O RING 3 L512 SPRING 1
L163 O RING 2 L541 BUSHING 1
Fig. 4-7 1~1.4 (7.4~10) L171 CAPSCREW; M6×45 4
24-34
4.3 HYDRAULIC CIRCUIT
Table 4-4
601 513 307 54 306
No. NAME
51 Main passage (P1 side)
24-35
4.4 OPERATION
(1) Control valve in neutral
The oil delivered by hydraulic pump P1 The oil delivered by hydraulic pump P2 also
enters port P1 of the control valve and passes goes past the main passage (54), passes
through the travel straight spool (307) and through the bypass circuit (55) that goes
the main passage (51). It then passes through through the left travel, swing, boom conflux
the bypass circuit (52) that passes the right and arm circuits and then the P2 bypass cut
travel bucket and boom circuits and then the spool (309) and is brought back to the
P1 bypass cut spool (309) and is brought back hydraulic tank via the tank port (T).
to the hydraulic tank via the tank port (T).
309
P1
P2
Flow of hydraulic oil from hydraulic pump P2 Flow of hydraulic oil from hydraulic pump P1
24-36
(2) Functions for travel action
1) At independent travel
If travel operation (forward) is performed, the Meanwhile, the oil which has returned from
secondary pilot pressure from ports (2) and the right travel A side and the left travel A
(4) of the travel pilot valve acts upon ports side passes between the outer circumference
PBr and PBL of the control valve and moves of the left travel spool (306) and the casing
the right and left travel spools (306). and returns to the hydraulic tank via the
The pressurized oil delivered by pump (P1) tank port (T) of the low pressure circuit (D).
flows to the main passage (51) past the travel At backward travel action (when the
straight spool (307), passes between the outer secondary pilot pressure acts upon ports PAr
circumference of the right travel spool (306) and PAL of the control valve), the pressurized
and the casing and is supplied to the right oil works the same way as in the forward
travel motor B by way of port Br. travel action.
In the meantime, the pressurized oil
delivered by pump (P2) passes between the
outer circumference of the left travel straight
spool (306) and the casing, runs to port BL
and is supplied to the left travel motor A side,
the same way as the pressure oil by pump
(P1).
B A
Br Ar
306
PILOT PORT
PBr PAr
51 52 51
24-37
2) At travel straight motion
If an actuator except the one for travel action is The pressure oil delivered by pump P2 flows,
actuated with the travel system in in most amount of oil, in the C→D direction
position [Ⅰ], the secondary pressure of the and the main passage (54), becomes the oil
electromagnetic proportional valve [C] acts pressure for the right travel and the left
upon port PTb of the control valve and moves travel motions and realizes simultaneous
the travel straight spool (307) right in order operation of the actuator and travel action.
to take position [Ⅱ]. (travel straight function)
The result is that the pressurized oil The secondary pressure of the solenoid
delivered by pump P1 flows from A to B in proportional valve [C] is applied additionally
most amount of oil and becomes the pressure and shifts the travel straight spool (307) to
for the actuators except one for travel action. the right to take the position Ⅲ. All of A to D
ports connect with the T-port in order to
P1
unload the pressure of the circuits as a whole.
P2 CMR2 CMR1 (unload function)
CA
T
PTb
DB
T C D A B T Position [Ⅰ]
CA
T
DB
CA
T
DB
At unload action
SECTION C-C Position [Ⅲ]
24-38
(3) Bucket
1) When the bucket is digging
When the bucket is digging, secondary pilot the bucket spool (304) and the casing by way
pressure coming from port (1) of the pilot of the U-shaped passage and is supplied to
valve enters port PBc of the control valve and the bucket cylinder head (H) via port (Bc).
moves the bucket spool (304) to the left. In the meantime, the oil which has returned
The pressure oil delivered by pump (P1) flows from the bucket cylinder rod side goes
to the bypass circuit (52) past the main between the outer circumference of the
passage (51), but since it is blocked by the bucket spool (304) and the casing through the
bucket spool (304) that has shifted, it pushes port (Ac) and returns to the hydraulic oil
the check valve open, enters the parallel tank by way of the low pressure circuit (D)
circuit (53), pushes the load check valve (512) and the tank port (T).
open, goes between the outer circumference of
D (52) 304
PILOT PORT
PAC PBC
AC BC
(53)
U-SHAPED PASSAGE
512(LCc)
R H
BUCKET CYLINDER
24-39
2) When the bucket is dumped
When the bucket is dumped, secondary pilot outer circumference of the bucket spool (304)
pressure from port (2) of the pilot valve and the casing via the U-shaped passage and
enters port PAC of the control valve and supplied to the bucket cylinder rod (R) via
moves the bucket spool (304) to the right. port (AC).
The pressure oil delivered by the pump P1 In the meantime, the oil which has returned
flows to the bypass circuit (52) through the from the bucket cylinder head goes between the
main passage (51), but since it is blocked by outer circumference of the bucket spool (304)
the bucket spool (304), it pushes the check and the casing through the port (Bc) and is
valve open, enters the parallel circuit (53) the supplied to the hydraulic oil tank by way of the
load check valve (512) open, goes between the low pressure circuit (D) and the tank port (T).
PAC
PBC
AC BC
U-SHAPED PASSAGE
512 (LCc)
R H
BUCKET CYLINDER
24-40
(4) Boom
1) When the boom is up
When the boom is up, secondary pilot The pressure oil then passes through the U-
pressure from port (3) of the pilot valve shaped passage, Pushes the boost check valve
enters port PAb of the control valve and open via chamber E of the boom spool (301),
moves the boom spool (301) to the right. It enters chamber BH.
also acts upon port PB1 (Refer to next page) Or the pressure oil enters chamber BH,
and change over the boom conflux spool (305). passing between the outer circumference of
At the same time the secondary pressure of the boom spool (301) and the casing, pushes
the electromagnetic valve [B] acts upon port the lock valve poppet (514) open, flows into
PCa of the control valve and change over the the port (Ab) and is supplied to the boom
P2 bypass cut spool (309). cylinder head (H).
The pressurized oil delivered by the pump P1 Meanwhile, the oil port (Bb) which returns
flows into the bypass circuit (52) through the from the boom cylinder rod (R) goes between
main passage (51), but since it is blocked by the outer circumference of the boom spool
the boom spool (301), it pushes the check (301) and the casing, flows into the tank port
valve open, enters the parallel circuit (53) (T) via the low pressure circuit (D) and
and pushes the load check valve (512) open. returns to the hydraulic tank.
PAb PBb
H H
BOOM CYLINDER
Fig. 4-15 When boom is up (Boom spool)
24-41
2) Conflux for boom up
The oil delivered by the pump P2 flows into The oil then pushes the load check valve
the main passage (54), but since the bypass (512) open, passes between the outer
circuit (55) and the parallel circuit (56) are circumference of the boom conflux spool (305)
closed by the P2 bypass cut spool (309) which and the casing via the A side of the U-shaped
has shifted as explained in 1) above (Refer to passage, enters port Ab through the conflux
Fig. 4-16), the oil enters the parallel circuit passage in the casing and combines with the
(56) from travel spool. (Refer to Fig. 4-17) pressure on the pump P1 side.
PCa
BOOM CONFLUX
PB1
24-42
3) When the boom is down (in H or S mode)
When the work mode selector switch on the conjunction of the boom spool whereupon the
gauge cluster is set to the H (heavy digging) back pressure of lock valve poppet (514)
mode or S (save energy) mode, operation is as connects with DrC.
follows. The returned oil then enters chamber BH and
If the boom down action is performed, the runs into the boom spool (301) through the
secondary pilot pressure from port (4) of the circular notch of the boom spool (301). Since
pilot valve acts upon port PBb of the control the returned oil has sufficient pressure by the
valve and lock valve selector port PLC1 and weight of the boom, arm, etc. , it pushes the
shifts the boom spool (301) to the left, it also poppet C on the right of the illustration
change over the lock valve. through in the spool, passes through its outer
The pressure oil delivered by the pump (P1) circumference and is supplied to the boom
flows into the bypass circuit (52) through the cylinder rod side as the hydraulic oil for boom
main passage (51), but since it is blocked by down motion. (Boom fixed recirculation
the boom spool (301), it pushes the check function).
valve open, enters the parallel circuit (53), Some of the return oil from the head end of the
pushes the load check valve (512) open, boom cylinders forces open the boost check
enters the U-shaped passage, goes between valve, and flows through the low pressure
the outer circumference of the boom spool circuit D to the tank port T, and back to the
(301) and the casing and is supplied to the hydraulic oil tank. The purpose is to allow
boom cylinder rod side via port (Bb). excess return oil to escape to the tank. This
In the meantime, the oil which returns from excess oil is caused by the fact that the area of
the boom cylinder head enters the control the piston at the head end is larger than the
valve by way of port (Ab). Lock valve poppet area of the piston at the rod end.
(514) is located in front of boom spool (301), The boost check valve acts on oil flowing to
but the lock valve is pushed open as the the tank to secure an adequate amount of
lock valve selector spool is changed over in recirculating oil.
CONFLUX
LOCK VALVE PASSAGE
SELECTOR SPOOL BOOST CHECK IN CASING 301 (52) (53) POPPET C
D
PBb
PAb
PLC1
Drc
LOCK VALVE
SELECTOR
211
(CRb) Ab 512 Bb
CHAMBER BH 514 (LCb)
U-SHAPED PASSAGE
R R
SECTION F-F (Boom)
H H
BOOM CYLINDER
Fig. 4-18 When boom is down (in H or S mode)
24-43
(5) Arm
1) Arm out operation
If arm out operation is performed, the spool (302), it pushes the check valve open,
secondary pilot pressure from port (8) of the flows into the parallel circuit (56), pushes the
pilot valve acts upon ports PBa and PA1 of load check valve (512) open, goes between the
the control valve. (refer to next page) outer circumference of the arm spool and the
The pressure oil which enters port PBa shifts casing by way of the U-shaped passage, runs
the arm spool (302) leftwards. The pressure into chamber AR, pushes the lock valve
oil which enters port PA1 changes over the poppet (514) open and is supplied to the arm
arm conflux valve. cylinder rod side via port (Ba).
The secondary pressure of the electromagnetic In the meantime, the oil which returns from
proportional valve [D] acts upon port PCb of the arm cylinder bottom side passes between
the control valve and changes over the P1 the outer circumference of the arm spool
bypass cut valve (309). (302) and the casing, or chamber F in the arm
The pressure oil delivered by pump P2 flows spool (302) by way of the port (Aa), flows into
into the bypass circuit (55) by way of the main the tank port (T) from the low pressure
passage (54), but since it is blocked by the arm circuit (D) and returns to the hydraulic oil
tank.
ARM CYLINDER
H R
PBa
PAa
D (55)
302 CHAMBER F (56) U-SHAPED PASSAGE
24-44
2) Arm out conflux
In operation 1), the oil delivered by pump P1 Part of the delivered oil passes through the
flows into the bypass circuit (52) through the parallel circuit (53) and the restrictor,
main passage (51), but since the bypass combines with the pressure oil of the bypass
circuit (52) and the low pressure circuit (D) circuit (52), pushes the conflux check poppet
are blocked by the bypass cut spool (309), it (511) open, enters port Ba by way of the
does not run into the low pressure circuit (D). conflux circuit in the casing and finally
Meanwhile, since the arm conflux spool (308) combines with the pressure oil on the pump
has now been changed over, the pressure oil P2 side.
of the bypass circuit (52) goes between the
outer circumference of the arm conflux spool
(308) and the casing.
PCb PA1
ORIFICE
SECTION G-G (Arm conflux) SECTION
(X1)
Fig. 4-20 At arm out operation (Bypass cut spool and arm conflux spool)
24-45
3) When the arm in is operated the arm cylinder rod (R) enters the control
(under light load) valve through the port (Ba).
If the arm in operation is performed, the Lock valve poppet (514) is located before arm
secondary pilot pressure coming out of port(7) spool (302). Since the lock valve selector spool
of the pilot valve acts upon the PAa port of is changed over, the lock valve poppet (514) is
the control valve and the PLc2 port of the pushed open and the oil enters the AR
lock valve selector. This causes the arm chamber. Since the return oil has sufficient
spool(302) to move to the right and changes pressure by the weight of the arm, it flows
the lock valve. The secondary pressure of the into the arm spool, passes through the inside
solenoid proportional valve [A] acts on the Pis of the arm spool, the notch of the arm spool
port of the control valve and changes the arm and the recirculation passage (60), and flows
recirculation spool (310) to position [Ⅱ]. into arm recirculation spool (310).
The pressure oil delivered by the pump P2 Since the arm recirculation spool is at
flows into the bypass circuit (55) past the position [Ⅱ], the pressurized oil thus flowed
main passage (54), but since the bypass enters passage (61) through the inside of arm
circuit (55) is blocked by the arm spool (302), recirculation spool (310), pushes arm
the oil pressure pushes the check valve CP2 recirculation check valve poppet (512) open,
open, flows into the parallel circuit (56), and is supplied again to the arm cylinder
pushes the load check valve (512) open, goes head (H) as the hydraulic oil for arm digging.
between the outer circumference of the arm (arm recirculation function)
spool (302) and the casing, or chamber F in Part of the hydraulic oil admitted to arm
the arm spool (302) through the U-shaped recirculation spool (310) flows into tank port
passage and is supplied to the arm cylinder (T) from low pressure circuit (D) and returns
head (H) side via port (Aa). to the hydraulic oil tank.
Meanwhile, the oil which has returned from
(61) (60) ARM CYLINDER
LOCK VALVE
SELECTOR SPOOL
H R LOCK VALVE
D SELECTOR PLc2
512 (CRa)
211 Drd
(LCa) 514
CHAMBER AR
ARM VARIABLE (Aa) (Ba)
RECIRCULATION
POSITION [Ⅱ]
PAa
302 (55)
CHAMBER SECTION F-F (ARM)
512(CAr) F (56)
310 (61) (60) Ba
Pis
D SECTION G-G
Fig. 4-21 When arm in is operated (under light load)
24-46
4) When the arm in is operated Then, the hydraulic oil flowed into arm
(under heavy load) recirculation spool (310) does not flow to the
The arm oil recirculation function is effective arm cylinder head [H] that is heavily loaded,
when operating the arm cylinder quickly but flows to tank port (T) from low pressure
under a light load, but under a heavy load circuit(D) and returns to the hydraulic oil
(when heavy duty is required), this function tank. (recirculation cut)
wastes power.
The control valve switches automatically Sequenced conflux :
between oil recirculation under light load If the arm cylinder head (H) is loaded
conditions and no recirculation under heavy heavily, the solenoid proportional valves [C],
load conditions by detecting pump pressure. [D] operate in addition to the above-mentioned
This is called the variable recirculation recirculation cut action. As the result, each
function. When the arm is under a heavy secondary pressure acts upon the PTb and
load, that is, when no recirculation occurs, PCb ports of the control valve, changes the
the oil supply passage to the arm cylinder is travel straight spool (307) to position [Ⅱ]
the same as during recirculation described [Refer to the above 4.4.(2).2).] and changes
above, but the return oil passage is different. the P1 bypass cut spool (309).
The system detects the pump pressure at As the result, the oil flow from the pumps P1
heavy load condition [more than 200kgf/cm2 open check poppet CT2 because P1 bypass cut
(2840psi) of pump pressure]. This causes the spool (309) is shifted, and hydraulic oil of
secondary pressure of solenoid proportional pump P2 is confluxed in the parallel circuit
valve [A] to operate and changes the arm (56) of the control valve and are supplied to
recirculation spool (310) to position [I]. the arm cylinder head (H).
ARM CYLINDER
(61) (60) LOCK VALVE
SELECTOR SPOOL
H R PLc2
LOCK VALVE
Drd
D 514 CHAMBERSELECTOR
AR
Aa Ba Pisc
ARM VARIABLE
RECIRCULATION
POSITION [Ⅰ]
PAa
Pis
24-47
(5) Swing action
If swing action is performed, the secondary valve (CP2) open and enters the parallel
pilot pressure from port (5) or (6) of the pilot circuit (56).
valve acts upon port PAS1 or PBS2 of the Then the pressure oil pushes open the load
control valve and shifts the swing spool (303) check valve (512) for swing action, flow into
rightward or leftward. U-shaped passage of the swing spool (303).
If the secondary pilot pressure is acting on Then the pressurized oil which has entered
the PBS1 port, it is also acting upon the the U-shaped passage of the swing spool
PBS2 port by way of the external pipe. In the (303) passes between the outer circumference
swing motion, the secondary pilot pressure is of the swing spool (303) and the casing and is
admitted to the Pss port past the shuttle supplied to the A or B side of the swing motor
valve in the cover. through port AS or BS.
Since the Pss port is connected with the Pisc In the meantime, the oil which has returned
port by way of the external pipe, the pressure from the B or A side of the swing motor
acts as swing priority signal. passes between the outer circumference of
The pressurized oil delivered by the pump P2 the swing spool (303) and the casing through
enters the bypass circuit (55) through the the port (BS) or (AS), flows from the low
main passage (54), but since it is blocked by pressure circuit (D) to the tank port (T) and
the swing spool (303), it pushes the check returns to the hydraulic oil tank.
valve
A B
U-SHAPED PASSAGE
SWING MOTOR PARALLEL CIRCUIT (56) P2 SIDE
FOR SWING MOTION (LCs)
303 512
AS BS
Pss PAS
PBS2
PBS1
(55)
SECTION D-D
24-48
Swing main circuit is actuated by P2 pump Arm variable recirculation spool returns to
flow, but when the operation of swing and forced recirculation side according to swing
arm in are operated simultaneously, the pilot pressure. Return oil from arm cylinder
secondary pressure of travel straight valve rod (R) side is restricted in arm variable
switches it's spool and the secondary pressure recirculation valve.
of P1 cut proportional valve closes P1 cut And swing pilot pressure is led from “Pisc”
valve and oil of P1 pump confluxes port to sub-spool in arm spool, the pressure of
consequently with P2 pump circuit. The oil arm cylinder head (H) rises higher by
flows into swing and arm circuits in the same restricting opening of arm spool circuit
time because both circuits are paralleled. according to swing pilot pressure, as a result
Return oil pressure rises and also arm the oil P2 pump flows preferentially into
cylinder head (H) pressure rises because of swing circuit.
following two reasons. This is so-called swing priority control.
ARM CYLINDER
(61) (60) LOCK VALVE
SELECTOR SPOOL
Pisc
H R LOCK VALVE PLc2
CHAMBER AR SELECTOR Drd
D
514
Aa
ARM VARIABLE
RECIRCULATION
POSITION [Ⅲ]
PAa
Pis PCa
24-49
(7) Action of option valve (for P2 pump) :
If such an attachment as the dozer that uses pushes the check valve open, flows into
an option valve, the secondary pilot pressure parallel circuit (56), pushes the load check
from port (P) of the pilot valve acts upon the valve open, passes through the clearance
PAo2 or PBo2 port of the control valve and between the outer circumference of the option
shifts the option spool to the right or the left. spool and the casing and is supplied to each
At the same time, the secondary pressure of attachment from port (Ao2) or (Bo2).
solenoid proportional valve [B] acts upon the In the meantime, the oil returned from the
PCa port of the control valve and changes the attachment enters the control valve from port
P2 pilot bypass cut spool (309). (Bo2) or (Ao2), passes through the clearance
The hydraulic oil delivered by pump P2 runs between the outer circumference of the option
into bypass circuit (55) through the main spool and the casing and returns to the
passage (54), but since it is cut off by P2 hydraulic oil tank from the low pressure
bypass cut spool (309) that has shifted, the oil circuit (D) and the tank port (T).
PAo2
PBo2
(56) D
PCa
(55) 309
24-50
(8) Functions of lock valve
Lock valve (514) is located between arm That is to say, lock valve selector sub spool
cylinder rod side(R) and arm spool(302) of the (L511) is pressed against bushing (L541) by
control valve to decrease the leakage due to the action of spring (L512).
the holding pressure from the cylinder. In this position, the holding pressure from
Similarly, lock valve(514) is located between boom cylinder head (H) side passes through
arm cylinder head side(H) and boom passage Sa, passage (a) of bushing (L541) and
spool(301) of the control valve to decrease the around spool(L511), and connects to (b), then
leakage due to the holding pressure from the flows through passage Sb, consequently
cylinder. poppet (514) of the lock valve is pressed down
maintaining the seated condition, and the
1) When the main spool is neutral; leakage results in minimal quantity.
The boom spool (301) will be explained
hereinunder. The arm spool (302) will be
explained also.
When boom spool (301) is in neutral position,
it is held in the position shown in Fig. 4-26.
Sb
Sa
(301)
Fig. 4-26 Functions of lock valve (when the main spool is neutral)
24-51
2) At boom lower action:
The secondary pilot pressure from port (4) of This causes the orifice (b) of the bushing
the pilot valve acts upon the PBb port of the (L541) to connect with the passage Sb, the
control valve and the PLc1 port of the lock spring chamber of the lock valve poppet (514)
valve selector and shifts the boom spool (301) and the low pressure circuit. The lock valve
to the right. At the same time, the pressure poppet (514) is received by the ring-shaped
shifts the spool (L511) of the lock valve pressure bearing area that consists of the
selector to the right. guide diameter and the seat diameter of the
As the spool (L511) is shifted, the orifice (a) lock valve poppet (514), so that the lock valve
in the bushing (L541) closes. This shuts off poppet is pushed open upwards to release the
the continuity from passage Sa to passage Sb lock function.
in the lock valve selector B sub (212) and the
hold pressure received from the boom Note: The action in the above takes place
cylinder head (H) side ceases to act upon the before the opening (meter-out opening) that
spring chamber (RH) of the lock valve poppet brings the oil returning from the boom
(514). cylinder head (H) of the boom spool (301)
As the spool (L511) moves, continuity is during boom lower action, back to the
established from the orifice (b) of the bushing hydraulic oil tank; the action operates before
(L541) to the drain port (Drc) through the the boom spool strokes from its neutral
inside of the bushing (L541). position. Therefore, the action does not affect
the controllability of the boom lower motion.
L511 L512
CHAMBER
BOOM CYLINDER RH 514 PLc1 Drc
HEAD (H) SIDE
Sb
Sa
PBb
PAa
301
24-52
(9) Operation of main relief valve
The main relief valve is built in casing and
operates as follows:
541 512
Fig. 4-28
611 621
Fig. 4-29
R
512 611
Fig. 4-30
24-53
(10) Operation of port relief valve
The port relief valve is located between the
cylinder port and the low pressure passage,
functions as both a relief valve and an anti 301 A B
cavitation check valve, as mentioned below :
611 621
Fig. 4-32
511 B
3. When the poppet (611) opens, the hydraulic
pressure in chamber B falls which causes the
plunger (511) to open and allows the
hydraulic pressure of port (P) to flow directly
to (R). P
611
Fig. 4-33
24-54
5. SWING MOTOR UNIT
5.1 SPECIFICATION
(1) Appearance THREAD FOR EYE BOLT
AN PB L 2-M10
PG
DP2
SWING
SHOCKLESS
VALVE BLOCK REDUCTION
UNIT DRAIN HOSE
RELIFE
VALVE
DP
AN
GN
Hydraulic diagram
24-55
(2) Specification
MODEL
E135SR LC EVOLUTION E115SR EVOLUTION
Swing motor unit
Type RG06D19G3 ←
SAE#90~#140
Lubricate oil API Service Grade GL3 to 4 equivalent
(Shell spirax 90EP at shipment)
Lubricate oil (gal)
Reduction unit
1.7 (0.45) ←
volume
24-56
5.2 CONSTRUCTION
(1) Swing motor
992
351
355
051
V401-2
114
V401
117
121
702
111 113
743 123
742 993
464
485
116 117 432 471 443 106 101 491 304 437 124 122 301
Fig. 5-2 Swing motor
24-57
Tightning Tightning
torque No. NAME QTY torque No. NAME QTY
kgfym (lbfyft) kgfym (lbfyft)
101 DRIVE SHAFT 1 471 O RING; 1B G80 1
106 SPACER 3 472 O RING 1
111 CYLINDER 1 485 O RING; 1B P11 1
RETAINER
113 (SPHERICAL BUSHING) 1 487 O RING; 1B P11 2
114 CYLINDER SPRING 1 488 O RING; 1B P20 2
116 PUSH ROD 12 491 OIL SEAL 1
117 SPACER 2 702 BRAKE PISTON 1
121 PISTON 9 706 O RING 1
122 SHOE 9 707 O RING 1
123 PLATE 1 712 BRAKE SPRING 20
124 SHOE PLATE 1 742 FRICTION PLATE 3
131 VALVE PLATE 1 743 SEPARATOR PLATE 4
301 CASING 1 0.17(1.2) 980 PLUG; PF3/8 1
303 VALVE CASING 1 0.45(3.3) 981 PLUG; PF3/4 1
304 FRONT COVER 1 0.09(0.65) 982 PLUG; PF1/4 1
351 PLUNGER 2 6.6(48) 992 PLUG; PT1/2 1
355 SPRING 2 2.2(16) 993 PLUG; PT1/4 1
24(170) 401 SOCKET BOLT; M16×75 4 18(130) 051 RELIEF VALVE ; M33 2
432 SNAP RING 2 051-1 O RING; 1B G30 2
433 RING 1 051-2 BACKUP RING 2
SWING SHOCKLESS VALVE
437 SNAP RING 1 052 BLOCK 1
438 SNAP RING 1 V101 CASING 1
443 ROLLER BEARING 1 0.9(6.5) V151 PLUG; NPTF1/16 4
444 ROLLER BEARING 1 V161 O RING; 1B P22 2
451 PIN 2 3(22) V171 SOCKET BOLT; M8×70 8
SWING SHOCKLESS VALVE;
3.7(27) 464 VP PLUG; PF1/4 1 7(51) V401 M22 2
3.7(27) 468 VP PLUG; PF1/4 2 V401-1 O RING; 1B P20 2
11(80) 469 RO PLUG; M22 2 V401-2 BACKUP RING 2
24-58
2) Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 210
922
282
※ 921
202
203
311
285
※
312
913
402 910
801
925
920
926
102
401
915
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
102 CASING 1 401 ROLLER BEARING 1
201 DRIVE SHAFT 1 402 ROLLER BEARING 1
202 RING GEAR 1 403 NEEDLE BEARING 3
203 No.2 PLANETARY GEAR 4 10 (72) 602 SOCKET BOLT ; M12×100 10
204 No.2 SUN GEAR 1 801 OIL SEAL 1
210 No.1 PLANETARY GEAR 3 910 SPRING PIN 4
211 No.1 SUN GEAR 1 911 SNAP RING 3
230 No.2 CARRIER 1 912 SNAP RING 1
231 No.1 CARRIER 1 913 SNAP RING 1
282 No.2 PIN 4 915 SEAL 1
283 No.1 PIN 3 6.6 (48) 920 ADAPTER ; PT1/2 1
285 SIDE PLATE t=1 7 11 (80) 921 HOSE ; PF1/2 1
286 THRUST WASHER t=2 1 11 (80) 922 PLUG ; PF1/2 1
287 SIDE PLATE t=2 3 2.2 (16) 925 RELIEF FITTING 1s
311 LEVEL BAR 1 2.2 (16) 926 GREESE NIPPLE 1s
312 PIPE 1
24-59
5.3 OPERATION
5.3.1 OPERATION OF HYDRAULIC MOTOR CYLINDER BLOCK(111)
p×q
T=
2×π
p : Effective differential pressure kgf/cm2
q : Displacement per revolution c.c. /rev
24-60
(2) Operation of relief valve ORIFICE m PISTON (303)
DAMPING
1) Operation at boosted pressure AREA A1 SPRING (321) AREA A2 CHAMBER
1. Consider where the P port is pressurized CHAMBER g
h
from the tank pressure.
The pressure at the P, R ports is equal to the
tank pressure at the beginning, as shown in
Fig.5-6-(1). P
R
2. Condition shown in Fig.5-6-(2)
If the P port is pressurized, pressure is built PLUNGER (301) AREA A3 SPRING (322)
up in the g chamber via the orifice(m) in PISTON (302) SPRING CHAMBER
plunger (301). This pressure acts upon the
pressure receiving area (A2-A3) of piston
(303). Fig. 5-6-(1)
The force pushing the piston to the right
DAMPING
balances the action of spring (322), piston CHAMBER
m SPRING (321) PISTON AREA A2
(303) begins to shift to the right. Let the h
CHAMBER
pressure at this time be Pg1. The pressure in
the g chamber is held constant (Pg1) while
piston (303) is moving to the right.
The relief pressure (P1) at this time is P
expressed as below:
P1×A1=FSP1+Pg1×A2 ....... (1)
R
FSP1: Force of spring (321) AREA A3 SPRING (322)
4. Condition in Fig.5-6-(3)
When piston (303) arrives at its stroke end, P
the pressure of the g chamber becomes equal
R
to that of the P port. On that occasion, the
relief pressure (Ps) is as below: SPRING (322)
PLUNGER (301) SPRING CHAMBER
AREA A3
FSP1
Ps = ....... (2) Fig. 5-6-(3)
A1-A2
After going through the sequences 1 to 4
above, the relief pressure changes as
shown in Fig.5-6-(4).
2) Operation as pressure falls:
If the pressure against the P port disappears,
plunger (301) is pressed by spring (321) and
lands on the seat.
In the meantime, piston (303) is pushed by
spring (322) and moves to the left. On that
occasion, the oil to damping chamber (h) is Fig. 5-6-(4)
refilled swiftly from the outer circumference
of the piston and the R port, and shifts piston Fig. Operation of relief valve
(303) quickly till it comes back to its initial
condition.
24-61
(3) Operation of swing reactionless valve
24-62
5.3.3 OPERATION OF BRAKE SECTION
The cylinder (111) is jointed by drive shaft (101)
and a spline. Separator plate (743) is fixed in its
circumferential direction by circular grooves FORCE BY
HYDRAULIC
provided in casing (301). PRESSURE
Now, if the friction plate (742) splined to the outer
circumference of the cylinder is pressed against
casing (301) via separat or plate (743) and brake FORCE BY
SPRING
piston (702) by the action of brake spring (712), ACTION
frictional force is created between friction plate
(742) and casing (301) and between separator 712
plate (743) and brake piston (702). The frictional 702
force bounds the drive shaft to brake the motor.
OIL 743
In the meantime, when brake release pressure CHAMBER
742
applied to the oil chamber formed between brake
301
piston (702) and casing (301) overcomes the
101 111
spring force, the brake is released as brake piston
(702) moves till friction plate (742) is detached
from casing (301). Fig. 5-9 Operation of swing brake
201
401
24-63
6. TRAVEL MOTOR
6.1 SPECIFICATION
(1) Appearance
OIL LEVEL CHECK &
15-M16×P2.0 20-M16×P2.0
LUBRICATION PORT
(PT1/2)
A PF3/4
3-∅14 DRAIN PORT D1
PF1/2
TRAVEL
2-SPEED CHANGE
PORT P PF1/4
X ←
Z
DRAIN PORT D2
PF1/2 B PF3/4
Rotation direction Oil inlet Oil outlet OIL LEVEL CHECK &
LUBRICATION PORT
(Viewed from X side) port port (PT1/2)
Clockwise A B
Counterclockwise B A
Fig. 6-1 Travel motor ( With reduction unit and brake valve )
(2) Specification
Table 6-1
24-64
6.2 CONSTRUCTION
(1) Outline
2-SPEED
CHANGE
PISTON
PARKING
BRAKE
2-SPEED
CHANGE
VALVE
LOAD CHECK
VALVE
&
ANTI- SHOCKLESS
CAVITATION RELIEF
VALVE VALVE KIT
BRAKE
VALVE
Fig. 6-2
24-65
(2) Hydraulic motor
135
126 139
137 112 171
130 113 167
127 109 103
138
124 141 106
136 121 117 105
128 154 115
107
116
125 111
104
110
142 150 114
166 179 110
164 127 145 132
163 130
138 137 149
202 126 108
199 201 126 102
168 146 190 195 151
140 143
202 194 123 169
193 125
128
138 136
124 191
162
161
Fig. 6-3
24-66
(3) SRV (Shockless relief valve)
202
209
211
208 215
211
217 209 224
217
212 216
204
210
205 217
203
209
206 217
201 222 211
221 208
211
222 209 202
220 213
214
222 211
201
206
203
205
210
204
Fig. 6-4
24-67
(4) Reduction unit
21
31
22
2 21
5
30
23
9
23
4
33
1
29
27 27
17 25
7
14
20
22 35
3
36 8
6
15
19
Fig. 6-5
24-68
6.3 EXPLANATION OF FUNCTION
6.3.1 REDUCTION UNIT
(1) Function
This reduction unit is equipped with spur
gears (Hereinafter referred as 1st reduction
gear section) and differential gears
(Hereinafter referred as 2nd reduction gear
section), reduces the high rotation speed from
the Hydraulic motor, coverts it to low speed
large torque and rotates hub (1) (Casing).
SHAFT (102)
i1=-
Zi
Zs
i1 = Reduction rate of 1st reduction
gear section
Zi = Number of teeth of input gear
INPUT GEAR (6)
Zs = Number of teeth of spur gear
Fig. 6-6
2) 2nd reduction gear section
a) Three spur gears are engaged with
crankshaft respectively to transmit the power SPUR GEAR
from the 1st reduction gear section to 2nd
NEEDLE BEARING ROTATION
reduction gear section.
The eccentric bodies of crankshaft a and b ECCENTRIC
revolve eccentrically (revolution) while REVOLUING
rotating on its axis by rotating crankshaft. CRANK SHAFT (9)
Also, these eccentric bodies a and b and RV ROTATION
B
gears “A” (4) and “B” (5) transmit only A
the eccentric revolution.
And RV gears A and B revolve in the same
direction and number of revolutions as spur
gear and crankshaft.
b) Teeth number ZR of RV gears A and B is
always engaged with ZP pins (17) rotating
and changing the mesh part in order, by ECCENTRIC
RV GEAR B (5)
eccentrically revolving RV gears A and B. MOTION
By eccentrically revolving RV gears A and B RV GEAR A (4)
one turn, the pin revolves in the same Fig. 6-7
direction of eccentrical revolution in the
portion of difference between number
24-69
of teeth ZR and number of pins ZP
【(ZP-ZR) / ZP】.
This revolution of pin is transmitted to hub, HUB
producing output rotation of reduction unit. 23 24 1 2
22 3
At this point, the speed ratio of 2nd reduction 4 PIN (17)
gear section is as follows.
i2= (ZP-ZR)
ZP
RV GEAR A
i2 = Speed ratio of 2nd reduction AND B
gear section
ZR= Number of RV gears A and B teeth
ZP= Number of pins 360°
CRANK SHAFT
360°
REVOLVING
2×24 24
BODY SECTION
Then, the output revolution is as follows,
when the hydraulic motor shaft rotates one
23 24 1 2 22
23 24 1
time. 22
3 2
4 3
4
i= i1×i2
i1 = Speed ratio of 1st reduction
gear section
i2 = Speed ratio of 2nd reduction
gear section
24-70
4) Parking brake
101
The parking brake is used to the prevent
machine from running away or slipping while 109 104 103
parking on a slope using the friction plate
type brake mechanism, and is installed on
102
the hydraulic motor.
(2) Operation
1) Hydraulic oil fed by pump enters rear flange
(101) of travel motor, and is led from timing
plate (109) to cylinder block (104) through
brake mechanism. This pressure oil is led to
only the one side of Y1-Y2 tied between top 105
dead point and bottom dead point of piston
stroke (105). And the pressure led to one side
of cylinder block pushes 4 or 5 pistons (105),
generating the power (F1kgf= Pkgf / cm2× Y1 F3
Acm2). This power enters on swash plate F3
(103), but swash plate (103) is fixed having
an angle (α) against axis of drive shaft (102), ri
and divided into component of force (F2, F3).
And the radial component of force (F3) F3
generates various torque (T=F3×ri) against
line Y1-Y2. The total torque [T=∑(F3×ri)] is
connected to turning effort, and rotates
Y2
cylinder block (104) through piston (105).
This cylinder block (104) is connected with
drive shaft (102) with spline, and rotates
CYLINDER BLOCK
drive shaft (102) to transmit torque.
PISTON
α
F1
A P
F3
F2
24-71
2) braking
a) Operation (Brake released)
The pressure oil is led to through port (A), 112
opens valve (127), and led to port (C) on the
section side of hydraulic motor to rotate
hydraulic motor.
At the same time, the pressure oil enters
chamber (b) through passage (a) from the
D C
small hole of spool (123), and exerts on the
end of spool to generate the force.
Then the force of spring (128) slides the spool P,S a b
placed on the neutral position leftward. 128 123
The sliding of spool forms the space (passage)
between spool and rear flange with spool
groove. This passage is connected to port (D)
and port (B) of the return circuit of the
hydraulic motor, and the return oil returns to
tank side, enabling hydraulic motor to rotate.
Then, the sliding of spool (123) leads pressure
oil to port (P) and port (S). The pressure oil
B A
led to port (P) moves piston (112) of parking DRAIN 127
brake, and releases parking braking force.
(For details, refer to item“Parking brake”). Fig. 6-12
If pressurized oil is supplied from port (B) the
movements of spool (123) and valve (127) are
reversed so that the hydraulic motor is
rotated reversely.
b) Self-traveling
While machine is being operated, as the
112
travel speed is increased due to steep slope,
the oil flow rate of the hydraulic motor is
higher than the supply flow rate of the
hydraulic oil pump. The rotation of the
hydraulic motor in this case is called a self-
traveling (Overrun). D C
While self-traveling, the oil pressure is
lowered similar to the stopping condition. P,S a b
Then brake valve is moved similar to the
stopping condition, throttles passage in the 128 123
return side of hydraulic motor, and generate
back pressure.
In addition, the force of inertia decreases the
revolution of hydraulic motor to revolution
having a balance with the supply flow rate of
pump.
B A
DRAIN 127
Fig. 6-13
24-72
c) At stop and at loss of speed (braking action)
If the pressurized oil which has been supplied Accordingly, the hydraulic oil of chamber (D)
from port (A) during travel action is flows to the chamber (C) at relatively low
suspended the hydeaulic force pressing the pressure and controls the pressure at
spool disappears. Then spool (123) which has chamber (D). At the same time, the hydraulic
been moving to the left tries to return to the pressure prevents cavitation of chamber (C).
right (neutral condition) by the action of When the piston (213) arrives at the stroke
spring (128) via spring retainer (125). At the end, the pressure in chambers (g), (f)
same time, the hydraulic motor tries to turn increases. The right-hand valve (210) is
by inertia, though the hydraulic oil supply closed again. When the right-hand valve
from port (A) is suspended. The oil (201) is closed, the oil at port (D) rises
discharged from the hydraulic motor has no further. If the left-hand valve (201) opens, the
way to escape, with the result that the oil in port (D) acts upon port (C) and opens
hydraulic oil in port (D) is boosted. The the relief valve at a much higher pressure
hydraulic oil thus boosted passes through the than a set value of it. In this way, the
right-hand valve (201) and enters the hydraulic motor is braked smoothly by
chambers (f) and (g), in that order. The piston controlling the pressure in port (D) in two
(213) moves to the right as shown in the steps.
figure so that the pressure does not rise. In
that period, the valve (201) on the right is
pushed open by the pressure of the chamber
(D).
E
B
A
C
f
201
a
g
213
b
Fig. 6-14
24-73
3) Parking brake
a) The pressure oil led through brake valve
actuates on spool (123) of brake valve on the
112 116 115 104
hydraulic motor section, opens passage to
parking brake, and is led to cylinder chamber
(a) compressed of spindle (2) and piston (112)
on the reduction gear section.
If the pressure of oil which is 8kgf/cm2
(110psi) or higher it exceeds the force of
spring moving piston (112) toward rear flange
(101) side.
This movement of piston (112) reduces the
push power to separator plate (116), (117)
and friction plate (115), and makes the
movement of friction plate (115) which is
installed to cylinder block (104) on hydraulic
motor section free releasing the brake power
to cylinder block (104).
113 a 117
Fig. 6-15
b) Stopping
If pressure oil from brake valve is cut, and
the pressure in cylinder chamber (a) lowers
8kgf/cm2 (110psi) or less, the piston (112)
goes to rightward by the force of spring (113).
Also, the force of the spring pushes separator 112 116 115 104
plate (116), (117) and friction plate (115),
which is in a free state because piston (112) is
pushed, against spindle (2) on the reduction
gear section. The frictional force produced by
the push power stops the rotation of cylinder
block (104), and transmits braking torque
18.2 kgfym (132ftylbs) to hydraulic motor
shaft. And since oil is controlled through the
proper oil passage, it results in smooth
operation.
113 a 117
Fig. 6-16
24-74
4) High and low speed change mechanism
a) At low speed
In case the travel 2-speed select pilot
pressure is not supplied from port (D), valve
(163) is pushed up by the action of spring THE TRAVEL
2-SPEED SELECT
(166) and the hydraulic pressure from port PILOT PRESSURE
(A) or (B). This shuts off the pressure of (C) 163
103
and the oil in the P chamber is released to
the drain (motor casing) via the valve. The θ1 SURFACE Y
result is that the swash plate(103) takes the 166 161
max. tilting angle θ1 which in turn
CHAMBER P
maximizes the piston stroke volume,
making the hydraulic motor run at low speed.
b) At high speed
In case the travel 2-speed select pilot
DRAIN
pressure 51kgf/cm2 (725psi) is supplied from
por t(D), valve (163) is pushed down, Fig. 6-17
overcoming the action of spring(166) and the
pressure from port (A) or (B). The
pressurized oil at port (C) is admitted to
chamber P via valve (163). THE TRAVEL
2-SPEED SELECT
Piston (161) is pushed till swash plate (103)
PILOT PRESSURE
hits the surface X and is held. 163
On that occasion, the swash plate (103) takes 103
the min. tilting angle θ2 which in turn θ2 SURFACE X
minimizes the piston stroke volume to make 161
166
the hydraulic motor run at high speed.
CHAMBER P
b) Automatic selection of low speed during high
speed operation :
The pressure at port (A) or (B) increases as
the load of the hydraulic motor increase
DRAIN
during high speed operation, and when the
pressure arrives at 290kgf/cm2 (4120psi), it Fig. 6-18
overcomes the pilot pressure [51kgf/cm2
(725psi)] at port (D).
