Page 1

HYDRAULIC EXCAVATOR SHOP MANUAL

model

CX40B CX50B

INDEX 1

SPECIFICATIONS

2

MAINTENANCE

3

SYSTEM

4

DISASSEMBLING

5

TROUBLESHOOTING

6

ENGINE

7

INSTALLATION PROCEDURES FOR OPTIONAL ATTACHMENT

8

SUPPORTING DATA

No. 9-91940 GB

Printed by Studio ti - 22204 - 2004.07


SAFETY PRECAUTIONS

0-1


SAFETY PRECAUTIONS

GENERAL SAFETY INFORMATION

alert against possible damage to the machine and its components and is represented as follows:

SWARNING

SCAUTION

Do not operate or perform any maintenance on this machine until all instructions found in the OPERATION & MAINTENANCE MANUAL have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor.

(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.

(1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine. (2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations. (3) Messages of safety appear in the manual and on the machine: All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION". 1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:

SDANGER 2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:

SWARNING 3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to

0-2


SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

SWARNING

SWARNING

Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death.

The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.

(6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.

The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section: SPECIFICATIONS.

(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly. (8)

Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.

(9)

To avoid back injury, use a hoist when lifting components which weigh 20 kg (45 lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.

The following is a list of basic precautions that must always be observed. (1)

(2)

Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.

(3)

Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys.

(4)

If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.

(5)

Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack stands, capable of supporting the machine, before performing any disassembly.

(10) To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11) Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely. (12) Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. (13) Always use the proper tools that are in good condition and that are suited for the job at hand. Be

0-3


SAFETY PRECAUTIONS sure you understand how to use them before performing any service work.

been damaged or altered should be checked for balance before reusing.

(14) Reinstall all fasteners with the same part number. 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 or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.

(15) Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted. (16) Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid. (17) Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed. (18) The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work. (19) Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks. (20) Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly. (21) Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has

0-4


INDEX

CX40B CX50B

Title

Index No.

OUTLINE

1

SPECIFICATIONS

2

ATTACHMENT DIMENSIONS

3

TOOLS

11

STANDARD MAINTENANCE TIME TABLE

12

MAINTENANCE STANDARDS AND TEST PROCEDURES

13

HYDRAULIC SYSTEM

22

ELECTRICAL SYSTEM

23

COMPONENTS SYSTEM

24

WHOLE DISASSEMBLING & ASSEMBLING

31

ATTACHMENTS

32

UPPER SLEWING STRUCTURE

33

TRAVEL SYSTEM

34

HYDRAULIC SYSTEM

42

ELECTRICAL SYSTEM

43

ENGINE

44

ENGINE

51

SUPPORTING DATA

71

DATA

OPT.

E/G TROUBLESHOOTING

DISASSEMBLING

SYSTEM

MAINTENANCE

SPECIFICATIONS

SAFETY PRECAUTIONS

APPLICABLE MACHINES

0-5


SAFETY PRECAUTIONS

[MEMO]

0-6


1. OUTLINE TABLE OF CONTENTS 1.1 GENERAL PRECAUTIONS FOR REPAIRS ..................................................... 1-3 1.1.1 PREPARATION BEFORE DISASSEMBLING .............................................. 1-3 1.1.2 SAFETY IN DISASSEMBLING AND ASSEMBLING .................................... 1-3 1.1.3 DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT ............ 1-3 1.1.4 ELECTRICAL EQUIPMENT .......................................................................... 1-4 1.1.5 HYDRAULIC PARTS ..................................................................................... 1-5 1.1.6 WELDING REPAIR ....................................................................................... 1-5 1.1.7 ENVIRONMENTAL MEASURE ..................................................................... 1-5 1.2 INTERNATIONAL UNIT CONVERSION SYSTEM ............................................ 1-6


1. OUTLINE

1-1


1. OUTLINE

1.1

GENERAL PRECAUTIONS FOR REPAIRS

(2) Suspend warning tag "DO NOT OPERATE" from the doorknob or the operating lever, and have a preliminary meeting before starting work.

1.1.1

PREPARATION BLING

(3) Stop the engine before starting inspection and maintenance to prevent the operator being caught in machine.

BEFORE

DISASSEM-

(4) Identify the location of a first-aid kit and a fire extinguisher, and also where to make contact in a state of emergency.

(1) Understanding operating procedure Read OPERATION & MAINTENANCE MANUAL carefully to understand the operating procedure.

(5) Choose a hard, level and safe place, and place the attachment on the ground securely.

(2) Cleaning machines Remove soil, mud, and dust from the machine before carrying it into the service shop to prevent loss of work efficiency, damage of parts, and difficulty in rust prevention and dust protection while reassembling.

(6) Use a lifter such as a crane to remove heavy parts (20 kg [45 lbs] or more) from the machine. (7) Use proper tools, and replace or repair defective tools. (8) Support the machine and attachment with supports or blocks if the work is performed in the lifted condition.

(3) Inspecting machines Identify the parts to be disassembled before starting work, determine the disassembling procedure by yourself considering the workshop situations etc., and request procurement of necessary parts in advance.

1.1.3

(4) Recording Record the following items for communication and prevention of recurring malfunction.

(1) Removing hydraulic equipment 1) Before disconnecting pipes, release the hydraulic pressure of the system, or open the return side cover and take out the filter.

1) Inspection date and place. 2) Model name, applicable machine number, and hour meter read.

2) Carefully drain oil of the removed pipes into a containers without spilling on the floor.

3) Trouble condition, place and cause.

3) Apply plugs or caps on the pipe ends to avoid oil spillage and dust intrusion.

4) Visible oil leakage, water leakage and damage. 5) Clogging of filters, oil level, oil quality, oil contamination and loosening of connections.

4) Clean off the external surface of the equipment before disassembling, and drain hydraulic and gear oil before placing it on the workbench.

6) Result of consideration if any problem exists based on the operation rate per month calculated from hour meter indication after the last inspection date.

(2) Disassembling hydraulic equipment 1) Do not disassemble, reassemble or modify the hydraulic equipment without the permission of the manufacturer, who is not responsible for the performance and function of the product after modification.

(5) Arrangement and cleaning in service shop 1) Tools required for repair work. 2) Prepare space to place the disassembled parts. 3) Prepare oil containers for draining oil etc. 1.1.2

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

2) When disassembling and reassembling for unavoidable reason, refer the work to qualified personnel who have the specific knowledge or completed the parts service training.

SAFETY IN DISASSEMBLING AND ASSEMBLING

3) Provide matching marks to facilitate reassembling work. (1) Wear appropriate clothes with long sleeves, safety shoes, safety helmet and protective glasses.

4) Before starting the work, read the manual of disassembling procedure, if it is provided, and decide whether the work can be performed by yourself.

1-3


1. OUTLINE 5) Use the special jig and tools without fail if they are specified.

SWARNING

6) If it is hard to remove a part according to the procedure, do not try it by force but investigate the cause.

Operation of the hydraulic equipment without filling hydraulic oil or lubricant or without performing air bleeding will result in damage to the equipment.

7) Place the removed parts in order and attach tags to facilitate the reassembling.

3) Perform air bleeding of the hydraulic pump and slewing motor after loosening the upper drain plug, starting the engine and keep it in low idle condition. Complete the air bleeding when seeping of hydraulic oil is recognized, and tightly plug.

8) Note the location and quantity of parts commonly applied to multiple locations. (3) Inspecting parts 1) Ensure that the disassembled parts are free from seizure, interference and uneven contact. 2) Measure and record wear condition of parts and clearance.

4) Perform air bleeding of the travel motor and the hydraulic cylinders by running the engine for more 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.

SWARNING

(4) Reassembling hydraulic equipment

Do not allow the hydraulic cylinder to bottom on the stroke end just after the maintenance.

1) Turn ON the ventilation fan or open windows to maintain good ventilation prior to starting the cleaning of parts. 2) Perform rough and finish cleaning before assembling.

5) Perform air bleeding of pilot line by performing a series of digging, slewing and travel.

3) Remove washing oil by air and apply clean hydraulic or gear oil for assembling.

6) Check hydraulic oil level after placing the attachment to the oil check position, and replenish oil if necessary.

4) Always replace the removed O-rings, backup rings and oil seals with new ones by applying grease in advance.

1.1.4

ELECTRICAL EQUIPMENT

5) Remove dirt and moisture from and perform degreasing on the surface where liquid gasket to be applied. 6) Remove rust preventive agent from the new parts before use.

(1) Do not disassemble electrical equipment.

7) Fit bearings, bushings and oil seals using special jigs.

(3) Turn the key OFF prior to connecting and disconnecting work.

8) Assemble the parts utilizing matching marks.

(4) Disconnect the connector by holding it and pressing the lock. Do not pull the wire to apply force to the caulking portion.

(2) Handle it carefully not to drop and give a shock.

9) Ensure all the parts are completely assembled after the work.

(5) Connect the connector and ensure it is completely locked.

(5) Installing hydraulic equipment 1) Ensure hydraulic oil and lubricant are properly supplied.

(6) Turn the key OFF prior to touching the terminal of starter or generator.

2) Perform air bleeding when:

(7) Remove the ground (earth) terminal of battery when handling tools around the battery or its relay.

1. Hydraulic oil changed 2. Parts of suction side piping replaced

(8) Do not splash water on the electrical equipment and connectors during machine washing.

3. Hydraulic pump installed 4. Slewing motor installed

(9) Check for moisture adhesion inside the waterproof connector after pulling it out, since it is hard to remove moisture from the connector.

5. Travel motor installed 6. Hydraulic cylinder installed

1-4


1. OUTLINE If moisture adhesion is found, dry it completely before the connection.

1.1.6

(1) Refer repair welding to qualified personnel according to the appropriate procedure.

SWARNING

(2) Disconnect the ground (earth) cable of the battery before starting the repair. Failure to do so will cause damage to the electrical equipment.

Battery electrolyte is hazardous. Battery electrolyte is dilute sulfuric acid. Exposure of skin or eyes to this liquid will cause burning or loss of eyesight. If the exposure occurs, take the following emergency measures and seek the advice of a medical specialist. •

When skin exposed: Wash with water and soap sufficiently.

When eyes exposed: Immediately wash away with city water continuously for more than 10 minutes.

(3) Move away the articles in advance that may cause fire if exposed to sparks. (4) Before starting the repair of the attachment, do not fail to cover the plated surface of the piston rod with flameproof sheet to prevent it from being exposed to sparks. 1.1.7

When swallowed: Drink a large amount of milk or water.

When clothes exposed: Immediately undress and wash.

1.1.5

(2) Industrial waste disposal Dispose of the following parts according to the relevant regulations: Waste oil and waste container Battery (3) Precautions for handling hydraulic oil Exposure of eyes to hydraulic oil will cause inflammation. Wear protective glasses before handling to avoid an accident. If an eye is exposed to the oil, take the following emergency measures:

HYDRAULIC PARTS

When an eye exposed: Immediately wash away with city water sufficiently till stimulative feeling vanishes.

When swallowed: Do not let vomit, and receive medical treatment immediately.

When skin exposed: Wash with water and soap sufficiently.

(1) O-ring •

Ensure O-rings have elasticity and are not damaged before use.

Use the appropriate O-rings. O-rings are made of various kinds of materials having different hardness to apply to a variety of parts, such as the part for moving or fixed portion, subjected to high pressure, and exposed to corrosive fluid, even if the size is same.

Fit the O-rings without distortion and bend.

Always handle floating seals as a pair.

(4) Others Use replacement parts and lubricants authorized as the genuine parts.

(2) Flexible hose (F hose) •

Use the appropriate parts. Different parts are used depending on the working pressure even the size of fitting and the total length of the hose is same.

