CASE CX20B MINI EXCAVATOR Service Repair Manual

HYDRAULIC EXCAVATOR SHOP MANUAL

model

CX20B CX22B CX27B

INDEX 1

SPECIFICATIONS

2

MAINTENANCE

3

SYSTEM

4

DISASSEMBLING

5

TROUBLESHOOTING

6

ENGINE

7

INSTALLATION PROCEDURES FOR OPTIONAL ATTACHMENT

8

SUPPORTING DATA

No. 9-91841 EN

Printed by Studio ti - 53004 - 2004.12

0-1

SAFETY PRECAUTIONS

0-1

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

GENERAL SAFETY INFORMATION

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

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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

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INDEX

CX20B CX22B CX27B

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

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SAFETY PRECAUTIONS This Manual may be properly revised due to the improvement of products, modification of specifications, etc. And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries.

For the section in which the description is hardly understood, contact our distributor.

NOTE: This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 8 Chapters, Specification, Maintenance, System, Disassembly, Troubleshooting, Engine, and Installation Procedures for Optional Attachment, and Supporting Data.

•

The Chapter "Specification" describes the specifications for entire machine and material, which are instructive for replacement and repairing of attachments.

•

The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjustments for entire machine.

•

The Chapter "System" describes the operating system like hydraulic system, electric system, components, and so on.

•

The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.

•

The Chapter "Troubleshooting" describes how to find the fault equipment.

•

The Chapter "Engine" describes the engines making use of the "Maintenance Manual" provided by the suppliers.

•

The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required.

•

The Chapter "Supporting Data" describes the contents of added material in A3 size like hydraulic circuit diagram, electric circuit diagram, and so on. It is recommended to use together with the texts in respective Chapter and Section.

The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are contained. Therefore, the order must be placed with respective formal number with due confirmation on the Parts Manual for applicable machine

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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 manufacturer’s 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

(3) Derived Units

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

Table 1-3

Introduction

Base units Table 1-1

Derived units

m2

Volume

cubic meter

m3

Velocity

meter per second

m/s m/s2 kg/m3

Table 1-4

2. Construction of SI Unit System

SI units

SYMBOL

square meter

(4) Derived Units bearing Peculiar Designations

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

SI unit system

UNIT

Area

Acceleration meter per second squared Density kilogram per cubic meter

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.

Supplementary units Table 1-2

QUANTITY

QUANTITY

UNIT

SYMBOL

FORMULA

Frequency

hertz

Hz

1/s

Force Pressure and Stress

newton

N

kg • m/s 2

pascal

Pa

N/m2

joule

J

N•m

watt

W

J/s

Quantity of electricity

coulomb

C

A•s

Electric potential difference, Voltage, and Electromotive force

volt

V

W/A

farad

F

C/V

Energy, Work and Quantity of heat Power

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

Length

meter

m

Quantity of static electricity and Electric capacitance

Mass Time

kilogram second

kg s

Electric resistance

ohm

Electric current

ampere

A

(t+273.15)K

K

celsius degree or degree

C

kelvin

Celsius temperature Illuminance

lux

lx

lm/m2

Table 1-1 QUANTITY

Thermodynamic temperature Amount of substance Luminous intensity

UNIT

SYMBOL

mol

mol

candela

cd

(2) Supplementary units Table 1-2 QUANTITY Plane angle

radian

UNIT

Solid angle

steradian

SYMBOL rad sr

1-6

V/A

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

MULTIPLICATION FACTORS

giga

G

10 9

mega

M

10 6

kilo

k

10 3

hecto deca

h da

10 2 10

deci

d

10–1

centi

c

10–2

milli micro

m µ

10–3 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

Torque Pressure

kgf•m kgf/cm2

Motive Power

PS

kW

1 PS= 0.7355 kW

Revolution

rpm

min–1

r/min *1

1 kgf= 9.807 N

N•m kgf•m= 9.807 N•m MPa 1 kgf/cm2= 0.09807 MPa

*1 Units that are allowed to use.

1-7

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 ......................................................................................... 2-11 2.8 ENGINE SPECIFICATIONS ............................................................................ 2-13 2.8.1 SPECIFICATIONS ...................................................................................... 2-13 2.8.2 ENGINE PERFORMANCE CURVE ............................................................ 2-14

2. SPECIFICATIONS

2-1

2. SPECIFICATIONS

2.1

COMPONENTS NAME

32

33 30 31

36

15 16 17

34

8 35

18 12

37

19

13

3

14

5 4

11 29

6 1

20 7 28 27 24 25

2 26

10 21

23 9

22

No. 1 5 9 13 17 20 24 28 32 36

NAME Engine Air cleaner Hydraulic pump Travel lever Dozer operating lever Battery Idler assy Dozer blade Dipper cylinder Bucket cylinder

No. 2 6 10 14 18 21 25 29 33 37

NAME Oil filter Muffler Slewing motor Safety lock lever Throttle lever Swivel joint Lower roller Dozer cylinder Light Bucket

No. 3 7 11 15 19 22 26 30 34

2-3

NAME No. NAME Radiator 4 Reservoir tank Fuel tank 8 Hydraulic reservoir Swing cylinder 12 Control valve Canopy 16 Operating lever Monitor panel (gauge cluster) Travel motor 23 Slewing bearing Upper roller 27 Rubber track Boom 31 Boom cylinder Dipper 35 Link

2. SPECIFICATIONS

2.2

MACHINE DIMENSIONS Unit: mm (ft•in)

55

1400 (4’7.1") 610 (2’0.0") 555 (1’9.9") 90 (3.5")

170(6.7")

(1) CX20B (CANOPY)

R700 ") (2’3.6

45 (1.8")

60

3820 (12’6.4") 1670 (5’5.7") 1310 (4’3.6") 700 (2’3.6")

480 (1’6.9")

250 (9.8")

345 300 (13.6") (11.8")

2460 (8’0.9")

1400 (4’7.1")

1350 (4’5.1") 250 (9.8")

1490 (4’10.7") 1870 (6’1.6") 2260 (7’5.0")

1150 (3’9.3") 1400 (4’7.1")

55

1400 (4’7.1") 610 (2’0.0") 555 (1’9.9") 90 (3.5")

170(6.7")

(2) CX22B (CAB)

R740 (2’5.1")

45 (1.8")

60

3820 (12’6.4") 1710 (5’7.3") 1350 (4’5.1") 740 (2’5.1")

480 (1’6.9")

250 (9.8")

345 300 (13.6") (11.8")

2460 (8’0.9")

1400 (4’7.1")

1350 (4’5.1") 250 (9.8")

1490 (4’10.7") 1870 (6’1.6") 2260 (7’5.0")

1150 (3’9.3") 1400 (4’7.1")

