Hyundai R22-7 Mini Excavator Repair Manual - PDF DOWNLOAD

SERVICE MANUAL

SER. NO. HY2270001~

INTRODUCTION To insure a long life for the machine and the engine and to prevent failure and problems, proper operation, maintenance and repairs are indispensable.

This service manual includes an “outline,” “structure and operation,” “inspection and adjustment,” “disassembly and assembly,” “standard maintenance,” and “repair and replacement of parts” of the machine which are necessary to carry out the inspections and repairs in the repair shop.

We hope that this manual helps you to efficiently and effectively carry out repairs by providing and accurate description of the product and the correct repair techniques.

CONTENTS 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Precautions on Maintenance Outline Attachment Engine Main Pump Hydraulic Oil Filter Control Valve Joystick Slew Motor Travel Motor Hydraulic Cylinder Swivel Joint Crawler Spring Case and Grease Cylinder Idler Sprocket Track Roller Electrical Equipment Troubleshooting

1 PRECAUTIONS ON MAINTENANCE 1. Correct operation Correct operation means to follow the correct “procedure” and “method.”

Procedure focuses on speed and accuracy of each job.

In the method, are addressed what type of facility, tools, instruments, materials, oil should be used, how and which part should be checked, adjusted or disassembled, and what matters to attend to.

2. Precautions on operation 1. Safety check Check that stoppers and sleepers are correctly installed for the vehicle jack-up operation.

2. Preparation Prepare all of the tools and inspect and adjust the instruments.

3. For efficiency 1) Understand the state before disassembly.

What is the problem? Is disassembly absolutely necessary?

2) Before disassembly Determine whether match marks are necessary. For the electrical system, disconnect the cable from the battery terminal.

3) Precautions for disassembly In stead of checking all of the disassembled parts at once, check each part individually as it is disassembled. When removing the hydraulic unit or the hoses, mount a dust cap on the connection.

4) Repair of disassembled parts Keep the disassembled parts in order. Clearly distinguish the parts to be replaced with new parts from those to be reused. Packings, seals, rings, split pins must be replaced.

NOTE: Electrical equipment, rubbers and V belts (which are easily affected by water and oil) must be handled carefully in order to prevent soiling them.

5) Clean disassembled parts Thoroughly clean the disassembled parts.

6) Assembly Perform the assembly correctly (tightening torque, application of Three Bond, screw lock, grease, use of seal tape, etc.). Also install the hose correctly.

Hose mark

Hose mark

1-1

2 OUTLINE CONTENTS 2-1 2-2 2-3 2-4 2-5 2-6 2-7 2-8

Location of serial No. Name of each part Dimensions and specification Weight list Oil and grease supply points List of supply oil and grease When to repair Hydraulic circuit diagram

2-1 Location of Serial Number

2-1

2-2 Name of each part 1

1.

2.

13 3.

4.

5.

6.

11 7.

12 8.

9.

15 10.

11.

12.

10 13.

14.

15.

16.

17.

14 18.

19.

20.

21.

9 22.

23.

19 24.

25.

25

3

4 5

6

7 8 2 24 23

18

17

21

22

10

16

20

3

5

9

6 13

12 11

8

7

1

17

2

16 15

19

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Boom Boom cylinder Arm cylinder Arm Bucket cylinder Bucket links Dump link Bucket Swing frame Engine cover Fuel tank Hydraulic tank Cabin Counter weight Operator's seat Crawler Dozer blade Dozer cylinder Travelling motor Track roller Front idler Grease cylinder Swing post Swing cylinder Operation levers Meter unit Starter switch Horn switch Fuse box Right operation lever Left operation lever Accelerator lever Dozer operation lever Right travelling lever Left travelling lever Swing pedal P.T.O. pedal Safety lock lever Slew lock pin Overdrive switch Heater switch(for Cabin) Wiper switch(for Cabin) Manual boom lowering lever Cigarette lighters

FU

SE

14

4

2-2

18

520 50

455

2-3

1150 1380

255

Ｒ1

280 80

2510

3745 2365 1795

3965 4065

2820 4075

1745(1795) 1405(L80゜Swing)(1445)

1325 1255

1255

2-3 Dimensions and Specifications 465

275 190

885 50

2250(Height)

Model Machine weight

Robex22-7

Canopy rubber Canopy steel

kg

Cabin rubber Cabin steel

2,200 2,250

3

Standard bucket capacity/width

m /mm

Type Engine

2,080 2,130

0.06 / 450 MITSUBISHI L3E

cc kW(PS) / min-1

952 12.5(17) / 2,400

Overall length Dimensions Overall width

mm

4,075

mm

1,380

Overall height

mm

2,250

Max.digging depth

mm

2,365

Max.vertical digging depth Max.digging height

mm mm

1,795 3,745

Max.dumping height

mm

2,510

Max.digging radius

mm

4,065

Reach at ground

mm

3,965

Min. turning radius front

mm

1,745

swing Rear turning radius

mm mm

1,405 1,255

Boom swing angle L/R

deg

80 / 50

Max.digging force(Bucket)

kN

16.3

Max.digging force(Arm)

kN

11.2

Working range

Performance

Displacement Rated output

Max.drawbar pull

kN

16.2

Travel speed(low) / (high) Slew speed

km / h min-1

2.2 / 3.8

Gradeability

Angle

30°

Pump Hydraulic system

Underbody

Capacity

11.5 Piston × 2+Gear

Type Oil flow

/ min

24.0 × 2+15.4

Oil flow

/ min

48.0

Main relief pressure Dozer blade width×height

MPa mm

18.6 × 2+17.2 1,380 × 280

Shoe width×tumbler center

mm

230 × 1,325

P.T.O

Ground

Cabin rubber

pressure

Cabin steel

kPa

33.5 34.2

Type of travelling motor

Piston

Crawler tension system Hyd.oil capacity

Grease cylinder 33.0

Fuel capacity

29.0

Engine oil capacity

3.5

Cooling water capacity

5.6

Noise level LwA/LpA

dB

2-4

93 / 82

2-4 Weight list Unit: kg Part name

Part name

Boom

70

Slew bearing

29

Arm

40

Track frame

179

Bucket

57

Dozer

74

Dump link

9.4

Crawler(steel)

84×2

Bucket link(R)

1.7

Crawler(rubber)

59×2

Bucket link(L)

2.0

Idler

8×2

Boom joint pin

2.0

Adjust cylinder

12×2

Arm joint pin

1.7

Track roller

5.0×6

Bucket pin

1.7×2

Sprocket

4×2

Bucket link pin

1.5

Slew motor

15

Swing post

36

Turning motor

25×2

Swing post pin

4.1

Joystick

2.0×2

Swing frame

258

Engine

94

Hydraulic oil tank

28

Radiator

7.0

Fuel tank

16

Battery

12

Engine cover(A)(B)

24

Seat plate

16.5

Engine cover(C)

8.0

Swivel joint

11

Counter weight

200

Pump

15

Boom cylinder

20

Pump frange

9

Arm cylinder

20

Control valve

23

Bucket cylinder

17

Tops roof

110

Swing cylinder

16

Cabin

230

Dozer cylinder

13

2-5

2-5 Oil and grease supply points Boom arm joint pin

Fuel tank

Hydraulic tank

Bucket link pin Engine

Bucket pin

Travel motor

Dozer joint pin

Track roller Boom joint pin Adjust cylinder Swing post pin Front idler

Swing cylinder head pin

2-6

Slew gear

2-6 List of lubrication Name

Quantity of oil/water

Type of oil according to ambient condition -10°C~40°C

-20°C~0°C

Engine cooling water

5.6

Soft water (antifreeze is mixed in water)

Fuel tank (effective capacity)

29

Diesel fuel with freezing point below -7°C

Engine lubricating oil

3.5

SAE10W-30

Travel motor (reduction gear)

0.33

SAE 30

Hydraulic tank

33

ISO VG 46

Track roller (1 piece)

100cm3

SAE 30

Front idler (1 piece)

40cm3

SAE 30

Genuine oil Be sure to use Castrol Hyspin 46.

Table of recommended Lubricants No.

LUBRICANT

SHELL

MOBIL

1

Engine Oil

Myrina oil 10W-30

Delvac Super10W-30

2

Gear Oil

Spirax Heavy Duty 140

Mobilub HD 85W-140

3

Hydraulic Oil

ISO VG 46 (equivalent)

ISO VG46 (equivalent)

4

Cup Grease

Alvinia 2

Mobilux 2

5

Anti Freeze

Anti Freeze

Anti Freeze

6

Diesel Fuel

—

—

*Use class CD engine oil (API Service Classification)

Cooling water (antifreeze) *To prevent the cooling system from freezing, add antifreeze to the cooling water.

Replace the cooling water after 1 year from its delivery, because the effect will decrease. *Use "Long-life coolant" for the antifreeze. *Mixing ratio of antifreeze.

Temperature -5°C -10°C -15°C -20°C -25°C -30°C Amount of antifreeze 1.3 1.6 2.0 2.3 2.7 3.2 Engine inside capacity 1.7

Radiator capacity 3.5

Reserve tank capacity 0.4

2-7

Total 5.6

2-7 When to repair It is difficult to judge when to perform periodic inspections, maintenance and repairs.

Although the wearing rate of each component differs depending on the grade of daily inspection, the skill in machine operation, the working conditions, the quality of used lubricating oil, the frequency of oil replacement, the quality of land to be dug, the digging rate, the schedule for maintenance and repairs should be decided considering the state of engine, the indication of the hour meter, the degree of wear in each part, the state of hydraulic system, your experience and data.

2.7.1 Category of maintenance Prestart-up inspection

Execute every day before beginning operation

Maintenance after the first 25 service hours

Execute every 25 hours by the hour meter

Maintenance after the first 50 service hours

Execute once a week (every 50 hours by the hour meter)

Maintenance after the first 100 service hours

Execute every 100 hours by the hour meter

Maintenance after the first 250 service hours

Execute every 250 hours by the hour meter

Maintenance after the first 300 service hours

Execute every 300 hours by the hour meter

Maintenance after the first 500 service hours

Execute every 500 hours by the hour meter

Maintenance after the first 1,000 service hours

Execute every 1,000 hours by the hour meter

Maintenance after the first 2,000 service hours

Execute every 2,000 hours by the hour meter

2-8

2-7-2 Maintenance procedure Inspection and maintenance item Engine oil pan

Inspection and maintenance interval (hours) 7

50

Check oil level

Replace the engine oil (New machine only)

Replace the engine oil

Replace the cartridge (New machine only)

Replace the cartridge

1 Engine oil filter

Fuel filter

3

Engine valve clearance

4

Fan belt

5

Fuel tank

6

Check water Radiator (sub-tank) level

8

Hydraulic oil tank

Clean

Inspect and adjust

Check oil level

Drain water and sediment, clean strainer Replace and clean Check and clean Check and clean

Check oil level

Replace the element Replace oil

Drain water and sediment

Hydraulic line filter

Replace the cartridge (New machine only)

Replace the cartridge

Hydraulic suction filter

Clean the element (New machine only)

Replace the element

11 Bucket teeth and others

Inspect Inspect and grease

12 Slew bearing Inspect crawler

13 tension(grease

cylinder) and grease the crawler

1,000

Check and adjust

9

10

500

Replace the element

Inspect and adjust (New machine only)

Radiator fin Air cleaner

250

Check and clean

2

7

100

Check and adjust

14 Battery liquid amount and specific gravity

Inspect, clean and supply distilled water

15 Inspect each body Check and 16

17

18 19 20

tighten part for loosening and damage Each lever and Inspect instrument Lubricating oil of slew/travelling reduction gear Lubricating oil of track roller/Front Idler reduction gear Inspect Electrical wiring Inspect Water and oil leakage in each body part Inspect and grease Inspect attachment attachment

Replace oil (after the first 500 service hours only for a new machine)

Replace oil

Replace oil

Supply oil and grease 2-9

2-7-3 Prestart inspections (1)Prestart inspections

1

Item Engine oil pan

Content Check oil level

2

Fuel tank

Check fuel level

3

Radiator

Check water level

4

6

Each oil/grease supply point Inspect each body part for looseness and damage Each lever and instrument

7

Hydraulic oil tank

Check oil level

8

Bucket teeth and others

Wear

9

Electrical wiring

Looseness and tears

10

Fan belt

Check and adjust

5

Remarks Before starting engine Check that the fuel level is above the center of level gauge.