Tighten the fitting at the specified torque. Ensure no kink, tension, interference nor oil leakage is recognized.

ENVIRONMENTAL MEASURE

(1) Run the engine at the place that is sufficiently ventilated.

When a large amount of the liquid flows out: Neutralize with sodium bicarbonate or wash away with city water.

WELDING REPAIR

1-5


1. OUTLINE

1.2

INTERNATIONAL UNIT CONVERSION SYSTEM (Based on MARKS’ STANDARD HANDBOOK FOR MECHANICAL ENGINEERS)

(3) Derived Units Table 1-3

Introduction Although this manual includes International System of Unit and Foot-Pound System of Units, if you need SI unit, refer to the following international system of units. Given hereinafter is an excerpt of the units that are related to this manual.

Base units Table 1-1 SI units

Derived units

Derived units of base units Table 1-2 Derived units bearing peculiar designations Table 1-4

Prefixes of SI (n-th power of 10, where n is an integer) Table 1-5

(1) Base units Table 1-1 QUANTITY

UNIT

SYMBOL

Length

meter

m

Mass

kilogram

kg

Time

second

s

Electric current

ampere

A

Thermodynamic temperature

kelvin

K

Amount of substance

mol

mol

Luminous intensity

candela

cd

UNIT

SYMBOL

Plane angle

radian

rad

Solid angle

steradian

sr

(2) Supplementary units Table 1-2 QUANTITY

SYMBOL

square meter

m2

Volume

cubic meter

m3

Velocity

meter per second

m/s

Acceleration

meter per second squared

m/s2

Density

kilogram per cubic meter

kg/m3

Table 1-4

2. Construction of SI Unit System

SI unit system

UNIT

Area

(4) Derived Units bearing Peculiar Designations

1. Etymology of SI Unites French: Le Systeme International d’ Unites English: International System of Units

Supplementary units Table 1-2

QUANTITY

1-6

QUANTITY

UNIT

SYMBOL

FORMULA

Frequency

hertz

Hz

1/s

Force

newton

N

kg • m/s 2

Pressure and Stress

pascal

Pa

N/m2

Energy, Work and Quantity of heat

joule

J

N•m

Power

watt

W

J/s

Quantity of electricity

coulomb

C

A•s

Electric potential difference, Voltage, and Electromotive force

volt

V

W/A

Quantity of static electricity and Electric capacitance

farad

F

C/V

Electric resistance

ohm

Celsius temperature

celsius degree or degree

C

(t+273.15)K

Illuminance

lux

lx

lm/m2

V/A


1. OUTLINE (5) Prefixes of SI Table 1-5 PREFIX

SYMBOL MULTIPLICATION FACTORS

giga

G

109

mega

M

106

kilo

k

103

hecto

h

102

deca

da

10

deci

d

10–1

centi

c

10–2

milli

m

10–3

micro

µ

10–6

nano

n

10–9

pico

p

10–12

(6) Unit Conversion Table 1-6 QUANTITY Gravitational

SI

CONVERSION FACTOR

Mass

kg

kg

Force

kgf

N

1 kgf = 9.807 N

N•m

kgf•m = 9.807 N•m

Torque

kgf•m

Pressure

kgf/cm2

Motive Power

PS

kW

1 PS = 0.7355 kW

Revolution

rpm

min–1

r/min *1

MPa 1 kgf/cm2 = 0.09807 MPa

*1 Units that are allowed to use.

1-7


1. OUTLINE

[MEMO]

1-8


2. SPECIFICATIONS TABLE OF CONTENTS 2.1 COMPONENTS NAME ..................................................................................... 2-3 2.2 MACHINE DIMENSIONS .................................................................................. 2-4 2.3 SPECIFICATIONS AND PERFORMANCE ....................................................... 2-6 2.4 MACHINE & COMPONENTS WEIGHT (DRY) ................................................. 2-7 2.5 TRANSPORTATION ......................................................................................... 2-9 2.6 TYPE OF CRAWLER SHOES ........................................................................ 2-11 2.7 TYPE OF BUCKET ......................................................................................... 2-12 2.8 ENGINE SPECIFICATIONS ............................................................................ 2-14 2.8.1 SPECIFICATIONS ...................................................................................... 2-14 2.8.2 ENGINE PERFORMANCE CURVE ............................................................ 2-15


2. SPECIFICATIONS

2-1


2. SPECIFICATIONS

2.1

COMPONENTS NAME

32 30 36

33

34 15 16

17

8 18

35 19

31

12 3

37 13

5

11

4

14

1

29 28 24 27

20 25

2

7 6

26 21

23

9 22 10

No.

NAME

1 Engine

No.

NAME

No.

2 Oil filter

NAME

3 Radiator

No.

NAME

4 Reservoir tank

5 Air cleaner

6 Muffler

7 Fuel tank

8 Hydraulic tank

9 Hydraulic pump

10 Slewing motor

11 Swing cylinder

12 Control valve 16 Operating lever

13 Travel lever

14 Safety lock lever

15 Canopy

17 Dozer operating lever

18 Throttle lever

19 Monitor panel (gauge cluster)

20 Battery

21 Swivel joint

22 Travel motor

23 Slewing bearing

24 Idler assy

25 Lower roller

26 Upper roller

27 Rubber crawler shoe

28 Dozer blade

29 Dozer cylinder

30 Boom

31 Boom cylinder

32 Arm cylinder

33 Light

34 Arm

35 Link

36 Bucket cylinder

37 Bucket

2-3


2. SPECIFICATIONS

2.2

MACHINE DIMENSIONS Unit: mm (ft•in)

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(1) CX40B (CANOPY)

115 {4.53"}

0

1940 {6'4.4"}

R980 } {3'2.6"

5000 {16'4.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

1940 {6'4.4"}

115 {4.53"}

R980 } {3'2.6"

0

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(2) CX40B (CAB)

5000 {16'4.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1630 {5'4.2"} 1820 {5'11.7"} 2330 {7'7.7"} 2780 {9'1.4"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

2-4


2. SPECIFICATIONS Unit: mm (ft•in)

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(3) CX50B (CANOPY)

1940 {6'4.4"}

5230 {17'1.9"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

140 {5.51"}

R980 } {3'2.6"

25 {0.98"}

1960 {6'5.2"} 750 {2'5.5"} 725 {2'4.5"} 70 {2.76"}

(4) CX50B (CAB)

5230 {17'1.9"}

1940 {6'4.4"}

635 {2'1.0"}

345 {13.6"}

2600 {8'6.4"}

2140 {7'0.3"} 1570 {5'1.8"} 980 {3'2.6"}

1690 {5'6.5"} 1970 {6'5.6"} 2480 {8'1.6"} 2910 {9'6.6"}

400 {15.7"} 1560 {5'1.4"} 1960 {6'5.2"}

2-5


2. SPECIFICATIONS

2.3

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY Model Applicable Machines Shoe Type

CX40B

CX50B

PH05-03501~

PJ04-03001~

Rubber shoe Iron shoe (OPT) Rubber shoe Iron shoe (OPT)

Slewing Speed

min-1 {rpm}

Travel Speed

km/h (mph)

Gradeability

8.8 {8.8}

8.8 {8.8}

Low (1st)

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

Low (1st)

High (2nd)

2.8

4.6

2.8

4.6

2.8

4.6

2.8

4.6

% (degree)

58(30)

ENGINE Model (YANMAR)

4TNV88-XYB

Type

Water-cooled, 4-cycle type Swirl chamber type diesel engine

Number of cylinders-Bore × Stroke

4 - ø88 mm × 90 mm (3.46 in × 3.54 in)

Total Displacement

L

Output Rating

2.189 (134 cu•in)

kW/min-1 {PS/rpm}

30.4 / 2400 {41.3 / 2400}

N•m/min-1 (lbf•ft/rpm)

98.4 / 1440 (72.6 / 1440)

Maximum Torque Starting Motor Generator

V × kW

12 × 2.3

V×A

12 × 55

HYDRAULIC COMPONENTS Hydraulic Pump

Variable displacement axial piston + gear pump

Hydraulic Motor

Axial piston

Hydraulic Motor w/Reducer (Travel)

2-Axial piston, 2-Speed motor

Control Valve

11-spool multiple control valve

Cylinder (Boom, Arm, Swing, Bucket, Dozer)

Double action cylinder

Return Filter

Safety valve containing/Filter Type (30µ)

SIDE DIGGING & DOZER Type Boom Swing Angle Stroke of Dozer (above/below)

Boom swing by hydraulic cylinder Right

60°

Left

70°

mm (in)

505 / 325 (19.9/12.8)

495 / 375 (19.5 / 14.8)

WEIGHT Rubber shoe

Iron shoe

Rubber shoe

Iron shoe

4200 (9260)

4300 (9480)

4630 (10200)

4730 (10400)

1930 (4260)

2280 (5030)

1670 (3680)

1770 (3900)

1720 (3790)

1820 (4010)

Machine Weight

kg (lb)

Upper slewing body

kg (lb)

Travel system

kg (lb)

Attachment (Boom+STD Arm+STD Bucket)

kg (lb)

505 (1110)

535 (1180)

Oil & Water

kg (lb)

95 (209)

Note: This figure is calculated with standard bucket.

2-6


2. SPECIFICATIONS

2.4

MACHINE & COMPONENTS WEIGHT (DRY) Unit: kg (lb) CX40B

MODEL

RUBBER SHOE CANOPY

CAB

IRON SHOE CANOPY

CAB

COMPLETE MACHINE

4200 (9260) 4340 (9570) 4300 (9480) 4440 (9790)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

1930 (4260) 2070 (4560) 1930 (4260) 2070 (4560)

UPPER FRAME

570 (1260)

CANOPY / CAB

85 (187)

← 220 (485)

← 85 (187)

← 220 (485)

170 (375)

35 (77)

5 (11)

37 (82)

4 (9)

110 (243)

SWING CYLINDER

39 (86)

SLEWING MOTOR

40 (88)

CONTROL VALVE

35 (77)

COUNTERWEIGHT

270 (595)

GUARD • BONNET

145 (320)

BOOM CYLINDER

47 (104)

1670 (3680)

1770 (3900)

525 (1160)

76 (168)

65×2 (143×2)

UPPER ROLLER

5×2 (11×2)

LOWER ROLLER

9×10 (20×10)

FRONT IDLER

42×2 (93×2)

IDLER ADJUSTER

30×2 (66×2)

SPROCKET

14×2 (31×2)

RUBBER CRAWLER SHOE

210 ×2 (463×2)

400 mm (15.7") IRON SHOE

260×2 (573× 2)

ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET

LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME SLEWING BEARING TRAVEL MOTOR

SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM BUCKET CYLINDER BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD)

22 (49)

170 (375)

27 (60)

505 (1110)

230 (507)

160 (353)

42 (93)

170 (375)

105 (232)

27 (60)

13 (29)

4×2 (9×2)

107 (236)

95 (210)

HYDRAULIC OIL

45 (99)

FUEL

44 (97)

FLUIDS (ASSY OF FOLLOWINGS)

Note: Bucket weight is shown with standard bucket weight.