2-4

2. SPECIFICATIONS Unit: mm (ft•in)

55

1500 (4’11.1") 610 (2’0.0") 555 (1’9.9") 90 (3.5")

170(6.7")

(3) CX27B (CANOPY)

R750 ") (2’5.5

45 (1.8")

60

4130 (13’6.6") 1720 (5’7.7") 1360 (4’5.5") 750 (2’5.5")

520 (1’8.5")

250 (9.8")

345 300 (13.6") (11.8")

2500 (8’2.4")

1400 (4’7.1")

1440 (4’8.7") 250 (9.8")

1590 (5’2.6") 1980 (6’6.0") 2410 (7’10.9")

1250 (4’1.2") 1500 (4’11.1")

55

1500 (4’11.1") 610 (2’0.0") 555 (1’9.9") 90 (3.5")

170(6.7")

(4) CX27B (CAB)

R750 (2’5.5")

45 (1.8")

60

4130 (13’6.6") 1720 (5’7.7") 1360 (4’5.5") 750 (2’5.5")

520 (1’8.5")

250 (9.8")

345 300 (13.6") (11.8")

2500 (8’2.4")

1400 (4’7.1")

1440 (4’8.7") 250 (9.8")

1590 (5’2.6") 1980 (6’6.0") 2410 (7’10.9")

1250 (4’1.2") 1500 (4’11.1")

2-5

2. SPECIFICATIONS

2.3

SPECIFICATIONS AND PERFORMANCE

SPEED AND GRADEABILITY Model Applicable machines Shoe Type Slewing Speed Travel Speed Gradeability

CX20B / 22B CX27B PM07-07001~ PV10-27001~ Rubber shoe Iron shoe (OPT) Rubber shoe Iron shoe (OPT) 8.7 {8.7} 8.7 {8.7} min-1 {rpm} Low High Low High Low High Low High km/h (mph) (1st) (2nd) (1st) (2nd) (1st) (2nd) (1st) (2nd) 2.3 4.1 2.3 4.1 2.3 4.1 2.3 4.1 % (degree) 58 (30)

ENGINE Model (YANMAR) Type Number of cylinders-Bore × Stroke Total Displacement L Output Rating kW/min-1 {PS/rpm} N•m/min -1 Intermediate Torque (Net) (lbf•ft/rpm) Starting Motor V × kW Generator V×A

3TNV82A-SYB Water-cooled, 4-cycle type Swirl chamber type diesel engine 3 - ø82 mm × 84 mm (3.23 in × 3.31 in) 1.330 (81.2 cu•in) 15.9 / 2200 {21.6/2200} 79.0 ~ 86.0 / 1320 ± 100 (58.3 ~ 63.4 / 1320 ± 100) 12 × 1.7 12 × 40

HYDRAULIC COMPONENTS Hydraulic Pump Hydraulic Motor Hydraulic Motor w/Reducer (Travel) Control Valve Cylinder (Boom, Dipper, Swing, Bucket, Dozer) Return Filter

Variable displacement axial piston + gear pump Axial piston 2-Axial piston, 2-Speed motor 10-spool multiple control valve Double action cylinder Safety valve containing/Filter Type (30µ)

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

Right Left mm (in)

Boom swing by hydraulic cylinder 55° 70° 425 / 290 (16.7/11.4) 445 / 335 (17.5/13.2)

WEIGHT Machine Weight Upper slewing body Travel system Attachment (Boom+STD Dipper+STD Bucket) Oil & Water

Rubber shoe 2100 (4630) kg (lb) 1090 (2400) kg (lb) 720 (1590) kg (lb)

Iron shoe 2240 (4940) ← 850 (1870)

Rubber shoe 2490 (5490) 1310 (2890) 830 (1830)

Iron shoe 2620 (5780) ← 960 (2120)

kg (lb)

240 (530)

300 (660)

kg (lb)

50 (110)

←

Note: This figure is calculated with standard bucket.

2-6

2. SPECIFICATIONS

2.4

MACHINE & COMPONENTS WEIGHT (DRY) Unit: kg (lb) CX20/22B

MODEL

RUBBER SHOE IRON SHOE CANOPY CAB CANOPY CAB 2100 (4630) 2240(4940) 2230 (4920) 2370 (5230) 1090 (2400) 1230 (2710) 1090 (2400) 1230 (2710)

COMPLETE MACHINE UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS)

265 (584)

UPPER FRAME

80 (176)

CANOPY / CAB

← 220 (485)

← 80 (176)

← 220 (485)

130 (287)

←

←

←

HYDRAULIC PUMP RADIATOR

18 (40) 3 (7)

← ←

← ←

← ←

HYDRAULIC TANK

30 (66)

←

←

←

4 (9)

←

←

←

59 (130)

←

←

←

SWING CYLINDER SLEWING MOTOR

23 (51) 32 (71)

← ←

← ←

← ←

CONTROL VALVE

24 (53)

←

←

←

ENGINE

FUEL TANK SWING BRACKET

COUNTERWEIGHT

290 (639)

110 (243)¨

290 (639)

97 (214)

←

←

←

23 (51) 720 (1890)

← ←

259 (571)

←

←

←

110 (243)

GUARD • BONNET BOOM CYLINDER LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME

← 850 (1870)

← ←

36 (79)

←

←

←

TRAVEL MOTOR

27x2 (60x2)

←

←

←

LOWER ROLLER FRONT IDLER

6x6 (13x6) 17x2 (37x2)

← ←

← ←

← ←

IDLER ADJUSTER

11x2 (24x2)

←

←

←

5x2 (11x2)

←

←

←

75 (165) X2

←

—

—

— 11 (24)

— ←

140 (309) X2 ←

← ←

100 (220)

←

←

←

19 (42) 240 (530)

← ←

← ←

← ←

105 (232)

←

←

←

72 (159)

←

←

←

22 (49)

←

←

←

75 (165) 44 (97)

← ←

← ←

← ←

15 (33)

←

←

←

6 (13)

←

←

←

2×2 (4×2)

←

←

←

57 (126) 50 (110)

← ←

← ←

← ←

HYDRAULIC OIL

24 (53)

←

←

←

FUEL

22 (49)

←

←

←

4 (9)

←

←

←

SLEWING BEARING

SPROCKET 250 mm (9.8”) RUBBER CRAWLER SHOE 250 mm (9.8”) IRON SHOE SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM DIPPER CYLINDER DIPPER ASSEMBLY ARM BUCKET CYLINDER BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD) FLUIDS (ASSY OF FOLLOWINGS)

COOLANT

Note: Bucket weight is shown with standard bucket weight.