Valve (163) is then pushed upward. The oil in
the P chamber is released to the drain (motor
casing) via valve (163). THE TRAVEL
2-SPEED SELECT
On that occasion, swash plate (103) hits the PILOT PRESSURE
surface Y of the spindle and takes the max. 163
tilting angle θ1. The angle is held to make 103
the hydraulic motor run at low speed. θ1
SURFACE Y
166 161
CHAMBER P
DRAIN
Fig. 6-19
24-75
7. SWIVEL JOINT
7.1 DOZER SPECIFICATION
7.1.1 GENERAL VIEW (SPEC.1)
Y
↓
H
H F
C
A E D
B
G
I
D
C VIEW Y
F E
↑
Z Fig. 7-1 General view of swivel joint
VIEW Z
7.1.2 SPECIFICATION
Table 7-1
Item Spec.1
Working pressure 350kgf/cm2(4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
A,B,C,D
Rated flow 315 /min(83gal/min)
Working pressure 210kgf/cm2(2990psi)
High pressure ports
Max. impact pressure 525kgf/cm2(7470psi)
F,G
Rated flow 210 /min(55gal/min)
Low pressure ports Working pressure 5kgf/cm2(71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 50kgf/cm2(710psi)
H,I Rated flow 15 /min(4gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E,F,G PF1/2
H,I PF1/4
Length: L 420mm(16.5″)
Weight 63kg(139 lbs)
24-76
7.1.3 CONSTRUCTION
T= Tightening torque: kgfym (lbfyft)
Y
↓
E
2 places
6 F
D
C E B
1
D A
H
G
C
H I
B 13
T=1(7.2) VIEW Y
7
3 E
4 8 9
2 places 4 places
Table 7-2
No. NAME Q’TY No. NAME Q’TY
1 BODY 1 7 O RING; 1A G125 1
2 STEM 1 8 SOCKET BOLT; M8×20 2
3 THRUST PLATE 1 9 SOCKET BOLT; M8×30 4
4 COVER 1 12 PLUG; PT1/2 2
5 SEAL ASSY 7 13 PLUG; PT1/8 1
6 O RING 2
24-77
7.2 STANDARD SPECIFICATION
7.2.1 GENERAL VIEW (SPEC.2)
C D E
D E
A
F
C
B
A
VIEW Z
E
Z
7.2.2 SPECIFICATION
Table 7-3
Item Spec. 2
Working pressure 350kgf/cm2 (4980psi)
High pressure ports
Max. impact pressure 525kgf/cm2 (7470psi)
A,B,C,D
Rated flow 255 /min (67gal/min)
Low pressure ports Working pressure 5kgf/cm2 (71psi)
E Rated flow 50 /min(13gal/min)
Low pressure ports Working pressure 51kgf/cm2 (725psi)
F Rated flow 30 /min (8gal/min)
Revolution 15rpm
A,B,C,D PF1
Ports size E PF1/2
F PF1/4
Length (height) 320mm (12.6″)
Weight 27kg (60 lbs)
24-78
7.2.3 CONSTRUCTION
B
C
E
2
X
6
A
1
X
D VIEW Y
C
12
F
B
F
5
7 SECTION XX
3
9
4 E 8
Fig. 7-4 Construction
Table 7-2
No. NAME Q’TY No. NAME Q’TY
1 BODY 1 6 SEAL ASSY 2
2 STEM 1 7 O RING ; 1A G95 1
3 THRUST PLATE 1 8 SOCKET BOLT; M8×20 2
4 COVER 1 9 SOCKET BOLT; M8×30 4
5 SEAL ASSY 5 12 PLUG 1
7.2.4 OPERATION
The swivel joint consists mainly of body (1) and The body (1) and the stem (2) rotate mutually.
stem (2) that rotate mutually, thrust plate (3) The oil flowing in from body (1) or stem (2) keeps
preventing both components from falling off, cover on flowing to stem (2) or body (1) past the
(4) closing one side of body (1), seal (5) that circumferential groove between body (1) and stem
partitions off the circuits and seal assy (6) and O (2); the oil flow is never shut off because of
ring (7) that prevent external leaks. rotation. Further, an oil groove for lubrication
Four ports for the travel main circuits are that connects with the drain port is provided, in
provided on body (1) and stem (2). Further, four order to prevent the body (1) from seizure with
oil passing grooves are arranged in the inner the stem (2).
surface of body (1), with seal (5) fixed above and This construction keeps on connecting the circuits
below the circumferential groove. between the swing bodies by means of a swivel joint.
24-79
8. CYLINDER
8.1 SPECIFICATION
(1) Appearance
Manufacturing No.
Stamp position
(2) Specification
Table 8-1 Unit: mm (ft-in)
Center distance
Cylinder bore / Dry
of mounting pins
Use Rod Dia. Stroke Full extend B / Cushion weight
Full retract A kg (lb)
∅100 / ∅70 1,038 2,526 / 1,488 With cushion
Boom 94 (210)
E135SR EV.
on rod side
on rod side
∅110 / ∅65 220 880 / 660
Dozer (4.33″/ 2.56″) (8.66″) (2′11″/ 2′2″) Without 57 (130)
24-80
8.2 CONSTRUCTION
(1) Boom cylinder T=Tightening torque ; kgfym (lbfyft)
3 B 6
Z
→
T=1.8~2.2(13~16)
M10×1.5
28,29 27
26
2 14 13 9 8 10 11 12 7 15 4 1 19 20 21 16 18 17 22 23 24 5
PT1/8
C
∅1.2 PT1/4
(0.047″) 25 T=21~22(150~160)
Fig. 8-2 Construction of boom cylinder
(The figure shows the right-hand cylinder.)
24-81
(2) Arm cylinder E135SR LC EVOLUTION, E115SR EVOLUTION
T=Tightening torque; kgfym (lbfyft)
B M10×1.5 B
Z
→
31 32 29
T=1.8~2.2
(13~16)
30
VIEW Z DETAIL 20 DETAIL B DETAIL C
2,3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3
C
PT1/4
PT1/8
A 23 T=35~37
(250~410)
24
25
26
27 T=5 (36)
28
DETAIL A Fig. 8-3 Construction of arm cylinder
24-82
(3) Bucket cylinder E135SR LC EVOLUTION, E115SR EVOLUTION
PT1/8
25 26,27 T=1.8~2.2(13~16)
T=1.5 (11)
T=190(1370) T=100(720)
2 3 12 11 7 6 8 9 10 5 13 4 1 17 18 19 14 16 15 20 21 22 2,3
B
C
23 T=21~22
(150~160)
24-83
(4) Dozer cylinder
T=Tightening torque; kgfym (lbfyft)
B
2 3 3 2
DETAIL B
T=70(510)
10 11 9 7,8 12 23 5 1 4 18 6 15 16 17 21 14
2-PT1/8
(Grease nipple hole)
19,20 22 24
24-84
Hydraulic cylinder construction
(See Fig. 8-2, 8-3, 8-4, 8-5)
By construction the hydraulic cylinder consists
mainly of cylinder tube assy (1), piston rod assy
(4) that takes out the motion of pistons
reciprocating in the cylinder tube assy, and rod
cover (14) that serves as both a lid and a guide.
Cylinder tube assy (1) is equipped with a piston
mount (crevice) that connects piston rod assy (4)
with other parts.
In addition to these main components, piston seal
(8) and wear ring (9) are located between cylinder
tube assy (1) and piston rod assy (4); buffer seal
(20), rod packing (21) and dust seal (22) are
located between piston rod assy (4) and rod cover
(14); and an O ring and a backup ring are placed
between cylinder tube assy (1) and rod cover (14). CUSHION RING(13) CHAMBER “A”
TANK PATH “B”
8.2.2 OPERATION PISTON(5)
If pressurized oil is fed alternatively to the oil ROD(4)
inlet and outlet provided in the cylinder, force
acts on the piston which in turn causes the piston BOTTOM ROD SIDE
24-85
(Cushion on head side) PLUNGER
This construction is similar to the one of cushion TANK CHAMBER “A”
on rod side. In a state of intermediate stroke
pressing rod side, an oil in chamber “A” returns
to tank by passing through paths “B” and “C” at
a fixed flow rate.
Next, in a state of just before stroke end,
plunger plunges into path “B”. At this time,
an oil in chamber “A” path clearance “D” and
restricted path “C”, an oil flow volume PATH “B” E CLEARANCE “D”
returning to tank suddenly drops and the RESTRICTED PATH “C”
piston part movement slows down.
RESTRICTOR VALVE
SPRING
SPRING SEAT
PLUG
O RING
DETAIL E
Fig. 8-9 Cushioning action on the head side
24-86
9. CONTROL VALVE (FOR DOZER OR EXTRA)
B1
T
P
A1
4-∅10.5Drill
Item Specification.
Model KVS-65-1
Main relief pressure 210kgf/cm2(2990psi)
at 50 /min(13gal/min)
A1,B1 port relief 280kgf/cm2(3980psi)
pressure at 30 /min(7.9gal/min)
Max. pressure 250kgf/cm2(3550psi)
Rated flow 52 /min(14gal/min)
Acceptable back
pressure(working) 3.5kgf/cm2(50psi)
24-87
(3) Construction
9 B1 side
Dozer blade up side
8
B1
3
3
A1
6
9
A1 side
Dozer blade 7
down side
Tightening
torque No. NAME Q’TY
kgfym (lbfyft)
1.9(14) 1 NUT 4
2 TIE ROD 2
4.7(34) 3 NUT 2
4 TIE ROD 1
5 INLET SECTION ASSY 1
6 OUTLET SECTION ASSY 1
7 SPOOL SECTION ASSY 1
8 MAIN RELIEF VALVE ASSY 1
9 OVER LOAD RELIEF VALVE ASSY 2
24-88
Part II: ELECTRIC EQUIPMENT
1. LIST OF ELECTRIC EQUIPMENTS
Group Code NAME Group Code NAME Group Code NAME
C-1 Mechatro controller (E115SR EV.) M-1 Starter motor (24V×4.5kW) SV-1 Swing parking sol.
C-1 Mechatro controller (E135SR LC EV.) M-2 Governor motor SV-3 2-speed travel sol.
CONTROLLER
SOLENOID
MOTOR
C-2 M-4 Washer motor (tank assy) SV-6 Clockwise sol
C-2 Gauge cluster (EU Spec.) M-9 Fuel pump SV-7 Counter-clockwise sol.
M-11 Fuel supply pump SV-9 Nibbler open sol.
C-4 Air conditioner controller (A/C Acc.) SV-10 Nibbler close sol.
R-1 Battery relay
D-1 Diode R-3 Glow relay PSV-A Arm variable recirculation proportional valve
PROPORTIONAL VALVE
D-2 Diode R-4 Safety relay PSV-B P2 bypass cut proportional valve
D-3 Diode R-5 Wiper motor relay PSV-C Travel straight proportional valve
DIODE
SOLENOID
D-4 Diode R-6 Washer motor relay PSV-D P1 bypass cut proportional valve
D-5 Diode R-7 Horn relay PSV-P1 P1 pump proportional valve
D-6,7,8,9 R-8 Work light relay PSV-P2 P2 pump proportional valve
R-10 Cab work light relay 1
E-1 Fuse box RELAY R-11 Cab work light relay 2
E-1 Alternator (SK115SR) R-18 Travel alarm relay
E-2 Alternator (SK135SR(LC)) R-19 Flasher relay
E-3 Hour meter R-20 Timer relay SW-1 Key switch
E-4 Horn (Low) R-22 Clockwise relay
E-5 Horn (High) R-23 Counter-clockwise relay SW-3 2-speed travel switch
ELECTRIC FITTINGS
E-6 Cigarette lighter R-24 Nibbler open relay SW-4 Swing parking release switch
E-7 Tuner AM & FM R-25 Nibbler colse relay SW-5 KPSS release switch
E-8 Speaker (Left) SW-6 E/G water temperature switch [105℃(221°F)]
E-9 Speaker (Right) SE-1 Pressure sensor (low pressure) bucket digging SW-7 E/G oil pressure switch
E-10 Receiver drier (A/C Accessory) SE-2 Pressure sensor (low pressure) bucket dump SW-8 Air filter clogging switch
E-11 A/C compressor (A/C Accessory) SE-3 Pressure sensor (low pressure) boom up SW-10 Horn switch left
E-14 Resistor (P1, P2 pump proportional valve) SE-4 Pressure sensor (low pressure) boom down SW-11 Lever lock switch (Limit SW.)
E-15 Travel alarm SE-5 Pressure sensor (low pressure) swing SW-13 Air conditioner switch (Panel assy)
E-16 DC-DC converter SW-16 Auto accel release switch (Desel)
E-17 Power socket 12V SE-7 Pressure sensor (low pressure) arm in SW-17 Swing flasher select switch
E-25 Battery (95E41R) SE-8 Pressure sensor (low pressure) arm out SW-20 Horn switch right
SWITCH
SE-9 Pressure sensor (low pressure) travel right SW-21 Work light switch
L-1 Boom work light left SE-10 Pressure sensor (low pressure) travel left SW-22 Single/Conflux flow select switch
L-2 Work light right SE-11 Pressure sensor (low pressure) ; P2 option SW-23 Wiper inter lock switch
SENSOR
L-3 Room light (Cab) SE-11 Pressure sensor (low pressure) ; N&B (Opt.) SW-30 Rotary light switch
L-4,5,78 Cab work light (front) SE-12 Pressure sensor (low pressure) ; Offset left opt. SW-32 Overload display switch
LIGHT
L-8 Engine room light SE-12 Pressure sensor (low pressure) ; Offset right opt. SW-37 Hydraulic oil temp. switch
L-9 Boom work light (RL) SE-13 E/G speed sensor SW-38 Warm-up switch
L-10 Cab work light (Re) SE-14 E/G water temperature sensor SW-39 Overload pressure switch
L-11,1 Swing flasher (right, left) SE-15 Fuel sensor SW-42 Engine room light switch
2
L-15 Rotary light SE-16 Accel potentiometer SW-43 Jib press switch : option
SE-20 Pressure sensor (low pressure) ; P1 option SW-44 Extra press switch : option
SE-20 Pressure sensor (low pressure) ; Jib extend / contract opt. SW-46 Clockwise sw.
SE-22 Pressure sensor (high pressure) ; P1 pump SW-47 Counter-lockwise sw.
SE-23 Pressure sensor (high pressure) ; P2 pump SW-48 Nibbler open sw.
SE-26 Pressure sensor (low) ; Revolution R/L Opt. SW-49 Nibbler close sw. 24-89
2. SPECIFICATION OF ELECTRIC EQIUPMENTS
File No.
Name of part Specification Description
Use
CN-18
C-1
Controller
Mechatro controller
CALSONIC KANSEI
C-2 Maker CO. LTD,
Rated voltage DC24V
Controller More than 3MΩ at
Insulation resistance 500Vmegger
LCD
Gauge cluster
CALSONIC KANSEI
C-2 Maker CO. LTD,
Rated voltage DC24V
Controller More than 3MΩ at
Insulation resistance 500Vmegger
LCD
Gauge cluster
24-90
File No.
Name of part Specification Description
Use
Controller
Air conditioner
controller
24-91
File No.
Name of part Specification Description
Use
Forward current 3A
Diode
Key switch relay Surge current 200A
Battery relay
Gauge cluster
E-1
24-92
File No.
Name of part Specification Description
Use
E-1
Fuse capacity and circuit name
E-2
Rated output 24×30A M5 BATTERY TERMINAL
Alternator
Generator
HEX 24
R TERMINAL ROTATING
DIRECTION M5
R TERMINAL E TERMINAL
YAZAKI 7322-1424-40
CIRCUIT
24-93
File No.
Name of part Specification Description
Use
M6 B TERMINAL
Alternator M5 E TERMINAL
PULLY A TYPE
Generator
YAZAKI
7322-1424-40
M5
E TERMINAL
CIRCUIT
Service meter
24-94
File No.
Name of part Specification Description
Use
E-4,5 Type
Tuner
1 L SPEAKER(+)
Radio (AM & FM) 2 R SPEAKER(+)
3 ACC(+B)
4 OPEN
5 L SPEAKER(-)
6 R SPEAKER(-)
7 GND(-)
8 BACK UP(+)
9 OPEN
E-7 1 OPEN
2 SPEAKER(+)
3 ACC(+B)
Tuner 4 OPEN
5 OPEN
Radio (AM) 6 SPEAKER(-)
7 GND(-)
8 BACK UP(+)
9 OPEN
24-95
File No.
Name of part Specification Description
Use
Rated input 8W
Speaker
Impedance 8Ω
Radio
Frequency 33.3Hz
E-10
Receiver drier
2-M6×1.0
Cover (clutch)
CP3.96MA
YAZAKI 7120-8019
AVX1.25(BLACK)
AVX1.25(GREEN)
24-96
File No.
Name of part Specification Description
Use
∅4.7±0.3
(0.185″±0.012
E-15 Rated voltage DC12V~36V Fasten earth cord directly to band by eye-let
i l
Rated current 0.2A at 24V
Alarm
Frequency 2200±100Hz
Travel
AMPLIFICATION
CIRCUIT BACK SWITCH
SERVICE
VOLTAGE
DC12V~36V
CONSTANT
VOLTAGE GND POWER
CIRCUIT AV0.5 SOURCE
BLACK AV0.5 R/G ↑
A
VIEW A
BLOCK CIRCUIT DIAGRAM
VIEW A
24-97
File No.
Name of part Specification Description
Use
Socket
Power socket
Voltage 12V
Battery
Capacity 5HR 80Ah
407L×175W×250H
24-98
File No.
Name of part Specification Description
Use
Bulb 24V,70W
Light (halogen)
M14×1.5
Bulb DC 24V,70W
Light (halogen)
Effective area of lens 71cm2
Work light (right)
BRACKET
DRAIN HOLE (Turnable)
M12×1.25×25
CA104 CB104
(POWER SUPPLY) (EARTH)
Light
BULB
OFF ON
A
SECTION DOOR
SWITCH
24-99
File No.
Name of part Specification Description
Use
Light
A
SECTION A
DRAIN HOLE
YAZAKI
AV0.5B AV0.5B
ISUZU 897225-1991
Motor
Starter motor
CIRCUIT
M8
M TERMINAL TO S TERMINAL
SEFETY
RELAY
DRAIN PIPE
24-100
File No.
Name of part Specification Description
Use
LIMIT
Excitation sequence SWITCH
Brown(A) Red(B)
Step
1 2 3 4
Lead
A - + + -
Orange(A) Yellow(B)
B - - + +
A + - - +
B + + - -
MOTOR LIMIT SWITCH
CONNECTOR CONNECTOR
Limit switch connector Motor connector
Lead Connec- Lead Connec-
6 No. color tion 1 2
No. color tion
5 White COM 1 Blown A
5 6 Red NO 2 Orange A
7 7 Yellow NC 3 Red B
3 4
4 Yellow B
HOUSING : 6181-0072(SUMITOMO DENSO) HOUSING : 6181-0073(SUMITOMO DENSO)
TERMINAL : 1500-0134(SUMITOMO DENSO) TERMINAL : 1500-0105(SUMITOMO DENSO)
LIMIT
RETAINER : 6918-0327(SUMITOMO DENSO) RETAINER : 6918-0329(SUMITOMO DENSO)
SWITCH
WATER MOTION
WATER
RESISTANCE : 7165-0118(SUMITOMO DENSO) RESISTANCE : 7165-0118(SUMITOMO DENSO) RANGE
VIEW Z
Wiper
24-101
File No.
Name of part Specification Description
Use
(+) (-)
M-4 Rated voltage DC 24V
MOTOR PUMP
GROMMET M6×1
◯,+BLACK /
WATERPROOF
CONNECTOR (MALE)
VINYL TUBE (WHITE) YAZAKI 7322-9021
L=100 (3.94″)
◯,-
VIEW Z
35 /min (9.2gal/min)
Flow [at 3m (9ft-10in) head]
Fuel supply pump
Q-H CURVE
RED JIS
HEAD H (m)
(+) CA-104
BLACK JIS
(-) CB-104
FLOW Q ( /min)
24-102
File No.
Name of part Specification Description
Use
At start 24V2000A
R-1 Rated voltage / (0.1sec.)
current At charge 28V100A
(continuous)
Relay
Exciting current Less than 0.4A / 24V TERMINAL A
TERMINAL FLW2.0
Battery relay More than B
FLW2.0
Contact force 3.5kgf (7.7 lbs)
F HOUSING :
Closed circuit voltage Less than 16V SUMITOMO
7123-4220-30
F TERMINAL :
Open circuit voltage Less than 7V SUMITOMO
7116-3251
More than 3MΩ / REAR HOLDER :
Insulation resistance 500V megger SUMITOMO
7157-6801-30
MODEL WATER
RESISTANCE :
NUMBER STAMPING L SUMITOMO
POSITION IN A TER- B 7157-3580-60
MINAL TERMINAL
FLOWING DIRECTION OF PRODUCTION PROCESS ←Z
MAIN CURRENT
AVS1.25L
AVS1.25B AVS1.25G
TERMINAL A TERMINAL B EARTH
A1→ ←B1 TERMINAL
EARTH TERMINAL
B
TERMINAL A1 LOCK SECTION
HOUSING AMP
174359-2
RETAINER AMP L TERMINAL
1-174360-1 or 7
TERMINAL AMP
TERMINAL B1 171661-1
WIRE SEAL AMP
VIEW Ⅰ 172888-2 or 172886-2
BLACK
CIRCUIT DIAGRAM
EARTH VIEW Z
↑
Z
1 3
1 2
3 4
2 4
CONNECTOR ON CONNECTOR ON
INTERNAL CONNECTION DIAGRAM MATED SIDE. MATED SIDE.
YAZAKI 7323-3010 YAZAKI 7323-2228
VIEW Z
24-103
File No.
Name of part Specification Description
Use
Relay
Safety relay
CIRCUIT
M8
M TERMINAL TO S TERMINAL
SEFETY
RELAY
DRAIN PIPE
Relay
Wiper motor, Washer motor,
Horn relay, Work light relay,
Travel alarm,
Hand control extra
CIRCUIT
24-104
File No.
Name of part Specification Description
Use
For wiper
(Power window OPT)
VIEW Z ↑
Z
CONNECTION DIAGRAM
R-19
UPPER
FLASHER L
B E
DRIVE CIRCUIT
FLASHER R
C F
DRIVE CIRCUIT
Timer relay
Er
EMPTY Er EMPTY
24-105
File No.
Name of part Specification Description
Use
SE-13 Rated
GND(BLACK)
Z↓
SE-14 Resistance characteristics
50℃ 80Ω
Sensor
60℃ 56.3Ω
E/G Water (Coolant) M16×1.5
temperature 80℃ 29.5Ω TORQUE
2.5 kgfym
100℃ 16.5Ω (18 lbfyft)
106℃ 14.3Ω
VIEW Z
120℃ 10Ω
24-106
File No.
Name of part Specification Description
Use
FLOAT
SE-15 FULL
1/4 (49.5)
+12 1/4
EMPTY 80+2 FUEL LEVEL
WARNING LAMP "ON" POSITION
EMPTY
FUEL METER SENSOR SWITCH
Er
Er
24V3W FLU
Er
DC
24V
FLOAT AMP CONNECTOR
3MA-JMⅡ+
HOUSING:174359-2
TERMINAL:171661-1
RETAINER:1-174360-1
HARNESS SEAL:172888-2
VIEW A
DIAL
POTENTIO
BRACKET
CIRCUIT
24-107
File No.
Name of part Specification Description
Use
4-∅11
Solenoid valve assy
Refer to hydraulic
symbol
SOCKET BOLT M5
PLUG
PT 1/16
SECTION A-01-02-A
24-108
File No.
Name of part Specification Description
Use
No.
Solenoid
Rated feed press 50kgf/cm2 (710psi)
Proportional valve
for pumps P1,P2 Allowable back press 10kgf/cm2 (140psi)
Tightening torque
0.5kgfym (3.6 lbfyft)
O RING HEX 32
1B P20
24-109
File No.
Name of part. Specification Description
Use
SW-1
Connection table
Switch T B G1 G2 ACC M ST
P
H
Starter switch
OFF
ACC
ON
START
AUTO RETURN
AUTO RETURN
VIEW A
“K250” STAMPED
A
→
TERMINAL
ARRANGEMENT
Switch
CA103
24-110
File No.
Name of part Specification Description
Use
Single-pole double-throw
SW-4 Type (alternate) INSULATION TAPE
R B W
Rated DC 30V,10A
Switch
Insulation resistance
Swing parking
release VINYL TUBE
YAZAKI
RED(2) 7122-2237
Contact T No.
1 2 3 7114-2020
construction : position
M12P1
SW-5 Type ST-425N
12PAM-HD
SUMITOMO 6098-0252
TERMINAL 8230-4282
M4×0.7
SW-6 Rated voltage DC 24V, DC 12V ↓Z
Operating ON 105±2℃
Switch temperature (221±35.6°F)
Contact type A
E/G water (Coolant)
temperature switch Insulation resistance
More than 100MΩ
[105℃(221° F)] (500V megger) HEX 21
VIEW Z
PT3/8
24-111
File No.
Name of part Specification Description
Use
PT1/8 M4×0.7
2A / 125V (AC)
Switch
Voltage 600V
Air filter Insulation resistance 1MΩ
clogging switch
CB104
PT1/8
Torque 0.15 kgfym
(1 lbfyft)
Current 3A
Switch
Horn, Clockwise,
Counter clockwise,
Nibbler open,
Nibbler close,
LEAD WIRE : AVFF 0.75ft
PROTECTION
TUBE
VIEW B
SUMITOMO DENSO
HOUSING ITEM No. : 6090-1031 (2P MALE)
SUMITOMO DENSO
TERMINAL ITEM No. : 8230-4282
24-112
File No.
Name of part Specification Description
Use
Switch HEX17
CONNECTION TABLE
Safety lock lever
1
NO 2PAM
○
2 ○
COM ○
NC YAZAKI HOUSING 7122-2228
TERMINAL 7114-2020
①
②
Switch
Air conditioner
operation panel
Single-pole single-throw
SW-16 Type (Alternate)
TERMINAL CONNETION
RED /
Terminal R RW
Position WHITE
OFF
ON
TERMINAL CONNECTION
Terminal R RW
Position RED /
WHITE
OFF
ON
24-113
File No.
Name of part Specification Description
Use
Horn
M10×0.75
SUMITOMO DENSO
HOUSING P/N : 6090-1031
(2P MALE)
SUMITOMO DENSO
TERMINAL P/N : 8230-4282
TERMINAL CONNECTION
Terminal R RW
Position RED / WHITE
(RW)
OFF
ON
TERMINAL CONNECTION
Terminal R RW
Position RED / WHITE
(RW)
OFF
ON
24-114
File No.
Name of part Specification Description
Use
Single-pole single-throw
SW-23 Contact arrangement ON-(OFF)
momentary
Switch More than 100MΩ 8.7□
Insulation resistance (500V megger)
14□
Wiper inter lock
switch
BLACK CB104
RED
CA104
TERMINAL CONNECTION
Terminal RED / WHITE
Position
R RW (RW)
OFF
ON
TERMINAL CONNECTION
Terminal R RW RED / WHITE
Position
(RW)
OFF
ON
SW-37
Switch
switch
24-115
File No.
Name of part Specification Description
Use
TERMINAL CONNECTION
Terminal R RW
RED/WHITE
Position (RW)
OFF
ON
Overload pressure
switch
2-5.5 ∅BORE
NC COMMON
CIRCUIT
+ -
G1/4
TERMINAL CONNECTION
RED /
Terminal R RW
Position WHITE
OFF
ON
CA104 CB104
TERMINAL:YAZAKI TERMINAL:YAZAKI
:7113-1020-02 :7115-1050-02
CAP:YAZAKI CAP:YAZAKI
:7120-8012 :7120-1010
24-116
File No.
Name of part Specification Description
Use
(0.315″)
φ8
BUTTON SPRING TERMINAL
24-117
NOTE
24-118
SECTION 25 AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
1-7
3 5
1-1
5-1 1-3
3-3
5-2
1-4
3-1 1-5
4
8
9
8-10 8-9 8-7
8-3
8-10
8-4
8-9
8-8
8-6
8-10 8-5
8-11
8-1
8-12
AIR-CONDITIONER GROUP
No. NAME Q’TY No. NAME Q’TY
1 AIR-CONDITIONER ASSY 1 8 AIR DRYER ASSY 1
1-1 AIR-CONDITIONER 1 8-1 RECEIVER 1
1-3 SENSOR 1 8-3 L TUBE 1
1-4 PLATE 1 8-4 D HOSE 1
1-5 MACHINE SCREW 1 8-5 S HOSE 1
1-7 CAP 1 8-6 L HOSE 1
3 COMPRESSOR ASSY 1 8-7 D TUBE 1
3-1 AIR-COMPRESSOR 1 8-8 S TUBE 1
3-3 PULLEY ASSY 1 8-9 CAPSCREW 2
4 PANEL ASSY 1 8-10 CAPSCREW 3
5 AIR FILTER ASSY 1 8-11 CAPSCREW 1
5-1 COVER 1 8-12 BRACKET 1
5-2 FILTER 1 9 CONDENSER 1
25-1
1.2 AIR-CONDITIONER PIPING
32
26
19
32 22
31 16
8 35 1
28 6
27
10
4
11
4 11
11
6
27
2
13 11
19 11
7
15
12
8
21
12 38
24
21
10 24
21
13 11 12
20
23
3
17
11
20 20
18
23
17
Fig. 2 A/C piping
25-2
E135SR EVOLUTION
Air-conditioner piping
E115SR EVOLUTION
Tightening torque Tightening torque
kgfym (lbfyft)
No. NAME Q’TY kgfym (lbfyft)
No. NAME Q’TY
1 BRACKET 1 ← 0.45 (3.3) 17 CAPSCREW;M6×45 6 ←
2 SUPPORT 1 ← 18 CAPSCREW;M6×20 2 ←
3 SUPPORT 1 ← 19 WASHER;M8 6 ←
4 HOSE;L=3300 2 ─ 20 WASHER;M6 8 ←
HOSE;L=3200 ─ 2 21 WASHER;M10 3 ←
5 SPACER 2 ← 22 LOCK WASHER;M8 4 ←
6 TUBE;L=3000 2 ← 23 LOCK WASHER;M6 6 ←
7 TUBE;L=1900 1 ← 24 NUT;M10 2 ←
8 TUBE;L=1900 1 ← 6.6 (48) 26 CAPSCREW;M10×60 2 ←
10 TUBE;L=1600 1 ← 27 CLIP 4 ←
11 CLIP 8 ← 28 GROMMET 1 ←
12 CLIP 3 ← 6.6 (48) 31 CAPSCREW;M10×50 2 ←
4.0 (29) 13 SEMS BOLT;M8×20 4 ← 32 WASHER;M10 4 ←
4.0 (29) 15 CAPSCREW;M8×16 2 ← 35 V -BELT 1 ←
CAPSCREW;M8×10
0.45 (3.3) 16 4 ← 38 CAPSCREW;M10×25 1 ←
0
25-3
2. CONSTRUCTION OF MAIN COMPONENTS
2.1 AIR-CONDITIONER
(1) Intake unit
51 64
1 62
61 50
64 61
62
52 62
61 61
48
53
62 62
43
49
62
62
62
57
61
45 62
61 44
45
47
42
61 46
55 (2.1.3)
63
63 60
63
25-4
(2) AIR-CONDITIONER UNIT
39
36
40
61 27
7 5
37 61 20
64
9 62 21
64
1
62 62 65 26 22
31
14 62
36 60 62
60 4
19
30 62
29 18 17 62
10 32
24 4
23 34
25 67 35
24
67 62
33 11 62
24 23
62 16
12 15
67
67
8 56
23 2
59
58 62 64
20
28 62
1 62
3 41
6 64
5
6
13
56 (2.1.5)
54 (2.1.4)
25-5
No. NAME QTY No. NAME QTY No. NAME QTY
1 ACTUATOR 3 24 LEVER 3 47 BLOWER MOTOR 1
2 VALVE 1 25 CAM 1 48 CASING 1
3 THERMISTOR 1 26 ROD 1 49 CASING 1
4 CLAMP 2 27 ROD 1 50 FILTER 1
5 ROD HOLDER 2 28 ROD 1 51 LEVER 1
6 SENSOR HOLDER 2 29 DAMPER 1 52 LEVER 1
7 CLAMP 1 30 DAMPER 1 53 DAMPER 1
8 EVAPORATOR 1 31 DAMPER 1 54 FLANGE PLATE 1
9 CASING 1 32 DAMPER 1 55 SENSOR 1
10 CASING 1 33 DAMPER 1 56 SEMS BOLT 1
11 CASING 1 34 DAMPER 1 57 GASKET 1
12 THERMAL INSULATION MATERIAL 1 35 HEATER CORE 1 58 O RING 1
13 THERMAL INSULATION MATERIAL 1 36 CONTROLLER 1 59 O RING 1
14 PACKING 1 37 RELAY 1 60 TAPPING SCREW 6
15 PACKING 1 38 CLAMP 1 61 TAPPING SCREW 13
16 PACKING 1 39 BAND 1 62 SCREW 30
17 BRACKET 1 40 DUCT CAP 1 63 SEMS BOLT 3
18 CLAMP 1 41 HARNESS 1 64 TAPPING SCREW 9
19 PLATE 1 42 RESISTER 1 65 SCREW 1
20 LEVER 2 43 CASING 1 66 CAPSCREW 2
21 LEVER 1 44 CASING 1 67 TAPPING SCREW 4
22 LEVER 1 45 BRACKET 2
23 LEVER 3 46 HOSE 1
25-7
2) Inversely to 1) above, the pressure at which a
gas condenses for a temperature is
determined. This pressure is called
saturation pressure.
Fig.6 illustrates the relationships between
the saturation temperature and the
saturation pressure in the case of refrigerant
R134a used in the sir-conditioner. At the
temperature and the pressure on the lower
righthand side of the curve in Fig.6, the
refrigerant take a gaseous state, while at the
temperature and the pressure on the upper
lefthand side of the curve, the refrigerant
takes a liquid state.
Let us think of a case where an air-
conditioner is operated in the midst of
summer. As the refrigerant evaporates, it
absorbs evaporation heat from the air of the
compartment. In order to cool the inside of
the compartment down to 25℃ (77° F), the
refrigerant must transform (evaporate) from
a liquid to a gaseous state at a lower
temperature. It can be seen from Fig.6 that
R134a under a pressure above the
atmospheric pressure is capable of cooling the
inside of the compartment sufficiently. (If a
refrigerant that requires a pressure below the
atmospheric pressure to cool it to a required
temperature is used, air is mixed into the
circuits, thereby deteriorating the
performance of the cooling unit.) In the
process in which gaseous refrigerant is
brought back to a liquid state, the refrigerant
is cooled and condensed by the outer air
exceeding 35℃ (95° F).
Accordingly the refrigerant is capable of
condensing at a pressure exceeding
10.2kgf/cm2 (145psi), as seen from Fig.6.
3.2 COOLING CIRCUIT
Fig.7 illustrates the cooling circuit of the car
air-conditioner.
In this circuit diagram, the portion that cools
the air of the compartment is the evaporator.
The object air is cooled off by utilizing the INSIDE OF COMPARTMENT
fact that the refrigerant takes heat off the
surrounding area as evaporation heat as it
evaporates in the cooling circuit. Since the
part at which vaporization of the refrigerant
takes place is the evaporator, cooled air is EVAPORATOR EXPANSION
constantly delivered to the circumference of BLOWER
VALVE
25-11
(5) Receiver Dryer (See Fig.13)
1) Receiver Tank REFRIGERANT SIGHT GLASS
On the air-conditioner, the revolution of the INLET
compressor varies greatly which causes the REFRIGERANT
proper flow of refrigerant in the cooling OUTLET
circuit to vary. It is the receiver tank that
receives the variations. When the cooling
circuit does not need much refrigerant, the
receiver tank stores extra refrigerant
temporarily and supplies it when the cooling
circuit needs much refrigerant. The receiver
tank also stores an extra amount of PRESSURE SWITCH
refrigerant to be used for filling balance and
supplement small amounts of leakage of the
refrigerant through penetration into rubber
hoses.
2) Dryer
If water is mixed in the cooling circuit, it
deteriorates the compressor valves and oil,
corrodes the metallic parts of the circuit or DESICCANT
clogs the circuit as the water freezes in the
expansion valve. It is desirable that the
SUCTION PIPE
amount of water mixed in the refrigerant
should be held below a concentration of
30ppm. The air-conditioner uses a molecular
sieve as desiccant suited for the circuit, in
FILTER
order to absorb water content that intrudes
into the circuit when the dryer is installed or
when refrigerant is charged.
3) Sight Glass
This is a peep window with which the
refrigerant level in the circuit is determined,
the only means of confirming the inside of the RECEIVER TANK
circuit visually.
4) Filter
5) Pressure Switch
This machine employs pressure switches of
high/low pressure type.
The pressure switch protects the circuit by
cutting off the power supply to the
compressor when high pressure increases Fig. 13 Receiver dryer
abnormally high [more than 32kgf/cm2
(460psi) ].
The pressure switch also detects the leakage
of refrigerant by cutting the power supply to
the compressor when the pressure of the
circuit falls below 2kgf/cm2 (28psi).
25-12
4. DISASSEMBLY AND ASSEMBLY
4.1 PRECAUTIONS TO BE EXERCISED IN
OPERATION
(1) Special Refrigerator Oil
This air-conditioner uses special refrigerator Table 2 Unit : kgfycm (lbfyft)
oil SP20 for use with new refrigerant R134a.
Oils other than SP20 may not be used. Since Pipe Fastening Part Tightening Torque
SP20 tends to absorb moisture and may D hose and compressor
200~250 (14~18)
corrode paint and resin, the following points (M8 bolt)
must be noted: D hose and condenser 200~250 (14~18)
1) Keep open all pipe connections on a new L hose and condenser 120~150 (8.7~11)
compressor and the component parts of the L hose and receiver dryer
80~120 (5.8~8.7)
installed refrigeration circuit (M6 bolt)
(Remove valves and caps at the pipe openings L hose and air-conditioner unit 120~150 (8.7~11)
of the compressor, just before connecting S hose and air-conditioner unit 300~350 (22~25)
popes. If you have removed a pipe joint for Inlet of expansion valve 120~150 (8.7~11)
repair, put a cap to both ports immediately.) Outlet of expansion valve 200~250 (14~18)
2) Use care so SP20 does not adhere to the Pressure sensing part of
expansion valve 70~90 (5.0~6.5)
painted surface and resin parts. In case SP20
has adhered to such surfaces, wipe it off Table 3 Unit : kgfycm (lbfyft)
immediately.
Screw Size Tightening Torque
(2) The receiver dryer is filled with desiccant to
absorb moisture in the circuit. Therefore, N4, T4 machine screw, M4 8~12 (0.58~0.87)
remove the valve at the pipe port N5, T5 machine screw, M5 20~25 (1.4~1.8)
immediately before connecting pipes. M6 (mounting part of
80~120 (5.8~8.7)
L hose joint)
(3) Tightening Torque
M6 (except mounting part of
1) Pipe Joints (See Table 2.) 100~120 (7.2~8.7)
L hose joint)
When connecting pipe joints, coat the O ring M8 (mounting parts of S, D
200~250 (14~18)
with special oil (SP20) and fasten to the hose joints)
tightening torque indicated in the table, M8 (mounting part of A/C unit) 100~120 (7.2~8.7)
using a double spanner. M8 (other than those
120~160 (8.7~12)
2) Screws and Bolts (See Table 3.) mentioned above)
(4) Amount of Oil for Compressor (See Table 4.) M10 400~550 (29~40)
The compressor SD7H (HD type) is filled with
240cc (15cuyin) of oil. If the oil volume is Table 4
small, seizure at high revolution and
Part to be Replaced Amount to be filled in
shortening of service life will occur. If the oil
volume is large, the cooling ability will be Evaporator 40cc (2.4cuyin)
deteriorated. Condenser 40cc (2.4cuyin)
Once the air-conditioner is operated, part of Compressor Drain out the volume of oil
the oil is dispersed in the refrigeration left in the compressor to be
circuit. Therefore, when replacing the parts replaced, from the new
compressor.
in Table 4, adjust the oil level to that of table.
(5) Before performing operation, stop the engine
and turn off all power supplies to the
equipment related to the air-conditioner.
(6) After the operation is over, confirm that all
faults have been repaired completely, by
operating the air-conditioner.
25-13
4.2 REMOVAL AND INSTALLATION OF THE UNIT
(1) Removing the blower unit INNER / OUTER
AIR MOTOR
1) Remove the connectors connected to the ACTUATOR
inner/outer air select motor actuator, the CONNECTOR
blower motor and the blower controller. Also
remove the harness from the blower casing.
HARNESS
EVAPORATOR
SENSOR BLOWER
CONNECTOR CONTROLLER BLOWER MOTOR
CONNECTOR CONNECTOR
Fig. 14
2) Draw out the inner air filter from the intake
casing. Remove four cross-recessed screws INNER AIR FILTER INTAKE
T5×14 (T1) from the top of the intake casing, CASING
MOUNTING
using a screwdriver. Then remove the intake SCREWS
casing. (4 PCS.)
INTAKE
CASING
3) Remove three cross-recessed screws T5×14 BLOWER
(T1) fastening the blower casing with the unit CASING
MOUNTING
casing. Then separate the blower unit from SCREWS
the air-conditioner unit. (3 PCS.)
UNIT BLOWER
(2) Replacing the blower motor CASING
1) Disconnect the cooling hose that is connected
between the blower motor and the blower Fig. 15
casing.
25-14
(4) Removing the heater core
1) After discharging the cooling water,
disconnect the heater hose from heater core.
HEATER CORE
2) Remove one cross-recessed screw N5×16 (T2)
each for the AHC bracket fixing the heater PIPE CLAMP
core to the unit and for the pipe clamp. Then
remove the AHC bracket and the pipe clamp PIPE CLAMP
and draw out the heater core from the unit MOUNTING
casing. SCREW
(1 PC.)
AHC BRACKET AHC MOUNTING
3) Assembly is the reverse order of disassembly. SCREW (1 PC.)
Fig. 17
(5) Removing the upper and lower parts of the
air-conditioner unit casing
1) Draw out the connectors for the mode motor
actuator and the evaporation sensor.
2) Separate the rod 120 from the rod holder that ROD 120
REAR OF
is fixed to the lever MAL1 on the mode motor UNIT CASING
ROD HOLDER
actuator.
MOUNTING SCREW
LEVER MAL1
3) Remove three cross-recessed screws N4×22
(T2) fastening the mode motor actuator that MOUNTING BOTTOM OF
UNIT CASING
install the bottom of the unit casing to the SCREW
back of the unit casing. Then separate the MOUNTING MODE MOTOR
mode motor actuator. SCREW ACTUATOR
BOTTOM OF
UNIT CASING
TOP / BOTTOM
UNIT CASING
MOUNTING
SCREWS (11 PCS.)
Fig. 19
25-15
(6) Replacing the evaporator and the expansion
valve
1) Remove the evaporator assy from the bottom EVAPORATOR
of the casing, together with the casing
insulator and the expansion valve.
Fig. 22
25-16
2) Replacing the air mix motor actuator
Disconnect the connector connected with the
motor actuator.
Separate the rod 67 linking the motor
LEVER AM ROD 67
actuator with the lever AM, from the rod
ROD HOLDER
holder.
LEVER MAL1
Remove three cross-recessed screws T4×14
AIR MIX MOTOR
(T1) fastening the motor actuator. Then ACTUATOR
remove the motor actuator with the rod
holder and the lever MAL1, from the unit.
Remove the rod holder and the lever MAL1
from the motor actuator and install them to a
new motor actuator. Assembly is the reverse
order of disassembly.
Fig. 23
3) Replacing the inner/outer air select motor
actuator
Disconnect the connector connected with the
motor actuator.
Separate the motor actuator with lever MAL2
from the unit. LEVER MAL2
Remove the lever MAL2 from the motor
actuator and install it to a new motor
actuator, in the reverse order of disassembly.
Fig. 24
25-17
5. CHARGING REFRIGERANT
5.1 PRECAUTIONS TO BE EXERCISED IN (3) Charging
OPERATION 1) When warming the can in which refrigerant
(1) Always assign a person in charge of handling is charged, do not fail to open the service can
refrigerant. valve and the low pressure valve of the gauge
Refrigerant charge operation involves manifold and warm the can in warm water of
dangers as it handles high pressure gas.