Check that the amount of water in sub-tank is within a specified level.

Oil and grease

Refer to page 2-6

Looseness, removal, water and oil leakage

Refer to tightening torque list.

Operation check

Whether abnormal operation exists or not Add oil if its level falls below the specified level. (Be careful of the position of machine.)

Check whether the replacement of parts is necessary or not.

Loosened terminal, torn covering, etc.

10 to 12 mm sag at the center

(2)Post operation inspections Item

Content

1

Each body part

Clean, check for water and oil leaks.

Looseness, failure, etc.

2

Fuel tank

Fuel supply

3

Cooling water

Drain

2-10

Remarks Treatment of the part where cleaning was not sufficient such as dirt sticking to the body or muddy water remaining on the body.

Add fuel Only when the danger of freezing exists

Tightening Torque List At prestart inspections, always check the bolts and nuts for looseness. If any bolt or nut is loose, retighten according to the table below.

N-m

Tightening torque of the bolt and nut (Body)

Material

8.8

10.9

12.9

N-m

N-m

N-m

M6

12.5

16

20

M8

30

39

45

M10

62

72

80

M12

100

120

130

M14

160

195

220

M16

250

305

340

Size

N-m

Tightening torque of the hydraulic pipings

PT screw

PF screw

Torque N-m

Size 1 — 4 3 — 8 1 — 2 3 — 4 1 1 1— 4 1 1— 2

Torque N-m

Size 1 — 4 3 — 8 1 — 2 3 — 4

36 55 86 130

1

195 300 400

2-11

27-30 47-52 57-63 108-120 126-140

2-7-4 Maintenance after the first 50 service hours Item 1 3

Engine oil pan and Engine oil filter Engine valve clearance

Content Replace engine oil and filter Inspect and adjust

Remarks Only for a new machine. After this, every 250 service hours Only for a new machine. After this, every 500 service hours

2-7-5 Maintenance every 50 service hours 5

Fuel tank

Drain sediment and water Clean the strainer

6

Radiator fin

Clean the fins

12

Slew bearing

Inspect and grease Liquid quantity

14

Battery

Specific gravity

Clean 20

Each oil/grease supply point

Oil and grease

2-12

Remove the drain plug on the lower part of the tank Wash strainer with diesel fuel Dust sticking to the fin affects the cooling effect and causes overheating Always grease the machine after it is used in water Whether the liquid level is proper or not. If short, add distilled water 1.26 when fully charged; 1.20 when discharged (Recharge the battery when 1.20.)

Clean each part, brush and connect terminal and apply grease Refer to page 2-6

2-7-6 Maintenance after the first 100 service hours Item

Content

9

Hydraulic line filter

Replace the cartridge

10

Hydraulic suction filter

Clean the element

Remarks Only for a new machine. After this, every 500 service hours Only for a new machine. After this, every 500 service hours

2-7-7 Maintenance every 100 service hours Item

Content

2

Fuel filter

Clean the element

7

Air cleaner

Clean the dust cover, clean or replace the element

Remarks After cleaning, open the cock to vent air Check also for a loosened band

2-7-8 Maintenance every 250 service hours Item

Content

Engine oil

Replace the engine oil

Engine oil filter

Replace the cartridge

Hydraulic oil tank

Drain water and sediment

1

8

Remarks Remove the drain plug on the lower part of the tank. (After 50 service hours for a new machine) After 50 service hours for a new machine After air is vent, loosen the drain plug

2-7-9 Maintenance after the first 500 service hours

17

Item

Content

Lubricating oil of slew and travelling reduction gears

Replace lubricating oil

Remarks Replace oil after the first 500 service hours. Every 1,000 service hours after this (Refer to Table of Oil/Grease Supply Points)

2-7-10 Maintenance every 500 service hours 2 3

Item Fuel filter Engine valve clearance

Content Replace the element Check valve clearance

6

Radiator

Replace cooling water and clean the radiator

7

Air cleaner

Replace the element

9

Hydraulic line filter

Replace the cartridge

10

Hydraulic suction filter

Replace the element 2-13

Remarks Clean the inside of bowl Clearance between the valve and the rocker Remove the drain plug, clean the radiator and add water to the sub-tank up to the specified level.

After 100 service hours for a new machine

2-7-11 Maintenance every 1,000 service hours 1

Item Engine oil pan

8

Hydraulic oil tank

17

Lubricating oil of slew and travelling reduction gears

Content Clean engine oil pan Replace the hydraulic oil and clean the oil tank Replace the lubricating oil

Remarks

Clean the inside of the tank Refer to Table of Oil/Grease Supply Points. (For new machine, every 500 service hours)

2-7-12 Maintenance every 2,000 service hours 15

Item Track roller

Remarks

Content Replace

Table of Oil/Grease Supply Points No.

Oil/Grease Supply Point

1

Travelling motor

Specified oil (genuine part)

Quantity

Gear oil 85W 2 3

330 cm3 100 cm3

Track roller Front idler

40 cm3

2-14

Time Every 1,000 service hours (At first, replace after the first 500 service hours) Every 2,000 hours Every 2,000 hours

2-15

PS

Right travelling motor

T

Slew motor

Dr

Dr

R/G

P2

P1

A

B

B

A

Oil cooler

B A

filter

Engine Return

Hydraulic oil tank

P3

Left travelling motor

R/G

PP

PTO

Boom cylinder

Bucket cylinder

Arm cylinder

Pi6

Pi8

Swing cylinder Pi2

Dozer cylinder

Pi3

B1

A1

B2

A2

B3

A3

B4

A5 A4

B5

A6

B6

A7

B7

A8

B8

A9

B9

T1

T2

P3

P1

G

Pi5

Pi7

Pi1

P2

Pi4

2

Pi4

Pilot filter

4 1

Pi3 Pi2

PL

J/S valve(L) T P

PR

PL

3

2

Pi1 Pi8

PS

1

PR

J/S valve(R) T P

4

Pi7 Pi6

3

Pi5

2-8 Hydraulic circuit diagram

Item Boom cylinder

ø65×ø35<450st

Arm cylinder

ø65×ø35<500st

Bucket cylinder

ø60×ø40<400st

Swing cylinder

ø60×ø35<425st

Dozer cylinder

ø70×ø40×100st

Slew motor

2-160DOS-E3768

Travel motor

PHV-190-39-1-8003A

Engine

Pump flow rate

Pressure

Pump capacity

Item P1

10cm3/rev

P2

10cm3/rev

P3

6.4cm3/rev

P1

18.6MPa(190kgf/cm2)

P2

18.6MPa(190kgf/cm2)

P3

17.2MPa(175kgf/cm2)

Port relief

22.5MPa(230kgf/cm2)

Slew

11.8MPa(120kgf/cm2)

Q1

24 /min.

Q2

24 /min.

Q3

15.4 /min.

Type

L3E

Constant output

12.5kW(17ps)

Speed

2,400min-1

Torque

55 N-m/1,600min-1

Main relief

2-16

3 ATTACHMENT CONTENTS 3-1 Standard of maintenance 3-1-1 Attachment 3-2 Inspection and adjustment 3-2-1 Measuring the fall of the attachment of its own weight 3-2-2 Measuring the speed of the attachment cylinder

3-1 Standard of maintenance 8

3-1-1 Attachment

9

10

7

13 6 11 14 12 4 3 5

15 17

16

a

b

2. Swing cylinder rod

C

E

D

F

3. S w i n g p o s t bracket and swing post

4. Boom joint

G

5. Boom cylinder head

b

a

b

a

b

a

b

B

1. Swing cylinder head

a

a b

a

b

a A

b

2

1

I

H

6. Boom cylinder rod

7. Arm cylinder head 3-1

J

8. Arm cylinder rod

b

a

b

a b

a L

b

a

K

N

P

O

Q

M

10. Bucket cylinder head

11. Bucket cylinder rod

12. Bucket/dump link joint

V

b

a

T S

b

a

R

b

a

b

a

9. Boom/arm joint

W

U

a

14. A r m / b u c k e t joint

15. Dozer joint

b

13. Arm/bucket link joint

X

17. Dozer cylinder rod

3-2

16. Dozer cylinder head

Unit: mm No. Item

Basic Dimension Allowable Clearance

A

Swing cylinder head pin and head bracket

ø35

1.0

B

Swing cylinder rod pin and swing post

ø35

1.0

C

Swing post pin and bush

ø50

1.0

D

Swing post pin and swing post bracket

ø50

1.0

E

Boom joint pin and bush

ø35

1.0

F

Boom joint pin and swing post

ø35

1.0

G

Boom cylinder head pin and swing post

ø35

1.0

H

Boom cylinder rod pin and boom

ø35

1.0

I

Arm cylinder head pin and boom

ø35

1.0

J

Arm cylinder rod pin and arm

ø35

1.0

K

Boom/ arm joint pin and bush

ø35

1.0

L

Boom/ arm joint pin and boom

ø35

1.0

M

Bucket cylinder head pin and arm

ø35

1.0

N

Bucket cylinder rod pin and dump link

ø35

1.0

O

Bucket cylinder rod pin and bucket link

ø35

1.0

P,T Bucket pin and bush

ø35

1.0

Q,U Bucket pin and bucket

ø35

1.0

R

Bucket link pin and bush

ø35

1.0

S

Bucket link pin and bucket link

ø35

1.0

V

Dozer joint pin and frame

ø30

1.0

W Dozer cylinder head pin and dozer

ø30

1.0

Dozer cylinder rod pin and frame

ø30

1.0

X

3-3

Unit: mm No.

Item a

Criterion Standard b clearance

Spacer Part Number

Dimension

1

Clearance between swing cylinder head and swing post

52

50

2.0 〜 3.5

MBU3-00020 MBU3-00021

2

Clearance between swing cylinder rod and head bracket

51

50

1.0 〜 2.5

〃

3

Clearance between swing post and frame

184

183

1.0 〜 2.0

MBU3-00026 MBU3-00027

ø51×t0.5 ø51×t1.0

4

Clearance between boom and swing post

174

172.5

1.2 〜 2.8

MBU3-00020 MBU3-00021

ø36×t0.5 ø36×t1.0

5

Clearance between boom cylinder head and swing post

51

50

1.0 〜 2.5

〃

〃

6

Clearance between boom cylinder rod and boom

51

50

0.5 〜 2.0

〃

〃

7

Clearance between arm cylinder head and boom

51

50

0.5 〜 2.0

〃

〃

8

Clearance between arm cylinder rod and arm

51

50

0.5 〜 2.0

〃

〃

9

Clearance between boom and arm

129.5

129

0.5 〜 2.0

〃

〃

10

Clearance between bucket cylinder head and arm

51

50

0.5 〜 2.0

〃

〃

11

Clearance between bucket cylinder rod and dump link

52

50

1.0 〜 2.5

〃

〃

12

Clearance between dump link and bucket

135

134.5

1.0 〜 2.5

13

Clearance between arm and bucket link

135

134.5

0.5 〜 1.0

14

Clearance between arm and bucket

135

134.5

0.5 〜 1.0

15

Clearance between dozer and frame

22

19

2.5 〜 3.5

16

Clearance between dozer cylinder head and frame

46

45

0.5 〜 2.0

17

Clearance between dozer cylinder rod and dozer

46

45

0.5 〜 2.0

3-4

MBU3-00020 MBU3-00021

ø36×t0.5 ø36×t1.0

〃

ø36×t0.5 ø36×t1.0

3-2 Inspection and adjustment 3-2-1 Measuring the natural fall of the attachment 1. Measuring the location of the attachment Set the temperature of the hydraulic oil to 50±5°C. Adjust the height of arm/bucket joint so that it equals that of the boom joint. Then, retract the dozer cylinder to the minimum length and stop the engine.