2-7

2. SPECIFICATIONS Unit: kg (lb) CX27B MODEL

RUBBER SHOE IRON SHOE CANOPY CAB CANOPY CAB 2490 (5490) 2630 (5800) 2620 (5780) 2760 (6090)

COMPLETE MACHINE UPPER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) UPPER FRAME CANOPY / CAB ENGINE HYDRAULIC PUMP RADIATOR HYDRAULIC TANK FUEL TANK SWING BRACKET SWING CYLINDER SLEWING MOTOR CONTROL VALVE COUNTERWEIGHT GUARD • BONNET BOOM CYLINDER LOWER FRAME ASSEMBLY (ASSY OF FOLLOWINGS) LOWER FRAME SLEWING BEARING TRAVEL MOTOR LOWER ROLLER FRONT IDLER IDLER ADJUSTER SPROCKET 250 mm (9.8”) RUBBER CRAWLER SHOE 250 mm (9.8") IRON SHOE SWIVEL JOINT DOZER DOZER CYLINDER ATTACHMENT ASSEMBLY (ASSY OF FOLLOWINGS) BOOM ASSEMBLY BOOM DIPPER CYLINDER DIPPER ASSEMBLY DIPPER BUCKET CYLINDER BUCKET LINK IDLER LINK BUCKET ASSEMBLY (STD) FLUIDS (ASSY OF FOLLOWINGS) HYDRAULIC OIL FUEL COOLANT

1310 (2890) 1450 (3200) 1310 (2800) 1450 (3200) 265 (584) 80 (176) 130 (287) 18 (40) 3 (7) 30 (65) 4 (9) 59 (130) 23 (51) 32 (71) 24 (58) 290 (639) 97 (214) 24 (53) 830 (1830) 328 (723) 36 (79) 27X2 (60X2) 6X8 (13X8) 17X2 (37X2) 11X2 (24X2) 5X2 (11X2) 80 (176) X2 — 11 (24) 117 (260) 20 (44) 300 (662) 125 (276) 88 (194) 28 (62) 95 (209) 51 (112) 17 (37) 6 (13) 2 × 2 (4×2) 64 (141) 50 (110) 24 (53) 22 (49) 4 (9)

Note: Bucket weight is shown with standard bucket weight.

2-8

← 220 (485) ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

← 80 (176) ← ← ← ← ← ← ← ← ← ← ← ← 960 (2120) ← ← ← ← ← ← ← — 147 (324) X2 ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

← 220 (485) ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← — ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ← ←

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 dipper cylinder fully.

3.Lower the boom.

4.If machine cannot be transported with dipper cylinder fully extended, remove bucket or attachment and extend dipper cylinder.

(2) TRANSPORTATION DIMENSION AND WEIGHT OF ATTACHMENT 1) BOOM WITH DIPPER CYLINDER Model L×H×W mm (ft•in) Weight w/dipper cyl. kg (lb)

CX20B / 22B 1960 × 760 × 220 (6’5.2") (2’5.9") (8.7")

CX27B 2230 × 730 × 220 (7’3.8") (2’4.7") (8.7")

100 (220)

125 (276)

H

L 2) DIPPER & BUCKET Model L×H×W mm (ft•in) Weight kg (lb)

CX20B / 22B 1870 × 400 × 450 (6’1.6") (1’3.7") (1’5.7") 130 (287)

CX27B 2050 × 400 × 500 (6’8.7") (1’3.7") (1’7.7") 160 (353)

H

L

2-9

2. SPECIFICATIONS 3) ARM Model L×H×W mm (ft•in) Weight kg (lb)

CX20B / 22B 1280 × 390 × 250 (4’2.4") (1’3.4") (9.8") 75 (165)

CX27B 1690 × 430 ×250 (4’8.7") (1’7.7") (9.8") 95 (209)

H L

4) BUCKET (Standard bucket) Model Heaped capacity m3(cu•yd) L×H×W mm (in) Weight kg (lb)

CX20B / 22B

CX27B

0.066 (0.086)

0.08 (0.105)

640 × 530 × 450 (2’1.2") (1’8.9") (1’5.7") 44 (97)

650 × 550 × 500 (2’1.6") (1’9.7") (1’7.7") 46 (101)

H

L

5) DOZER w/o cylinder weight Model L×H×W mm (in) Weight kg (lb)

CX20B / 22B 1020 × 285 × 1400 (3’4.2") (11,2") (4’7.1") 100 (220)

CX27B 1,280 × 330 × 1,700 (3’7.7") (11.4") (4’11.1") 117 (258)

H L

2-10

2. SPECIFICATIONS

2.6

TYPE OF CRAWLER SHOES Type

Total Crawler width mm (ft•in)

Number of Link

1400 (4’7.1")

76

26 (3.8)

27 (3.9)

250 (9.8")

1500 (4’11.1")

80

28 (4.1)

30 (4.4)

CX20B / 22B 250 (9.8")

1400 (4’7.1")

39

27 (3.9)

29 (4.2)

1500 (4’11.1")

41

30 (4.4)

31 (4.5)

Model

Shoe width mm (in)

Ground pressure kPa (psi) CANOPY CAB

Rubber shoe CX20B / 22B 250 (9.8")

CX27B

Iron shoe (option)

CX27B

2.7

250 (9.8")

TYPE OF BUCKET TYPE

DIPPER

Width mm (ft•in)

Digging buckets Digging buckets Digging buckets Digging buckets Digging buckets Digging buckets Digging buckets Digging buckets Cleaning buckets

250 (9.84”) 300 (11.81”) 350 (1’1.78”) 450 (1’5.62”) 500 (1’7.68”) 600 (1’11.62”) 700 (2’3.55”) 1000 (3’3.37”) 1200 (3’11.24”)

Heaped capacity m3 (cu.yd) (ISO 7451)

CX20B /22B Length Weight kg (lb) 1280 mm (4’2.39” in)

0.030 (0.04) 0.035 (0.05) 0.040 (0.05) 0.066 (0.09) 0.080 (010) 0.088 (0.11) 0.096 (0.12) 0.102 (0.13) 0.118 (0.15)

32.92 (72.58) 36.65 (80.80) 40.38 (89.02) 44.60 (98.33) 46.68 (102.91) 54.60 (120.37) 59.56 (131.31) 47.23 (104.12) 53.78 (118.56)

2-11

CX27B Length 1440 mm (4’8.69” in)

2. SPECIFICATIONS

SWARNING u

The buckets with this length, during left dipper 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 dipper support.

l:

Width with lateral cutter

m: 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/m 3. n: Digging for light applications for operations of digging,sand loading/unloading of gravel, clay, earth in friabile and dry state, ditch cleaning, etc.

