Hitachi Ex8-2b Excavator Service Repair Manual – PDF DOWNLOAD

Technical Manual EX8-2B

SECTION 1

GENERAL ; CONTENTS; ; Group 1 Specification Specifications ............................................T1-1-1 Working Ranges and Machine Dimensions for Transportation ..................T1-1-2 Engine Specification ..................................T1-1-3

Group 2 Component Layout Main Component ......................................T1-2-1 Electrical System......................................T1-2-2 Monitor Panel ...........................................T1-2-3

522T-1-1

(Blank)

522T-1-2

GENERAL / Specifications SPECIFICATIONS

Item

Unit

Front Attachment Bucket Capacity (Heaped) Machine Weight Base Machine Dry Weight Engine A: Upperstructure Width B: Overall Transportation Height C: Rear End Swing Radius D: Minimum Ground Clearance E: Counterweight Clearance F: Engine Cover Height G: Undercarriage Length

ҥ 3 m kg (lb) kg (lb) − mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in)

H: Undercarriage Width

mm (ft in)

I: Sprocket Center to Idler Center J: Track Shoe Width Ground Pressure Swing Speed Travel Speed Gradeability

mm (ft in) mm (ft in) kPa (kgf/cm2, psi) -1 min (rpm) km/h (mph) % (deg.)

Fixed Undercarriage Undercarriage Width ExWidth Type tension/Retraction Type Standard Canopy Standard Canopy Boom swing type 0.022 PCSA heaped (0.020 CECE heaped) 740 (1630) 770 (1700) 780 (1720) 810 (1790) 570 (1260) 600 (1320) 610 (1340) 640 (1410) -1 KUBOTA Z482-B 6.4 kW/2450min (8.7 PS/2450 rpm) 720 (2’ 4”) 720 (2’ 4”) 1350 (4’ 5”) 2040 (6’ 8”) 1335 (4’ 6”) 2045 (6’ 9”) 820 (2’ 8”) 820 (2’ 8”) 165 (0’ 6”) 130 (0’ 5”) 385 (1’ 3”) 390 (1’ 3”) 965 (3’ 2”) 970 (3’ 2”) 1225 (4’ 0”) 1225 (4’ 0”) 720 / 900 (2’4” / 2’11”) 810 (2’ 8”) (Retraction/Extension) 900 (2’ 11”) 900 (2’ 11”) 180 (0’ 7”) 180 (0’ 7”) 19.6 20.6 20.6 21.6 (0.20, 2.8) (0.21, 3.0) (0.21, 3.0) (0.22, 3.1) 9.2 (9.2) 2.0 (1.2) 58 (30)

M522-11-002

T1-1-1

GENERAL / Specifications WORKING RANG ] MACHINE DIMENSION FOR TRANSPORTATION

L (Left) R (Right)

K (Left) K (Right) M522-11-003

Category Item A: B: C: D: E:

Maximum Digging Reach Maximum Digging Depth Maximum Cutting Height Maximum Dumping Height Overall Transport Height

mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in)

F: Overall Transport Length G: Minimum Swing Radius H: Minimum Swing Radius with Maximum Boom-Swing Angle I: Blade Bottom Highest Position J: Blade Bottom Lowest Position K: Maximum Boom Swing Angle L: Offset Distance

mm (ft in) mm (ft in) mm (ft in) mm (ft in) mm (ft in) Deg. mm (ft in)

M522-11-001

0.70 m Arm Fixed Undercarriage Undercarriage Width ExWidth Type tension/Retraction Type 2800 (9’ 2”) 2800 (9’ 2”) 1525 (5’ 0”) 1520 (4’ 11”) 2800 (9’ 2”) 2805 (9’ 2”) 2035 (6’ 8”) 2040 (6’ 8”) 1350 (4’ 5”) / 1355 (4’ 5”) / Canopy: 2040 (6’ 8”) Canopy: 2045 (6’ 8”) 2745 (9’ 0”) 2745 (9’ 0”) 1025 (3’ 4”) 1025 (3’ 4”) 775 (2’ 6”) 775 (2’ 6”) 155 (0’ 6”) 170 (0’ 6”) Left 90 Right 50 Left 300 Right 390 (0’ 11”) (1’ 3”)

T1-1-2

155 (0’ 6”) 170 (0’ 6”) Left 90 Right 50 Left 300 Right 390 (0’ 11”) (1’ 3”)

GENERAL / Specifications ENGINE SPECIFICATION Item Engine Manufacturer Model Type Cyl. Number-Bore×stroke Piston displacement Rated horsepower Compression ratio Dry weight Firing order Rotation direction Length×Width×Height Starting system Manufacturer Motor Voltage⋅Output Alternator Manufacturer Type Voltage Output Fuel system Type Governor Performance Lubrication Oil Consumption Fuel Consumption Rate (NET) Injection Timing Maximum Output Torgue Injection Pressure Compression Pressure Valve Clearance Idle Speed

KUBOTA Z482-B Diesel 4 cycle, vertical, water cooled, swirl chamber type 2-67 mm (2.6 in) × 68 mm (2.7 in) 3 0.479 L (29.2 in ) -1 6.4 kW/2450 min (8.7 PS/2450 rpm) 23 69 kg (152 Ib) 1-2 Clockwise (viewed from fan side) 356 mm (1 ft 2 in)×385 mm (1 ft 3 in)× 492 mm (1 ft 7 in) MITSUBISHI DC series reduction type 12 V ⋅ 0.8 kW KOKUSAN AC type 12 V ⋅ 12.5 A Bosch MD type Centrifugal ball, mechanical type 9 mL/hr or less 285 g/kW⋅hr or less 210 g/PS⋅hr or less 17° before top dead center 26 N⋅m (2.66 kgf⋅m) or more/ -1 1400 to 1600 min 2 11.8 MPa (120 kgf/cm ) 2 3.4 MPa (35 kgf/cm ) or more 0.145 mm (0.006 in) to 0.185 mm (0.007 in) +50 -1 Fast: 2650 0 min -1 Slow: 1150±50 min

T1-1-3

GENERAL / Specifications (Blank)

T1-1-4

GENERAL / Component Layout MAIN COMPONENTS

2 3

4

1

5 6

7 8

9

13 12 11

T522-01-02-001

10

1234-

Bucket Cylinder Arm Cylinder Boom Cylinder Control Valve

5 - Boom-Swing Cylinder 6 - Swing Device 7 - Pump Device

8 - Hydraulic Oil Tank 9 - Radiator 10 - Travel Device

T1-2-1

11 - Fuel Tank 12 - Center Joint 13 - Blade Cylinder

GENERAL / Component Layout ELECTRICAL SYSTEM 1 2 3

4

5 6 7

8

9 10 11

17 18

16 15 14

13 12

19

20 T522-01-02-002

21

1234-

Work Light Horn Overheat Indicator Engine Oil Pressure Indicator 5 - Key Switch 6 - Alternator Indicator

78910 -

Hour Meter Fuse Box Fusible Link Engine Stop Solenoid

11 - Battery

12 13 14 15 -

Fuel Pump Horn Relay Timer Solenoid Starter Relay 2 (Hour Meter) 16 - Starter Relay 1 (Starter)

T1-2-2

17 18 19 20 -

Regulator Thermo Switch Alternator Engine Oil Pressure Switch

21 - Starter

GENERAL / Component Layout MONITOR PANEL

1

2

3

4

M522-01-008

1 - Overheat Indicator

2 - Hour Meter

3 - Engine Oil Pressure Indicator

T1-2-3

4 - Alternator Indicator

GENERAL / Component Layout (Blank)

T1-2-4

SECTION 2

SYSTEM ; CONTENTS; ; Group 1 Hydraulic System Hydraulic System.......................................T2-1-1

522T-2-1

(Blank)

522T-2-2

SYSTEM / Hydraulic System HYDRAULIC SYSTEM Return oil from the cylinders and motors flows back to the hydraulic oil tank via the control valve.

The main pumps draw hydraulic oil from the hydraulic oil tank and discharge pressure oil to the control valve.

Changing flow direction and flow rate, pressure oil from the control vale flows to and actuates motors and cylinders, respectively.

Arm Cylinder

Boom Cylinder

Bucket Cylinder

Pressure Oil Output Port

Control Valve

9

8

7

6

5

4

3

2

Boom Swing Cylinder

1

1- Travel (Right) 2- Boom 3- Bucket Swing Motor

4- Swing 5- Aux.

Center Joint

6- Blade 7- Travel

Main Pump 2

8- Arm 9- Swing

Main Pump 1 Filter Hydraulic Oil Tank

Engine

Radiator

Center Joint

Main Circuit Suction Circuit Delivery Circuit

Travel Motor

Blade Cylinder

Return Circuit Drain Circuit

Travel Motor

Travel (Left)

Travel (Right) T522-02-01-001

T2-1-1

SYSTEM / Hydraulic System (Blank)

T2-1-2

SECTION 3

COMPONENT OPERATION ; CONTENTS; ; Group 1 Pump Device Outline ......................................................T3-1-1 Function ...................................................T3-1-2

Group 2 Swing Device Swing Motor ..............................................T3-2-1

Group 3 Control Valve Outline ......................................................T3-3-1 Main Relief Valve .......................................... T3-3-2 Overload Relief Valve ................................... T3-3-3 Overload Relief Valve (Swing) ...................... T3-3-4 Make-Up Valve ............................................. T3-3-5

Group 4 Travel Device Outline .......................................................... T3-4-1 Travel Reduction Gear.................................. T3-4-2 Travel Motor.................................................. T3-4-3 Counterbalance Valve................................... T3-4-4

Group 5 Others Swing Bearing............................................... T3-5-1 Center Joint .................................................. T3-5-2 Track Adjuster............................................... T3-5-4

522T-3-1

(Blank)

522T-3-2

COMPONENT OPERATION / Pump Device OUTLINE The pump device is a direct-engine-drive tandem type.

It supplies high pressure oil to the main circuit and has inlet port (3) and delivery port 1 (1) and 2 (2).

1

2

T522-03-01-001

3

1 - Delivery Port 1

2 - Delivery Port 2

3 - Inlet Port

T3-1-1

COMPONENT OPERATION / Pump Device FUNCTION Drive gear (1) meshes with the engine output shaft.

Gear drive (1) and (3) are mutually connected by coupling (2). Driven gear (4) and (5) are connected to drive gear (3) and (1), respectively.

When drive gear (1), (3) and driven gear (4), (5) rotate, hydraulic oil fills the spaces between the teeth on each gear. It is transferred to the outlet port along the inside of the housing.

1

2

3 Suction Port Drive Gear

Drive Gear

Housing

T522-03-01-002

5

1 - Drive Gear 2 - Coupling

4

3 - Drive Gear

4 - Driven Gear

T3-1-2

Delivery Port

5 - Driven Gear

T502-02-03-002

COMPONENT OPERATION / Swing Device SWING MOTOR The swing motor is a orbit motor.

The main components are; valve (8), valve drive (1), valve plate (9), gerotor (10), drive (2) and pinion gear (7).

Valve drive (1) is combined with valve (8) and star (11) inside of gerotor (10), and drive (2) is combined with star (11) inside of gerotor (10) and pinion gear (7).

8

1

9

10 2

3

11

4

5

6

7

T522-03-02-001

1 - Valve Drive 2 - Drive 3 - Valve Plate

4 - Ball Bearing 5 - Housing 6 - Ball Bearing

7 - Pinion Gear 8 - Valve 9 - Valve Plate

T3-2-1

10 - Gerotor 11 - Star (Gerotor)

COMPONENT OPERATION / Swing Device Operational Principle The pressure oil delivered from port BM (7) flows into the chambers in gerotor (5) through valve (2) and port (valve plate) (3). Star (9) is eccentrically installed to valve drive (4) and drive (10). Therefore, when the pressure oil flows into gerotor (5), star (9) in gerotor (5) revolves while rotating on its axis. The rotation force of star (9) drives pinion shaft (6).

In addition, the rotation force of star (9) drives valve (2) via valve drive (4). Valve (2) has 12 ports which offer oil passages for both the high and low pressure oil alternately. Valve plate (3) has seven ports connected to the seven chambers in gerotor (5). When valve (2) is driven, the relative position between valve plate (3) and valve (2) changes so that the pressure oil inlet port position is displaced in sequence, producing continuous rotation force.

1

2 7 3 8 4

5

9 10

11 12

6

T502-02-04-002

1 - Check Valve 2 - Valve 3 - Port (Valve Plate)

4 - Valve Drive 5 - Gerotor 6 - Pinion Shaft

7 - Port BM 8 - Port AM 9 - Star (Gerotor)

T3-2-2

10 - Drive 11 - Inlet Pressure Oil 12 - Return Oil

COMPONENT OPERATION / Control Valve OUTLINE Overload relief valve (swing) regulates oil pressure in the swing hydraulic circuit. It is provided in the swing hydraulic circuit.

Make-up valve prevents cavitation in the actuator hydraulic circuit. It is provided in the left boom-swing hydraulic circuit.

Operation type of the all spools is a direct driven type.

The control valve controls oil pressure, flow rate and flow direction of the main circuit.

The main components are; spool, main relief valve, overload relief valve, overload relief valve (swing) and make-up valve.

Main relief valves regulate the main circuit oil pressure between the main pump and the control valve. They are provided on both ends of the control valve.

Overload relief valves regulate the actuator hydraulic circuit oil pressure between the control valve and the actuators. They are provided in the boom and arm hydraulic circuit.

Main Relief Valve

Overload Relief Valve

Make-Up Valve

9 1

2

3

4

5

6

7

Main Relief Valve

10

8

T522-03-03-001

Overload Relief Valve (Swing)

Overload Relief Valve

1 - Travel (Right) 2 - Dummy 3 - Boom

4 - Bucket 5 - Boom-Swing 6 - Aux.

7 - Blade 8 - Travel (Left)

T3-3-1

9 - Arm 10 - Swing

COMPONENT OPERATION / Control Valve MAIN RELIEF VALVE The main relief valves are provided on the port P1 and the port P2. It prevents the oil pressure in the main circuit from exceeding the set pressure.

Oil pressure in the main circuit acts on poppet (1).

Poppet (1) opens and relieve oil pressure when it increases and overcomes spring (2) force.

1

2

HP

LP

T501-02-06-004

1 - Poppet

2 - Spring

T3-3-2

COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE The overload relief valves are provided between the control valve and cylinder port. It prevents oil pressure in actuator circuit from exceeding the set pressure.

Oil pressure in the actuator circuit acts on poppet (1).

Poppet (1) opens and relieve oil pressure to port LP when the oil pressure increases and overcomes spring (2) force.

1

2

HP

LP

T501-02-06-006

1 - Poppet

2 - Spring

T3-3-3

COMPONENT OPERATION / Control Valve OVERLOAD RELIEF VALVE (SWING) The overload relief valve (swing) is provided between the control valve and the swing motor. It has two operations; one is the relief operation which prevents oil pressure in the swing circuit from exceeding the set pressure, and the other is the make-up operation which prevents cavitation.

Relief Operation When oil pressure increases up to the set pressure of spring (10), the pressure oil pushes piston (7). Then pilot poppet (9) opens being pushed by piston (7).

The pressure oil flows to port LP via piston (7), orifice (4), room A (5), annular orifice (6), passage (8) and periphery of socket (1) in sequence. Main poppet (2) opens because oil pressure in the room A (5) decreases. Thereby, oil pressure from port HP is relieved to port LP via passage (3).