2-7


2. SPECIFICATIONS Unit: kg (lb) CX50B MODEL

RUBBER SHOE CANOPY

COMPLETE MACHINE

CAB

IRON SHOE CANOPY

CAB

4630 (10200) 4770 (10500) 4730 (10400) 4870 (10700)

UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

2280 (5030) 2420 (5340) 2280 (5030) 2420 (5340)

UPPER FRAME

570 (1,260)

CANOPY / CAB

85 (187)

ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK

← 220 (485)

← 85 (187)

← 220 (485)

170 (375)

35 (77)

5 (11)

37 (82)

4 (9)

110 (243)

39 (86)

SLEWING MOTOR

40 (88)

CONTROL VALVE

35 (77)

COUNTERWEIGHT

580 (1,280)

GUARD • BONNET

145 (320)

FUEL TANK SWING BRACKET SWING CYLINDER

BOOM CYLINDER LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME

58 (128)

1720 (3790)

1820 (4010)

545 (1,200)

← ←

76 (168)

TRAVEL MOTOR

65×2 (143×2)

UPPER ROLLER

5×2 (11×2)

LOWER ROLLER

SLEWING BEARING

9×10 (20×10)

FRONT IDLER

42×2 (93×2)

IDLER ADJUSTER

30×2 (66×2)

SPROCKET

14×2 (31×2)

RUBBER CRAWLER SHOE

210 ×2 (463×2)

400 mm (15.7") IRON SHOE

275 ×2 (606×2)

22 (49)

175 (386)

27 (60)

535 (1,180)

240 (529)

165 (364)

50 (110)

180 (397)

115 (256)

BUCKET CYLINDER

27 (60)

BUCKET LINK

13 (29)

4×2 (9×2)

112 (247)

95 (210)

HYDRAULIC OIL

45 (99)

FUEL

44 (97)

6 (13)

SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM ARM CYLINDER ARM ASSEMBLY ARM

IDLER LINK BUCKET ASSEMBLY (STD) FLUIDS (ASSY OF FOLLOWINGS)

COOLANT

Note: Bucket weight is shown with standard bucket weight.

2-8


2. SPECIFICATIONS

2.5

TRANSPORTATION

(1) LOADING MACHINE ON A TRAILER 1) Keep trailer bed clean. Put chocks against truck wheels. 2) Use a ramp or loading deck. Ramps must be strong enough, have a low angle, and correct height. Load and unload machine on a level surface. 3) Travel machine onto ramps slowly. Center the machine over the trailer. 4) Lower all attachment. 5) Stop engine. Remove key from switch.

SWARNING Do not put chains over or against hydraulic lines or hoses. 6) Fasten machine to trailer with chains or cables. During transportation, the bucket or attachments may hit the canopy or the cab. Therefore, set the machine in the transporting position by observing following points: 1. Extend the bucket cylinder fully. 2. Extend the arm cylinder fully. 3. Lower the boom. 4. If machine cannot be transported with arm cylinder fully extended, remove bucket or attachment and extend arm cylinder. (2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT 1) BOOM WITH ARM CYLINDER Model

CX40B

CX50B

L×H×W mm (ft•in)

2790 × 1070 × 310 (9’1.8") (3’6.1") (12.2")

2910 × 1040 × 310 (9’6.6") (3’4.9") (12.2")

Weight w/arm cyl. kg (lb)

223 (492)

237 (523)

H

L 2) ARM & BUCKET (Standard bucket) Model

CX40B

CX50B

L×H×W mm (ft•in)

2630 × 510 × 600 (8’7.5") (20.1") (23.6")

2770 × 510 × 650 (9’1.1") (20.1") (25.6")

Weight kg (lb)

164 (362)

175 (386)

H

L

2-9


2. SPECIFICATIONS 3) ARM Model

CX40B

CX50B

L×H×W mm (ft•in)

1870 × 420 × 250 (6’1.6") (16.5") (9.84")

2010 × 420 × 250 (6’7.1") (16.5") (9.84")

Weight kg (lb)

164 (362)

175 (386)

H L

4) BUCKET (Standard bucket) Model

CX40B

CX50B

Heaped capacity m3(cu•yd)

0.14 (0.18)

0.16 (0.21)

L×H×W mm (ft•in)

780 × 690 × 650 (30.7") (27.2") (25.6")

780 × 690 × 750 (30.7") (27.2") (29.5")

Weight kg (lb)

89 (196)

98 (216)

H

L 5) DOZER w/o cylinder weight Model

CX40B

CX50B

L×H×W mm (ft•in)

1130 × 335 × 1960 (3’85") (13.2") (6’5.2")

1190 × 335 × 1960 (3’11") (13.2") (6’5.2")

Weight kg (lb)

170 (375)

175 (386)

H L

2-10


2. SPECIFICATIONS

2.6

TYPE OF CRAWLER SHOES Type

Rubber shoe

Iron shoe (option)

Shoe width mm (in)

Total Crawler width mm (ft•in)

Number of Link

CX40B

400 (15.7")

1960 (6’5")

CX50B

400 (15.7")

CX40B

CX50B

Model

Ground pressure kPa (psi) CANOPY

CAB

68

26 (3.77)

27 (3.92)

1960 (6’5")

72

26 (3.77)

27 (3.92)

400 (15.7")

1960 (6’5")

36

26 (3.77)

27 (3.92)

400 (15.7")

1960 (6’5")

38

27 (3.92)

28 (4.06)

2-11


2. SPECIFICATIONS

2.7

TYPE OF BUCKET TYPE

ARM

Width mm (ft•in)

Heaped capacity m3 (cu.yd)

Weight kg (lb)

(ISO 7451)

Digging buckets

300 (11.81”)

0.050 (0.06)

56.14 (123.37)

Digging buckets

450 (17.72”)

0.090 (0.11)

74.01 (163.16)

Digging buckets

550 (21.65”)

0.120 (0.15)

82.43 (181.72)

Digging buckets

600 (23.62”)

0.130 (0.17)

85.89 (189.35)

Digging buckets

650 (25.59”)

0.140 (0.18)

89.33 (196.94)

Digging buckets

700 (27.56”)

0.160 (0.21)

92.79 (204.57)

Digging buckets

750 (29.53”)

0.180 (0.23)

97.73 (215.45)

Digging buckets

800 (31.49”)

0.200 (0.26)

101.22 (223.15)

Digging buckets

900 (35.43”)

0.220 (0.28)

109.64 (241.71)

Cleaning buckets

1200 (47.24”)

0.220 (0.28)

113.17 (249.49)

Cleaning buckets

1400 (55.11”)

0.240 (0.31)

126.22 (278.26)

Cleaning buckets

1500 (59.05”)

0.260 (0.34)

132.44 (291.98)

2-12

CX40B Length 1870 mm (6’1.62” ft•in)

CX50B Length 2010 mm (6’7.13” ft•in)


2. SPECIFICATIONS

SWARNING ◆ The buckets with this length, during left arm slewing higher than 1 m from ground, can interfere with the cabin. For a safe use, consult the Dealer and ask for left slewing limiter of the arm support. ●: Width with lateral cutter ❍: Width without lateral cutter : Generic digging for digging and sand loading operations, gravel, clay, earth in general, etc.. The specific weight of the material should not be higher than 1400 kg/m3. ■: Digging for light applications for operations of digging,sand loading/unloading of gravel, clay, earth in friabile and dry state, ditch cleaning, etc.

2-13


2. SPECIFICATIONS

2.8

ENGINE SPECIFICATIONS

2.8.1

SPECIFICATIONS Model

CX40B, CX50B

Engine Model

4TNV88-XYB

Type

Vertical, 4-cycle water-cooled diesel engine

No. of cylinders - Bore × Stroke

4 - 88 mm (3.46 in) × 90 mm (3.54 in)

Total displacement

2.189 liter (134 cu•in)

Compression ratio

19.1

Rated output

30.4 kW (41.3 PS) at 2400 rpm

Maximum torque

139.3 ~ 147.1 N•m (103 ~ 109 lbf•ft) at 1440 rpm

Low idling

1175 ± 25 rpm

High idling

2600 ± 25 rpm

Fuel consumption rate

Less than 242 g / kWh (178 g / PS•h)

Allowable tilting angles

Continuous ; 30 for all direction

Rotating direction

Counterclockwise as seen from flywheel side

Firing order

1-3-4-2-1

Fuel injection timing (FID, b.T.D.C.)

15.5±1

Fuel injection pressure Valve action

Valve clearance

19.6

MPa (2840

psi)

Open

Close

Intake valve

b.T.D.C. 15 ± 5

a.B.D.C. 45 ± 5

Exhaust valve

b.T.D.C. 56 ± 5

a.B.D.C. 18 ± 5

Intake valve

0.2 mm (0.008 in) in cold condition

Exhaust valve

Thermostat action

0.2 mm (0.008 in) in cold condition Start 71 ± 1.5 C (160 ± 3 F) / Full open 85 C (185 F)

Compression pressure

3.4 ± 0.1 MPa (500 ± 14 psi) at 250 rpm

Lubrication oil pressure

0.44 MPa (64 psi) at 2300 rpm

Dimensions L × W × H

684 × 554 × 662 mm (26.9 × 21.8 × 26.1 in)

Dry weight

170 kg (375 lb)

Governor

Mechanical centrifugal governor (All speed type)

Fuel filtration

cartridge type paper filter

Lubrication system

Forced lubrication with trochoid pump

Cooling system

Liquid cooling / Radiator

Starter capacity

12 V × 2.3kW 12 V × 55 A

Generator capacity Starting aid

Air heater (12 V - 400 W)

Cooling water capacity: Max / Engine

6.0 / 2.7 liter (1.59 / 0.71 gal)

Engine oil volume: Max / Effective

7.4 / 4.0 liter (1.96 / 1.06 gal)

2-14


2. SPECIFICATIONS 2.8.2

ENGINE PERFORMANCE CURVE

CX40B, CX50B Model: 4TNV88A-XYB Rated Output: 30.4 kW / 2400 min-1 (41.3 PS / 2400 rpm) [Sd] 4

Sd

2 0

GT

600

[GT]

500 (148) 200 400

[T]

(129) 175 300 (111)

150

T

(92) 125

50

(68)

(74) 100

45

(61)

(55)

75

40

(54)

(37) 50 g/kWh

35

(48)

[ F ] (235) 320

30

(41)

25

(34)

PS

(221)

300

(206)

280

20

(27)

(191)

260

15

(20)

(177)

240

10

(14)

(162)

220

5

(7)

(147)

200

F

kW g/PSh

800

0

1000

1200

1400

1600

1800

2000

2200

2400

2600

min-1{rpm} F Fuel consumption volume =

ρ X 1000

XPXα

242 = X 21.2 X α 0.835 X 1000 = 8.81 α F. Fuel consumption rate (g/kwh) P. Shaft output (kw)

ρ. Specific gravity α. Standard load factory (0.60 ~ 0.70) Fuel consumption in normal operation; 5.29 ~ 6.17 L/h (load factor: (0.60 ~ 0.70))

T. Shaft torque F. Fuel consumption rate PS.Power output GT. Exhaust temperature Sd. Smoke: Bosch

2-15

2800

PS

[PS]


2. SPECIFICATIONS

[MEMO]

2-16


3

3. ATTACHMENT DIMENSIONS TABLE OF CONTENTS 3.1 BOOM ............................................................................................................... 3-3 3.1.1 BOOM DIMENSIONAL DRAWINGS ............................................................. 3-3 3.1.2 BOOM MAINTENANCE STANDARDS ......................................................... 3-4 3.2 ARM .................................................................................................................. 3-7 3.2.1 ARM DIMENSIONAL DRAWINGS ................................................................ 3-7 3.2.2 ARM MAINTENANCE STANDARDS ............................................................ 3-9 3.3 BUCKET .......................................................................................................... 3-13 3.3.1 BUCKET DIMENSIONAL DRAWINGS ....................................................... 3-13 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-14 3.4 DOZER ............................................................................................................ 3-15 3.4.1 DOZER DIMENSIONAL DRAWINGS ......................................................... 3-15 3.4.2 DOZER MAINTENANCE STANDARDS ..................................................... 3-16 3.5 SWING ............................................................................................................ 3-18 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ........................................ 3-18 3.5.2 SWING PORTION MAINTENANCE STANDARDS .................................... 3-19


3. ATTACHMENT DIMENSIONS

3-1


3. ATTACHMENT DIMENSIONS

3-2


3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWINGS

Fig. 3-1 Boom Dimensional Drawings Table 3-1 Unit: mm (ft•in) No.