2-12

2. SPECIFICATIONS

2.8

ENGINE SPECIFICATIONS

2.8.1

SPECIFICATIONS

Model Engine Model Type No. of cylinders - Bore × Stroke Total displacement Compression ratio Rated output Maximum torque Low idling High idling Fuel consumption rate Allowable tilting angles Rotating direction Firing order Stating fuel injection timing Automatic injection advance range Fuel injection pressure Valve action Valve clearance

Intake valve Exhaust valve Intake valve Exhaust valve

Thermostat action Compression pressure Lubrication oil pressure Dimensions L × W × H Dry weight Governor Fuel filtration Lubrication system Cooling system Starter capacity Generator capacity Starting aid Cooling water capacity: Max / Engine Engine oil volume: Max / Effective

CX20B / 22B, CX27B 3TNV82A-SYB Vertical, 4-cycle water-cooled diesel engine 3 - 82 mm (3.23 in) × 84 mm (3.31 in) 1.330 liter (81 cu•in) 19.2 15.9 kW (21.6 PS) at 2200 rpm 79.0 ~ 86.0 N•m (58.3 ~ 63.4 lbf•ft) at 1320 ± 100 rpm 1200 ± 25 rpm 2375 ± 25 rpm 242 ± 10 g / kWh (178 ± 7 g / PS•h) Continuous; 30° for all direction Counterclockwise as seen from flywheel side 1-3-2-1 (FIT) (at 2.5 mm) b.T.D.C. 16.0 ± 1° (FIR) b.T.D.C. 2.5 ± 1° 19.6 MPa (2840 psi) Open Close b.T.D.C. 15 ± 5° a.B.D.C. 45 ± 5° b.T.D.C. 56 ± 5° a.B.D.C. 18 ± 5° 0.2 mm (0.008 in) in cold condition 0.2 mm (0.008 in) in cold condition Start 71 ± 1.5 °C (160 ± 3 °F) / Full open 85 °C (185 °F) 3.16 ± 0.1 MPa (460 ± 14 psi) at 250 rpm 0.392 MPa (57 psi) at 2200 rpm 565 × 494 × 611 mm (22.2 × 19.4 × 24.1 in) 128 kg (282 lb) Mechanical centrifugal governor (All speed type) cartridge type paper filter Forced lubrication with trochoid pump Liquid cooling / Radiator 12 V × 1.7 kW 12 V × 40 A Air heater (12 V - 400 W) 4.0 / 1.8 liter (1.06 / 0.48 gal) 5.5 / 1.9 liter (1.45 / 0.50 gal)

2-13

2. SPECIFICATIONS 2.8.2

ENGINE PERFORMANCE CURVE

CX20B / 22B, CX27B Model: 3TNV82A-SYB Rated Output: 15.9 kW / 2200 min-1 (21.6 PS / 2200 rpm) 6

[Sd] 4

Sd 2 0 600

GT (Ibf ft) N m (74) 100

500

[T]

400

T

(59) 80

[GT]

300 (44) 60 200 (30) 40 100 (15) 20 15

0 g/PSh

[F]

(20)

PS 12.5 (17)

g/kWh

(257) 350

10

(239) 325

(14)

7.5 (10)

(221) 300 5

(7)

(202) 275 (184) 250

2.5 (3) ps

F

0 KW

(165) 225 (147) 200 800

1000

1200

1400

1600

1800

2000

2200

2400

min 1{rpm} F Fuel consumption volume =

ρ X 1000

XPXα

242 = X 15.9 X α 0.835 X 1000 = 4.61 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: 2.77 ~ 3.23 L/h (load factor: (0.60 ~ 0.70)

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

2-14

2600

[PS ]

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 ................................................................................................................ 3-10 3.2.1 ARM DIMENSIONAL DRAWINGS .............................................................. 3-10 3.2.2 ARM MAINTENANCE STANDARDS .......................................................... 3-12 3.3 BUCKET .......................................................................................................... 3-17 3.3.1 BUCKET DIMENSIONAL DRAWINGS ....................................................... 3-17 3.3.2 DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION .......................... 3-18 3.4 DOZER ............................................................................................................ 3-19 3.4.1 DOZER DIMENSIONAL DRAWINGS ......................................................... 3-19 3.4.2 DOZER MAINTENANCE STANDARDS ..................................................... 3-20 3.5 SWING ............................................................................................................ 3-23 3.5.1 SWING BRACKET DIMENSIONAL DRAWINGS ........................................ 3-23 3.5.2 SWING PORTION MAINTENANCE STANDARDS .................................... 3-24

3. ATTACHMENT DIMENSIONS

3-1

3. ATTACHMENT DIMENSIONS

3.1

BOOM

3.1.1

BOOM DIMENSIONAL DRAWINGS

Fig. 3-1 Boom Dimensional Drawings Table 3-1

No.

NAME

A B C D E F

Boom length Distance between pins of boss Distance between pins of bracket Height of boom cylinder rod pin Height of Dipper cylinder (head side) pin Boom width Inner width of bracket for boom cylinder (rod side) mounting Boom end inner width Boom end outer width Inner width of bracket for dipper cylinder (head side) Boom pin dia.

[Bushing outer dia.]

Boom cylinder (rod side) pin dia.

Pin dia. of dipper end Dipper cylinder (head side) pin dia.

G H J K d1 d2 d3 d4

3-3

Unit: mm(ft-in) DIMENSIONS CX20B / 22B CX27B 1880 (6’2.02") 2150 (7’0.65” R1040 (3’4.94") R1030.5 (3’4.57") R1028.5 (3’4.49") R1084.5 (3’6.70") 277 (10.91") 262 (10.31") 678.5 (2’2.71") 640 (2’1.20") 160 (6.30") ← 56 (2.20")

←

125 (4.92") 195 (7.78") 51 (2.01") ø40 (1.57") [ø50 (1.97")] ø40 (1.75") ø40 (1.75") ø35 (1.38")

← ← ø56 (2.20”) ← ← ← ø40 (1.57”)

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

• CX20B / 22B

Pos.

Item

A

Boom

B

Boom cylinder (Head side)

C D

Boom cylinder (Rod side) Dipper cylinder (Head side)

Standard dimensions Tolerance Tolerance Pin dia. on bushing on pin dia. bore dia.

–0.02 +0.06 –0.05 +0.01 (-0.0008) (+0.0024) (-0.0020) (+0.0004) ø40 –0.02 +0.18 (1.5748) –0.08 +0.05 (-0.0008) (+0.0071) (-0.0031) (+0.0020) –0.02 +0.18 –0.05 +0.05 ø35 (-0.0008) (+0.0071) (1.3780) (-0.0020) (+0.0020)

Unit: mm (in) Clearance Standard Standard Serviceabi Remedy value for value lity limit repair 0.03~ 0.11 (0.0012~ 0.0043) 0.07~ Replace 0.7 1.0 0.26 bushing (0.039) (0.0028~ (0.028) or pin 0.0102) 0.09~ 0.23 (0.0028~ 0.0091)

(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

3. ATTACHMENT DIMENSIONS Table 3-3

• CX27B

Pos.