1

2

3

4

5

Make-up Operation When oil pressure in port HP becomes lower than that of port LP, socket (1) is opened by the oil pressure difference so that pressure oil is supplied to port HP, preventing cavitation.

6

7

8

9

10

HP

LP

T522-03-03-002

1 - Socket 2 - Main Poppet 3 - Passage

4 - Orifice 5 - Room A 6 - Annular Orifice

7 - Piston 8 - Passage

T3-3-4

9 - Pilot Poppet 10 - Spring

COMPONENT OPERATION / Control Valve MAKE-UP VALVE The make-up valve is provided between cylinder port HP and tank port LP and functions to prevent cavitation.

Make-up Operation When oil pressure in cylinder port HP becomes lower than that in tank port LP, poppet (1) opens due to oil pressure difference so that pressure oil is supplied to cylinder port HP, preventing cavitation.

1

2 LP

HP

LP

T501-02-06-008

1 - Poppet

2 - Spring

T3-3-5

COMPONENT OPERATION / Control Valve (Blank)

T3-3-6

COMPONENT OPERATION / Travel Device OUTLINE The travel device consists of travel motor (1), counterbalance valve (2), travel reduction gear (3) and sprocket.

3

2

T522-03-04-001

1

1 - Travel Motor

2 - Counterbalance Valve

3 - Travel Reduction Gears

T3-4-1

COMPONENT OPERATION / Travel Device TRAVEL REDUCTION GEAR The travel reduction gear is a one stage reduction planetary gear type.

Shaft (2) of travel motor (3) is combined with ring gear (1) through planetary gear (4). Rotation of shaft (2) is transferred to ring gear (1) after the rotation speed is reduced to enhance torque power.

When ring gear (1) rotates, sprocket installed on ring gear (1) also rotates together.

1

2

3

4

1 - Ring Gear

T522-03-04-001

2 - Shaft

3 - Travel Motor

T3-4-2

4 - Planetary Gear

COMPONENT OPERATION / Travel Device TRAVEL MOTOR The travel motor is a orbit motor.

The main components are; shaft (1), drive (3), valve (4), valve plate (5), gerotor (6) and so on.

Star (7) inside of gerotor (6) is combined with drive (3) and drive (3) with shaft (1).

Operational principle is same as that of the swing motor (refer to T3-2-2).

1

2

3

4

8

5

6

7 T522-03-04-003

1 - Shaft 2 - Casing

3 - Drive 4 - Valve

5 - Valve Plate 6 - Gerotor

T3-4-3

7 - Star (Gerotor) 8 - X-Ring

COMPONENT OPERATION / Travel Device COUNTERBALANCE VALVE Travel Operation When pressure oil from the control valves is supplied to port P1, it pushes check valve L (3) open and flows to motor port M1 (2). On the other hand, though the return oil from the travel motors returns to motor port M2 (5), it is blocked by check valve R (4).

When oil pressure increases more, the pressure oil acts on chamber L (12) through orifice (13) inside of spool (10) and shifts spool (10) to the right.

As a result, the return oil from the travel motors flows to port P2 through spool notch (9) of spool (10).

Eventually, oil flow occurs and the travel motors starts rotating.

When the control levers return to the neutral position, spool (10) is pulled back to the original position by spring (8) force and blocks the circuit to stop the travel motors.

Descending Operation When the machine travels down a slope, the travel motors are forcibly driven by the machine weight so that the motors work like a pump.

When the travel motors draw pressure oil, the oil pressure on port P1 and chamber L (12) decreases.

Thereby, spool (10) moves to the left and restricts the return circuit from the travel motors. As a result, the oil pressure on motor port M2 (5) increases so that the hydraulic brake is activated. When spool (10) restricts the return circuit from the travel motors, the oil pressure on port P1 increases again and spool (10) moves to the right.

The hydraulic brake prevents the travel motors from running away by repeating the above operation.

T3-4-4

COMPONENT OPERATION / Travel Device

Control Valve 1

2

3

P1

4

P2

5

6

T522-03-04-002

12

1234-

Spring L Motor Port M1 Check Valve L Check Valve R

13

11

10

5 - Motor Port M2 6 - Spring R 7 - Chamber R

9

8 - Spring R 9 - Spool Notch 10 - Spool

T3-4-5

8

7

11 - Spring L 12 - Chamber L 13 - Orifice

COMPONENT OPERATION / Travel Device (Blank)

T3-4-6

COMPONENT OPERATION / Others SWING BEARING The swing bearing supports the upperstructure weight and allows the upperstructure to rotate smoothly.

The swing bearing is a single-low ball type. It consists of outer race (1), inner race (2), ball (5), support (4), seal (3) and so on.

Outer race (1) is bolted to the upperstructure and inner race (2) is bolted to the undercarriage. The internal gear of inner race (2) meshes with the output shaft of the swing reduction gear.

1

4 2

3

5

T507-03-02-001

1 - Outer Race 2 - Inner Race

3 - Seal

4 - Support

T3-5-1

5 - Ball

COMPONENT OPERATION / Others CENTER JOINT The center joint is a 360° rotating joint. It allows pressure oil to flow to and from travel motor (7) without twisting hoses when the upperstructure rotates.

Spindle (9) is fastened to the undercarriage with a lock pin and body (11) to the undercarriage with four bolts.

Thereby, body (11) fixes to the undercarriage and spindle (9) rotates during swing operation.

The pressure oil flows to right and left travel motors (7) and blade cylinder (8) through the passage of spindle (9) and body (11).

O-ring (10) prevents oil leak from the clearance between spindle (9) and body (11).

5

8

3

6

4

1

2 7

T522-03-05-002

T3-5-2

COMPONENT OPERATION / Others

9

10

6

5 2

3 1

4 11

Mounting face to the track frame

T522-03-05-003

1 - Port B (Travel Left Reverse) 2 - Port D (Travel Left Forward) 3 - Port C (Travel Right Forward)

4 - Port A (Travel Right Reverse) 5 - Port E (Blade Lower)

7 - Travel Motor

10 - O-Ring

8 - Blade Cylinder

11 - Body

6 - Port F (Blade Raise)

9 - Spindle

T3-5-3

COMPONENT OPERATION / Others TRACK ADJUSTER The track adjuster is to adjust the track sag.

When adjusting screw is turned clockwise, the track sag decreases. When it is turned counterclockwise, the track sag increases.

1

T522-03-05-001

1 - Adjusting Screw

T3-5-4

SECTION 4

OPERATIONAL PERFORMANCE TEST ; CONTENTS; ; Group 1 Introduction

Group 4 Component Test

Operational Performance Test ....................T4-1-1

Main Relief Valve Set Pressure..................... T4-4-1

Preparation for Performance Tests..............T4-1-2

Overload Relief Valve Set Pressure .............. T4-4-3

Group 2 Engine Test

Group 5 Standard

Engine Speed ............................................... T4-2-1

Operational Performance Standard .............. T4-5-1

Engine Compression Pressure..................... T4-2-2 Valve Clearance............................................ T4-2-3 Nozzle Check................................................ T4-2-4 Injection Timing............................................. T4-2-6

Group 3 Excavator Test Travel Speed................................................. T4-3-1 Track Revolution Speed ............................... T4-3-2 Mistrack Check ............................................. T4-3-3 Travel Motor Leakage................................... T4-3-4 Swing Speed................................................. T4-3-5 Swing Function Drift Check .......................... T4-3-6 Swing Motor Leakage ................................... T4-3-7 Swing Bearing Play....................................... T4-3-8 Hydraulic Cylinder Cycle Time ...................... T4-3-9 Dig Function Drift .........................................T4-3-11 Control Lever Operating Force ................... T4-3-12 Control Lever Stroke................................... T4-3-13

522T-4-1

(Blank)

522T-4-2

OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TEST Use operational performance test procedure to quantitatively check all system and functions on the machine.

Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test data with the standard values.

2. According to the evaluation results, repair, adjust, or replace parts or components as necessary to restore the machine’s performance to the desired standard.

3. To economically operate the machine under optimal conditions.

Kinds of Tests 1. Base machine performance test is to check the operational performance of each system such as engine, travel, swing, and hydraulic cylinders.

2. Hydraulic component unit test is to check the operational performance of each component such as hydraulic pump, motor, and various kinds of valves.

Performance Standards “Performance Standard” is shown in tables to evaluate the performance test data.

Precautions for Evaluation of Test Data 1. To evaluate not only that the test data are correct, but also in what range the test data are.

2. Be sure to evaluate the test data based on the machine operation hours, kinds and state of work loads, and machine maintenance conditions.

The machine performance does not always deteriorate as the working hours increase. However, the machine performance is normally considered to reduce in proportion to the increase of the operation hours. Accordingly, restoring the machine performance by repair, adjustment, or replacement shall consider the number of the machine’s working hours.

Definition of “Performance Standard” 1. Operation speed values and dimensions of the new machine.

2. Operational performance of new components adjusted to specifications. Allowable errors will be indicated as necessary.

T4-1-1

OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION TESTS

FOR

PERFORMANCE

Observe the following rules in order to carry out performance tests accurately and safely.

THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test.

TEST AREA 1. Select a hard and flat surface.

2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended.

3. If required, rope off the test area and provide signboards to keep unauthorized personnel away.

PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail.

2. Operate the machine carefully and always give first priority to safety.

3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings.

4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings.

MAKE PRECISE MEASUREMENT 1. Accurately calibrate test instruments in advance to obtain correct data.

2. Carry out tests under the exact test conditions prescribed for each test item.

3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean values of measurements if necessary.

T4-1-2

T105-06-01-003

T505-06-01-003

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE SPEED Be sure to check the engine speed before performing all other tests, since it always affects test results.

Preparation: 1. Warm up the machine, until the engine coolant temperature reaches 50 °C (122 °F) or more, and hydraulic oil temperature is 50±5 °C (122±9 °F).

2. Move the engine speed control lever from slow idle to fast idle. Confirm that the fuel injection pump governor lever comes into contact with the slow-idle and fast-idle stoppers.

3. Connect an engine tachometer to the fuel injection line.

Measurement: 1. Slow idle.

Start the engine. Place the engine speed control lever in the slow idle position and measure the speed of the engine.

2. Fast idle.

Start the engine. Place the engine speed control lever in the fast idle position and measure the speed of the engine.

3. Repeat measurement three times and calculate the mean value.

Evaluation: Refer to T4-5 Standard.

T4-2-1

OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary 1. Measure compression pressure in the cylinders to check for a reduction in engine power.

2. Check exhaust gas color and the amount of blowby gas from crankcase. Keep track of engine oil consumption.

3. Check for abnormalities in the intake system, including the air cleaner.

Preparation: 1. Confirm that clearances are correct.

2. Confirm that the battery is charged properly.

3. Run the engine until the coolant temperature gauge reaches the operating range.

4. Stop the engine. Remove the glow plugs from each cylinder.

5. Install an compression tester (KUBOTA: 0790930208) in place of the glow plug in one cylinder.

(Be sure to sufficiently tighten the adaptor and compression gauge to prevent air leakage.)

Measurement: 1. Run the engine from 5 seconds to 10 seconds.

Record the compression of each cylinder.

2. Repeat measurement three times and calculate the mean value.

Evaluation: Refer to T4-5 Standard.

T4-2-2

T105-06-02-001

OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE Summary: 1. Perform the measurement when the engine is cold.

2. Before removing the head cover, clean the area around the head cover to prevent the entry of dust into the engine.

Preparation: 1. Remove the head cover.

2. Locate the top dead center (TDC) in the compression stroke. Align “1TC mark” on the flywheel with “Punch Mark”.

In this position, cylinder No. 1 is at the top dead center in the compression stroke.

Punch Mark

NOTE: The flywheel can be easily turned after the glow plugs are removed.

1TC Mark 1⋅4TC Mark

T523-06-02-005

Measurement: 1. Measure the valve clearance between the rocker arm and the valve.

2. When the measurement is started from No.1 cylinder, measure the clearances of the valves marked ({) in the following table.

Cylinder No.

1 Valve

Cylinder No.1 at top dead center Cylinder No.1 at overlap

I

2 E

I

{ {

Valve Clearance E

{ ×

3. Turn flywheel 360°, then measure the valve indicated with the mark (×).

T532-06-02-001

Evaluation: Refer to T4-5 Standard.

Adjustment: If the measured value is not within specification, loosen the lock nut and adjust valve clearance by turning the adjusting screw, then tighten lock nut while holding the adjusting screw.

T4-2-3

OPERATIONAL PERFORMANCE TEST / Engine Test NOZZLE CHECK Summary: 1. Check the injection pressure and the spray pattern with a nozzle tester.

2. Before starting work, clean the nozzle holder mounting area to avoid contamination in the engine.

Preparation: 1. Remove the nozzle holders.

Remove all nozzle holders and fuel injection pipings from the engine.

2. Attach a nozzle holder to the nozzle tester Measurement: CAUTION: Never touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood toxication.

T509-02-10-003

Adjusting Shim

1. Injection pressure After attaching the nozzle holder to the nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure.

Use shims to adjust the pressure. Increasing the number of the shims increases the pressure, and vice versa.

NOTE: Pressure variation per shim 0.1 mm = 2 0.98 MPa (10 kgf/cm , 142 psi) 2. Spray pattern Attach the nozzle holder to the nozzle tester.

Strongly make several strokes of the tester and check the fuel spray pattern.

For this test, do not activate the pressure gauge.

NOTE: Use clean diesel oil.

T4-2-4

T523-06-02-002

OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: Refer to T4-5 Standard.

Normal

Abnormal

2. Spray pattern standards (1) No visibly coarse distribution (2) No stray sideways sprays.

(3) Fine spray size and intermittent injection during initial injection stage.

(4) No post-injection dripping (5) Correct injection angles T523-06-02-001

T4-2-5

OPERATIONAL PERFORMANCE TEST / Engine Test INJECTION TIMING Preparation: 1. Remove injection pipes (1). Place the fuel infection pump governor lever in the fast-idle position.

2. Rotate the flywheel counterclockwise. Check that fuel fills the injection pump delivery holder.

3. Rotate the flywheel so that “Mark” on the flywheel circumference is positioned just before “Punch Mark” on the rear end plate.

4. Then, Slowly rotate the flywheel further from this point. When the fuel begins to expand from the injection pump delivery holder, read the positions of “angle mark” and “V mark”. If they are not aligned, make an adjustment.

1

T523-06-02-004

Mark

Punch Mark

Adjustment: 1. Remove bolt (2) and nut (3) from injection pump (4).

2. Adjust timing position by increasing or decreasing the number of shims (6) between injection pump (4) and body (5).

3. When delaying timing, increase the number of shims (6). When advancing timing, decrease the number of shims (6).

T523-06-02-005

3

2

4 6 5

T523-06-02-003

T4-2-6

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL SPEED Summary: To check overall performance of travel drive system (between main pump and travel motor), measure the time required for the excavator to travel a test track.

Preparation: 1. Adjust the track sag of both tracks to be equal.

2. Prepare a level and solid test track 20 m (65.5 ft) in length, with an extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.

3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground with the arm and bucket rolled in.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

End

Arm roll-in, Bucket roll-in Start Raise bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground.

20 m (65.5 ft) 3 to 5 m (9.8 to 16 ft) extra length for acceleration/deceleration

Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast-idle speed.