40℃ (104° F) or below (to an extent that you
Always assign a person familiar with how
do not feel hot when you put your hand in the
work is done for handling refrigerant.
water.) If the can is put in hot water or
z Always wear protective goggles. (You
may lose your sight if the refrigerant heated by a direct fire, the pressure of the
gets in your eyes.) can may rise sharply, thereby blowing off the
z The refrigerant in liquid state is at can.
very low temperature [approx. - 2) When charging refrigerant while running the
26℃(-15° F)]. Therefore, handle it engine, do not open the high pressure valve
with care. (You may get a frostbite if (HI) of the gauge manifold in any case.
the refrigerant is sprayed over your (4) Others
skin.) Re-use of service cans is prohibited by law;
(2) Storage and Transportation never use them again. Do not allow foreign
1) Hold the service can (hereinafter called can) matter to enter the air-conditioner circuit.
less than 40℃ (104° F). Since high pressure
Air, water and dust are detrimental to the
gas of R134a is filled in the can in a
refrigeration cycle. Install the components of
saturated liguefied state, the pressure in the
the air-conditioner correctly and speedily.
can increases sharply as temperature rises.
The can may blast as the result. Pay full attention to the entry of water and
It is for this reason why the can temperature dust.
must be kept below 40℃ (104° F).
2) For storage, choose a cold bark place not z Be careful about overcharge of gas.
exposed to direct sunlight. z Fasten pipes to a specified torque.
3) If the can is placed near a fire source, it is
subject to radiation heat and gets hot. This
causes the inside pressure to rise and may
cause the can to blow out. Therefore, never
bring the can close to a fire.
4) The inside of the closed compartment gets
very hot as the radiation heat of the sunlight
enters the compartment. The areas of the
compartment which are exposed to direct
sunlight may rise to a dangerous
temperature level. Therefore, do not bring the
can into the compartment. Also, the inside of
the trunk room may rise to a dangerous
temperature level even in the summer time.
Use sufficient care, therefore, taking the
above into account.
5) Note that if the can has scratches, marks and
distortion, the strength of the can will
deteriorate.
1. Do not drop or knock on the can.
2. When transporting, loading or
unloading cans and packages
containing cans, do not throw or drod
them.
6) Store cans beyond the reach of children.
25-18
5.2 OPERATING PROCEDURE
(1) Refrigerant charge into the air-conditioner 2) The “gas charging operation” consists of
consists mainly of “vacuum making filling refrigerant in the circuit after forming
operation”, and “gas charge operation”. vacuum. Filling gas not only depends upon
1) The “vacuum making operation” consists of the cooling performances of the air-
removing water in the air-conditioner circuit. conditioner, but also affects the service life of
If only a little water remains in the circuit, the component parts of the circuit. Extreme
the small holes of the expansion valve are overcharge will make the circuit pressure
frozen during operation. This causes the extremely high and causes the cooling
circuit to clog up or rust, resulting in a performance to deteriorate. On the contrary,
variety of malfunctions. Therefore, before undercharge causes poor circulation of the
filling refrigerant in the circuit, make lubricating oil of the compressor and causes
vacuum and allow the water in the circuit to seizure of the moving parts of the
boil and vaporize. Water in the circuit is thus compressor.
eliminated. The gas filling operation involves handling of
high pressure gas; filling gas according to
incorrect operation procedure is dangerous.
Fill refrigerant correctly following the
(2) Operation Chart operation procedures and cautions stated in
this manual.
Vacuum making operation Refrigerant filling operation
(3) Tools
Table 5 unit : mm
No. Name of Part Q’TY Sketch Service No. Name of Part Q’TY Sketch Service
1 Gauge 1 4 Quick joint 1 Low
23.5 pressure
manifold side
5 T joint 1 For service
can valve
25-19
5.3 CHARGING PROCEDURE
5.3.1 VACUUM MAKING OPERATION
HIGH
(1) Connecting Gauge Manifold (See Fig.25.) PRESSURE GAUGE
LOW PRESSURE
1) Close the high pressure valve (HI) and the GAUGE GAUGE MANIFOLD
low pressure valve (LO) of the gauge (CLOSED) LOW HIGH PRESSURE
manifold. PRESSURE VALVE
VALVE (CLOSED)
2) Connect the charging hoses (red and blue) BLUE RED
with the service valves of the compressor.
HIGH
Red hose : High pressure side (HI) of the PRESSURE YELLOW
gauge manifold→high pressure SIDE
DIS
side (DIS) of compressor LOW
Blue hose : Low pressure side (LO) of gauge PRESSURE
manifold→low pressure side SIDE
SUC
(SUC) of compressor
Some kinds of gauge manifolds are not LOW PRESSURE VALVE (OPEN) (CLOSE)
equipped with an open/close valve in HIGH PRESSURE VALVE (OPEN) (CLOSE)
the center. More than 30 min
25-20
(3) Air-tightness Check
Close the high pressure valve and the low
pressure valve of the gauge manifold, leave it
as it is for more than five minutes and make
sure that the gauge indication does not
return toward O.
25-21
(3) Charging from Low Pressure Side
(See Fig.30.)
1) Make sure that the high-pressure and low-
HIGH PRESSURE
pressure valves of the gauge manifold and VALVE (CLOSE)
LOW PRESSURE
the service can valve are closed. VALVE
(MUST BE CLOSED
2) Start the engine and run the revolution to POSITIVELY)
OPEN CLOS
1500±100rpm and fully open the cab door WHEN AIR BUBBLES RED
IN THE SIGHT GLASS
and the windows.
DISAPPEAR
3) Turn on the air-conditioner switch, set the BLUE
YELLOW
DIS
fan switch to Max and the temperature
control switch to cool Max.
SERVICE CAN
4) When charging gas, set the discharge VALVE (OPEN)
pressure of the compressor to 14~16kgf/cm2 SUC
(200~230psi).
5) Open the low pressure valve of the gauge COMPRESSOR SERVICE CAN
OPERATION (DO NOT TURN IT OVER)
manifold and the service can valve and fill in
refrigerant till air bubbles of the sight glass Fig. 30 Gas charging operation
of the receiver go away. (See Fig.31.) (Low pressure side)
[Total amount of gas to be charged : 800 +500 g
+0.1
(1.8 0 lbs )]
SIGHT GLASS
6) When refrigerant charge is over, close the low
pressure valve of the gauge manifold and the
service can valve.
25-22
(4) Criterion for Checking the Amount of
Refrigerant Filled in
25-23
6. ELECTRIC CIRCUIT
6.1 WIRING DIAGRAM AND CONNECTORS
25-24
6.2INSPECTING FUNCTIONAL PARTS
3 1
(1)Relay (24-4PE)
1)Coil resistance : 320Ω (across 1 and 2) 4 2
2)Operating voltage : DC20~30V
3)The coil of the relay has polarity : Care is As viewed from A
needed.
A
4) Turn on and off the power to the blower
motor by controlling the controller.
5) Check: Check conductance across 3 and 4 in
the following condition :
Apply 20~30V across terminals 1 and 2 :
through
No voltage applied across terminals 1 and 2 : Fig. 33 Relay
not through
25-25
(4)Pressure Switch (Attached to Receiver PRESSURE SWITCH
Dryer)
1) Contents of checking (specification)
Low pressure side OFF pressure :
2.0±0.2kgf/cm2 (28±3psi)
Low pressure side return pressure :
OFF pressure +0.3kgf/cm2 (4.3psi) or below
High pressure side OFF pressure :
32±2kgf/cm2 (455±28psi)
High pressure side return pressure :
OFF pressure-6±2kgf/cm2 (-85±28psi)
2) Performance
Low pressure side : To prevent actuation of
the compressor clutch
where refrigerant is
deficient
High pressure side : To prevent actuation of
the compressor clutch
where pressure rises
abnormally because of
the clogging of the
refrigeration circuit, etc.
2) Performance
In order to prevent freezing of the evaporator,
the blowoff air temperature of the evaporator Fig. 38 Thermistor
is controlled by turning the compressor clutch
ON and OFF. The thermistor operates as the
sensor of the control.
25-26
7. TROUBLESHOOTING
【Temperature does not fall.】 Note) M/A : Motor actuator
If A/C switch is pushed, “HL.E” is indicated on the set temp. display of the panel.
NO YES
“HL.※” is shown on the set temp. display of the panel. Connector for air mix M/A is
Note) ※ is any of the disconnected or in poor contact.
NO YES numbers 0 ~ 9. M/A is broken.
※※E on display. Main harness shows poor conductance.
A snow mark on the A snow mark on panel is flashing.
panel is flashing. Inspect and correct or replace parts.
NO YES NO YES
※1 Air mix damper is Chilly air flowing Inspect and correct or replace parts.
in COOLMAX. into inner air sensor
NO YES NO YES
NO YES
25-27
【Temperature does not rise.】
NO YES
HL. ※ is shown on the set temp display the panel. Note) ※ is any of the numbers 0~9
NO YES
NO YES
NO YES
If M/A action is at Inspect warm water piping.
stop, eliminate cause, Controller or Inspect duct or
correct and measure inner air sensor eliminate causes
operating force. [less is out of order. for warm air entry.
than 1.5kgf (3.3lbf):OK]
Inspect and replace.
NO YES
25-28
【Blower motor does not run.】
At air flow HI, battery voltage acts across Note) Measure with
both terminals (+) and (-) of blower motor. connector set.
NO YES
Replace.
Note 1) Always turn off air- NO YES
conditioner, starter
key switch and light
switch before work.
Wire harness is Battery voltage acts across Remove blower amplifier and check for
faulty. Inspect white / green (0.85) and conductance across blue / black (0.85)
and correct or replace. body of blower motor relay. and black wires ; you get conductance.
NO YES NO YES
NO YES
HL. ※ is shown on the set temp. display of panel. Note) ※ is any of the
numbers 0~9.
NO YES
Air flow rate is constant regardless of readings. z Inner air sensor and harness
are disconnected or shorted.
z Inner sensor connector is
disconnected or in poor contact.
Replace blower
amplifier or controller. Inspect and correct or replace parts.
25-29
【Magnet clutch does not engage.】
NO YES
Replace compressor.
NO YES
NO YES
NO YES
NO YES
NO YES
Inspect or replace.
Replace
25-30
【Modes do not change.】
NO YES
Inspect or replace.
Repair. Each damper lever does not disengage.
NO YES
NO YES
25-31
【Trouble with refrigeration cycle.】
Both high and low pressures are lower. Low pressure is higher.
Air bubbles are seen in sight glass. Air bubbles are High pressure
seen in sight glass. is lower.
NO YES
Cooling does not work Oil oozes out from Compressor Hot air Compressor
if run at high speed. piping and parts. cylinder does comes out of cylinder gets
not get hot. heater unit. very hot.
NO YES NO YES
Frost deposits.
Air bubbles are seen in sight glass.
NO YES
Thermistor does
High pressure gets Condenser is not cool off.
lower slowly. fouled or clogged.
NO YES
YES
25-32
SECTION 31 DISASSEMBLY AND ASSEMBLY
TABLE OF CONTENTS
31-1
NOTE
31-2
SECTION 32 ATTACHMENT
TABLE OF CONTENTS
2. Bucket................................................................................................................... 32-1
2.1 Removing bucket ............................................................................................................................ 32-1
2.2 Attaching bucket ............................................................................................................................. 32-2
2.3 Procedure for adjusting clearance ................................................................................................. 32-3
ARM CYLINDER
BOOM CYLINDER
DOZER BLADE
2. BUCKET
3. ARM
BUCKET CYLINDER
HEAD PIN (G)
IDLER LINK PIN (I) BUCKET DRIVE PIN (J) BOOM CYLINDER HEAD PIN (B)
BUCKET CYLINDER IDLER LINK BUCKET LINK
BUCKET CYLINDER ROD PIN (H) BUCKET ATTACHING PIN (K)
2. BUCKET
A
A DRIVER
(2) Removing pin (2)
Expand slit of ring (1) with driver, and 1 2
remove it. Push out the pin (2) with driver
(-).
SECTION AA
Fig. 2-2 Removing pin (2)
32-1
(3) Removing bucket attaching pin (K).
Lift up bucket, position it so that bucket
attaching pin (K) is not loaded, adjust bucket K
link, and pull out bucket attaching pin (K).
32-2
2.3 PROCEDURE FOR ADJUSTING CLEARANCE
Adjustment of clearance between bucket and
arm 251±0.5 (9.88″±0.197″)
1) Shift O ring (3) toward the bucket boss, using 14;WASHER New bucket
a spatula. (a→b) 12;LOCK B
WASHER 3;O RING
10;CAPSCREW b
2) When adjusting clearance (B), bring the non- a
adjusting side of the bucket in contact with
the arm.
8;SHIM 13;PIN
5) An average of 5 shims (8) of 1mm (0.04in)
Install pin (13) until the top of
thickness are set in the plate (6) fixed by the
pin is even surface with bushing.
three capscrews M16×50 (10). The clearance
can be decreased by 1mm (0.04in) if one shim Fig. 2-6 Adjusting clearance between
is removed. bucket and arm
: 22mm
32-3
3. ARM
3.1 REMOVING ARM
(1) Put the machine in position to remove arm.
Extend the arm cylinder, retract the bucket
cylinder to a maximum and bring the arm
down on the ground.
H G
D A
A 8
D
DUST SEAL
Insert resin shim into cylinder side. SHIM
SECTION
Fig. 3-3 Detail of bucket cylinder rod pin (H)
(4) Removing cylinder head pin (G)
After adjustment of shim, the total
Loosen nut (3), remove capscrew M12×110 Insert resin shim gap should be within 0.6~2.0mm
(2), and push out pin (G). SHIM into cylinder side. (0.02~0.08in).
SHIM
: 19mm
2
G
3
SECTION
Fig. 3-4 Detail of bucket cylinder head pin (G)
32-4
(5) Removing bucket cylinder
Sling tube of bucket cylinder with nylon
sling, and remove it.
6
SHIM Insert resin shim into cylinder side.
SECTION
F
Fig. 3-6 Detail of arm cylinder rod pin (E)
(7) Removing boom top pin (F) After adjustment of shim, the total
Loosen remove capscrew (3), and pull out gap should be within 0.5mm (0.02in).
SHIM
boom top pin (F).
Insert resin shim
: 19mm into arm side.
SHIM
Put block between arm cylinder and boom.
Insert pin (F) into the original hole. F
SECTION
32-5
(8) Slinging arm assy
Sling arm with nylon sling and remove it.
Arm weight ;
E115SR EVOLUTION; 280kg (620 lbs)
E135SR EVOLUTION; 350kg (770 lbs)
32-6
4. BOOM
4.1 PREPARATION FOR REMOVING AND
ATTACHING BOOM
When removing and attaching boom in the
position shown in Fig.4-1, to remove and
attach boom foot pin (A), removing and
attaching of cab and guard are required.
A
4.2 REMOVING BOOM
(1) Put the machine in position to remove boom.
Place top end of boom down on block, etc.
giving attention for arm cylinder rod not to be
extended. BLOCK
3
C
8
4
(4) Preparing for disconnecting cylinder pipes
Retract boom cylinder rod, and place one side
SHIM
of cylinder on block. (See Fig.4-2.)
SECTION AA
Fig. 4-3 Detail of boom cylinder rod pin (C)
32-7
(5) Disconnecting piping of arm cylinder and bucket
cylinder
Release pressure in hydraulic tank, and
disconnect pipe at section DD.
: 36mm, 41mm
After disconnection of pipe, plug every pipe.
Plug : 4-(4) BUCKET•H
ARM• R
ARM• H BUCKET•H
SECTION_DD Unit : mm (inch)
(6) Lifting up boom assy temporarily Fig. 4-4 Boom piping disconnection
Lift up boom cylinder with nylon sling so that
boom foot pin (A) is not loaded.
Weight of single boom :
E115SR EV. : 630kg (1400 lbs)
E135SR EV. : 720kg (1600 lbs)
BOOM FOOT PIN A
1 SECTION_AA 3,4
Fig. 4-6 Details of boom foot pin (A) section
SHIM
After adjustment of shim, the
total gap should be within
0.6~1.0mm (0.02~0.04in).
Opposing flats 32
32-9
4.3 ATTACHING BOOM A
(1) Attaching boom foot pin (A)
Screw tool 10. slide hammer M24 into boom
foot pin (A) first, and fit boom assy.
Attach it in the reverse procedure of
removing, paying attention to the following B
points.
32-10
5. DOZER 1(LH)
2(RH)
4
5.1 REMOVAL 3
(1) Removing position (See Fig. 5-1)
Put a suitable height stand on the dozer side,
and stabilize the dozer while making sure
that the dozer installing pin is not loaded.
(2) Removing cover (See Fig. 5-1)
Remove capscrews (3) (4), then remove covers
(1) (2). Fig. 5-1 Dozer removing position
: 17mm 2 1,4,5,6 3
(3) Remove hydraulic pipe, and plug connections
of both ends.
: 27mm
(4) Hanging dozer cylinder temporarily SECTION A
Hang dozer cylinder with a nylon sling, etc.
(5) Holding dozer cylinder (See Fig. 5-2、Fig. 5- Section A details
3)
Remove nut (3) and capscrew (2) of pin (1) on
the dozer cylinder rod side, pull pin (1) out,
retract the cylinder and support it with stand
SEPARATE
like timber, etc.
HYDRAULIC PIPE
: 19mm
(6) Removing dozer (See Fig. 5-4) Fig. 5-2 Dozer cylinder rod side installing pin
1) Remove nut (3), capscrew (2) and shims (5)
(6) (7), and pull pin (1) out.
2) Move the hydraulic excavator rearward
slowly, and remove the dozer.
5.2 INSTALLATION
Install the dozer by the reverse procedure of the
removal in the following points. Fig. 5-3 Holding of dozer cylinder
(1) Before inserting dozer and dozer installing
2 1 BOSS 3
pin, apply grease on the pin section.
(2) Perform the adjustment with shims referring
to the Maintenance Standard. BODY SIDE
(3) After inserting the capscrew, apply Loctite
#242 on the double nut, and lock the dozer
installing pin keeping about 2mm (0.08in)
apart from the boss. 5,6,7 4
(4) Tightening torque (DUST SEAL)
M12 11.7 85
SECTION AA (Fig. 5-2)
32-11
Part II: DISSAMBLY AND ASSEMBLY EQUIPMENT
1. CYLINDER
1.1 PREPARATION BEFORE DISASSEMBLY (2) Work bench
Before assembly, secure a dustfree workshop and The work bench must have strength and rigi-
necessary equipment and facilities. dity capable of accommodating the total
length of the cylinder in its most retracted
1.1.1 WORK AREA condition and of withstanding the repulsive
The following working area is required for force of the tightening torques of the cylinder
disassembly: head and the piston nut. Since a vise is
(1) Ample space attached to the bench, the width of the work
For the disassembly of the hydraulic cylinder, bench must be sufficiently large.
the cylinder tube and the piston rod must be (3) Support stand
drawn out. For this reason, the first condition If the clevis part of the piston rod is fully
is that the working area is long enough for extended in a free condition, the bushing and
the work. In terms of width, it is also the seals may be damaged as the rod bushing
necessary to keep sufficient space so and the piston are twisted due to the weight
disassembly, cleaning and measuring of the rod. A stand is required to support the
equipment are placed and the work can be rod to prevent such.
performed. (4) Hydraulic source
(2) Suitable working environment A Hydraulic source is required for
The hydraulic cylinder is a precision- disassembly and assembly of the cylinder
machined product that uses seals and head and piston nut and for oil leak tests
packings made of rubber and plastic after completion of assembly.
materials. For this reason full care should be (5) Jet air source
exercised so the hydraulic cylinder is free It is used for drying after oil draining and
from dust, dirt, and in particular, such hard cleaning of the cylinder.
particles as sand, metal chips, and weld slag (6) Cleaning bath, cleaning oil and detergent
(spatter). If the hydraulic cylinder is (7) Oil pan and oil reservoir
assembled with hard particles adhered on An oil pan is necessary to contain oil drained
such components as the cylinder tube and the from the cylinder and oil spilt during work.
piston rod, the tube inner surface and the rod An oil reservoir is required to collect oil spilt
surface are scratched as the cylinder on the floor and waste oil.
operates, consequently disabling it in worst (8) Others
cases. Damage to the piston seals and the rod Oil extracting hoses, wooden skids, rag and
seals will result in oil leaks. For this reason, sawdust in which oil soaked are also
grinding and welding operation should not be necessary.
performed in the neighbourhood of the working
area to keep it clean.
1.1.2 APPARATUS
The following equipment are required for
disassembly:
(1) Hoist or crane
The hoist or crane must be capable of
carrying the cylinder in an assembled
condition. It must also be capable of marking
level and liner movement under load for
retracting and extending the piston rod and
the tube.
32-12
1.1.3 NECESSARY TOOLS
Tools and jigs vary with types of cylinder, but it is
necessary to prepare the tools in Table 1-1 as a
guideline.
32-13
1.2 CONSTRUCTION OF CYLINDER (AN EXAMPLE OF BOOM CYLINDER)
T=Tightening torque ; kgfym (lbfyft)
3 B 6
Z
→
T=1.8~2.2(13~16)
M10×1.5
28,29 27
26
2 14 13 9 8 10 11 12 7 15 4 1 19 20 21 16 18 17 22 23 24 5
PT1/8
C
∅1.2 PT1/4
32-14
1.3 DISASSEMBLY
Fig. 1-5
32-15
z At this time, the weight of piston rod
KNOCK THIS EDGE
(4) is loaded on rod cover (16). WITH A PLASTIC
LIFT HERE.
Therefore, lift the top end of the MALLET.
piston rod with a crane or something
to the extent that only the rod
weight may be held.
1
12
11
Fig. 1-9 Remove wear ring (11) and dust ring (12)
32-16
1.3.2 REMOVING PISTON ASSY 16 WOOD
1) Fix piston rod (4) by holding its clevis section 4 PIECE
in a vise. Fix the piston rod (4) rigidly as 7
piston nut (13) is tightened to a high torque.
13
z Note that the tightening torque
differs with the type, the working
pressure and the mounting method
of the piston (7), though the rod
diameter remains the same.
z It is also necessary to place a
suitable supporting block near the
piston(7). In case a V-block is used,
WOODEN V-BLOCK
put rag or something over the rod to (PLACE RAG.)
prevent it from being scored
Fig. 1-10 How to loosen piston nut (13)
2) Scrape off the caulked part of setscrew (14) of
piston nut (13) by means of a hand drill and DRILL
loosen and remove setscrew (14).
13
14
32-17
5) Remove the rod cover (16) from piston rod (4). LIFT WITH A CRANE. STRIKE WITH
If it is too heavy to move, move it by striking A PLASTIC MALLET.
the flanged part of the rod cover (16) with a PULL STRAIGHT.
plastic mallet. Pull it straight with the rod NOTE:
cover (16) lifted with a crane or the like. DO NOT
DAMAGE
PISTON ROD
Take care so rod bushing (17) and the SURFACE.
lip of pistons (22), (23), (24) may not be
damaged by screw the piston rod (4).
16 17 22 23 24 4
6) Separate O ring (8) and backup ring (9) from Fig. 1-14 Removing rod cover (16)
piston (7).
After removing two backup rings (9), remove 9 10-1 10-3 10-2
O ring (8). The backup ring (9). comes off
easily if the slit on its circumference is 7
extended. O ring (8) can be taken off by
stretching it with an earpick-like spatula.
10-1
32-18
1.3.4 DISASSEMBLING ROD COVER ASSY SPATULA
1) Remove O ring (21) and back-up ring (20).
Remove back-up ring (20) and O ring (21) in 21
that order. Back-up ring (20) come off if the
slit on the circumference is widened. Remove
20
O ring (21) by pulling and stretching them (REMOVE THESE
with an spatula like earpick. FIRST.)
16
24
WOOD PIECE
WOOD PIECE
VISE
32-19
1.3.5 REMOVING PIN BUSHING PUSH WITH A PRESS.
Cylinder tube (1) is pressed hard in the pin
bushing (2) of piston rod (4). When disassembling METAL PIECE A
them, use the jig A and push the rod with a press.
2 BASE
1.4 CLEANING
1) When the cylinder has been disassembled,
wash all parts with a suitable commercial
detergent.
1.5 ASSEMBLY
Start assembly with the subassemblies listed
below:
○ Cylinder tube assy
○ Piston assy
○ Rod cover assy
32-20
1.5.2 ASSEMBLING PISTON ASSY PRESS HERE
1) Coat O ring (8) with hydraulic oil (or vaseline METAL
if not available) and set it in place, using the
inserting jig.
2) A special jig shown in Fig. 1-23 is required to
fit slipper seal (10-1). Push slipper seal (10-1)
HOLDING
in by means of a press or something and JIG “G”
using the pressing jig that is shown in the
figure.
z After fitting the slipper seal (10-1), Fig. 1-23 Installing slipper seal (10-1)
wind vinyl tape a few turns around
HOLDING JIG “G”
the slipper seal and do not take it off
for piston seal.
immediately before piston (7) is set
in cylinder tube (1).
z Attach wear ring (11) and dust ring
(12) when inserting piston (7) into HANDLE
cylinder tube (1).
Fig. 1-24 Installing slipper seal (10-1)
METAL RING
32-21
3) Fit buffer seal (22) and rod packing (23) in PUT IN GROOVE FROM THIS SIDE.
their grooves in that order. Before setting
packings, coat them with hydraulic oil (or
vaseline if not available). If you forget the
coating, the packings may be scored. When
attaching seals, deform them in a heart
shape as illustrated.
32-22
2) Apply hydraulic oil or grease to the O. D. of LIFT WITH A CRANE
piston rod (4), the bore of packings (22,23,24) 16
ROD COVER ASSY
and rod bushing (17). Hold the rod cover assy PRESS IN.
carefully and slide it over piston rod (4),
taking care not to damage the lip of dust seal
(24). It may be difficult in some cases to slide
the rod cover assy over the piston rod (4) TURN
because of the resistance of rod packing (23) CLOCKWISE.
and buffer seal (22). In such a case, force it
in, using a suitable plate and piston nut (13),
(See Fig. 1-29.) In this operation, hold the rod
cover assy horizontally with a crane.
3) After lifting rod cover (16) to the level where 13 AUXILIARY PLATE 17 22 23 24 4
FOR PUSHING
it is pressed by piston nut (13), remove piston
nut (13) and the plate. Press in the rod cover Fig. 1-29 Inserting rod cover
assy about 300mm (12in) further. In some
cases, the rod cover assy must be pressed into
piston rod (4) by striking the flanged part rod
cover (16) with a wooden or plastic mallet.
32-23
3) Turn in piston nut (13) till it gets tight.
Always tighten the piston nut (13) to a
specified torque (Refer to II-1-16.)
HOOK WRENCH
Always correct the threads of the 13
tapped hole in piston nut (13) before
fixing piston nut, using a tap. 1.0~1.5m TURN CLOCKWISE.
(3′3″~4′11
4) Screw in and set setscrew (14). Fig. 1-31 Tightening piston nut (13)
:4mm
After tightening the setscrew to a specified 14 ANTI-LOOSENING CAULKING
4
torque of 1.5kgfym (11 lbfyft), caulk the two
places of the screw threads of the piston nut
side to secure the setscrew.
13 V-BLOCK
32-24
3) Turn up socket bolt (25). Match the bolt holes 25
of the rod cover flange to the tapped holes in
the cylinder assy, and screw in socket bolts PLACE RAG.
(25) one by one. Tighten the bolts to a
specified torque, taking care so the bolts may
not be tightened unevenly.
:12mm,
Tightening torque :
21~22kgfym (150~160 lbfyft)
32-25
1.7 MAINTENANCE STANDARDS
1.7.1 INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see
that excessive wear, crack and other faults that
are detrimental to use are not present.
32-26
1.7.2 LIMIT OF SERVICEABILITY 1.7.3 TIGHTENING TORQUE
Serviceability limits represent the limits of wear
A B C
on the sliding surfaces of the cylinder tube and
the rod that have no such faults as may degrade
the sealing effect.
(1) Clearance between piston rod and rod
bushing Replace the bushing if the clearance
between the piston rod and the rod bushing Fig. 1-40
exceeds 0.25mm (0.00984in). E115SR EV.
(2) Bend of piston rod E135SR EV. Table 1-4 Unit : kgfym (lbfyft)
The allowable bend of the rod is maximum A B C
Cylinder
1mm / 1m (0.04″/3′3″). For measurement, Piston nut Piston Socket bolt
support both ends of the parallel section of 190 100 21~22
the piston rod with V-blocks, set a dial Boom
(1400) (720) (150~160)
indicator in the center between the two V-
block turn the piston rod, and read the 190 100 35~37
Arm
difference between the maximum and (1400) (720) (250~270)
minimum oscillations on the dial indicator.
190 100 21~22
Bucket
(1400) (720) (150~160)
Rod cover
90 50
Dozer 50~70
(510) (360)
(360~510)
32-27
1.8 TROUBLESHOOTING Table 1-16
Trouble Faulty Part Cause Remedy
1. Oil leakage through 1. Rod packing 1. Foreign matter is 1. Remove foreign matter.
sliding surface of piston included in the bore of
rod oil ring is formed on rod packing
piston rod, and the ring 2. Lips on outer and inner 2. Replace rod packing.
grows up to oil drops, diameter surfaces of rod
and they drip. packing are scored.
3. Other rod packing are 3. Replace rod packing.
faulty.
2. Buffer seal 1. Foreign matter is caught 1. Remove foreign matter.
in the bore of buffer seal.
2. Flaw is present on the 2. Replace buffer seal.
bore of buffer seal.
OIL LEAKS FROM HERE. 3. Other buffer seals are 3. Replace buffer seal.
faulty.
3. Dust seal 1. Foreign matter is include 1. Remove foreign matter.
in the bore of dust seal.
2. Lip on the bore of dust 2. Replace dust seal.
seal is scored.
3. Other dust seals are 3. Replace dust seal.
faulty
4. Piston rod 1. Flaw is present on the 1. Smooth out the sliding
sliding surface of piston surface with an oilstone.
rod. If leakage occurs even if
the sliding surface is
finished below 1.6S, rod
packings may be scored.
Disassemble and inspect
it and replace rod
packings as required.
If leakage will not stop by
that treatment, replace
piston rod.
2. Hard chromium plating 2. Replate.
has peeled off
2. Oil leaks from the 1. O ring 1. O ring is damaged. 1. Replace O ring.
perimeter of cylinder 2. Backup ring 1. Backup ring is damaged. 1. Replace backup ring.
head
WELDS
4. Cylinder falls by it-self. 1. Piston seal 1. Foreign matter is caught 1. Remove foreign matter.
[When the rod is loaded on the sliding surface of
with a static load equal slipper seal
to the maximum 2. Flaw is present on the 2. Replace slipper seal.
working pre-ssure sliding surface of slipper
multiplied by the area seal.
of the cylinder bore, the 3. Other back rings are 3. Replace back ring.
maximum movement of faulty.
the piston is more than 2. Wear ring 1. Sliding surface of wear 1. Replace wear ring.
0.5mm (0.02″) in ten rings is scored.
minutes.] 3. O ring 1. O ring is scored. 2. Replace O ring.
32-28
1.9 TOOLS AND JIGS LIST
The tool and jig list provides the materials and the 2) The pin section of pin wrenches (symbol “PS”) and
dimensions of tools and jigs so that they may be utilized pin hook wrenches (symbol “PF”) is loaded with
in manufacturing in a service shop. Follow the directions large shearing force. Therefore, take care when
given below in selecting, manufacturing and using the selecting pin material and welding the pin to the
tools and jigs. body. It is recommended to use the shank section of
disused drills (Fig. 1-41).
1) For the rod cover, piston nut and others that require
large tightening torques, use eye wrenches (symbol
“FS”) as much as possible. The tools and the jigs are
so designed dimensionally that they can withstand
the maximum tightening torques even if material
SS400 (JIS) is used. However, the hook of the tool
USE THIS
(symbol “PS”) may be distorted if struck with a
PORTION.
hammer. If such occurs, apply reinforcement weld
and finish it by grinding.
Fig. 1-41
1.9.1 ALLEN WRENCH_AW_
(FOR CYLINDER HEAD SOCKET BOLT)
B
A MATERIAL : SNCM 6 OR SCM 3
SURFACE TREATMENT :
C
Fig. 1-42
Table 1-7 Unit : mm (inch)
Cylinder Used A B C Socket Bolt
Arm 140 (5.51_) 56 (2.20_) 14 (0.551_) M16
Boom, Bucket 125 (4.92_) 45 (1.77_) 12 (0.476_) M14
1.9.2 DUST SEAL PRESSING JIG [SYMBOL E]
D
E
MATERIAL : SS400 (JIS)
∅A SURFACE TREATMENT : PARKERIZING
_
∅B
15° ∅C
Fig. 1-43
32-29
1.9.3 EYE WRENCH (SYMBOL FS)
MATERIAL: SS400 (JIS), FINISH BY GRINDING
AFTER GAS CUTTING
DRILL
MORE THAN R25 (0.984″)
Fig. 1-44
2d DRILL
PIN (S45C)
SECTION BB
Fig. 1-45
32-30
1.9.3 BUSHING EXTRACTION JIG (SYMBOL A)
(For clevis)
Fig. 1-46
Fig. 1-47
Table 1-12 Unit : mm (inch)
Machine
E115SR EVOLUTION E135SR EVOLUTION
Models
Cylinder Used
d D1 D2 Q L d D1 D2 Q L
94.5 96 75 21.5 65 94.5 96 75 21.5 65
Bucket
(3.72″) (3.78″) (2.95″) (0.846″) (2.56″) (3.72″) (3.78″) (2.95″) (0.846″) (2.56″)
94.5 96 75 21.5 65 99.5 101 80 23.5 65
Boom
(3.72″) (3.78″) (2.95″) (0.846″) (2.56″) (3.92″) (3.98″) (3.15″) (0.925″) (2.56″)
109.5 111 90 22.5 65 114.5 116 95 22.5 65
Arm
(4.31″) (4.37″) (3.54″) (0.886″) (2.56″) (4.51″) (4.57″) (3.74″) (0.886″) (2.56″)
32-31
1.9.7 SLIPPER SEAL HOLDING-DOWN JIG MATERIAL: NYLON
(SYMBOL D)
O RING
Fig. 1-48
Table 1-13 Unit : mm (inch)
Machine models E115SR EVOLUTION E135SR EVOLUTION
Cylinder Used D O ring D O ring
Bucket 95 (3.75″) 1B P95 95 (3.74″) 1B P95
Boom 95 (3.75″) 1B P95 100 (3.94″) 1B P100
Arm 110 (4.33″) 1B P110 115 (4.53″) 1B P115
Dozer 115 (4.53″) 1B P115 115 (4.53″) 1B P115
MATERIAL: SS400
Weld it before
drilling
Fig. 1-49
32-32
SECTION 33 UPPER STRUCTURE
TABLE OF CONTENTS
ANTENNA
(4) Remove window washer tube
1.2 INSTALLATION
Mount it in reverse procedure of Dismounting
A1
according to the Tightening Torque Table.
Tightening torque
Tightening position Tool kgfym (lbfyft)
Lower section of hand rail
Sems bolt (B2) 17 4.7 (34)
Nut M16 24 19.5 (140)
Fig. 1-3 Slinging cab
Capscrew (A1) 17 4.7 (34)
33-1
2. OPERATOR SEAT
2.1 REMOVAL
(1) Remove seat. (Include upper slide). B1
1) Remove 4 sems bolts (A17) M6.
2) Remove bracket (A8).
3) Remove 4 sems bolts (A16) M8 of bracket (A5). A17
4) Remove seat M6×16
[Approx.15kg (33 lbs) with bracket] A8 M8×20
A7
: 8mm, 13mm
A11
M8×20
A16
(2) Remove slide on lower side of seat.
A17
1) Remove 4 sems boltss (A13) M8.
2) Remove support (A4). A14
3) Remove 4 capscrews (A15) M8.
4) Remove rail (A3). A5
: 6mm A4
A13
(3) Remove seat stand M8×25
1) Remove 4 capscrews (A9) M10.
2) Remove seat stand (A1).
A20-3
: 8mm A20-2
Weight of seat stand ; 17kg (37 lbs) A20-6
A3 M8×16
A15
2.2 INSTALLATION
A20-4 A11
Install it in reverse procedure of removing
according to the tightening torque table. M8×30
A20 A18
A20-5
Tightening torque A13
Tightening position Tool A14
kgfym (lbfyft) M8×25 A19
Capscrew (A7) 6 2.4 (17) A15
M8×16 A2
Capscrew (A9) 8 4.7 (34) M10×25 A6
A9 A1
Sems bolt (A13) 13 2.4 (17) A12 M8×30
Sems bolt (A16) 13 2.4 (17) A10 A18
Sems bolt (A17) 8 0.97 (7) A19
Sems bolt (A18) 13 2.4 (17)
A2
Reference : Movement on rail : 90mm (3.54in)
Forward : 30mm (1.18in)
Backward : 60mm (2.36in)
Floor plate
Fig. 2-1 Dismounting and mounting seat
33-2
3. BATTERY
RIGHT FRONT COVER
3.1 REMOVE
(1) Open right front cover.
1) Open it with engine key.
2) Open cover.
3) Fix it with stay.
Fig. 3-1
(2) Remove battery cable
1) Cable (between ground and battery _ )
(Always remove _ terminal first and install it STAY
at last. )
2) Cable (between battery + and _ )
3) Cable (between battery + and battery relay) BATTERY RELAY
: 13mm
3.2 INSTALL
A2
(1) Install counterweight in the reverse
procedure of removing.
Battery attaching bolt A3
: 17mm,
Tightening torque : 1.1kgfym (8.0 lbfyft) A1 B1
33-3
4. INSTRUMENT PANEL
4.2 REMOVAL 12 12
(1) Remove RH, LH instrument panel
1) Remove 8 sems-bolts (12) M5.
: Cross recessed screw driver
12
12
2) Lift instrument panel
12
PILOT
4.3 INSTALLATION VALVE
19 M8 X 25
Install it in reverse procedure of removing according
20
to the tightening torque table. M6 X 16
Tightening Tightening torque
Tool
position kgf·m (lbf·ft) SUPPORT
Sems bolt (19) 13 2.4 (17)
cross recessed 0.27 (2.0)
Sems bolt (12)
screw driver SEAT STAND
33-4
5. COUNTERWEIGHT
5.1 PREPARATION FOR REMOVAL BONNET
(1) Removing bonnet assy.
Remove bonnet on engine. (See Fig. 6-6.)
B3
(2) Removing counterweight
B4
1) Remove 4 capscrews (B1) M24×120.
: 36mm
2) Remove shim (B3), (B4). C3
C2
3) Remove counterweight (A1).
COUNTERWEIGHT
(3) Removing counterweight (Add-on)
(ADD-ON)
1) Attach two eye bolts M20 to the add-on
counterweight and lift it up temporarily.
B2
Weight of counterweight (Add-on);
B1
E115SSR EVOLUTION, E135SSR EVOLUTION;
Approx. 600kg (4340 lbs) Fig. 5-2 Removing counterweight
2) Remove 3 capscrews (C2) M20×120 and Add-
on counterweight (C1). (4) Apply Loctite #262 on capscrews (B1), and
: 30mm tighten them with washers (B2).
: 36mm
5.3 INSTALLATION Tightening torque : 105kgfym (760 lbfyft)
(1) Install counterweight in the reverse
procedure of removing. (5) Remove slinging tools, and attach plugs (B4).
(6) Mounting Add-on counterweight
(2) Install shim (B3), (B4) as it was. 1) Apply Loctite #262 on capscrews (C2) and
tighten them with washers (C3).
(3) Slinging counterweight : 30mm
Check that the attaching bolts can be Tightening torque : 57kgfym (410 lbfyft)
screwed in by hand. 2) Remove eye bolt, and attach plugs (C4).
33-5
6. GUARD
11 1
6.1 PREPARATION FOR REMOVAL 6 2
(1) Remove guard in the following procedure.
For removing equipment 3
Items (1) to (5),(10) and (24).
For dismounting engine
Items (3) to (5) and (15).
4
10 24
Fig. 6-1 Guard assy
6.2 REMOVE GUARD
1
(1) Remove cover assy (1)
1) Open cover assy (1) and lift it up.
2) Remove two nuts (56)M12.
3) Remove cover assy (1).
: 19mm
Weight : 15kg (33 lbs)
56
Fig. 6-2 Removing cover assy (1)
(2) Remove panel assy (2)
1) Remove two sems bolts (41)M12×25. 41
2) Remove two nuts (56).
3) Remove panel assy (2).
: 19mm
56
Weight : 13kg (27 lbs)
33-6
(4) Remove bonnet assy (5)
1) Remove washer (63) and gas spring (37). 5
2) Remove four sems bolts (41) M12×30.
3) Lift up bonnet assy (5) with nylon sling.
: 19mm
Weight : 28kg (62 lbs)
41
63
37
63
Fig. 6-5 Removing bonnet assy (5)
(5) Remove guard (3)
1) Remove four capscrews (82) M10×25. 42 82
2) Remove guard (3).
: 17mm
Weight : 3.5kg (8 lbs)
64
(9) Remove cover (11) 46 11
1) Remove three machine screw (46).
2) Remove cover (11).
33-7
(10) Remove guard (18),(19)
1) Remove six sems bolts (41) M12×25. 18 41
41
2) Remove two sems bolts (42)M12×30.
41
3) Remove guard (18),(19). 85
: 19mm
41
42 12
(15) Remove bracket assy (12)
1) Remove two sems bolts (42) M12×30. 45
2) Remove bracket assy (12).
73
: 19mm
Weight : 7kg (15 lbs)
Fig. 6-11 Removing bracket assy (12),(16)
(16) Remove bracket assy (27) and cover assy (73)
1) Remove three sems bolts (42) M12×30.
2) Lift up bracket assy (27) with nylon sling.
: 19mm
Weight : 29kg (64 lbs)
33-8
(17) Remove bracket assy (15) 42 42
1) Remove four sems bolts (42) M12×30.
31 62
2) Lift up guard assy (15) together with bracket
(14) with nylon sling.
: 19mm 71
Weight :
Bracket assy (15)10.5kg (23 lbs) 42
Bracket assy (14) 2.0kg (4.4 lbs)
42
14
3) Remove shim (102), (103). 27
42 15 42
42 102
103
6.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
33-9
7. UNDER COVER
7.1 REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,9)
1) Remove attaching bolts (8) M12×25.
2) Remove covers.
: 19mm
7
6-2
6
9 8 1 6-1
8
8 5
8
2
4
3 8
8
8
8
7.2 INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,9)
: 19mm
Tightening torque : 8.1kgfym (59 lbfyft)
33-10
8. AIR CLEANER
8.1 PREPARATION FOR REMOVAL 36
(1) Opening bonnet assy (5)
5
1) Unlock it with starter key.
2) Open bonnet (5) and support it with stay (36).
8.2 REMOVAL 4
(1) Pulling out hose (3) (See Fig.8-3.).
1) Loosen clips (8), (9) on both sides of hose (3). Fig. 8-1 Preparation for removal
2) Pulling out hose (3)
: Flat-blade screw driver
8.3 INSTALLATION
(1) Installing is the reverse order of removing
with attention paid to the following items:
1) Attach grommet (4) to the guard, before
installing the air cleaner.