Item

A

Boom foot

B

Boom cylinder (Head side)

C D

Boom cylinder (Rod side) Dipper cylinder (Head side)

Standard dimensions Tolerance Tolerance Pin dia. on bushing on pin dia. bore dia. +0.06 –0.02 +0.01 –0.05 (-0.0008) (+0.0024) (-0.0020) (+0.0004) –0.02 +0.18 –0.08 +0.05 ø40 (1.5748) (-0.0008) (+0.0071) (-0.0031) (+0.0020) +0.18 –0.02 +0.05 –0.05 (-0.0008) (+0.0071) (-0.0020) (+0.0020)

Unit: mm (in) Clearance Standard Standard Serviceabi Remedy value for value lity limit repair 0.03~ 0.11 (0.0012~ 0.0043) 0.07~ Replace 0.7 1.0 0.26 bushing (0.039) (0.0028~ (0.028) or pin 0.0102) 0.09~ 0.23 (0.0028~ 0.0091)

(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.

3-5

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

D

D

C

C

A

B A B

PL 1 L1

A-A

C-C

B-B

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

3-6

D-D

3. ATTACHMENT DIMENSIONS Table 3-4

• CX20B / 22B Unit: mm (in) Clearance X adjusted with shim Pin length (total of both sides) Standard Remedy Standard Serviceabili No. Dimensions value for No. Dimensions value ty limit repair Standard dimensions

Sec.

Item

160

Boom A-A Boom

L1 Swing bracket

B-B

C-C

Boom cylinder (Head side)

Boom cylinder (Rod side)

(6.299 160 (6.299

Boom cylinder L2 Swing bracket

PL1

271 (10.67)

0.1~0.5 (0.004~ 0.020)

PL2

249 (9.80)

0.5~0.9 (0.020~ 0.035)

PL3

138 (5.43)

0.1~0.5 (0.004~ 0.020)

PL4

145 (5.71)

)

(2.165

)

56 (2.205

Boom cylinder

1.0 (0.039)

)

55 L3

(2.165

)

56 (2.205

Dipper cylinder

1.5 (0.059)

Adjusted with shim

)

50 L4

Boom

0.2~0.7 (0.008~ 0.028)

55

Boom

Dipper cylinder D-D (Head side)

)

(1.969

)

51 (2.008

)

3-7

3. ATTACHMENT DIMENSIONS Table 3-5

• CX27B Unit: mm (in) Clearance X adjusted with shim Pin length (total of both sides) Standard Remedy Standard ServiceabilNo. Dimensions value for No. Dimensions value ity limit repair Standard dimensions

Sec.

Item

160

Boom A-A Boom

L1 Swing bracket

B-B

C-C

Boom cylinder (Head side)

Boom cylinder (Rod side)

(6.299 160 (6.299

Boom cylinder L2 Swing bracket

(2.165

(2.205

Boom cylinder

271 (10.67)

)

0.1~0.5 (0.004~ 0.020)

PL2

249 (9.80)

0.5~0.9 (0.020~ 0.035)

PL3

138 (5.43)

0.1~0.5 (0.004~ 0.020)

PL4

145 (5.71)

1.0 (0.039)

)

55 L3

(2.165

)

56

Dipper cylinder

1.5 (0.059)

Adjusted with shim

)

55 L4

Boom

PL1

)

56

(2.205

Dipper cylinder (Head side)

0.2~0.7 (0.008~ 0.028)

55

Boom

D-D

)

(2.165

)

56 (2.205

)

3-8

3. ATTACHMENT DIMENSIONS

3.2

ARM

3.2.1

ARM DIMENSIONAL DRAWINGS

Fig. 3-4 Dipper dimensional drawings Table 3-6 Unit: mm (ft-in) No.

Dimensions CX20B / 22B 980 (3’2.58") R270.5 (10.65") R883.5 (2’10.78") R180 (7.09") 303 (11.93") 158.5 (6.24")

Name

A

Dipper length

B

Distance between pins of boss and bracket

C

Distance between pins of boss and bracket

D

Distance between pins of boss and boss

E

Height between pins of boss and bracket

F

Height between pins of boss and bracket

3-10

CX27B 1120 (3’8.09") R280 (11.02”") ← ← ← 155 (6.10")

3. ATTACHMENT DIMENSIONS Table 3-6

No.

Unit: mm (ft-in) Dimensions CX20B / 22B CX27B 12 ← (0.47") 122 ← (4.80") 125 ← (4.92") 46 ← (1.81") 51 56 (2.01") (2.20") 245 ← (9.65") 230 ← (9.06") ø45 ← (1.77") ø45 ← (1.77") ø50 ← (1.97") ø35 ← (1.38") ø35 ← (1.38") ø40 ← (1.57") ø35 ← (1.38") ø35 ø40 (1.38") (1.57")

Name

G

Height between pins of boss and center

H

Boss width

J

Boss width

K

Bracket inner width

L

Bracket inner width

M

Idler link dimension

N

Bucket link dimension

D1 I.D. of boss D2 I.D. of boss D3 I.D. of boss d1

Pin dia.

d2

Pin dia.

d3

Pin dia.

d4

Pin dia.

d5

Pin dia.

3-11

3. ATTACHMENT DIMENSIONS 3.2.2

ARM MAINTENANCE STANDARDS

(1) Clearance of pin and bushing

Fig. 3-5 Clearance of pin and bushing on dipper section Table 3-7 •CX20B / 22B Pos.

A B C D

D’

E

F

G

Standard dimensions Tolerance on Item Tolerance Pin dia. bushing bore on pin dia. dia.

Dipper point –0.03 (Connected part of bucket) –0.05 +0.07 Bucket link (-0.0012) +0.02 (Bucket side) (-0.0020) Idler link (+0.0028) (Connected part of dipper) (+0.0008) Bucket link ø35 (Idler link side) +0.15 (1.3780) Bucket cylinder +0.05 (Rod side) (+0.0098) (+0.0020) –0.02 +0.18 –0.05 Bucket cylinder +0.05 (-0.0008) (Head side) (+0.0071) (-0.0020) (+0.0020) +0.06 Dipper foot ø40 +0.01 (Connected part of boom) (1.5748) (+0.0024) (+0.0004) +0.18 Dipper cylinder ø35 +0.05 (Rod side) (1.3780) (+0.0071) (+0.0020)

3-12

Standard value 0.05~ 0.12 (0.0020~ 0.0047) 0.04~ 0.12 (0.0016~ 0.0047) 0.07~ 0.20 (0.0028~ 0.0079) 0.07~ 0.23 (0.0028~ 0.0091) 0.03~ 0.11 (0.0012~ 0.0043) 0.07~ 0.23 (0.0028~ 0.0091)

Unit: mm (in) Clearance Standard Serviceabil- Remedy value for ity limit repair

0.7 (0.028)

1.0 (0.039)

Replace bushing or pin

3. ATTACHMENT DIMENSIONS Table 3-8 •CX27 Standard dimensions Tolerance on Tolerance Pos. Item Pin dia. bushing bore on pin dia. dia.