2. Start traveling the machine in the acceleration zone with the travel levers at full stroke.

3. Measure the time required to travel 20 m (65 ft 5 in).

4. After measuring the forward travel speed, turn the upperstructure 180° and measure the reverse travel speed.

5. Repeat steps (2) and (4) three times in each direction and calculate the mean values.

Evaluation: Refer to T4-5 Standard.

Remedy: Refer to T5-2 “Troubleshooting A”.

T4-3-1

3 to 5 m (9.8 to 16 ft) extra length for acceleration/deceleration T570-06-03-001

OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: With the track raised off ground, measure the track revolution cycle time to check the total track drive system.

Preparation: 1. Adjust the track sag of both side tracks equally.

2. On the track to be measured, mark one shoe with chalk.

CAUTION: Support the lifted track securely using wooden blocks.

3. Swing the upperstructure 90° and lower the bucket to raise the track off ground. Keep the boom-arm angle between 90 to 110° as shown.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast-idle speed.

2. Operate the travel control lever of the raised track in the full forward or reverse stroke.

3. Measure the time required for 3 revolutions of shoe in both directions.

4. Raise the other track and repeat the procedures.

5. Repeat steps (2) and (3) three times for each track and calculate the mean values.

Evaluation: Refer to T4-5 Standard.

NOTE: The measured values may vary widely. The evaluation based on the results obtained from the 20 m (65.5 ft) travel speed check is more recommendable.

Remedy: Refer to T5-2 “Troubleshooting A”.

T4-3-2

90 to 110° Mark

T570-06-03-009

OPERATIONAL PERFORMANCE TEST / Excavator Test MISTRACK CHECK Summary: 1. Allow the machine to travel 10 m (32.7 ft). Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points to check the performance equilibrium between both sides of the travel device systems (from the main pump to the travel motor).

2. If measured on a concrete surface, the tread deviation has a trend to decrease.

Preparation: 1. Adjust the track sag of both tracks to be equal.

2. Provide a flat, solid test yard 10 m (32.7 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration.

3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground with the arm and bucket rolled in.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Max Distance

10 m

Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast-idle speed.

2. Start traveling the machine in the acceleration zone with the travel levers at full stroke.

3. Measure the distance between a straight 20 m (65.5 ft) line and the tread made by the machine.

4. After measuring the tracking in forward travel, swing the upperstructure 180° and measure that in reverse travel.

5. Repeat steps (3) and (4) three times in each direction and calculate the mean values.

Evaluation: Refer to T 4-5 Standard.

Remedy: Refer to T5-2 "Troubleshooting A".

T4-3-3

T570-06-03-002

OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL MOTOR LEAKAGE Summary: Measure the amount of travel motor slippage on a slope, which is due to travel motor inner oil leak.

Preparation: 1. The surface of the test slope must be even, with a gradient of 15°.

2. Mark a white line on the travel device cover.

3. Raise the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground with the arm and bucket cylinders fully extended (rolled in) 4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Measure the moving (rotation) amount before parking brake starts to operate.

1-1. Climb the slope and set travel levers in neutral.

1-2. Measure the moving (rotation) amount of the mark on the cover of travel reduction gear between the positions when the levers are placed in neutral and when the machine stops moving.

2. Measure the slip amount of travel motor at parking.

2-1. Climb the slope and place the travel levers in neutral.

2-2. Stop the engine.

2-3. After parking the machine, makes aligning marks on the side frame and a track link or shoe.

2-4. After 5 minutes, measure discrepancy between the marks.

T570-06-03-010

Position when the machine stops moving.

Position when the travel levers are in neutral.

Moving (rotation) amount

Mark

T107-06-03-002

Evaluation: Refer to T4-5 Standard.

Amount of slippage after 5 minutes T505-06-03-005

T4-3-4

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING SPEED Summary: Measure the time required to swing three complete turns to check the total swing drive system (between main pump and swing motor).

Preparation: 1. Check the lubrication of the swing gear and swing bearing.

2. Place the machine on level, solid ground with ample space for swinging. Do not conduct this test on slopes.

3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the arm top pin is even with the boom foot pin. The bucket must be empty.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F) CAUTION: Before starting the measurement, make sure that there are no person or obstacles within the swing area.

Measurement: 1. Run engine at fast idle speed. Operate swing control lever fully.

2. Measure the time required to swing 3 turns in one direction.

3. Operate swing control lever fully in the opposite direction and measure the time required for 3 turns.

4. Repeat steps (2) and (3) three times each and calculate the average values.

Evaluation Refer to T4-5 Standard.

Remedy: Refer to T5-2 “Troubleshooting A”.

T4-3-5

Even with the Boom Foot Pin. T570-06-03-003

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: To check the valve unit performance, measure the swing drift on the bearing outer circumference when stopping after a 90° full speed swing.

Preparation: 1. Check the lubrication of the swing gear and swing bearing.

2. Place the machine on level, solid ground with ample space for swinging. Do not conduct this test on slopes.

3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is even with the boom foot pin. The bucket must be empty.

4. Make two chalk marks: one on the swing bearing and one directly below it on the track frame.

5. Swing the upperstructure 90°.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Make aligning marks on the swing bearing outer circumference and track frame.

T570-06-03-004

CAUTION: Before starting the measurement, make sure that there are no person or obstacles within the swing area.

Measurement: 1. Start and run engine at fast idle speed. Operate the swing control lever fully to swing the upperstructure. When the marks on the swing bearing and track frame meet, return the swing lever to the neutral position.

2. After the swing movement stops, measure the arc length between two aligning marks along the circumference of the swing bearing.

3. Align the marks again, swing 90° then test in the opposite direction.

4. Repeat steps (1) and (2) three times each and calculate the mean values.

Swing the upperstructure 90° to the test start position.

T570-06-03-005

Measure the arc length along the circumference of the swing bearing.

Mark on the track frame

Evaluation: Refer to T4-5 Standard.

Mark on the swing bearing T105-06-03-010

Remedy: Refer to T5-2 “Troubleshooting A”.

T4-3-6

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: To check swing parking brake performance, measure the upperstructure drift after parking the machine on a slope with the upperstructure positioned 90° to the slope.

(Mechanical brake for swing parking is installed on swing motor.)

Preparation: 1. Check the lubrication of the swing gear and swing bearing.

2. Load the bucket with either soil or a weight equivalent to the weight standard.

With: 30 kg (66 lb) 3. Roll the arm out, roll the bucket in, and position the arm top pin height flush with the boom foot pin.

4. Park the machine on a flat slope with a gradient of 15±1°.

5. Climb the slope, then swing the upperstructure 90ѯtoward the slope. Make aligning marks on the swing bearing circumference and track frame.

6. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Start the engine and maintain engine speed at slow idle. After 5 minutes, measure the difference between the marks along the swing bearing circumference and the track frame.

2. Perform the measurement under the following two conditions: ⋅When the brake is applied(with the pilot control shut-off lever in the LOCK position). ⋅When the brake is released(with the pilot control shut-off lever in the UNLOCK position).

3. Perform the measurement on both right and left swing directions.

4. Perform the measurement three times in each direction and calculate the average values.

T570-06-03-006

Measure the arc length along the swing bearing circumference.

Mark on the track frame Mark on the swing bearing

Evaluation: Refer to T4-5 Standard.

T105-06-03-010

Remedy: Refer to T5-2 "Troubleshooting A".

T4-3-7

OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: Measure the swing play using a dial gauge to check the wear of bearing races and balls.

Preparation: 1. Check swing bearing mounting bolt for looseness.

2. Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and noiseless.

3. Install a dial gauge with a magnetic base on the track frame as shown.

4. Position the upperstructure so that the boom aligns with the tracks facing towards the travel motors.

5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race as shown.

6. Bucket should be empty.

Magnetic Base

Dial Gauge

Round Frame Trunk

NOTE: The measured value may differ depending on where the dial gauge magnetic base is located. Mount the magnetic base directly onto the round frame trunk or as close to the round frame trunk as possible.

Measurement: 1. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is even with the boom foot pin. Record the dial indicator reading (h1).

2. Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h2).

3. Calculate bearing play (H) from this data (h1 and h2) as follows: H = h2 − h1 Evaluation: Refer to T4-5 Standard.

T105-06-03-014

T105-06-03-015

Measurement : (h 1)

Even with the Boom Foot Pin. T505-06-03-026

Measurement : (h 2)

T505-06-03-027

T4-3-8

OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME

Boom Cylinder

Summary: 1. To totally check the front attachment function performance by measuring each cylinder cycle time.

2. Bucket should be empty.

Preparation: 1. Take the following machine position: 1-1. When measuring the boom cylinder: With the arm cylinder fully retracted and the bucket cylinder fully extended, lower the bucket to the ground.

1-2. When measuring the arm cylinder: With the bucket cylinder fully extended, adjust the boom and arm cylinder strokes so that when the arm is moved half the full stroke, the arm longitudinal center line perpendicularly points to the ground and the bucket bottom clearance above the ground is approx. 0.5 m (20 in).

T570-06-03-011

Arm Cylinder

0.5 m

T570-06-03-012

Bucket Cylinder

1-3. When measuring the bucket cylinder: Adjust the boom and arm cylinder strokes so that when the bucket is moved half the full stroke, the bucket edge points to the ground perpendicularly.

1-4. When measuring the boom swing cylinder: Set the boom swing cylinder in either the right or left swing stroke end position.

1-5. When measuring the blade cylinder: Lower the bucket to the ground to raise the machine front off the ground and secure the height space to allow the blade to move upand-down full stroke.

T105-06-03-020

Boom Swing Cylinder

2. Maintain hydraulic oil temperature at 50±5 °C (122±9 °F).

Blade Cylinder

T523-06-03-006

T570-06-03-007

T4-3-9

OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Run engine at fast idle speed 2. Operate each cylinder as follows: (The cylinder stroke excludes the cushion range.)

2-1. Measure the boom cylinder.

Measure the time required to raise or lower the boom while operating the boom control lever full stroke.

2-2. Measuring the arm cylinder.

Measure the time required to roll in or out the arm while operating the arm control lever full stroke.

2-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the bucket while operating the bucket control lever full stroke.

2-4. Measuring the boom swing cylinder Measure the time required to swing the front attachment from right to left or vice versa while operating the boom swing pedal full stroke.

2-5. Measuring the blade cylinder Measure the time required to raise or lower the blade while operating the blade control lever full stroke.

3. Repeat each measurement three times and calculate the average values.

Evaluation: Refer to T 4-5 Standard.

Remedy: Refer to T5-2 “Troubleshooting A�.

T4-3-10

OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT Summary: With the bucket loaded, measure dig function drift, which can be caused by oil leakage in the control valve and / or boom, arm, and bucket cylinders.

NOTE: When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge trapped air prior to testing.

Extension

Retraction

Retraction

Preparation: 1. Load the bucket with either soil or a weight equivalent to the weight standard.

With: 30 kg (66 lb) 2. With the arm cylinder fully retracted and the bucket cylinder fully extended, position the arm top pin height flush with the boom foot pin. Confirm no offset.

3. Retract arm cylinder and bucket cylinder approx.

20 to 50 mm to away from the cushion range.

4. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Arm Top Pin is even with Boom Foot Pin.

Front Drift

T570-06-03-008

Extension

Boom and Bucket Cylinder Retraction

Measurement: 1. Stop the engine.

2. After five minutes, measure boom and bucket cylinder retraction, arm and blade cylinder extension, and amount of bucket drift.

3. Repeat step 2. three times and calculate the mean values.

Mark

Mark

T110-06-03-002

Evaluation: Refer to T4-5 Standard.

Arm and Blade Cylinder Extension

Remedy: Refer to T5-2 “Troubleshooting A”.

Mark

T110-06-03-001

T4-3-11

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: Use a spring scale to measure the maximum force needed to move each control lever and pedal.

Measure the operating force at the center of each lever grip.

Preparation: 1. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

CAUTION: Before the measurement, make sure there are no personnel or obstacles within the swing area.

Measurement: 1. Start the engine. Place the fuel lever in the fastidle position.

2. Measure the maximum operating force for each boom, arm, bucket, swing lever, blade and engine speed control full stroke using a spring scale.

3. When measuring the operating force of the travel levers, raise one track off the ground with the front attachment, and operate the travel lever of the raised side track full stroke. Measure the maximum operating force.

4. Repeat each measurement three times and calculate the mean values.

T107-06-03-003

Evaluation: Refer to T4-5 Standard.

T107-06-03-004

T4-3-12

OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Measure each lever stroke at the center of each lever grip. Measure the boom swing pedal stroke at the top of the pedal.

Preparation: Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Stop the engine.

2. Measure the boom, arm, bucket, swing and travel control lever strokes at the grip top center from the neutral position to the stroke end.

On the swing pedal, measure the straight distance between the center and fully depressed positions at tip of the pedal.

On the engine speed control lever, measure the distance between the slow and fast idle positions at center of the top on the grip.

3. Take the measurements by the straight stroke distances.

4. Conduct the measurement three times.

Calculate the average values.

Evaluation: Refer to T4-5 Standard.

T4-3-13

T107-06-03-005

OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank)

T4-3-14

OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE Summary: Measure the main relief valve setting pressure at the main delivery port.

Preparation: 1. Stop the engine.

2. Turn the filling cap on the hydraulic oil tank to bleed air.

3. Install adapter (ST 6451) and pressure gauge assembly (ST 6933). : 19 mm, 22 mm 4. Start the engine and check for oil leakage from the pressure gauge connection.

5. Maintain the hydraulic oil temperature at 50±5 °C (122±9 °F).

Measurement: 1. Run the engine at fast-idle speed.

2. Slowly operate each control lever or pedal to fully extend or retract each cylinder to relieve pressure.

Measure the relief pressure at this time.

3. When measuring the travel function, secure the tracks against an immovable abject.

Slowly operate the swing lever to relieve the travel function.

4. Repeat the measurement three times and calculate the average values.

Evaluation: Refer to T4-5 Standard.

T4-4-1

T522-04-03-001

OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: Adjust the main relief valves if necessary. The main relief valves are installed on the positions as follows.

Main Relief Valve

Main Relief Valve

T522-03-03-001

1. Loosen the lock nut on the main relief valve. : 10 mm

Lock Nut

Adjusting Screw

2. Turn the adjusting screw to adjust the pressure setting, looking at the pressure gauge.

3. Do not exceed the upper limit on the standard.

4. Tighten the lock nut.

Pressure Increases

: 6 N⋅m (0.6 kgf⋅m, 4.3 lbf⋅ft)

T505-06-04-006

NOTE: Standard change in pressure.

Screw Turn Change in Mpa 2 Relief (kgf/cm ) Pressure (psi)

1/4 1.7 (17.9) (256)

1/2 3.5 (35.8) (513)

Pressure Decreases

1 6.9 (71.5) (1024)

5. After completing the adjustment, recheck the set pressure.

T4-4-2

OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRESSURE Checking the pressure setting of the overload relief valves on the machine is not recommended for the following reasons: 1. With the return circuit from the control valve blocked, the circuit pressure must be increased by applying an external load. This checking method is hazardous and the results obtained with this method are unreliable.

2. Pressure setting of the overload relief valve must be made at a specified oil flow rate normally far smaller than the delivery flow rate of the main pump. Accordingly, even if the engine speed is reduced and the main relief valve pressure setting can be reset higher than the setting pressure of the overload relief valve, the main pump supplies too much oil to correctly measure the setting pressure of the overload valve.

The main relief valve has pre-leaking function.

Accordingly, the main relief valve pressure setting may not be reset higher than the set pressure of the overload relief valve plus the pressure at preleaking.