2) Provide an insertion allowance of 40mm 8
(1.6in) on both ends of air hoses (2),(3). 9 3
3) Tightening torque
Tightening Torque 5
No. NAME kgfym (lbfyft)
1-5 INDICATOR 0.4 (2.9)
5 CAPSCREW 2.0 (14)
8,9 CLIP 0.3 (2.2) 4
9 1
(2) Spare parts for deteriorated elements
1-5 10
INNER FILTER ELEMENT (10)
O RING (1-5)
Fig. 8-3 Removing air cleaner
33-11
9. MUFFLER
5
9.1 PREPARATION FOR REMOVAL 18
(1) Remove bonnet assy (5). (See Fig.6-5.) 19
3
(2) Remove cover (3).(See Fig.6-6.)
9.2 REMOVAL
(1) Remove U bolt (3).
1) Remove four nuts (5) M8.
2) Remove two U bolts (3).
: 13mm Fig. 9-1 Preparation for removal
9.3 INSTALLATION B C
42
Installing is the reverse order of removing with
41 A
attention paid to the following items:
19 PROCEDURE OF
(1) Procedure of fastening U bolt (3) FASTENING U BOLT
1) Tighten four nuts (A) till there is no space
and make sure that the dimension C is even Fig. 9-2 Removing guard (18), (19)
all around.
2) Tighten nuts (A) to specified torque and 5
3
confirm the C dimensions on the right and
left once again. (1)
3) Tighten nuts (B) to specified torque and make
16
sure that U bolts (3) are not inclined.
5
4) Tightening torque 8
Nut A : 0.9kgfym(6.5 lbfyft) 12
Nut B : 1.1kgfym(8.0 lbfyft)
10
2
(2) Tightening torque : (4)
Tightening torque 5
No. NAME kgfym (lbfyft) REMARK
Tightening
5 NUT ; M8 1.1 (8.0) exhaust tube
8 CAPSCREW ; M10 7.2 (52)
APPLY
12 CAPSCREW ; M10 6.6 (48) Loctite #262
16 CLIP 0.3 (2.2)
33-12
10. FUEL TANK
From WATER
SEPARATOR
10.1 PREPARATION FOR REMOVAL OUT
(1) Draining fuel. 12
1) Open cap (A3). 12 138
7 11
2) Loosen cock (B8) under the tank. 7
From 13 12
(See Fig.10-3.) E/G FUEL
13
RETURN
10 10
3) Draining fuel 14
6 12
Capacity of tank : 168 (44gal) 13
12 15
10.2 REMOVAL
8
(1) Remove the tank, the upper frame and the
bracket connecting plates (B10). Fig. 10-2 Removing water separator (1)
1) Remove two sems bolts (B11) M12×30.
2) Remove plate (B10).
: 19mm B14
B15
A3 B16 B11
1) Remove a capscrew (B14) M12×40. B10
: 19mm
A2 B5
(2) Remove fuel tank assy (A1) B6
B4
1) Remove four capscrews (B1) M16×40.
2) Hook the wire to the lifting eye on the fuel B3
tank assy and remove the fuel tank.
Weight : 83kg (183 lbs)
: 24mm
: 200mm (Extension bar) A1
10.3 INSTALLATION A5
(1) Installing is done in the reverse order of
removing. A4
Tank attaching bolt M16×40 B1
A7
: 24mm Apply loctite #262 B2
B8 A6
Tightening torque : 22.0kgfym B17,B18
(160 lbfyft) Fig. 10-3 Removing fuel tank
33-13
11. HYDRAULIC TANK
1
11.1 PREPARATION FOR REMOVAL
(1) Upper structure 45 degrees swung. 2
Swing upper structure to make the removal
of suction hose for pump installed under
hydraulic oil tank easier.
(ELEMENT)
Keep pressing until the hissing stops.
22
A2
33-14
(6) Draining hydraulic oil
Place pump in tank and draw up hydraulic
oil.
Capacity of tank : Approx. 94 (25gal)
(Included 7 (1.9gal) of inner filter case.)
33-15
11.3 INSTALLATION
O RING
(1) Cleaning hydraulic oil tank
33-16
12. PUMP (MAIN)
A6 A12
12.1 PREPARATION FOR REMOVAL
(1) Remove counterweight.
SUCTION
(3) Remove six capscrews (A12) M10. STRAINER
4 13
: Special service tool No.6-1 of 5
opposing flats 10mm 11
40mm
(1.57in)
2) Remove tube (1) of suction hose (4) from 6 12 1
pump. Fig. 12-3 Removing hose (5), (6) and
suction tube (1)
33-17
(3) Removing other hoses
1) Disconnect hoses of the following ports.
(See Fig. 12-4.)
Connected A3
Port Size Tool to Remarks
Dr3 Psv1
Dr1 PF1/2 27 Tank Drain
Proportional For control B4
Psv1,2 PF1/4 19 valve block valve
Gear pump
A3 PF3/8 22 Line filter delivery port
for pilot Psv2
Suction port
B3 PF3/4 36 Tank
for pilot
Drain port
Dr3 PF3/8 22 Tank for pilot B1
C/V for Delivery port Dr1
A4 PF1/2 27 dozzer for dozer
Suction port A4 A2
B4 PF1 41 Tank A1
for dozer B3
33-18
T=22kgfym (160 lbfyft)
12.3 INSTALLATION Do not use Loctite. (The
T=Tightening torque
Installing is done in the reverse order of removing. attached bolts are coated
with micro capsule coating.)
(1) Installing bracket (1)
2-4 1 4 T=19.5kgfym (140 lbfyft)
Install bracket (1) to the pump and
temporarily fasten them together by means of
socket bolts (4).
: 14mm
(2) Installing hub (2-2) 2
Insert hub (2-2) into the spline of the pump
till the end face of the spline enters 4mm
(0.157in) inward (Refer to the DetailⅠ.) and Ⅰ
attach two set screws (2-5).
: 14mm 2-5
T=11kgfym
Tightening torque : 11kgfym (80 lbfyft) (80 lbfyft)
(3) Installing coupling rubber (2-7)
3 T=6.6kgfym(48 lbfyft)
Insert coupling rubber (2-7) into hub (2-2) 2-3 Apply Loctite #262
T=22kgfym(160 lbfyft) equivalent
and attach socket bolts (2-4). Do not use Loctite. (The
On that occasion, do not coat socket bolts (2- attached bolts are coated
with micro capsule coating.)
4) with Loctite. (Socket bolts (2-4) are with
micro capsule coating.)
: 14mm 2-7
Tightening torque : 22kgfym (160 lbfyft) 2-2
(4) Installing the pump 2-4
Lift the pump with bracket level and dock it DETAILⅠ
in so bolts (2-3) enter the holes in coupling
2-5
rubber (2-7). (0.157˝)
Attach capscrews (3) back in position.
Fig. 12-6 Installing Hydraulic pump
: 17mm
Tightening torque : 6.6kgfym (48 lbfyft)
(5) Tighten socket bolts (4) regularly. HYDRAULIC PUMP
: 14mm
Tightening torque : 19.5kgfym
(140 lbfyft)
(6) Attach hoses (5), (6) of the delivery side with
half clamp capscrews (12).
: 17mm
(7) Install the section tube (1) attaching socket
bolts (13) M12 (4pcs.)
: 10mm, (※Special service tool No.6-1) 11
Tightening torque : 10kgfym (72 lbfyft) 12
33-19
(9) Remove suction stopper
41
42
19
33-20
13. RADIATOR & OIL COOLER
13.1 PREPARATION FOR REMOVAL T=Tigtening torque
B3 B1
Hose insert
allowance B2
45mm(1.8in)
A1 B19
B18
A4 B20 B8 B19
C1 B19
Hose insert allowance
45mm (1.8in)
UPPER
FRAME A2
T=16.4kgfym B5-2
B5-3 B18
(199 lbfyft)
A4 Apply Loctite #262 B8
B7
T=10.3kgfym (44 lbfyft)
B14 B15
B16 B17
B5
Sub tunk
B6
To counterweight
Fig. 13-1 Radiator & oil cooler
DETAIL OF SUB TANK
33-21
(5) Removing under cover installed on lower side
of radiator.
1) Remove eight sems bolts (8) M12×25.
2) Remove cover (2), (3).
: 19mm
3
8
8
Fig. 13-3 Removing under cover (2), (3)
(6) Drain down of radiator
Put container 18 (4.8gal) under drain cock
hose for draining water.
(Water capacity of radiator : 7 (1.8gal))
A5
18
17
Fig. 13-5 Moving condensers and receiver tank
13.2 REMOVAL
(1) Remove radiator stay (A1)
1) Remove two sems bolts (A4) M12. A1
: 19mm A4
A4
33-22
(2) Remove sub tank (B5) B5-2
1) Loosen clip (B18) on one side of hose (B8) and B5-3 B18 B8
pull out hose. B7
2) Remove four capscrews (B14) M8×20 and B14
separate sub tank (B5) from bracket (B6). B15
B16
: 13mm B17
C1 B19
B1
B19
Fig. 13-10 Removing water lower hose (B1)
33-23
13.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
33-24
14. ENGINE
14.1 PREPARATION FOR REMOVING (7) If necessary, remove pump, air cleaner,
(1) Remove guard (See Fig. 6-6, 6-7 and 6-12.) silencer and radiator.
(2) Remove counterweight (See Fig. 5-1 and 5-2.) (8) Remove harness and connector
Starter B terminal
1) Starter cable
(3) Remove battery ground (See Fig. 3-2.) E/G sub harness terminal
CN-351M
(4) Remove air cleaner hose (See Fig. 8-3.) CN-318F
2) Main harness E/G sub
CN-352F harness
(5) Remove radiator hose (See Fig. 13-8 and 13-10.)
3) Engine grounding able
(6) Remove fuel hose and heater hose, and if
necessary air-con hose. Prepare a stand which withstands the
weight of the engine assy and can place
the removed engine firmly.
THERMOSTAT SPEED
WATER
SEPARATOR
THERMO SENSOR
FUEL FILTER
ELEMENT
ALTERNATOR
ASSY
OIL SWITCH
THERMO SWITCH
OIL FILTER
ELEMENT
OIL FILTER (BY-PASS)
STARTER ASSY
ELEMENT
(FULL FLOW) V-BELT
V-BELT
(A/C)
33-25
PIPE FOR HEATER
E/G LIFTING FITTING
TURBO CHARGER
ロ
WATER
(COOLANT)
E/G LIFTING TEMPERATURE
FITTING FUEL FILTER ELEMENT SENSOR
THERMOSTAT
STARTER
MOTOR INJECTION
PUMP
FUEL RETURN
PIPE
ALTERNATOR
FUEL SUCTION PIPE
OIL PRESSURE SW.
OIL FILTER OIL FILTER DRAIN COCK
ELEMENT ELEMENT (FOR ENGINE BLOCK)
SAFETY RELAY (BYPASS) (FULL FLOW) DRAIN PLUG
EARTH CABLE
E115SR EV.
Fig. 14-2 SK135SR yDZ
E135SR EV. Outside view of Engine
33-26
14.2 REMOVAL
5
4
8 6 CAPSCREW
T=23kgfym (170 lbfyft)
Apply Loctite #271
8 WASHER
4 CAPSCREW
T=23kgfym(170 lbfyft)
Apply Loctite #271
1
9 PLATE
9 2 RUBBER MOUNT
RUBBER MOUNT 1
2 13 SHIM
14 SHIM
3 RUBBER MOUNT
7 NUT
13
14 13 13
3 14 14
7 3 3
7 7 Clearance Adjustment of Engine Mount
33-27
15. MULTI CONTROL VALVE (OPT.)
15.1 PREPARATION FOR REMOVAL 2
(1) Bleed pressure air in hydraulic oil tank
(See Fig. 11-2.)
12
(2) Remove cover assy (1) (See Fig. 6-2 )
(3) Remove panel assy (2) (See Fig. 6-3 )
17
(4) Remove cover assy (6) (See Fig. 6-4 )
(5) Shift bracket (1) for multi control valve if CLIP 15
necessary. (See Fig. 15-1.)
(6) Tag harness and remove it. 1
(7) Attach tag to hose between multi control
valve and main C/V, and write numbers C1 to
C8 in it.
Remove hose on multi control valve side, and 4
plug connection. Fig. 15-1 Removing bracket
for multi control valve
15.2 REMOVAL
(1) Attach tag on which hose name is entered to
the remote control hoses between multi
control valve and pilot V, and write numbers
P1 to P8 on it.
(2) Remove hoses P1 to P8 on multi control valve
side and plug connection.
(3) Remove three capscrews (17) M8×20.
(4) Remove multi valve (2).
: 13mm
(5) Removing and shifting bracket (1) for multi
control valve
1) Remove two capscrews (21) M10×20.
2) Remove support (15).
3) Remove four capscrews (4) M12×45.
4) Move bracket (1).
17
Fig. 15-2 Connection between
15.3 INSTALLATION multi control valve and C/V
(1) Installing is done in the reverse order of
removing
(2) Relations between pilot valve and multi
control valve hose
33-28
15.4 MULTI CONTROL LEVER REASSEMBLING Specification with multi control valve
PROCEDURE 352 353 271 472 471 401 261 201 273 274
(1) Changing from “with multi valve” to
“multiless valve”
1) Be certain that the engine stops.
M
2) Set multi control valve to ISO (Y) position.
275 O RING
(161)
3) Remove four socket bolts (271) and two socket 462
bolts (273). 461
S SENSOR
BLOCK
: 6mm
Fig. 15-4
4) Remove repair kit “with multi valve” and
C/V assy with multi
attach repair kit “multiless valve”.
No. NAME Q’TY
S SENSOR BLOCK 1S
5) Then check that the inside O ring (161) is
M REPAIR KIT WITH MULTI 1S
free from distortion. 161 z O RING 1
201 z COVER FOR MULTI 1
6) Check that whirl stop pin (355) and spring 261 z DUST SEAL 1
pin (356) are fitted on cover of valve 271 z SOCKET BOLT 4
“multiless control”, and install it on sensor 273 z SOCKET BOLT 2
block (S). 274 z SPACER 2
275 z SLEEVE 4
7) Fit socket bolt (271) and tighten it to the 352 z KNOB 1
specified torque. 353 z LEVER 1
: 6mm 401 z PIN 1
Tightening torque ; 4.3kgfym (31 lbfyft) 461 z O RING 1
462 z BACK UP RING 1
471 z SPRING PIN 1
(2) Changing from “multiless valve” to “with
472 z WING BOLT 1
multi valve”
1) Stop engine, and remove repair kit for Specification of multiless control valve
“multiless valve” in the reverse procedure of 271 355 356 354
the said procedure, and attach repair kit for
“with multi valve”.
Y
O RING (161)
S SENSOR
BLOCK
Fig. 15-5
33-29
16. CONTROL VALVE
16.1 PREPARATION FOR REMOVAL
(1) Remove cover assy (1) (See Fig. 6-2.)
16.2 REMOVAL
(1) Removing hoses for each piping
Attach tag on hose, and write port name in it,
then remove hoses.
Ports Functions Ports on upper sides (on machine) Ports Functions
LEFT← FRONT SIDE →RIGHT
SIDE SIDE
REAR SIDE
Bb Boom down
Ab Boom up
REAR SIDE
33-30
Ports Functions Ports on right sides (on machine) Ports Functions
FRONT SIDE
UPPER← →LOWER
SIDE SIDE
Ba Arm out
REAR SIDE
Ports Functions Ports on bottom sides (on machine) Ports Functions
LEFT← REAR SIDE →RIGHT
SIDE SIDE
PBo2 Option valve
PCa P2 bypass cut
PA1 Arm conflux
Drd Drain
PBb Boom down PBa Arm out
PLc2 Arm lock valve reliese
PBc Bucket digging PB1 Boom conflux
FRONT SIDE
16.3 INSTALLATION
(1) Installing is done in the reverse order of remove.
: 19mm,
Tightening torque : 12.3kgfym(89 lbfyft)
(2) Make certain that attachment moves 2 7
normally in operation.
4
(3) Check oil level and that it is free from oil 1
leakage. Fig. 16-1 Removing main control valve
33-31
17. PILOT VALVE (FOR ATT)
17.1 PREPARATION FOR REMOVING
PANEL ASSY
The removing procedure for right and left is the
same, so the preparation for left side is described
29
here. 28
(1) Put attachment on ground, stop engine and
release pressure in tank.
PF3/8
(7) Remove harness connector for horn. VALVE SIDE Opposing
PF1/4
Opposing
Flats 22 Flats 19
(8) Attach tag to hoses for identification.
MARK “F”
17.2 REMOVAL
(1) Remove hoses from your side to far side in PF3/8
PF1/4
order. P PORT CONNECTOR
: 19mm,22mm HOSE SIDE (WITH FILTER)
1~4,5~6,T PORT CONNECTOR
(2) Shift boots. Fig. 17-2 Pilot valve connector
(3) Remove four socket bolts (A1) M6. FRONT OF THE MACHINE
: 5mm
T 8 ARM(R) 4 BOOM(R) 2
(GREEN) T (GRAY) BUCKET
(4) Remove pilot valve. (R)
6 (BLUE)
SWING
(5) Plug hose ends. Plug PF1/4 (R.H)
5 (RED)
SWING(L.H)
17.3 INSTALLATION (GRAY)
1
Install it in the reverse order of removal and P
P BUCKET(H)
tighten it to the below tightening torque. 7 ARM(H) (RED)
: 5mm T=1.5kgfym (11 lbfyft)
(BLUE) 3
BOOM(H)
: 19mm T=3.0kgfym (22 lbfyft)
LEFT SIDE RIGHT SIDE
: 22mm T=5.0kgfym (36 lbfyft)
Fig. 17-3 Pilot valve port position (from upper side)
33-32
18. PILOT VALVE (FOR TRAVEL)
18.1 PREPARATION FOR REMOVING
(1) Release pressure in hydraulic oil tank
18.2 REMOVAL
7 (M10×25)
(1) Disconnect pressure sensor connectors at two
places from under floor harness.
18.3 INSTALLATION
Install it in the reverse order of removal and
tighten it to the below tightening torque.
Hose
: 19mm T=3.0kgfym (22 lbfyft)
: 22mm T=5.0kgfym (36 lbfyft)
: 8mm T=4.7kgfym (34 lbfyft)
: 17mm T=4.7kgfym (34 lbfyft)
Pressure sensor Fig. 18-1 Attaching and detaching pilot V
: 19mm T=3.5kgfym (25 lbfyft)
33-33
19. SWING UNIT
19.1 PREPARATION FOR REMOVING 10
(1) Park machine on flat and solid ground and
put attachment and dozer on ground.
33-34
(2) Loosen one nut (B12) M10 from under side of
upper frame and remove drain hose clip (B8)
for reduction unit. 1
: 17mm
19.4 INSTALLATION
Installing is done in the reverse order of removing.
1) Attach a socket bolt (2) to the most right
tapped hole in the mounting surface of the
swing unit and attach capscrews (1) to other
nine tapped holes.
2) Tighten capscrews (1) and socket bolts (2).
: 30mm
: 17mm
Tightening torque : 55.0kgfym (400 lbfyft)
Apply Loctite #262
33-35
20. SWIVEL JOINT
20.1 PREPARATION FOR REMOVE 20.2 REMOVAL
(1) Remove attachment assy (1) Remove travel motor hose and tube
(Refer to 1. section : Attachment) [Refer to Travel section under Hydraulic
system(8)]
(2) Remove cab (Refer to 1. CAB) 1) Remove tube (A5), (A6). (E port : PF1/2)
: 32mm
(3) Remove guard (Refer to 6. GUARD) Tightening torque :
15.0kgfym (108 lbfyft)
(4) Remove swing reduction unit if necessary. 2) Remove tubes (A1), (A2). (A, B port : PF1)
(Refer to 19. SWING MOTOR UNIT) : 36mm
B1 A2 Tightening torque :
B4 A4 22.0kgfym (160 lbfyft)
B1
B4 (H) 3) Remove tubes (A3), (A4). (C, D port : PF1)
B4 : 36mm
A25
B1 Tightening torque :
A3 B6
B5 22.0kgfym (160 lbfyft)
4) Remove two hoses (A13). (F, F port : PF1/4)
B2-1
B2-1 B2 A13 : 19mm
B2
B4 A13 Tightening torque : 3.7kgfym (27 lbfyft)
B1 B5 5) Remove hoses (A24), (A25). [Only dozer spec.]
A1 B5
B6 (G, H port : PF1/2)
(G)
A24 B3 : 32mm
A6
A5 FOR DOZER SPEC.
Tightening torque :
(A) 15.0kgfym (108 lbfyft)
(A)
(A)
A4 A6
A12 (D2)
A1
A13 A10 (B)
A13 A2
A15
A3 A8 (A)
A15
A5 A4
A13 (A)
B4 B1 (D)
SWIVEL JOINT (B)
A2
A13
B4
B1 (F)
A3
B2-1
B2
(C) (E) A13
B5
(A)
(F)
A1
A6
B3
A5
(A)
Fig. 20-1 Removing piping (undercarriage)
33-36
(2) Disconnecting the hoses on the top part of DRAIN HOSE
swivel joint
[Refer to Swivel Joint under, Hydraulic
system (4), (5).] A30
A29
1) Remove drain hose. (E port : PF1/2) A28
: 27mm Machine
Tightening torque : 8.0kgfym (58 lbfyft) front side
2) Remove hoses (A27), (A30).
(A, C port : 1-14UNS)
: 32mm
Tightening torque :
14.0kgfym (100 lbfyft) A27
3) Remove hoses (A28), (A29). A24
(Only on machine
(B, D port : 1-14UNS) with dozer)
: 32mm
Tightening torque :
14.0kgfym (100 lbfyft)
4) Remove hose (20). 20
A25
(2-speed change over port : PF1/4) 35 (Only on machine with dozer)
: 19mm
Tightening torque : 3.0kgfym (22 lbfyft) Fig. 20-2
C3 CAPSCREW
5) Remove dozer hoses (A24), (A25). (Only on M20×120
machine with dozer) (F, G port : 1-14UNS) T=16kgfym
: 32mm (116 lbfyft)
Tightening torque : C5
14.0kgfym (100 lbfyft)
(3) Remove whirl-stop of swivel joint. Fig. 20-3 Removing whirl-stop nut & the
1) Loosen the nut (C5) M20. capscrew
2) Remove a capscrew (C3)M20×120. B9
: 30mm
B13
(4) Remove joint for piping (Refer to Fig.20-2) B7
1) Remove two elbows (B5). (F, G port)
2) Remove connector (35) for travel 2-speed
change over (1). (PF1/4) B1
: 19mm
Tightening torque : 3.7kgfym (27 lbfyft)
33-37
(6) Remove capscrew for installation
Attach eye bolt, lift it up temporarily, and
remove three capscrews (2) M12×25.
: 19mm
(special service tool No.6-10)
EYE BOLT
LOWER FRAME
2
CAPSCREW
M12×25
LOCTITE #262
T=11kgfym(80 lbfyft)
1
SWIVEL JOINT
20.3 INSTALLATION
(1) Installing is done in the reverse order of
LOWER FRAME
removing.
Piping tightening torque
Tool Tightening torque kgfym(lbfyft)
Size
HEX O ring type Hydraulic hose
33-38
21. UPPER FRAME
21.1 PREPARATION FOR REMOVAL
(1) Remove attachment
WIRE ROPE
∅16×2.5m
(0.630″) (8ft
(2) Remove cab (Refer to 1. CAB.)
CHAIN BLOCK
(3) Remove guard (Refer to 6. GUARD)
21.2 REMOVAL
(1) Lifting up upper frame temporarily LIFTING JIG No.12 FOR UPPER FRAME
Attach two upper frame lifting jigs into the
mounting holes in the counterweight, attach Fig. 21-1 Temporarily lift upper frame
two chain blocks to the boom foot, and
temporarily lift the upper frame from four
points. MATCH
Wire rope ; ∅16 (0.630″)×2.5m(8ft 2in), 2pcs. MARK
∅16 (0.630″)×1.5m(4ft 11in), 2pcs.
Chain block ; For 1,000kg (2,200 lbs) 2pcs.
33-39
21.3 INSTALLATION
(1) Installing is done in the reverse order of
removing.
(2) Cleaning mating surfaces of upper frame and Apply Loctite #515 to the race surface over the whole
circumference (hatched) on the inside of capscrew.
swing bearing.
33-40
Part II: DISASSEMBLING AND ASSEMBLING EQUIPMENT Table 1-1
1. HYDRAULIC PUMP・REGULATOR TIGHTENING
REGULATOR TORQUE No. NAME Q’TY
kgfym (lbfyft)
1.1 HYDRAULIC PUMP
1.1.1 STRUCTURAL EXPLODED VIEW 111 SHALBF (F) 1
(1) Main pump 113 SHALBF (R) 1
116 1st GEAR 1
534 406
792 261 123 ROLLER BEARING 2
531,548 702 124 NEEDLE BEARING 2
532 774
732 710 127 BEARING SPACER 4
789
535 141 CYLINDER BLOCK 2
886 ENGINE
SIDE 151 PISTON 18
953
808 152 SHOE 18
153 PLATE 2
(RETAINER PLATE)
724
156 SPHERICAL BUSHING 2
728 719
113 467 313 157 CYLINDER SPRING 18
808 124 211 SHOE PLATE 2
127 954
123 212 SWASH PLATE 2
127 214 TILTING BUSHING 2
824 271 901
710 251 SWASH PLATE SUPPORT 1
(F)
262 312
717 252 SWASH PLATE SUPPORT 1
406 490 490 111 (R)
251 885 261 SEAL COVER (F) 1
719
262 SEAL COVER (R) 1
401 116 886 271 PUMP CASING 2
124 312 VALVE BLOCK 1
314
313 VALVE PLATE 1
141 GEAR PUMP (for CW rotation)
(FOR DOZER)
157 314 VALVE PLATE 1
(for CCW rotation)
711
156 24 (170) 401 SOCKET BOLT ; M16×175 8
886
153 885 1.2 (8.7) 406 SOCKET BOLT : M6×16 8
725
466 3.7 (27) 466 VP PLUG ; PF1/4 2
151,152 TIGHTENING
05
TORQUE No. NAME Q’TY 11 (80) 467 VP PLUG ; PF1/2 3
211
kgfym (lbfyft) 468 VP PLUG ; PF1/2 1
214 Refer to Fig.1-34
725 O RING : 1B P11 2
212 0.9 (6.5) 490 PLUG ; NPTF1/16 15
728 O RING : 1B P18 4 24 (170) 531 TILT PIN; M20×1.5 2
732 O RING : 1B P16 2 24 (170) 532 SERVO PISTON ; 2
GEAR PUMP
(FOR PILOT) 774 OIL SEAL 1 M20×1.5
789 BACKUP RING 2 534 STOPPER ( L) 2
Refer to Fig.1-2 792 BACKUP RING 2 535 STOPPER (S) 2
13 (94) 808 HEX. NUT ; M16 4 548 FEED BACK PIN 2
824 SNAP RING 2 702 O RING ; 1B G30 2
885 VALVE PLATE PIN 2
886 SPRING PIN 4 711 O RING : 1B G95 1
901 EYE BOLT ; M10 2 717 O RING ; 1B G120 2
953 SET SCREW 2 719 O RING ; 1B G115 2
954 SET SCREW 2 724 O RING ; 1B P8 18
Fig. 1-1 Structural exploded view of main pump The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
33-41
(2) Gear pump (for pilot)
433
A
434
351
435
312
353
311
732
SECTION AA 309 310 307 308 355 434 850 466 725 728 467
Table 1-2
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
307 POPPET 1 1.7 (12) 433 FLANGE SOCKET ; M8×40 2
308 SEAT 1 1.7 (12) 434 FLANGE SOCKET ; M8×55 2
309 SPRING SEAT 1 3.4 (25) 435 FLANGE SOCKET ; M10×35 2
310 SPRING 1 1.6 (12) 466 VP PLUG ; PF1/4 1
311 ADJUSTING SCREW 1 5.4 (39) 467 ADAPTER ; PF1/2-PF3/8 1
3 (22) 312 LOCK NUT ; M14 1 700 RING 1
351 GEAR CASE 1 710 O RING ; 1B G80 1
353 DRIVE GEAR 1 725 O RING ; 1B P11 1
354 DRIVEN GEAR 1 728 O RING ; 1B P18 1
355 FILTER 1 732 O RING ; 1B P16 1
361 FRONT CASE 1 850 SNAP RING 1
33-42
1.1.2 DISASSEMBLY AND ASSEMBLY OF MAIN
PUMP
(1) Tools Table 1-3
The following list shows the tools required for Tool name Dimension
remove and install.
Allen wrench Opposing flats 4,5,6,8,14mm
Eye wrench
Socket wrench
Wrench with double Opposing flats 19, 27mm
heads (single head)
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
: 27mm
REGULATOR
z Drain out oil from the plug of the
front pump and the rear pump.
33-43
5) Remove socket bolt (401)
Loosen socket bolts (401) that fasten swash
plate support (251), pump casing (271) and
valve block (312).
: 14mm
33-44
8) Remove seal cover (F) 406
Remove socket bolt (406) and seal cover F
(261). 261
: 5mm
212 (211)
33-45
13) Remove valve plate
Remove valve plate (313, 314) from valve
block (312).
314
(313:OPPOSITE SIDE)
33-46
(3) Installing procedure
1) Precautions to be exercised in installation
Assembly is a reverse order of disassembly,
but notice the following.
1. Repair scored parts at disassembly. Get
replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and
dry them with jet air.
3. Do not forget to coat the sliding areas and
bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as O
rings and oil seals.
5. Tighten socket bolts and plugs to specified
torques in this manual, using a torque
wrench.
6. Do not mix up front pump parts with rear
pump parts.
33-47
4) Installing shalbf
Install shalbf (111) fitted with bearing (123),
bearing spacer (127) and snap ring (824), to
swash plate support (251). 251
33-48
7) Installing valve plate
Install valve plate (313), (314) to valve block
(312) by aligning pin.
33-49
1.1.3 MAINTENANCE STANDARDS
(1) Replacement standards for abrasive parts However, always replace such parts that
Replace or readjust parts that exceed the show excessive damage on appearance.
following standards of wear.
Unit: mm (in)
Standard Recommended
Part name and inspection item value for Remedy
dimension replacement
Clearance between piston and 0.028 0.056
Replace piston or cylinder.
cylinder bore (D-d) (0.0011˝) (0.0022˝)
3.9 3.7
Thickness of shoe (t) Replace piston shoe assy.
(0.154˝) (0.146˝)
31.3 30.2
Free height of cylinder spring (L) Replace cylinder spring .
(1.23˝) (1.19˝)
Combined height of retainer plate and 10.5 9.8 Replace a set of spherical
spherical bushing (H-h) (0.413˝) (0.386˝) bushing or retainer plate.
H
h
t δ
L
Gap between piston and shoe : δ
thickness of shoe: t Free height of cylinder spring: L
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Valve plate (sliding section) Surface roughness requiring correction 3-Z
Swash plate (shoe plate face)
Cylinder (sliding section) Standard surface roughness
(correction value) Less than 0.4Z (lapping)
Roughness of each surface
33-50
1.1.4 TROUBLESHOOTING
(1) Locating causes of troubles
The pump is usually fitted with a regulator. Check that the hunting of the regulator and
auxiliary valves and auxiliary pumps, and the attached valve’s relief valve are of regular
this makes fault location extremely difficult frequency. In case vibration and sound are
However. faults would be found out easily if abnormal, the pump may be making a
the following check items were attended to. cavitation or internally broken.
1) Inspecting the filter and drain oil 3) When two pumps are used
Inspect the filter element to check for In case two single pumps or motors are used
abnormal contaminations. Some metallic or when a double pump is used. change pump
particles will be deposited on it as the shoe pipelines. This will make clear that the
and the cylinder wear off. In case metallic pumps are faulty or the circuit after the
particles are found in large quantity, the pumps is faulty.
elements may be damaged. In that case check
the drain oil in the pump casing as well. 4) Pressure measurements
If the problem is related to control functions,
2) Checking for abnormal vibration and sound avoid disassembling the pumps carelessly,
Check that the pump does not vibrate and but look for causes by measuring pressures.
make an abnormal sound.
(2) Troubleshooting
1) Overloading to engine
33-51
(2) Pump’s oil flow rate is extremely low and delivery pressure is not available.
2. Pump’s internal parts are 2) Replace damaged parts. 2) Check filter and drain oil.
seized or broken.
3. Attached pump is out of order. 3) Replace damaged parts. 3) Remove attached pump and check
shaft joint.
4. Attached valve is out of order. 4) Check attached valve. 4) Refer to Manual for Attached
Particularly poppet, Valve.
seat and spring.
5. Regulator is piped incorrectly. 5) Pipe correctly.
6. Relief valve in attached valve 6) Repair attached valve. 6) See the Manual for Attached
is hunting. Valve.
33-52
1.2 REGULATOR
1.2.1 STRUCTURAL EXPLODED VIEW
656 402
733
627
646
624
496 601
801
924
415
543
545
541
079 756
755
614
733
887
658
724
325 418 708
496 652
897
Table 1-4
651
TIGHTENING TIGHTENING
643 611 TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
631
079 SOLENOID PROPORTIONAL
REDUCING VALVE
1 643 PISTON 1
731
325 VALVE CASING 1 646 SPRING 1
1.2 (8.7) 402 SOCKET BOLT ; M6×16 4 651 SLEEVE 1
1.2 (8.7) 407 SOCKET BOLT ; M6×30 4 652 SPOOL 1
755
407 466 3.0 (22) 415 SOCKET BOLT ; M8×45 6 656 COVER 1
0.7 (5.1) 418 SOCKET BOLT ; M5×12 2 0.9 (6.5) 658 PLUG ; NPTF1/16 1
1.6 (12) 466 VP PLUG ; PF1/4 1 708 O RING ; 1B G75 1
0.9 (6.5) 496 PLUG 9 724 O RING ; 1B P8 5
541 SEAT 2 731 O RING ; 1B P25 1
543 STOPPER 2 733 O RING ; 1B P18 2
545 BALL 2 755 O RING ; 1B P11 2
601 CASING 1 756 O RING ; 1B P12.5 2
611 FEEDBACK LEVER 1 1.6 (12) 801 HEX. NUT ; M8 1
3.7 (27) 614 FULCRUM PLUG ; PF1/4 1 887 PIN 1
624 SPRING SEAT 1 897 PIN 1
627 PLUNGER 1 924 SET SCREW 1
631 SLEEVE 1
33-53
1.2.2 DISASSEMBLY AND ASSEMBLY
(1) Tools
The right list shows the tools required for Table 1-5
remove and install.
Tool name Dimension
3) Remove regulator
REGULATOR
Remove socket bolts (415) and separate the
regulator from the pump body.
: 6mm
325 (079)
407
33-54
5) Remove cover
Remove socket bolt (402) and cover (656).
: 5mm
631(643)
Fig. 1-24 Removing sleeve (631)
and pilot piston (643)
33-55
10) Drawing out the check valve 541
The disassembly is complete when the check
valve [seat (541), ball (545), and stopper
(543)] have been drawn out.
543 (545)
z The check valves are placed on two
places; the mating surface of the
pump casing and on the matching
surface of the valve casing.
601
Fig. 1-27 Drawing out the check valve.
(3) Installing procedure
Assembly is a reverse order of disassembly,
but notice the following.
1. Do not fail to correct parts damaged during
disassembly and get replacement parts ready
beforehand.
2. Entry of foreign matter causes faulty
functions; clean parts thoroughly, dry them
with jet air and work in a clean place.
3. Tighten bolts and plugs to specified torques.
4. Do not fail to coat the moving parts with
clean hydraulic oil, before proceeding to
assembly.
5. In principle, replace seals such as O rings
with new ones.
541
1) Placing the check valve
Fit the check valve to casing (601).
601
Fig. 1-28 Placing the check valve.
651(652)
Fig. 1-29 Fitting the sleeve (651)
and the spool (652).
33-56
3) Installing feedback lever 611(897)
Insert pin (897) of feedback lever (611) into
the pin hole olbfhe sleeve and fix the
feedback lever with fulcrum plug (614).
: 19mm,
Tightening torque : 3.7kgfym (27 lbfyft)
656 402
Fig. 1-32 Installing cover (656)
6) Assembling the sleeve and the pilot piston
Assemble sleeve (631) and pilot piston (643)
into casing (601).
33-57
1.3 PTO GEAR CASING
1.3.1 STRUCTURAL EXPLODED VIEW
414
117 128
126 435
826 886 711
326
128
414
115
827 886 262
728
125 468
118
125
825
435
435
Table 1-6
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
115 IDLE SHALBF 1 3.4 (25) 435 FLANGE SOCKET ; M10×20 4
117 2nd GEAR 1 7.5 (54) 468 VP PLUG ; PF3/4 1
118 3rd GEAR 1 711 O RING ; 1B G85 1
125 BALL BEARING 2 728 O RING ; 1B P24 1
126 ROLLER BEARING 1 825 SNAP RING 1
128 BEARING SPACER 2 826 SNAP RING 1
262 COVER 1 827 SNAP RING 1
326 GEAR CASING 1 886 PIN 2
3.4 (25) 414 SOCKET BOLT ; M10×20 2
33-58
1.3.2 DISASSEMBLY AND ASSEMBLY
(1) Tools
The right list shows the tools required for Table 1-7
remove and install.
Tool name Dimension
2) Cleaning
Remove dust and rust, etc. on pump surface
with wash oil.
3) Drain oil
Drain out the oil in the pump casing by
removing drain port plug (467), (468).
FLANGE SOCKET (M10)
: 27mm
TIGHTENING TORQUE : 3.4kgfym (25ftylbs)
435
GEAR PUMP
Fig. 1-35 Removing gear pump
5) Remove PTO gear casing
Remove flange socket (435) and PTO gear
casing.
: 8mm HOLE FOR FLANGE
SOCKET (435)
PTO
GEAR CASING
33-59
6) Removing the 2nd gear, the roller bearing HOLE FOR
IDLE SHAFT (115)
and the bearing spacer
Remove snap ring (827) and idle shaft (115).
Then draw out 2nd gear (117), roller bearing
(126) and bearing spacer (128). 117(126,128)
118
33-60
2. CONTROL VALVE
2.1 GENERAL PRECAUTIONS 2.3 DISASSEMBLY
1) As all the hydraulic components are precisely Regarding the construction of the control valve,
machined, it is essential to carry out refer to 4.2 Construction, 4. Control.
disassembly and reassembly in an especially The figures in parentheses after part names in
clean location. the contents represent those in the above-
2) When handling the control valve, take special mentioned Fig.1-1 structural exploded view.
care to prevent the entry of foreign matter,
such as dust or sand. Place the control valve on the workbench with the
3) Cap each port of the control valve before ports facing upward.
removing the valve from the machine. Before
disassembly, confirm that each cap is in place Disassemble the valve in a clean
and then clean the exterior of the assembly. location, and be careful not to damage
Use an appropriate workbench. Lay a clean flange surfaces or plate mounting
sheet of paper, rubber mat, or the like over surfaces.
the workbench.
4) When carrying or moving the control valve,
hold the body, and never put pressure on a
lever, an exposed spool, or the end cover.
Handle the valve with care.
5) Tests(for relief characteristics, leaks,
overload valve setting, flow resistance, etc.)
that are desired after disassembly and
reassembly require hydraulic testing
apparatus.
For this reason, do not disassemble hydraulic
units that you are capable of disassembling
but cannot test or adjust.
Prepare beforehand washing fluid, hydraulic
oil, grease, etc. . Fig. 2-1 Preparation for disassembly
(valve upper side)
2.2 TOOLS
Prepare the following tools before disassembling
the control valve.
33-61
(1) Remove option valve block 213(272)
1) Loosen the socket bolts (272) and remove the
option valve (213).
: 10mm
33-62
3) Fix the arm recirculation spool assy with vise
via a protective plate (aluminum plate, etc.)
and remove bolt (333). Then separate spring
seat (332), springs (325), (326) and stopper 333
(337) from arm recirculation spool (310).
332
326(337)
325
310
2) Draw out the assy of cut spool (309), spring Fig. 2-8 Removing cut spool spring cover (204)
seat (332), springs (325), (326), stopper (337) 309
and bolt (333) from casing A (101) or casing B
(102).
3) Fix the cut spool assy with vise via a Fig. 2-9 Drawing out cut spool assy
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (325), (326) and stopper (337)
from cut spool (309). 333
332
326(337)
325
309
33-63
273
(5) Disassembling the arm spool
1) Loosen socket bolts (273) and remove spring 201(262)
cover (201) for arm and O ring (262).
: 6mm
2) Draw out the assy of arm spool (302), spring Fig. 2-11 Removing arm spool spring cover (201)
seat (332), springs (324), (329), stopper (337)
302
and bolt (333) from casing A (101).
3) Fix the arm spool assy with vise via a Fig. 2-12 Drawing out arm spool assy
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (324), (329) and stopper (337)
333
from arm spool (302).
: 6mm 332
324(337)
4) Do not disassemble the arm spool (302) 329
further unless there is any problem.
302
Take care so as not to distort arm spool
(302) by overtightening it in the vise.
(6) Disassembling the boom spool Fig. 2-13 Disassembling arm spool assy
1) Loosen socket bolts (273) and remove spring 273
cover (201) for boom and O ring (262). 201(262)
: 6mm
301
(7) Disassembling the boom conflux spool Fig. 2-17 Disassembling boom spool (301)
1) Loosen socket bolts (273) and remove spring
cover (201) for boom conflux and O ring (262).
201(262)
: 6mm
273
Fig. 2-18 Removing boom conflux
spool spring cover (201)
33-65
2) Draw out the assy of boom conflux spool
(305), spring seat (332), springs (325), (326), 305
stopper (337) and bolt (333) from casing A
(101).
33-66
3) Fix the bucket spool assy with vise via a
protective plate (aluminum plate, etc.) and
remove bolt (333). Then separate spring seat
(332), springs (328), (329) and stopper (337) 333
from bucket spool (304).
332
328(337)
329
304
273 201(262)
Fig. 2-24 Removing swing spool spring cover
2) Draw out the assy of swing spool (303), spring
seat (332), springs (324), (329), stopper (337)
and bolt (333) from casing A (101).
303
When drawing out the spool assy, use
care so as not to score casing A (101) or
casing B (102).
303
33-67
(10) Disassembling the travel spool
(left travel and right travel)
1) Loosen the socket bolts (273) and remove the
spring cover (201) and the O ring (262) for
travel.
: 6mm
273 201(262)
3) Fix the travel spool assy with vise via a Fig. 2-28 Drawing out travel (right) spool assy
protective plate (aluminum plate, etc.).
Remove bolt (333) and separate spring seat
(332), springs (325), (327) and stopper (338)
from travel spool (306).
333
332
327(328)
325
306
(11) Disassembling travel straight spool Fig. 2-29 Disassembling travel (right) spool
1) Loosen the socket bolts (273) and remove the (306)
spring cover (201) and the O ring (262) for
travel straight.
: 6mm
273 201(262)
Fig. 2-30 Removing travel straight
spool spring cover
33-68
2) Draw out the assy of travel straight spool
(307), spring seat (332), springs ※1 (325),
※2 (326), stopper ※3 (337) and bolt (333) 307
from casing B (102).