Dipper point –0.03 A (Connected part of bucket) –0.05 +0.07 Bucket link (-0.0012) B +0.02 (Bucket side) (-0.0020) Idler link (+0.0028) C (Connected part of dipper) (+0.0008) Bucket link D ø35 (Idler link side) +0.15 (1.3780) Bucket cylinder +0.05 D’ (Rod side) (+0.0098) (+0.0020) –0.02 +0.18 –0.05 Bucket cylinder +0.05 E (-0.0008) (Head side) (+0.0071) (-0.0020) (+0.0020) +0.06 +0.01 Dipper foot F (+0.0024) (Connected part of boom) ø40 (+0.0004) +0.18 (1.5748) Dipper cylinder +0.05 G (Rod side) (+0.0071) (+0.0020)

Standard value 0.05~ 0.12 (0.0020~ 0.0047) 0.04~ 0.12 (0.0016~ 0.0047) 0.07~ 0.20 (0.0028~ 0.0079) 0.07~ 0.23 (0.0028~ 0.0091) 0.03~ 0.11 (0.0012~ 0.0043) 0.07~ 0.23 (0.0028~ 0.0091)

Unit: mm (in) Clearance Standard Serviceabil- Remedy value for ity limit repair

0.7 (0.028)

1.0 (0.039)

(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.

3-13

Replace bushing or pin

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

A-A

B-B

C-C

E-E

D-D

F-F

G-G

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

3-14

3. ATTACHMENT DIMENSIONS Table 3-9 • CX20B / 22B

Unit: mm (in) Clearance X adjusted with Pin length shim (total of both sides) Standard Servicea Remedy Standard Dimensions value for bility No. Dimensions value repair limit

Standard dimensions Sec.

Item No.

122

Dipper A-A Dipper point

L1

(4.803

(4.843

L2

Dipper L3 Link side

L4

D-D

(4.843 ) 122 (4.803) — (—)

(1.772

(1.850

L5 Idler link

246.5 (9.70)

0.1~0.5 (0.004~ 0.020)

—

PL3

172.5 (6.79)

(4.803 — (—)

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059) Adjust- PL5 ed with shim

)

)

0.1~0.5 (0.004~ 0.020)

172.5 (6.79)

—

45

Head side L6

(1.772

)

46

Dipper

(1.811

0.5~0.9 (0.020~ 0.035)

PL6

145 (5.71)

PL7

195 (7.68)

PL8

145 (5.71)

)

125

Dipper F-F Dipper foot

)

122

Bucket link

Bucket cylinder (Head side)

PL2

See "NOTE"

)

47

Link side

E-E

(4.803

0.5~2.1 (0.020~ 0.083)

45

Rod side

Bucket link (Idler link side)

246.5 (9.70)

123

Bucket

Bucket link (Rod side)

)

122

Link side

Idler link C-C (Connected part of dipper)

PL1

123

Bucket

B-B Bucket link

)

L7

(4.921

)

125

Boom

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

(4.921) 50

Rod side G-G

Dipper cylinder (Rod side)

L8 Dipper

(1.969

)

51 (2.008

0.5~0.9 (0.020~ 0.035)

)

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

3-15

3. ATTACHMENT DIMENSIONS Table 3-10 • CX27B

Unit: mm (in) Clearance X adjusted with Pin length shim (total of both sides) Standard Servicea Remedy Standard Dimensions value for bility No. Dimensions value repair limit

Standard dimensions Sec.

Item No.

122

Dipper A-A Dipper point

L1

(4.803

(4.843

L2

Dipper L3 Link side

(4.803

L4

D-D

(4.843 ) 122 (4.803) — (—)

(1.772

(1.850

)

0.1~0.5 (0.004~ 0.020)

—

L5 Idler link

(4.803 — (—)

Less than 0.5 (0.020)

1.0 (0.039)

246.5 (9.70)

PL3

172.5 (6.79)

1.5 (0.059) Adjust- PL5 ed with shim

)

122

Bucket link

)

0.1~0.5 (0.004~ 0.020)

172.5 (6.79)

—

45

Head side L6

(1.772

)

46

Dipper

(1.811

0.5~0.9 (0.020~ 0.035)

PL6

145 (5.71)

PL7

195 (7.68)

PL8

138 (5.43)

)

125

Dipper F-F Dipper foot

PL2

See "NOTE"

)

47

Link side

Bucket cylinder E-E (Head side)

0.7~2.3 (0.028~ 0.091)

45

Rod side

Bucket link (Idler link side)

246.5 (9.70)

123

Bucket

Bucket link (Rod side)

)

122

Link side

Idler link C-C (Connected part of dipper)

PL1

123

Bucket

B-B Bucket link

)

L7

(4.921

)

125

Boom

Less than 0.5 (0.020)

1.0 (0.039)

1.5 (0.059)

(4.921) 55

Rod side G-G

Dipper cylinder (Rod side)

L8 Dipper

(2.165

)

56 (2.205

0.5~0.9 (0.020~ 0.035)

)

(Note) •

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

3-16

3. ATTACHMENT DIMENSIONS

3.3

BUCKET

3.3.1

BUCKET DIMENSIONAL DRAWINGS

J

J

Fig. 3-7 Bucket dimensional drawings Table 3-11 Model No. Heaped Capacity m3 (cu.yd) A Distance between pin and bracket B Distance between bucket pin and tooth 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 plate H Outer tooth distance J Pitch between teeth d1 Pin dia. d2 Pin dia.

CX20B /22B 0.066 (0.086) 180 (7.09") R630 (2’0.80") 387 (1’3.24") 165 (6.50") 123 (4.84") 450 (1’5.72”) 351 (1’1.82") 387 (1’3.24") 162 (6.38") ø35 (1.57") ø35 (1.57")

3-17

Unit: mm (ft-in) CX27B 0.08 (0.105) ← R655 (2’1.79") 437 (1’5.20”) ← ← 500 (1’7.69") 401 (1’3.79") 437 (1’5.20") 187 (7.36") ← ←

3. ATTACHMENT DIMENSIONS 3.3.2

DETAIL DIMENSIONAL DRAWINGS OF LUG SECTION

Fig. 3-8 Dimension of lug section Table 3-12

Portion Dimensions

Plate outer dia. øA

Boss thickness B

80 (3.15)

21 (0.83)

3-18

Pin bore dia. øC 35 (1.378

)

Unit: mm (in) Lug plate thickness D 12 (0.472)

3. ATTACHMENT DIMENSIONS

3.4

DOZER

3.4.1

DOZER DIMENSIONAL DRAWINGS

Fig. 3-10 Dozer dimensional drawings Table 3-14

No.