Therefore, when the setting pressure of the overload relief valve must be checked correctly, remove the overload relief valve from the machine and check the overload relief valve unit performance using the test stand and test block prepared for this purpose. (to check the performance with proper flow rate.)

If the poppet of overload relief valve seats to the body of control valve, the test block requires precise machining.

Use other control valve unit for the measurement instead of the test block.

3. As an easier method, however, measure the relief pressure of each cylinders in the same method as of main relief pressure setting in previous section.

Then, when each relief pressure meets its respective specifications, judge that the setting pressure of the overload relief valve is correct.

Measurement: Repeat the measurement three times and calculate the average values.

Evaluation: Refer to T4-5 Standard.

T4-4-3

OPERATIONAL PERFORMANCE TEST / Component Test (Blank)

T4-4-4

OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL PERFORMANCE STANDARD Refer to the correspondence section in T4-2 and after for the details of each measurement method. * Hydraulic oil temperature: 50±5 °C is required for the standard measurement condition.

Item

Standard

ENGINE SPEED Slow Idle Speed Fast Idle Speed

min-1

1150 ± 50 2650 ± 50

ENGINE COMPRESSION PRESSURE (After Warming Up)

VALVE CLEARANCE (IN, EX) NOZZLE INJECTION PRESSURE INJECTION TIMING (Before Top Dead Center)

MPa (kgf/cm2) mm

HYDRAULIC CYLINDER CYCLE TIME Boom Raise Boom Lower Arm Roll-In Arm Roll-Out Bucket Roll-In Bucket Roll-Out Right Boom Swing Left Boom Swing Blade Raise Blade Lower ∗

0.145 to 0.185 13.7 (140)

MPa (kgf/cm2)

TRAVEL SPEED TRACK REVOLUTION SPEED MISTRACK (Fast Speed ⋅ Slow Speed) TRAVEL MOTOR LEAKAGE SWING SPEED SWING FUNCTION DRIFT SWING MOTOR LEAKAGE SWING BEARING PLAY

NOTE:

2.8 to 3.2 (29 to 33)

17°

deg.

35.6 ± 1.5 15.1 ± 1.5

sec/20 m sec/3 rev.

200 or less

mm/10 m mm/3 min sec/3 rev. mm/90° mm/5 min mm

30 or less 19.7 ± 1.5 50 or less 0 ∗ 0.3 to 0.7 ∗ Allowable Limit: 2

sec

2.1 ± 0.3 2.1 ± 0.3 3.8 ± 0.3 2.8 ± 0.3 2.9 ± 0.3 2.1 ± 0.3 3.7 ± 0.5 3.7 ± 0.5 1.5 ± 0.5 20. ± 0.5

Reference Value

T4-5-1

Remarks

OPERATIONAL PERFORMANCE TEST / Standard * Hydraulic oil temperature: 50±5 °C is required for the standard measurement condition.

Item

Standard

DIG FUNCTION DRIFT Boom Cylinder Arm Cylinder Bucket Cylinder Bucket Bottom Front Attachment Drift

mm/5 min

10 or less 8 or less 5 or less 10 or less 100 or less

CONTROL LEVER/PEDAL OPERATING FORCE Boom Lever Arm Lever Bucket Lever Swing Lever Travel Lever Blade Lever Boom Swing Pedal Fuel Lever

N (kgf)

19.6 or less (2.0 or less) 19.6 or less (2.0 or less) 19.6 or less (2.0 or less) 19.6 or less (2.0 or less) 14.7 or less (1.5 or less) 24.5 or less (2.5 or less) 58.8 or less (6.0 or less) 68.6 or less (7.0 or less)

CONTROL LEVER/PEDAL STROKE Boom Lever Arm Lever Bucket Lever Swing Lever Travel Lever Blade Lever Boom Swing Pedal Fuel Lever MAIN RELIEF PRESSURE OVERLOAD RELIEF PRESSURE

mm

61 ± 10 63 ± 10 61 ± 10 63 ± 10 62 ± 10 58 ± 10 19.5 ± 5/17 ± 5 63 ± 10

MPa (kgf/cm2) 2

MPa (kgf/cm )

17.2 ± 1.0 (175 ± 10) 18.6 ± 1.0 (190 ± 10) +1.5 +1.5 7.4 -1.0 (75 -1.0) (Swing)

T4-5-2

Remarks

SECTION 5

TROUBLESHOOTING ; CONTENTS; ; Group 1 Diagnosing Procedure Introduction ...............................................T5-1-1 Diagnosing Procedure................................T5-1-2

Group 2 Troubleshooting A Troubleshooting A Procedure ....................... T5-2-1 Starter Does Not Rotate ............................... T5-2-2 Actuator Operating System Troubleshooting .......................................... T5-2-3 Front Attachment System Troubleshooting .......................................... T5-2-4 Swing System Troubleshooting .................... T5-2-8 Travel System Troubleshooting .................... T5-2-9 Blade System Troubleshooting ................... T5-2-10

Group 3 Troubleshooting B Troubleshooting B Procedure ....................... T5-3-1 Malfunction of Alternator Indicator ................ T5-3-2 Malfunction of Engine Oil Pressure Indicator ...................................................... T5-3-3 Malfunction of Overheat Indicator................. T5-3-4 Malfunction of Hour Meter ............................ T5-3-5

Group 4 Electrical System Inspection Precautions for Inspection and Maintenance ............................................... T5-4-1 Fuse Continuity Test ..................................... T5-4-3 Battery Voltage Check .................................. T5-4-4 Voltage Check............................................... T5-4-5 Continuity Check........................................... T5-4-6

522T-5-1

(Blank)

522T-5-2

TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Troubleshooting charts shown in this section indicate the orderly procedures for inspecting and finding out the cause(s) of problems in the machine.

This section is comprised of three groups: Troubleshooting A (diagnosis of machine by symptom), Troubleshooting B (diagnosis of monitor) and Electric System Check.

• Troubleshooting A (diagnosis of machine by symptom) This procedure is used when operating the diagnosis by the symptom.

Example: Starter does not rotate.

• Troubleshooting B (diagnosis of monitor) This procedure is used when there are malfunction on components regarding monitor, such as gauges or indicators.

Example: Fuel gauge does not operate.

• Electric System Check This procedure is used when the information on precaution for electric system inspection or inspection method is needed.

Example: Fuse inspection.

T5-1-1

TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE Follow the five basic steps shown below for efficient troubleshooting.

1. Know the system Study the appropriate technical manuals. Know what the system is composed of and how it works, as well as the construction, functions and specifications of the system components.

2. Ask the operator Before inspecting, get the full story of malfunctions from a witness --- the operator. (a) How the machine has been used and properly operated? (b) When was the trouble noticed, and what work was the machine doing at that time? (c) What is the character of the trouble? Did the trouble slowly get worse, or did it appear suddenly for the first time? (d) Did the machine have any trouble previously?

If so, which parts were repaired or replaced before?

3. Inspect the machine Before starting troubleshooting, check the machine's daily maintenance points, as shown in the operator's manual.

Check the electrical system, including batteries.

Trouble in the electrical system such as low battery voltage, loose connections and blown fuses will result in malfunction of the controllers, causing total operational failure of the machine.

T107-07-01-001

T107-07-01-002

Note that if the troubleshooting is performed without noticing that the fuse is blown, it may lead to the incorrect diagnosis results which causes significant loss of time. Make sure to check the fuse before performing the troubleshooting.

Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection.

T107-07-01-003

T5-1-2

TROUBLESHOOTING / Diagnosing Procedure 4. Inspect the actual trouble on the machine Reproduce the trouble on the machine and make sure the actual phenomenon.

In case some trouble cannot be actually confirmed, obtain the details of the malfunction from the operator.

Also check for any incomplete connections of the wire harnesses.

5. Check by Each System CAUTION: Always stop the engine before disconnecting the harnesses or lines. If they are disconnected while the engine running, it may cause improper operation of the machine, or the pressurized oil may spout.

T107-07-01-004

Use "Troubleshooting A, B" in this chapter to confirm the operation condition for each equipment.

6. Trace causes Before reaching a conclusion, check the most suspectable causes again. Try to trace what the real cause of the trouble is.

Make a plan of appropriate repairing procedure, to avoid consequential malfunctions.

T107-07-01-006

T107-07-01-007

T5-1-3

TROUBLESHOOTING / Diagnosing Procedure (Blank)

T5-1-4

TROUBLESHOOTING / Troubleshooting A TROUBLESHOOTING A PROCEDURE (DIAGNOSIS OF MACHINE BY SYMPTOM) This procedure is used when operating the diagnosis by the symptom.

• How to Read the Troubleshooting Flow Charts YES (OK) ѕ

(2)

After checking or measuring item (1), select either YES (OK) or NO (NOT OK) and proceed to item (2) or (3) next.

(1)

NO (NOT OK)

ѕ

·Key switch: ON

ѕ

(3)

As shown to the left, measuring methods or items to be referred to are indicated in the spaces under the box. Take care to measure or check correctly. Incorrect measuring or checking methods may result in making troubleshooting impossible, and may damage components.

The thick-line box indicates the causes. Scanning through thick-line boxes, possible causes can be focused.

NOTE: The connector drawings show the harness end connectors seen from the open end side.

Wire Harness Side

Open End Side

Harness End Connector

T158-05-03-001

T5-2-1

TROUBLESHOOTING / Troubleshooting A STARTER DOES NOT ROTATE • Battery voltage should be 12 V or more. Battery density should be 1.28 or more.

• Be sure to inspect connection prior to troubleshooting.

YES

Faulty starter.

Check if battery voltage is 12 V at terminal S (50) of starter.

Faulty starter relay, or broken harness between starter relay 1 and key switch.

YES

·Key switch: START NO

Check if battery voltage is 12 V at terminal C of Key switch.

YES

Faulty key switch.

NO

Faulty fusible link, or broken harness between key switch and battery.

·Key switch: START

NO

Check if battery voltage is 12 V at terminal B of Key switch.

Starter Voltage Check

S (ST) B T523-07-02-001

Key Switch Voltage Check C ACC

B R

Br R2

T505-07-03-001

T5-2-2

TROUBLESHOOTING / Troubleshooting A ACTUATOR OPERATING SYSTEM TROUBLESHOOTING All machine functions are slow.

• As the main circuit consists of 2 systems (2 main relief valves are provided), the possibility of failure in the main relief valve is small.

YES

Faulty main pump.

Check if engine speed is normal. ·Refer to “OPERATIONAL PERFORMANCE TEST”.

Faulty engine.

NO

The actuator does not stop even if the control lever is returned to the neutral position.

• As the all spools of the control valve are a direct driven type, there is a possibility of link failure of the control lever.

T5-2-3

TROUBLESHOOTING / Troubleshooting A FRONT ATTACHMENT SYSTEM TROUBLESHOOTING All front attachment function power are weak.

• As the main circuit consists of 2 systems (2 main relief valves are provided), the possibility of failure in the main relief valve is small.

YES

Faulty pump.

Check if engine speed is normal. ·Refer to “OPERATIONAL PERFORMANCE TEST”.

Faulty engine.

NO

T5-2-4

TROUBLESHOOTING / Troubleshooting A Cylinder (s) in one system does not move.

Completion. (Stuck control YES valve spool)

Check if overload YES relief valve corresponding to cylinder (s) is normal. ·Refer to “OPERATIONAL PERFORMANCE TEST”.

Check if control lever link corresponding to cylinder (s) is normal.

Check if problem YES disappears after control valve spool corresponding to cylinder (s) is disassembled and cleaned.

NO

Faulty seal of cylinder (s).

NO

Faulty overload relief valve corresponding to cylinder (s).

Faulty control lever link corresponding to cylinder (s).

NO

T5-2-5

TROUBLESHOOTING / Troubleshooting A Front attachment cylinders leaking (drift) is large.

YES

Normal

Check if each front attachment cylinder drift is within standard.

NO

YES

Faulty seal in cylinder.

NO

Scored control valve spool, or damaged spring, or loosed spool end.

Check if oil leaks inside cylinder.

• Boom cylinder inner leak check 1. With the bucket cylinder fully retracted and the arm cylinder slightly extended from the fully retracted position, lower the bucket tooth tip to the ground.

2. Disconnect the hydraulic hose at the rod side of boom cylinder, and drain the oil inside of cylinder and hose. (install a plug on disconnected hose end.)

3. Retract the rod of the arm cylinder to raise the bucket from the ground.

If the oil comes out from the disconnected hose line and the rod of the boom cylinder is retracted, the oil is leaking in the boom cylinder.

If the oil does not come out from the disconnected hose line and the rod of the boom cylinder is retracted, the oil is leaking in the control valve.

T5-2-6

T563-05-03-001

TROUBLESHOOTING / Troubleshooting A When the arm control lever is operated (boom raise, arm roll-out), front attachment drops briefly, then begin to move.

YES

Internal leakage in cylinder.

Check if load check valve inside of control valve functions normally. ¡Visual check after disassembly

Faulty load check valve.

NO

NOTE: 1. During the initial stage of operation, the oil pressure and the flow rate from the pump are low. If the load check valve is failed, the oil in the bottom side of the cylinder flows back into the circuit through the load check valve, causing the boom cylinder the boom temporarily retract because of the road on the boom cylinder.

2.

If the oil is leaking from bottom side (A) to the rod side (B) due to the failed piston or tube of the boom cylinder, the boom cylinder temporarily retracts as oil pressure and flow rate from the pump is low during the initial stage of operation.

Then, the cylinder cannot support the load, reducing cylinder force and increasing the cylinder drift in this case.

T5-2-7

(B) At failure in load check valve (A)

T105-07-04-012

TROUBLESHOOTING / Troubleshooting A SWING SYSTEM TROUBLE SHOOTING Upperstructure does not swing, or its speed is slow.

Completion. (Faulty control YES valve spool) Check if problem YES disappears after control valve spool is disassembled and cleaned.

Faulty swing motor.

Check if swing YES motor relief pressure is normal.

NO

·Refer to “OPERATIONAL PERFORMANCE TEST”.

Check if control valve spool moves by full stroke.

Faulty overload relief valve.

NO

Stuck control valve spool, or improper adjustment of link.

NO

T5-2-8

TROUBLESHOOTING / Troubleshooting A TRAVEL SYSTEM TROUBLE SHOOTING The machine mistracks.

YES

YES

Check if problem is reversed when the travel hoses under the center joint are switched.

Faulty center joint.

Faulty travel motor.

NO

Check if control valve spool moves by full stroke.

Stuck control valve spool, or improper adjustment of link.

NO

Right Travel Forward

Left Travel Reverse Left Travel Forward

Right Travel Reverse

T563-05-03-002

T5-2-9

TROUBLESHOOTING / Troubleshooting A BLADE SYSTEM TROUBLESHOOTING Blade does not move, or its speed is slow.

YES

Check if problem disappears after blade spool of control valve is disassembled and cleaned.

NO

Completion. (faulty spool.)

Remove blade cylinder, and fully retract the blade cylinder.

Connect only the line to the rod side.

Check for oil leaks from bottom side port of cylinder when blade is raised.

T5-2-10

YES

Oil leak in cylinder.

Faulty center joint.

NO

TROUBLESHOOTING / Troubleshooting B TROUBLESHOOTING B PROCEDURE (DIAGNOSIS OF MONITOR) This procedure is used when there are malfunction on components regarding monitor, such as gauge or indicators.