325 ※1(322)
307
33-69
2) Draw out the assy of arm conflux spool (308), 308
spring seat (332), spring (325), (326), stopper
(337) and bolt (333) from casing B (102).
601
Fig. 2-38 Removing main relief valve(601)
33-70
602
512(522)
33-71
514
524
Fig. 2-43 Removing arm lock valve poppet (514)
3) Check valve in the travel straight section
(CT1)
Remove plug (552). Then remove poppets 552
(512) and spring (522).
: 10mm CT1
522
512
SECTION H´ -H´
Fig. 2-44 Removing check valve
in the travel straight section
4) Check valve in the main relief valve section
(CMR1,CMR2)
513
Remove plug (552) and remove poppet (513)
522
and spring (522). CMR1
: 10mm 552
CMR2
552
Those plugs that are not mentioned in
the foregoing disassembly procedure 522
are blind for extra holes and cast-on 513
holes; do not remove them unless SECTION C-C
necessary. Fig. 2-45 Removing check valve
in the main relief valve section
973
(17) Disassembling casing
1) Loosen socket bolts (973), (974) and separate
casing A (101) and casing B (102).
: 12mm
33-72
(18) Disassembling main relief valve
1) Remove plug (103) and seat (541) by pulling
them by hand as snap ring (121) is fixed.
2) Draw out spring (521) and plunger (512) from
inside seat (541).
3) Remove locknut (671) and adjust screw (651).
Remove spring plate (612), spring (621) and
poppet (611).
4) Separate snap ring (121), spacer (122), O ring
(561) and backup ring (562) from plug (103).
541 121 103
Filter (125) and filter stopper (124) are
assembled with plug (103) by means of Fig. 2-47 Disassembling main relief valve
snap ring (123).
Therefore, it can not be disassembled
any further.
33-73
(20) Disassembling option valve
1) Loosen the socket bolts (S271) and remove
the spring cover (S202) and the O ring (S261)
for option.
: 6mm
33-74
2.4 INSPECTION AFTER DISASSEMBLY 7) Remove any slight defects found during the
Thoroughly clean all disassembled parts with above inspection by lapping.
wash oil, and dry them with jet air. Place each 8) If any abnormal part is found, replace the
part on a clean sheet of paper or cloth for relief valve as an assy.
inspection.
33-75
Plugs (552) and (556) look similar; use (5) Assembling travel straight spool
care of the parts combination and 1) Put a mouthpiece (aluminum plate, etc.)
assembling position. in the vise and hold the center of travel
straight spool (307) in it. Set spring seat
3) Travel straight sections (CT1) (332), springs ※1 (325), ※2 (326) and stopper
Fit poppets (512) and spring (522), put O ring ※3 (337) and tighten bolts (333) to the
(562) in plug (552) and fasten it to the specified torque.
specified torque.
z When tightening bolts (333), coat
Use care of the assembling position of them with Loctite #262.
poppet (512) for travel straight. z Be careful so as not to distort travel
straight spool (307) by over-tightening
4) Main relief valve sections (CMR1, CMR2) it in the vise.
Fit poppets (513) and spring (522), put O ring
(562) in plug (552) and fasten it to the 2) Assemble the travel straight spool assy in 1)
specified torque. into casing B (102).
z Before tightening bolts (333), coat z When tightening bolts (333), coat
them with Loctite #262. them with Loctite #262.
z Be careful so as not to distort arm z Be careful so as not to distort travel
conflux spool (308) by overtightening spool (306) by overtightening it in
it in the vise. the vise.
2) Fix the arm conflux spool assy in 1) into 2) Assemble the travel spool assy in 1) into
casing B (102). casing A (101), B (102).
Fix the arm conflux spool assy into When assembling the travel spool assy
casing B (102) slowly and carefully and into casings A (101), B (102), do it
never force it in. slowly and carefully ; never force it in.
3) Attach spring cover (204) with O ring (262) to 3) Fit O ring (262) to the spring side of the
the spring side of the arm conflux spool assy. travel spool assy. Then attach spring cover
Then fasten socket bolts (273) to the specified (201) to the assy and tighten socket bolts
torque. (273) to the specified torque.
33-76
(7) Assembling swing spool (9) Assembling boom conflux spool
1) Put a mouthpiece (aluminum plate, etc.) to 1) Put a mouthpiece (aluminum plate, etc.) and
the vise and hold the center of swing spool hold the center of boom conflux spool (305) in
(303). Set spring seat (332), springs (324), the vise. Set spring seat (332), springs (325),
(329) and stopper (337) and tighten bolts (326) and stopper (337) and tighten bolts
(333) to the specified torque. (333) to the specified torque.
z When tightening bolts (333), coat z When tightening bolts (333), coat
them with Loctite #262. them with Loctite #262.
z Be careful so as not to distort swing z Use care so as not to distort boom
spool (303) by overtightening it in conflux spool (305) by overtightening
the vise. it in the vise.
2) Assemble the swing spool assy in 1) into 2) Fix the boom conflux spool assy in 1) into
casing A (101). casing A (101).
When assembling the swing spool assy When assembling the boom conflux
into casing A (101), do it slowly and spool assy into casing A (101), do it
carefully ; never force it in. slowly and carefully ; never force it in.
3) Put O ring (262) to the spring side of the 3) Fit O ring (262) to the spring side of the boom
swing spool assy and attach spring cover conflux spool assy and attach spring cover
(202) to the assy. Then tighten socket bolts (201) to the assy. Then tighten socket bolts
(273) to the specified torque. (273) to the specified torque.
z When tightening bolts (333), coat z When tightening bolts (333), coat
them with Loctite #262. them with Loctite #262.
z Be careful so as not to distort bucket z Be careful so as not to distort boom
spool (304) by overtightening it in spool (301) by overtightening it in
the vise. the vise.
2) Assemble the bucket spool assy in 1) into 2) Install the boom spool assembly reassembled
casing B (102). in Article 1) above in casing B (102).
When assembling the bucket spool assy When assembling the boom spool assy
into casing B (102), do it carefully and into casing B (102), do it slowly and
slowly ; never force it in. carefully ; never force it in.
3) Fit O ring (262) to the spring side of the 3) Attach O rings (262) to the spring side of the
bucket spool assy and attach spring cover boom spool assy. Then fit spring cover (201)
(201) to the assy. Then tighten socket bolts to the assy and tighten socket bolts (273) to
(273) to the specified torque. the specified torque.
33-77
(11) Assembling arm spool
1) Put a mouthpiece (aluminum plate) in the (13) Assembling arm recirculation spool
vise and hold the center of arm spool (302) in 1) Put a mouthpiece (aluminum plate) in the
the vise. Set spring seat (332), springs (324), vise and hold the center of arm recirculation
(329) and stopper (337) and tighten bolts spool (310) in the vise. Set spring seat (332),
(333) to the specified torque. springs (325), (326) and stopper (337) and
tighten bolts (333) to the specified torque.
z When tightening bolts (333), coat
them with Loctite #262. z When tightening bolts (333), coat
z Take care so as not to distort arm them with Loctite #262.
spool (302) by overtightening it in z Take care so as not to distort arm
the vise. recirculation spool (310) by over-
tightening it in the vise.
2) Fit the arm spool assy in 1) to casing A (101).
2) Fit the arm recirculation spool assy in 1) to
When assembling the arm spool assy casing A (101).
into casing A (101), do it slowly and
carefully ; never force it in. When assembling the arm recirculation
spool assy into casing A (101), do it
3) Attach spring cover (201) with O ring (262) to slowly and carefully ; never force it in.
the spring side of the arm spool assy. Then
tighten socket bolts (273) to the specified 3) Attach spring cover (204) with O ring (262) to
torque. the spring side of the arm recirculation spool
assy. Then tighten socket bolts (273) to the
(12) Assembling cut spool specified torque.
1) Put a mouthpiece (aluminum plate, etc.) in a
vise and hold the center of cut spool (309) in (14) Assembling spool covers
the vise. Set spring seat (332), springs (325), 1) Travel, boom, bucket, swing and arm.
(326) and stopper (337) and fasten bolts (333) Fit O ring (265) to spool cover (206) and
to the specified torque. tighten socket bolts (273) to the specified
torque.
z Before tightening bolts (333), coat
them with Loctite #262. 2) Travel straight and boom conflux
z Use care so as not to distort cut spool Fit O ring (265) to spool cover (206) and
(309) by overtightening it in the vise. tighten socket bolts (273) to the specified
torque.
2) Fit the cut spool assy in 1) into casing A (101)
and casing B (102). (15) Assembling main relief valve
1) Fit spacer (122), snap ring (121), O rings
When assembling the cut spool assy (163), (561) and backup ring (562).
into casing A (101), B (102), do it 2) Fix poppet (611) and spring (621) to plug
slowly with care ; never force it in. (103) in 1) above. Then fix spring seat (612)
in 2) fitted with O rings (661).
3) Attach spring cover (204) with O ring (262) to
the spring side of the cut spool assy. Then Make sure that poppet (611) is snugly
fasten socket bolts (273) to the specified placed in the seat of plug (103).
torque.
33-78
3) Temporarily assemble adjust screw (651) and (17) Assembling option valve
lock nut (671) to plug (103). 1) Fit O ring (S161) to casing (S101).
2) Assemble poppet (S512) and spring (S522) to
4) Assemble plunger (512) and spring (521) into casing (S101) and fasten plug (S551) with O
seat (541). ring (S561) to the specified torque.
3) Put a mouthpiece (aluminum plate, etc.) in
5) Assemble the seat in 4) to the plug (103) assy the vise and hold the center of option spool
under 3) and fix it with snap ring (121). (S301) in it. Set spring seat (S337), springs
(S323), (S324) and stopper (S333) and tighten
6) Pressure adjustment is performed in accor- bolts (S334) to the specified torque.
dance with “Maintenance Standard and Test
Procedure”. Leave adjust screw (651) tempo- z When tightening bolts (S334), coat
rarily assembled. them with Loctite #262.
z Be careful so as not to distort option
(16) Assembling Port Relief Valve spool (307) by overtightening it in
1) Assemble spring seat (612) with poppet (611), the vise.
spring (621) and O ring (661), into plug (102)
that is fitted with O rings (162), (561) and 4) Assemble the option spool assy in 3) into
backup ring (562). Then temporarily assem- casing (S101).
ble adjust screw (651) and locknut (671).
When assembling the option spool assy
Make certain that poppet (611) is into casing B (102), do it carefully and
snugly fitted in the seat of plug (102). slowly ; never force it in.
2) Fit O ring (563) and backup ring (564) to seat 5) Put O ring (S261) to the spring side of the
(541) and attach the seat to plunger (511) and option spool assy, attach spring cover (S202)
assemble piston (301) and springs (521), to the assy and tighten socket bolts (S271) to
(522). the specified torque.
3) Assemble the seat (541) assy in 2) into body 6) Install spool cover (S204) with O ring (S262)
(101) and tighten the plug (102) assy in 1) to and fasten socket bolt (S271) to the specified
the specified torque. torque.
Confirm that springs (521), (522) are 7) Install port relief valve (S603) to casing
guided properly. (S101) and fasten it to the specified torque.
33-79
2.6 MAINTENANCE STANDARDS
(1) Inspection of components
Spool 1) Look for scratches, galling, rusting 1) If a defect detectable with your
and corrosion. fingernail is found on the sliding part of
the outer circumference, replace the
spool.
2) Inspect ends that are sealed with an 2) If the sliding part is damaged, replace
O ring. the spool.
3) Insert the spool in the casing bore, 3) If the spool damages the O ring or does
and move it while turning it. not move smoothly, repair or replace
the spool.
Poppet 1) Look for damage on the poppet and 1) If sealing is incomplete, correct or
the spring. replace the seal.
2) Insert the poppet in the casing, and 2) If the poppet moves lightly without
move it. catching, it is normal.
Spring and 1) Look for rust, corrosion, deformation, 1) If damaged heavily, replace.
related parts and breakage of the spring, spring
seat, plug and cover.
Spool seal and 1) Look for external oil leak. 1) Repair or replace.
related parts 2) Look for rust, corrosion and deformation 2) Repair or replace.
of sealing plate.
Main relief valve 1) Look for rust and damage on outer 1) Replace.
Port relief valve surface.
2) Inspect the contact face of the valve 2) If damaged, replace.
seat.
3) Inspect the contact face of the poppet. 3) If damaged, replace.
4) Look for spring abnormality. 4) Replace.
5) Inspect the O ring, backup ring, and 5) As a general rule, replace all parts with
seal. new ones.
33-80
2.7 TROUBLESHOOTING
1) If an abnormal condition is noticed, check to If any part of the system is to be
see if the problem is with the control valve disassembled, take dust protection measures
itself, one of the main pumps, the gear pump, beforehand.
or a circuit. To this end, you will need to 3) Moving parts must be handled with care. If
measure pilot pressure, pump delivery they are damaged, smooth the damage using
pressure, load pressure, etc. If any part of the an oil stone or the like.
system is to be disassembled for inspection, 4) Take care not to damage the contact face of O
follow the disassembly and reassembly rings. A damaged contact face will certainly
procedures in this manual. cause oil leaks.
2) Dust is the enemy of hydraulic components.
Pay strict attention to protection from dust.
33-81
Trouble Cause Remedy
3. Excessive natural 1) Excessive clearance between 1) Replace spool.
falls of attachment casing and spool.
under its own
2) Spool is not completely in 2) Measure secondary pilot pressure.
weight when spool
neutral position.
is in neutral.
z Foreign matter between casing z Disassemble, clean and smooth sticking
and spool, or sticking spool. part with oil stone.
z Broken or deformed spring. z Replace spring.
z Clogged pilot circuit. z Remove foreign matter.
5. Bucket, boom, arm 1) Malfunctioning main spool. 1) Measure secondary pilot pressure.
or swing does not z Excessive clearance between z Replace spool.
operate. casing and spool.
z Foreign matter between casing z Disassemble and clean.
Slow to start up
and spool.
(or poor power).
z Sticking spool. z Smooth stuck part with oil stone.
Slow response.
z Broken or deformed return z Replace spring.
spring.
z Clogged pilot circuit. z Remove foreign matter.
33-82
Trouble Cause Remedy
6. Swing priority 1) Operating fault of arm recirculation 1) The same way as 5-1).
function does not spool [the same way as 5-1) below].
operate.
33-83
3. PILOT VALVE (FOR ATT)
3.1 INSTALLATION VIEW
(1) Cross-sectional view
312
501
302
Apply grease
on rotating and
sliding sections.
213 301 Be careful the
assembling
direction.
151 212
Apply
246 grease on
218-2 top section.
211
214
218-1
216-2 216-1
241-1
241-2
201-2 201-1
011-1
011-2
131
217 122
Secondary
pressure 101
adjusting shim 121 Not to be
target value at 126
PORT 2,4 PORT 1,3 125 reused.
center
t=0.4 (0.016˝ ), 111
1 piece Fig. 3-1 Pilot valve (for ATT)
33-84
(2) Explosion view
011-1
011-2
312
241-1
241-2
217
501
217
201-1
302 201-2
301 101
151
213
33-85
3.2 DISASSEMBLY
(1) Plug each port of pilot valve, and clean it.
P port : PF1/4
1~4 and T port : PF3/8
33-86
z When the force of return springs
(011-1), (011-2) is low, plug is left in
casing (101) due to sliding resistance
of O ring (214).
211
101
211
Fig. 3-7 Removing plug (211)
(7) Remove push rod (212), plug (211), pressure
reducing valve assy (spool), return springs 212
(011-1), (011-2) from casing (101).
125
33-87
(10) Remove port plate (111), O ring (122) from 126 SPRING
casing (101).
111
(11) Remove bushing (131) from casing (101).
131
122
101
211 212
33-88
(17) Remove inside seal (213) from plug (211) with
small driver.
213
Fig. 3-14 Removing seal (213)
3.3 CLEANING PARTS
(1) Clean parts with wash oil roughly.
3.4 ASSEMBLING
(1) Fit bushing (131) and O ring (122) to casing
(101). (See Fig.3-10.)
121
(3) Fit washer 2 (217), springs (241-1), (241-2), Fig. 3-15 Installing port plate (111)
spring seats (216-1), (216-2) to spool (201-1), 201-1
(201-2). or 201-2
241-1 216-1
or or
(4) Push spring seat (216-1) in the range of that 241-2 216-2
the movement is 7mm (0.276in) or less, and
install spools (201-1) through the large hole
of spring seat. (See Fig.3-11.)
For spring seat (216-2), push spring seat
(216-2) in 9.4mm (0.370in) or less and install
spool (201-2).
217
Fig. 3-16 Assembling pressure reducing valve
33-89
(5) Place spring (011-1) into ports 1,3 of casing
(101), and then install pressure reducing PRESSURE REDUCING
valve assy in it. VALVE ASSY
Place spring (011-2) into ports 2,4 and install 011-1
it.
101
Install the removed respective assy into
respective holes.
O RING (214)
For the assembling Fig. 3-17 Installing O ring (214) and seal (213)
direction of seal (213).
101 211
Fig. 3-20 Installing plug assy
33-90
2) When the force of spring (011-1), (011-2) is
high, attach plate (151) and press 4 push rods
by hand at the same time, and tighten joint 301
(301) temporarily.
151
33-91
3.5 MAINTENANCE STANDARDS
Check items Standard Remarks
When leakage quantity reaches to Conditions
1000cc/min. or more where handle is set in Primary pressure 3.0kgf/cm2
neutral position, or to 2000cc/min. or more in (43psi)
Leakage
operation, replace spool with new one. Hydraulic oil viscosity 2.3 cSt
If leaked, even if the spool is replaced,
replace pilot valve assy with new one.
When the wear of sliding section is 10μm This condition may be the same as the
Spool more than the that of non sliding section, above.
replace it with new one.
Push rod When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on In case of the looseness due to the
circle plate (302) on control section and joint loosening on tightening section, adjust
Looseness of
section (301) due to wear is produced, replace it.
control section
them with new ones.
It is very difficult to find defective section. The following table explains the several estimated causes.For
repair, refer to the estimated causes and corrective actions.
The following table explains general phenomenon, estimated causes and corrective actions. However,
most machine problems are not caused by the failure of only one part, but involve relations with other
parts. Therefore corrective action other than those described in this table is often required. The following
table does not cover causes and corrective actions for all the troubles. So it may be necessary to perform
further investigation of troubles and causes.
33-92
3.7 JIG
(1) Jig for removing and installing joint (301)
SECTION AA
BUSHING
①
Material;
SCM415 (N)
Carburizing
and Quenching
②
Material; S45C
A A
Detail of bushing
Material;
SCM415 (N)
Carburizing and Quenching
Q’ty; 2
33-93
4. PILOT VALVE (FOR TRAVEL)
↓Z 33 2 36 33
4.1 CONSTRUCTION 13 12 28
(1) Sectional view 36 14 42
19
37 25
26
1,3 30
20
34 25
22 15
21 42
20
39 20
32 17
33 36 33
44,16 40
6 7 SECTION AA
18 8
24
25,42
41
27
4 10,11 35
9 31 5 29
4-M10
T=4.3±0.4 38
(31±2.9)
24,41
SECTION BB
VIEW Z
Fig. 4-1 Sectional view of pilot valve (for travel)
☆Apply Loctite #262
TIGHTENING TIGHTENING
TORQUE NO. NAME Q’TY TORQUE NO. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
1 ORIFICE (SHIM) 4 22 SPRING 4
☆1.5 (11) 2 SEAT 2 1.0 (7.2) 24 PLUG ; PF1/8 3
3 ORIFICE (SHIM) 4 2.5 (18) 25 PLUG ; PF1/4 3
4 SPOOL 4 6.0 (43) 26 SOCKET BOLT ; M10×60 2
5 BODY 1 0.5 (3.6) 27 FLANGE BOLT 4
6 STOPPER 4 1.5 (11) 28 SET SCREW ; M8 4
7 SPRING 4 29 WASHER 4
8 SPRING 4 30 WASHER 2
9 NAME PLATE 1 31 RIVET 2
10 SHIM t=0.2 4 32 PIN ; ∅5 4
11 SHIM t=0.1 4 33 BALL 6
12 CAM 2 34 BALL 4
13 BOOTS 2 35 BALL 4
14 PIN 2 36 BALL 6
15 COVER 2 37 U PACKING 4
16 PISTON 4 38 O RING ; 1A P5 4
17 GUIDE 4 39 O RING ; 1A P24 4
18 SLEEVE 4 40 O RING ; 1A P26 4
19 HOLDER 4 41 O RING ; 1B P8 3
20 RING 12 42 O RING ; 1B P11 3
21 ORIFICE (SHIM) 4 44 PISTON ASSY 4
33-94
(2) Explosion view
13
26
30
28
12 LIP DETAIL
37 14
15
6
27
18
36
DAMPER SECTION
19
8
1,3
10,11,29
REDUCING VALVE SECTION
16,44
20 21
4
34
22
20 7
20
39 40
17 32
38
24
41 5
33-95
1. Tools used 3. Disassembling the damper (See Fig.4-3.)
Tool name Use (1) Draw out piston assy (44) and guide (17) from
For fixing the valve cover (15).
Vise
body z The damper is drawn out easily if it is pushed
Small vise from the ball side (36).
For disassembling the
(Place a copper plate on
reducing valve spool (2) Draw out four balls (36), holders (19) and
the mouthpiece.)
orifices (1), (3) from piston assy (44).
Allen wrench 3, 4, 5, 6, 8mm
z On that occasion, align the hole in the cover,
Scriber the piston assy and the guide as a set as each
For disassembling the
(or a sharp point rod of
U-packing part is shop fitted. Therefore, if parts for
the same shape)
Hex rod for torque different locations are assembled, functional
3, 4, 5, 6, 8mm
wrench faults may occur in some cases.
Torque wrench z Ring (20), orifice (21), spring (22) and ball
For picking up ball (36) (34) can not be separated from the piston
Magnet bar assy as they are assembled with ring (20)
and holder (19)
pressed in.
z Disassembly and assembly procedures
It is usual that disassembly and assembly are
executed at the maker’s factory, but in
unusual cases, do the work at a service shop
where skilled technicians are available.
Hydraulic parts are precision products of 37
small clearance. Therefore, disassembly and 15
assembly work shall be performed in a clean
place where there is little dust in the
following manner:
Never knock on precision parts in case they
do not operate smoothly.
Replace seal parts such as O rings and U 36
packings with new ones. 19
1,3
2. Disassembly 44,16
(1) Put a plug into each port (P,T,1,2,3,4,5,6) of 20
the valve and clean the outside. 21
(2) Fix the valve after cleaning it in a vise. 34
(3) Remove two boots (13). 22
(4) Loosen 2×2 places of socket head set screws 20
20
(28) and remove them from cam (12). 39
: 4mm 17
33-96
(3) Separate four O rings (39) from guide (17). (3) Draw out two balls (36) from body (5) by
(4) Remove four U packings (37) from cover (15), attracting the balls to a magnet.
using a scriber. z Balls (33), (35) are for circuit plugs and press
fitted to body (5). Therefore, they are not
4. Disassembling the reducing valve section separable.
(See Fig.4-4.)
(1) Separate three socket plugs (24) from body
32
5. Disassembling the reducing valve spool assy
(See Fig.4-5.) 38
z The outer diameter of reducing valve spool (4) 24
is finished with a small clearance against the
hole of body (5). Therefore, put a copper plate 5
41
on the mouthpiece of the vise at disassembly
so as not to score the outer diameter.
Note that the spool is deformed if the vise is Fig. 4-4 Disassembling the reducing valve
tightened too much.
(1) Fix spool (4) in a vise (Put a copper plate
against the mouthpiece.) and loosen four 27
socket flange bolts (27). 18
: 3mm
6. Disassembling the shuttle (See Fig.4-6.) Fig. 4-5 Disassembling the reducing spool assy
z The shuttle is unseparable basically as seat
(2) is fixed with adhesive agent (Loctite 33 33
#262.). 36 36
(1) Remove two socket plugs (25) from body (5). 2 2
: 6mm
33 33
(2) Remove two seats (2) from body (5).
: 5mm
33-97
7. Assembly 11. Assembling the damper (See Fig.4-3.)
z Clean and degrease parts before assembly. In (1) Fit four U packings (37) to cover (15).
particular, clean the body with a nylon brush z On that occasion, place the cover so the lip of
or something. the U packing faces down (damper chamber
Foreign matter intruded into the valve causes side).
functional faults to occur. (2) Insert four piston assemblies (44) into cover
z Prepare new seals (O rings and U packings) (15).
and coat the surface with hydraulic oil or a z In that case, make sure that each piston is
thin film of grease. set in the same hole where it was before
disassembly.
8. Assembling the shuttle. (See Fig.4-7.) The performances of the piston are not
(1) Put two balls (36) into body (5). affected at all if it is placed in any direction
(2) Coat the screwed part of seat (2) with on the circumference.
Loctite#262 and fit two of them to body (5). (3) Fit O ring (39) to guide (17). Install four
: 5mm, Tightening torque : guides to cover (15).
1.5±0.1kgfym(11±0.7 lbfyft) z Fix the guide in the same hole where it was
set before disassembly.
(3) Set O rings (42) to socket plugs (25) and
fasten two plugs to body (5).
: 6mm, Tightening torque :
2.5±0.2kgfym (18±1.4 lbfyft) 33 33
36 36
2 2
9. Assembling the reducing valve spool assy
(See Fig. 4-5.) 33 33
(1) Fix spool (4) in a vise. (Put copper plates
against the mouthpiece.) Set washer (29),
shims (10), (11), spring (8) and sleeve (18), in
that order, and tighten them with four socket
flange bolts (27). 42 42
: 3mm, Tightening torque : 25 25
0.5±0.1 kgfym (3.6±0.7 lbfyft) Fig. 4-7 Assembling the shuttle
33-98
(4) Set orifices (1), (3) to piston assy (44) that is In case such scratches and burrs can not be
set in the cover. corrected with ease, replace the parts with
z The orifices absorbs rattles that are made new ones in pairs.
when cam (12) is in neutral: either orifice (3) If you feel the moving parts of the reducing
may be at the top or at the bottom. valve, body (5) and spool (4) unsmooth,
z In case the cam rattles very much because correct them to be free from scratches and
the cam and the pin are worn out after long burrs, using #1000 emery paper. If it is
hours of use, increase the number of orifices. difficult to correct, replace the parts with new
However, if many orifices are set when there ones in pairs.
is no gap, the reducing valve spool is actuated (4) If you feel the moving parts of the cam
at neutral and pressure is built up in the assembly such as, cam (12), pin (14) and
secondary pressure port. When there is no cover (15), correct them to be free from
gap on the cam at neutral, do not increase the scratch and burr, using #1000 emery paper. If
orifices. it is hard to correct, replace the parts with
(5) Set four holders (19) and balls (36) to piston new ones.
assembly (44). 13
28
(6) Install two dampers on the reducing valve 36 12
and fasten them with socket bolts (26) with 19 14
washers (30). 37 15 35
16,44
In that case, parallel pin (32) set in body (5)
is placed in the hole of cover (15) to position 20
34 26
the reducing valve and the damper in place. 22
20 39 30
: 8mm, Tightening torque : 17 32
6±0.5kgfym (43±3.6 lbfyft) 40 6 1,3
18 27 21 38
(7) Set cam (12) to cover (15) and insert pin (14).
24
On that occasion, check the gap of the cam 41
8 20
and if the gap is large, increase orifices (1), 7 25,42
(3) according to item (4) above. 4 10,11,29
z Ball (36) and holder (19) can be drawn out
5
easily by magnet bar. If a magnet bar is not
available, place the valve on its side and give 13 Fig. 4-9
vibration to it.
(8) When the gap adjustment of the cam has
been finished, apply grease to the moving 28
parts of cam (12), pin (14), cover (15) and ball
(36). 12
(9) Attach 2×2 pcs. set screws to cam (12) and 26
30
tighten them.
: 4mm, Tightening torque :
1.5±0.1kgfym (11±0.7 lbfyft) 14
(10) Fit two boots (13).
DAMPER
33-99
5. SWING MOTOR UNIT
5.1 CONSTRUCTION
(1) Swing motor
992
351
355
051
V401-2
114
V401
117
121
702
111 113
743 123
742 993
464
485
116 117 432 471 443 106 101 491 304 437 124 122 301
Fig. 5-1 Swing motor
33-100
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
101 DRIVE SHAFT 1 471 O RING ; 1B G80 1
106 SPACER 3 472 O RING 1
111 CYLINDER 1 485 O RING ; 1B P11 1
113 RETAINER 1 487 O RING ; 1B P11 2
(SPHERICAL BUSHING)
114 CYLINDER SPRING 1 488 O RING ; 1B P20 2
116 PUSH ROD 12 491 OIL SEAL 1
117 SPACER 2 702 BRAKE PISTON 1
121 PISTON 9 706 O RING 1
122 SHOE 9 707 O RING 1
123 PLATE 1 712 BRAKE SPRING 20
124 SHOE PLATE 1 742 FRICTION PLATE 3
131 VALVE PLATE 1 743 SEPARATOR PLATE 4
301 CASING 1 0.17 (1.2) 980 PLUG ; PF3/8 1
303 VALVE CASING 1 0.45 (3.3) 981 PLUG ; PF3/4 1
304 FRONT COVER 1 0.09 (0.7) 982 PLUG ; PF1/4 1
351 PLUNGER 2 6.6 (48) 992 PLUG ; PT1/2 1
355 SPRING 2 2.2 (16) 993 PLUG ; PT1/4 1
24 (170) 401 SOCKET BOLT ; M16×75 4 18 (130) 051 RELIEF VALVE ; M33 2
432 SNAP RING 2 051-1 O RING ; 1B G30 2
433 RING 1
437 SNAP RING 1 052 SWING SHOCKLESS 1
VALVE BLOCK
438 SNAP RING 1 V101 CASING 1
443 ROLLER BEARING 1 0.9 (6.5) V151 PLUG ; NPTF1/16 4
444 ROLLER BEARING 1 V161 O RING ; 1B P22 2
451 PIN 2 3 (22) V171 SOCKET BOLT ; 8
M8×60
3.7 (27) 464 VP PLUG ; PF1/4 1 7 (51) V401 SWING SHOCKLESS 2
VALVE ; M22
3.7 (27) 468 VP PLUG ; PF1/4 2 V401-1 O RING ; 1B P20 2
11 (80) 469 RO PLUG ; M22 2 V401-2 BACKUP RING 2
33-101
(2) Swing reduction unit
602 230 231 204 286 211 912 285 287 911 283 403 210
922
282
※ 921
202
203
311
285
※
312
913
402 910
801
925
920
926
102
401
915
201
z Coat the parts marked ※
with Three-Bond #1104B.
M10,Depth 20mm(0.78in)
Fig. 5-2 Swing reduction unit
TIGHTENING TIGHTENING
TORQUE No. NAME Q’TY TORQUE No. NAME Q’TY
kgfym (lbfyft) kgfym (lbfyft)
102 CASING 1 401 ROLLER BEARING 1
201 DRIVE SHAFT 1 402 ROLLER BEARING 1
202 RING GEAR 1 403 NEEDLE BEARING 3
203 No.2 PLANETARY GEAR 4 10 (72) 602 SOCKET BOLT ; M12×100 10
204 No.2 SUN GEAR 1 801 OIL SEAL 1
210 No.1 PLANETARY GEAR 3 910 SPRING PIN 4
211 No.1 SUN GEAR 1 911 SNAP RING 3
230 No.2 CARRIER 1 912 SNAP RING 1
231 No.1 CARRIER 1 913 SNAP RING 1
282 No.2 PIN 4 915 SEAL 1
283 No.1 PIN 3 6.6 (48) 920 ADAPTER ; PT1/2 1
285 SIDE PLATE t=1 7 11 (80) 921 HOSE ; PF1/2 1
286 THRUST WASHER t=2 1 11 (80) 922 PLUG ; PF1/2 1
287 SIDE PLATE t=2 3 2.2 (16) 925 RELIEF FITTING 1s
311 LEVEL BAR 1 2.2 (16) 926 GREESE NIPPLE 1s
312 PIPE 1
33-102
5.2 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
5.2.1 TOOLS AND JIGS
(1) Spanner wrench
Opposing
Name Size Flats mm Applicable parts Tool
BORE DIA.∅11
(0.433˝ )
2×NUT M10
M10
33-103
5.2.2 DISASSEMBLY PROCEDURE
1) Cleaning the swing motor
Place a wire sling around the motor, lift it up
and clean it. After cleaning, dry it with jet
air.
z Choose a clean place. Place a rubber Fig. 5-4 Fixing the motor to the work bench
sheet or a cloth on the work bench. and putting a matching mark
Exercise care so as not to damage
parts.
303
4) Remove relief valve 051
Loosen relief valve (051) and separate it from
valve cover (303).
: 41mm
33-104
7) Remove valve casing and valve plate
Loosen socket bolt (401) and separate valve
casing (303) from casing (301). [If the socket
401
bolt (401) are loosened, the valve casing floats
off casing (301) by the force of brake spring
(712).] 303
Then separate valve plate (131) from valve
301
casing (303).
: 14mm
33-105
11) Remove separator plate
437
Draw out friction plate (742) and separator
plate (743) from casing (301).
304
301
301
PRESS
15) Remove inner race of roller bearing (443)
Remove snap ring (432) and spacer (106) DRIVE SHAFT
from drive shaft (101) and draw out the inner
race of roller bearing (443) by means of a
ROLLER BEARING
press.
33-106
16) Remove oil seal
Draw out oil seal (491) from front cover (304),
utilizing the jig.
304
(491)
z Do not reuse the removed oil seal.
FRONT COVER
Fig. 5-15 Removing oil seal
17) Remove roller bearing
Separate roller bearing (444) from valve
casing (303), using a slide hammer bearing
puller.
444
z Do not reuse the removed bearing.
303
106
SPACER
Fig. 5-18 Installing roller bearing (443)
33-107
432
301
33-108
Wind protective tape
101
116
33-109
11) Installing retainer 113
Then mount retainer (113) fitted with spacer
(117) on the cylinder.
117
121,122
13) Assembling the piston sub assy into the cylinder Fig. 5-28 Installing the piston sub assy to
Assemble piston sub assy (121,122) with the plate
plate (123) into cylinder (111) and insert it in
121,122,123
place, aligning it with the spline of drive
111
shaft (101).
101
14) Installing separator plate and friction plate
Fig. 5-29 Assembling the piston sub assy
Replace casing (301) so front cover (304) side
into the cylinder
faces down. Then Assemble separator plate
(743) and friction plate (742) into casing
(301), in that order. 743
Fit four separate plates and three friction
plates.
33-110
742
301
33-111
18) Insert outer race of roller bearing
Insert the outer race of roller bearing (444)
into valve casing (303), knocking it lightly by
means of a steel bar.
444
z Knock on the outer circumference of
the outer race evenly around and fix
303
it so it stops at the step of the valve
casing.
Apply grease.
33-112
22) Installing relief valve
Fit backup ring (162) and O ring (161) to 051(161,162) 303
relief valve (051) and fasten the relief valve
against valve casing (303).
: 41mm, Tightening torque :
18kgfym (130 lbfyft)
33-113
5.3 DISASSEMBLY AND ASSEMBLY OF SWING
REDUCTION UNIT
5.3.1 TOOLS AND JIGS
(1) Tools
NAME REMARKS
Allen wrench Opposing flats 6,10mm
Socket wrench
Adjust wrench
Double ended wrench
Hammer
Plastic mallet
Screwdriver
Torque wrench
Liquid packing Three-Bond #1104B
Oil container for
shrinkage fit work 80~100℃ (176~212°
F)
33-114
5.3.2 DISASSEMBLY PROCEDURE
(1) Remove swing motor unit and drain oil
Remove the swing motor unit from the
machine, loosen plug (902) at the oil outlet,
discharge the gear oil and place the unit on a
work bench.
211
z Receive gear oil in a clean container
and inspect for the presence of worn
particles.
(3) Remove No.1 sun gear (211) Fig. 5-41 Removing No.1 sun gear
403 210
Fig. 5-44 Removing needle bearing
33-115
3) Remove side plate (285) under the planetary
285
gear.
33-116
(8) Disassembly No.2 carrier assy
201
33-117
(11) Remove drive shaft
Support the flanged part of the drive shaft so
the shaft end faces down and place the drive
shaft on a work bench. Draw out the shaft
downwards, while tapping the center of it
with a plastic mallet.
801
33-118
5.3.3 ASSEMBLY PROCEDURE
402
(1) Assembly drive shaft assy
801
1) Insert bearing seal 102
GREASE
Insert bearing seal (915) into drive shaft
(201). 401
915
201
2) Press-fitting roller bearing Fig. 5-54 Assembling drive shaft
Coat the inside of roller bearing (401) with
sufficient grease and press it into the drive
shaft, using a press. Set the inner race firm GREASE
into the shaft by knocking on the steel bar,
till the hammer springs back. Then apply
grease so it reaps as shown in Fig.5-55.
z Grease : EP type
(Shell Alvania grease EP2)
z Roller bearing (401) has a bank in
the middle. Push grease in to both
sides before assembling the bearing
into the shaft. 201
Fig. 5-55 Applying grease to roller bearing
(2) Place casing (102) on a level bench.
33-119
(6) Press-fitting roller bearing
JIG
Insert roller bearing (402) by using the jig
that holds down both the inner race and the
outer race and also using a press.
Always use the jig [5.3.1 (2)] and set it
properly.
402
33-120
(12) Installing No.2 carrier assy
Install the No.2 carrier assy into the ring
gear. No.2
CARRIER
ASSY
231
286
3) Installing thrust washer
Put in thrust washer (286) in the center.
403
285
Fig. 5-64 Installing side plate
and needle bearing
33-121
5) Installing needle bearing and No.1 planetary
gear
Fit needle bearing (403) and No.1 planetary
gear (210).
210
287
(16) Installing No.1 sun gear
Assemble No.1 sun gear (211). Fig. 5-66 Installing side plate and snap ring
33-122
5.4 MAINTENANCE STANDARDS
5.4.1 SWING MOTOR
(1) Replacement standards for parts
If part are worn out beyond the below
standards, replace or recondition them.
However if they show excessive damage on
their surface, replace them.
Recommended
Standard Value for
Item Dimension Replacement Remedy
mm (in) mm (in)
Clearance between piston and
cylinder bore (D-d)
0.016 0.046
Replace piston or cylinder.
d D (0.00063) (0.00181)
0.3
0 Replace piston and shoe assembly.
(0.012)
σ
4.0 3.8
Replace piston and shoe assembly.
(0.157) (0.150)
3.5 3.1
t Replace.
(0.138) (0.122)
33-123
(2) Standard for correcting sliding surfaces
If the surface roughness of the sliding surface
of a part exceeds the following standard,
correct it or replace the part.
33-124
5.4.2 REDUCTION UNIT
(1) Parts inspection and replacement standards
1) If pitching is seen on the tooth surface of the
sun gear, the planetary gear and the ring
gear; (Single pit is more than ∅1mm(0.039in)
and the area occupancy of all pits is more
than 5%.)
2) Oil seal
Replace the oil seal if the lip face of it is
scored and worn.
Always replace when the reduction gear is
disassembled for inspection or some reason.
33-125
(2) Table of parts to be replaced together
No. 201 401 402 203 230 282 285 910 210 231 283 403
Roller bearing
No.2 carrier
No.1 carrier
Needle cage
Drive shaft
Spring pin
Side plate
No.2 pin
No.1 pin
NAME
33-126
5.5 TROUBLESHOOTING
5.5.1 SWING MOTOR
(1) Hydraulic motor does not rotate.
33-127
(3) Revolution does not rise to set value.
33-128
(6) Oil leaks
1) Oil leak from oil seal
Trouble Cause Remedy
Oil leaks from oil 1. Lip of seal contains dirt and 1. Replace oil seal.
seal damaged. 2. Shift the lip and shaft positions or
2. Shaft is damaged or worn. replace oil seal.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen
abnormally high, with the result that
lip of oil seal has turned up. 4. Disassemble and correct.
4. Shaft is rusted.
33-129
5.5.2 REDUCTION UNIT
Hydraulic motor inlet pressure has risen. Overloaded Reduce the motor of load.
Rotating sound is heard from Motor shaft is broken. Replace hydraulic motor.
hydraulic motor.
Rotating sound is not heard Pump and valve are out of Check for fault and correct.
from hydraulic motor. order.
2) Oil leakage
Oil leaks through matching surface. Liquid packing is not applied. Disassemble and apply
liquid packing.
3) Temperature is high.
Temperature of reduction unit casing The gear oil is not filled up or Check oil level and fill oil
is high. the oil level is low. up to a specified level.
33-130
6. SWIVEL JOINT
6.1 CONSTRUCTION VIEW
(1) Specification 1 (2) Specification 2
STANDARD SPECIFICATION DOZER SPECIFICATION
10 H E
D H
10
F
F C E B
11
E
X
X
SECTION XX A F G 2
2
2 6
6
1
1
D
C
C
B
B
A
A
G
5
7 F
9 5
3 E 8
4
7
3 4 E 8 9
Table 6-1
Q’TY Q’TY
NO. NAME NO. NAME
Spec.1 Spec.2 Spec.1 Spec.2
1 BODY 1 1 7 O RING(1A G95) 1 1
2 STEM 1 1 8 SOCKET BOLT (M8×20) 2 2
3 THRUST PLATE 1 1 9 SOCKET BOLT (M8×30) 4 4
4 COVER 1 1 10 PLUG 1 1
5 SEAL ASSY 5 7 11 PLUG ― 2
6 O RING 2 2
33-131
6.2 DISASSEMBLY AND ASSEMBLY
6.2.1 TOOLS Table 6-2
Symbol Tool Name Used for Remarks
1. Steel hammer
a Hammer
2. Wooden or plastic mallet
1. Allen wrench
c Wrench 2. Double-ended and single-ended wrench
3. Extension pipe
Disassembly
g Vise Vise movable over 150mm (6in)
Assembly
h Loctite #290
j Cleaning oil
33-132
6.2.4 DISASSEMBLY 2
1
The part numbers used in this disassembly 4
procedure correspond to those of a construction 9
drawing in Fig.6-1.
33-133
(4) Removing seals SPATULA(f)
1) Pull out O ring (6) from the O ring groove
with the aid of a spatula.
6
Use the tip of the spatula taking not to mar
the body. Also do not strike the spatula.
BUCK-UP RING
DETAIL(5)
GROOVES
FOR O RING
GROOVES
FOR
HYDRAULIC PIN(e)
GROOVES
FOR 5
SLIPPER SEAL
SEAL ASSY
33-134
(2) Assembling stem
Lightly coat the outer circumference of stem Press in by applying your weight
(2) and the inner surface of body (1) with by your both hands.
grease or vaseline and slowly insert stem (2)
into body (1).
2 STEM
It stem (2) is pressed in too fast, the seal
may be damaged. Do it slowly.
The clearance between body (1) and stem (2)
is about 0.1mm (0.004in). Push stem straight O RING 6
along the shaft center.
1 BODY
5
SEAL ASSY
WORK BENCH
PIPE
33-135
6.3 MAINTENANCE STANDARDS
6.3.1 INSPECTION PROCEDURE AND REMEDY
Table 6-3
2,000Hrs. Seal for oil Check oil leakage outside Replace O ring, if any oil leakage can be
leakage outside found.