DIMENSIONS

NAME

CX40B

CX50B

A

Boom length

2670 (8'9.12")

2790 (9'1.84")

B

Distance between pins of boss

R1406 (4'7.35")

R1434 (4'8.46")

C

Distance between pins of bracket

R1475 (4'10.1")

R1487.5 (4'10.6")

D

Height of boom cylinder rod pin

470 (18.5")

457.5 (18.0")

E

Height of arm cylinder (head side) pin

941.5 (37.1")

908 (35.7")

F

Boom width

250 (9.84")

G

Inner width of bracket for boom cylinder (rod side) mounting

76 (2.99")

H

Boom end inner width

175 (6.89")

J

Boom end outer width

265 (10.4")

K

Inner width of bracket for arm cylinder (head side)

d1

Boom pin dia. [Bushing outer dia.]

66 (2.60")

ø50 (1.97") [ø60 (2.36")]

d2

Boom cylinder (rod side) pin dia.

ø50 (1.97")

d3

Pin dia. of arm end

ø60 (2.36")

d4

Arm cylinder (head side) pin dia.

ø45 (1.77")

3-3


3. ATTACHMENT DIMENSIONS 3.1.2

BOOM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing on boom section

Fig. 3-2 Clearance of pin and bushing on boom section Table 3-2 Unit: mm (in) Standard dimensions Pos.

Item

A

Boom

B

Boom cylinder (Head side)

C

Boom cylinder (Rod side)

D

Arm cylinder (Head side)

Pin dia.

Clearance

Tolerance Tolerance on bushing on pin dia. bore dia. +0.061 0 (+0.0024) ( 0 )

ø50 (1.97)

–0.02 –0.08 (-0.0008) (-0.0031)

+0.25 +0.05 (+0.0098) (+0.0020)

Standard value

Standard value for repair

Serviceabili ty limit

0.7 (0.028)

1.0 (0.039)

0.02~ 0.141 (0.0008~0.0 056)

0.07~ 0.33 (0.0028~ 0.0130)

ø45 (1.77)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

The part number for pins may be changed owing to improvement, use them only for reference.

3-4

Remedy

Replace bushing or pin


3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on boom and cylinder installation section

Fig. 3-3 Clearance in thrust direction on boom section

3-5


3. ATTACHMENT DIMENSIONS Table 3-3 Unit: mm (in) Standard dimensions Sec.

Item No. Dimensions

L1 Swing bracket

B-B

Boom cylinder (Head side)

Boom cylinder C-C (Rod side)

(9.84

(9.84

Boom cylinder L2 Swing bracket

0.1~0.5 (0.004~ 0.020)

PL1

377 (14.8)

0.1~0.5 (0.004~ 0.020)

PL2

264 (10.4)

0.5~0.9 (0.020~ 0.035)

PL3

213 (8.39)

0.1~0.5 (0.004~ 0.020)

PL4

200 (7.87)

)

(2.95

)

77 (3.03

Boom cylinder

)

1.0 (0.039)

75 L3

(2.95

)

76

Arm cylinder

1.5 (0.059)

Adjusted with shim

)

65 L4

Boom

Remedy Standard ServiceabilNo. Dimensions value for ity limit repair

75

(2.99

Arm cylinder (Head side)

)

250

Boom

D-D

Standard value

Pin length

250

Boom A-A Boom

Clearance X adjusted with shim (total of both sides)

(2.56

)

66 (2.60

)

3-6


3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWINGS

Fig. 3-4 Arm dimensional drawings

3-7


3. ATTACHMENT DIMENSIONS Table 3-4 Unit: mm (ft•in) No.

Dimensions

Name

CX40B

CX50B

1430 (4'8.30")

1560 (5'1.42")

A

Arm length

B

Distance between pins of boss and bracket

R405 (15.9")

C

Distance between pins of boss and bracket

R1118 (3'8.02")

D

Distance between pins of boss and boss

R230.5 (9.07")

E

Height between pins of boss and bracket

311 (12.2")

F

Height between pins of boss and bracket

211 (8.31")

191.5 (7.54")

G

Height between pins of boss and center

12 (0.472")

H

Boss width

150 (5.91")

J

Boss width

175 (6.89")

K

Bracket inner width

61 (2.40")

L

Bracket inner width

61 (2.40")

66 (2.60")

M

Idler link dimension

320 (12.6")

N

Bucket link dimension

310 (12.2")

D1 I.D. of boss

ø55 (2.17")

D2 I.D. of boss

ø55 (2.17")

D3 I.D. of boss

ø75 (2.95")

d1

Pin dia.

ø45 (1.77")

d2

Pin dia.

ø45 (1.77")

d3

Pin dia.

ø60 (2.36")

d4

Pin dia.

ø45 (1.77")

d5

Pin dia.

ø45 (1.77")

3-8


3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Fig. 3-5 Clearance of pin and bushing on arm section Unit: mm (in) Standard dimensions Pos.

Item

A

Arm point (Connected part of bucket)

B

Bucket link (Bucket side)

C

Idler link (Connected part of arm)

Pin dia.

ø45 (1.77)

Bucket link (Idler link side)

D

Tolerance on pin dia.

–0.02 –0.05 (-0.0008) (-0.0020)

D’

Bucket cylinder (Rod side)

E

Bucket cylinder (Head side)

F

Arm foot (Connected part of boom)

ø60 (2.36)

G

Arm cylinder (Rod side)

ø45 (1.77)

Clearance

Tolerance on bushing bore Standard value dia. +0.064 +0.005 (+0.0025) (+0.0002)

0.025~ 0.114 (0.0010~ 0.0045)

+0.076 +0.035 (+0.0030) (+0.0014)

0.055~ 0.126 (0.0022~ 0.0050)

+0.073 +0.032 (+0.0029) (+0.0013)

0.052~ 0.123 (0.0020~ 0.0048)

+0.25 +0.05 (+0.0098) (+0.0020)

0.07~ 0.30 (0.0028~ 0.0118)

+0.061 0 (+0.0024) ( 0 ) +0.25 +0.05 (+0.0098) (+0.0020)

Standard value for repair

Serviceability limit

0.7 (0.028)

1.0 (0.039)

0.02~ 0.111 (0.0008~ 0.0044) 0.07~ 0.30 (0.0028~ 0.0118)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

The part number for pins may be changed owing to improvement, use them only for reference.

3-9

Remedy

Replace bushing or pin


3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on arm and cylinder installation section

Fig. 3-6 Clearance in thrust direction on arm section

3-10


3. ATTACHMENT DIMENSIONS Table 3-6 • CX40B

Unit: mm (in) Standard dimensions

Sec.

Item No.

L1 Bucket

Bucket link (Rod side)

L2

Arm L3 Link side

L4

L5

150 (5.91)

287.5 (11.3)

— (—)

(2.165

)

(5.91

0.6~1.0 (0.024~ 0.039)

PL3

210.5 (8.29)

1.5 (0.059)

PL5

210.5 (8.29)

0.1~0.5 (0.004~ 0.020)

)

PL6

183 (7.20)

PL7

265 (10.4)

PL8

183 (7.20)

2.0 (0.079) Adjusted with shim

60 L6

(2.36

0.5~0.9 (0.020~ 0.035)

)

61

Arm

(2.40

)

175

Arm L7

(6.89

Less than 0.5 (0.020)

)

175

Boom

(6.89

1.0 (0.039)

1.5 (0.059)

)

60

Rod side L8 Arm

0.1~0.5 (0.004~ 0.020)

— (—)

Head side

Arm cylinder (Rod side)

PL2

)

150

Idler link

G-G

287.5 (11.3)

See "NOTE"

)

57±0.4 (2.24±0.016)

Bucket link

F-F Arm foot

0.7~2.2 (0.028~ 0.087)

55

Rod side

Bucket cylinder (Head side)

)

PL1

151

D-D

E-E

(5.91

(5.94

Link side

Bucket link (Idler link side)

151

150

Bucket Idler link C-C (Connected part of arm)

Standard Service- Remedy Standard value for ability No. Dimensions Dimensions value repair limit

(5.94

Link side B-B Bucket link

Pin length

150 (5.91)

Arm A-A Arm point

Clearance X adjusted with shim (total of both sides)

(2.362

)

61 (2.402

0.5~0.9 (0.020~ 0.035)

)

(Note) •

Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

3-11


3. ATTACHMENT DIMENSIONS Table 3-7 • CX50B

Unit: mm (in) Standard dimensions

Sec.

Item No.

L1 Bucket

Standard Service- Remedy Standard value for ability No. Dimensions Dimensions value repair limit

151 (5.94

L2

(5.91

(5.94

Bucket link (Rod side)

Arm L3 Link side

L4

L5

— (—)

(2.165

L6

(5.91

)

(2.36

)

61

Arm

(2.40

0.6~1.0 (0.024~ 0.039)

PL3

210.5 (8.29)

1.5 (0.059)

0.1~0.5 (0.004~ 0.020)

2.0 (0.079) Adjust- PL5 ed with shim

L7

0.5~0.9 (0.020~ 0.035)

PL6

183 (7.20)

PL7

265 (10.4)

PL8

183 (7.20)

)

(6.89

)

175

Boom

(6.89

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

)

65

Rod side L8

(2.56

)

66 (2.60

0.5~0.9 (0.020~ 0.035)

)

(Note) •

210.5 (8.29)

175

Arm

Arm

287.5 (11.3)

60

Head side

Arm cylinder G-G (Rod side)

)

— (—)

Idler link

F-F Arm foot

0.1~0.5 (0.004~ 0.020)

150

Bucket link

Bucket cylinder (Head side)

PL2

)

150 (5.91)

57±0.4 (2.24±0.016)

D-D

E-E

287.5 (11.3)

See "NOTE"

)

55

Rod side Link side

Bucket link (Idler link side)

PL1

151

Bucket Idler link C-C (Connected part of arm)

0.7~2.2 (0.028~ 0.087)

)

150

Link side B-B Bucket link

Pin length

150 (5.91)

Arm A-A Arm point

Clearance X adjusted with shim (total of both sides)

Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

3-12


3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

BUCKET DIMENSIONAL DRAWINGS

Fig. 3-7 Bucket dimensional drawings Table 3-8 Unit: mm (in) No. A

Model

CX40B

CX50B

Heaped Capacity m3 (cu.yd)

0.14 (0.17)

0.16 (0.20)

228.5 (9)

Distance between pin and bracket

B

Distance between bucket pin and tooth end

R802 (31.6)

C

Inner width of bucket top end

568 (22.36)

668 (26.29)

D

Inner width of lug

181 (7.12)

E

Inner width of bracket

151 (5.94)

F

Outer width of side cutter

650 (25.59)

700 (27.56)

G

Outer width of bucket bottom plate

510 (20.08)

610 (24.01)

H

Outer tooth distance

500 (19.68)

600 (23.62)

J

Pitch between teeth

166 (6.53)

200 (7.87)

J0

Pitch between teeth

166 (6.53)

200 (7.87)

d1

Pin dia.

ø45 (1.77)

d2

Pin dia.