• How to Read the Troubleshooting Flow Charts YES (OK) ѕ

(2)

After checking or measuring item (1), select either Yes (OK) or No (NOT OK) and proceed to item (2) or (3) next.

(1) NO (NOT OK)

ѕ

·Key switch: ON

(3)

As shown to the left, measuring methods or items to be referred to are indicated in the spaces under the box. Take care to measure or check correctly. Incorrect measuring or checking methods may result in making troubleshooting impossible, and may damage components.

The thick-line box indicates the causes. Scanning through thick-line boxes, possible causes can be focused.

ѕ

NOTE: The connector drawings show the harness end connectors, seen from the open end side.

Wire Harness Side

Open End Side

Harness End Connector

T158-05-03-001

T5-3-1

TROUBLESHOOTING / Troubleshooting B MALFUNCTION OF ALTERNATOR INDICATOR • Be sure to inspect connection prior to troubleshooting.

YES

Burnt indicator bulb.

Disconnect alternator indicator plug of YES red and white harness. Check if voltage is 12 V. When key switch is turned to “ON” position, indicator does not light. ·Key switch: ON ·Engine: Stop

·Key switch: ON ·Engine: Stop

Disconnect alternator plug of red and white harness.

Check if voltage is 12 V. ·Key switch: ON ·Engine: Stop

NO

Broken harness between alternator and indicator.

Faulty alternator (regulator).

NO

Even if engine rotates, indicator does not light off.

Faulty alternator (regulator).

T5-3-2

TROUBLESHOOTING / Troubleshooting B MALFUNCTION OF ENGINE OIL PRESSURE INDICATOR • The indicator lights on condition that engine oil +20 +0.2 pressure becomes lower than 39 kPa (0.4 0 2 kgf/cm ).

• Be sure to inspect connection prior to troubleshooting.

YES

When key switch is turned to “ON” position, indicator does not light on. ·Key switch: ON ·Engine: Stop ·The pressure might not be released for 1 to 2 minutes just after the engine stops. This is normal

When oil pressure switch is disconnected and harness end terminal is connected to body, engine oil pressure indicator lights on. ·Key switch: ON NO

Faulty engine oil pressure switch.

Reconnect the removed terminal.

When engine oil pressure indicator plug of white and red harness is connected to the body, indicator lights on.

YES

·Key switch: ON ·Ground the connector to the body using a clip without disconnecting.

NO

YES

Even if engine starts, indicator does not light off. ·Check if oil filter is clogged or not.

Broken harness between engine oil pressure switch and engine oil pressure indicator.

Burnt indicator bulb.

Faulty engine oil pressure switch.

Check if engine oil pressure indicator lights off when engine oil pressure switch is disconnected. ·Key switch: ON ·Engine: Stop NO

T5-3-3

Short-circuited harness between engine oil pressure switch and engine oil pressure indicator.

TROUBLESHOOTING / Troubleshooting B MALFUNCTION OF OVERHEAT INDICATOR • The indicator lights on when coolant temperature is above 115 ± 3 °C (239 ± 40 °C).

• Be sure to inspect connection prior to troubleshooting.

YES

When key switch is turned to “ON” position, overheat indicator does not light on. ·Key switch: ON ·Engine: Stop

Disconnect overheat switch terminal.

Connect harness end terminal to the body. Check if indicator lights on. ·Key switch: ON NO

Faulty overheat switch.

Reconnect the disconnected terminal.

Check if overheat indicator lights on when overheat indicator plug of blue and white harness is connected to the body. ·Key switch: ON ·Ground the connector to the body using a clip without disconnecting.

YES

Overheat indicator does not stop blinking. ·Key switch: ON

YES

NO

Broken harness between overheat switch and overheat indicator.

Burnt indicator bulb.

Faulty overheat switch.

Check if overheat indicator stops blinking when overheat switch terminal is disconnected. ·Key switch: ON

NO

T5-3-4

Short-circuited harness between overheat switch and overheat indicator.

TROUBLESHOOTING / Troubleshooting B MALFANCTION OF HOUR METER • Be sure to inspect connection prior to troubleshooting.

YES

While engine runs, hour meter does not operate.

Faulty alternator, or alternator indicator.

Check if alternator indicator lights on. ·Engine: Running

Faulty hour meter.

NO

T5-3-5

TROUBLESHOOTING / Troubleshooting B (Blank)

T5-3-6

TROUBLESHOOTING / Electrical System Inspection PRECAUTIONS FOR INSPECTION AND MAINTENANCE 1. Disconnect the power source.

Be sure to remove the negative terminals from the batteries first when taking wire harnesses and connectors off for repair or replacement work.

Failure to do so can result in damage to the wire harnesses, fuses, and fusible links and, in some cases, cause fire due to short circuiting.

2. Color coding of wire harnesses.

The color codes of the wire harnesses in the electrical system are shown below.

In cases on the design sheet where two colors are indicated for one wire, the left initial stands for the base color, while the right initial stands for the marking color.

Code R L Or Y Br Gr

Color Red Blue Orange Yellow Brown Gray

Code W G Lg B P V

Color White Green Light Green Black Pink Violet

NOTE: 1) Code BW indicates a black base wire with white fine-line marking.

2) Initials "O" and "Or" both stand for the color orange.

3) Wires with longitudinal stripes printed on them are not color coded. Be sure not to confuse them with color coded wires 3. Precautions for connecting and disconnecting terminal connectors.

(1) When disconnecting harnesses, grasp them by their connectors. Do not pull on the wire itself.

Be sure to release the lock first before attempting to separate connectors, if a lock is provided.

(2) Water-resistant connectors keep water out so that if water enters them, water will not easily drain from them. When checking water resistant connectors, take extra care not to allow water to enter the connectors. In case water should enter the connectors, reconnect only after the connectors are thoroughly dried.

(3) Before connecting terminal connectors, check that no terminals are bent or coming off. In addition, as, most connectors are made of brass, check that no terminals are rusting.

(4) When connecting terminal connectors provided with a lock, be sure to insert them together until the lock "clicks."

T5-4-1

Right

Wrong

T107-07-06-001

Right Rust Wrong (Deformation) Wrong (Coming off, Separation) T107-07-06-002

TROUBLESHOOTING / Electrical System Inspection 4. Precaution for using a circuit tester.

(1) Before using a circuit tester, refer to the instructions in the circuit tester manual.

Then, set the circuit tester to meet the object to be measured, voltage range and current polarity.

(2) Before starting the connector test, always check the connector terminal numbers, referring to the circuit diagram.

When the connector size is very small, and the standard probe size is too large to be used for testing, wind a fine piece of sharpened wire or a pin around the probe to make the test easier.

T5-4-2

Wind a piece of wire

Tester Probe

Sharpen the end of the wire T107-07-06-003

TROUBLESHOOTING / Electrical System Inspection FUSE CONTINUITY TEST Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection.

Checking fuse continuity with a tester is far superior to sight inspection.

1. Turn the key switch ON When key switch is turned ON, the power is supplied to all circuit from key switch R2 and Acc Terminal (Refer to Circuit Diagram).

Fuse Box

2. Remove the fuse box cover and set the correct voltage measurement range of the tester.

(Measurement range: 0 to 30 V) 3. Connect the negative probe to the vehicle ground, and touch the outside terminal of each fuse with the positive probe of the tester.

If approx. 12 V is confirmed, there is no problem on a fuse.

Number

Capacity

1

15A

Connected to Engine Stop Solenoid

2

15A

Work Light, Monitor

3

20A

Fuel Pump

4

15A

Horn

M522-07-021

1 2 3 4

M522-07-023

T5-4-3

TROUBLESHOOTING / Electrical System Inspection BATTERY VOLTAGE CHECK 1. Turn key switch OFF 2. Measure between battery plus terminal and the ground (vehicle) using a voltmeter.

Correct Voltage Reading: 12 V NOTE: If voltage is abnormal, re-charge or replace the battery.

3. Start the engine.

4. Measure the battery voltage again.

Correct Voltage Reading: Approximately 14.5 V

V

NOTE: If voltage is abnormal, check the charging system.

T505-07-01-002

T5-4-4

TROUBLESHOOTING / Electrical System Inspection VOLTAGE CHECK Turn switches ON so that the specified voltage is supplied to the check point. Measure voltage.

Diagnose the circuit by checking it specified voltage is supplied or not.

12 volt circuit (example: the horn circuit) Check the circuit in either the upstream (from the power source) or downstream (from the accessory) order to locate the failed section in the circuit.

Set the following check conditions: • Key switch position: ON (When checking points (4) to (8).

• Horn switch position: ON (When checking points (9) or (10) • Tester black terminal (negative): Connected to the vehicle (ground) • Tester red terminal (positive): Connected to the checking point • Power source: Batteries (12 volts) Evaluation If the measured voltage is 0.5 V or less than the battery voltage, some incorrect contacts may exist at connectors.

B

BR ACC R2

C

OFF ON START

1

2 4

3

5 6

8

7

9 10

An example of the checking order (horn circuit) 1

2

3

4

5

6

T5-4-5

7

8

9

10

R1

TROUBLESHOOTING / Electrical System Inspection CONTINUITY CHECK Single-line continuity check Disconnect both end connectors of the harness and check continuity between ends: If the ohm-meter reading is: 0 Ω = Continuity ∞ Ω = Discontinuity NOTE: When the one end connector is far apart from the other, connect one end of connector (A) or the vehicle frame using a clip. Then, check continuity of the harness through the vehicle frame as illustrated.

If the ohm-meter reading is:

0 Ω = Continuity ∞ Ω = Discontinuity

Ɂ

̓ Connect to the vehicle frame.

A

Connect to the vehicle frame.

̓

Ɂ

a

A

Single-line short-circuit check Disconnect both end connectors of the harness and check continuity between one end connector of the harness and the vehicle frame: If the ohm-meter reading is: 0 Ω = Short circuit is present. ∞ Ω = No short circuit is present.

Multi-line continuity check Disconnect both end connectors of the harness, and connect two terminals (A) and (B), using a jumper wire at one end of the connector, as illustrated. Then, check continuity between terminals (a) and (b) at the other connector. If the ohm-meter reading is ҁ̓, either line (A)-(a), or (B)-(b) is in discontinuity. To find out which line is discontinued, conduct the single line continuity check on both lines individually, or after changing the connected terminals from (A)-(B) to (A)(C). Check continuity once more between terminals (a) and (c).

Harness

A

ѱ ̓

Short circuit between the harness and the vehicle frame.

T107-07-05-003

ȀFirst Connected

Ɂ ɂ Ƀ

ȡ Ȣ ȣ Second Connected

NOTE: By Conducting the multi-line continuity check twice, it is possible to find out which line is discontinued. With terminals (A) and (C) shortcircuited, check continuity between terminals (a) and (c).

̓

T107-07-05-004

Short circuit between harnesses.

A B C

ѱ

If the ohm-meter reading is: 0 Ω = Line (B)-(b) has discontinuity. ∞ Ω = Line (A)-(a) has discontinuity.

Multi-lines short circuit check Disconnect both end connectors of the harness, and check continuity between terminals (A) and (B) or (C).

If the ohm-metor reading is: 0 Ω = Short circuit exists between the lines. ∞ Ω = No Short circuit exists between the lines.

T5-4-6

Ɂ ɂ Ƀ

̓

T107-07-05-005

TROUBLESHOOTING / Electrical System Inspection 5V System Circuit • Voltage between Terminal No. 1 and the vehicle Turn OFF the key switch, and disconnect the connector. Measure the voltage between terminal No. 1 (5 V power supply) on the machine harness end connector and the vehicle (ground) under the following conditions.

Power Source

Signal or Ground Ȓ

ȑ Two-Polarities

Key Switch: ON Black (Negative) Terminal of Tester: Vehicle (Ground) Red (Positive) Terminal of Tester: Terminal No. 1

V

T107-07-05-006 Power Source Signal Ground

Standard Voltage: If 5±0.5 V, the circuit is normal up to terminal No. 1.

Ȓ

ȑ

Three-Polarities

ȓ

V

• Voltage between Terminal No.1 and Ground Terminal Turn OFF the key switch, and disconnect the sensor connector. Measure the voltage between terminal No. 1 (5 V power supply) on the machine harness end connector and the ground terminal (terminal No. 2 for two-polarities or terminal No. 3 for three-polarities connector) under the following conditions.

T107-07-05-007

ȑ

Ȓ

Two-Polarities

V

Key Switch: ON Black (Negative) Terminal of Tester: Connected to the ground Terminal (Terminal No. 2 or No. 3) Red (Positive) Terminal of Tester: Connect to Terminal No. 1 Standard Voltage: If 5±0.5 V, the circuit is normal up to terminal No. 1 or ground terminal (terminal No. 2 or No. 3).

T107-07-05-008

ȑ

Ȓ

ȓ

Three-Polarities

V

T107-07-05-009

T5-4-7

TROUBLESHOOTING / Electrical System Inspection (Blank)

T5-4-8

THE ATTACHED DIAGLAM LIST (The following diagrams are attached to this manual.)

1. EX8-2B ELECTRICAL CIRCUIT EX8-2B MAIN HARNESS

Attach to Technical Manual, Vol.No. T522E-00

EX8-2B ELECTRICAL CIRCUIT DIAGRAM

Switch; Start Preheat Lamp; Head Start

Starter Key

Starter Key

Fuse Box

Pump; Fuel

Relay; Starter 1

Solenoid; Stop

Overheat Switch (Built in engine)

Pump; Fuel (Attached to engine)

Relay; Starter 2 (Hour meter) (Attached to engine)

Relay; Horn

Engine Oil Pressure Switch (Built in engine)

Timer; Solenoid (Attached to engine)

Battery

Regulator

Charge Water Oil

Connector terminal arrangement Sight view of harness connector terminal seen from A side is shown

Hour; Meter Connector NOTE: 1. Wire should be 0.85mm2 in diameter, and AV or AVS wire, unless otherwise specified.

2. Color of each wire depends on JASOD607-82.

Relay; Starter 2 (Attached to engine)

Symbol Explanation Horn

Harness Ground Body Ground

Glow Plug (Built in engine)

Starter Motor 12V 0.8KW (Built in engine)

AC Alternator 12V 150W (Built in engine)

Horn Switch Built in control lever grip

Regulator Adjusted Voltage 14.5V (Attached to engine) Relay (Horn)

Blug connector Flat terminal

Connector Screw terminal * The meanings of the ground symbols above are different from the meaning in IEC.

Attach to Technical Manual, Vol.No.T522E-00

EX8-2B MAIN HARNESS

Hour Meter

Horn Switch

Horn

(Waterproofing) (Waterproofing) (Waterproofing) (Waterproofing)

Boom Light (Waterproofing)

Fuel Pump

Fusible Link

Stop Solenoid

Glow Plug

Starter

(Waterproofing) (Waterproofing) Overheat Ind.

(Waterproofing) Overheat (Waterproofing) Engine Oil Pressure Ind.

(Waterproofing)

Engine Oil Pressure Switch (Waterproofing)

(Waterproofing)

(Waterproofing)

Ground

Alternator Ind.

Alternator

Glow Plug

Key Switch Key Switch

Alternator Alternator Ground Stop Solenoid Boom Light

Horn Switch Horn Horn Switch Horn Regulator

Alternator Ind. Ground

Overheat Ind. Engine Oil Pressure Ind.

Alternator Ind. Overheat Ind.

Overheat

Engine Oil Pressure Ind.