NAME

A B C D E

Blade width Blade height Distance from dozer attaching pin center to cutting edge end Inner width of dozer attaching bracket Width of dozer attaching bracket Distance from dozer attaching pin center to attaching pin on dozer cylinder head side Attaching bracket inner width on dozer cylinder head side Horizontal distance from dozer attaching pin center to edge end Vertical distance from dozer attaching pin center to edge end Dozer attaching pin dia.

Attaching pin dia. on dozer cylinder head side

F G H J d1 d2

3-19

Unit: mm (ft-in) Dimensions CX20B / 22B CX27B 1400 (4’7.12") 1500 (4’11.06") 300 (11.81") ← R976 (3’2.43") R1065 (3’5.93") 500 (1’7.69") ← 60 (2.36") ← R552 (1’9.73")

R600 (1’11.62")

52 (2.05") 944 (3’1.17") 248 (9.76") ø35 (1.38") ø45 (1.77")

← 1034 (3’4.71") 255 (10.04") ← ←

3. ATTACHMENT DIMENSIONS 3.4.2

DOZER MAINTENANCE STANDARDS

Fig. 3-15 Dozer maintenance standards A-B-C = Pin (1) Clearance of pin and bushing Table 3-15 • CX20B / 22B Pos.

Item Dozer blade cylinder (Head side) Dozer blade cylinder (Rod side)

A B

C

Dozer blade foot

Unit: mm (in) Standard dimension Clearance Tolerance Tolerance Standard Standard Serviceabi Remedy value for Pin dia. on pin dia. on bushing lity limit value repair bore dia.

–0.06 +0.20 0.11~ ø45 –0.09 +0.05 0.31 (1.772) (-0.0024) (+0.0079) (0.0043~ Replace 0.7 1.0 (-0.0035) (+0.0020) 0.0122) bushing –0.06 +0.22 0.18~ (0.028) (0.039) or pin ø35 –0.09 +0.12 0.31 (1.378) (-0.0024) (+0.0087) (0.0071~ (-0.0035) (+0.0047) 0.0122)

(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.

3-20

3. ATTACHMENT DIMENSIONS Table 3-16 • CX27B Pos.

Item Dozer blade cylinder (Head side) Dozer blade cylinder (Rod side)

A B

C

Dozer blade foot

Unit: mm (in) Standard dimension Clearance Tolerance Tolerance Standard Standard Serviceabi Remedy Pin dia. on pin dia. on bushing value for value lity limit bore dia. repair –0.06 +0.20 0.11~ ø45 –0.09 +0.05 0.31 (1.772) (-0.0024) (+0.0079) (0.0043~ Replace 0.7 1.0 (-0.0035) (+0.0020) 0.0122) bushing –0.06 +0.22 0.18~ (0.028) (0.039) or pin ø40 –0.09 +0.12 0.31 (1.575) (-0.0024) (+0.0087) (0.0071~ (-0.0035) (+0.0047) 0.0122)

(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.

3-21

3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the dozer and cylinder installation section Table 3-17 • CX20B / 22B

Unit: mm (in) Standard dimensions

Pos.

A

Item

Dozer blade cylinder (Head side)

No.

Dimensions

B

L1

Dozer blade foot

(1.969

)

No. Dimensions

PL1

L2 Lower frame

0.6~2.0 (0.023~0.079) After shim adjustment

(1.969 52 (2.047

When clearance X exceeds 3.5 mm, PL2 adjust it with shim.

PL3

63 (2.480

107 (4.21)

)

60±0.3 (2.362±0.012) L3

107 (4.21)

)

50

Rod side

Lower frame

Remedy

52

Dozer blade

Dozer blade C

Pin length

50

Head side

(2.047

Dozer blade cylinder (Rod side)

Clearance X adjusted with shim (total of both sides)

119 (4.69)

) Table 3-18

• CX27B

Pos.

A

Unit: mm (in)

Item

Dozer blade cylinder (Head side)

No.

Standard dimensions Clearance X Dimensions adjusted with shim (total of both sides)

B

L1

C

(1.969

)

PL1

L2 Lower frame

0.6~2.0 (0.023~0.079) After shim adjustment

(1.969 52 (2.047

When clearance X exceeds 3.5 mm, PL2 adjust it with shim.

PL3

63 (2.480

)

(NOTE) •

122 (4.80)

)

60±0.3 (2.362±0.012) L3

122 (4.80)

)

50

Rod side

Lower frame

No. Dimensions

52

Dozer blade

Dozer blade Dozer blade foot

Remedy

50

Head side

(2.047

Dozer blade cylinder (Rod side)

Pin length

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

3-22

127 (5.00)

3. ATTACHMENT DIMENSIONS

3.5

SWING

3.5.1

SWING BRACKET DIMENSIONAL DRAWINGS E H

d3

D B

A

G

d2

C F1

d4

F

F2

J

d1

Fig. 3-12 Swing bracket dimensional drawings Table 3-19 Unit: mm (in) No. A B C D E F F1 F2 G H J d1 d2 d3 d4

NAME Distance between swing center pin and boom foot pin Distance between boom foot pin and boom cylinder pin - ditto Distance between swing center pin and swing cylinder pin - ditto Inside width of swing center - ditto - ditto Inside width of boom foot Inside width for installing boom cylinder Inside width for installing swing cylinder Pin dia. of swing center Pin dia. of boom foot Pin dia. of boom cylinder Pin dia. of swing cylinder

3-23

DIMENSION 70 (2.76) 136 (5.35) 228 (8.98) R222.5 (8.76) 215.5 (8.48) 291 (11.46) 66 (2.60) 62.5 (2.46) 160 (6.30) 56 (2.20) 56 (2.20) ø60 (2.36) ø40 (1.57") ø40 (1.57") ø35 (1.38")

3. ATTACHMENT DIMENSIONS 3.5.2

SWING PORTION MAINTENANCE STANDARDS

(1) Clearance of pin and bushing B

C

A

D

I I Fig. 3-13 Clearance of pin and bushing on swing portion Table 3-20

Pos.

Item Swing cylinder (Rod side) Swing cylinder (Head side) Swing center (Upper side) Swing center (Lower side)

A B C D

Standard dimension Tolerance on Standard Tolerance on bushing bore Pin dia. value pin dia. dia. +0.10 0.02~ ø35 0 0.15 –0.02 (1.378) (+0.0039) (0.0008~ –0.05 (0) 0.0059) +0.11 0.05~ (-0.0008) ø60 +0.03 0.16 (-0.0020) (2.362) (+0.0043) (0.0020~ (+0.0012) 0.0063)

Unit: mm (in) Clearance Standard Serviceabili Remedy value for ty limit repair

0.7 (0.028)

1.0 (0.039)

(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.