4,000Hrs. All sealing Replace all sealing parts such as slipper
In principle, parts seal with back-up ring and O ring.
disassemble
and check re- All sliding parts Check abnormal wear, scoring Repair or replace referring to their limit
gardless of oil or corrosion caused by foreign of serviceability.
leakage or not. matters or seizure.
When All parts Check them for seizure, foreign Repair or replace referring to their limit
disassembled matters, abnormal wear, and of serviceability.
for repair defect of seals. O rings should be replaced.
Table 6-4
33-136
Parts Maintenance Standards Remedy
BACK-UP RING
1.5mm (max.)
(0.06in)
BACK-UP RING
33-137
6.3.3 INSPECTION AFTER ASSEMBLY
After completion of assembly, inspection for oil 1
leakage, pressure resistance, etc., using a device
as shown in the figure right.
9
(1) High pressure port (A,B,C,D port) Connect to
Install a changeover valve and pressure body side
gauge to the stem side port and body side
2
port respectively, and while watching the
Connect to
pressure gauge (for high pressure) installed stem side
on the body side and also by regulating high
pressure relief valve (7), gradually increase
3
the pressure and when the pressure has
reached 1.5 times the maximum working 8
pressure, close stop valve (3) and lock in the
hydraulic oil in the swivel. Keep stop valve
(6) on the low pressure relief valve side closed 7
at this time.
Table 6-5
Item Description Remarks
High and Low Pressures
1 Pressure Gauge
are required.
2 Swivel Joint
3 Stop Valve
Relief Valve for Setting Pressure :
5
low pressure 5kgf/cm2 (71psi)
6 Stop Valve
Relief Valve for Setting Pressure
7
high pressure (Working pressure×1.5times)
8 Directional Valve
9 Piping, etc.
33-138
6.4 TROUBLESHOOTING
Table 6-6
33-139
NOTE
33-140
SECTION 34 TRAVEL SYSTEM
TABLE OF CONTENTS
34402 60413254
Part I: REMOVING AND INSTALLING
1. NAME OF TRAVEL SYSTEM
8. SWING BEARING
2. CRAWLER
DOZER BLADE
7. TRAVEL MOTOR
6. SPROCKET GUARD 5. FRONT IDLER
LOWER FRAME
3. UPPER ROLLER GREASE NIPPLE OF THE
4. LOWER ROLLER
TRACK SPRING ADJUSTER
(TRACK ROLLER)
Fig. 1-1 Designation and location of undercarriage
2. CRAWLER
2. Winding crawler
Insert an iron pry into the hole of the master
pinhole. Bring the attachment down on the
ground, holding it by hand as shown in Fig.
2-5. Then hold up the lower frame by 1 to
2cm (0.4 to 0.8in) so the machine weight is
not exerted upon the shoes. Then put an lever
into the hole of the master pin. Holding the
top end of the track link by hand as shown in Fig. 2-5 Winding crawler
Fig.2-5, rotate the sprocket in the backward
direction and roll up the crawler around.
Connecting
position of master pin
Fig. 2-6 Preparation for press fitting master pin
34-2
4) Press fitting of master pin
Apply press fitting jig on master pin, and
strike it with a mallet to press fit.
34-3
4) Insert iron pipe in the crawler, turn sprocket
Rotating direction
backward slowly, and slide crawler at the
point where rubber crawler is floated from
the pipe to remove.
Weight of rubber crawler (one side) :
E115SR EVOLUTION 675kg (1490 lbs)
E135SR EVOLUTION 790kg (1740 lbs)
(2) Installing
1) Install crawler by reversing the procedure of PIPE
removal. That is, engage crawler with Fig. 2-11 Removing rubber crawler
sprocket, place it upper roller, and engage it
with idler using bar while turning sprocket
slowly.
2) Check that rubber crawler retaining
projection is matched with front idler,
sprocket, lower roller respectively and
completely, and then tighten grease nipple
for crawler adjuster, and adjust the tension GREASE NIPPLE
: 19mm,
Tightening torque of grease nipple: “A”
6kgfym (43 lbfyft)
34-4
2.3 CONSTRUCTION
(1) Shoe assy E115SR EVOLUTION 7
4
Shoe ; 600 (STD)
• 3
Shoe ; 700
SHOE ASSY • Shoe ; RUB PAD500 7
• 8
Shoe ; 500
Shoe ; F500
•
Shoe ; T800
1
No. NAME Q’TY 5 11
• TRACK LINK ASSY 1 ←
1 • • TRACK LINK (R.H) 41 ← 8 2
2 • • TRACK LINK (L.H) 41 ←
6
3 • • BUSHING 40 ←
4 • • PIN 40 ← 9
5 • • MASTER BUSHING 1 ←
6 • • MASTER PIN 1 ←
7 • • SEAL 80 ←
8 • • MASTER COLLAR 2 ←
9 • SHOE ; 600 (STD) 41 ―
• SHOE ; 700 41 ―
• SHOE ; RUB PAD500 41 ―
• SHOE ; 500 41 ―
• SHOE ;F500 ― 41 10
• SHOE ;T800 ― 41
Fig. 2-13 Shoe assy
10 • SHOE BOLT 164 ―
• SHOE BOLT ― 164
11 • SHOE NUT 164 ←
34-5
(3) Rubber crawler
34-6
(2) Track link assy STD
E F
G D
B
Fig. 2-16
34-7
2.5 TOOLS AND JIGS
34-8
3. UPPER ROLLER
3.1 UPPER ROLLER ASSY 3 2
3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
2
(2) Removing upper roller (5)
1) Remove nuts on support tightening section,
and also remove capscrew.
: 30mm (M20) Fig. 3-2 Removing upper roller
IDLER SIDE
3.3 INSTALLING
5
Installing is done in the reverse order of COUNTERSINKING
removing. 3
(1) Inspection
Before reassembling, check it that it rotates
up
smooth manually and for leakage.
2) Insert it until collar comes in contact with Fig. 3-3 Installing upper roller
support.
: 30mm (M20),
Tightening torque : 55kgfym (400 lbfyft)
34-9
3.4 CONSTRUCTION
34-10
7) Removing floating seal (7).
Take out floating seal (7) from upper roller 7
(1).
7
34-11
Push with press
4) Installing floating seals (7).
Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2
34-12
3.6 MAINTENANCE STANDARD
STD
B
F
A
34-13
3.7 TOOLS AND JIGS
(1) Tightening tools
For STD Type
Unit : mm (in)
NAME OPPOSING FLATS
Socket 19, 24
Allen wrench 8
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
∅100 (3.94˝)
(3.23˝)
∅82
160(6.30˝)
f Stand jig
∅40 (1.57˝)
For
(0.709˝)
g extruding
18
bushing
∅37 (1.46˝)
For
h extruding
(1.18˝)
30
shaft
(2.05˝)
∅52
(1.6339 +0.0039 )
Bushing
)
i
∅41.5 +0.1
+0.1
31 2 (0.0787˝)
0
+0.0039
fixing jig
0
0
(1.22˝)
∅37.6
(1.4803 0
36 40
(1.42˝) 76 (1.57˝)
(3.00˝)
34-14
4. LOWER ROLLER (TRACK ROLLER)
4.1 LOWER ROLLER ASSY
E115SR EVOLUTION
LOWER ROLLER ASSY E135SR EVOLUTION
No. NAME Q’TY REMARKS
2 CAPSCREW 48 M16×75
CAPSCREW ─ M18×80
3 ROLLER ASSY 12
ROLLER ASSY ─
2 Apply Loctite #262.
STD, LC : T=28.5kgfym (206 lbfyft) 3
L : T=40.5kgfym (293 lbfyft)
Fig. 4-1 Lower roller assy
4.2 REMOVAL
(1) Where crawler is removed
1) Preparation for removal
Loosen grease nipple to slacken the link.
Put square timbers on the front and rear
sides of under section of lower frame, and
stabilize the machine.
2) Removing lower roller
Remove cap screw (2).
: STD: 24mm (M16)
4.3 INSTALLATION
(1) Securing lower roller temporarily
Apply Loctite #262 on 4 capscrews (2) and Fig. 4-3 Installing lower roller
tighten them temporarily.
: STD: 24mm (M16)
(2) Securing lower roller regularly.
GREASE NIPPLE
Bring the machine completely down on the
ground and tighten attaching cap screws (2)
to a specified torque.
Tightening torque :
STD: 28.5kgfym (206 lbfyft)
34-15
4.4 CONSTRUCTION
1
4) Removing shaft (2)
In addition, push out and remove shaft (2)
2
together with the lower collar (7) and O ring
(6).
JIG m
34-16
5) Removing collar (7), O ring (6)
Insert shaft (2) with collar (7) and O ring (6)
5
removed in the said procedure into roller (1)
directing the collar (7) side upward, and take
out collar (7) and O ring (6) from shaft (2) in
the same procedure as that described in Item
3).
7
6) Removing floating seal (5)
Take out floating seal (5) from collar (7).
Fig. 4-8 Removing out floating seal (5)
34-17
(2) Installing
6 2
1) Attach O ring (6) to one side
Install O ring (6) to groove on shaft.
z Replace O ring with new one.
z Grease O ring.
6 7
5) Attach floating seal (5) to roller side
Fit floating seal (5) to inner holes on both Fig. 4-13 Inserting pin (4)
ends of roller (1).
z Check that the seal surface is free
from flaws, rusts, etc. before reusing
the floating seal.
34-18
7) Installing O ring (6) Press
Install O ring (6) to groove on shaft.
10) Filling oil Fig. 4-15 Installing O ring (6), collar (7)
Remove plug (8) and fill in 150cc (9.2cu・in)
of engine oil API grade CD#30.
34-19
4.6 MAINTENANCE STANDARD
C C
Clearance 2.5±0.5mm
(0.1in±0.02in)
A B D E
34-20
4.7 TOOLS AND JIGS
(1) Tightening tools
For STD type
Unit : mm (in)
NAME OPPOSING FLATS
Socket 19,24
Allen wrench 6
(2) Jig
Unit : mm (in)
No. NAME SHAPE
k V-block
Pin (4)
extrusion
rod
200 (7.87˝)
Bushing
n extrusion ∅16 (0.630˝)
rod
245 (9.65˝)
P extrusion
∅49 (1.93˝)
jig
∅70 (2.76˝)
30 (1.18˝)
80
Bushing 50 (3.15˝)
Q (1.97˝)
fixing jig
∅49.5±0.1
(1.949±0.004˝)
34-21
5. CRAWLER IDLER (IDLER ADJUSTER ASSY)
5.1 CRAWLER IDLER ASSY
1
CRAWLER IDLER ASSY STD 2
No. NAME Q’TY REMARKS
1 • CRAWLER IDLER 2
• CRAWLER IDLER ─
1-1 • • IDLER ASSY 1
• • IDLER ASSY ─
1-2 • • ADJUST ASSY 1
• • ADJUST ASSY ─ 4 3
Apply Loctite #262 Grease nipple is
1-3 • • GREASE NIPPLE 1 equivalent positioned on the
1-4 • • CAPSCREW 2 M12×35 M12 : T=11.7kgfym(85 lbfyft) outside of machine.
M16 : T=28.5kgfym(210 lbfyft) T=6kgfym (43 lbfyft)
• • CAPSCREW ─ M16×45
Fig. 5-1 Front idler assy
5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)
(3) Installing
Installing is done in the reverse order of
removing.
(4) Where idling assy (1) has to be separated Fig. 5-2 Removing and installation the front idler
Loosen capscrew (4), and separate idler assy 1
(1) from idler adjuster assy (2).
: STD: 19mm
Weight of idler assy : 71kg (160 lbs)
Weight of idler adjuster assy : 58kg (130 lbs)
4 3
Fig. 5-3 Separating idler assy (1)
from idler adjuster assy
34-22
5.3 IDLER ASSY STD 1
5.3.1 CONSTRUCTION
8 4
5
5.3.2 REMOVING AND INSTALLING R
(1) Removing
1) Drain oil
Remove plug (8) on the side of collar (4) to
drain.
: 5mm
Push with press
4) Removing collar (4) from shaft (2) S Fig. 5-6 Removing collar (4)
If removal of collar (4) on the opposite side is 2 4
required, turn over front idler and proceed
with the procedure described in Item 3).
34-23
5) Removing bushing (3)
With idler (1) mounted on the stand, tap
bushing (3) lightly by hammer, while placing
the bushing drawing rod (T) against the end
face of bushing (3) evenly all round, till it
comes out.
34-24
7) Installing collar (4)
Fit the half of floating seal (6) on the other 8 2
collar (4), press fit it in shaft, and drive pin 4
(5) in with hummer. 5
8) Filling oil・Inspection 1
Fill in 200cc (12.2cuyin) of engine oil API
grade CD #30 through the plug hole of collar
(4), wind seal tape and tighten plug (8).
DETAIL OF TREAD
34-25
5.3.4 TOOLS AND JIGS
(1) Tightening tools
For STD Type
Unit : mm (in)
NAME OPPOSING FLATS
Socket 19
Allen wrench 5
(2) Jigs
Unit : mm (in)
No. NAME SHAPE
340 (13.4˝)
Shaft
S push out
jig ∅59 (2.32˝)
300 (11.8˝)
Bushing
T drawing ∅16 (0.630˝)
rod
∅87 (3.43˝)
30 (1.18˝)
Bushing 85
V Press 55
(3.35˝)
fitting jig (2.17˝)
∅59.5±0.1
(2.343±0.004˝)
∅80 (3.15˝)
Collar
W Press
30 (1.18˝)
fitting jig
34-26
5.4 IDLER ADJUSTER ASSY STD
1
5.4.1 CONSTRUCTION
34-27
5.4.2 DISASSEMBLY AND ASSEMBLY
(1) Disassembly M30 HOLDING-DOWN NUT
1) Spring set special jig
Before disassembling and assembling the RETAINER PLATE
idler adjuster assy, prepare spring setting jig
(V).
5) Slinging work idler adjuster Fig. 5-16 Slinging work idler adjuster
Set the idler adjuster assy on the stand of
the jig, with its bracket side facing up.
34-28
6) Fixing idler adjuster assy
Fit retainer plate to bracket (2), tighten 3
holding-down nuts alternately, and secure
idler adjuster assy.
HOLDING-DOWN NUT
: 46mm
3 RETAINER PLATE
Fig. 5-17 Fixing idler adjuster assy
7) Compression of spring (5)
Remove spring pin (4), press spring (5) lifting
it with jack so that nut (3) can be turned 5
freely, and remove nut (3).
: 46mm
34-29
(2) Assembly W
Assembly is done in the reverse order of
disassembly.
1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1) into spring (5) and
attach lifting eye nut (W) to screw M45 at the
5
tip of the grease cylinder. Lift the grease
cylinder by crane and erect it in the center of
the jig stand upright.
: 46mm
2
3) Compressing spring (5) and removing nut (3)
Extend the hydraulic jack, compress spring
4
(5) to a set length and screw in nut (3) to the
3
screwed part at the tip of grease cylinder (1).
5
Set length of the spring : 358mm (14.1in) 1
: 46mm
: 70mm(M45)
: 75mm(M48)
34-30
6) Installing oil seal (8), O ring (7) 1
Fit oil seal (8) and O ring (7) to grease
8
cylinder (1).
7
z Grease oil seal (8) and O ring (7). 6
34-31
5.4.3 MAINTENANCE STANDARD
STD
STANDARD
No. ITEM
VALUE
A Installed length of spring mm 354.8 (14.0in)
About 423
B Free length of spring mm
(16.7in)
C Stroke mm 40 (1.57in) C
D Set length mm 606 (23.9in) E
Nor scoring
E Outside view of piston and rusting
Tightening torque of 6kgfym
F grease nipple (43 lbfyft)
3.2 A, B
F
(0.13in) D
34-32
6. SPROCKET
6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to Section 1.
"Crawler", lift up crawler frame with
attachment, and put it on square timbers to
float and stabilize.
: 24mm
STD: 15pcs.
2
6.2 INSTALLING 1
(1) Check before installing Fig. 6-2 Removing sprocket
Check the mating portion of the travel
reduction unit and the sprocket, eliminate
burrs and contamination thoroughly and
install the sprocket.
: 24mm,
Tightening torque : 28.5kgfym (210 lbfyft)
(1.102˝) B
R28 R15(0.591˝)
C
R5(0.197˝)
A
Fig. 6-4(1/2) Sprocket
STD Table 6-2 Unit:mm(in)
No. NAME STANDARD VALUE REPAIRABLE LEVEL SERVICE LIMIT REMEDY
∅601±3 ∅590 ∅588 Reinforcement weld,
A O.D. of sprocket
(23.661±0.118) (23.2) (23.1) repair or replace.
Width of
B sprocket teeth 49-30 (1.923-0.118
0 ) 44 (1.73) 42 (1.65) Replace.
Width of Reinforcement weld,
C sprocket bottom 37 (1.46) 32 (1.93) 30 (1.18) repair or replace.
34-34
6.4 TOOLS AND JIGS
(1) Tightening tools
Unit : mm
NAME OPPOSING FLATS
Socket 24
34-35
7. TRAVEL MOTOR
2 Apply Loctite #262
7.1 TRAVEL MOTOR INST. T=18.5kgfym (130 lbfyft)
STD
INSTALL ASSY
No. NAME Q’TY REMARKS
1 SPROCKET 2 1
2 CAPSCREW 70 M16×45
For installing the
sprocket 30pcs.
For installing the 2
travel motor 40pcs. Apply Loctite #262
5 TRAVEL MOTOR ASSY 2 equivalent
5 T=28.5kgfym (210 lbfyft)
D2(PF1/2)
B(PF3/4)
Ⅰ
P(PF1/4)
A(PF3/4)
D1(PF1/2)
VIEW Ⅰ
Fig. 7-1 Installing travel motor
34-36
7.2 REMOVING 1,2
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to
float and stabilize. 7
: 19mm
(3) Preparation of oil pan Fig. 7-2 Removing and installing cover (1), (2)
: 24mm
2 STD: 15pcs.
: 24mm
2
STD: 20pcs.
34-37
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on
the side close to sprocket installing section
and remove the motor.
Weight of motor :
STD: Approx. 144kg (320 lbs)
7.3 INSTALLING
Installing of the travel motor piping is performed
in the reverse order of removal.
1) Cleaning
Tightening RE-
Check that contact surface of travel motor NAME SIZE Tools No. Torque
and crawler frame is free from burr and kgfym(lbfyft) MARKS
34-38
8. SWING BEARING
8.1 SWING BEARING ASSY
ASSY
No. NAME Q’TY REMARKS
1 SWING BEARING 1
2 CAPSCREW 36 M16×45 FRONT
3
Loctite #262 or equivalent Inner S zone section of
to be applied swing bearing
T=28.5kgfym (206 lbf yft)
Fig. 8-1 Swing bearing assy
SECTION A-A
GREASE BATH
34-39
8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces
of swing bearing and lower frame are free
from dust and stain.
FRONT A A
(2) Installing
Install swing bearing on lower frame meeting
the matchmarks and positioning the S mark
on inner race as shown in the figure.
SECTION A-A
(5) Filling grease.
Fill grease bath with 6.4kg (14 lbs) of grease
NLGI-2 (containing molybdenum disulfide) or Fig. 8-5 Removing and installing capscrew (3)
equivalent.
8.4 CONSTRUCTION
3・ 62
ASSY
No. NAME Q’TY No. NAME Q’TY 1
1 OUTER RACE 1 6 SEAL 1 9
2 INNER RACE 1 7 GREASE NIPPLE 7
3 BALL 108 (PT1/8) 1 8
4 RETAINER 108 8 TAPER PIN 1 5
5 SEAL 1 9 PLUG 1 Fig. 8-6 Cross-sectional view of swing bearing
34-40
4) While rotating outer race (1) little by little,
take out ball (3) and retainer (4) through plug 1
hole, in that order.
2
4
3
(2) Installing
1) After cleaning grooves for seal (6) on inner
surface on the upper side of outer race (1),
and for seal (5) on the outer surface of inner
race (2), apply adhesive agent Cyano-bond
PO-1, fit seal (5), and place them on a surface 1
plate. PUSH ROD 6
2) Lower outer race (1) to the position where
2
upper surface of inner race (2) and lower
portion of seal groove is mated, put adjusting 3
5
washer under outer race (1) so that outer SQUARE
WOODEN BLOCK
raceway surface of ball (3) aligns with inner
raceway, and support it. Fig. 8-9 Fitting balls (3)
3) Insert ball (3) and retainer (4), on which
grease is applied, through plug (9) hole on Eye bolt
outer race (1), alternately.
34-41
Part II: DISASSEMBLING AND ASSEMBLING EQUIPMENT
1. REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
1.1 CONSTRUCTION OF TRAVEL MOTOR
1.1.1 CROSS-SECTIONAL VIEW OF TRAVEL
MOTOR ASSEMBLY
135 116 115 117 104 105 107 106 111 108 103 167 149 171 4 132 5
139 23
128 125 123 127 130 137 121
112 35
136 138 143 22
109
124 126 154 20
164 14
142 138
166
A 25
163
9
165
7
138
15
101 B 6
141
8
199
36
195 102
194 169
193 19
220 3
A
214 33
213 21
210 224
29
204 215 140
191
205 212
192 161
202 222
168 150 179 27 30 113 2 145 31 114 110 151 1 17 162
203 216
209 206 217 209 221 201 211 208 170 174
146
190 SECTION BB
SECTION AA
34-42
132
21 149 171
167
1.1.2 EXPLODED VIEW OF REDUCTION UNIT 1.1.3 EXPLODED VIEW OF HYDRAULIC MOTOR
103
31 102
106
105
107
169
22 111
104
191 110
2 114
162
161
110
21 145
30 108
5
23 151
126
9 137
130
23
127 150
4 124 121 117
136 138 154
141 115
27 128
27
1 116
125
135
139
142
166 112
164 109 113
163
17 33 168
138
165 140 179 127
130
192 137
195 126
29 199 101
202
146 190 143 194
209 123
25 211 193
7 208
14 211 217 138 125
215
20 209 224
128
22 216
35 204 212 136
210 217 124
217 209
3 205
203 222 217
8 206 211
201 221 208 211
36 209
222 202
6 213 222
15 214 220
221
174 201
206
170
19 203
Fig. 1-2
205 210
204
Fig. 1-3
34-43
No. NAME Q’TY No. NAME Q’TY No. NAME Q’TY
34-44
1.2 TOOLS AND JIGS
(1) Standard tools
Socket wrench 1
(Ratchet handle)
Adapter for torque wrench Nominal 17, 19, 27, 32, 36 Socket 1 of each
Nominal 6, 8, 10 Hex key 1 of each
Hammer Nominal 12 1
34-45
(2) Tightening torque
(3) Tools
34-46
(4) Jigs
1 5
This is used to carry out the work for This is used to press fit oil seal (132) into oil
assembly and disassembly of travel motor seal fitting hole of spindle (2).
easy and safe.
2 6
Retainer metal (Ⅰ) Jig for adjusting the preload to the bearing
3 7
Special nut
This is used to insert / remove spring (114), This is used to press fit bearing (21) in hub
washer (110), snap ring (145) into / from (1), and also used to measure clearance of
cylinder block (104). bearing (21) in shaft direction.
4 8
This is used to pull out or insert bearing This is used to remove outer race of bearing
(149) from shaft (102). (21).
34-47
No. NAME No. NAME
9 13
10 14
11 15
12
34-48
1.3 PREPARATION FOR DISASSEMBLY 1.3.3 DISASSEMBLING PROCEDURE.
1.3.1 GENERAL PRECAUTIONS FOR (1) Cleaning travel motor.
DISASSEMBLY (2) Place travel motor.
1) All the hydraulic equipment is manufactured (3) Drain lubricating oil.
in precision, so the work should be carried (4) Remove cover.
out in a clean and dust free place. Also use (5) Remove input gear and spur gear.
clean tools and wash oil, dry them by (6) Remove rear flange.
compressed air, and don’t use waste cloth, (7) Remove parts installing rear flange.
paper, etc. (8) Disassemble brake valve section on rear
2) Prior to starting work, plug every port on the flange.
removed travel motor, and remove soil, oil, (9) Disassemble the 2-speed selector valve.
etc. on the surface of motor. (10) Disassemble the inner parts of shockless
3) Matchmarks are put on the mating surfaces relief valve.
of part while disassembling. Carry out the (11) Disassemble parking brake section.
work putting every removed part in order, (12) Disassemble hydraulic motor section.
and taking care not to cause damage. (13) Take out spring from cylinder block.
4) Sealing parts, such as O ring, backup ring, (14) Pull out shaft.
etc. are not to be reused. (15) Remove the bearing inner race.
While disassembling, all parts should be (16) Remove hold flange.
prepared collating removed parts with parts (17) Remove retainer metal.
on the seal kit list. (18) Remove spindle.
5) Some parts are supplied and replaced as a (19) Remove bearing, RV gear assy and pin.
sub-assy. For those parts, refer to the “Parts (20) Take out bearing.
Manual”. (21) Remove spindle.
(22) Disassemble hold flange.
z Figures in parenthesis ( ) noted (23) Rough cleaning of every part.
immediately after part name (24) Finish clean
correspond to the figures in the
construction drawing. (Fig. 1-1, 1-2,
1-3) 1.3.4 WEIGHT OF COMPONENT
34-49
1.3.5 REMOVING
(1) Cleaning travel motor Eye bolt
1) Tighten the eye bolts into the tapped holes of
the spindle (2). 2
Eye bolt ; M16
Socket bolt
34-50
(3) Draining lubricating oil.
z If you want to disassemble only the
rear flange, go to (6) 1).
4) Place a hook and a wire sling on the PT eye Fig. 1-9 Removing cover (8)
bolts, lift it up and remove cover (8).
6
Fig. 1-10 Removing input gear (6)
34-51
1) Remove three snap rings (25) from 9
crankshaft (9).
25
Fig. 1-11 Removing snap ring (25)
2) Remove three spur gears (7) from crankshaft 9
(9).
7
Fig. 1-12 Removing spur gear (7)
(6) Removing rear flange (101)
1) Turn over the travel motor
z This work is intended to remove the
plug easily when removing the inside
of the rear flange. On that occasion,
loosen the plug so it can be removed
by hand.
z Do not loosen the plug if you do not
remove the inside of the rear flange.
2) Loosen two plugs (124)
: 36mm
3) Loosen two plugs (126)
: 10mm
z When disassembling the inside of
body (212), loosen plugs (204), (214) 170
and sleeve (202) before loosening
socket bolts (170).
4) Loosen four socket bolts (170), and remove 212
body (212) from rear flange (101).
: 6mm
34-52
6) Remove eight socket bolt (143).
: 8mm
143
Fig. 1-14 Removing socket bolts (143)
7) Remove rear flange (101) from spindle (2).
109 (141)
8) Remove eight springs (113). 113
9) Remove parallel pins (142) from spindle (2).
10) Remove O ring (27),(30) from spindle (2).
34-53
(8) Removing the brake valve from the rear
flange.
1) Remove two plugs (124) from rear flange
(101). 101
: 36mm
101
130
126
127
Fig. 1-20 Removing valve (127)
34-54
(9) Disassemble the 2-speed selector valve
1) Remove plug (165) from rear flange (101).
: 10mm
165
101
101
163,164,166
Fig. 1-22 Removing spool kit (163),(164)
(10) Disassembling shockless relief valve.
1) Remove plug (214)
: 10mm
z Remove plug (214) in the condition
where shockless relief valve is 214
installed on rear flange (101) to
make the work easier.
213
34-55
z When it is difficult to remove, attach PISTON(213)
thread M3 to threaded hole (M3)
used to disassemble piston (213) and
M3
pull it out.
z Then take care not to damage piston
bore.
BODY
215
Fig. 1-26 Removing piston (215)
6) Remove out two balls (216) from body (212)
216 212
Fig. 1-27 Removing ball (216)
7) Remove sleeve (202) from body.
: 27mm
34-56
8) Remove O rings (208), (209) and two backup
rings (211) from sleeve (202).
202 212
205
204
Fig. 1-31 Removing shim (205)
13) Remove spring retainer (203), spring (206)
and valve (201) from sleeve (202).
202
201
Fig. 1-32 Removing spring retainer (203)
34-57
206 202
Fig. 1-33 Removing spring (206)
201 202
2 112
Fig. 1-36 Blowing jet air
34-58
2) Remove O ring (135),(139) from piston (112). 112
(135,139)
z Do not reuse removed O ring (135),
(139).
34-59
7) Remove the piston assy (105),(106) from
retainer plate (107).〔Nine pistons〕
104
34-60
(14) Removing out shaft (102).
1) Removing swash plate (103) from spindle (2).
162
4) Draw out the 2-speed switch piston
assy[piston (161) and shoe (162)] and spring
(191) from spindle (2). 161
191
34-61
When removing the snap ring, the snap ring
jumps off if the tip of pliers comes off from the
snap ring hole. Use care so as not injure yourself.
3
8) Put match marks on hold flange (3) and
spindle (2) with paint marker.
34-62
(18) Removing spindle.
1) Tighten two eye bolts into the tapped holes of Eye bolt M16
spindle (2) so they are located in diagonally
opposite positions.
Bearing(21)
34-63
(21) Removing the spindle fittings.
1) Remove floating seal (31) from spindle (2).
31 2
22
34-64
(23) Rough washing of parts. 2 3
1) Distinguish the four parts ; hub (1), spindle
(2), cover (8), and rear flange (101) from other 101
parts (hereafter called built-in parts).
2) Put the hub, spindle, cover and rear flange in
a cleaning bath and clean them.
34-65
1.4 ASSEMBLY
1.4.1 GENERAL PRECAUTIONS FOR ASSEMBLY 2) Replacement parts that need adjustment of
(1) Assembly it by reversing the procedure of the axial clearance of bearing (22):
disassembly. Spindle kit
RV gear assy
(2) Assemble it in clean air condition.
(2) The assembling procedure varies according
(3) Don’t use cloth gloves during assembly. to the procedure of the above described parts.
Replace
(5) Clean every part sufficiently, and blow them part. 〔Parts to be replaced〕
with compressed air don’t use waste cloth. zHub (1)
zSpindle kit
(6) Prior to assembling, apply clean hydraulic oil zBearing (21)
to moving and sliding portions of hydraulic Yes
motor valve. 1.4.4
Procedure for
(7) Tighten bolt and plug to the specified torque adjusting the pre-
using torque wrench. load of bearing (21)
34-66
1.4.3 INSTALLING PROCEDURE
(1) Installing hub (1).
34-67
(2) Assembling spindle section.
1) Apply grease on O ring of floating seal (31), F/S fixture (Ⅱ)
and fit floating seal in the groove of spindle
Floating seal
(2).
z To fix the floating seal, mount F/S F/S fixture(Ⅲ)
fixture (I), the floating seal and F/S
fixture (II), in that order and push
the F/S fixture (II) in till it comes in
contact with the F/S fixture (I).
Remove the fixtures and make
Spindle
certain that the end face of the
groove of spindle is level, within Fig. 1-55 Installing floating seal (31)
1mm (0.0394in), with the surface of
the floating seal. Eye bolt
2
7) Assemble the RV gear assembly into spindle
(2), while holding the tip of crankshaft (9).
34-68
(3) Installing hold flange Mallet
1) Insert bearing (21) to hub (1)
Fixing jig
z The O.D. of bearing (21) is set to the Bearing (21)
bore of hub (1) by press fitting.
Hammer the press fitting jig lightly
little by little till they are set evenly. Hub
In that case, set bearing (21) in hub
(1) scurely.
34-69
z Fasten three reamer bolts (19) 19
equally little by little. If you fasten
one or two bolts first, hold flange (3)
tilts, making bearing (21) unable to
be pressed into hold flange (3). This
causes reamer bolts (19) to seize
themselves. Therefore, tighten them
evenly all round.
34-70
(6) Installing spur gear (7). 7
9
1) Install three spur gears (7) to crankshaft (9).
z Put the matching marks (punched)
of three spur gears (7) as shown
below and fix them to crankshaft (9).
Position the
matching marks
(punched) on the
spur gears (7) and
install them.
Hold flange
Fig. 1-63 Installing spur gears (7)
25 9 7
Fig. 1-64 Fixing snap rings (25)
(7) Press fitting shaft Press
1) Put collar (169) into the shaft (102).
Shaft
2) Put bearing (149) in a heating bath and heat
it at 100±10℃ (212±18° F) for ten minutes Bearing
and pressing it into shaft (102). (Inner race)
Retainer
metal (Ⅱ)
z Carry out the insertion work with
leather gloves. Use care so as not to
get burns.
34-71
4) Fix two parallel pins (171) into the pin holes
of spindle (2). 2
5) Coat two pivots (167) spherical side with
lithium grease and fix it into parallel pins
(171) of spindle (2). 162
6) Coat spring (191) with grease and fit it to
161
piston assy [piston (161) and shoe (162)].
7) Apply hydraulic oil to the moving parts of the
piston assy [piston(161) and shoe (162)]. Then 191
install the assy into the piston hole of spindle
(2).
110
z Put snap ring (145) in with its sharp
corner directed to the inlet.
z Insert washer (110) in contact with
snap ring (145) with its sharp corner 114
directed to snap ring (145).
104
104
z If the tip of the pliers gets out of the
hole of the snap ring, the snap ring
jumps out. Be careful about it.
z Put a plastic sheet over cylinder Fig. 1-69 Fixing snap ring (145)
block (104) so the contact surface of
cylinder block is not scored in
contact with timing plate (109).
34-72
(10) Assembling hydraulic motor
1) Put three rollers (151) into the holes of
cylinder block (104) and place washers (111)
and thrust balls (108) on them.
151
104
Fig. 1-70 Installing rollers (151)
2) Fit nine piston assy to retainer plate (107).
z After fixing it, immerse the whole
unit in hydraulic oil.
3) Fit retainer plate (107) and 9 piston assy to
cylinder block (104).
z Match retainer plate (107) with the
spherical part of thrust ball (108) 105, 106 107
and install them.
108
4) Assemble cylinder block (104) fitted with
swash plate (103), thrust ball (108), washer 104 (151)
(111), retainer plate (107), piston assy (105),
(106) and roller (151), to shaft (102) that is
placed level. (to make a hydraulic motor assy) Fig. 1-71 Assembling piston assy
5) Place the lifting tool (I) to the tip of shaft and retainer plate (107)
(102) and place the shaft upright.
6) Attach the lifting tool (Ⅰ) and lift it up by
crane.
z Lower the shaft slowly till the pivot
hole in swash plate (103) matches
pivot (167) fitted into spindle (2).
z Lower the shaft so as not to score oil
seal (132).
7) Assemble the hydraulic motor assy to spindle Lifting tool
(2), while lowering it slowly.
8) After assembling it, remove the lifting tool
(Ⅰ).
9) Make certain that there is no rattling of
cylinder block (104) by turning it by hand.
z After assembly, do not hold up 2 103
cylinder block (104). Otherwise,
washer (111) comes off from thrust
ball (108), and the hydraulic motor
does not rotate properly.
34-73
(11) Installing parking brake.
115
34-74
z Coat the spool with hydraulic oil and
insert the spool into the rear flange.
z Insert the spool by aligning the hole
of the rear flange with the spool and
prevent the inner surface of the rear
flange and the outer surface of the 123
spool from being damaged by mutual
interference.
z In case damage resulting from inter-
ference should occur to the holes in the
rear flange and the outer surface of
the spool, internal leaks will occur
101
after assembly, ultimately Fig. 1-76 Inserting spool (123)
deteriorating the performances of the
travel motor.
34-75
3) Assemble plug (165) into rear flange (101)
and tighten it up to a specified torque.
34-76
2) Install two parallel pins (142) to spindle (2). 101
109 (141)
113
4) Align two parallel pins (142) set in spindle (2)
with the pin holes of the rear flange and
install rear flange (101) to spindle (2).
205
4) Put shim (205) to plug (204).
34-77
z Piston seal (221) consists of an O
ring and a Teflon ring.
z Coat piston seal (221) with grease.
z Put in the O ring and the Teflon PISTON SEAL (221)
ring, in that order, when attaching
piston seal.
VALVE (201)
201 202
Fig. 1-85 Inserting valve (201)
6) Insert valve (201), spring (206), spring
retainer (203) in sleeve (202), and install plug
(204) in which shim (205) is placed to the
specified torque.
: 10mm, 202 206
Tightening torque : 8kgfym (58 lbfyft)
204 202
34-78
8) Install the assembled sleeve (202) to body 202 212
(212) to the specified torque.
z Fix it with vise to make tightening Fig. 1-88 Fixing sleeve (202)
work easier.
216 212
Fig. 1-90 Inserting ball (216)
12) Install two plugs (215) to body (212) to the
specified torque.
: 6mm
Tightening torque : 3kgfym (22 lbfyft)
34-79
zCoat piston (213) with hydraulic oil 212
and put it in. To set piston (213),
align the hole of body (212) with the
axis of the piston. (in order to
prevent the body hole from being
scored by contact)
z Do not change the pairing of piston
(213) and body (212) as they are shop
fitted.
4) Put ball (36) in the hole of input gear (6). Eye bolt
34-80
3) Match the bolt holes in cover (8) to the tapped
holes in hub (1).
4) Tighten ten socket bolts (35) to a specified
torque. 35
: 10mm,
Tightening torque: 10.4kgfym (75.2 lbfyft)
33
34-81
1.4.4 THE SPECIFIED PRE-LOAD MUST BE
APPLIED TO BEARING (21)
3) Since the dimension “B” of the bearing pre- Fig. 1-100 Determining clearance “C”
load adjusting jig is known, determine the
clearance “C” by the following formula :
A : Actual value
“C”=“A”-“B” B : Dimensions of jig body
C : Dimension to be
specified
34-82
4) Then determine dimension “D” of hold D Surface E
flange (3).
34-83
1.4.5 PROCEDURE OF AXIAL CLEARANCE
ADJUSTMENT OF BEARING (22) Retainer (Ⅳ)
5) Thickness measurement of snap rings Fig. 1-104 Installing snap ring satisfying
z Set thickness of snap ring (max.) the set thickness
Thickness of Thickness of
MAX.= thickness + presently set
gauge snap ring
34-85
1.5 SERVICE STANDARDS
1.5.1 SERVICE STANDARDS FOR PARTS
(1) Replace all seals (O ring, oil seal, floating seal) once used even if no damage is seen.
Item
No. Parts Trouble Reference value Allowable value
Spindle kit
(2) Spindle z Severe damage to
(3) Hold flange appearance
(19) Reamer bolt z Abnormal wear such as
scoring is present.
RV gear assy
(4) RV gear (A) z The RV gear tooth surface
(5) RV gear (B) shows uneven wear.
(9) Crankshaft z Crankshaft-related parts
(22) Taper roller bearing do not move smoothly when
(23) Needle roller bearing crankshaft (9) is turned.
34-86
Item
No. Parts Trouble Reference value Allowable value
34-87
1.5.2 PERFORMANCE INSPECTION
z After completing the maintenance, carry out the performance inspection in the following procedure
2) Test procedure
Mounting ............ Install motor in body (sprocket section), and connect pipe.
1
hydraulic motor
However, don’t install crawler.
and piping
[To carry out performance test of motor (No load)]
Note : 1. Connect pipes so that pressure gauge is installed,
and the drain rate of hydraulic motor can be
measured.
2. Never use hammer to mount motor, but mount it
using bolts holes softly.
3 Performance inspection
of motor
Warming up ............Warm up motor until the temperature rises to the following temperature
1 z Hydraulic oil temp 45~55℃ (113~131°
F)
z Reduction unit outer temp. 40~80℃ (104~176°
F)
Performance test.... Measure the following items, and determine if it is allowable or not.
2 Allowable standard-Hydraulic motor drive pressure 16kgf/cm2 (228psi) or less at 10rpm
(1st-speed) Hydraulic motor drain rate 1.2 (0.32gal) / min. or less at 10rpm
34-88
1.6 TROUBLESHOOTING
Relief set pressure is low. …… Set it correctly.
Motor does
not start. Brake valve is out of order. …… If spool or valve is seized,
replace it. On other cases,
repair.
Machine slides down on a Internal leakage from brake …… Replace brake valve.
slope. valve increased (Replace rear flange.)
34-89
Gear oil is short. …… Refill to a proper level.
Surface temperature of
reduction unit casing is Pitching occurs to bearing. …… Replace motor with reduction
high. unit.
Abnormal sound is heard. Motor or reduction unit is broken. …… Replace motor with reduc-
tion unit.
34-90
Speed does not change from High speed select check valve …… Inspect.
low to high. does not operate properly Repair or replace if necessary.
Speed does not change from Select valve does not operate …… Check if spool is normal and
high to low. properly. repair or replace if necessary.
34-91
NOTE
34-92
SECTION 41 TROUBLESHOOTING (MECHATRO CONTROL)
TABLE OF CONTENTS
Electric Hydraulic
P1 Pump proportional
P2 Pump proportional
Low pressure sensor
proportional valve
Proportional valve
proportional valve
proportional valve
Actuator
Solenoid valve
Solenoid valve
Solenoid valve
P1 bypass cut
P2 bypass cut
valve
Swing motor
Travel right
E E E S S S S V V V S S
Travel left
│ │ │ V V V V │ │ │ V V
Bucket
Bucket
22 23 1 │ │ │ │ 1 3 4 │ │
Swing
Boom
~
Boom
valve
Arm
A B C D
Arm
Operating condition 1 2
10
Bucket digging ○ ○ ○ ○ ○ ○
Bucket dump ○ ○ ○ ○ ○ ○
Swing operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Travel LH / RH operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(1st. speed)
Travel LH / RH operation ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(2nd speed)
41 -2
3. TROUBLESHOOTING OUTLINE ; MECHATRO CONTROL
OPERATING Pilot secondary pressure Pressur sensor Pump proportional valve Proportional valve
Max ; 700mA
41-3
4. CHECK POINTS FOR MECHATRO SYSTEM (FOR TROUBLESHOOTING)
4.1 ATTACHING POSITION OF SENSOR AND ELECTRIC EQUIPMENTS
(1) Position of under floor harness and proportional valve block
SAFETY LOOK LEVER SOL. (SV-4)
TRAVEL STRAIGHT PSV. (PSV-C) TO INST-HARNESS
OPT. EXTRA P1 BY-PASS CUT PSV. TRAVEL TWO-SPEED SOL. (SV-3)
PRESS. SENSOR (PSV-D)
(P1 OPT.) (SE-20)
P2 BY-PASS
CUT PSV. (PSV-B)
ARM VALUABLE
RECIRCULATION PSV.
(PSV-A)
PRESS, SENSOR
(TRAVEL LEFT) (SE-10)
PRESS, SENSOR
(TRAVEL RIGHT) (SE-9)
OPT. N&B
PRESS. SENSOR
(P2 OPT.) (SE-11)
PROPORTIONAL SOL.
(PUMP P1) (PSV-P1)
PROPORTIONAL SOL.
(PUMP P2) (PSV-P2)
41-4
(3) Attaching position of low pressure sensor Tightening torque Tightening torque
3.5kgfy m (25 lbsy ft ) 3.5kgfy m (25 lbsy ft )
(SE-2) BUCKET DUMP (SE-3) BOOM UP
Tightening torque
3.5kgfy m (25 lbsy ft ) Tightening torque
(SE-5) SWING L&R 3.5kgfy m (25 lbsy ft ) Tightening torque
(SE-7) ARM IN 3.5kgfy m (25 lbsy ft )
(SE-4) BOOM DOWN
VIEW Ⅰ
Tightening torque
3.5kgfy m (25 lbsy ft )
(SE-1) BUCKET DIGING
Ⅱ
Tightening torque
3.5kgfy m (25 lbsy ft )
(SE-8) ARM OUT VIEW Ⅱ
41-5
4.2 EQUIPMENT
(1) Solenoid proportional valve block
4 3 1
T
T
Tightening torque P1
0.7±0.07kgfym
(5±0.5 lbsy ft ) D C B A
HYDRAULIC SYMBOLS
4 3 1
P1
D C B A
P1
TERMINAL NO.