2. Measurement Draw a reference line on the cylinder head with a Magic Marker and measure the length from the line to the cylinder tube. Measure the length again 3 minutes later.

Then record the difference in the length Unit: mm or less Cylinder name

Standard value

Allowance

Boom cylinder

3

10

Arm cylinder

3

10

Bucket cylinder

3

10

Dozer cylinder

3

10

Make 1 and 2 the same height.

W: Weight

About: 108kg

Arm cylinder Bucket cylinder

Boom joint...1,

Dozer cylinder

Boom cylinder Arm/bucket joint...2, Mark: Direction of cylinder movement

3-5

New standard value

Allowable limit

2.3±0.5

3.3

Down

2.3±0.5

3.3

Dig

2.6±0.5

3.6

Dump

2.9±0.5

3.9

Dig

2.9±0.5

3.9

Dump

2.3±0.5

3.3

Up

1.2±0.3

1.5

Down

0.8±0.3

1.1

Right swing

Condition

6.6±0.5

7.6

Left swing

3-2-2 Measuring the speed of attachment cylinder (at full engine speed and oil temperature 50±5°C)

6.3±0.5

7.3

Machine position

Up

BOOM Extend cylinder to the Maximum length

Unit

Make bucket teeth touch the ground ARM Extend cylinder to the maximum length

Retract cylinder to the minimum length BUCKET Extend cylinder to the maximum length

sec

Retract cylinder to the minimum length DOZER Lift dozer to the maximum height

Make Dozer contact the ground SWING Retract cylinder to the minimum length

Extend cylinder to the maximum ground

3-6

4 ENGINE CONTENTS 4-1 Specification 4-2 Performance curve 4-3 Location of serial number 4-3-1 Engine 4-3-2 Standard engine speed

4-1 Specification Engine

L3E-W231NSA

Type

Vertical 4 cycle 3 cylinder

Number of cylinders–bore × stroke

952 cm3

Ignition order

1–3–2

Overall length

640mm

Overall width

450mm

Overall height

550 mm

Rated output

12.5kW(17ps)/ 2,400 min-1

Performance

Displacement(cc)

Dimensions

3–76 mm×70mm(2.99”× 2.76”)

55N-m / 1,600min-1

Maximum torque Maximum idling speed(rpm)

2,650 min-1

Minimum idling speed(rpm)

1,100 min-1±30

Fuel consumption(g/ps.h)

280g/kW-h(206 g/ps.h)

Dry weight

88kg

Fuel oil

Diesel fuel

Fuel pump

Bosh type

Governor

Centrifugal type

Generator

12V × 40A

Starter

12V × 1.2kW

Battery

12V × 36Ah

4-1

4-2 Performance curve

55.0 N-m/1,600±100min-1

12.5kW/2,400min-1

kgf-m 6

50

5

40

4

Output torque

kW PS 20 15

Nm 60

18

14

10

12

5 280g/kW-h

6

280 200 270 260 190 2,650

12

16 20 Engine speed(min-1)×102

4-2

+30 -10

min-1

24

Fuel consumption

8

g/PS-h

10 g/kW-h

Brake horse power

16

4-3 Location of serial number 4-3-1 Engine

Engine No. (identification plate)

4-3-2 Standard engine speed (at new machine delivery) Conditions

Idling speed

Maximum idling speed Speed when 1P relief is used

2,550 +500 min-1 2,450 +500 min-1

4-3

5 MAIN PUMP CONTENTS 5-1 Specification 5-2 Structure 5-3 Removing and installing the pump 5-3-1 Removing the pump 5-3-2 Installing the pump 5-4 Performance test of the hydraulic pump 5-4-1 Measuring instrument 5-4-2 Preparation 5-4-3 Connecting tester 5-4-4 Measuring procedure

5-1 Specification P3 P2 P1

M O S1

pump type S1 P1 P2 P3

Port size

L1 L2 L3 L4 L5 L6 Displacement(rev) Rated pressure

Direction of rotation Weight

P1 P2 P3 P1 P2 P3

PVD-08-20L3PS-6G-4920A SAE J518b-1 1/4 PF3/8 PF3/8 PF3/8 221mm 134mm 201.5mm 88mm 45mm 24mm 10mm 10mm 6.4mm 18.6MPa(190kgf/cm2) 18.6MPa(190kgf/cm2) 17.2MPa(175kgf/cm2) Clockwise seen from shaft side 15kg 5-1

5-2 Structure 23

25

3

27

1

18

21

16

28

27 21 19 26 12

30

10

15

11 27

8

24

7

5

9

31

4

22

6

29

20 14 13 17 2 34 33 32 41

39 38 40 37 36 35

1. Body 2. Body 3. Shaft 4. Cylinder 5. Valve plate 6. Piston 7. Shoe 8. Shoe holder 9. Barel holder 10. Swash plate 11. Needle 12. Pin 13. Packing 14. Spring C

15. Spring T1 16. Spring holder 17. Spring guide 18. Rod 19. Washer 20. Retainer 21. Stopper pin 22. Pin 23. Bearing 24. Bearing 25. Oil seal 26. Conical washer 27. Snap ring 28. O-ring 5-2

29. O-ring 30. Plug 31. Spring pin 32. Socket head bolt 33. Nut 34. Seal washer 35. Plug 36. Gear pump 37. Coupling 38. Collar 39. O-ring 40. O-ring 41. O-ring

5-3 Removing and installing the pump 5-3-1 Removing the pump 1. Remove the nipple, TEE, elbow and hoses around the pump. Attach a cap to the removed hoses to keep dust off. Store the nipples and elbows in treated oil.

2. Remove the pump mounting bolts(1).

3. Remove the pump from the flange 2. If removal is difficult, insert a screwdriver and remove the pump little by little with equal force applied on the right and left sides.

5-3-2 Installing the pump 1. Replace with a new pump and install it on the pump flange 2. Check that the spline of the shaft fits smoothly with the boss of the coupling.

When tightening the bolts 1, tighten the left and right side bolts slowly and evenly.

Bolt

Tightening torque

M12 × 30

9~11.5 kg-m

* Precautions on installing the pump 1.Make sure there is no misalignment.

3 2

1

5-3

5-4 Performance test of the hydraulic pump

Hydraulic pressure tester

5-4-1 Measuring instrument Measuring range of flow rate ( / min) Measuring range of pressure Measuring range of temperature (°C) Port size Pressure gauge Tachometer Hose for testing

7~ 200 0 ~ 34.3MPa(350kgf/cm2) 0 ~ 150 PF1 O ring type 49.0MPa(500kg/cm2), 4.9MPa(50kgf/cm2) Diesel tachometer (digital type) Equivalent to the hose of 20.6MPa (210kgf/cm2) high pressure (Nominal size PF3/ 8-PF3/ 8×1m)

5-4-2 Preparation 1. Park machine on flat ground and stop engine.

5-4-3 Connecting tester 1. Remove the hose on the pump port of the control valve.

2. Connect the removed hose to the outlet of the tester.

3. Connect the hose on the discharge of the pump to the inlet of the tester.

4. Connect pressure gauge to port measuring port.

5-4-4 Measuring procedure Open the throttle valve of the tester and start the engine. Read the pressures on the pressure gauge and measure the flow at that time. At the same time, record the engine speed.

5-4

Hydraulic pressure tester OUT Throttle valve

IN CLOSE OPEN

5-5

5-4-5 P-Q characteristic curve How to indicate a pressure value on P-Q characteristic curve.

175 +10 = 100 2 P_Q characteristics curve ②P3=17.2MPa(175kgf/cm2)

Pump flow Q'ty q1,q2cc/rev (q1=q2)

P1+P2 2

10

①P3=0.98MPa(10kgf/cm2)

0

37.2 Rated pressure P1+P2 MPa (P1=P2) P1, P2≦18.6MPa

5-6

6 HYDRAULIC OIL FILTER CONTENTS 6-1 Installation 6-2 Hydraulic oil filter 6-2-1 Line filter 6-2-2 Suction filter 6-2-3 Pilot filter 6-3 Maintenance procedure 6-3-1 Replacing the line filter 6-3-2 Replacing the suction filter 6-3-3 How to clean the suction filter

6-1 Installation

右J/S Right J/S 左J/S Left J/S

6-1

6-2 Hydraulic oil filter 6-2-1 Line filter (SP08)

Filtration accuracy Filtration capacity Opening pressure of bypass valve Proof pressure Oil temperature

10+ 50 /min (Max.) 0.15MPa (1.5kgf/cm2) 0.69MPa (7kgf/cm2) -20°C~120°C

2-PT1 Tightening torque 19.6Nm(2kgf/m)

6-2-2 Suction filter

Grain size Oil temperature

6-2

150 mesh -20°C~120°C

6-2-3 Pilot filter

PT 1/4

PT 1/4

Tightening torque: 58.8~78.5N-m (6-8kgf-m)

Filtration capacity

2 /min.(Max.)

Proof pressure

3.92MPa(40kgf/cm2)

Filtration accuracy

31 +

Filtration area

5 cm2

Oil temperature

-30°C~120°C

6-3

6-3 Maintenance procedure 6-3-1 Replacing the line filter 1. Stop the engine.

2. Remove the line filter (6-2-1) with a filter wrench.

3. Check whether any foreign matter is sticking inside the element. If necessary, replace the cartridge assembly. * In general, inspect and maintain line filters after the first 100 service hours, then every 500 service hours.

6-3-2 Replacing the suction filter 1. Stop the engine.

2. Remove the bolts which retain the filter to the hydraulic oil tank, and pull off the filter.(62-2).

3. Remove the suction filter to check whether the net of the element is damaged. * Replace with a new one if the net is damaged or the mesh is widened.

6-3-3 Replacing the pilot filter 1. Stop the engine.

2. Remove the pilot filter (6-2-3) with a wrench (27 mm width).

3. Remove the filter to check whether the net of the element is damaged. * Replace with a new one if the net is damaged or the mesh is widened.

6-3-4 How to clean the suction filter 1. Prepare a can with clean treated oil. Immerse the element in it.

2. Using a brush, wash out foreign matter sticking to the element. Use a hard brush if the element is heavily stained.

3. After cleaning, blow compressed air inside the strainer to blow off the treated oil.

4. While cleaning the element, check the hydraulic oil tank at the same time, remove any sediment inside the tank and rinse out the tank.

5. Attach pipes to install the filter to the tank. When installing the filter, fit the O ring in the flange side groove firmly so that hydraulic oil does not leak.