ø45 (1.77)

3-13


3. ATTACHMENT DIMENSIONS 3.3.2

DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Fig. 3-8 Dimension of lug section Table 3-9 Unit: mm (in) Portion Dimensions

Plate outer dia. øA

Boss thickness B

ø75 (2.95)

15 (0.59)

3-14

Pin bore dia. øC ø45 (1.77

)

Lug plate thickness D 10 (0.39)


3. ATTACHMENT DIMENSIONS

3.4

DOZER

3.4.1

DOZER DIMENSIONAL DRAWINGS

Fig. 3-10 Dozer dimensional drawings Table 3-10 Unit: mm (ft•in) No.

Dimensions

NAME

CX40B

CX50B

A

Blade width

1960 (6'5.17")

B

Blade height

346 (1'1.62")

C

Distance from dozer attaching pin center to cutting edge end

R1092 (3'6.99")

R1149 (3'9.24")

D

Inner width of dozer attaching bracket

531 (20.9")

E

Width of dozer attaching bracket

69 (2.72")

F

Distance from dozer attaching pin center to attaching pin on dozer cylinder head side

R712 (28.0")

62 (2.44")

1046 (3'5.18")

1105.3 (3'5.72")

Vertical distance from dozer attaching pin center to edge end

313 (12.3")

d1

Dozer attaching pin dia.

ø40 (1.57")

d2

Attaching pin dia. on dozer cylinder head side

ø55 (2.17")

G

Attaching bracket inner width on dozer cylinder head side

H

Horizontal distance from dozer attaching pin center to edge end

J

3-15


3. ATTACHMENT DIMENSIONS 3.4.2

DOZER MAINTENANCE STANDARDS

Fig. 3-11 Dozer maintenance standards A-B-C = Pin (1) Clearance of pin and bushing Table 3-11 Unit: mm (in) Standard dimension Pos.

Item

A

Dozer blade cylinder (Head side)

B

Dozer blade cylinder (Rod side)

C

Dozer blade foot

Pin dia.

ø55 (2.17)

ø40 (1.57)

Clearance

Tolerance on Tolerance on Standard val- Standard val- Serviceabilipin dia. bushing bore ue ue for repair ty limit dia. –0.15 –0.21 (-0.0059) (-0.0083)

+0.25 +0.05 (+0.0098) (+0.0020)

0.20~ 0.46 (0.0079~0.01 81)

–0.06 –0.09 (-0.0024) (-0.0035)

+0.215 +0.115 (+0.0085) (+0.0045)

0.175~ 0.305 (0.0069~0.01 20)

1.5 (0.059)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

The part number for pins may be changed owing to improvement, use them only for reference.

3-16

2.0 (0.079)


3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the dozer and cylinder installation section Table 3-12 Unit: mm (in) Standard dimensions Pos.

A

Item

Dozer blade cylinder (Head side)

No.

Dimensions

B

L1

C

(2.362

)

)

60

Rod side L2 Lower frame

Lower frame

No. Dimensions

PL1

141 (5.55)

PL2

141 (5.55)

PL3

137 (5.39)

62

Dozer blade

(2.362

2.0~3.5 (0.079~0.035) Adjusted with shim

)

62 (2.441

)

69±0.5 (2.72±0.020)

Dozer blade Dozer blade foot

Remedy

60

Head side

(2.441 Dozer blade cylinder (Rod side)

Clearance X adjusted with shim (total of both sides)

Pin length

L3

72 (2.83

2.5~4.5 (0.079~0.177)

)

(NOTE) •

Clearance X shall be adjusted using shims, if clearance exceeds the standard value for repair.

3-17


3. ATTACHMENT DIMENSIONS

3.5

SWING

3.5.1

SWING BRACKET DIMENSIONAL DRAWINGS

E

H

d3

D

B

G

A

d2

C F1

F J

F2 d4

d1 Fig. 3-12 Swing bracket dimensional drawings Table 3-13

Unit: mm (in) No.

NAME

DIMENSION

A

Distance between swing center pin and boom foot pin

B

Distance between boom foot pin and boom cylinder pin

67 (2.64)

C

- ditto -

D

Distance between swing center pin and swing cylinder pin

E

- ditto -

290 (11.4)

F

Inside width of swing center

329 (13.0)

207.6 (8.17) 320.7 (12.6) R307.5 (12.1)

F1 - ditto -

78.5 (3.09)

F2 - ditto -

76 (2.99)

G

Inside width of boom foot

250 (9.84)

H

Inside width for installing boom cylinder

77 (3.03)

J

Inside width for installing swing cylinder

73 (2.87)

d1

Pin dia. of swing center

ø80 (3.15)

d2

Pin dia. of boom foot

ø50 (1.97)

d3

Pin dia. of boom cylinder

ø50 (1.97)

d4

Pin dia. of swing cylinder

ø50 (1.97)

3-18


3. ATTACHMENT DIMENSIONS 3.5.2

SWING PORTION MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

B

C

A

D Fig. 3-13 Clearance of pin and bushing on swing portion Table 3-14 Unit: mm (in) Standard dimension Pos.

Item

A

Swing cylinder (Rod side)

B

Swing cylinder (Head side)

C

Swing center (Upper side)

D

Swing center (Lower side)

Pin dia.

ø50 (1.97)

ø80 (3.15)

Tolerance on Tolerance on bushing bore pin dia. dia.

–0.02 –0.05 (-0.0008) (-0.0020)

+0.150 0 (+0.0059) ( 0 ) +0.061 +0.009 (+0.0024) (+0.0004)

Clearance Standard value 0.02~ 0.20 (0.0008~0.00 79) 0.029~ 0.111 (0.0001~0.00 44)

Standard value for repair

Serviceability limit

1.5 (0.059)

2.0 (0.079)

(Note) •

The tolerance for bushing inside diameter means the dimension after fitting of it into place.

The part number for pins may be changed owing to improvement, use them only for reference.

3-19


3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on swing bracket and cylinder installation section

PL1 X

PL2

L1

X

L2

B-B

A-A

1

C-C, D-D Fig. 3-14 Clearance in thrust direction on swing portion 1. Washer - To be install the groove to the lower side [t=2.3 (0.091�)]

3-20


3. ATTACHMENT DIMENSIONS Table 3-15 Unit: mm (in) Standard Dimension Sec.

Item No.

Swing A-A cylinder (Rod side)

Dimensions

L1

(2.76

L2

0.5~0.9 (0.020~ 0.035)

PL1

146.5 (5.77)

PL2

151 (5.94)

Replace PL3 washer

155 (6.1)

1.5 (0.059)

Adjusted with PL4 shim

142 (5.59)

1.5 (0.059)

— Adjusted with shim

)

(2.76

)

72 (2.83

Upper frame

0.5~0.9 (0.020~ 0.035)

1.0 (0.039)

)

73 L3

(2.87

)

78.5

Bracket

(3.09 Upper frame

)

73 L4

Bracket

Remedy Standard Serviceability No. Dimensions value for limit repair

70

Cylinder

Swing center D-D (Lower side)

)

73

Bracket

Swing B-B cylinder (Head side) Upper frame

Standard value

Pin length

70

Cylinder

(2.87

Swing center C-C (Upper side)

Clearance X adjusted with shim (total of both sides)

(2.87

)

78.5 (2.99

Less than 0.5 (0.020)

)

3-21


3. ATTACHMENT DIMENSIONS

[MEMO]

3-22


11. TOOLS TABLE OF CONTENTS 11.1 TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS ........................... 11-3 11.1.1 METRIC COARSE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES.................................................................................... 11-3 11.1.2 METRIC FINE THREAD STANDARD TIGHTENING TORQUE VALUES. MAKE CERTAIN TO TIGHTEN ALL CAPSCREWS & NUTS TO PROPER TORQUE VALUES. .................................................................................. 11-4 11.2 SCREW AND TOOL SIZES ............................................................................ 11-5 11.2.1 CAPSCREW ............................................................................................. 11-5 11.2.2 CAPSCREW (SOCKET BOLT) ................................................................ 11-5 11.3 TORQUE SPECIFICATIONS FOR JOINTS AND HOSES ............................. 11-5 11.3.1 JOINTS FOR PIPING (O-RING SEALING TYPE) ................................... 11-5 11.3.2 HYDRAULIC HOSE (30° FLARE TYPE) ................................................. 11-5 11.4 TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS ............ 11-6 11.4.1 SLEEVE TYPE TUBE FITTINGS ............................................................. 11-6 11.5 SPECIAL SPANNERS FOR TUBES ............................................................... 11-7 11.6 SPECIAL TOOLS ............................................................................................ 11-7 11.7 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ......... 11-7 11.8 COUNTERWEIGHT LIFTING JIG ................................................................... 11-8 11.9 UPPER FRAME LIFTING JIG ......................................................................... 11-9


11. TOOLS

11-1


11. TOOLS

11.1

TORQUE SPECIFICATIONS FOR CAPSCREWS & NUTS

The following Torque Specifications are provided for use when actual torque value of a fastener is not known. Check the capscrews and nuts for their looseness and dropping off before the start of daily work and at the periodical maintenance. Retighten the loosened ones, and install new ones for the dropped off. For the new machine, the check and retightening of them must be carried out at first 50 hours operation. For the replacement of them, make sure to use the same size of genuine parts. Refer to the table below for the tightening and retightening of capscrews. •The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening torque for such capscrews, consult with an authorized Distributor. Over-tightening may cause damages on the parts to be fixed. •In case that the tightening torque is specified in the manual, use such torque values regardless to the table below. •Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M 5 or less.

1

1. Classification 11.1.1

Metric Coarse Thread Standard Tightening Torque Values. Make Certain to tighten all Capscrews & Nuts to proper torque values. Torque value Unit: N•m (lbf•ft)

Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M6

P=1

4.4±0.5 (3.2±0.4)

3.7±0.4 (2.7±0.3)

9.6±1.0 (7.1±0.7)

8.1±0.8 (6.0±0.6)

17.4±1.8 (12.8±1.3)

14.7±1.5 (10.8±1.1)

M8

P=1.25

10.7±1.1 (7.9±0.8)

9.0±0.9 (6.6±0.7)

23.5±2.0 (17.3±1.5)

19.6±2.0 (14.5±1.5)

42.2±3.9 (31.1±2.9)

35.3±3.9 (26.0±2.9)

M10

P=1.5

21.6±2.0 (15.9±1.4)

17.9±1.8 (13.2±1.3)

46.1±4.9 (34.0±3.6)

39.2±3.9 (28.9±2.9)

83.4±8.8 (61.5±6.5)

70.6±6.9 (52.1±5.1)

M12

P=1.75

36.3±3.9 (26.8±2.9)

31.4±2.9 (23.2±2.1)

79.4±7.8 (58.6±5.8)

66.7±6.9 (49.2±5.1)

143±15 (105±11)

121±12 (89.2±8.9)

M14

P=2

57.9±5.9 (42.7±4.4)

49.0±4.9 (36.1±3.6)

126±13 (92.9±9.6)

106±10 (78.2±7.4)

226±20 (167±15)

191±19 (141±14)

M16

P=2

88.3±8.8 (65.1±6.5)

74.5±6.9 (55.0±5.1)

191±20 (141±15)

161±16 (119±12)

343±39 (253±29)

284±29 (209±21)

M18

P=2.5

122±12 (90.0±8.9)

103±10 (75.8±7.2)

265±29 (195±21)

226±20 (167±15)

481±49 (355±36)

402±39 (297±29)

M20

P=2.5

172±17 (127±13)

144±14 (106±10)

373±39 (275±29)

314±29 (232±21)

667±69 (492±51)

559±59 (412±44)

M22

P=2.5

226±20 (167±15)

192±20 (142±15)

500±49 (369±36)