1-COMMON
2-OUT PUT (+)
3-POWER SUPPLY (+)
19×21.9 HEX
HEX 22
VIEW A
O RING P11 O RING P14
PF3/8
PF1/4
41-6
SECTION 42 TROUBLESHOOTING (HYDRAULIC)
TABLE OF CONTENTS
Reduction parts
Bucket cylinder
Right shockless
Right shockless
Bucket digging
Boom lowering
E/G revolution
Boom cylinder
Parking brake
Parking brake
Left shockless
Left shockless
Bucket dump
Shuttle valve
Boom raising
Arm cylinder
Bypass valve
Bucket spool
Travel spool
Swing spool
Swivel joint
Boom spool
Pilot pump
Classification
Lock valve
Arm spool
P1 pump
P2 pump
Arm out
Group No.
Arm in
Motor
Trouble
Device No. 1 2 3 4 5 6 7 8 9 10 11
No operation is possible. ○ ○ ○ ○ ○ ○ ○
(1) Machine operates freely even
though lever is in neutral. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
All actions ○ ○ ○ ○ ○ ○
Speed is low.
Up ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in conflux ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm out conflux ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Power lacks.
All motions ○ ○ ○ ○ ○ ○
Bucket digging and dump ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(3)
Boom Up ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Hydraulic systems
Arm in ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Bucket digging ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Fine operation
impossible.
Boom Up&Down ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
(4)
Swing ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Arm in and out ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Travel 1, 2 speed change
(5) impossible ○ ○ ○ ○
Travel operation
42 -1
2. TROUBLESHOOTING
(1)-1
No operation is possible.
NO
The primary pressure of pilot pump is about 50kgf/cm2 (710psi). Inspect or replace pilot pump and pilot relief valve.
YES
NO
The pilot valve P port inlet pressure is approx. 50kgf/cm2 (710psi). Inspect or replace lever lock solenoid valve.
YES
NO
The secondary pressure of pilot valve is approx. 50kgf/cm2 Inspect or replace pilot valve.
42-2
(1)-2
NO
Pump NO The secondary pilot pressure of the system YES Inspect or replace pilot
delivery that is moving freely is generated when the
pressure in lever is in neutral. valve.
unloaded
NO
condition is
approx. The spool returning spring of the circuit that YES Inspect or replace spool
is moving freely is broken. assy and pilot cover.
5kgf/cm2
(71psi)or NO
lower. The spool of the system that is operating NO The outer YES
circumference of Replace spool assy.
YES freely moves smoothly by hand. (Remove
pilot cover.) spool is scratched.
NG
YES NO
Replace control valve.
Pilot pressure at ports PCa, PCb (P1, P2 YES Inspect or replace the proportional valve for bypass cut
bypass cut valve) is approx. 5.5kgf/cm2 valve that is defective.
(78psi).
NG
NO
Inspect or replace proportional valve block.
Return spring of bypass cut valve spool is YES Inspect or replace bypass cut valve spool assy and pilot
broken. lid.
NO
Bypass cut valve spool moves smoothly by NO Spool is scored on YES Replace bypass cut valve
hand. (together with P1 and P2 bypass cut inspection. spool assy.
valves)
NO NG
YES
Replace control valve.
Spool of the circuit that operates freely is scored on inspection. Replace spool assy.
NO Inspect or replace NG Inspect the cylinder of the circuit that NG Inspect or replace control
overload relief valve. operates freely and replace if faulty. valve.
(Inside leak)
42-3
(2)-1
All attachment motions are slow.
(Service diagnosis)
Command current readings of pump NO The sum of pump NO To electric
proportional valve are at standerd levels(below) pressures(P1+P2)during check
during operation. troubleshooting.
operation is
P1 ; approx. 645mA by bucket operation, ※1 460kgf/cm2 (6540psi).
P2 ; approx. 645mA by swing operation, ※2
YES Inspect or replace boost
YES check, bypass check piping.
Do motions get normal if the coupler(PSV-C) for YES
travel straight proportional valve is To electric troubleshooting.
disconnected?
NO
NO Inspect or replace pilot pump
Primary pilot pressure is 50kgf/cm2 (710psi). and pilot relief valve.
YES
Secondary pilot pressure at PTb port (travel YES Inspect or replace travel
straight) is approx. 5.7kgf/cm2 (81psi). straight proportional valve.
NO NG
Inspect or replace
proportional valve block.
Main relief pressure lies within standard level NO Inspect or replace main relief NG Replace control valve or
P1,P2 ; 350kgf/cm2 (4980psi), ※3 valve. pump.
YES
42-4
(2)-2
NO
Secondary pilot pressure at PBc, PAc ports (bucket NO
digging and dump ports) is 50kgf/cm2 (710psi). Inspect or replace pilot valve.
YES
(Service diagnosis) Pump pressure during check operation lies
Command current readings of pump NO within standard value(below). YES To electrical
proportional valve are within standard P1 ; digging approx 50kgf/cm2(710psi) troubleshooting.
levels(below) during full lever operation. dump approx 150kgf/cm2(2130psi)
655mA in bucket operation, ※1 P2 ; approx 5kgf/cm2(71psi)
YES
NO Inspect or replace boost NG
Inspect or replace control valve.
check, bypass check piping.
Relief pressure lies within standard levels(below) Inspect overload relief valve
NO Relief pressures for both YES
when bucket operation is changed. digging and dump operations on the faulty pressure side
350kgf/cm2(4980psi), ※2 are abnormal. and replace valve if defective.
YES NO Confirm the check valve
before main relief valve for NG
control valve. Check the seat Replace control valve.
of it as well. (CMR1,CMR2)
YES
Return spring for bucket spool is broken. Replace bucket spool assy.
NO
Bucket spool moves smoothly by hand. (Remove NO Outer circumference of YES
pilot cover.) Replace bucket spool assy.
bucket spool is scored.
YES NO NG
Replace control valve.
YES
Replace control valve.
Note ; ※1~※2 marked show E135SR EVOLUTION. Inspect bucket cylinder for oil
tightness and replace if
In the case of E115SR EVOLUTION values are ※1 ; 640mA defective.
and ※2 ; 330 kgf/cm2 (4690psi).
42-5
(2)-3 Service Diagnosis 26 ; mechatoronic (C-1) controller
Only the boom raise motion is slow.
(Service diagnosis 26)
Control current of P2 bypass cut proportional NO
valve is approx. 670mA when full lever To electric troubleshooting.
operation is performed for boom raise motion.
YES
Secondary pilot pressure at port PCa (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi). cut proportional valve. proportional valve block.
YES
Pilot pressure at PAb, PB1 ports (boom raise NO Inspect or replace ATT pilot
and boom conflux) is 50kgf/cm2 (710psi). valve.
YES
Does the pump delivery
(Diagnosis 24,25)
pressure lie at normal levels
Command current readings for pump NO during check operation? NO
To electric troubleshooting.
proportional valve lie within standard levels Normal values for P1 & P2 ;
(below) during the above operation. approx. 130kgf/cm2(1850psi)
P1 ; approx. 650mA, ※1 YES
P2 ; approx. 650mA, ※2 Hasn't the weight changed by NO Change ATT to normal one
YES the change of ATT's? and reconfirm.
YES
Inspect or replace boost NG Inspect or replace control
check, bypass check piping. valve.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut valve spool moves smoothly by
bypass cut valve spool is assy.
hand. (Remove pilot cover.)
scored.
YES NG
NO
Replace control valve.
Return spring of boom spool is broken. YES Inspect or replace boom spool
(Remove pilot cover.) assy and pilot cover.
NO
Boom spool moves smoothly by hand. NO Outer circumference of boom YES
Replace boom spool assy.
(Remove pilot cover.) spool is scored.
YES NO NG
Replace control valve.
42-6
(2)-4
Motions other than boom down are slow.
(Service diagnosis 22)
Control current for travel straight proportional
valve is approx. 350mA. NO
To electric troubleshooting
(Are the motions slow if coupler (PSV-C) for travel
straight proportional valve is disconnected?)
YES
Pilot pressure at port PTb (travel straight) is YES Inspect or replace travel NG Inspect or replace
approx. 5.7kgf/cm2(81psi). straight proportional valve. proportional valve block.
NO
Inspect or replace travel
YES
Return spring for travel straight spool is broken. straight spool assy and pilot
cover.
NO
Outer circumference of travel YES
Travel straight spool moves smoothly by hand. NO Replace travel straight spool
straight spool is scored.
(Remove pilot cover.) assy.
YES NO NG
Replace control valve.
42-7
(2)-6
Only arm out operation is slow.
Return spring of P1 bypass cut valve spool is NO Inspect or replace P1 bypass cut
broken. valve spool assy and pilot cover.
YES Outer circumference of P1
P1 bypass cut valve spool moves smoothly by NO YES Replace P1 bypass cut valve
bypass cut valve spool is
hand.(Remove pilot cover.) scored. spool assy.
YES NO NG
Replace control valve.
42-8
(3)-1
All ATT operating power is poor.
(3)-2
Bucket digging power is poor.
42-9
(3)-3
Boom up operating power is poor.
42-10
(3)-4
Arm in power is poor.
YES
Arm variable recirculation spool return spring is YES Inspect or replace arm spool
broken. assy and pilot cover.
NO
NO Outer circumference of arm YES Replace arm variable
Arm variable recirculation spool moves smoothly
variable recirculation spool is recirculation spool assy.
by hand. (Remove pilot cover.)
scored.
YES NG
NO
Replace control valve.
42-11
(4)-1
Machine can not perform fine operation of bucket digging and dump.
NO
Unload pressure of P1 NO No-load independent operating NO Refer to “Only bucket
pump is less than 5kgf/cm2 speed is within a standard
motion is slow.”.
(71psi) when bucket digging value.
lever is at neutral.
YES
YES Secondary pilot pressure at
port PCb (P1 bypass cut valve) YES Inspect or replace P1 NG Inspect or replace
bypass cut proportional
is approx. 5.7kgf/cm2 (81psi) proportional valve block.
valve.
when lever is at neutral.
NO
P1 bypass cut spool return YES Inspect or replace P1 bypass
spring is broken. cut spool assy and pilot cover.
NO
P1 bypass cut spool moves NO Outer circumference of YES Replace P1 bypass cut
smoothly by hand. (remove P1 bypass cut spool is
spool assy.
pilot cover.) scored.
NG
YES NO
Replace control valve.
42-12
(4)-2
Machine can not perform fine operation of boom up and down motions.
YES NO NG
Replace control valve.
YES
Replace control valve.
42-13
(4)-3
Machine can not perform fine swing operation.
NO
Secondary pressure of swing pilot valve is approx. 6kgf/cm2 YES Inspect or replace swing NG Inspect or replace
(85psi), while pilot pressure of parking brake solenoid valve is parking solenoid valve. proportional valve
0kgf/cm2 (0psi).
block.
NO
Unload pressure of P2 Pilot pressure of port PCa (P2
pump is approx. 5kgf/cm2 NO bypass cut valve) is approx. YES Inspect or replace NG Inspect or replace
proportional valve for
(71psi) or less when swing 5.7kgf/cm2 (81psi) when swing proportional valve
P2 bypass cut valve.
lever is at neutral. lever is at neutral. block.
YES NO
Return spring for P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES Replace P2 bypass
smoothly by hand. (Remove P2 bypass cut spool is
cut spool assy.
pilot cover.) scored.
NG
YES NO
Replace control valve.
NO
Swing spool moves NO Outer circumference of swing YES
smoothly by hand. spool is scored. Replace swing spool assy.
YES NO NG
Replace control valve.
42-14
(4)-4
NO
P2 pump unload pressure is NO Secondary pilot pressure at NO Inspect or replace NG Inspect or replace
less than 5kgf/cm2 (71psi) port PCa (P2 bypass cut valve) proportional valve for proportional valve
when arm lever is at is approx.5.7kgf/cm2 (81psi). P2 bypass cut valve. block.
neutral.
YES
YES Return spring of P2 bypass cut YES Inspect or replace P2 bypass
spool is broken. cut spool assy and pilot cover.
NO
P2 bypass cut spool moves NO Outer circumference of YES Replace P2 bypass
smoothly by hand. P2 bypass cut spool is
cut spool assy.
(Remove pilot cover.) scored.
NG
YES NO
Replace control valve.
NO
Arm spool moves smoothly NO Outer circumference of arm YES
by hand. spool is scored. Replace arm spool assy.
YES NO NG
Replace control valve.
(5)
Travel 1st and 2nd speeds can not be changed over.
42-15
(6)
Travel independent speed is low.
YES NO NG
42-16
(7)
Travel power is poor.
YES
(Service diagnosis 22)
Command current for travel straight NO
To electrical troubleshooting.
proportional valve is approx. 350mA.
YES
YES Since the delivery rate of pump is small and travel speed is
Power lack is felt on a steep slope or in
low in heavy duty condition, power lack is felt in some cases,
muddy fields.
but it is normal.
NO
Is the secondary pilot NO Inspect or replace travel pilot
pressure for travel approx.
valve.
24kgf/cm2 (340psi)?
YES
Is a pivot turn possible? NO Pilot pressure at port PTb NO Inspect or replace NG Inspect or replace
(travel straight valve) is travel straight proportional valve
(in both directions)
approx. 5.7kgf/cm2 (81psi). proportional valve. block.
YES
YES
YES Inspect or replace travel
Return spring of travel straight
straight spool assy and pilot
spool is broken.
cover.
NO
Travel straight spool moves NO Outer circumference of YES Replace travel
travel straight spool is
smoothly by hand. straight spool assy.
scored.
YES NO NG
Replace control valve.
YES NO NG
Replace control valve.
Relief pressure lie within
standard value in both NO Inspect or replace travel
travel speeds. motor relief valve.
350kgf/cm2 (4980psi), ※1
YES
Inspect or replace travel
motor.
42-17
(8)-1
Machine does not travel straight.
(8)-2
Machine deviates in travel independent motion.
In idle run, the right and the left crawlers rotate Does the machine deviates in
NO NO Inspect or replace control
at different speeds. (H-mode, Hi idle, opposite direction if delivery valve.
1st-speed) ports are exchanged?
YES YES
Pump pressure for P1 and P2
Current readings for travel straight NO lies within NO Inspect or replace control
proportional valve(PSV-C) for both P1 and P2 valve.
50~70kgf/cm2 (710~1000psi)
are approx.670mA during travel idling.
YES YES
Secondary pilot pressure for NO Inspect or replace travel pilot
travel is 24kgf/cm2 (340psi). valve.
YES
To electrical troubleshooting.
42-18
(9)
Machine drifts on a slope. (Machine can not be held on a slope.)
Machine can not be held on a slope when engine YES Inspect or replace travel
is off. motor.
NO
Secondary pilot pressure for travel is 0kgf/cm2 NO Inspect or replace remote
(0psi). control valve.
YES
YES Inspect or replace travel spool
Return spring of travel spool is broken. assy and pilot cover.
NO
NO Outer circumference of travel YES
Travel spool moves smoothly by hand. spool is scored. Replace travel spool.
YES NO NG
Replace control valve.
42-19
(10)
Swing motion dose not work.
NO
Is the pilot pressure of parking SOL reduce to NO Inspect or replace swing NG
0kgf/cm2 (0psi)when the secondary pressure of Inspect or replace
pilot valve is 6kgf/cm2(85psi)? . parking solenoid. proportional valve block.
Secondary pressure of swing pilot valve is NO Dirt or something is stuck in YES Inspect or replace slow return
the restrictor of slow return valve.
50kgf/cm2(710psi) for both ways.
valve.
YES NO
Inspect or replace pilot valve.
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
NO Outer circumference of swing YES
Swing spool moves smoothly.(Remove pilot cover.) Replace swing spool assy.
spool is scored.
YES NO NG
Replace control valve.
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi), ※1 motor relief.
YES NG
42-20
(11)
Swing speed is slow.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned Inspect or replace slow return
the restrictor of slow return
to the full in either direction. valve.
valve.
YES NO NG
Secondary pilot pressure at PCa port (P2 bypass NO Inspect or replace P2 bypass NG Inspect or replace
cut valve) is approx. 25kgf/cm2 (360psi) when
cut proportional valve. proportional valve block.
swing lever is shifted to the full.
YES
YES Inspect or replace P2 bypass
Return spring of P2 bypass cut spool is broken. cut spool assy and pilot cover.
NO
NO Outer circumference of P2 YES Replace P2 bypass cut spool
P2 bypass cut spool moves smoothly by hand.
bypass cut spool is scored. assy.
YES NO NG
Replace control valve.
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi), ※1
motor relief.
YES NG
Machine drifts very much when swing parking YES Inspect or replace swing
is released (arm in action) on a slope. motor.
NO
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
NO Outer circumference of swing YES
Swing spool moves smoothly. Replace swing spool assy.
spool is scored.
YES NO NG
Replace control valve.
42-21
(12)-1
Swing power is poor.
Secondary pilot pressure for swing motion is NO Dirt or something is stuck in YES
approx. 50kgf/cm2 (710psi) when lever is turned the restrictor of slow return Inspect or replace slow return
to the full in either direction. valve. valve.
YES NO
Inspect or replace pilot valve .
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi), ※1 motor relief.
YES NG
Machine drifts very much when swing parking YES Inspect or replace swing
is released (arm in action) on a slope. motor.
NO
The pressure at the P/B(PG) port of swing motor NO Inspect or replace P2 bypass NG
is 50kgf/cm2(710psi) when swing lever is turned Inspect or replace
cut proportional valve. proportional valve block.
to the full or during arm in action.
YES
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
NO Outer circumference of swing YES
Swing spool moves smoothly.(Remove pilot cover.) spool is scored. Replace swing spool assy.
YES NO NG
Replace control valve.
42-22
(12-2)
Swing motion drifts very large.
Swing relief pressure lies within standard level. NO Inspect or replace swing
285kgf/cm2(4050psi), ※1
motor relief valve.
YES
Macine can be held on a slope during swing NO Replace the lining of swing
motion. motor parking brake.
YES
Machine drifts very much when swing parking YES Inspect or replace swing
is released (arm in action) on a slope. motor.
NO
42-23
(13)-1
Swing parking is not held on a slope.
(13)-2
Abnormal sound is heard
during swing motion.
Abnormal sound occurs during swing relief YES Inspect or replace swing
action. motor relief valve.
NO
YES Inspect or replace swing
Abnormal sound occurs when swing motion stops.
shockless valve.
NO
Swing relief pressure lies within standard level. Control current for P2
NO bypass cut proportional valve NO
285kgf/cm2(4050psi), ※1 To electrical troubleshooting
is approx. 585mA.
YES
YES
Pressure at P2 bypass cut port PCa
NO Inspect or replace NG Inspect or replace
is about 20kgf/cm2(280psi)during P2 bypass cut proprotional valve
swing operation. proprotional valve. block.
YES
Main relief pressure lies YES Inspect or replace NO Inspect or replace
within standard level. swing motor relief
swing motor.
350kgf/cm2(4980psi), ※2 valve.
NO
Outer circumference of P2 YES Inspect or replaceP2 bypass
cut valve spool is scored. cut valve spool assy and pilot
cover.
NO
P2 bypass cut spool moves
smoothly by hand.
YES Inspect or replace main relief
(Remove pilot cover) valve.
NO
Outer circumference of P2 YES Replace P2 bypass cut valve
bypass cut valve spool is
spool assy.
scored.
NO NG
Replace control valve.
YES Inspect or replace swing spool
Return spring of swing spool is broken.
assy and pilot cover.
NO
Swing spool moves smoothly by hand. NO Outer circumference of swing YES
(Remove pilot cover) spool is scored. Replace swing spool assy.
YES NO NG
Replace control valve.
Note ; In the case of E115SR EVOLUTION value are ※1 ; 265kgf/cm2 (3770psi) and ※2 ; 330kgf/cm2
42-24
SECTION 43 TROUBLESHOOTING (ELECTRIC)
TABLE OF CONTENTS
(9)
(8)
(7)
(6)
(5)
(4)
(3)
(2)
(1)
(14)
Fine operation
Power is poor Speed is slow
impossible
changed
impossible.
slow.
slow.
slow.
slow.
Arm in
Boom up
All operate
All operate
lever is at neutral.
Bucket digging
Bucket digging
○
○
○
○
○
Boom up pressure sensor
3 6
2 5
1 4
・ ・
・ ・
Boom down pressure sensor
9
8
7
・
・
○
○
Arm in pressure sensor
・
・
12
11
10
○ ○
○ ○
○ ○
○ ○
○
○ ○
○ ○
Arm out pressure sensor
・
・
15
14
13
Bucket digging pressure sensor
・
・
18
17
16
・
・
21
20
19
○
○
○
○
○
○ ○ ○ ○ ○ ○ ○
○
○
○
Swing pressure sensor
・
・
27
26
25
○
Travel right pressure sensor
Operation pressure sensor
・
・
30
29
28
○ ○ ○ ○ ○ ○ ○ ○ ○
Travel left pressure sensor
・
・
33
32
TROUBLE DIAGNOSIS TABLE; ELECTRIC
Accelerator potentio
Accel motor start point indexing LS
○ ○
○ ○
○ ○
○ ○
P2 pump pressure sensor
3 6 9
2 5 8
・ ・ ・
・ ・ ・
Alternator voltage
○
Key SW ON
Key SW GLOW
CN-12
○
Travel 1-2speed SW
○
○
○
Swing P/B release SW
KPSS release SW
Power supply & other signal
・
21
・
・
Offset left
6
5
4
・
・
Offset right
CN-13
○ ○
○ ○
1
Overload sw.
6
C1 mechatro controller
27
26
Gauge cluster
Sealed grounding
2
11 13 15 16 25 28 1
・
Sealed grounding
5
4
・
○
○
○
○ ○
Battery relay
・
26
6 8 10 12 14 15 17 19 21 22 24 25
4
3
・
Timer relay
43-1
Electrical equipments
Proportional valve C D E L M R
Governor motor
Air compressor
Receiver dryer
Washer motor
Gauge cluster
Speaker right
Starter motor
Flasher relay
Battery relay
Power socket
Travel alarm
Wiper motor
Rotary light
Safety relay
Timer relay
Hourmeter
Room light
Horn relay
Glow relay
Alternator
Fuse box
Resistor
Battery
Battery
Diode
Horn
Group No.
P P P P P P B C C D D D D D E E E E E E E E E E E E E E E L L L L L L L L L M M M M M M R R R R R R R R R R R R
Trouble S S S S S S 1 2 4 1 2 3 4 5 1 2 3 4 6 7 8 9 10 11 14 15 16 17 25 1 2 3 4 8 9 10 11 15 1 2 3 4 9 11 1 3 4 5 6 7 8 10 11 18 19 20
System
V V V V V V ・ ・ ・
Pin │ │ │ │ │ │ 5 5 12
No. A B C D P P ・
1 2 6
・
7
No motions operate. ○ ○ ○
(1) Machine moves freely when lever
is at neutral. ○ ○
All operate ○ ○ ○
Only bucket speed is slow. ○
Speed is slow
Bucket digging
(3)
Boom up
Arm in ○
○
Fine operation
Bucket digging
impossible
(4)
Electric systems
ATT swing)
(14)
43-2
Electrical equipments
SE SV SW
Single/Conflux select SW
Work light switch (OPT)
Option ; Offset
Option ; Extra
Horn switch
Travel right
Boom down
Fuel sensor
Accelerator
Key switch
A/C switch
Levolution
Travel left
filter clogging
Boom up
Arm out
Arm in
Group No.
S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S S
Trouble
System
E E E E E E E E E E E E E E E E E E E V V V W W W W W W W W W W W W W W W W W W W W W W
Pin 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 20 22 23 26 1 3 4 1 3 4 5 6 10 11 13 16 17 20 21 22 23 30 32 37 38 39 42 43 44
No. ・ ・
11 7
・
8
No motions operate. ○ ○ ○ ○
(1) Machine moves freely when lever
is at neutral. ○ ○ ○ ○
All operate
Bucket digging
(3)
Boom raising
Arm digging
○ ○
Fine operation
Bucket digging
impossible
(4)
Electric systems
ATT swing)
(14)
43-3
2. SELF DIAGNOSIS TABLE 3. SERVICE DIAGNOSIS TABLE
The self diagnosis detects errors in the control I/O´s of the pressure sensors and the proportional valves The results of service diagnosis at this time point are displayed in up to 22 items according to data
while the machine is in operation and shows them on the multi display of the gauge cluster. from the mechatro controller.
Displaying procedure:
DISPLAY ITEM
1) Turn“ON”the starter switch with the buzzer stop switch pressed.
No Contents Display of monitor No Contents Display of monitor 2) A mechatro controller parts number and a program version are displayed as the No.1 item.
3) The display advances like No.2, No.3.... each time the screen change switch is pressed.
P1 by-pass cut propo-
1 Mechatro controller fail 16 4) The display returns like No.40, No.39... each time the buzzer stop switch is pressed.
valve fail
5) The display does not disappear unless the starter switch is turned“OFF”.
P2 by-pass cut propo-
2 ROM data 17
valve fail
E135SR LC EVOLUTION E115SR EVOLUTION
Travel priority propo-
3 Mechatro set error 18 No.1 No.1
valve fail
MAIN CONTROLLER P/No. MAIN CONTROLLER P/No.
Boom up pressure Arm variable recircula- PROGRAM VERSION PROGRAM VERSION
4 19
sensor fail tion propo-valve fail VER 5.20 VER 5.20
Multi display
Boom down pressure Pump P1 pressure
5 20
sensor fail sensor fail Screen change sw.
Arm in pressure sensor Pump P2 pressure Buzzer stop sw.
6 21 SERVICE DIAGNOSIS DISPLAY
fail sensor fail
No. DISPLAY No. DISPLAY No. DISPLAY No. DISPLAY
Arm out pressure sensor Travel two-speed No.1 No.8 No.14 No.24
7 22 MAIN CONT. P/No. RELAY PRESS. SENSOR PROPO-VALVE
fail solenoid valve fail
YV22E00008F1 I-2 BAT. RELAY C-1 PUMP P1 E-1 P1 PUMP
Bucket digging pressure Swing parking solenoid 1 or 8 COMP. OFF 14 3.4V 350k 24 COMP. 727mA 29k
8 23 YY22E00022F1 MEAS. OFF C-2 PUNP P2 MEAS. 727mA 29k
sensor fail valve fail PROGRAM VER KEY SWITCH OFF 3.4V 350k POWER SHIFT 100mA
VER 5.20
Bucket dump pressure Governor motor current No.2 No.9 No.15 No.25
9 24 E/G SET 2310 PRESS. SENSOR PRESS. SENSOR PROPO-VALVE
sensor fail fail
MEAS 2310 B-1 BOOM UP B-16 P1 OPT. E-2 P2 PUMP
Swing right pressure Governor motor starting 2 E/G PRS. LIVE 9 4.9V 30k 15 4.9V 30k 25 COMP. 727mA 29k
10 25 KPSS SW H B-2 BOOM DOWN B-17 P2 OPT. MEAS. 727mA 29k
sensor fail point indexing fail 4.9V 30k 4.9V 30k POWER SHIFT 100mA
43-4
4. TROUBLESHOOTING
(1)-1
No motions operate.
Note: (1)-1 matches the Groupe No.
Inspect if there is no
disconnection in fuse box.
43-5
(1)-2
NO
Replace ATT pilot valve.
43-6
(2)-2
Only bucket motion is slow.
NO
Arm in pilot pressure is approx. 35kgf/cm2
YES
(500psi) or over when arm in lever is shifted Inspect ATT pilot valve.
to the full.
NO To hydraulic
(2)-6 troubleshooting
Only arm out motion is slow.
Fine operation of bucket digging and dump motions can not be performed.
43-8
Continued from P8. Continued from P8.
YES NO
Arm out operation pressure YES Trouble disappears if arm YES Arm out operation
sensor (SE-8) shows approx. out operation pressure pressure sensor (SE-8) is
1.3V or over when lever is at sensor (SE-8) is replaced. faulty.
neutral.
NO
NO Arm out pilot pressure is
YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
when lever is at neutral.
Inspect harness between
NO arm out operation pressure
sensor (SE-8) and
C-1 controller.
NO
(4)-2 Replace C-1 controller.
(Service diagnosis No. 9) (”P1 bypass cut proportional valve” is displayed on the guage cluster.)
Boom up (down) Trouble gets normal if
operation pressure NO connector of P1 bypass cut NO To hydraulic
sensor shows 0.7V proportional valve troubleshooting
or over when lever (PSV-D) is disconnected.
is at neutral.
YES (Service diagnosis No.10)
YES Arm in operation pressure
Trouble disappears if arm in YES Arm in operation pressure
sensor (SE-7) shows approx. YES
operation pressure sensor
1.3V or over when lever is sensor (SE-7) is faulty.
(SE-7) is replaced.
at neutral.
NO
NO Arm in pilot pressure is
6kgf/cm2 (85psi) or over YES
Inspect ATT pilot valve.
when lever is at neutral.
NO Inspect harness between
arm in operation pressure
sensor (SE-7) and
(Service diagnosis No.10)
C-1 controller.
Arm out operation pressure Trouble disappears if arm
sensor (SE-8) shows approx. YES out operation pressure YES Arm in operation pressure
1.3V or over when lever is sensor (SE-8) is faulty.
sensor (SE-8) is replaced.
at neutral.
NO
NO
Arm out pilot pressure is YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
when lever is at neutral.
Inspect harness between
NO arm in operation pressure
sensor (SE-8) and
C-1 controller.
NO
Arm in pilot pressure is
YES
6kgf/cm2 (85psi) or over Inspect ATT pilot valve.
when lever is at neutral.
Trouble gets NO
Replace C-1 controller.
normal if
connector of NO To hydraulic
swing parking troubleshooting
solenoid (SV-1) is
disconnected.
YES
43-10
(4)-4
Fine operation of arm in and out motions is not possible.
NO NO
Boom up pilot pressure is
YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
when lever is at neutral.
NO Inspect harness between
boom up operation
(Service diagnosis No.10) pressure sensor (SE-3) and
Arm out operation pressure C-1 controller.
Trouble disappears if arm
sensor (SE-8) indicates 1.3V YES YES Arm out operation
out operation pressure
or over when lever is at pressure sensor (SE-8) is
sensor (SE-8) is replaced.
neutral. faulty.
NO
NO
Arm out pilot pressure is YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
when lever is at neutral.
NO Replace C-1 controller.
Arm in operation pressure
sensor (SE-7) indicates 1.3V YES Trouble disappears if arm in YES Arm in operation pressure
operation pressure sensor
or over when lever is at sensor (SE-7) is faulty.
(SE-7) is replaced.
neutral.
NO NO
Arm in pilot pressure is more YES
than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
lever is at neutral.
NO
Replace C-1 controller.
43-11
(5)
Travel 1-2 speeds can not be changed.
43-12
(6)
NO NO
Bucket digging pilot pressure is YES
more than 6kgf/cm2 (85psi) when Inspect ATT pilot valve.
lever is at neutral.
NO Replace C-1 controller.
(Service diagnosis No.11)
Bucket dump operation pressure
YES Trouble disappears if bucket dump YES Bucket dump operation
sensor (SE-2) indicates more than operation pressure sensor (SE-2) is pressure sensor (SE-2) is
1.3V when lever is at neutral. replaced. faulty.
NO NO
Bucket dump pilot pressure is more YES
than 6kgf/cm2 (85psi) when lever is Inspect ATT pilot valve.
at neutral.
NO Replace C-1 controller.
(Service diagnosis No.9)
Boom up operation pressure sensor YES Trouble disappears if boom up YES Boom raise operation
(SE-3) indicates more than 1.3V operation pressure sensor (SE-3) is pressure sensor (SE-3) is
when lever is at neutral. replaced. faulty.
NO NO
Boom up pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at Inspect ATT pilot valve.
neutral.
NO Replace C-1 controller.
(Service diagnosis No.9)
Boom down operation pressure
sensor (SE-4) indicates more than
YES Trouble disappears if boom down YES Boom lower operation
operation pressure sensor (SE-4) is pressure sensor (SE-4) is
1.3V when lever is at neutral. replaced. faulty.
NO NO
Boom down pilot pressure is more YES
than 6kgf/cm2 (85psi) when lever is Inspect ATT pilot valve.
at neutral.
NO Replace C-1 controller.
(Service diagnosis No.12)
Swing operation pressure sensor YES Trouble disappears if swing YES Swing operation pressure
(SE-5) reads more than 1.3V when operation pressure sensor (SE-5) is sensor (SE-5) is faulty.
lever is at neutral. replaced.
NO NO
Swing pilot pressure is more than YES
6kgf/cm2 (85psi) when lever is at Inspect ATT pilot valve.
neutral.
NO Replace C-1 controller.
43-13
Continued from P13
43-14
Continued from P14 Continued from P14
43-15
(10)
(11)
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
43-16
(12)
NO
Swing pilot pressure is approx. YES Inspect or replace ATT
35kgf/cm2 (500psi) or over when
pilot valve
lever is shifted to the full.
NO
Check piping
43-17
(13)-1
YES
24V is alive across
pink/black and black wires YES
To hydraulic
of connector (CN-254F) for
troubleshooting
swing parking solenoid
(SV-1).
NO
Swing parking release NO
switch (SW-4) is at Turn to NORMAL.
NORMAL.
YES
(Service diagnosis No.12)
Swing operation pressure
YES Trouble gets normal if YES Swing operation pressure
sensor (SE-5) reads more
swing operation pressure sensor (SE-5) is faulty.
than 1.3V when lever is at
sensor (SE-5) is replaced.
neutral.
NO NO
Swing pilot pressure is more YES
than 6kgf/cm2 (85psi) is Inspect ATT pilot valve.
when lever is at neutral.
NO Inspect harness between
swing operation pressure
sensor (SE-5) and C-1
controller.
Arm in operation pressure Trouble gets normal if arm YES
sensor (SE-7) reads more YES in operation pressure sensor Arm in operation pressure
than 1.3V when lever is at (SE-7) is replaced. sensor (SE-7) is faulty.
neutral.
NO
NO Arm in pilot pressure is YES
more than 6kgf/cm2 (85psi) Inspect ATT pilot valve.
when lever is at neutral.
Inspect harness between
NO
arm in operation pressure
sensor (SE-7) and
C-1 controller.
43-18
SECTION 44 TROUBLESHOOTING (ENGINE)
TABLE OF CONTENTS
(7)
(6)
(5)
(4)
Group No.
(11)
start.
Over heat
revolution.
warming-up E/G
○
Oil cooler element clogged.
Fuel system trouble(Air or water entered.)
○
○
○
○
○
OiL filter clogged.
○
○ ○
○
Air cleaner clogged.
Filters
○
○
○
○ ○
○ ○ ○
○
V-belt slips.
Inspection
○
Breather hose bent.
Cooling water level
Fuel is of poor quality or leaking.
○
○ ○
Specific gravity of battery fluid
○
Fluid
○
○
○
leaking, or the engine oil level not proper.
○ ○
Blowby gas is much.
Gas leaks from valve and gasket.
○ ○
○ ○
○ ○ ○
○ ○ ○ ○
○
○
Engine oil is oo much.
Visual check
Gas / fluid
○
Starter key
○
○ ○ ○ ○
Battery relay
○
○
○
Mechatoronic controller
Mechatoro “A” adjust.
Shovel side
○
○
○ ○
○
Stepping motor
Electrical fittings
○ ○
○ ○ ○
Accel potentiometer
○
Safety relay
Glow relay
○ ○
Glow
Starter motor
Engine side
○ ○
Starter relay
Electrical fittings
Alternator
Feed pump function
○
○ ○
○ ○
Inspect nozzle.
system
○
○ ○ ○
○ ○
○ ○
Stop
Injection pump
position
○ ○ ○ ○
○ ○ ○ ○
Valve clearance
○ ○ ○ ○ ○ ○
○ ○ ○ ○
Fuel is mixed.
○
○
○
○
Check thermostat.
○ ○ ○
Cooling
○ ○ ○
OK
44-2
(2)
Check starter power is strong or WEAK Check battery fluid level and
Charge or replace battery.
weak. specific gravity.
OK
Check compression
Check engine itself. pressure and valve
clearance. Check that
valve spring is not
Check that air filter clogged
Check air suction system. fatigued, that piston
lamp lights.
liner is not worn, that
OK OK piston ring is not worn,
Check that air cleaner clogged that head gasket is not
sensor. faulty and that flywheel
gear is not damaged.
Also check radiator and
thermostat.
YES
Check electric system. E/G side 24V is alive on glow plug. Glow plug is faulty.
NO
Harness between glow
24V is alive on wire No. 66 (5W) YES relay and glow plug is
of CN-153F on glow relay (R-3). faulty.
NO
Harness between glow
24V is alive on wire No.53 (5Y) NO
relay and battery relay
of CN-154F on glow relay (R-3).
is faulty.
OK
24V is alive across wire No. 62 YES
of CN-155F on glow relay (R-3) Replace glow relay.
and earth.
NO Harness between key
NO
Ground connection is poor. switch and glow relay is
faulty.
CN-154F CN-153F ① ③
① ②
③ ④
CN-155F CN-155F
② ④
Internal connection Fig.1 Glow relay terminals and connector
44-3
(3)
※1
Idling revolution is too
high. Adjust mechatro“A”.
Adjust mechatro“A”.
Max revolution is too high.
44-4
Note ; (6) matches the group No. on page 1. The same is true on the following pages.
(6)
E/G output is insufficient.
Check that E/G water OK
temperature lamp is on and Check the contents of
Overheat
that buzzer sounds. excavating.
NO
Check E/G water
temperature switch, gauge
Inspect electric system.
cluster, electric wiring and
OK connectors.
Check air suction Check that air filter clogged OK Check that air cleaner is
system. display of warning not clogged.
OK
Check fuel feed Check that air is not mixed in
system. fuel. Bleed air.
OK OK
Check water separator and Check feed pump
gauze filter. Check also that performance, injection
poor quality fuel is not used. pump, injection nozzle and
injection timing.
OK
Check that poor quality fuel is
Check fuel system. not used. Replace fuel.
44-5
(8)
Exhaust is abnormal.
OK
Check that air cleaner is not
Exhaust gas is black. clogged. Replace air element.
OK
Check engine oil viscosity.
Check that engine oil is not too
much.
Check injection nozzle,
OK injection timing, injection
Check that gas is not leaking pump and valve clearance.
from head gasket. Check that valve spring is not
fatigued and that piston ring is
not faulty.
(9)
Excessive oil consumption.
44-6
(11)
E/G does not stop Confirm governor Check if governor Check that governor
when starter key is lever stop bolt motor is not faulty motor link
turned off. position. mechanically. connecting bolts are
not loose.
OK
Wire number 60 of Check resistance
Check that terminal instrument panel NG across terminals M Replace starter key
M of starter key right harness and B on starter if resistance across
switch shows 0V. CN-43F shows 0V. key. M and B is 0Ω.
See Fig.3.
OK
Check that battery Does resistance
relay terminal B2 Wire No.805 of body NG across C1 controller
measures 0V four harness CN-150F Check C1 controller. terminals 11-1 and
seconds after key is measures 0V. 15-24 measure 72
turned off. Ω?
(12) OK
When starter key is Replace C1
Does battery NG Replace battery
turned off, power is Check that battery controller if
terminals A and B
cut off but engine relay operates. relay. resistance measures
measure 0Ω?
does not stop. 0Ω.
See Fig.2.
H COIL
BRACKET EARTH
TERMINAL B2
Circuit diagram
L TERMINAL
L TERMINAL Ⅰ
44-7
NOTE
44-8
SECTION 51 ENGINE
TABLE OF CONTENTS
51-II
SECTION 1: GENERAL
TABLE OF CONTENTS
51-1
51-2
51-3
51-4
51-5
51-6
E115SR EV. E135SR LC EV.
51-7
E135SR LC EV. E115SR EV.
51-8
51-9
51-10
51-11
51-12
51-13
51-14
51-15
51-16
51-17
51-18
51-19
51-20
SECTION 2: ENGINE PROPER
TABLE OF CONTENTS
51-21
51-22
51-23
51-24
51-25
51-26
51-27
51-28
51-29
51-30
51-31
51-32
51-33
51-34
51-35
51-36
51-37
51-38
51-39
51-40
51-41
51-42
51-43
51-44
51-45
51-46
51-47
51-48
51-49
51-50
51-51
51-52
51-53
51-54
51-55
51-56
51-57
51-58
51-59
51-60
51-61
NOTES
51-62
SECTION 3: LUBRICATION SYSTEM
TABLE OF CONTENTS
51-63
51-64
51-65
51-66
SECTION 4: COOLING SYSTEM
TABLE OF CONTENTS
51-67
51-68
51-69
51-70
51-71
NOTES
51-72
SECTION 5: FUEL SYSTEM
TABLE OF CONTENTS
51-73
51-74
51-75
NOTES
51-76
SECTION 6: TROUBLESHOOTING
51-77
51-78
51-79
51-80
51-81
51-82
SECTION 7: SPECIAL TOOLS
51-83
51-84
SECTION 8: REPAIR STANDARD
51-85
51-86
51-87
51-88
51-89
51-90
51-91
51-92
51-93
51-94
51-95
51-96
51-97
51-98
SECTION 9: TURBOCHARGER
TABLE OF CONTENTS
51-99
51-100
51-101
51-102
51-103
51-104
SECTION 10: STARTER
TABLE OF CONTENTS
51-105
51-106
51-107
51-108
51-109
51-110
51-111
51-112
51-113
51-114
51-115
51-116
51-117
51-118
51-119
51-120
51-121
51-122
51-123
51-124
51-125
51-126
51-127
51-128
SECTION 11-1: ALTERNATOR (24V-50A)
TABLE OF CONTENTS
51-129
51-130
51-131
51-132
51-133
51-134
51-135
51-136
51-137
51-138
51-139
51-140
51-141
51-142
51-143
51-144
51-145
NOTES
51-146
SECTION 11.2: ALTERNATOR (24V-30A)
TABLE OF CONTENTS
51-147
51-148
51-149
51-150
51-151
51-152
51-153
51-154
51-155
51-156
51-157
51-158
51-159
NOTES
51-160
1. LIST OF ADDITIONAL PARTS
How to utilize the list of additional modification parts
This manual describes the parts which are added and canceled on the basis of “Parts Manual” for
standard machines when the machine is modified into the machines equipped with breaker.
The manual consists roughly of two sections : Breaker and Nibbler & Breaker. Each of the section is
divided into five parts, 1. Upper structure, 2. Boom, 3. 2.45m (8′) arm, and 2.95m (9′8″) arm, 4.
Connector, 5. Idler link, each being assigned a kit number. The cab guard should be ordered optionally.
In the case of the arm, select a kit No. suited for the length of arm and attachment (Nibbler, Breaker) for
ordering.
63-1
(2) NIBBLER & BREAKER E135SR LC EVOLUTION
Classifi-
NAME
cation
Upper structure modification kit No.