6. Add new hydraulic oil through the hydraulic oil intake.

Total amount of hydraulic oil : 33

6-4

7 CONTROL VALVE CONTENTS 7-1 Specification 7-2 Disassembly and assembly 7-2-1 Replacing the O ring on the contact surface and each block assembly 7-2-2 Replacing the O ring on the spool 7-2-3 Removing the load check valve and replacing the O ring 7-2-4 Replacing the relief valve assembly and the O ring 7-3 Structure of the relief valve 7-3-1 Main relief valve 7-3-2 Port relief valve 7-3-3 Suction valve 7-4 Precautions for handling 7-4-1 Handling 7-4-2 Installation 7-4-3 Operation

Pa1

Pa2

Pa7

P2

Pa9 A9

A8

A7

P2

A6

A5

A4

A3

Boom

Pb1

A1 B1

A2 B2 Pb2

A3 B3 Left travelling

Pa7

Bucket

B5 A5 A4 B4 Right travelling

P.T.O.

B6 A6

B7 A7 Swing

Pa9

Arm

B8 A8 Dozer

A

Pb7

Pb9 B9 A9 Slew

T2

T1

P1

P3

G

Dr

P,P

7-1 Specification

Pa2

Pa1

A2

A1 T1

P3

P1

249

T2

B9

B8

B7

B6

B5

B4

B3

B2

Pb2

Pb9

B1

Pb1

Pb7 434

Port T1,T2 A1~A9, B1~B9, P1 〜 P3 Pa1,Pa2,Pa7,Pa9,P.P Pb1,Pb2,Pb7,Pb9,Dr

Port size G1/2 G3/8 G 1/ 4

18.6MPa(190kgf/cm2)at 24 /min 17.2MPa(175kgf/cm2)at 16 /min 22.5MPa(230kgf/cm2)at 5 /min

P1 and P2 Main relief pressure P3 Main relief pressure A1, B1, A6, B6, A8 Port relief pressure 7-1

1

18

16 8

25

9 DRIVE:R

16 26

10 16 P.T.O.

15

15

16

ARM

18 DRIVE:L 11

ARM

BUCKET 12

18

16

26

15 16

16 BOOM 13

14

15

15

25

15

16 19

21

21

16 20

18

2

16 17

15 3

4

19

15

16

16

15

24

5

6

15 TURNING

7

15

16 23 16

DOZER

SWING 19

15

16 17

1. Control valve assembly 2. Block assembly 3. Block assembly 4. Block assembly 5. Block assembly 6. Block assembly 7. Block assembly 8. Block assembly 9. Block assembly 10. Block assembly 11. Block assembly 12. Block assembly 13. Block assembly

14. Block assembly 15. O-ring 16. O-ring 17. Relief valve assembly 18. Relief valve assembly 19. Anti-boid valve assembly 20. Rod 21. Nut 22. Relief valve assembly 23.Relief valve assenbly 24.Relief valve assembly 25.Relief valve assembly 26.Plug 7-2

1

2 27, 28, 29, 30

3 4 3 5 6 7

FOR DRIVE(R)(L)/SWING P.T.O./DOZER

31 8 9 10 1112

17 18 13 14 19 15 16

32, 33, 34 20 21

FOR ARM

22 23 24 25 26

FOR BOOM/BUCKET/TURNING

1. O-ring 2. Wiper ring 3. Spring seat 4. Spring 5. Cap screw 6. Cap 7. Socket head bolt 8. Spring seat 9. Spring 10. Spring seat 11. Poppet 12. Spring 13. Spacer 14. Spool end

15. Cap 16. Socket head bolt 17. O-ring 18. Wiper ring 19. O-ring 20. Spring seat 21. Spring 22. Spring sea 23. Spur end 24. O-ring 25. Cap 26. Socket head bolt 27~34. Spool 7-3

7-2 Disassembly and assembly 7-2-1 Replacing the O ring on the contact surface and each block assembly 1. Loosen the nut of tie rod.

2. Remove each block. Be careful not to damage the machine contact surface.

3. When disassembled, it is recommended to replace the O rings on the contact surface.

4. When assembling, clean the contact surface so that no dust sticks to the surface. Then attach the O ring and reassemble in the reverse order of the above procedure. When attaching the O ring, give grease to it.

5. Tighten nut temporarily.

6. After tightening, place them on their side. Pressing the inlet cover and end cover from above, check the level of the mounting legs and tighten the nut.

The tightening torque of the tie rod nut is 2.4kgf-m. While tightening them, check that the spool of each block operates smoothly.

7-4

7-2-2 Replacing the O ring on the spool 1. On the lever side 1) Remove the mounting screws (1) of the O-ring presser from the block.

2) Replace the backup ring (2) and O-ring (3).

3) When mounting the O-ring presser, be sure not to damage the O-ring.

2. On the cap side 1) Loosen the cap mounting screws (4) and remove the cap (5).

Take out spool (6) and replace O-ring (7) 2) Rinse the spool and insert it in the body.

3) When installing the spring cap, be careful not to damage the O-ring.

Tightening torque of the cap mounting screw is 0.9 kgf-m.

The spool is replaced in the units of the block assembly.

4 5

72 6 2 1

3 Load check valve Load check spring

7-2-3 Removing the load check valve 1. Remove the load check spring and load check valve from the valve block.

2. Keep each load check valve in order so as not to confuse it with other valve block.

2. Clean the parts sufficiently before assembling them.

7-2-4 Replacing the relief valve assembly and the O-ring.

1. Remove the inlet section assembly and the relief valve.

2. If necessary, replace the O-ring or the relief valve assembly.

3. During installation, give grease to the O-ring.

4. When the relief set, cap nut of adjusting screw and hexagon nut are loosened, always check relief set pressure using the pressure gauge.

At this time, the relief set pressure and flow rate shall be conformed to the specification indicated on the page of external drawing.

5. When the relief valve assembly is removed, check whether the small hole on the center of relief piston is clogged with foreign matter.

7-5

7-3 Structure of the relief valve 7-3-1 Main relief valve 7

2

1 8 6

5

9

4 16 17

3

Part Cap nut Installation of the relief valve 15

12

14 11 10

1. Cap 2. Plug 3. Sleeve 4. Main poppet 5. Pilot sheet 6. Pilot poppet

Tightening torque 29.4N-m(3.0kgf-m) 68.6N-m(7.0kgf-m)

13

7. Adjuster kit 8. Pilot spring 9. Spring 10. O-ring 11. Backup ring 12. O-ring

13.O-ring 14.Name plate 15.O-ring (1B-P10) 16.O-ring 17.Backup ring

7-3-2 Port relief valve 9

2

8

6

14

1

15

Part Cap nut Installation of the relief valve

10 11

Tightening torque 29.4N-m(3.0kgf-m) 68.6N-m(7.0kgf-m)

4 5

18

17

16

13 12

1. Cap 2. Plug 3. Poppet 4. Poppet 5. Piston 6. Pilot poppet

7

3

7. Spring 8. Pilot spring 9. Adjuster kit 10. O-ring 11. Backup ring 12. O-ring

7-6

13. Backup ring 14. O-ring 15. O-ring 16. Wave washer 17. Name plate 18. O-ring (1B-P10)

7-4 Precautions for handling (Installation and operation should conform to the following items.)

7-4-1 Handling When handling and carrying valves, be careful neither to drop them nor bang the spool end and cap.

When stocking a valve for a long time, plug each port to prevent dust and water from entering it.

7-4-2 Installation 1. Tighten the valve joints with the specified tightening torque. Be careful so that no unnecessary force acts on the valve through the piping.

2. Install the operation link so that the spool moves correct in the direction of shaft.

3. Be careful when welding near a valve, because the high temperature and spatter may damage the O ring of the spool and the dust seal.

4. Do not paint the spool.

5. Never remove the plug on each port to prevent dust from entering until piping work begins.

7-4-3 Operation 1. Before operation, check that the hydraulic circuit and the oil are both clean (cleanliness of hydraulic oil must be higher than the NAS12 class).

2. Keep the oil temperature between -20°C and 80°C. If the temperature falls below 0°C, warm up the machine.

3. Never raise the set pressure of the main relief valve and port relief valve beyond the specified set pressure. If the set pressure differs from the specified value, adjust it in the following manner.

1) Procedure for adjusting the main relief valve: a. Install a pressure gauge between the pump and control valve in the measuring position. If there is a mounting hole for the pressure gauge, use it. b. Raise the temperature of the hydraulic oil to 50 to 60°C and set the engine speed to the rated value. c. Operate the control lever to read the indication of the pressure gauge when cylinder reaches the stroke end. d. When raising the pressure, remove the cap nut and turn adjusting screw of the relief valve installed on the inlet section clockwise with an Allen wrench.

Relief valve pressure adjustment DOWN

Main relief valve

Approx. 17.8MPa (181kgf/cm2) per rotation

Port relief valve

Approx. 15.7MPa (160kgf/cm2) per rotation

UP Cap nut

e. Always lock the valve when it is set to the specified pressure.

7-7

8 JOYSTICK (PILOT VALVE) CONTENTS 8-1 Specification 8-2 Structure

30

20.4 19.5–1.5

10.2 5–1

0

3.0 2.5

3.5

35.7

3.02

30.8

3.0

Single-Operating Torque

2.52 2.14

2.0

2.0

1.91–0.15

1.78 1.34

1.0 0.49

0

1.0 –0.1 0

0.95

Secondary Pressure

2

1.1

0 6 6.5 7

4

30.6 25.7 21.8

20.4 18.2 13.7

10.2 9.7

0

Push-rod Stroke(mm) 0

5

10

15

19

86.5

Operating Angle

110

26.5 P

1 26° 26° 45°

8-1

T

3 2

4

Operating Torque(kgf-cm)

30.6

Double-Operating Torque

3.5

35.7

Operating Torque(Nm)

19°

Secondary Pressure(MPa)

25°

Secondary Pressure(kgf/cm2)

8-1 Specification

8-2 Structure 1

24

23

25 22 29

26

21 13

20

9

19

27

12 11

14

15 18 10

16 28

17 2

8 5

7

4

3

6

1. Joystick valve Ass'y 2. Casing 3. Port plate 4. Seal washer 5. O-ring 6. Hex. bolt 7. Spring pin 8. Bush 9. Plate 10. Spool

11. Plug 12. Push rod 13. Seal 14. O-ring 15. Spring seat 16. Washer 2 17. Spring 18. Spring 19. Joint 20. Circular plate 8-2

21. Adjiusting nut 22. Lock nut 23. Lever 24. Knob 25. Spring pin 26. Bush 27. Connector 28. Housing(4P) 29. Bellows

9 SLEW MOTOR CONTENTS 9-1 Specification 9-2 Structure 9-3 Standard of maintenance 9-3-1 Slew bearing & slew case 9-4 Inspection and adjustment 9-4-1 Measuring the natural slew distance 9-4-2 Measuring the over slew distance after stopping 9-4-3 Measuring the required time for slewing

9-1 Specification

Direction of rotation (seen from the output shaft) Oil outlet

Clockwise

A

B

Counterclockwise

B

A

47

196

Direction of rotation Oil inlet

A

Port size

A

G 3/8 O-ring Port

B

G 3/8 O-ring Port

T

G 3/8 O-ring Port

64

Initial oil replace Second and later replace

28

63

85

Port

500Hr 1,000Hr

194

T

12 A

20

45

12

64

16

B

23.2

25.4

View A

Type Output torque Output speed Hydraulic motor Capacity Flow rate Overload relief set pressure Pinion gear Module No. of threads Z Weight

9-1

2-160DOS-E3768 296 Nm(30.2kgf-m) 78min-1 158 cm3/rev 30 /min.

11.8MPa(120kgf/cm2) at 12 /min.