Engine Oil Pressure Switch Starter

Hour Meter Hour Meter Starter

Timer; Solenoid Starter Relay

Hour Meter Relay

(Waterproofing) Regulator

Regulator

Horn Relay

Fuse Box

EX8-2B HYDRAULIC CIRCUIT(STANDARD) Hitachi Authorized Dealer Use Only

Diesel Engine Pump

Control Valve Set pressure Return filter Arm

Travel (Left)

Blade

AUX.

Swing

Bucket

Boom

Dummy

Travel (Right)

Swing

100 Mesh oil tank

Pressure gauge

Pressure gauge AUX. port

Arm cylinder

Boom cylinder Center joint

Swing device

Swing cylinder

Bucket cylinder

Blade cylinder

Travel device

EX8-2B HYDRAULIC CIRCUIT (UNDERCARRIAGE WIDTH EXTENSION/RETRACTION) Hitachi Authorized Dealer Use Only

Diesel Engine Pump

Control Valve Set pressure Return filter Arm

Travel (Left)

Blade

AUX.

Swing

Bucket

Boom

Undercarriage width extension/retraction

Travel(Right)

Swing

100Mesh oil tank

Pressure gauge

Pressure gauge AUX. port

Arm cylinder

Boom cylinder

Center joint

Swing device Span cylinder

Bucket cylinder

Swing cylinder

Blade cylinder

Travel device

Workshop Manual EX8-2B

SECTION 1

GENERAL INFORMATION —CONTENTS— Group 1 Precautions for Disassembling and Assembling Precautions for Disassembling and Assembling........................................... W1-1-1

Group 2 Tightening Tightening Torque Specifications ............ W1-2-1 Torque Chart .......................................... W1-2-2 Piping Joint ............................................ W1-2-5

522W-1-1

ϑBlankϒ

522W-1-2

GENERAL INFORMATION / Precautions for Disassembling and Assembling Floating Seal Precautions

A

1. In general, replace the floating seal with a new one after disassembling.

If the floating seal is to be reused, follow these procedures: (1) Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect surfaces.

(2) Check slide surface (C) on seal ring (A) for scuffing, scoring, corrosion, deformation or uneven wear.

B

W105-03-05-019

(3) Check O-ring (B) for tears, breaks, deformation or hardening.

2. If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.

(1) Clean floating seal and seal mounting bores with cleaning solvent.

Use a wire brush to remove mud, rust or dirt.

After cleaning, thoroughly dry parts with compressed air.

(2) Clean the floating seal and seal mounting bores. Check the bore surface for scuffing or scoring by touching the surface with finger.

Correct

Twist of O-ring

Incorrect

Bent of O-ring

(3) Check that the O-ring is not twisted, and that it is installed correctly on the seal ring.

W105-03-05-020

(4) After installing the floating seal, check that seal surface (C) is parallel with seal mating face (D) by measuring the distances at point (a) and (b), as illustrated. If these distances differ, correct the O-ring seating.

D Correct

C

Incorrect a

a

B

b

aҧb

W1-1-3

b

aŇ?b

W110-03-05-004

GENERAL INFORMATION / Precautions for Disassembling and Assembling Precautions for Using Nylon Sling 1. Follow the precautions below to use nylon slings safely.

• Attach protectors (soft material) on the corners of the load so that the nylon sling does not directly contact the corners. This will prevent the nylon sling from damage and the lifted load from slipping.

• Lower the temperature of the lifted load to lower than 100 °C (212 °F). If unavoidably lifting a load with a temperature of 100 °C (212 °F) or more, reduce the load weight.

• Do not lift acid or alkali chemicals.

• Take care not to allow the sling to become wet.

The load may slip.

• When required to use more than one sling, use slings with the same width and length to keep the lifted load balanced.

• When lifting a load using an eyehole, be sure to eliminate any gaps between the sling and load.

(Refer to the right illustration.) Reduce the load weight so that it is less than 80 % of the sling breaking force.

• Avoid using twisted, bound, connected, or hitched slings.

• Do not place any object on twisted or bent slings.

(Refer to the right illustration.)

• When removing the slings from under the load, take care not to damage the nylon slings. Avoid contact with protrusions.

• Avoid dragging slings on the ground, throwing slings or pushing slings with a metal piece.

• When using with other types of slings (wire rope) or accessories (shackle), protect the joint so that the nylon sling is not damaged.

• Store the nylon slings indoors so they won’t deteriorate with heat, sun light, or chemicals.

Correct Eyehole Lifting Method

W102-04-02-016

Incorrect Eyehole Lifting Method

W105-04-01-008

Bent Sling

W1-1-4

W162-01-01-009

GENERAL INFORMATION / Precautions for Disassembling and Assembling

CAUTION: If a load is lifted with a damaged nylon sling, serious personal injury may result. Be sure to visually check the nylon sling for any damage before using.

Damaged Appearance

Broken Sewing Thread

W162-01-01-002

Scuffing

2. Before using a nylon sling, visually check the nylon sling for any damage corresponding to examples shown to the right. If any damage is found, cut and discard the sling. Even if no damage is found, do not use slings older than 7years.

W162-01-01-003

Fuzz

Broken Sewing Thread

W162-01-01-004

Broken Sewing Thread

W162-01-01-005

Broken Sewing Thread

Scoring

Fuzz

Separation of Belt

Scuffing

W162-01-01-006

W162-01-01-007

Broken Warp

W162-01-01-008

W1-1-5

GENERAL INFORMATION / Precautions for Disassembling and Assembling ϑBlankϒ

W1-1-6

GENERAL INFORMATION / Tightening TIGHTENING TORQUE SPECIFICATIONS Bolts and Nuts of Machine: Standard Torque Chart No. 1 2 3 4

Descriptions Engine cushion rubber mounting nut Engine bracket mounting bolt Hydraulic oil tank mounting bolt Fuel tank mounting nut

Bolt Dia mm

Q'ty

8 10 10 8

8 8 4 1

8 8 8 10 6 10 10 10 10 14 6 8 10 12

2 3 4 4 4 12 12 17 17 8

5 Hydraulic hoses and union joints 6 7 8 9 10

Pump mounting bolt Pump cover mounting bolt Control valve mounting bolt Swing device mounting bolt Battery mounting nut

11 Swing bearing mounting bolt

Swing Device Track

12 Travel device mounting bolt * 13 Sprocket mounting bolt* 14 Lower roller mounting bolt* 15 Cover mounting bolt 16 Counterweight mounting bolt NOTE: (1) Apply lubricant (i.e. white zinc B dissolved into spindle oil) to reduce their friction coefficients.

(2) Remove rust, dirt, and dust before installing fasteners.

(3) Apply LOCTITE to threads of fasteners indicated with * marks in the above chart.

W1-2-1

2

Wrench Size mm

N]m

(kgf]m)

(Ibfâ‹…ft)

13 17 17 13 19 22 27 13 13 13 17 10 17 17 8 8 22 10 13 17 19

9.8 49 49 9.8 29.5 39 64 9.8 9.8 9.8 49 4.2 64 64 64 64 175 5 9.8 49 88

(1) (5) (5) (1) (3) (4) (6.5) (1) (1) (1) (5) (0.4) (6.5) (6.5) (6.5) (6.5) (18) (0.5) (1) (5) (9)

(7.2) (36) (36) (7.2) (22) (29) (47) (7.2) (7.2) (7.2) (36) (2.9) (47) (47) (47) (47) (130) (3.7) (7.2) (36) (65)

Torque

GENERAL INFORMATION / Tightening TORQUE CHART CAUTION: Use tools appropriate for the work to be done. Makeshift tools and procedures can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Otherwise, tightening tools may slip, potentially causing personal injury.

Bolt Types Tighten nuts or bolts correctly to torque specifications.

Four different types and grades of bolt are employed.

Make sure to employ correct bolts and tighten them correctly when assembling the machine or components.

Hexagon T Bolt

SA-040

Hexagon H Bolt

Hexagon M Bolt

Socket Bolt

W162-01-01-001

Specified Tightening Torque Chart Hexagon T Bolt, Socket bolt Bolt Wrench Wrench Dia. Size N⋅m (kgf⋅m) (lbf⋅ft) Size M 8 13 6 29.5 (3) (22) M 10 17 8 64 (6.5) (47) M 12 19 10 108 (11) (80) M 14 22 12 175 (18) (130) M 16 24 14 265 (27) (195) M 18 27 14 390 (40) (290) M 20 30 17 540 (55) (400) M 22 32 17 740 (75) (540) M 24 36 19 930 (95) (690) M 27 41 19 1370 (140) (1010) M 30 46 22 1910 (195) (1410) M 33 50 24 2550 (260) (1880) M 36 55 27 3140 (320) (2310)

H Bolt N⋅m 19.5 49 88 137 205 295 390 540 690 1030 1420 1910 2400

W1-2-2

(kgf⋅m) (lbf⋅ft) (2) (14.5) (5) (36) (9) (65) (14) (101) (21) (152) (30) (220) (40) (290) (55) (400) (70) (505) (105) (760) (145) (1050) (195) (1410) (245) (1770)

M Bolt N⋅m 9.8 19.5 34 54 78 118 167 215 275 390 540 740 930

(kgf⋅m) (1) (2) (3.5) (5.5) (8) (12) (17) (22) (28) (40) (55) (75) (95)

(lbf⋅ft) (7.2) (14.5) (25.5) (40) (58) (87) (123) (159) (205) (290) (400) (540) (690)

GENERAL INFORMATION / Tightening IMPORTANT: The following items are applied to both fine and coarse pitch threads.

1. Apply lubricant (i. e. white zinc B dissolved Into Spindle oil) to nuts and bolts to reduce their friction coefficients.

The plated bolts require no lubricant.

2. Torque tolerance is Ń° 10 %.

3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force.

4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application.

5. Make sure that nut and bolt threads are clean before installing.

Remove dirt or corrosion, if any.

Bolt Tightening Order When tightening two or more bolts, tighten them alternately, as shown, to ensure even tightening.

Equally tighten upper and lower

Tighten diagonally 1

1st to 4th

Tighten from center and 12

9

4

1

6

7

14

13

8

5

2

3

10

11

3

6 4

5 2

2nd to 3rd W105-01-01-003

W1-2-3

GENERAL INFORMATION / Tightening Service Recommendations for Spilt Flange IMPORTANT: 1. Be sure to clean and Inspect sealing surfaces. Scratches / roughness cause leaks and seal wear.

Unevenness causes seal extrusion. If defects cannot be polished out, replace the component.

2. Be sure to use only specified Orings. Inspect O-rings for any damage. Take care not to file Oring surfaces. When installing an O-ring into a groove, use grease to hold it in place.

3. While lightly tightening split flange halves, check that split is centered and perpendicular to the port. Hand-tighten bolts to hold parts in place. Take care not to pinch the O-ring.

4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening.

5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before tightening of the others, resulting in damage to O-rings or uneven tightening of bolts.

W105-01-01-015

WRONG

W105-01-01-016

W105-01-01-008

WRONG

RIGHT

Do not bend it round

Bend along edge sharply

Nut and Bolt Locking

RIGHT

WRONG

RIGHT

• Lock Plate IMPORTANT: Do not reuse lock plates. Do not try to bend the same point twice.

• Cotter Pin IMPORTANT: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening.

Bend along edge sharply

RIGHT

RIGHT

WRONG

• Lock Wire IMPORTANT: Apply wire to bolts in the bolttightening direction, not in the boltloosening direction.

RIGHT

Loosen

W105-01-01-009

WRONG

Tighten

W105-01-01-010

W1-2-4

GENERAL INFORMATION / Tightening PIPING JOINT

1

4

3

2

5

IMPORTANT: The torques given in the chart are for general use only.

Do not use these torques if a different torque is given for a specific application.

M202-07-051

Joint Body

Union Joint Metal sealing surfaces (4) and (5) of adaptor (l) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.

37ѯ 30ѯ

IMPORTANT: 1. Do not over-tighten nut (3).

Excessive force will be applied to metal sealing surfaces (4) and (5), possibly cracking adaptor (1). Be sure to tighten nut (3) to specifications.

2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint.

Take care not to damage them when connecting/disconnecting.

Description 30ѯmale

37ѯfemale

Male Union Joint

Female Union Joint W105-01-01-017

Wrench Size mm Union Nut 19 22 27 36 41 50 60 70 19 22 27 36 41 50

Wrench Size mm Hose Fittings 19 22 27 36 41 50 60 70 17 19 22 30, 32 36 46

Tightening Torque N⋅m (kgf⋅m, Ibf⋅ft) 59 (6, 44) 98 (10, 72) 118 (12, 87) 235 (24, 173) 295 (30, 218) 490 (50, 361) 670 (68, 494) 980 (100, 23) 44 (4.5, 32) 59 (6, 44) 118 (12, 87) 235 (24, 173) 295 (30, 218) 490 (50, 361)

NOTE: Tightening torque of 37ѯmale coupling without union is similar to tightening torque of 37ѯfemale.

W1-2-5

GENERAL INFORMATION / Tightening O-ring Seal Joint

7

6

9

O-ring (6) seats against the end face of adaptor (7) to seal pressure oil.

IMPORTANT: 1. Be sue to replace O-ring (6) with a new one when reconnecting.

2. Before tightening nut (9), confirm that O-ring (6) is seated correctly in O-ring groove (8). Tightening nut (9) with O-ring (6) displaced will damage O-ring (6), resulting in oil leakage.

3. Take care not to damage O-ring groove (8) or sealing surface (10).

Damage to O-ring (6) will cause oil leakage.

4. If nut (9) is loose and oil is leaking, do not re-tighten nut (9).

Replace O-ring (6) with a new one and check that O-ring (6) is correctly seated in place, tighten nut (9).

W1-2-6

8

Wrench Size mm Union Nut 19 22 27 36 41 50

Wrench Size mm Hose Fittings 17 19 22 30, 32 36 46

10

Hose Fittings M104-07-033

Tightening Torque N⋅m (kgf⋅m, Ibf⋅ft) 59 (6, 44) 98 (10, 72) 118 (12, 87) 235 (24, 173) 295 (30, 218) 490 (50, 361)

GENERAL INFORMATION / Tightening Screw-In Connection PT

Depending on types of screw and sealing, different types of screw fittings are used.

IMPORTANT: Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.

30ѯ

Male Tapered Thread

PF

Male Straight Thread W105-01-01-018

Male Tapered Thread Wrench Size mm Tightening Torque Hose Fittings N⋅m (kgf⋅m, Ibf⋅ft) 17, 19 59 (6, 44) 19, 22 98 (10, 72) 27, 22 118 (12, 87) 36, 32 235 (24, 173) 41 295 (30, 218) 50 490 (50, 301) 60 670 (68, 494) 70 980 (100, 723) Seal Tape Application Seal tape is used to seal clearances between male and female threads, so as to prevent any leaks between threads.

Be sure to apply just enough seal tape to fill up thread clearances. Do not overwrap.

Internal Thread

External Thread

Clearance

• Application Procedure

W105-01-01-019

Confirm that the thread surface is clean and, free of dirt or damage.

Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

Leave one to two pitch threads uncovered

Low-Pressure-Hose Clamp Tightening Torque Low-pressure-hose clamp tightening torque differs depending on the type of clamp.

T-Bolt Type Band Clamp: 4.4 N]m ( 0.45 kgf]m, 3.25 lbf]ft ) Worm Gear Type Band Clamp:5.9 to 6.9 N]m (0.6 to 0.7 kg]m, 4.3 to 5.1 lbf]ft)

W1-2-7

M114-07-041

T-Bolt Type

Worm Gear Type

M114-07-043

M114-07-042

GENERAL INFORMATION / Tightening Connecting Hose RIGHT

WRONG CAUTION: When replacing hoses, be sure to use only genuine AIRMAN service parts.