3-24

Replace bushing or pin

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

PL 1

PL 2

B

A

B

A

B-B A-A C, D

1

C, D

2

X

X 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)] 2. Washer [t= 2.3 (0.091)]

3-25

3. ATTACHMENT DIMENSIONS Table 3-21 Standard Dimension Sec.

Item No.

Swing A-A cylinder (Rod side)

Dimensions 55

Cylinder L1

(2.165

(2.205

Swing center C-C (Upper side)

Swing center D-D (Lower side)

0.5~0.9 (0.020~ 0.035)

1.5 (0.059)

L2

(2.165 57

L3 Bracket Upper frame L4

(2.244 ) 59±0.5 (2.322 ± 0.020) 66 ± 1 (2.598 ± 0.039) 59 ± 0.5 (2.322 ± 0.020) 62.5 ± 1 (2.460 ±0.039)

114 (4.49)

PL2

126 (4.96)

Replace PL3 washer

120.5 (4.74)

Adjusted with PL4 shim

126 (4.96)

Adjusted with shim

)

)

PL1

—

55

Upper frame

Bracket

)

56

Bracket

Cylinder Swing B-B cylinder (Head side) Upper frame

Unit: mm (in) Clearance X adjusted with shim Pin length (total of both sides) Standard Remedy Standard Serviceabilivalue for No. Dimensions value ty limit repair

0.1~0.5 (0.004~ 0.020)

1.0 (0.039)

—

—

0.5~0.9 (0.020~ 0.035)

3-26

1.5 (0.059)

—

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) 1 ................................................................ 1-5 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 APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS ......... 11-7 11.7 COUNTERWEIGHT LIFTING JIG ................................................................... 11-8

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 manufacturer’s genuine parts.

Refer to the table below for the tightening and retightening of capscrews.

•

The table below is not applicable for the capscrews to fix the cover, etc., made of plastic. For the tightening torque for such capscrews, consult with an authorized our Distributor. Over-tightening may cause damages on the parts to be fixed.

•

In case that the tightening torque is specified in the manual, use such torque values regardless to the table below.

•

Numerical indication on the capscrew head shows the classification for strength (e.g., 7 = 7 T). No indication is provided for smaller size of capscrews, M 5 or less.

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

M12

P=1.75

21.6±2.0 (15.9±1.4) 36.3±3.9 (26.8±2.9)

17.9±1.8 (13.2±1.3) 31.4±2.9 (23.2±2.1)

46.1±4.9 (34.0±3.6) 79.4±7.8 (58.6±5.8)

39.2±3.9 (28.9±2.9) 66.7±6.9 (49.2±5.1)

83.4±8.8 (61.5±6.5) 143±15 (105±11)

70.6±6.9 (52.1±5.1) 121±12 (89.2±8.9)

M14

P=2

M16

P=2

57.9±5.9 (42.7±4.4) 88.3±8.8 (65.1±6.5)

49.0±4.9 (36.1±3.6) 74.5±6.9 (55.0±5.1)

126±13 (92.9±9.6) 191±20 (141±15)

106±10 (78.2±7.4) 161±16 (119±12)

226±20 (167±15) 343±39 (253±29)

191±19 (141±14) 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

M27

P=3

294±29 (217±21) 431±39 (318±29)

235±29 (173±21) 353±39 (260±29)

637±69 (470±51) 941±98 (694±72)

520±49 (383±36) 765±78 (564±58)

1160±118 (856±87) 1700±167 (1250±123)

11-3

941±98 (694±72) 1370±137 (1010±101)

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 588±59 (434±44)

490±49 (361±36)

1285±127 (948±94)

1079±108 (796±80)

2300±235 (1700±173)

1940±196 (1430±145)

794±78 (586±58) 1030±98 (760±72)

667±69 (492±51) 863±88 (637±65)

1726±177 (1270±131) 2226±226 (1640±167)

1451±147 (1070±108) 1863±186 (1370±137)

3110±314 (2290±232) 4010±402 (2960±297)

2610±265 (1930±195) 3360±333 (2480±246)

M30

P=3.5

M33

P=3.5

M36

P=4

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 M8

P=1.0

M10

P=1.25

M12

P=1.25

M16

P=1.5

M20

P=1.5

M24

P=2

M30

P=2

M33

P=2

M36

P=3

4.8T

7T

10.9T

No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication 11.3±1.1 9.5±1.0 24.5±2.0 20.6±2.0 44.1±3.9 37.3±3.9 (8.3±0.8) (7.0±0.7) (18.1±1.5) (15.2±1.5) (32.5±2.9) (27.5±2.9) 22.6±2.0 (16.7±1.5) 39.2±3.9 (28.9±2.9)

18.7±1.9 (13.8±1.4) 33.3±2.9 (24.6±2.1)

48.1±4.9 (35.5±3.6) 85.3±8.8 (62.9±6.5)

41.2±3.9 (30.3±2.9) 71.6±6.9 (52.8±5.1)

87.3±8.8 (64.4±6.5) 154±16 (114±12)

73.5±6.9 (54.2±5.1) 129±13 (95.2±9.6)

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)

186±19 (137±14) 314±29 (232±21)

155±16 (114±12) 265±29 (195±21)

402±39 (297±29) 686±69 (506±51)

333±29 (246±21) 569±59 (420±44)

726±69 (535±51) 1240±118 (915±87)

608±59 (448±44) 1030±98 (760±72)

637±59 (470±44) 853±88 (629±65)

530±49 (391±36) 706±70 (521±52)

1390±137 (1030±101) 1860±186 (1370±137)

1157±118 (853±87) 1550±155 (1140±114)

2500±255 (1840±188) 3350±334 (2470±246)

2080±206 (1530±152) 2790±275 (2060±203)

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 M12

17 19

M36 M42

55 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 M12

8 10

M30 M36

22 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 3/8

19 22

36±2 (27±1) 74±5 (54±4)

1/2

27

108±9.8 (80±7)

11.3.2

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 1/4

17 19

15±2.0 (11±1) 29±4.9 (22±4)

3/8

22

49±4.9 (36±4)

1/2

27

78±4.9 (58±4)

3/4 1

36 41

118±9.8 (87±7) 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 22 × 3.0

32 36

177±20 (130±14) 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)

APPLICATION OF SCREW LOCKING AND SEALING COMPOUNDS Service

Screw locking compound Sealing compound

Manufacturer Loctite #242

Features

Three-Bond 1360K

Low strength

#262

1374

Middle strength

#271

1305

High strength

#515

1215

Sealing

11-7

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