3 13 15kg

9-2 Structure 1

12

13

14 view A-A

8

11

A

9

2

7

A

10

6

5

4

3

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

Slew motor Ass’y Seal Kit X-ring O-ring Seal, shaft face O-ring O-ring 9-2

Seal, inner face Seal, outer face O-ring O-ring O-ring O-ring Relief valve Assy

9-3 Standard of maintenance 9-3-1 Slew bearing and slew case

M10×60

P=1.5 12.9

Tightening torque 80Nm

M12×30

P=1.75 12.9

Tightening torque 130Nm

M12×40

P=1.75 12.9

Tightening torque 130Nm

9-3

9-4 Inspection and adjustment 9-4-1 Measuring the natural slew distance 1. Position of the machine Maintain the hydraulic oil temperature at 50±5°C. Make a slope or use a sleeper to incline the machine by 12°. Set the attachment diagonally, put a weight (W) in the bucket (filling the bucket with soil), retract the arm cylinder to the minimum length, make the boom parallel to the slope and stop engine.

12°

2. Measurement Put a mark on the slew bearing outer race and the truck frame and measure the flow rate (deviation rate) of 3 minutes. (Moving distance of slew bearing outer race)Valid gear length Unit mm or less Standard value

Allowance

Weight W kg

100

200

108

9-4-2 Measuring the over slew distance after stopping Maintain the oil temperature at 50±5°C while the engine is running at full speed. Stretch the arm to the maximum length on a flat place. Make the boom joint pin (1) and arm bucket pin (2) put on a horizontal line, put a weight(W) in the bucket (filling the bucket with soil), slew the Machine by one turn and measure the over slew length (at bucket edge) after stopping.

Unit : deg Standard value

Weight W kg

45

108 (1)

(2) W

9-4-3 Measuring the required time for slewing Extend the bucket cylinder to maximum length, empty the bucket and measure the required time for slewing 5 turns following the first turn.

Unit : sec or less Standard value

Allowance

26±4

42 9-4

10 TRAVEL MOTOR CONTENTS 10-1 Specification 10-2 Structure 10-3 Operation 10-4 Handling the travel motor 10-5 Measuring travel motor idling and travelling time 10-6 Inspection and adjustment

10-1 Specification

Dr port Dr port 231.5 40

A port

PP port

PCD 170

P.C.D. 180

99

B port

10-M10

2-Rc 1/16 (P.G. port)

9-M10

Direction of rotation (viewing from output axis) Direction Oil pouring Oil discharging of rotation port port B

A

Counterclockwise

A

B

RED

Clockwise

DR A B

PP

Port A,B

Port size G 3/8

PP,Dr

G 1/4 Item

Output torque (Nm) -1

Output speed (min ) Reduction ratio 3

Hydraulic motor

Capacity (cm /rev)

1,859(190kgf-m) 36.3/69.6 1/39 16.1/8.4 2

Working pressure (MPa)

18.6(190kgf/cm )

Output speed of hydraulic motor (min-1)

1416/2714

Flow rate ( /min)

Others

Reduction gear

Item

Equivalent capacity (cm3/rev)

627.9/327.6

Oil

ISO-VG46

Oil temperature(°C)

-20~100

Filtering (+M) Lubricating oil Weight(kg)

22.8

10-1

10 Engine oil equivalent to SAE-30CD(330cm3) 25

10-2 Structure 64

63 64 65 71

65 49 67

81

56

61

52 59 69

79 76

15

44

54

19 10

80 15 14

51

8

68 55

15

60

22

13 16

1

73

45

13

23

21

36

38

20 15

22 46

40

6 27

5

12 11

18

9 7 4 19

8

3

50

72

39

57 35

36

26

67

74 53

77

62 34

31

30

43

70 28

29 32

58

2

78 75

17

10 42 25 37 41

33

24

1. Body-1 2. Spool 3. Check valve 4. Spring guide 5. Spool 6. Shuttle spool 7. Spring V1 8. Spring V2 9. Spring V3 10. Plug 11. Plug 12. Plug 13. Choke 14. Ring 15. Plug 16. Pulg 17. O-ring 18. O-ring 19. O-ring 20. Choke 21. Needle 22. Plug 23. O-ring 24. Body 2 25. Shaft 26. Cylinder barrel 27. Valve plate

28. Piston 29. Shoe 30. Shoe holder 31. Barrel holder 32. Swash plate 33. Control piston 34. Pin 35. Spring C 36. Retainer 37. Bearing 38. Bearing 39. O-ring 40. O-ring 41. Oil seal 42. Ball 43. Snap ring 44. Screw 45. Spring pin 46. Pin 47. Plug 48. O-ring 49. Body 50. Cover 51. Carrier 2 52. B1 gear 53. B2 gear 54. S1 gear 10-2

48

47

55. S2 gear 56. Ring 57. B2 pin 58. O-snap ring 59. Thrust plate 1 60. Thrust plate 2 61. Needle 62. Needle 63. Floating seat 64. O-ring 65. Bearing 66. Thrust washer 67. Snap ring 68. Snap ring 69. Snap ring 70. Snap ring 71. Snap ring 72. Spring pin 73. O-ring 74. O-ring 75. O-ring 76. Name plate 77. Plug 78. Plug 79. Plug 80. O-ring 81. Thrust washer

10-3 Handling the travelling motor Add lubricating oil according to the following procedure.

1. The cover has three plugs. Turn the motor so that oil intake port is the top of the motor.

Use them as the oil intake port, oil quantity check port and oil drain port, starting from the top in that order.

G3/8 Oil intake port G 1/8 Oil quantity check port Oil level

G 3/8 Oil drain port

2. First, remove the plugs from the oil intake and oil quantity check port with an Allen wrench.

3. Add lubricating oil through the oil intake until the oil comes out of oil quantity check port.

4. Plug the oil intake, oil drain and oil quantity check port.

Amount of lubricating oil

330cc

Schedule for replacing lubricating oil: First: After the first 500 service hours Second and later times : Every 1,000 service hours Standard maintenance Tightening torque Sprocket tightening torque

72 N-m

Motor tightening torque

72 N-m

10-3

10-4 Measuring crawler idling and travelling time 1. Idle crawler for ten turns and measure the required time.

Unit : sec Standard value Low

31±2

High

53±2

(Engine running at full speed and oil temperature of 50±5°C)

2. After travelling 3m on ground level, measure the required time to travel 20m.

Standard value Low

19±2

High

33±2

(Engine running at full speed and oil temperature of 50±5°C)

10-5 Inspection and adjustment 1. Measuring meander distance in travelling Measure the meandering distance by travelling on hard ground.

Unit : mm or less Standard value

Max.

200

500

(Engine running at full speed and oil temperature of 50 ± 5˚C) 9.0m(29.5 ft)

10-4

11 HYDRAULIC CYLINDER CONTENTS 11-1 Structure 11-2 Disassembly and assembly 11-2-1 Disassembly procedure 11-2-2 Procedure for disassembling inner parts 11-3 Assembly 11-3-1 Assembly procedure 11-3-2 Inspection procedure 11-3-3 Precautions for assembly

11-1 Structure

H

J

C

B

A

D

I

F K

G2

G1

E

Cylinder Item Weight kg Trust Pushing force* Pulling

Boom

Arm

Bucket

Swing

Dozer

20

20

17

16

13

kN

61.8

52.6

71.6

kN

43.9

34.7

48.2

A

Pin diameter (rod)

mm

ø35

ø30

B

Pin diameter (head) mm

ø35

ø30

C

Rod diameter

mm

ø35

ø40

D

Cylinder bore

mm

E F G1 G2

ø60

ø70

Maximum extended length mm

1,195

1,295

1,095

1,160

555

Maximum contracted length mm

745

795

695

735

455

Stroke

mm

450

500

400

425

100

Clevis width

mm

H

Tightening torque N-m(kgf-m)

I

tightening torque

J

ø65

294(30.0)

N-m(kgf-m)

Tightening torque N-m(kgf-m) Size of piston screw K (size × pitch) Main relief Pressure MPa(kgf-cm2)

45

50 284(29.0)

304(31.0)

399(40.7)

559(57.0)

6.8(0.7) 469(47.8) M24 × 1.5 18.6(190) 11-1

M27 × 1.5

11-2 Disassembly and assembly 1

3

34

26

29 25

20

26 21

19

23 22

20 28

24 16

14

15

17

18

13 31

12 11

27 6 5 8 10

9

4

32

7

26 25

33

30

2

26

The illustration shows a boom cylinder.

1. Cylinder Ass'y 2. Tube 3. Rod 4. Cylinder head 5. Rod bush 6. U-ring 7. Wiper ring 8. O-ring 9. Backup ring 10. O-ring 11. Piston 12. Slide ring

13. Seal ring Ass’y 14. Steel ball 15. Set screw 16. Pin bush 17. Dust seal 18. Cylinder head Ass’y 19. Piston Ass’y 20. Rod packing Ass’y 21. Piston packing Ass’y 22. Packing Ass’y 23. Set screw 24. Cushion bearing 11-2

25. Pin bush 26. Dust seal 27. Cylinder seal 28. Retainer 29. Piston 30. Rod packing 31. Piston packing 32. Packing 33. Grease nipple 34. Grease nipple

11-2-1 Disassembly procedure 1. Hold the cylinder with the vice.

Tighten the vice carefully; do not deform the cylinder. Blow air alternately from ports A and B and operate the piston rod to drain oil from the cylinder inside. To remove the piston, pull the piston rod about a third of the length.

A Hard wood Vice

B

Counterclockwise

2. Loosen and remove the cylinder head from the cylinder tube assembly with a hook wrench.

Rubber or waist

3. Disassembling the piston rod assembly Slowly turn the piston rod assembly to remove it from the cylinder tube assembly.

Place the removed piston rod assembly on a wooden bench or a waste to prevent damage.

Pull out

11-3

4. Disassembling the piston assembly Hold the piston rod assembly with a vice.

• Put the waste between hard wood and the piston to prevent the surface sliding from being damaged.

• Set the piston rod assembly on a level block so that it becomes parallel to the level block.

Be careful because the piston rod assembly may come out of the vice and be damaged if it is set diagonally.

Hard wood

11-2-2 Procedure for disassembling inner parts 1. Remove the piston assembly from the piston rod assembly (after removing the set bolts).

Then remove the cushion bearing in the direction of the arrow.

2. Disassembling rod cover Put piston rod assembly on a holding jig on the work bench.

Make a working face for the rod cover assembly on the workbench and move the rod cover to and fro to remove it.

Remove the backup ring then the O ring with a screwdriver. If they are to be reused, be careful not to damage them.

Holding jig

Packing case Backward Forward

3. Disassembling the packing assembly Remove the packing by prying it with an eyeleteer or a screwdriver. Be careful not to damage the groove of the cover and piston. Because it is difficult to remove the dust seal and rod packing without damaging them, remove them by inserting a eyeleteer or a similar tool and prying them out. Be careful not to damage the groove on the cover and piston.

4. Disassembling the piston rod and cylinder tube assembly As the bushes are pressed fit to the rod head, press them out with a pressing machine to remove them. For a spherical bearing, the snap ring must be removed first.

11-4

Press (example of a cylinder rod)

11-3 Assembly 11-3-1 Assembly procedure 1. The assembly procedure is the reverse of disassembly.

2. Before assembly, check whether metallic powder or other foreign matter is not sticking to any of the parts and whether the parts can be reused.

3. Coat hydraulic oil on each part before assembling them.

4. Assemble beforehand the parts into the following assemblies.

• Cylinder tube assembly • Rod cover assembly • Piston rod • Piston assembly

11-3-2 Inspection procedure Clean each disassembled part with light oil or treated oil except for the packings.