Using hoses other than genuine AIRMAN hoses may cause oil leaks, hose rupture or separation of fitting, possibly resulting in a fire on the machine.

Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.

W105-01-01-011

RIGHT

WRONG Rubbing Against Each Other

If hoses rub against each other, wear to the hoses will result, leading to hose rupture.

Take necessary measures to protect hoses from rubbing against each other.

Take care so that hoses do not come into contact with moving parts or sharp objects.

W105-01-01-012

WRONG Clamp

RIGHT Clamp

Rubbing Against Each Other W105-01-01-013

WRONG

Rubbing Against Each Other

RIGHT

Clamp W105-01-01-014

W1-2-8

SECTION 2

UPPERSTRUCTURE —CONTENTS— Group 1 Pump Device Remove and Install Pump Device ...... W2-1-1

Group 2 Control Valve Remove and Install Control Valve ...... W2-2-1

Group 3 Swing Device Remove and Install Swing Device...... W2-3-1 Disassemble Swing Reduction Gear.. W2-3-4 Assemble Swing Reduction Gear ...... W2-3-6

522W-2-1

ϑBlankϒ

522W-2-2

UPPERSTRUCTURE / Pump Device REMOVE AND INSTALL PUMP DEVICE CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the hydraulic system.

W522-01-01-001

W2-1-1

UPPERSTRUCTURE / Pump Device Removal 1. Remove the floor mat. Remove floor plate (2) by loosening bolts (1).

2

: 13 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

1

W522-02-01-001

2. Disconnect all hoses from the pump.

Cap all disconnected hose ends. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

3. Remove mounting bolts (3) from the pump device.

Remove the pump device.

3

: 13 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

W522-02-01-002

Installation NOTE: Refer to “Removal” for wrench size and tightening torque.

1. Install the pump device with the mounting bolts.

2. Connect all hoses to the pump device.

3. Install the floor plate and the floor mat.

IMPORTANT: After connecting the hoses, check the hydraulic oil level. Start the engine and check the hoses for oil leaks.

W2-1-2

UPPERSTRUCTURE / Control Valve REMOVE AND INSTALL CONTROL VALVE CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

W522-01-01-001

W2-2-1

UPPERSTRUCTURE / Control Valve 1

Removal 1. Loosen bolts (1), (2) and (3) to remove cover (4). : 13 mm

2 4

3

W522-02-02-001

2. Disconnect all hoses from the control valve. Cap all disconnected hose ends.

Also attach identification tags to the disconnected hoses for reassembly. : 19 mm, 22 mm, 27 mm

W522-02-02-002

3. Loosen nuts (5), then remove the ball joints. Ȁ

5

5

: 13 mm 4. Remove cotter pins (6) from the travel, blade and swing spools. Remove joint pin (7). Remove the pin used for the swing lever at the lower side of the control valve.

7

6 W522-02-02-003

5. Remove bolts (8) to remove the control valve.

8

: 13 mm

W522-02-02-004

W2-2-2

UPPERSTRUCTURE / Control Valve Installation 1. Install the control valve with bolts (8).

8

: 13 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

W522-02-02-004

2. Insert joint pins (7) into the spools of the travel, blade and boom-swing and install cotter pins (8).

Install the pin used for the swing lever at the lower side of the control valve.

5

5

3. Secure the ball joint with nuts (5). : 13 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

7

8 W522-02-02-003

4. Connect all hoses to the control valve. : : : : : :

19 mm 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) 22 mm 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 27 mm 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

1

5. Install cover (4) with bolts (1), (2) and (3).

W522-02-02-002

2

: 13 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft)

4

IMPORTANT: After connecting the hoses, check the hydraulic oil level. Start the engine and check all hoses for oil leaks.

3

W522-02-02-001

W2-2-3

UPPERSTRUCTURE / Control Valve ϑBlankϒ

W2-2-4

UPPERSTRUCTURE / Swing Device REMOVE AND INSTALL SWING DEVICE CAUTION: Escaping hydraulic fluid pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface and lower bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank. Keep the vacuum pump running continuously while working on the system.

W522-01-01-001

W2-3-1

UPPERSTRUCTURE / Swing Device Removal 1. Remove the floor mat. Remove floor plate (2) by loosening bolts (1).

ăˆŽ

: 13 mm

1

W522-02-01-001

2. Disconnect all hoses from the swing device. Cap all disconnected hose ends. : 19 mm

3. Remove mounting bolts (3) from the swing device.

Remove the swing device. : 17 mm W522-02-01-002

ăˆ?

W2-3-2

UPPERSTRUCTURE / Swing Device Installation 1. Secure the swing device with bolts (3). : 17 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

2. Connect all hoses to the swing motor. : 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

W522-02-01-002

3. Secure floor plate (2) with bolts (1). Install the floor mat.

3 2

: 13 mm : 9.8 N⋅m (1 kgf⋅m, 7.2 lbf⋅ft) IMPORTANT: After connecting the hoses, check the hydraulic oil level. Start the engine and check all hoses for oil leaks.

1

W522-02-01-001

W2-3-3

UPPERSTRUCTURE / Swing Device DISASSEMBLE SWING REDUCTION GEAR 4 3 2 1

7

6

5

8

10 13 15

12

9

11 18

14

17

10

16

19 20 17 10 21 22 17

24

23 25 26 27 28 29

W522-02-03-001

1 2 3 4 5 6 7 8

-

Pin (2 Used) Spring (2 Used) Housing Bolt (4 Used) Plug (2 Used) O-Ring (2 Used) Steel Ball (2 Used) Plug

910 11 12 13 14 15 16 -

O-Ring O-Ring (3 Used) O-Ring Seal Seal Plate Valve Valve Plate

17 18 19 20 21 22 23 24

-

W2-3-4

O-Ring (3 Used) Valve Drive Gerotor Drive Shaft Valve Plate Seal Retaining Ring Bearing

25 26 27 28 29

- Housing - Bearing - Ring - Pinion Gear - Plug

UPPERSTRUCTURE / Swing Device Disassemble Swing Reduction Gear • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before disassembling.

7. Remove O-ring (17) and retaining ring (23) from housing (25).

1. Secure the flange in a vise, put pinion gear (28) downwards.

8. Tap pinion gear (28) with a plastic hammer and remove it from housing (25).

IMPORTANT: When remove housing (3), be sure not to lose pins (1) (2 used), springs (2) (2 used), O-ring (10) and O-ring (11).

2. Remove bolts (4) (4 used) from the swing device and remove housing (3).

9. Remove ring (27) from housing (25).

IMPORTANT: If it is not necessary, do not remove bearings (24) and (26).

: 14 mm 10. Remove bearing (24) and (26) from housing (25).

3. Remove seals (12) and (13), plate (14) and valve (15) from valve plate (16) in this order.

11. Remove both pieces of plug (5), O-ring (6) and steel balls (7) from housing (3).

IMPORTANT: When removing valve plate (16), be sure not to lose O-ring (17) and Oring (10).

4. Remove valve plate (16) and valve drive (18) from the swing device.

5. Remove gerotor (19) and drive shaft (20) from valve plate (21).

IMPORTANT: When remove valve plate (21), be sure not to lose seal (22).

6. Remove O-ring (17), O-ring (10) and valve plate (21) from housing (25) in this order.

W2-3-5

UPPERSTRUCTURE / Swing Device ASSEMBLE SWING REDUCTION GEAR

4

5

3

6

12 14 15

2 1 13

11

7

16

10 18

19

10 17 10

21

22

24

23

25

17 20

27

26

28

29

W522-02-03-002

1 2 3 4 5 6 7 8

-

Pin (2 Used) Spring (2 Used) Housing Bolt (4 Used) Plug (2 Used) O-Ring (2 Used) Steel Ball (2 Used) Plug

9 - O-Ring 10 - O-Ring (3 Used) 11 - O-Ring 12 - Seal 13 - Seal 14 - Plate 15 - Valve 16 - Valve Plate

17 18 19 20 21 22 23 24

-

W2-3-6

O-Ring (3 Used) Valve Drive Gerotor Drive Shaft Valve Plate Seal Retaining Ring Bearing

25 26 27 28 29

-

Housing Bearing Ring Pinion Gear Plug

UPPERSTRUCTURE / Swing Device Assemble Swing Reduction Gear • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before assembling.

IMPORTANT: Replace the seals with the new ones.

Also apply grease on the seals before installing.

1. Install bearings (24) and (26) into housing (25) with a plastic hammer.

2. Install ring (27) into housing (25), and then install pinion gear (28) with a press.

3. Secure the flange of housing (25) in a vise, and then install retaining ring (23) onto pinion gear (28).

22

4. Install seal (22) into valve plate (21).

5. Install O-ring (17) and drive shaft (20) into housing (25), then install valve plate (21) into housing (25).

6. Install O-rings (17) and (10) onto valve plate (21) and install gerotor (19) onto valve plate (21).

NOTE: When installing, align both drain holes of valve plate (21) and gerotor (19).

7. Install valve drive (18) into gerotor (19).

W2-3-7

21 W522-02-03-003

UPPERSTRUCTURE / Swing Device

5 3

6

12 14

2 1 13 7 10 18 10

19

17 10

21

W522-02-03-002

W2-3-8

UPPERSTRUCTURE / Swing Device 8. Install valve plate (16) onto valve drive (18).

9. Install both steel balls (7), O-rings (6) and plugs (5) into housing (3).

10. Install springs (2) and pins (1) into housing (3).

11. Install seal (12) and (13) onto plate (14).

12. Install plate (14) into housing (3) while aligning the notches of the plate to the pins (1).

3 13 14 12

W522-02-03-005

W2-3-9

UPPERSTRUCTURE / Swing Device

4 3 14 15 11 10

16

29

W522-02-03-002

W2-3-10

UPPERSTRUCTURE / Swing Device IMPORTANT: Assembling valve drive (18) is very important work to set the rotational direction of the motor. Check the location where the gear tooth of valve drive (18) aligns with the star protuberance in gerotor (19). Insert the gear of valve drive (18) while aligning the gear at the location 15ѯ ѯ from the side hole of valve (15).

If mis-aligned, the motor may reversely rotate, possibly causing serious injury.

18

Star

13. Install O-ring (11) and (10) into housing (3). Insert a screw driver from the port hole of housing (3).

Holding plate (14) with a screw driver, install housing (3) onto valve (15).

NOTE: When installing, align both drain holes of housing (3) and valve plate (16).

14. Install bolts (4) (4 used) into the housing. : 14 mm : 49 to 54 N⋅m (5.0 to 5.5 kgf⋅m, 36 to 40 lbf⋅ft)

W2-3-11

Aligned with Star

15

15ѯ W522-02-03-004

UPPERSTRUCTURE / Swing Device ϑBlankϒ

W2-3-12

SECTION 3

UNDERCARRIAGE —CONTENTS— Group 1 Travel Device Remove and Install Travel Device .......... W3-1-1 Disassemble Travel Device .................... W3-1-3 Assemble Travel Device ......................... W3-1-6 Maintenance Standard ......................... W3-1-12

Group 2 Center Joint Remove and Install Center Joint............. W3-2-1

522W-3-1

ϑBlankϒ

522W-3-2

UNDERCARRIAGE / Travel Device REMOVE AND INSTALL TRAVEL DEVICE CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes causing serious injury. Avoid this hazard by relieving pressure before disconnecting any hydraulic lines.

Hydraulic oil and components may be not just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface, and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

W522-01-01-001

W3-1-1

UNDERCARRIAGE / Travel Device Removal 1. Remove bolts (1) to remove cover (2). : 6 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

2. Disconnect hoses (4) from the travel device.

Cap the disconnected hose (4) ends.

2

: 22 mm : 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

1 W507-03-02-001

3. Remove travel device mounting bolts (5) to remove the travel device (3).

㈐

: 8 mm : 64 N⋅m (6.5 kgf⋅m, 47 lbf⋅ft)

Installation NOTE: Refer to “Removal” section for wrench size and tightening torque.

1. Install travel device (3) with bolts (5).

2. Connect the hoses (4) to travel device (3).

3. Install cover (2) onto the track frame with bolts(1).

IMPORTANT: After connecting the hoses, check the hydraulic oil level. Start the engine and check all hoses for oil leaks.

Also, to prevent the travel motor from seizing, be sure to perform break-in operation after installation.

CONDITIONS:1. Engine speed: The slowest speed.

2. Operate time: 2 minutes or more.

W3-1-2

3

5 W522-03-01-007

UNDERCARRIAGE / Travel Device DISASSEMBLE TRAVEL DEVICE

10 8

7 6

5 3 1

9

3

4

23 22

2

21 19 20 11

19 18 40 39

17 15

14

16 37

13 12

34

24

35

38

39

36

33 28

31

25

32

30 28

29 28 26

27

25

42

25 43 41

W522-03-01-003

12345678910 11 -

Pin (3 Used) Needle Bearing (3 Used) Spacer (6 Used) Idler Gear (3 Used) Carrier Spacer Spacer Cover Plug (2 Used) C-Ring Shaft

12 13 14 15 16 17 18 19 20 21 22

-

Casing Bushing X-Ring Back Up Ring Seal Plate O-Ring Floating Seal Bearing (2 Used) Retaining Ring Wheel Retaining Ring

23 24 25 26 27 28 29 30 31 32 33

-

W3-1-3

O-Ring Pin O-Ring (3 Used) O-Ring (2 Used) Spacer plate O-Ring (3 Used) Gerotor Valve Plate Spacer Drive Valve

34 35 36 37 38 39 40 41 42 43

- Plate - Plate (2 Used) - Spring (2 Used) - Back Up Ring - O-Ring - Back Up Ring (2 Used) - O-Ring (2 Used) - O-Ring - End Cover - Bolt (4 Used)

UNDERCARRIAGE / Travel Device 10 8

7 6

5 3 1

4

9

3

23 22

2

21 19 20 11

19 18 40 39

17 14

15

16 37

13 12

34

24

35

38

39

36

33 28

31

25

32

30 28

29 28 26

27

25

42

25 43 41

W522-03-01-003

W3-1-4

UNDERCARRIAGE / Travel Device Disassemble Travel Device • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before disassembling.

12. Remove shaft (11) and retaining ring (22) from wheel (21). Remove wheel (21) from casing (12).

1. Loosen bolts (43) (4 used). Remove end cover (42) assembly, O-rings (26) and (41).

NOTE: If it is hard to remove wheel (21), re-install shaft (11) and use a puller to remove wheel (21). If it is not necessary, do not remove bushing (13).

: 14 mm 2. Remove spacer plate (27), spacer (31), O-rings (25) and (28) from gerotor (29).

3. Remove gerotor (29), O-rings (25) and (28) from valve plate (30).

4. Remove valve plate (30) from casing (12).

Remove O-rings (25) and (28).

5. Remove valve (33) and drive (32) from casing (12).

13. Remove floating seal (18) from wheel (21).

IMPORTANT: Unless necessary, do not remove bearing (19).

14. Tap the inner race to remove bearing (19), then remove retaining ring (20). Remove bearing (19) in another side with the same procedure.

15. Remove O-ring (17), seal plate (16) and pin (24) from casing (12).

6. Blow in the small hole of plate (34) to remove the plate.

NOTE: Remove seal plate (16) with a screw driver.