422±39 (311±29)

902±88 (665±65)

755±78 (557±58)

M24

P=3

294±29 (217±21)

235±29 (173±21)

637±69 (470±51)

520±49 (383±36)

1160±118 (856±87)

941±98 (694±72)

M27

P=3

431±39 (318±29)

353±39 (260±29)

941±98 (694±72)

765±78 (564±58)

1700±167 (1250±123)

1370±137 (1010±101)

11-3


11. TOOLS Torque value Unit: N•m (lbf•ft) Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M30

P=3.5

588±59 (434±44)

490±49 (361±36)

1285±127 (948±94)

1079±108 (796±80)

2300±235 (1700±173)

1940±196 (1430±145)

M33

P=3.5

794±78 (586±58)

667±69 (492±51)

1726±177 (1270±131)

1451±147 (1070±108)

3110±314 (2290±232)

2610±265 (1930±195)

M36

P=4

1030±98 (760±72)

863±88 (637±65)

2226±226 (1640±167)

1863±186 (1370±137)

4010±402 (2960±297)

3360±333 (2480±246)

11.1.2

Metric Fine Thread Standard Tightening Torque values. Make certain to tighten all Capscrews & Nuts to proper torque values. Torque value Unit: N•m (lbf•ft)

Classification Nominal size

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication

M8

P=1.0

11.3±1.1 (8.3±0.8)

9.5±1.0 (7.0±0.7)

24.5±2.0 (18.1±1.5)

20.6±2.0 (15.2±1.5)

44.1±3.9 (32.5±2.9)

37.3±3.9 (27.5±2.9)

M10

P=1.25

22.6±2.0 (16.7±1.5)

18.7±1.9 (13.8±1.4)

48.1±4.9 (35.5±3.6)

41.2±3.9 (30.3±2.9)

87.3±8.8 (64.4±6.5)

73.5±6.9 (54.2±5.1)

M12

P=1.25

39.2±3.9 (28.9±2.9)

33.3±2.9 (24.6±2.1)

85.3±8.8 (62.9±6.5)

71.6±6.9 (52.8±5.1)

154±16 (114±12)

129±13 (95.2±9.6)

M16

P=1.5

92.2±8.8 (68.0±6.5)

77.5±7.8 (57.2±5.8)

196±20 (145±15)

169±17 (125±13)

363±39 (268±29)

304±29 (224±21)

M20

P=1.5

186±19 (137±14)

155±16 (114±12)

402±39 (297±29)

333±29 (246±21)

726±69 (535±51)

608±59 (448±44)

M24

P=2

314±29 (232±21)

265±29 (195±21)

686±69 (506±51)

569±59 (420±44)

1240±118 (915±87)

1030±98 (760±72)

M30

P=2

637±59 (470±44)

530±49 (391±36)

1390±137 (1030±101)

1157±118 (853±87)

2500±255 (1840±188)

2080±206 (1530±152)

M33

P=2

853±88 (629±65)

706±70 (521±52)

1860±186 (1370±137)

1550±155 (1140±114)

3350±334 (2470±246)

2790±275 (2060±203)

M36

P=3

1070±108 (789±80)

892±88 (658±65)

2330±226 (1720±167)

1940±196 (1430±145)

4200±422 (3100±311)

3500±353 (2580±260)

11-4


11. TOOLS

11.2

SCREW AND TOOL SIZES

11.2.1

Capscrew

Nominal screw size (d) M6

B mm Tool size 10

Nominal screw size (d)

B mm

M24

36

M8

13

M30

46

M10

17

M36

55

M12

19

M42

65

M16

24

M48

75

M20

30

11.2.2

d

Tool size

B

Capscrew (Socket bolt)

Nominal screw size (d)

B mm Tool size

Nominal screw size (d)

B mm

d

Tool size

M6

5

M20

17

M8

6

M24

19

M10

8

M30

22

M12

10

M36

27

M14

12

M42

32

M16

14

M48

36

(M18)

14

B

11.3

TORQUE SPECIFICATIONS FOR JOINTS AND HOSES

11.3.1

JOINTS FOR PIPING (O-RING SEALING TYPE)

Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

14

17±2 (12±1)

1/4

19

36±2 (27±1)

11.3.2

3/8

22

74±5 (54±4)

1/2

27

108±9.8 (80±7)

3/4

36

162±9.8 (119±7)

1

41

255±9.8 (188±7)

HYDRAULIC HOSE (30° FLARE TYPE)

Nominal screw size (PF)

Spanner size (mm)

Tightening torque N•m (lbf•ft)

1/8

17

15±2.0 (11±1)

1/4

19

29±4.9 (22±4)

3/8

22

49±4.9 (36±4)

1/2

27

78±4.9 (58±4)

3/4

36

118±9.8 (87±7)

1

41

137±15 (101±11)

NOTE: The application of the tightening torque is subject to a dry condition.

11-5


11. TOOLS

11.4

TORQUE SPECIFICATIONS FOR SLEEVE TYPE TUBE FITTINGS

11.4.1

SLEEVE TYPE TUBE FITTINGS

Tube size OD × Thickness (mm)

Spanner size (mm)

Tightening Torque N•m (lbf•ft)

10 × 1.5

19

44±4.9 (33±4)

15 × 2.0

27

147±20 (110±14)

18 × 2.5

32

177±20 (130±14)

22 × 3.0

36

216±20 (160±14)

28 × 4.0

41

275±29 (200±22)

35 × 5.0

55

441±44 (330±33)

11-6


11. TOOLS

11.5

SPECIAL SPANNERS FOR TUBES

Applicable tube diameter mm (in)

Part No.

HEX mm (in)

27

15 (0.591)

(1.063)

32

18 (0.709)

(1.26)

36

22 (0.866)

(1.417)

41

28 (1.102)

11.6

Dimensions of a special spanner mm

(1.614)

SPECIAL TOOLS Unit: mm (in)

No.

Tools name

1

Torx driver (with tamper proof) T25 (for M5)

11.7

Tools No.

Shape

Use

4.4 (0.17")

For instrument R.H cover

—

APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS Service

Manufacturer Loctite

Three-Bond

Features

#242

1360 K

Low strength

Screw locking compound

#262

1374

Middle strength

#271

1305

High strength

Sealing compound

#515

1215

Sealing

11-7


11. TOOLS

11.8

COUNTERWEIGHT LIFTING JIG

Q’ty: 2 set Material: Mild steel UNIT: mm (in)

49 9 (1.93") (0.35")

(2.36")

40 (1.57")

")

.95

(0 24

C 420

0. 5(

12 (0.47")

112 (4.41") 60

30 (1.12")

170 (6.69")

")

310 (12.2")

40

(1.5

8")

0 R15 ) 1" (5.9 100 (3.94")

477 (18.8")

527 (20.7")

10 (0.39") (539) {21.2"}

20(4)-90 {0.79"(0.16")-3.54"}

10 C

70 (2.76") 10 (0.39")

3 (0.12") 10 (0.39")

R50 (1.9 7")

)

9"

.3 (0

12 (0.47")

300 (11.8")

3 (0.12")

100 (3.94")

R

R (1 50 .9 7" )

135 (5.32")

50 (1.97")

Fig. 11-1 Counterweight lifting jig

11-8

160 (6.30")


11. TOOLS

11.9

UPPER FRAME LIFTING JIG

Q’ty: 2 set Material: Mild steel UNIT: mm (in)

79

. (0

(1.97")

")

50

40(2)-100 {1.58"(0.079")-3.94"}

24( 0.9 5")

20

C 2-

5 (0.20")

244 (9.61")

16 (0.63")

310 (12.2")

100 (3.94")

15 (0.59")

")

58

1. 0(

4

40(2)-120 {1.58"(0.079")-4.72"}

12 (0.47")

420 (16.5")

(536) {21.1"}

167 (6.58") 50 (1.97")

5 ) C2 .98" (0

(0

Fig. 11-2 Upper frame lifting jig

11-9

0 R2 9") .7 (0

C1 .3 0 9" )

50

0 R3 8") .1 (1

5 (0.20")

(1.97")

12 (0.47")

470 (18.5")

5 (0.20")

16 (0.63")

R


11. TOOLS

[MEMO]

11-10


12. STANDARD MAINTENANCE TIME TABLE TABLE OF CONTENTS 12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ............................................................................................ 12-4


12. STANDARD MAINTENANCE TIME TABLE

12-1


12. STANDARD MAINTENANCE TIME TABLE

12-2


12. STANDARD MAINTENANCE TIME TABLE PREFACE (1) Working Conditions 1) Technicians: One or more technicians qualified (with five years or more of field experience and having completed the training in the operation of vehicle type construction machinery) to be provided. 2) Facilities: General jigs, tools, apparatus, testers to be provided. The maintenance workshop to be equipped with a good enough capacity of building with crane and inspection instruments necessary for specific self inspection activities. 3) Place: The workshop to be located on a flat land at which the work is able to perform and to which a service car or truck crane is accessible. (2) Applicable Range of Standard Maintenance Time 1) Standard maintenance time: Direct maintenance time plus spare time. 2) Direct maintenance time: Net time actually spent for maintenance. 3) Spare time: Time for transportation of the machine for maintenance, preparation for safety work, meeting for the work and physiological time for the needs of body. (3) Excluded Time (not included in the standard maintenance time) 1) Repairing time: Time for machining, sheet metal processing, welding, gas cutting, removing broken screw, taking care of parts and painting. 2) Items excluded from maintenance time because of uncertainty in time: Receiving the vehicle into shop, transportation, delivery, final inspection and investigation of causes for trouble, diagnosis and inspection. 3) Indirect time: Time for field work, preparation of required parts, etc., before starting work, going to and from the site, waiting due to user’s convenience at the site and paper work for reports, bills, etc. 4) Special time: Working time at early morning, at mid night and on holidays shall be separately calculated. 5) Separate calculation: The cost for service cars, trucks with crane and truck cranes shall be separately calculated. (4) Applicable Machine for Estimation of Standard Maintenance Time 1) Standard machine. 2) A well maintained machine combined with standard attachments which has operated in a normal circumstances.

12-3


12. STANDARD MAINTENANCE TIME TABLE

12.1

STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR

(1) Standard maintenance time table 1) Units of working time: 6 minutes = 0.1 hour 2) Calculating method of standard maintenance time: Maintenance time = Working time × Number of workers (Working time = Maintenance time / Number of workers) 3) When more than one work are done: a. Add each standard maintenance time b. A net time (readily starting) is given except covers easily removed by hand. c. Assy works include the following works marked with black dot • 4) O / H: The removing and installing time are not included. 5) Abbreviations in the table. ASSY :

Assembly

SOL :

Solenoid

Rem. :

ATT

:

Removal

Attachment

SW

:

Switch

Inst. :

Installation

BRG :

Bearing

V

:

Valve

O/H

Overhaul

C/V

:

Control valve

F hose:

Flexible hose

Cyl

:

Cylinder

E/G

Engine

:

:

(2) Classification of work code No.

GROUP

01

Attachment

02

Canopy and Guard

03

Upper Structure

04

Under carriage

GROUP No.

REMARKS To indicate removing, installing, replacement and overhaul.

WORK TO BE DONE

UNIT

01 Bucket ASSY

Rem.l/Inst.

1 pc.

02 • Bucket removing / installing position

Preparation

1 pc.

Rem./Inst.

1 pc.

EQUIPMENT PORTION

00 Bucket portion

03 • Bucket installing pin 04 • Bucket drive pin

01 Attachment

05 • Bucket sling and transfer 06 Bucket (Single) 07 • Bushing

• Bucket cylinder removing / installing 12 position and piping 13 • Bucket cylinder rod pin 14 • Bucket cylinder head pin

UNIT: HOUR

Refer to 32.1.2 Include adjustment

0.4

Include stopper pin.