Packings are cleaned with petroleum hydraulic oil.

Other types of oil will remarkably shorten the life of the packing.

Thoroughly clean the sliding surface, oil hole, O ring, packing groove, etc. If the part is not used for a long time after being cleaned, execute a rust proof treatment.

(Coating hydraulic oil is effective for rust prevention to a certain degree.)

1. Check all parts for flaws, cracks, deformation, rust, or burrs which may affect the operation. (Inside of the tube, rod, etc.)

2. Check each part for metallic powder or other foreign matter sticking to it.

3. Check the sliding surface of piston rod for damage, uneven abrasion, discoloring, or any defect which may affect its operation.

4. Packings and seals are usually replaced with new one. If you must reuse them, check that there are no tears, cuts or foreign matter sticking to the packing.

11-3-3 Precautions for assembly Assemble the cylinder while paying attention to the following matters.

1. Replace the packings with new ones before assembly.

2. Execute assembly work paying attention to the direction of cushion bearings (boom, arm, bucket and swing) and seal rings (arm and swing).

3. Replace the set bolts with new ones.

In assembling, after tightening the set bolts, further tighten and firmly fix them by hitting with punch at two points on the periphery.

4. Tighten the rod cover, piston and nuts with a specified tightening torque shown in the attached table (page 11-1).

5. Check fully before starting assembly work.

11-5

12 SWIVEL JOINT CONTENTS 12-1 Specification and Structure 12-2 Structure, disassembly and assembly

12-1 Specification and Structure 0.3MPa(3kgf/cm2) Working pressure

T

2

3.4Mpa(35kgf/cm )

E

18.6MPa(190kgf/cm )

A 〜 D, F, P

G 1/4

E, F, P, T

G 3/8

A〜D

R 1/4

E, F, P, T

R 3/8

A〜D

2

Screw size(Body) Screw size(Shaft) Working speed

rpm

*A to F and P, T denote the position of the port.

A.C.E.P. port

Overdrive Control valve Travelling rightward

Control valve Travelling leftward E

45

B

A T

P

C

Control valve Dozer

D 45

F Control valve Travelling rightward

Control valve Travelling leftward

F

Dozer cylinder

E

Over drive

D

Rightward travelling motor

C

Leftward travelling motor Rightward travelling motor Leftward travelling motor

T

P

Dozer cylinder

B

Control valve-Dozer

A

B.D.F. port

Drain

12-1

12-2 Structure,disassembly and assembly 1

15 3 2

4

12 11

13

6 7

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

Swivel joint assembly Shaft Pin Hub Flange O-ring O-ring Back up ring Slipper seal O-ring Snap ring Thrust washer Dust seal Socket head bolt Plug Packing Ass’y

8 16

10

5

9 14

Disassembly: 1. Remove bolt (14) and Flange (5).

2. Remove the snap ring (11).

3. Remove the shaft (2) from the hub (4) upward. Because the shaft is tightened by the tension of the O ring, tap a hammer on the shaft by rotating it and pull it up. * Be careful so that O ring does not become trapped.

Assembly: 1. Before assembly, check the O ring and sliding part for flaws and other defects.

2. Assembly is usually executed in the opposite order of disassembly.

Coat a little hydraulic oil or grease on the O rings before assembly.

12-2

13 CRAWLER CONTENTS 13-1 Structure and operation 13-1-1 Crawler (Steel) 13-1-2 Track frame 13-2 Standard of maintenance 13-2-1 Crawler (Steel) 13-3 Disassembly and assembly 13-3-1 Installing the crawler 13-3-2 Removing the crawler 13-3-3 Track frame spring 13-3-4 Life of the rubber crawler 13-3-5 Handling the rubber crawler

13-1 Structure and operation 13-1-1 Crawler (steel)

230

1

2

90

1.

Shoe

2. Pin

13-1-2 Track frame

1

4

2

3

1. Idler 2. Track frame 3. Track roller 4. Spring

13-1

13-2 Standard of maintenance 13-2-1 Crawler (steel)

1

5

2 4

3

Standard value

Allowance

Remarks

90

94

46

43

Measure by stretching 5 links except for the master link Pad or replace

115

7

Pad or replace

Pin clearance

0.2

2

Replace

Bush outer diameter

22.15

21

Replace

No.

Item

1

Link pitch

2

Link height Grouser height

3 4 5

Unit

mm

13-2

13-3 Disassembly and assembly 13-3-1 Installing the crawler 1. Crawler After the sprocket put on the crawler (2), drive motor to bring it above the idler and for steel crawler, fix the master pin (3) into the hole. For a rubber crawler, the crawler by using the idler as it is. Install steel bar and heavy duty hammer into the undercarriage.

3 2

1

2. Tension the crawler Tighten the cartridge valve (1) of the adjust cylinder, grease and adjust the tension.

Steel: 25 to 35 mm Rubber: 10 to 15 mm

13-3

13-3-2 Removing the crawler 1. Loosen the crawler.

By loosen the cartridge valve (1) of the adjust cylinder, drain grease and loosen the crawler (2).

1

2. Crawler 1) Lift the main frame with attachment and put blocks under to lift the machine.

3

2) Turning in the direction of the idler side, remove crawler master pin (3) and then the crawler (2) from track frame.

Weight (steel crawler): 148 kg (74×2) 3) As rubber crawler is endless and of solid material, push the idler to the end and remove the rubber crawler by using steel bar from the idler.

Weight (rubber crawler): 102 kg (51×2)

13-4

2

13-3-3 Track frame spring

2-1

1

2-2

4

3-2 3-1

No.

Item

1

Deformation of frame

Bend Twist Opening of idler

2

3 4

Distance between upper and lower faces of idler guide Distance between left and right faces of idler guide Spring (free length)

2-1 Track frame 2-2 Idler frame 3-1 Track frame 3-2 Idler support Standard value Set length

Standard Allowable limit 5 (Overall length of track frame) 10 (Twist between left and right crawler frames) 5 Standard value 52 +1 -0 50 152 150 274 207

13-5

Unit: mm Remedy

Correct

Pad or replace

Replace Replace

13-3-4 Life of the rubber crawler Abrasion loss (mm) 20

su rfa ce

Standard life

10

Co nc ret e

15

al er n Ge

oil) g(s n i ap dsc Lan

5

0 500

1000

1500

2000

2500 3000 Service hours (H)

Check the remaining life of the rubber crawler by the abrasion loss in the rubber crawler height as shown in the figure below. Note that the life slightly differs depending on the conditions of site and the operation of the machine.

PRECAUTIONS: (1) Wipe immediately if fuel or hydraulic oil sticks to rubber crawler.

(2) Check that there are no sharp edges protruding on the ground.

(3) Avoid using on beach. (This may affect the adhesion of the core metal.)

(4) If the machine is going to be stored for a long time, never store it where it will be directly exposed to sunlight.

23

22.5

24

22

25

230

48 pitch

Description Total length of rubber crawler Steel cord Tension Steel cord No. of cords Range of working temperature Width × pitch

13-6

Value 3,552±10 5690N/piece 16±2×2row -25°C~55°C 230×48

13-3-5 Handling the rubber crawler 1. Do not run over or turn on a sharp edge If you run over or turn on a projecting sharp edge or a stepped grade, the machine will partially load on the rubber crawler and split it or cut the threads of the rubber crawler and the inner steel cord.

2. Prevent foreign matter from entering the rubber crawler Foreign matter will strain the crawler and cut it.

3. No sharp turns Do not turn sharply on a road with a high-friction factor (such as a concrete road).

4. Keep oil products away from the rubber crawler If you spill fuel or hydraulic fluid on the rubber crawler, clean it promptly.

5. Protect from salt Do not operate on beach (Core metal will rust due to salt corrosion).

6. Store indoors If the machine is not used for a long time, keep it indoors to prevent exposure to direct sunlight and rain.

13-7

14 SPRING CASE AND GREASE CYLINDER CONTENTS 14-1 Structure 14-2 Specification of spring 14-3 Disassembly and assembly 14-3-1 How to disassemble and assemble the adjust cylinder 14-3-2 How to disassemble and assemble the spring case

14-1 Structure 1

10

9

11

2

1. Idler folk 2. Cylinder 3. Rod 4. Cartridge valve 5. Grease nipple (PT1/8-C) 6. O-ring (1B-P30)

6

7

8

4

5

3

7. Back up ring (T2-P30) 8. Spacer(DSI) 9. Castle nut 10. Split pin 11. Spring

14-2 Specification of spring

ø I.D.

P.C.D.

ø O.D.

d

Set length L L0

Name No. of active coils Total number of coils Spring constant N/mm Set force kN Force at max. shrinkage kN Lo Free length mm

Value 8.5 10.5 288 14.1 33.4 256

Name Length at max. shrinkage mm ø O.D. (outer diameter)mm P.C.D. (Center diameter) mm øI.D. (Inner diameter) mm Wire diameter d mm L set length mm

14-1

Value 140 80 64 48 16 207

14-3 Disassembly and assembly

1. Idler folk 2. Cylinder 3. Rod 4. Cartridge valve 5. Grease nipple (PT1/8-C) 6. O-ring (1B-P30)

7. Back up ring (T2-P30) 8. Spacer (DSI) 9. Castle nut 10. Split pin 11. Spring

Cylinder effective stroke: 67 mm

14-3-1 How to disassemble and assemble the adjust cylinder 1. Disassembly a. Remove the cartridge valve from the adjust cylinder rod. b. Remove the cylinder rod from the adjust cylinder tube. c. Remove the snap ring, spacer, dust seal, backup ring and O-ring.

2. Assembly The assembly procedure is the reverse of the disassembly procedure. a. Attach the O-ring, backup ring and spacer to adjust cylinder tube. *Coat grease on the O-ring and dust seal before assembly. b. Attach the adjust cylinder rod to adjust the cylinder tube carefully so that the seals are not damaged. Apply grease before hand in the adjust cylinder tube. Attach the cartridge valve to the adjust cylinder rod so that the screw on the second step reaches the tapped hole. When attaching the adjust cylinder rod, tighten the cartridge valve after checking that grease comes out of the grease drain hole.

Note: • Adjust and assemble carefully so that air does not remain in the adjust cylinder tube.

• Coat grease on the piston of the cylinder tube rod before assembly.

Tightening torque of the cartridge valve: 183 to 206 N-m 14-2

14-3-2 How to disassemble and assemble the spring case 1. Disassembly Lower the spring force between the front idler and adjust cylinder tube using a pressing machine and the special purpose tool. a. Remove the castle nut for the mounting spring. b. Remove the spring from adjust cylinder tube.

Note: • Be careful when using the tool when removing the spring. Also, be careful during assembly.

2. Assembly The assembly procedure is the reverse of disassembly.

Attach the spring to adjust cylinder tube using the special tool and set the spring to the specified position with the castle nut.

After adjustment, completely bend the split pin.

Spring set length: 207 mm

14-3

15 IDLER CONTENTS 15-1 Standard of maintenance 15-1-1 Idler

15-1 Standard of maintenance

2

15-1-1 Idler

1

No. Item 1 2 3 4

Unit

Width of idler teeth mm Minor diameter mm Number of teeth Quality of lubricating oil cm3

Standard value 22 ø253 19 40

15-1

Allowance 16 ø241

Remarks Pad or replace Pad or replace Engine oil or gear oil

16 SPROCKET CONTENTS 16-1 Disassembly and assembly 16-1-1 Removing the sprocket 16-1-2 Installing the sprocket 16-2 Standard of maintenance 16-2-1 Sprocket

16-1 Disassembly and assembly 16-1-1 Removing the sprocket

1

2

1. Crawler Refer to the explanation on crawler removal.

2. Sprocket Remove sprocket mounting bolts (1) and then sprocket (2) from the travelling motor assembly.

16-1-2 Installing the sprocket 2

1. Sprocket Attach the sprocket to travelling motor assembly and tighten the mounting bolts (1).

Tightening torque: 72N-m 2. Crawler Refer to the explanation of crawler installation.