• Modification of the control valve
• Install of the guard
• Hydraulic tank assy
• Instrument panel assy
(1) Upper
63-2
1.2 ADDITIONAL PARTS FOR THE MODIFICATION OF THE BREAKER
(1) UPPER STRUCTURE BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
Upper structure modification KIT No. BREAKER
63-3
BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
17 • • CAPSCREW 3
18 • • WASHER 4
19 • • WASHER 4
20 • • CLIP 1
21 • • CONNECTOR 1
22 • • BUSHING 1
63-4
(3) 2.45M (8′) ARM BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
2.45M(8′) Arm modification KIT No. BREAKER
2.95M (9′8″) LONG ARM NOTE) COMMON TO NIBBLER & BREAKER BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
2.95M(9′8″) Long Arm modification KIT No. N&B, BREAKER
63-5
(4) CONNECTOR ASSY NOTE) COMMON TO OCEANIA & ASIA SPEC. BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
No Kit No. is given because it is provided after selection.
• CONNECTOR ASSY
1 • • CONNECTOR 1
2 • • PLUG 1
3 • • O RING 1
• CONNECTOR ASSY
1 • • CONNECTOR 1
2 • • PLUG 1
3 • • O RING 1
(5) REINFORCING THE IDLE LINK NOTE) COMMON TO OCEANIA & ASIA SPEC. BREAKER
Applicable
No. NAME Q’TY REMARK
Machines
Kit No. is not given because only one sort of part is provided.
63-6
1.3 ADDITIONAL PARTS FOR THE MODIFICATION OF THE NIBBLER & BREAKER
(1) UPPER STRUCTURE N&B
Applicable
No. NAME Q’TY REMARK
Machines
Upper structure modification KIT No. NIBBLER & BREAKER
63-7
N&B
Applicable
No. NAME Q’TY REMARK
Machines
20 • • CLIP 1
21 • • CONNECTOR 1
22 • • BUSHING 1
23 • • CLIP 1
24 • • CAPSCREW 1
25 • • LABEL 1
63-8
(3) 2.45M (8′) ARM N&B
Applicable
No. NAME Q’TY REMARK
Machines
2.45M(8′) Arm modification KIT No. NIBBLER & BREAKER
63-9
N&B
Applicable
No. NAME Q’TY REMARK
Machines
16 • • LOCK WASHER 5
17 • • LOCK WASHER 1
18 • • O RING 3
19 • • O RING 1
(4) CONNECTOR ASSY NOTE) COMMON TO OCEANIA & ASIA SPEC. N&B
Applicable
No. NAME Q’TY REMARK
Machines
No Kit No. is given because it is provided after selection.
• CONNECTOR ASSY
1 • • CONNECTOR 1
2 • • PLUG 1
3 • • O RING 1
(5) REINFORCING THE IDLE LINK NOTE) COMMON TO OCEANIA & ASIA SPEC. N&B
Applicable
No. NAME Q’TY REMARK
Machines
Kit No. is not given because only one sort of part is provided.
63-10
2. SUMMARY
2.1 GENERAL PRECAUTIONS (2) Functions of the option valve:
(1) Applications of Breaker or Nibbler & Breaker The option valve is equipped with spool which
Breaker piping .................... Applicable only when functions to send the pressure oil into nibbler
a breaker is mounted. and breaker, and also to switch the flow
...
Nibbler & breaker piping Applicable only when direction to the rod side or head side of the
a nibbler and a nibbler cylinder.
breaker are mounted.
(3) Action of the single / conflux flow switch:
(2) Modifying a Breaker and a Nibbler & The single/conflux flow select switch is
Breaker provided on the instrument panel and is
There are specific procedures to be followed connected to the harness to actuate the
when modifying a breaker and a nibbler & single/conflux flow select spool.
breaker. Therefore, when they are to be
modified at our service shop, contact the (4) Installing the operation pedal:
nearest breaker and nibbler manufacturer’s A pedal and a pilot valve are mounted to the
office, and obtain instructions, so that you floor plate and a remote control piping is
install the pipes and handle the machinery placed between the option valves and pedal,
correctly. in order to operate the breaker or the nibbler.
(3) Differences between a Breaker Piping and a (5) Installing the selector valve:
Nibbler & Breaker Piping For the machines equipped with nibbler and
z Breaker Piping breaker, the selector valve which functions to
There is a single oil flow from pump change the oil flow direction according to the
P2 to the breaker. The oil returns to use of breaker or nibbler is provided on the
the hydraulic tank directly. The flow main C/V in the inside of guard on the right
is single flow. side of slewing motor.
If the return oil from the breaker is fed back to (6) Reinforcement of the attachment:
the control valve, the pulsation of the breaker is Reinforcement plates are welded to the
transmitted to the oil cooler. This causes the standard arm (civil engineering services : for
machine to break down. general use) and to the idler links of the
nibbler & breaker attached machine.
z Nibbler Piping
The oil flows to the nibbler is conflux (7) When the machine equipped with breaker or
flow ; the oil flow is changed to the nibbler & breaker is modified, replace the
rod and the head of the nibbler return filter with filter for breaker and
cylinder. nibbler & breaker.
(KCME specification machine is unrelated.)
2.2 BASIC METHOD TO BE TAKEN WHEN
MOUNTING
When mounting the breaker or nibbler,
always execute the following seven items :
63-11
2.3 LAYING OF PIPING
(1) Breaker specification
6.1.2 or 6.1.3
ARM HYDRAULIC
PIPING 6.1.1
HYDRAULIC PIPING FOR BOOM
STOP 4.7
VALVE UPPER HYDRAULIC PIPING
RETURN HYDRAULIC PIPING
6.1.2 or 6.1.3 4.4 FILTER FOR BREAKER
ARM 4.3 OPTION VALVE
(ADD-ON VALVE)
6.3
HYDRAULIC
ARM TOP
BREAKER 4.3
PIPING
MAIN CONTROL VALVE
4.6
OPERATING
PEDAL
5.2
FLOOR MAT 5.3
REMOTE CONTROL PIPING
5.5 SINGLE / CONFLUX FLOW SELECT SWITCH
Fig. 2 Outside view of Nibbler & Breaker-attached machine
63-12
3. HYDRAULIC CIRCUIT DIAGRAM BREAKER SPECIFICATION
No. NAME TYPE
3.1 FUNCTION NOTE : 50 CONTROL VALVE (OPT.2) KADV22Y/S10102
(1) Hydraulic circuit for breaker 1. This hydraulic circuit is used to add to following circuit. 51 STOP VALVE ―
52 PILOT VALVE 07638-00000
REMARK
53 RETURN FILTER Y-487100
E115SR EVOLUTION STD
E135SR LC EVOLUTION STD
3) Pilot circuit
By depressing breaker pilot valve (52), the
pilot secondary pressure flows into PA02 port
of C/V and switches the breaker spool. The P2
bypass proportional valve secondary pressure
flows into PCa port of C/V and switches the
P2 bypass cut proportional valve.
4) Main circuit
The P2 pump delivery oil flows out through
A02 port of C/V and reaches to the breaker.
The return oil from the breaker flows into the
tank directly.
63-13
(2) Hydraulic circuit for Nibbler & Breaker NOTE : NIBBLER & BREAKER SPECIFICATION
This hydraulic circuit is used to add to following circuit. No. NAME TYPE
REMARK
50 CONTROL VALVE (OPT.2) KADV22Y/S10102
51 SELECTOR VALVE ―
E115SR EVOLUTION STD
52 STOP VALVE ―
E135SR LC EVOLUTION STD
53 PILOT VALVE 16030-00000
2. The OPT valve port relief pressure is adjusted before shipment. 54 RETURN FILTER Y-487100
However, when it is required to install at site, the relief pressure should be adjusted at site.
(5) Circuit for Nibbler & Breaker
3. Marking of selector valve (51.)
1) Nibbler & Breaker switch & pedal operation
Stamped N : NIBBLER
z Single / Conflux flow select switch
Stamped B : BREAKER
Single/Conflux Function of
4. Selection condition and proportional valve command when any of nibbler single & conflux Specification
flow select switch mechatrocontroller
flow or breaker is in service. Nibbler conflux flow Nibbler conflux flow(ON) Refer to Note 4.
"Selection condition
COMMAND SIGNAL OF SOLENOID PROPORTIONAL VALVE Nibbler single flow Nibbler conflux flow(OFF) and proportional
CONDITIONS FOR SELECTION
(W : ○ , W/O : ―) valve command when
SELECTOR Breaker Nibbler conflux flow(OFF) breaker is in service".
SINGLE/CONFLUX VALVE TRAVEL
SELECT SWITH P1 PUMP P2 PUMP STRAIGHT P1 CUT P2 CUT
(No.51) z Pedal
NIBBLER CONFLUX FLOW CONFLUX FLOW (ON) N ○ ○ ○ ○ ○ Foot pedal depressing
N&B Operating condition.
CONFLUX FLOW section.
NIBBLER SINGLE FLOW N ― ○ ― ― ○ Depress toe section. Nibbler close
(OFF) Nibbler
CONFLUX FLOW Depress heel section. Nibbler open
BREAKER B ― ○ ― ― ○ Depress toe section. Breaker stop operating.
(OFF) Breaker
Depress heel section. Breaker starts operating.
2) Mechatro system
Turn the single/conflux flow select switch to
the nibbler conflux side and the function of
mechatro controller is switched into the
nibbler conflux specification as shown in Note
4. Depress the N&B foot pedal and the pilot
secondary pressure flows into either of low
pressure sensors(SE-11), low pressure sensor
output voltage is input into the mechatro
controller, consequently the mechatro
controller executes the pilot signal processing
and outputs the command value
corresponding to the input voltage resulting
in the function shown by mark ○ in Note 4.
3) Pilot circuit
Depress N&B pilot valve (53), the pilot
secondary pressure flows into PA02 port of
C/V through B port and switches the N&B
spool. And the solenoid proportional valve
secondary pressure switches the travel
straight valve of C/V, P1 by-pass cut valve
and P2 bypass cut valve.
However, when the breaker is used with the 4) Main circuit
N&B circuit or the breaker circuit, the pedal P1,P2 pump delivery oil is confluxed in the
operation is reversed, that is, the port the C/V, is discharged through A02 port and is
pilot secondary pressure flows into is changed fed into nibbler H side, and consequently the
from PA02 to PB02, and the main circuit nibbler starts the closing action.
supply port is from A02 to B02. And the The return oil from the nibbler R side flows
return oil flows into the tank directly by into the hydraulic tank through B02 port of
Fig. 4 Hydraulic circuit for Nibbler & Breaker switching the selector valve. C/V.
63-14
3.2 ELECTRIC SYSTEM DIAGRAM FOR
NIBBLER & BREAKER
C-1 : MECHATRO CONTROLLER
63-15
3.3 HYDRAULIC COMPONENTS 2-M10-20/27 (FOR LIFTING) 3.3.3 PILOT VALVE FOR NIBBLER & BREAKER
4-M10 SCREW DEPTH 13
3.3.1 CONTROL VALVE ASSY
OPTION VALVE (BREAKER, NIBBLER & BREAKER) SECONDARY
PRESSURE OPERATING TORQUE
E115SR EV. E135SR LC EV.
CONTROL VALVE CONTROL VALVE
SECONDARY PRESSURE
ASSY (STD) ASSY (STD)
OPERATING FORCE
WITH OPT2 WITH OPT2
CIRCUIT DIAGRAM
OPERATING ANGLE
3-M10-20/27 (FOR LIFTING) T CONTROL DIAGRAM
P1(P2)
TRAVEL
PTb TRAVEL TRAVEL PAL PBL
TRAVEL LEFT LEFT
STRAIGHT STRAIGHT PBs2
Dra,Drb SWING PBs1
PBr TRAVEL SWING PAs
PAr
LEFT TRAVEL Pss
BUCKET RIGHT BOOM CUT PCa
PB1 CONFLUX
PBc PAc BOOM
BUCKET
CONFLUX PLc2
BOOM PAa ARM
Drd
PBb PAb BOOM ARM
ARM
P1 CUT Pis RECIRCU-
LATION
ARM
PA1 PCb P1 CUT ARM
CONFLUX
RECIRCULATION
PAo2 PBo2
OPTION 2
(P4)
(P3)
4-PF1/4
JISB2351 O
2-∅11THROUGH
CIRCUIT DIAGRAM
CONTROL DIAGRAM
Fig. 7 Pilot valve (Breaker)
63-16
4. MODIFICATION PROCEDURE FOR BREAKER
4.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a breaker-mounted
machine are as follows :
Table 1
Main modification Reference Main items to be
No. ITEM
points pages added and change
4.2 Modification of floor mat Cutout of floor mat. 4-1 Floor mat
Control
valve→Hydraulic Hose
piping for breaker
4.7 Upper hydraulic piping 4-6
Replace hose fitting Bracket
clamp Clamp
63-17
4.3 MODIFICATION OF THE CONTROL VALVE
(BREAKER, NIBBLER & BREAKER)
4.3.1 MODIFICATION PROCEDURE
Install the additional parts listed in Table 2
to the control valve of the standard machine,
as shown in Fig. 2. On that occasion, some
parts become unnecessary.
Table 2
MODIFICATION OF THE CONTROL VALVE
Table 3
No. NAME Q’TY REMARK
271 CAPSCREW 4 M12×25
271
63-18
4.4 REPLACEMENT OF RETURN FILTER OF 4.5 MODIFICATION OF THE GUARD
HYDRAULIC TANK (BREAKER, NIBBLER & BREAKER)
(BREAKER, NIBBLER & BREAKER) 4.5.1 MODIFICATION PROCEDURE
For machines in breaker and N&B specification, VALVE Install the additional parts listed in Table 5 to the 93
the hydraulic oil is deteriorated and contaminated guard of the standard machine, as shown in Fig.
earlier. So be sure to replace the return filters 6. On that occasion, some parts become
from standard ones to those in special use for unnecessary.
machines in breaker and N&B specification.
Table 5
INSTALL OF THE GUARD
63-19
4.6 CONTROL PIPING (BREAKER) Table 8
4.6.1 REMOTE CONTROL PIPING & BLOCK BLOCK CONTROL PIPING
CONTROL PIPING NOTE :
No. NAME Q’TY REMARK
(1) Modification procedure z Before starting the modification work, check parts
Assemble the additional parts listed in Table according to the Additional Parts List. B8 CONNECTOR 1 PF1/4
7 and 8 to the control valve of the standard z When disconnecting and reconnecting pipes, B11 ELBOW 1 PF3/8-PF1/4
machine, as shown in Fig. 8 and 9. On that take care, so as not to allow dirt and foreign
occasion, some of the existing parts must be matter to enter.
used and some of them become unnecessary.
A2
A3 A1
63-20
4.6.2 MAIN CONTROL PIPING (BREAKER) Table 11 TIGHTENING TORQUE
Modification Procedure CONTROL VALVE PIPING O ring type coupling Hydraulic hose
Install the additional parts listed in Table 11 No. NAME Q’TY REMARK Thread Spanner Tightening torque Tightening torque
size
to the main control piping of the standard 1 TEE 1 PF1/4 (PF) (mm) kgfym (lbfyft) kgfym (lbfyft) Note)
machine, as shown in Fig. 12. 8 CONNECTOR 1 PF1/4-PF3/8 1/4 19 3.7 (27) 3.0 (22) ※ Remove the existing plug
11 ELBOW 1 PF1/4-PF3/8 3/8 22 7.5 (54) PF3/8 and install this Elbow
(connector).
NOTE : 18 HOSE 1 PF1/4
63-21
4.7 UPPER HYDRAULIC PIPING (BREAKER)
4.7.1 MODIFICATION PROCEDURE
Fit the additional parts in table 12 and 13, NOTE :
according to Fig. 13. z Before starting the modification work, check parts
On that occasion, some parts become according to the Additional Parts List.
unnecessary. z When disconnecting and reconnecting pipes,
take care, so as not to allow dirt and foreign
TIGHTENING TORQUE
Hydraulic hose matter to enter.
(ORS Type) z At assembly, use care of O rings do not come off.
Spanner Tightening torque
Thread size
(mm) kgfym (lbfyft) z Regarding the tightening torque of O ring type
1-14UNS 32 14 (100) joints, hydraulic hoses and flareless joints, refer
1 3/16-12UN 36 18 (130) to the Remark of Table 12, 13 and the Tightening
Torque Table.
Hydraulic hose
O ring type coupling (30°flare)
Thread Spanner Tightening torque Tightening torque
size
(PF) (mm) kgfym (lbfyft) kgfym (lbfyft)
3/8 22 7.5 (54)
1/2 27 11(80)
3/4 36 16.5 (120)
1 41 26 (190) 14 (100)
Capscrew
Tightening torque
Thread size
kgfym (lbfyft)
M8 3.6 (26)
M10 7.2 (52)
M12 12.3 (89)
Table 13
UPPER HYDRAULIC PIPING
No. NAME Q’TY REMARK
1 BRACKET 1
4 CLAMP 1
24 WASHER 1
41 CAPSCREW 1 M12×90
48 BUSHING 1 Fig. 13 Upper hydraulic piping (Breaker)
63-22
4.7.2 PARTS TO BE DISUSED
Concerning the return hydraulic piping, the parts B4
listed in table 14 and Fig. 14 are disused from the
standard machine.
Table 14
No. PART Q’TY REMARK
NAME
B4 PLUG 1 PF1
63-23
4.8 INSTALL OF THE NAME PLATE (BREAKER)
Fit the labels shown in Table 16 to the cab of the 22
standard machine, according to Fig. 16.
Table16
INSTALL OF THE NAME PLATE
No. NAME Q’TY REMARK
21 LABEL 1
22 LABEL 1
(21)
21
RIGHTHAND VIEW OF CAB INTERIOR
(22)
63-24
5. MODIFICATION PROCEDURE FOR NIBBLER & BREAKER
5.1 MODIFICATION ITEM
The main items that are needed to modify the
standard machine into a nibbler & breaker-
mounted machine are as follows :
Table 1
Main modification Reference Main items to be
No. ITEM
points pages added and change
5.2 Modification of floor mat Cutout of floor mat. 5-1 Floor mat
Refer
to Modification of the Install of the option Option valve
4-2
4.3 control valve valve Capscrew
Refer
to Modification of the Replace return filter
Replace return filter 4-3 Plug (for return)
4.4 hydraulic tank canceled
Refer
to Part of the guard
Install of the guard 4-3 Guard
4.5 changed
Remote control piping Pilot valve Install of the Pilot valve
Pilot valve pedal control piping Pedal
5-3
Block control Install of the block
Block
Control piping (Block) and piping
5.3
piping
Main control piping Control piping for Hose
5-4
(Option valve) option valve Connector
Control
valve→Hydraulic piping Hose
5.4 Upper hydraulic piping for breaker 5-5
Replace hose fitting Bracket
clamp Clamp
Modification of the Install of the single
5.5 conflux flow select 5-6 Switch
instrument panel switch
5.6 Install of the name plate Add label 5-6 Label
63-25
5.3 CONTROL PIPING (NIBBLER & BREAKER) Table 3
5.3.1 REMOTE CONTROL PIPING & BLOCK BLOCK CONTROL PIPING
CONTROL PIPING NOTE :
No. NAME Q’TY REMARK
(1) Modification procedure z Before starting the modification work, check parts
Assemble the additional parts listed in Table according to the Additional Parts List. B8 CONNECTOR 1 PF1/4
2 and 3 to the control valve of the standard z When disconnecting and reconnecting pipes, B11 ELBOW 1 PF3/8-PF1/4
machine, as shown in Fig. 2 and 3. On that take care, so as not to allow dirt and foreign
occasion, some of the existing parts must be matter to enter.
used and some of them become unnecessary.
Table 5
No. NAME Q’TY REMARK
2 SUPPORT 1
4 COVER 1
8 SEMS BOLT 2
Capscrew
Tightening torque
Thread size
kgfym (lbfyft)
M8 3.6 (26)
M12 12.3 (89)
TO TANK
Table 8 TO TO
ATTACHMENT ATTACHMENT
UPPER HYDRAULIC PIPING
No. NAME Q’TY REMARK TO CONTROL TO CONTROL
VALVE (A02) VALVE (A02)
1 BRACKET 1
4 CLAMP 1 WHEN USING BREAKER WHEN USING NIBBLER
24 WASHER 1
41 CAPSCREW 1 M12×90
48 BUSHING 1 Fig. 7 Upper hydraulic piping (Nibbler & Breaker)
63-28
5.5 MODIFICATION OF THE INSTRUMENT 5.6 INSTALL OF THE NAME PLATE
22
PANEL (NIBBLER & BREAKER) (NIBBLER & BREAKER)
5.5.1 MODIFICATION PROCEDURE Fit the label shown in table 11 to the cab of the
Install the additional parts listed in Table 9 to the standard machine, according to Fig. 10.
instrument panel assy of the standard machine, Table 11
as shown in Fig. 8. On that occasion, some parts INSTALL OF THE NAME PLATE
become unnecessary.
No. NAME Q’TY REMARK
20 LABEL 1
Table 9
21 LABEL 1
INSTRUMENT PANEL ASSY 22 LABEL 1
No. NAME Q’TY REMARK 39 23 LABEL -
For single /
39 SWITCH 1 conflux Fig. 8 Modification of instrument panel
switching
(20) 21
RIGHTHAND VIEW OF CAB INTERIOR
Table 10 (21)
13 CAP 1
13
(22)
(23)
20
Do not set this switch to nibbler conbined flow
operation position when using breaker.
VIEW Ⅴ
Fig. 10 Labeling position
63-29
6. MODIFICATION PROCEDURE FOR ATTACHMENT
6.1 MODIFICATION ITEM FOR BREAKER ATTACHMENT
The main item that are needed to modify the standard boom and standard arm into a breaker-mounted
machine are as follows:
Table 1
Reference Modification
No. Specification Types of attachment
page item
Tapped
Modification of the 4.6M (15´1˝) boom 6-2
block weld
Breaker
6.1.1 6-3
N/B Install of
4.6M (15´1˝) boom hydraulic piping
the piping
6-4
Tapped
Breaker Modification of the 2.45M (8´) arm 6-5
block weld
6.1.2
Breaker Install of
2.45M (8´) arm hydraulic piping 6-6
N/B the piping
Tapped
Modification of the 2.95M (9´8˝) arm 6-7
Breaker block weld
6.1.3
N/B Install of
2.95M (9´8˝) arm hydraulic piping 6-8
the piping
6.3 Breaker Install of the
Connector assy 6-11
6.4 Nibbler connector
Breaker
6.5 Reinforcing of the idler link 6-12 Plate
N/B
63-30
6.1.1 MODIFICATION OF THE 4.6M (15fty1in) BOOM
(1) Modification of the 4.6M (15ft-1in)
boom〔Breaker, Nibbler & Breaker〕 NOTE :
Weld the additional parts listed in table 2 to z Use weld symbol B welding rod (mild steel 50kg
the boom of the standard specification, grade).
according to Fig. 1. z Seal the unwelded areas of the tapped block.
Table 2
BOOM ASSY 8,4
No. NAME Q’TY REMARK
1 BOOM ASSY (1) STD
BOOM ASSY ─ STD 8,4
2 TAPPED BLOCK 1
3 TAPPED BLOCK 1
4 TAPPED BLOCK 2
5 TAPPED BLOCK 2
6 TAPPED BLOCK 1
7 TAPPED BLOCK ─
VIEW Ⅰ
8 TAPPED BLOCK ─
9 TAPPED BLOCK ─
6,9
1
5
7,3,2
8 8
7
3
5 5
Fig. 1 Modification of the 4.6M (15ft-1in) boom (Breaker, Nibbler & Breaker)
63-31
(2) Hydraulic piping for 4.6M (15ft-1in) boom
(Breaker, Nibbler & Breaker) NOTE :
Install the additional parts listed in table 3 to z Apply Loctite #242 to the clamp mounting bolts.
the 4.6m (15ft-1in) boom modified under par. z At assembly, use care of O rings do not come off.
6.1.1 (1) as shown in Fig. 2.
HYDRAULIC PIPING
FOR 4.6M (15´1˝ )BOOM Table 3
No. NAME Q’TY REMARK No. NAME Q’TY REMARK
1 TUBE 1 10 CAPSCREW 1
2 TUBE 1 11 CAPSCREW 3
3 TUBE 1 12 LOCK WASHER 3
4 TUBE 1 13 LOCK WASHER 1
5 PLUG 2 14 LOCK WASHER 3
6 CLAMP 3 15 O RING 1
7 CLAMP 3 16 O RING 3
8 CLAMP 1 17 O RING 1
9 CAPSCREW 3 18 O RING 1
NOTE :
z For M-threads Tightening torque z Tightening torque of ORS coupling nuts.
Thread size Tightening torque Thread size Tightening torque
M10 6.7kgfym (48.5 lbfyft) 1-14UNS 14kgfym (101 lbfyft)
M12 11.7kgfym (85 lbfyft) 1 3/16-12UN 18kgfym (131 lbfyft)
M14 18.5kgfym (133 lbfyft) 1 7/16-12UN 21kgfym (152 lbfyft)
z For PF, PT-threads Tightening torque 1 11/16-12UN 33kgfym (241 lbfyft)
Thread size Tightening torque z Remove item 5 plug as necessary, and install an
PF1, PT1 26kgfym (188 lbfyft) accumulator recommended by the breaker
maker.
1,16
18,17,3 2,15
5
4,16
7 7
7
11,14 11,14 11,14
6
6 6
9,12
9,12 9,12
SECTION SECTION
SECTION
N&B・RETURN 10,13
8
N&B・SUCTION
SECTION
Fig. 2 Hydraulic piping for 4.6M (15ft-1in) boom (Breaker, Nibbler & Breaker)
63-32
6.1.2 MODIFICATION OF THE 2.45M (8ft) ARM
(BREAKER)
(1) Modification of the 2.45M (8ft) arm
When the additional parts listed in table 5 to NOTE :
the arm of the standard specification, z Use weld symbol B welding rods (mild steel 50kg
according to Fig. 4. grade).
z Seal the unwelded areas of the tapped block.
Table 5
2.45M (8ft) ARM ASSY
No. NAME Q’TY REMARK
ARM (1)
1 STD
ARM -
3 TAPPED BLOCK 1
4 TAPPED BLOCK 1
5 TAPPED BLOCK 2
4
5
5 3
5
SECTION AA WELDING PROCEDURE OF ITEM
5
Fig. 4 Modification of the 2.45M (8ft) arm (Breaker)
63-33
(2) Hydraulic piping for 2.45M (8ft) arm
(Breaker, Nibbler & Breaker) NOTE :
This hydraulic piping applies to both the z Apply Loctite #242 to the clamp mounting bolts.
breaker machine and the nibbler & breaker z For M-threads
machine. Install the additional parts listed in Thread size Tightening torque
table 6 to the 2.45m (8ft) arm body modified M8 3.4kgfym (25 lbfyft)
under par. 6.1.2 (1) as shown in Fig. 5. M12 11.7kgfym (85 lbfyft)
Table 6 z For PF,PT-threads Tightening torque
HYDRAULIC PIPING FOR Thread size Tightening torque
2.45M (8ft) ARM
PF3/4, PT3/4 16.5kgfym (120 lbfyft)
No. NAME Q’TY REMARK
z Tightening torque for ORS cupling nuts.
1 TUBE 1
Thread size Tightening torque
2 TUBE 1
1 3/16-12UNS 18kgfym (130 lbfyft)
3 HOSE 2
z At assembly, use care of O rings do not come off.
4 STOP VALVE 2
5 CONNECTOR 2
6 CLAMP 2
7 BRACKET 2
8 CAPSCREW 8
9 CAPSCREW 4
10 CAPSCREW 2
11 WASHER 8
12 WASHER 4
13 LOCK WASHER 6
14 O RING 4
3
1
3
2
14
5,14
4 8,11 10,13
10,13 6
9,12,13
7
8,11
7 SECTION SECTION
9,12,13
Fig. 5 Hydraulic piping for 2.45M (8ft) arm (Breaker, Nibbler & Breaker)
63-34
6.1.3 MODIFICATION OF THE 2.95M (9ft-8in)
ARM
(BREAKER, NIBBLER & BREAKER)
(1) Modification of the 2.95M (9ft-8in) arm
When the additional parts listed in table 7 to NOTE :
the arm of the standard specification, z Use weld symbol B welding rods (mild steel 50kg
according to Fig. 6. grade).
Table 7 z Seal the unwelded areas of the tapped block.
2.95M (9ft-8in) ARM ASSY
No. NAME Q’TY REMARK
1 ARM (1) STD
2 PLATE 1
3 PLATE 1
4 PLATE 2
5 PLATE 1
7 TAPPED BLOCK 1
8 TAPPED BLOCK 1
9 TAPPED BLOCK 2
2 9 4 8
3 5 9 4 7
9
9
DETAIL C
SECTION AA SECTION BB
63-35
(2) Hydraulic piping for 2.95M (9ft-8in) arm
(Breaker, Nibbler & Breaker) NOTE :
This hydraulic piping applies to both the z Apply Loctite #242 to the clamp mounting bolts.
breaker machine and the nibbler & breaker z For M-threads
machine. Install the additional parts listed in Thread size Tightening torque
table 8 to the 2.95m (9ft-8in) arm body as M8 3.4kgfym (24.5 lbfyft)
shown in Fig. 7. M12 11.7kgfym (85 lbfyft)
Table 8 M14 18.5kgfym (133 lbfyft)
HYDRAULIC PIPING FOR z For PF,PT-threads Tightening torque
2.95M(9ft-8in) ARM Thread size Tightening torque
No. NAME Q’TY REMARK PF3/4, PT3/4 16.5kgfym (120 lbfyft)
1 TUBE 1 z Tightening torque for ORS cupling nuts.
2 TUBE 1
3 HOSE 1 Thread size Tightening torque
4 HOSE 1 1 3/16-12UNS 18kgfym (130 lbfyft)
5 STOP VALVE 2 1 7/16-12UN 21kgfym (152 lbfyft)
6 CONNECTOR 2 z At assembly, use care of O rings do not come off.
7 CLAMP 1
8 CLAMP 1
9 BRACKET 2
10 CAPSCREW 8
11 CAPSCREW 4
12 CAPSCREW 1
13 CAPSCREW 1
14 WASHER 8
15 WASHER 4
16 LOCK WASHER 5
17 LOCK WASHER 1
18 O RING 3
19 O RING 1
1,18,19 4
2,18 3
18
5,18
5 10,14 13,17
12,16 7 8
11,15,16
9
14,10
Fig. 7 Hydraulic piping for 2.95M (9ft-8in) arm (Breaker, Nibbler & Breaker)
63-36
6.2 MODIFICATION ITEM FOR NIBBLER & BREAKER ATTACHMENT
The main item that are needed to modify the standard boom and standard arm into a nibbler & breaker-
mounted machine are as follows:
Table 1
Reference Modification
No. Specification Types of attachment
page item
Tapped block
Modification of the 4.6M (15´1˝ ) boom 6-2
Breaker
Refer to weld
6.1.1 N/B 6-3 Install of the
4.6M (15´1˝ ) boom hydraulic piping
6-4 piping
Tapped block
6.2.1 N/B Modification of the 2.45M (8´) arm 6-10
weld
Breaker
Refer to Install of the
2.45M (8´ ) arm hydraulic piping 6-6
6.1.2 N/B piping
Modification of the 2.95M (9´8˝ ) Tapped block
6-7
Breaker
Refer to arm weld
6.1.3 N/B Install of the
2.95M (9´8˝ ) arm hydraulic piping 6-8
piping
Refer to
Install of the
6.3 Breaker Connector assy 6-11
connector
6.4 Nibbler
Refer to Breaker
Reinforcing of the idler link 6-12 Plate
6.5 N/B
63-37
6.2.1 MODIFICATION OF THE 2.45M (8ft). ARM
(NIBBLER & BREAKER)
(1) Modification of the 2.45M (8ft) arm
1) When the additional parts listed in table 2 to NOTE :
the arm of the standard specification, z Use weld symbol B welding rods (mild steel 50kg
according to Fig. 1. grade).
Table 2 z Seal the unwelded areas of the tapped block.
8
2 9 4
3 5
9 4 7
9
9
DETAIL C
SECTION BB SECTION AA
63-38
6.3 CONNECTOR ASSY (BREAKER)
2 3 1
When using the machine with a breaker, attach
1-1/16-12UNF
the below parts to the tip of the stop valve. For
use with NPK, TOKU and KRUPP breakers.
Table 3
CONNECTOR ASSY FOR NPK
No. NAME Q’TY REMARK PF3/4
1 CONNECTOR 1 B : FOR NPK
2 PLUG 1
3 O RING 1 1B P24
Table 4
CONNECTOR ASSY 2 PF3/4 1 3 PF3/4
FOR TOKU, KRUPP
No. NAME Q’TY REMARK
1 CONNECTOR 1
2 PLUG 1
3 O RING 1 1B P24
Table 5
CONNECTOR ASSY
No. NAME Q’TY REMARK
1 CONNECTOR 1
2 PLUG 1 PF3/4
3 O RING 1 1B P24
63-39
6.5 REINFORCING THE IDLER LINK
(BREAKER, NIBBLER & BREAKER)
When using the machine as a nibbler & breaker 501±0.2 (19.7±0.0079)
machine, the right and left idler links need
reinforcement. Reinforce them according to table
(0.866) (1.14)
(2.17)
22 29
55
6 and Fig. 5.
(0.984)
25
100 100
Table 6 (3.94) (3.94)
IDLER LINK (R.H)
IDLER LINK (L.H)
No. NAME Q’TY REMARK
0
0 IDLER LINK (1) (RH)
0 IDLER LINK (1) (LH)
RH and LH
1 PLATE 2 in common
(0.394)
(1.77)
10
45
100 100
60 (3.94) 381 (15) (3.94) 60
(2.36) (2.36)
1
IDLER LINK (L.H)
501±0.2 (19.7±0.0079)
(0.866) (1.14)
(2.17)
22 29
55
(0.984)
25
100 100
(3.94) (3.94)
60 1 381 (15) 60
(2.36) 100 (3.94) 100 (3.94) (2.36)
(1.77)
45
(0.394)
10
0
IDLER LINK (R.H)
63-40
7. REMINDERS ON THE USE OF NIBBLER & BREAKERS
7.1 CHANGING OVER THE SELECTOR VALVE
A nibbler & breaker-attached machine is
equipped with a selector valve in both the
operation circuit and the main circuit. When
running the machine after completion of
modification, always set the selector valves
according to a nibbler or a breaker used.
63-41
7.2 FLUSHING METHOD
After completion of piping work, connect the high
pressure side and the low pressure side, as shown
in Fig. 3, open the stop valves on both sides and (ON) (OFF)
depress the operating pedal to perform flushing.
CONNECTOR(PF3/4)
z Before beginning flushing, run the
engine at low speed, depress the STOP VALVE
HOSE
breaker operating pedal and then
run the engine at high speed.
z Perform flushing operation for at
least 40 minutes, and during the
operation, make sure of no oil
leakage from each of the connections
of the newly attached breaker circuit An example of flushing time (23min.) in a single
and the nibbler & breaker circuits. process
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7.4.2 THROTTLE POTENTIOMETER
When operating the machine with a hydraulic
breaker, do the following operations :
Use the throttle potentiometer on the high idle
side. (Refer to Fig. 4.)
Foot pedal
depressing section Operating condition.
BREAKER ONLY
Depress heel section Breaker starts operation.
Pedal in neutral position. Breaker stops operating.
(2) Nibbler and breaker combined (conflux)
circuit.
Release pedal lock on the right front side of
driver’s seat to operate pedal.
z Hydraulic breaker
Foot pedal
depressing section Operating condition.
Pedal in neutral position. Breaker stops operating.
Depress heel section. Breaker starts operation.
z Nibbler
Foot pedal
depressing section Operating condition.
Depress toe section Nibbler close
Depress heel section Nibbler open N&B PEDAL
63-43
8. PRECAUTIONS TO BE EXERCISED ON BREAKERS
OF DIFFERENT MANUFACTURERS
There are some differences between manufac- Low pressure Measure the inlet pressure of the
turers as to the piping to breakers and the side: line filter on the breaker side by
handling of breakers. For this reason, consult actuating the breaker at full
with the manufacturer when mounting a breaker engine revolution in the H mode,
in the field. The following is a summary of how and in case the maximum
breakers should be handled that is extracted from pressure exceeds 55kgf/cm2 (780
manu-facturers’ catalog use and operation psi), install a low pressure
manuals. accumulator.
NOTE : This is a general outline of how breakers Max. < 55kgf/cm2 (780 psi)
should be used and may differ with excavator Regarding the capacity and the
models. Always contact the breaker charge pressure of accumulators,
manufacturer before field mounting. contact the breaker manufacturer
before installation.
(1) Placing high and low pressure accumulators
NPK They must be placed basically (2) Installation of a relief valve
(depending upon models). NPK Installation is not necessary.
(Contact the breaker manufacturer
T O K U
Check the oscillation of the as it is necessary depending upon
K R U P P pulsation of the breaker models.)
pressure and if pulsation is
O K A D A
large, always install accumu- Installation is necessary.
FURUKAWA lators. T O K U A relief valve is specified by
each breaker manufacturer.
Standard of judgment on the installation of K R U P P
Since the method of pressure
accumulators O K A D A setting of the relief valve
H
High pressure Measure the pulse oscillation by differs with breaker manufac-
side: pressure on the high pressure T A I S E I
side of the breaker at the turers, install a relief valve
inspection port for the pump’s FURUKAWA according to the manufac-
delivery pressure by actuating the turer’s instructions.
breaker at the full revolution of NOTE : Only the B series TOKU machine requires
the engine in mode H and set the a relief valve to be installed.
maximum pressure difference to
within 20% of the excavator’s INSTALLATION OF A RELIEF VALVE
system pressure 330kgf/cm2
(4690psi).
In case it exceeds 20%, install a
high pressure accumulator.
NOTE : The pulse oscillation is 330×20%=
2
66kgf/cm (940psi). Therefore, if it is more
than this level, an accumulator must be LOW PRESSURE SIDE (RETURN)
installed. HIGH PRESSURE SIDE
Install accumulator referring to the
result of verification test.
max PLUG
BOOM
min
Max. press-Min press < system press × 20%
63-44
6 (4) Changing over the breaker to high and low
4 speeds
N P K
2 These breakers are not so
T O K U
(PF1) 3 constructed as to be switched
TO TANK
T A I S E I over to high and low speed.
FURUKAWA
RETURN SIDE
5 1
KRUPP Breakers on and after MKB1200 are
constructed with a switching function.
It can be operated from inside the cab
by the installation of a solenoid valve.
TO BREAKER OIL SUPPLY SIDE For piping work, consult with the
breaker manufacturer.
1. HIGH PRESSURE HOSE 4. PLUG
2. NIPPLE 5. ELBOW NOTE : Piping work is not required in some cases if
3. ADAPTER 6. RELIEF VALVE a high-low changeover function is not
Fig. 2 necessary at user’s request.
On that occasion, it is necessary to fix the
(3) Restriction of engine revolution changeover valve contained in the breaker
N P K Full engine revolution may be used. to the low speed side beforehand. Consult
with the breaker manufacturer in that case.
T O K U There are restriction on the It is prohibited to use the high-low speed
K R U P P engine revolution. Since a changeover valve without laying high-low
specified revolution differs speed piping and without fixing the high-low
O K A D A
with breakers, follow the speed changeover valve.
T A I S E I breaker manufacturer’s inst-
FURUKAWA ructions.
HIGH-LOW SPEED
CHANGEOVER VALVE
NOTE : In the case of a breaker for which the
engine revolution is limited, the breaker
does not increase impact power and cycles
even at full engine revolution.
Since extra hydraulic oil returns to the RELIEF VALVE HYDRAULIC
BREAKER
hydraulic oil via the relief valve, it causes
the hydraulic oil temperature to rise and the TO CONTROL VALVE
fuel consumption to increase. Plaster the
label (furnished by the breaker maker)
indicating the revolution (Check the engine TO TANK
revolution.), to the throttle potentiometer
position. Always observe the indicated
CHECK VALVE
revolution.
Fig. 3
63-45
9. REFERENCE
Typical combinations are quoted from breaker When fitting a breaker, read through reminders
manufacturers’ catalog use as below, but on the use of breakers and cautions instructed by
concerning applicable breaker models, decide it breaker manufacturers.
after consultation with the breaker manufacturer.
Table 1
Working press Oil volume Total weight Total length Bucket
Applicable
Manufacturer kgf/cm2 used /min kg mm capacity m3
breaker
(psi) (gal/min) (lbs) (in) (cuyd)
120~140 160~200 1,450 2,156
H-10XB
(1,710~1,990) (42.2~52.8) (3,200) (84.9˝ )
N P K
130~150 35~60 410 1,644
H-4XB
(1,850~2,130) (9.24~15.8) (900) (64.7˝ )
100~140 110~140 1,000 0.55~0.70
TNB-10B
(1,420~1,990) (29.0~37.0) (2,210) (0.72~0.92)
120~140 140~160 1,400 0.70~0.90
TNB-14B
(1,710~1,990) (37.0~42.2) (3,100) (0.92~1.18)
100~160 45~80 391 1,476 0.25~0.35
T O K U TNB-6B
(1,420~2,280) (11.9~21.1) (860) (58.1˝ ) (0.33~0.46)
120~170 100~140 997 1,850 0.55~0.70
TNB-10E
(1,710~2,420) (26.4~37.0) (2,200) (72.8˝ ) (0.72~0.92)
130~170 130~170 1,500 2,190 0.70~0.90
TNB-14E
(1,850~2,420) (34.3~44.9) (3,300) (86.2˝ ) (0.92~1.18)
150~160 80~110 1,100~1,250 2,278 0.50~0.90
MKB1100
(2,130~2,280) (21.1~29.0) (2,430~2,760) (89.7˝ ) (0.65~1.18)
K R U P P
150~180 90~130 1,120~1,200 0.55~1.00
MKB1200
(2,130~2,560) (23.8~34.3) (2,470~2,650) (0.72~1.31)
150~180 110~ 1,450 2,240 0.70~
UB 11
(2,130~2,560) (29.0~ ) (3,200) (88.2˝) (0.92~ )
O K A DA
130~160 110~155 1,070 2,040 0.55~0.70
OUB 310
(1,850~2,280) (29.0~40.9) (2,360) (80.3˝ ) (0.72~0.92)
150~170 100~120 1,330 〔1,596〕 0.60~0.90
T A I S E I TF-150
(2,130~2,420) (26.4~31.7) (2,930) (62.8˝ ) (0.78~1.18)
160~180 125~150 1,400 2,119
FURUKAWA HB20G
(2,280~2,560) (33.0~39.6) (3,100) (83.4˝ )
[ ] Excludes chisels.
General precautions to be exercised on the installation of breakers by different manufacturers
Table 2
Installation of Installation of Restriction of
Manufacturer engine High-low speed changeover
accumulators a relief valve revolution
◎ NPK ○ × × changeover type not available.
TOKU
◎ △ ○ × changeover type not available.
Series B
TOKU
◎ ※○ × × changeover type not available.
Series E
changeover type available for large
― KRUPP △ ○ ○
machines.
changeover type available on
― OKADA △ ○ ○
special request.
― FURUKAWA △ ○ ○ changeover type not available.
63-46