0.1

0.1

- ditto -

1 pc.

0.1

Preparation

1 pc.

0.1

O/H

1 pc.

Replace

1 pc.

10 Arm portion 11 Arm ASSY

REMARKS

Not include removal / inst.

0.6 0.5

Refer to 32.1.3 Rem./Inst.

1 pc.

0.8

Preparation

1 pc.

0.2

Rem./Inst.

1 pc.

Include stopper pin.

0.1

- ditto -

1 pc.

Include stopper pin.

0.1

Include stopper pin.

0.1

15 • Bucket cylinder assy

- ditto -

1 pc.

16 • Arm cylinder rod pin

- ditto -

1 pc.

17 • Boom top pin

- ditto -

1 pc.

0.1

18 • Arm sling and transfer

- ditto -

1 pc.

0.1

12-4

0.1


12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

Rem./Inst.

1 pc.

20 Boom portion 21 Boom ASSY 22 • Boom removing / installing position 23 • Boom cylinder temporary slinging

UNIT: HOUR

Refer to 32.1.4 1.0

Preparation

1 pc.

0.1

- ditto -

1 pc.

0.1

24 • Boom cylinder rod pin

Rem./Inst.

1 pc.

25 • Boom cylinder piping

- ditto -

1 pc.

0.1

26 • Arm & Bucket piping

Include stopper pin.

0.1

- ditto -

1 pc.

0.2

Rem. / Inst.

1 pc.

0.1

28 • Boom foot pin

- ditto -

1 pc.

29 • Boom assy slinging

- ditto -

1 pc.

27 • Boom assy temporary slinging

01 Attachment

REMARKS

Include stopper pin.

0.1 0.1

30 Arm cylinder removing / installing

- ditto -

1 pc.

0.3

31 • Arm cylinder piping

- ditto -

1 pc.

0.1

32 • Arm cylinder head pin

- ditto -

1 pc.

33 • Arm cylinder slinging

- ditto -

1 pc.

Include stopper pin.

0.1 0.1

40 Boom cylinder removing / installing

- ditto -

1 pc.

0.3

41 • Boom cylinder piping

- ditto -

1 pc.

0.1

42 • Boom cylinder head pin

- ditto -

1 pc.

0.1

43 • Boom cylinder slinging

- ditto -

1 pc.

0.1

50 Bucket cylinder

O/H

1 pc.

2.5

51 • Pin bushing

Replace

1 set

O/H

1 pc.

61 • Pin bushing

Replace

1 set

70 Boom cylinder

O/H

1 pc.

71 • Pin bushing

Replace

1 set

60 Arm cylinder

80 Swing portion 81 Swing bracket assy

Include seal.

1.0 2.5

Include seal.

1.0 2.5

Include seal.

1.0

Refer to 32.1.5 Rem. / Inst.

1 pc.

82 • Swing cylinder rod pin

- ditto -

1 pc.

0.1

83 • Swing bracket slinging

- ditto -

1 pc.

0.1

84 • Swing center pin

- ditto -

1 pc.

0.1

85 Swing cylinder removing / installing

- ditto -

1 pc.

Rem. / Inst.

2 pcs.

0.2

- ditto -

1 pc.

0.1

88 Swing cylinder

O/H

1 pc.

89 • Pin bushing

Replace

1 pc.

Include seal.

1.0

Rem. / Inst.

1 set

Panel assy (3)

0.1

86 • Swing cylinder hose 87 • Swing cylinder head pin

Other necessary works 90 Dozer portion 91 Dozer ASSY

After removing boom.

After removing swing bracket.

0.4

0.3

2.5

Refer to 32.1.6 Rem. / Inst.

1 pc.

0.6

92 • Dozer cylinder hose

- ditto -

2 pcs.

0.2

93 • Dozer cylinder rod pin

- ditto -

1 pc.

0.1

94 • Dozer installing pin

- ditto -

2 pcs.

0.2

95 Dozer cylinder

O/H

1 pc.

96 • Pin bushing

Replace

1 set

12-5

2.5 Include seal.

1.0


12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

Rem. / Inst.

1 pc.

- ditto -

1 pc.

00 Canopy portion 01 Canopy assy 02 • Hand rail 11 Cab assy

0.1

Rem. / Inst.

1 pc.

0.4

- ditto -

1 pc.

0.1

Rem. / Inst.

1pc.

Refer to 33.1.2 0.1

22 Bonnet assy (2)

- ditto -

1pc.

0.1

23 Cover assy (3)

- ditto -

1pc.

0.1

24 Cover assy (4)

- ditto -

1pc.

0.1

25 Cover assy (5)

Rem. / Inst.

1pc.

0.1

Rem. / Inst.

1 pc.

1.0

32 • Air cleaner

- ditto -

1 pc.

0.1

33 • E / G control cable

- ditto -

1 pc.

0.2

34 • Deceleration motor (OPT)

- ditto -

1 pc.

0.1

35 • Filler neck

- ditto -

1 pc.

0.1

36 • Fuel air bleed hose

- ditto -

1 pc.

0.1

30 Control stand portion 31 Control stand ASSY 02 Canopy & Guard

0.2 Refer to 33.1.1

20 Bonnet & Guard 21 Cover assy (1)

UNIT: HOUR

Refer to 33.1.1

10 Cab portion 12 • Harness

REMARKS

37 • Harness Other necessary works

Refer to 33.1.14

- ditto -

1 set

Rem. / Inst.

1 set

Canopy

0.2

- ditto -

1 set

Floor cover

0.1

- ditto -

1 set

Guard (Cover, support)

0.4

- ditto -

1 pc.

Counterweight

0.4

- ditto -

1 pc.

Negative terminal of battery

0.1

Rem. / Inst.

1 set

- ditto -

1 pc.

40 Floor plate portion 41 Floor plate assy Other necessary works

0.3

Refer to 33.1.3

50 Counterweight portion

0.5 Canopy removal / inst

0.2

Refer to 33.1.5

51 Counterweight ASSY

Rem. / Inst.

1 pc.

0.4

52 • Lifting tools

Preparation

1 set

0.1

53 • Slinging

Rem. / Inst.

1 pc.

0.1

54 • Counterweight fixing bolt

- ditto -

1 set

0.1

Other necessary works

- ditto -

3 pcs.

Guards

0.3

00 Control portion

03 Upper structure

01 E / G control cable

Rem. / Inst.

1 pc.

0.2

02 Swing yoke

- ditto -

1 pc.

0.1

03 Swing cable

- ditto -

1 pc.

0.1

04 Other necessary works

- ditto -

1 set

10 Intake portion 11 Air cleaner ASSY 12 • Hose (1)

Cover and Hose

0.4

Refer to 33.1.11 Rem. / Inst.

1 pc.

0.3

- ditto -

1 pc.

0.1

13 • Hose (2)

- ditto -

1 pc.

0.1

14 • Element

Replace

1 pc.

0.1

Rem. / Inst.

1 pc.

20 Exhaust portion 21 Muffler ASSY

Refer to 33.1.13

12-6

0.4


12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

UNIT: HOUR

22 • Clamp

- ditto -

1 pc.

0.1

23 • Exhaust manifold attaching nuts

- ditto -

4 pcs.

0.1

24 • Muffler fixing bolt

- ditto -

4 pcs.

- ditto -

1 set

Other necessary works 30 E / G Accessory portion 31 Generator

0.1 Heat insulation cover

0.1

Refer to 33.1.12 & 33.1.15 Rem. / Inst.

1 pc.

0.6

32 • Connector

- ditto -

1 pc.

0.1

33 • Generator fixing bolt

- ditto -

2 pcs.

34 •

- ditto -

1 pc.

Include tension adjusting

0.3

- ditto -

1 set

Covers

0.1

- ditto -

1 pc.

Negative terminal of battery

0.1

V-belt

Other necessary works 36 Starter

0.1

Rem. / Inst.

1 pc.

0.5

37 • B-terminal

- ditto -

1 pc.

0.1

38 • S-terminal connector

- ditto -

1 pc.

0.1

39 •

Starter fixing bolt

- ditto -

2 pcs.

0.2

Other necessary works

- ditto -

1 set

Cover and Floor plate

0.1

- ditto -

1 set

Seat and Stand cover

0.3

- ditto -

1 pc.

Negative terminal of battery

0.1

Rem. / Inst.

1 pc.

0.6

Replace

1 pc.

0.2

40 Fuel portion 41 Fuel tank ASSY 03 Upper structure

REMARKS

42 • Fuel 43 • Hose (Supply; water separator side) 44 • Hose (Return; filter side)

Refer to 33.1.9

Rem. / Inst.

1 pc.

0.1

- ditto -

1 pc.

0.1

45 • Level sensor connector

- ditto -

1 pc.

0.1

46 • Fuel tank fixing bolt

- ditto -

4 pcs.

0.1

- ditto -

1 pc.

Other necessary works 50 Hydraulic oil tank portion 51 Hydraulic oil tank ASSY

0.2

Refer to 33.1.10 Rem. / Inst.

1 pc.

After removing fuel tank ;

1.6

Include pressure releasing & replacing O-ring

0.2

52 • Return filter

Replace

1 pc.

53 • Hydraulic oil

- ditto -

1 pc.

54 • Suction hose

Rem. / Inst.

1 pc.

Replace

1 pc.

55 • Strainer

Covers

0.2 0.2 Include replacing O-ring

0.1

56 • Pilot return hose

Rem. / Inst.

1 pc.

0.1

57 • Swivel drain hose

- ditto -

1 pc.

0.1

58 • SOL. valve return hose

- ditto -

1 pc.

0.1

59 • Slewing, C / V return hose

- ditto -

2 pcs.

0.2

60 • Tank fixing bolt

- ditto -

4 pcs.

- ditto -

1 pc.

Other necessary works

72 • Hydraulic oil 73 • Pilot delivery oil hose

0.2

- ditto -

1 pc.

Control valve

1.6

- ditto -

1 pc.

Solenoid valve

0.1

Preparation

1 pc.

Hyd. oil tank pressurizing

0.1

70 Pump portion 71 Pump ASSY

0.2 Covers

Refer to 33.1.6 1 pc.

After removing counterweight

Replace

1 pc.

Include pressure releasing

Rem. / Inst.

1 pc.

Rem. / Inst.

12-7

1.2 0.2 0.1


12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

WORK TO BE DONE

UNIT

UNIT: HOUR

74 • Suction hose

- ditto -

1 pc.

0.2

75 • Suction tube (pump side)

- ditto -

1 pc.

0.2

76 • Main pump delivery hose

- ditto -

3 pcs.

0.2

77 • Pump fixing bolt

- ditto -

2 pcs.

0.2

78 Pump ASSY Other necessary works

O/H

1 pc.

Feed

1 pc.

Hyd. oil in pump

0.1

Preparation

1 pc.

Hyd. oil tank pressurizing

0.1

Rem. / Inst.

1 pc.

80 Radiator portion 81 Radiator ASSY 82 • Coolant (LLC)

03 Upper structure

REMARKS

3.0

Refer to 33.1.16 1.2

Replace

1 pc.

0.2

83 • • Coolant density

Measuring

1 pc.

(0.2)

84 • Reserve tank hose

Rem. / Inst.

1 pc.

0.1

85 • Radiator hose

- ditto -

2 pcs.

0.2

86 • Cooler hose

- ditto -

2 pcs.

0.2

87 • Radiator fixing bolt

- ditto -

3 pcs.