16-1

1

16-2 Standard of maintenance 16-2-1 Sprocket

2

1

4 3

No. 1 2 3 4

Item Width of sprocket teeth Minor diameter of sprocket Tightening torque of sprocket mounting bolt Tightening torque of motor mounting bolt

Unit

Standard Allowance value

Remarks

mm mm

22 ø253

16 ø241

Pad or replace Pad or replace

N-m

72

—

(M10 P1.5)

N-m

72

—

(M10 P1.5)

16-2

17 TRACK ROLLER CONTENTS 17-1 Standard of maintenance 17-1-1 Track roller

17-1 Standard of maintenance 17-1-1 Track roller 4 3

5

No. 1 2 3 4 5 6 7

Item

Unit

Outer diameter of projected part mm Outer diameter of tread mm Width of projected part mm Overall width mm Width of tread mm Tightening torque for mounting roller N-m Quantity of lubricating oil cm2

2

1

6

Standard Allowance Remarks value ø106 ø98 Pad or replace ø86 ø83 Pad or replace 22 19 Pad or replace 99 — Pad or replace 28 — Pad or replace 318 < M20 × P2.5 < 100 Gear oil or engine oil

17-1

18 ELECTRICAL EQUIPMENT CONTENTS 18-1 Structure and function 18-1-1 Electric circuit diagram 18-2 Failure and remedy 18-2-1 Starter system 18-2-2 Alternator system

M

H

G

W Br

LIGHT

3

6

10

20

3

6

2

1

4 5

A

K

GLOW TIMER （3 seconds）

0.5Y

L

8

S2 S3 ST S4 S1

13 12 11 10

9

174047-2(AMP)

20

0.5LW

0.5LY

0.5B

0.5YR

0.5R

11

10

0.5LR

0.5GR

0.5WR

0.5R

0.5YG

1

R

7

5

MS GR

6

CN1

PM054-0271

D1

11

12

13

CN1

8

9

10

5

6

7

3

4

CN2

1

2

TERMINAL LAYOUT

UNIT CONTROL TIMER

S +1

G B

1

2

3

CN2

4

R

LW

B

40908-00011

STARTER SWITCH

C

R2

R2

B

C

Br ACC

B

（A）

OFF DRIVE START

CAP. 2.5 BR

ACC

40 C

40 R2

BR

R2

Y （Radio）

ROOF LIGHT

0.85Y

Y 0.85WR

CAB-3

WY Or

OrG

L

WL

+

OPTION

CABIN

LA206 EARTH

BrW

W

FUSE BOX 40901-04010 WB RL Br

RADIO

1.25WR

FUSE BOX （40901-04010）

AC R2 Br C

BK14-533

B

LY

RY

CAB-2

HEATER

C

R2

0.85RB 10 ACC

B

C

CAB-1

STARTER SWITCH WIRING（11620-01810）

30A68-10700（MITSUBISHI)

1

11

TERMINAL LAYOUT

31Ａ66-05100 （MITSUBISHI)

1

5

TYPE C

0.5RW

Br

YAZAKI 62 CONNECTOR M HOUSING：7122-7840

0.5W

G

Y

D1〜D5（1.1A、7321-9370-40) （2P MAL YAZAKI）

Y

(FRONT SW)

HORN

1.25W

W

1.25Y

(REAR SW)

SP45-00001(OP-0329-001-NO-CO) NIHON SEIKI

DUST ALARM

E/G OIL PRESS

ILLUMINATION

TEMP

HOUR

0.85RG

0.85RB

+

MM FUEL M L L L CHARGE L L GLOW L L L L L

CLUSTER

L

0.85Br

E

L

HEATER

0.85L

L

E

Br

0.5RL

WIPER WASHER

0.85RY

RB

0.5GW

0.5GR

J/S (RIGHT)

0.85LW

0.85B

G

Gry

0.85WL

0.85WL

0.5YG

W

H

0.5WB

R

0.85WL

M

0.5GW

RY

0.85RL

B

1.25L

L

0.5LW

LY

WIPER,WASHER OFF

0.5LB

G 0.85RY

0.85Or/G

W

L

0.85LW

0.85L

1.25B

0.85LW 1.25B

1.25B

Y 0.85W 5R

RY 0.85RG

1.25W 3WR

ROOM LAMP

0.85LW

WASHER MOTOR

2BW

（時計） R 0.85B

WIPER MOTOR +

0.5GW

LIGHTERS CIGARETTE

J2

0.5WR

0.85B

W

0.85Or Or

Gry

0.85Or/G OrG

L

0.85Br Br 10A HEATER

D2

B

GLOW RELAY MM43128201

2

STARTER RELAY MM4312801

3

CR2 2

4

3

CR1

J4

3Pオス

4

1

0.5WR

J1

J3

W

NO

NC

R

COM

SAFETY LEVER

S083-00080-00

0.85R

R

0.5LB

G

1.25RL RL 15A CTL CIRCUIT

LW

2W

B

1

D5

SAFETY STOP SRM-12CS

B L1 L2

CR3

0.5B C2 C1

OVER DRIVE SWITCH

0.85WB

Y

HOUR METER SRM-12CS

B L1 L2

CR4

1.25WY

B L1 L2

CR5

REV-LIGHT SRM-12CS OPTION

C2 C1

0.5LR

NO

OIL WATER PRESSURE TEMP AIR CLEANER

C2 C1

0.5R

RG

0.5LR 0.5B

L

0.85Or

0.85WY 0.5LW

NC、12V-5W

0.85L 0.5LY 0.5WR

HEATER

M4

D3

D4

B L1 L2

CR6

OPTION LIGHT SRM-12CS

C2 C1

O.H SW

L

R

7322-2128

9.7A 9秒

GLOW MM432-14801

0.5WB

L R

OVER HEAT BUZZER

S

5R

W

Pnk

W

0.85R 0.5B

Pnk

BATTRY ＆ BODY EARTH

UNLOAD VALVE

OVER DRIVE

HEAD LIGHT

WORKING LIGHT （BOOM)

SENDER UNIT

FUEL PUMP

STOP SOLENOID

WHT/GRN WHT/BLK BLK BLK/RED BLK/YEL BLK/WHT BLK/BLU

B/R B/Y B/W B/L

YEL/BLK ORANGE Y/B Or

WHT/BLU

YEL/GRN YEL/WHT Y/G Y/W

W/G W/B B

YEL/RED YEL/BLU Y/R Y/L

W/L

BLU/BLK YEL L/B Y

GRN/WHT WHT WHT/RED

BLU/RED BLU/WHT L/R L/W

GRN GRN/RED

RED/WHT RED/BLK BLU R/W R/B L

G/W W W/R

RED/GRN R/G

G G/R

RED RED/BLU RED/YEL R R/L R/Y

COLOR CODE

FUSIBLE LINK (STOP SOLENOID) 0.3W

EARTH

HORN

FL2

5B

BODY

EARTH

FUSIBLE LINK (MAIN)0.85R

BATTERY

HEAD LIGHT

0.5B

0.85B

0.5RW

1.25R

1.25R

-

E/G

55B24L（FB)

+

FL1

EB30 M8

5R

B

STARTER

0.85WB

1.25B

1.25Y

0.5YR

0.5B

0.85BY

1.25L

B

P

ALTERNATOR

M5

0.85YG 0.85RL

B

0.85WL

0.5R

(15A)

M E

0.5RL

0.85RL 5R

0.85WY 0.5GR

JIS D5403 PA

LW WL

2BW

0.85RW 0.85WR 0.85WR

5BY

1.25R

H L

0.5WB

B 3WR 3WR

0.85B 1.25W W

WL 10A WIPER,ROOM LAMP

10A

1.25R

SOL ING

CLOK

0.5R

0.5LW 0.5WY 0.5L

5R

WIPER

WB

1.25WY BrW 3A

15A

RADIO,HORN LIGHT PANEL

0.85BY L 10A FUEL PUMP

1.25WY WY 10A OPTION

0.5Y 0.5Y

0.85B 1.25B 0.5B 1.25WY

5BY 0.85W

0.5LR

0.85Y 0.85W 0.85Y

0.5LB 0.5L 0.5B

0.85Y 0.5Y

2R 2R FUSE （FB009) 2R 2R

18-1

1.25R

18-1-1 Electric circuit diagram

0.85W

2W

M E

18-1 Structure and function

18-2 Failure and remedy 18-2-1 Starter system Failure

Pinion does not come out even when the starter switch is pressed.

Cause - Disconnection of the wire harness, loose connection of the battery or switch terminal.

- Spline which engaged with the pinion of armature shaft is caught and the pinion cannot move.

- Malfunction of the plunger of magnetic switch, disconnection or the short-circuit of coil

Remedy Reconnect and tighten connections.

Free the spline Correct or replace

- Disconnection of the cable between the battery and the magnetic switch, loosening (bad earth) of the connecting wire between magnetic switch and motor terminals - Improper engagement of pinion and ring gear - Wrong installation - Brush is worn out or brush spring is touching.

- Commutator is dirty.

- Malfunction of armature or field coil - Loosening of field coil and brush - Loose connection of contractor - Contact surface of contractor is rough.

Reconnect cable, tighten connections (make good earth).

Starter rotates at its full speed before the pinion engages with the ring gear.

- Wrong adjustment of plunger gap (distance l) - Permanent set of pinion sleeve spring.

Adjust

Engine does not start even when the pinion engages with the ring gear and the starter rotates.

- Malfunction of overrun clutch

Replace

Starter does not stop even when starter switch is turned off.

- Short-circuit inside switch - Contractor drops and is always connected.

Replace switch Replace

Starter does not rotate even when the pinion engages with the ring gear.

18-2

Correct the engagement.

Reinstall Replace or adjust.

Clean commutator.

Correct or replace Tighten coil and brush.

Tighten connections.

Correct or replace

Replace

18-2-2 Alternator system Failure

Cause

Remedy Reconnect cord-tighten connections.

Cannot be charged.

- Cords between terminals are disconnected or connectors are in loose connection.

- Improper earth conection - Brush and slip ring do not contact.

- Coil is disconnected or burnt.

- Diode is damaged.

Tighten connections.

Insufficient charge

- Loose connection of cords between each terminal - Fan belt slips.

- Improper contact or insufficient movement of brush and slip ring - Short-circuit of coil - Defective diode

Overcharge

- Defective alternator

Replace

Noise

- Wrong installation - Defective fan belt - Defective bearing

Connect.

Replace.

Replace.

- Diodes on (+) and (-) sides broke down.

- Capacitor broke down.

- Alternator internal short-circuited

Replace.

Fuse melts.

18-3

Make good earth conections.

Connect or replace Replace Replace

Adjust.

Clean slip ring and brush holder.

Replace Replace

19 TROUBLESHOOTING CONTENTS 19-1 Troubleshooting 19-1-1 All functions not operational 19-1-2 Operation power is weak 19-1-3 No operation on boom, arm, bucket slewing 19-2 Travelling system 19-2-1 Right (or left) hand side of crawler does not work correctly 19-2-2 Travelling meander by slow speed on only right (left) hand side 19-2-3 Machine fails to hold on incline 19-3 Slewing system 19-3-1 No operation both (right/left)slewing 19-3-2 It is possible to turn right (left) but not left (right) 19-3-3 Turning acceleration slow, the overturn is highter than tolerance 19-3-4 Extreme slow turning speed 19-3-5 Turning movement when the machine is parked on a slope 19-4 Boom system (for arm and bucket cylinders the same method as follows.)