7. Remove O-rings (38), (40) and back up ring (37) and (39) (2 used) from plate (34).

8. Remove pins (35) (2 used) and springs (36) (2 used) from casing (12).

16. Remove back up ring (15) and X-ring (14) from casing (12) with a screw driver.

9. Remove C-ring (10), cover (8) and O-ring (23) from wheel (21) in this order.

10. Remove spacers (7), (6), carrier (5) assembly from wheel (21) in this order.

11. Remove pins (1), idler gears (4), needle bearings (2) and spacers (3) from carrier (5) in this order.

W3-1-5

UNDERCARRIAGE / Travel Device ASSEMBLE TRAVEL DEVICE 10

23

22

19

20

36

18

17

16

24

34

33

30

29

27

26

8 43 6 42 7

31

11

32

5

3

2

1

4

15 14

13

35

21

39 38

40

37

12 28

25

41

ȀȀȀ W522-03-01-001

12345678910 11 -

Pin (3 Used) Needle Bearing (3 Used) Spacer (6 Used) Idler Gear (3 Used) Carrier Spacer Spacer Cover Plug (2 Used) C-Ring Shaft

12 13 14 15 16 17 18 19 20 21 22 -

Casing Bushing X-Ring Back Up Ring Seal Plate O-Ring Floating Seal Bearing (2 Used) Retaining Ring Wheel Retaining Ring

23 24 25 26 27 28 29 30 31 32 33 -

W3-1-6

-Ring Pin O-Ring (3 Used) O-Ring (2 Used) Spacer plate O-Ring (3 Used) Gerotor Valve Plate Spacer Drive Valve

34 35 36 37 38 39 40 41 42 43 -

Plate Plate (2 Used) Spring (2 Used) Back Up Ring O-Ring Back Up Ring (2 Used) O-Ring (2 Used) O-Ring End Cover Bolt (4 Used)

UNDERCARRIAGE / Travel Device Assemble Travel Device • Read PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING (W1-1-1) carefully before assembling.

1. Install X-ring (14) and back up ring (15) into casing (12) in this order.

IMPORTANT: Degrease seal plate (16) and dry it with air blow. Align the lock pin hole on the reverse side of seal plate (16).

Apply a film of gear oil on the slide surface of the seal plate.

2. Install seal plate (16) after installing pin (24) and O-ring (17) into casing (12).

IMPORTANT: Degrease floating seal (18) and the surface on the wheel where floating seal (18) is installed, and dry with air.

Check that O-ring (17) is not twisted, and that floating seal (18) is installed correctly.

3. Install bearing (19), retaining ring (20), bearing (19) and floating seal (18) into wheel (21) in this order.

4. Install wheel (21) into casing (12).

5. Install retaining ring (22) and shaft (11) into wheel (21).

6. Install spacers (3) (2 used) and each three pieces of pins (1), needle bearings (2) and idler gears (4).

W3-1-7

UNDERCARRIAGE / Travel Device

10

23

36

34

33

8

6

7

11 32

5

35

21

39 38

40

37

12 28

25

ȀȀȀ W522-03-01-001

W3-1-8

UNDERCARRIAGE / Travel Device IMPORTANT: Do not block the drain hole of casing (12) with carrier (5).

7. Install carrier assembly (5) into wheel (21).

8. Install spacers (6) and (7) into wheel (21).

9. Install O-ring (23), cover (8) and C-ring (10) onto wheel (21).

10. Install pins (35) (2 used) and springs (36) (2 used) diagonally into casing (12).

IMPORTANT: Install O-ring (38) and (40), then install back up rings (37) and (38).

11. Install O-rings (38), (40) (2 used) and back up ring (37), (39) (2 used) onto plate (34).

Chuck Mark

32

IMPORTANT: Align pin (36) lock groove on plate (34) with pin (36).

W522-03-01-005

12. Install plate (34) into casing (12).

29

Star Protuberance

IMPORTANT: Face the chuck mark on drive (32) toward shaft (11).

32

13. Install drive (32) into casing (12).

IMPORTANT: Align the key groove in shaft (11) with the key in reverse side of valve (3).

14. Install O-rings (25), (28) and valve (33) into casing (12).

33

Key Groove

11

W522-03-01-006

W3-1-9

UNDERCARRIAGE / Travel Device

30

29

27

43

42

11 32

12 28

25

ȀȀȀ W522-03-01-001

W3-1-10

UNDERCARRIAGE / Travel Device 15. Install O-ring (25), (28) onto valve plate (30).

Install valve plate (30) onto casing (12), aligning bolt and drain holes on casing (12) and valve plate (30).

IMPORTANT: When assembling valve drive (18) set the rotation direction of the motor correctly. Install drive (32) into gerotor (29) eccentrically. Align the star protuberance in gerotor (29) with the most eccentric positioned gear tooth in drive (32).

If drive (32) is mis-aligned with gerotor (24), the motor may reversely rotate, possibly causing serious injury.

Star Protuberance

29

32

33

Key Groove

11

16. Install O-rings (25) and (28) into gerotor (29).

Install gerotor (29) onto casing (12), aligning the locations of the bolt and drain holes on casing (12) and gerotor (29).

W522-03-01-006

IMPORTANT: The punching hole punched hole side is at the Gerotor (29) side.

17. Install spacer plate (27) into casing (12).

IMPORTANT: When installing, align the locations of the bolt and drain holes on spacer plate (27).

18. Install O-rings (26) and (41) onto end cover (42), then install them into casing (12).

19. Install end cover (42) assembly with tightening bolts (43) (4 used). : 14 mm : 53 Nâ‹…m (5.4 kgfâ‹…m, 39 lbfâ‹…ft)

W3-1-11

UNDERCARRIAGE / Travel Device MAINTENANCE STANDARD Sprocket

D

C

B

E

A

W522-03-01-004

Unit: mm

Dimension

Standard

Allowable Limit

A

20.0

15.0

B

249.0

244.0

C

PCD275.0

D

291.0

286.0

E

71.2

-

-

Remedy

Replace

NOTE: 1 mm = 0.03937 in

W3-1-12

UNDERCARRIAGE / Center Joint REMOVE AND INSTALL CENTER JOINT CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing sever burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface, and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

W522-01-01-001

W3-2-1

UNDERCARRIAGE / Center Joint Removal 1. Remove the floor mat and floor plate.

NOTE: Refer to “SWING DEVICE� for removing the floor plate.

1

2. Disconnect all hoses at the upper side of the center joint.

Attach identification tags to the disconnected hose to aid reassembly. : 19 mm, 22 mm 3. Remove mounting bolt (1) of the stopper of the center joint. : 17 mm W522-03-02-001

2

4. Remove mounting bolts (3) under the cover to remove under cover (2). : 19 mm

3 W522-03-02-004

5. Disconnect all hoses at the lower side of the center joint. Cap all disconnected hose ends. : 14 mm, 22 mm 6. Remove mounting bolts (6) on the center joint to remove the center joint. : 13 mm 4 W522-03-02-002

W3-2-2

UNDERCARRIAGE / Center Joint Installation 1. Install the center joint with mounting bolts (4). : 13 mm : 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 2. Connect all hoses at the lower side of the center joint. : : : :

14 mm 20 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 22 mm 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

4 W522-03-02-002

2

3. Install under cover (2) with mounting bolts (3). : 19 mm : 88 N⋅m (9 kgf⋅m, 65 lbf⋅ft)

3 W522-03-02-004

4. Install the stopper of the center joint with installing bolt (1).

1

: 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 5. Connect all hoses at the upper side of the center joint. : : : :

19 mm 29 N⋅m (3 kgf⋅m, 21.7 lbf⋅ft) 22 mm 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) W522-03-02-001

6. Install the floor plate and floor mat.

NOTE: Refer to “SWING DEVICE” for floor plate instllation.

IMPORTANT: After installing, start the engine and check each hose connection for oil leaks.

W3-2-3

UNDERCARRIAGE / Center Joint ϑBlankϒ

W3-2-4

SECTION 4

FRONT ATTACHMENT —CONTENTS— Group 1 Front Attachment Remove and Install Front Attachment..... W4-1-1 Maintenance Standard ........................... W4-1-6

Group 2 Cylinder Remove and Install Cylinder ................... W4-2-1 Maintenance Standard ........................... W4-2-4

522W-4-1

ϑBlankϒ

522W-4-2

FRONT ATTACHMENT / Front Attachment REMOVE AND ATTACHMENT

INSTALL

FRONT

CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface, and lower the bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

W4-1-1

W522-01-01-002

FRONT ATTACHMENT / Front Attachment Removal 1. Place the machine on a solid, level surface, and lower the bucket to the ground.

4 3

2. Loosen bolts (1) to remove cover (2). : 17 mm 3. Remove bolts (3) and the plate. Pull out pin (4).

1

: 17 mm 2

W522-04-01-003

4. Place a support under the cylinder tube top end.

Operate the boom lever to retract the cylinder.

Thread a piece of wire through the rod hole and tie it to cylinder (5), so that the rod can not be extended.

5

Wire

W554-02-03-007

5. Remove the cover contained control valve.

NOTE: Refer to “CONTROL VALVE� for removing the cover. : 13 mm 6. Disconnect the hoses to the bucket and arm cylinders. Cap the disconnected hoses, also disconnect the harness to work light. : 19 mm

W522-02-02-002

W4-1-2

FRONT ATTACHMENT / Front Attachment 7. Loosen bolt (6) to remove clamp (7) and the rubber.

7

6

: 13 mm, 17 mm

W522-04-02-001

8. Loosen nut (10) for stopper bolt (9) on boom foot pin (8), then remove stopper bolt (9).

9

: 13 mm

CAUTION: Front attachment weight: 86 kg (190 lb) 8

9. Remove boom foot pin (8). Floating the boom foot, move the front attachment little forward. Lay the front attachment in a good balanced position.

10

W522-04-01-004

W4-1-3

FRONT ATTACHMENT / Front Attachment Installation CAUTION: Front attachment weight: 86 kg (190 lb) 1. Take the gravity center of the front attachment, and lift it up.

W522-04-01-003

2. Align the boom foot with the hole on the swing post. Drive boom foot pin (8).

9

3. Install stopper bolt (9) into boom foot pin (8).

Tighten nut (10).

8

: 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 10

4. Remove caps from the ends of hoses. Connect the hoses. Also connect the harness to the work light.

W522-04-01-004

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft) IMPORTANT: After filling the hydraulic oil tank with oil to the correct level, start the engine and check the hoses for oil leaks.

7

6

5. Install the rubber and clamp (7) with tightening bolt (6). : : : :

13 mm 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) 17 mm 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft) W522-04-02-001

W4-1-4

FRONT ATTACHMENT / Front Attachment 6. Align the holes of the boom and cylinder. Drive pin (4). Install bolts (3).

4

: 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

3

7. Install cover (2). Tighten bolt (1). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft) 1 2

W522-04-01-003

W4-1-5

FRONT ATTACHMENT / Front Attachment MAINTENANCE

STANDARD

Pin Bushing N

M

L

W522-04-01-002

F A C B

D

E

I

K

G

J

Q

P O

H W522-04-01-001

Unit: mm Key Letter A B C D E F G

Part Name Pin Bushing (Boom) Pin Bushing (Boom Cylinder) Pin Bushing (Boom Cylinder) Pin Bushing (Arm) Pin Bushing (Arm Cylinder) Pin Bushing (Arm Cylinder) Pin Bushing (Bucket Cylinder)

Standard 25 25 25 25 25 25 25 25 25 25 25 25 25 25

NOTE: 1 mm = 0.03937 in

W4-1-6

Allowable Limit 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5

Remedy

Replace

FRONT ATTACHMENT / Front Attachment

Key Letter H

I J K L M N O P Q

Part Name Pin Bushing (Bucket Cylinder) Bushing Link B Pin Bushing (Arm) Link B Pin Bushing (Link A) Pin Bushing (Arm) Pin Bushing (Main Frame) Pin Bushing (Boom Swing Cylinder) Pin Bushing (Boom Swing Cylinder) Pin Bushing (Blade) Pin Bushing (Blade Cylinder) Pin Bushing (Blade Cylinder)

Standard 25 25 25 25 25 25 25 25 25 25 25 35 35 25 25 30 30 25 25 25 25 25 25

NOTE: 1 mm = 0.03937 in

W4-1-7

Allowable Limit 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5 24.0 26.5 24.0 34.0 36.5 24.0 26.5 29.0 31.5 24.0 26.5 24.0 26.5 24.0 26.5

Remedy

Replace

FRONT ATTACHMENT / Front Attachment ϑBlankϒ

W4-1-8

FRONT ATTACHMENT / Cylinder REMOVE AND INSTALL CYLINDERS CAUTION: Escaping hydraulic fluid under pressure can penetrate the skin or eyes, causing serious injury. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines.

Hydraulic oil and components may be hot just after operation. Hot hydraulic oil may spout, possibly causing severe burns. Be sure to wait for hydraulic oil and components to cool before starting repair work.

Preparation 1. Place the machine on a solid, level surface, and the lower bucket to the ground.

2. Stop the engine. Loosen the hydraulic oil tank cap to release the air in the hydraulic oil tank.

3. Remove the cap. Install a vacuum pump on the hydraulic oil tank. Operate the vacuum pump to create negative pressure in the tank.

Keep the vacuum pump running continuously while working on the system.

W522-01-01-002

W4-2-1

FRONT ATTACHMENT / Cylinder Disassemble Boom Cylinder

4 3

1. Loosen bolts (1) to remove cover (2). : 17 mm 2. Remove bolts (3) and the plate. Pull out pin (4).

1

: 17 mm 2

W522-04-01-003

3. Place a support under the cylinder tube top end.

Operate the boom lever to retract the cylinder.

Thread a piece of wire through the rod hole and tie it to cylinder (5), so that the rod can not be extended.

5

Wire

W554-02-03-007

4. Disconnect hoses (6) from boom cylinder (5). Cap removed hoses (6). : 19 mm

6

W522-04-02-001

5. Loosen the nut to remove bolt (7). Pull out pin (8). : 13 Ďˆ

6. Remove boom cylinder (5).

5 7 8 W522-04-01-004

W4-2-2

FRONT ATTACHMENT / Cylinder Assemble Boom Cylinder 1. Align the pin holes on the swing post and boom cylinder (5).

2. Drive pin (8), then secure it with bolt (7). : 13 mm : 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)

5 7 8

3. Connect hoses (6) (2 used) to boom cylinder (5).

W522-04-01-004

: 19 mm : 29.5 N⋅m (3 kgf⋅m, 22 lbf⋅ft)

6

4. Start the engine and extend boom cylinder (5) to align the pin hole.

W522-04-02-001

4 3

5. Drive pin (4), then secure it with bolts (3).

1

: 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

2

ȖȎȀInstall cover (2) with bolts (1). : 17 mm : 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)

W522-04-01-003

IMPORTANT: After installing, move each control lever full stroke several times to bleed air from the hydraulic system.

W4-2-3

FRONT ATTACHMENT / Cylinder MAINTENANCE STANDARD

A

W105-04-02-094

Cylinder Name Boom Arm Bucket Swing Blade

Recommended O.D. size after re-plating (A) 25Ѱ0.016 mm 25Ѱ0.016 mm 25Ѱ0.016 mm 25Ѱ0.016 mm 25Ѱ0.016 mm

NOTE: 1 mm = 0.03937 in

W4-2-4