0.1

88 • Radiator lifting or slinging

- ditto -

1 pc.

0.1

Other necessary works

- ditto -

1 pc.

Counterweight

0.4

- ditto -

1 set

Covers

0.2

- ditto -

1 pc.

Duct

0.1

90 Engine (E / G) Installing portion 91 Engine ASSY 92 • Fuel hose 93 • Harness, connector and cable

Refer to 33.1.17 Rem. / Inst.

1 pc.

- ditto -

4 pcs.

Rem. / Inst.

1 set

1.0 For injection pump - 2 pcs. & For feed pump - 2 pcs.

0.2 0.3

94 • Engine fixing nut

- ditto -

1 pc.

0.2

95 • Engine slinging

- ditto -

1 set

0.2

- ditto -

1 set

Covers

0.2

- ditto -

1 pc.

Canopy

0.2

- ditto -

1 set

Control stand

1.0

- ditto -

1 pc.

Counterweight

0.4

Other necessary works

- ditto -

1 pc.

Air cleaner

0.2

- ditto -

1 pc.

Muffler

0.4

- ditto -

1 pc.

Pump

1.2

- ditto -

1 pc.

Radiator

1.0

- ditto -

1 pc.

Battery negative terminal

0.1

100 Control valve portion 101 Control valve ASSY

Refer to 33.1.7 Rem. / Inst.

1 pc.

1.6 Include attaching hose’s tag and plug

1.0

102 • Piping connector, hose

- ditto -

1 set

103 • Control cable, Yoke

- ditto -

1 set

104 • Fixing bolt

- ditto -

1 set

0.1

O/H

1 pc.

3.0

Rem. / Inst.

1 set

Covers

0.1

- ditto -

1 set

Hoses

0.2

Rem. / Inst.

1 pc.

105 Control valve ASSY Other necessary works 110 Slewing motor portion 111 Slewing motor ASSY

0.2

Refer to 33.1.19

12-8

1.0


12. STANDARD MAINTENANCE TIME TABLE WORK TO BE DONE

UNIT

REMARKS

UNIT: HOUR

112 • Piping connector, hose

- ditto -

7 pcs.

Include attaching hose’s tag and plug

0.5

113 • Fixing bolt

- ditto -

1 pc.

0.3

O/H

1 pc.

3.0

Rem. / Inst.

1 set

Floor plate, Covers

0.2

Feed

1 pc.

Hyd. oil in motor

0.1

GROUP No.

EQUIPMENT PORTION

114 Slewing motor ASSY Other necessary works 120 Swivel joint portion 121 Swivel joint ASSY

03 Upper structure

122 • Under cover

Refer to 33.1.20 Rem. / Inst.

1 pc.

- ditto -

1 pc.

2.5 0.1

Include attaching hose’s tag and plug

123 • Piping connector, hose

- ditto -

1 set

124 • Stopper

- ditto -

1 pc.

0.1

125 • Fixing bolt

- ditto -

1 set

0.2

O/H

1 pc.

2.0

Preparation

1 pc.

Removal / Inst. position. (Secure working space.)

0.1

1 pc.

Canopy removal / inst. (for easy working)

0.2

1 pc.

Floor plate cover (2) removal / inst.

0.1

126 Swivel joint ASSY Other necessary works

130 Upper frame portion 131 Upper frame ASSY 132 •

Fixing bolt

133 • Upper frame slinging 134 • Cleaning Other necessary works

01 Rubber crawler

1.5

Refer to 33.1.21 Rem. / Inst.

1 pc.

- ditto -

1 set

1.0 Apply sealant

0.3

- ditto -

1 pc.

0.3

Cleaning

1 pc.

0.2

Rem. / Inst.

1 pc.

Canopy

0.2

- ditto -

1 pc.

Guard (Cover, support)

1.5

- ditto -

1 pc.

Counterweight

0.4

Drain / Feed

1 pc.

Hydraulic oil

0.2

Rem. / Inst.

1 set

Swivel joint hose

0.5

- ditto -

1 set

Boom, Swing bracket

1.5

00 Travel portion

04 Under carriage

After removing slewing motor

Refer to 34.1.2 Rem. / Inst. One side

0.6

02 • Rubber shoe removing / inst. position. Preparation One side

0.1

03 • Tension adjusting

One side

0.2

Rem. / Inst. One side

0.2

04 • Crawler shoe

Adjusting

10 Upper roller portion 11 Upper roller ASSY 12 Upper roller

Refer to 34.1.3 Rem. / Inst.

1 pc.

O/H

1 pc.

20 Lower roller portion 21 Lower roller ASSY 22 Lower roller

32 Idler & Idler adjuster ASSY

0.2 1.0

Refer to 34.1.6 Rem. / Inst.

1 pc.

0.2

O/H

1 pc.

1.0

30 Front idler & Idler adjuster portion 31 Idler & Idler adjuster ASSY

After removing crawler shoe

Refer to 34.1.7 & 34.1.8 Rem. / Inst. One side After removing crawler shoe O/H

12-9

One side

0.5 0.1


12. STANDARD MAINTENANCE TIME TABLE GROUP No.

EQUIPMENT PORTION

33 Idler ASSY 34 Idler adjuster ASSY

WORK TO BE DONE

UNIT

O/H

One side

1.0

One side

0.5 Refer to 34.1.9

Replace

One side

50 Travel motor portion 04 Under carriage

51 Travel motor ASSY

UNIT: HOUR

- ditto -

40 Sprocket portion 41 Sprocket

REMARKS

After removing crawler shoe

0.5

Refer to 3 34.1.10 Rem. / Inst. One side After removing crawler shoe

1.0

52 • Motor cover

- ditto -

One side

53 • Hydraulic connector, hose

- ditto -

One side

54 • Motor fixing bolt

- ditto -

One side

0.3

55 • Motor slinging

- ditto -

One side

0.1

O/H

One side

3.0

- ditto -

One side

3.0

56 Travel motor 57 Travel reduction unit Other necessary works

Feed

62 • Slewing bearing fixing bolt 63 • Slewing bearing 64 • Slewing bearing slinging

Include attaching hose’s tag and plug

One side Hyd. oil in motor

60 Slewing bearing portion 61 Slewing bearing ASSY

0.1 0.6

0.1

Refer to 34.1.11 Rem. / Inst.

1 pc.

- ditto -

1 pc.

Cleaning

1 pc.

Rem. / Inst.

1 pc.

12-10

After removing upper frame

0.6 0.3

Decreasing / Replenishment

0.1 0.2


13. MAINTENANCE STANDARDS AND TEST PROCEDURES TABLE OF CONTENTS 13.1 HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS ........... 13-3 13.2 PERFORMANCE INSPECTION STANDARD TABLE .................................... 13-5 13.2.1

STANDARD VALUE TABLE .................................................................. 13-5

13.3 MEASURING ENGINE SPEED ....................................................................... 13-7 13.3.1

ENGINE SPEED MEASUREMENT ....................................................... 13-7

13.4 MEASURING HYDRAULIC OIL PRESSURE ................................................. 13-9 13.4.1

STANDARD FOR HYDRAULIC OIL PRESSURE MEASUREMENT ..... 13-9

13.4.2

PRESSURE MEASUREMENT AND ADJUSTMENT ............................. 13-9

13.5 MEASURING TRAVEL PERFORMANCES .................................................. 13-13 13.5.1

TRAVEL ............................................................................................... 13-13

13.5.2

TRAVEL DEVIATION ........................................................................... 13-13

13.5.3

MOVEMENT DRIFT DUE TO GRAVITY ............................................. 13-14

13.5.4

DRAIN RATE ON TRAVEL MOTOR .................................................... 13-14

13.6 MEASURING SLEW PERFORMANCES ...................................................... 13-15 13.6.1

SLEW TIME ......................................................................................... 13-15

13.6.2

OVERRUN WHEN SLEWING STOPS ................................................ 13-15

13.6.3

SLEW DRIFT DUE TO GRAVITY ........................................................ 13-15

13.6.4

DRAIN RATE OF TRAVEL MOTOR .................................................... 13-16

13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES .................. 13-17 13.7.1

CYLINDER SPEED .............................................................................. 13-17

13.7.2

GRAVITY DRIFT OF CYLINDERS ...................................................... 13-18

13.8 MEASURING SLEW BEARING PERFORMANCES ..................................... 13-19 13.8.1

SLEW BEARING-BUCKET TIP PLAY ................................................. 13-19

13.8.2

SLEW BEARING PLAY ........................................................................ 13-19

13.9 MEASURING CRAWLER TENSION ............................................................. 13-20 13.9.1

CRAWLER TENSION .......................................................................... 13-20


13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13-1


13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13-2


13. MAINTENANCE STANDARDS AND TEST PROCEDURES

13.1

HOW TO USE MAINTENANCE STANDARDS AND PRECAUTIONS

(1) Application 1) For New Machine: This manual is to be used to check the actual performance and functions of the machine compared with the PERFORMANCE STANDARDS. 2) At Specific Self-Inspection (as per LOCAL RULES); The maintenance standards are used to make them as the criteria to determine the time for reconditioning, adjustment and replacement. 3) At Deterioration of Performance; This manual is of the criteria of safe and economical judgment whether the deterioration of performance on the machine would be caused by any faults or normal deterioration due to machine operation for a long period. 4) For Replacement of Major Components; This manual is of the standard to determine the time for replacement to recover the performance of major components such as pump, etc. (2) Terminology 1) Standard Values: These are of the standard values to assemble and regulate a new machine. Where special notes are not given, these values are based on the machine with standard structure (the machine with standard attachments and shoes). 2) Standard Values for Repair: These are of the values at which the reconditioning is required. In order to ensure the performance and safety, it is strictly prohibited to use the machine with the parts and components being over the standard values. 3) Serviceability Limit: This is of the service limit for each part and component at which the reconditioning is impossible and they must be replaced to new ones. All the parts and components which are estimated to exceed the serviceability limit up to the next periodical inspection and maintenance, should be also replaced to new ones. The machine operation with the parts and components which have exceeded the serviceability limit, causes increase of troubles and down time of the machine, and also causes safety problems. (3) Precautions for Judgment: 1) Evaluation for Measured Data: It is inevitable some variation on the measured data due to differences between measuring conditions, peculiar variability on a new machine, old and new versions of the machine and measuring characteristics. The judgment for the measured data should be comprehensively conducted based on the extent of level of the measured data, instead of mere comparison with the standard values. 2) Determination for Reconditioning, Adjustment or Replacement: There are two kinds of deterioration of machine performance; one is due to normal wear with time elapsing of operation, and the other is recoverable to the standard values with the adjustment for pressure, etc. Therefore, the determination for reconditioning, adjustment or replacement should be conducted taking various factors into consideration such as operating hours, working conditions and maintenance conditions of the machine, so that the machine is able to be operated at the optimum performance level. (4) Other Precautions 1) Parts with Aging Effect: The rubber products such as hydraulic hoses, O-rings, oil seals, etc. are deteriorated with the aging effect. It is necessary to replace them to new ones at periodical intervals or at every overhaul. 2) Parts required Periodical Replacement: It is recommendable to designate the important hoses critical to secure the safety as Very Important Parts (V.I.P.), and periodically replace with new ones.

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13. MAINTENANCE STANDARDS AND TEST PROCEDURES 3) Inspection & Replacement of Lubricants: It is necessary for the user of the machine to fully familiarize himself with the procedures and precautions to handle the machine in safe and carry out the maintenance, as well as the procedures for inspection and lubrication. Refer to the OPERATION & MAINTENANCE MANUAL as well.

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Case cx40b mini excavator service repair manual  
Case cx40b mini excavator service repair manual  
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