19-4-1 No movement on boom cylinder 19-4-2 Slow action or lack of power on boom cylinder 19-4-3 Natural fall of boom 19-5 Swing system 19-5-1 No movement on swing system 19-5-2 Drifting swing cylinder

19-1 Troubleshooting 19-1-1 All functions not operational Check the level of HYD. oil.

If not enough

Pumps or couplings faulty.

Disassemble, check

Fill up with HYD. oil.

Replace pump Ass'y or couplings.

19-1-2 Operation power is weak Check the level of HYD. oil.

If not enough

Fill up with HYD. oil.

OK Abnormal noise occur from pump.

Yes

No

Check the level of HYD. oil flow from pump.

Flow low

Intake system faulty.

Clean up suction filter.

Repair faulty piping part.

HYD. oil has bubbles in it.

Check cause of bubbles and remove it.

Large internal leak on pump.

Deterioration of the HYD. oil

OK

Check the pressure on main relief valve.

OK

Faulty pump

Pressure incorrect

Replace pump Ass'y.

Replace HYD. oil.

Relief valve faulty adjustment.

Adjust to correct pressure.

Faulty relief valve.

Clean, disassemble, adjust or replace Ass'y.

Large internal leak on control valve.

Replace Ass'y.

19-1

19-1-3 No operation on boom, arm, bucket & slewing Check set condition of safety lock lever.

Reset or adjust limit switch.

OK

Check the wiring, short circuit of FUSE BOXLIMIT SWITCHSOLENOID VALVE.

Faulty

Refit wiring.

Fuse has blown.

OK

Replace fuse.

Check the action of limit switch or solenoid valve.

OK

Check the set pressure on pilot port.

Faulty

Check the pressure Incorrect Replace HYD. pump on pump No.3 and seals.

OK

OK

Check the pilot filter.

Faulty

Check control valve and inner parts of pilot system.

If it is faulty spool sticking, then flush out or replace. If the spring is weak, then replace.

Blocked up with contamination of pilot filter.

Clean or replace.

OK

Check the action of joystick.

Faulty

Clean or replace.

OK

Check parts of each port on control valve.

Clean or replace control valve.

19-2

19-2 Travelling system 19-2-1 Right (or left) hand side of crawler does not work correctly Faulty

Check the spool stroke.

Check the link system.

Faulty

Faulty linkage.

Adjustment or replace.

Faulty action on spool.

Replace seals or block Ass'y.

OK OK

Check the travelling for both(forward, backward)directions.

Problem changed to opposite direction

Only one direction

Internal leak on swivel joint.

Change over valve section port A⇔port B Faulty

Counter balance valve is faulty.

No travelling in either direction

Replace seals or Ass'y.

Check plunger, repair or replace Ass'y.

Replace or change over the relief valve with the other pump's port and then test.

OK

Low pressure

Faulty relief valve.

Contamination

Faulty

Check the action of the relief valves.

Action faulty (does not relieve pressure)

Adjust to correct pressure or replace relief valve.

Disassemble, clean or replace.

Replace pump Ass'y.

Pump was faulty.

Action OK (relieves pressure)

Faulty drive motor.

Check the counter balance valve.

Faulty

Check plunger, repair or replace Ass'y.

OK

Drive motor broken.

19-3

Replace motor Ass'y.

19-2-2 Travelling meander by slow speed on only right (left) hand side.

Yes

Is the meander distance within tolerance?

OK

No

Check the tension of crawler and check for the foreign matter present.

Remove any foreign matter and re-adjust to correct tension.

Faulty

OK Faulty

Check the spool stroke.

Check the link system.

Faulty

OK

Change over the outlet hoses No. 1, 2 pumps, then test travelling.

OK

Faulty linkage.

Adjustment or replace.

Faulty action on spool.

Replace seals or block Ass'y.

Problem changed to opposite direction

Replace pump Ass'y.

Faulty pump.

Nothing changed

Change over the relief valves right to left and test travelling.

Problem changed to opposite direction

Faulty relief valve.

Nothing changed

Change over the hoses from swivel joint to drive motor L/H to R/H, then test travelling.

Low pressure

Contamination Problem changed to opposite direction

Internal leak on swivel joint.

Adjust to correct pressure or replace relief valve.

Disassemble, clean or replace.

Replace seals or Ass'y.

Nothing changed

Faulty drive motor.

Check the counter balance valve.

Faulty

Check plunger, repair or replace Ass'y.

OK

Internal wear or breakage.

19-4

Repair or replace.

19-2-3 Machine fails to hold on incline If you can see any movement (outside tolerance).

Problem

Replace counter balance solved valve (brake valve).

Nothing changed Problem solved

Replace drive motor.

Faulty counter balance valve.

Replace counter balance valve.

Faulty drive motor.

Replace drive motor Ass'y.

19-5

19-3 Slewing system 19-3-1 No operation both (right/left) slewing.

Check the function of slewing operation system (dozer, swing).

Faulty

Change over relief valves to the other pump port, then test.

OK

Low pressure

Adjust to correct pressure or replace.

Faulty relief valve.

Relief valve is sticking

Disassemble, clean or replace.

Faulty OK

Change over outlet hoses to pump No.1's or No.2's, then test.

OK

Faulty

Faulty pump.

Replace seals or pump Ass'y.

Faulty control valve.

Replace valve or Ass'y.

Not relieving

Spool is sticking.

Replace seals or valve block.

Faulty turning relief valve.

Disassemble, clean or replace.

Is turning motor relieving or not?

It is relieving

Test turning when push bucket by hand.

No resistance

It has resistance

Take the turning motor off.

Check the pinion gear on turning motor and (also) bearing gear.

OK

Check turning when push bucket by hand.

Gear is damaged

Replace pinion gear or turning bearing.

Not turning

Seized turning bearing, etc.

It can be turned

Replace turning bearing.

Disassemble, repair or replace turning motor Ass'y.

Faulty turning motor.

19-6

19-3-2 It is possible to turn right (left) but not left (right)

Lever moved to left (right).

Not relieving

Change over control valve pilot port A⇔B, then test.

OK

Problem changed to opposite direction

Check the relief valve on turning, relieving or not.

Faulty control valve block.

Replace inner parts or valve block.

Faulty joystick.

Repair or replace joystick Ass'y.

Faulty relief valve.

Clean or replace.

It is relieving

19-3-3 Turning acceleration slow, the overturn is higher than tolerance Yes

Is the distance under tolerance?

OK

Above tolerance Low pressure

Check the turning circuit pressure.

Faulty relief valve.

Clean or replace.

OK

Replace turning motor Ass'y.

Internal leak on turning motor.

19-7

19-3-4 Extreme slow turning speed Does the turning speed meet the specified speed?

Yes

OK

Slow

Check the action of the turning operation system (dozer, swing).

OK

Check the turning circuit pressure.

OK

Faulty

Change over relief valves to the other pump port or replace, then test.

Low pressure

OK

Faulty relief valve.

Faulty relief valve.

Clean or replace.

Low pressure Adjust to correct

pressure or replace.

Relief valve is sticking

Disassemble, clean or replace.

Faulty

Change over outlet hoses to pump No.1's or No.2's, then test.

Internal leak on turning motor.

Faulty

Faulty control valve.

Replace valve or Ass'y.

19-3-5 Turning movement when the machine is parked on a slope Yes

Is the distance lower than tolerance?

OK

No

Check the turning pressure.

Low pressure

Faulty relief valve.

Clean or replace.

OK

Internal leak on turning motor.

Replace motor Ass'y.

19-8

19-4 Boom system(for arm and bucket cylinders the same method as follows) 19-4-1 No movement on boom cylinder Does

Check the movement move Change over boom section of boom for both port A⇔port B directions.

OK Does not move Faulty

Faulty port relief valve.

Disassemble, replace seals or replace.

Faulty joystick.

Replace inner parts or Ass'y.

Check the function of Faulty Change over relief valve boom operation to the other pump's port system (bucket, right or replace, then test.

Low hand travelling).

OK

pressure

Faulty relief valve.

Adjust to correct pressure or replace relief valve.

Relief valve is sticking

Disassmble, clean or replace.

Faulty

Change over outlet hoses from the other pump, then test.

OK

OK

Faulty pump.

Disassemble, replace seals, or replace relief valve.

Faulty control valve.

Replace valve block Ass'y.

Faulty

Check the inner parts of control valve.

Faulty

OK

Breakage on inside of cylinder.

OK

Replace inner parts or cylinder Ass'y.

19-9

If it is a sticking spool, then clean or replace. If spring is weak, then replace.

19-4-2 Slow action or lack of power on boom cylinder Correct

Check the cylinder working speed.

OK

Slow

Are the directions slow (lack of power)?

No

Change over relief valve port A⇔port B OK

OK Faulty

Check the action on boom operation system (bucket, right hand travelling).

Faulty

Faulty relief valve.

Adjust to correct pressure or replace relief valve.

Faulty joystick.

Replace inner parts or Ass'y.

Change over relief valve to the other pump port or replace, then test.

OK

Low pressure

Faulty relief valve.

Relief valve is sticking

Adjust to correct pressure or replace relief valve.

Disassemble, clean or replace.

Faulty

Change over outlet hoses from the other pump, then test.

OK

Disassemble, replace seals, or replace pump Ass'y.

OK

Faulty pump.

Faulty

Check the inner parts of control valve.

Faulty control valve.

Faulty

OK

Breakage on inside of cylinder.

OK

Replace inner parts or cylinder Ass'y.

19-10

Replace valve block Ass'y.

If it is sticking spool, then clean or replace. If spring is weak, then replace.

19-4-3 Natural fall of boom Check the fall is within tolerance.

Yes

OK

No

Change over relief valve boom cyl.⇔bucket, then check.

Faulty

Internal leak on boom cylinder.

Replace inner parts or cylinder Ass'y.

Internal leak on control valve (spool).

Replace valve block Ass'y.

OK

Check the internal leak on control valve.

Change over hoses Faulty boom section A⇔ boom section B. OK

Disassemble, clean or replace.

Faulty port relief valve.

19-11

19-5 Swing system 19-5-1 No movement on swing system Operation on just one direction.

Yes

Faulty suction valve.

Clean or replace.

No

Check the function of swing operation system (dozer, slewing).

Faulty

Replace or change over the relief valve with the other pump's port and then test.

Change over the outlet hoses No.2, 3 pumps and then test.

OK

Faulty

OK

Faulty control valve.

Replace valve block Ass'y or control valve Ass'y.

Faulty pump.

Replace pump Ass'y or disassemble and replace seals.

Low pressure

Faulty relief valve.

Contamination Faulty

Check the spool stroke.

Adjust to correct pressure or replace relief valve.

Disassemble, clean or replace.

Check the link system.

Faulty linkage.

Adjustment or replace.

Faulty action on spool.

Replace block Ass'y or seals.

Faulty

OK

Broken parts inside the swing cylinder.

Replace inner parts or cylinder Ass'y.

19-5-2 Drifting swing cylinder Air leaking out of swing cylinder. Check internal leak on control valve.

Change over hoses, then test.

If OK

Not working properly

Internal leak on control valve.

Replace block Ass'y or Ass'y. Otherwise clean or replace the suction valve.

Internal leak on swing cylinder.

Replace inner parts or Ass'y.

19-12