Hyundai R55-3 Crawler Excavator Repair Manual 2023 - PDF DOWNLOAD

SECTION 1 GENERAL Group 1 Safety Hints Group 2 Specifications

1-1 1-9

SECTION 1 GENERAL GROUP 1 SAFETY HINTS FOLLOW SAFE PROCEDURE Unsafe work practices are dangerous.

Understand service procedure before doing work; do not attempt shortcuts.

WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job.

13031GE01

WARN OTHERS OF SERVICE WORK Unexpected machine movement can cause serious injury.

Before performing any work on the excavator, attach a「Do Not Operate」tag on the right side control lever.

WARN DO NOT OPERATE

13031GE02

USE HANDHOLDS AND STEPS Falling is one of the major causes of personal injury.

When you get on and off the machine, always maintain a three point contact with the steps and handrails and face the machine. Do not use any controls as handholds.

Never jump on or off the machine. Never mount or dismount a moving machine.

Be careful of slippery conditions on platforms, steps, and handrails when leaving the machine.

13031GE03

1-1

PREPARE FOR EMERGENCIES Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

13031GE04

PROTECT AGAINST FLYING DEBRIS Guard against injury from flying pieces of metal or debris; Wear goggles or safety glasses.

13031GE05

PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.

Wear a suitable hearing protective device such as ear-muffs or earplugs to protect against objectionable or uncomfortable loud noises.

13031GE06

AVOID POWER LINES Serious injury or death can result from contact with electric lines.

Never move any part of the machine or load closer to electric line than 3m(10ft) plus twice the line insulator length.

13031GE07

1-2

KEEP RIDERS OFF EXCAVATOR Only allow the operator on the excavator. Keep riders off.

Riders on excavator are subject to injury such as being struck by foreign objects and being thrown off the excavator. Riders also obstruct the operator's view resulting in the excavator being operated in an unsafe manner.

13031GE08

MOVE AND OPERATE MACHINE SAFELY Bystanders can be run over. Know the location of bystanders before moving, swinging, or operating the machine.

Always keep the travel alarm in working condition. It warns people when the excavator starts to move.

Use a signal person when moving, swinging, or operating the machine in congested areas.

Coordinate hand signals before starting the excavator.

13031GE09

OPERATE ONLY FORM OPERATOR'S SEAT Avoid possible injury machine damage. Do not start engine by shorting across starter terminals.

NEVER start engine while standing on ground.

Start engine only from operator's seat.

13031GE26

PARK MACHINE SAFELY Before working on the machine: ·Park machine on a level surface. ·Lower bucket to the ground. ·Turn auto idle switch off. ·Run engine at 1/2 speed without load for 2 minutes. ·Turn key switch to OFF to stop engine. Remove key from switch.

·Move pilot control shutoff lever to locked position. ·Allow engine to cool.

1-3

SUPPORT MACHINE PROPERLY Always lower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment.

Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load.

Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.

13031GE10

SERVICE COOLING SYSTEM SAFELY Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands.

13031GE11

HANDLE FLUIDS SAFELY-AVOID FIRES Handle fuel with care; It is highly flammable.

Do not refuel the machine while smoking or when near open flame or sparks. Always stop engine before refueling machine.

Fill fuel tank outdoors.

13031GE12

Store flammable fluids away from fire hazards.

Do not incinerate or puncture pressurized containers.

Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; They can ignite and burn spontaneously.

13031GE13

1-4

BEWARE OF EXHAUST FUMES Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

If you must operate in a building, be positive there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring enough outside air into the area.

REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do all work outside or in a well ventilated area.

Dispose of paint and solvent properly.

Remove paint before welding or heating: ·If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. ·If you use solvent or paint stripper, remove stripper with soap and water before welding.

Remove solvent or paint stripper containers and other flammable material from area.

Allow fumes to disperse at least 15 minutes before welding or heating.

13031GE14

ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely.

Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.

13031GE15

1-5

SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing or necklace when you work near machine tools or moving parts.

If these items were to get caught, severe injury could result.

Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.

13031GE16

STAY CLEAR OF MOVING PARTS Entanglements in moving parts can cause serious injury.

To prevent accidents, use care when working around rotating parts.

13031GE17

AVOID HIGH PRESSURE FLUIDS Escaping fluid under pressure can penetrate the skin causing serious injury.

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Search for leaks with a piece of cardboard.

Protect hands and body from high pressure fluids.

13031GE18

If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

13031GE19

1-6

AVOID HEATING NEAR PRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.

Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area.

Install fire resisting guards to protect hoses or other materials.

13031GE20

PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and flame away from the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.

Do not charge a frozen battery; It may explode.

Warm battery to 16° C(60° F).

13031GE21

PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous.

It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid the hazard by: 1. Filling batteries in a well-ventilated area.

2. Wearing eye protection and rubber gloves.

3. Avoiding breathing fumes when electrolyte is added.

4. Avoiding spilling of dripping electrolyte.

5. Use proper jump start procedure.

If you spill acid on yourself: 1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.

3. Flush your eyes with water for 10-15 minutes.

Get medical attention immediately.

If acid is swallowed: 1. Drink large amounts of water or milk.

2. Then drink milk of magnesia, beaten eggs, or vegetable oil.

3. Get medical attention immediately.

13031GE22

1-7

USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures can create safety hazards.

Use power tools only to loosen threaded tools and fasteners.

For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.

Use only recommended replacement parts.(See Parts catalogue.)

13031GE23

DISPOSE OF FLUIDS PROPERLY Improperly disposing of fluids can harm the environment and ecology. Before draining any fluids, find out the proper way to dispose of waste from your local environmental agency.

Use proper containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them.

DO NOT pour oil into the ground, down a drain, or into a stream, pond, or lake. Observe relevant environmental protection regulations when disposing of oil, fuel, coolant, brake fluid, filters, batteries, and other harmful waste.

13031GE24

REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator's manual for correct safety sign placement.

13031GE25

LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

1-8

GROUP 2 SPECIFICATIONS 1. MAJOR COMPONENT

Swing cylinder Battery box

Hydraulic tank Oil cooler Engine Fuel tank

Swing post

Main pump Tooth

Arm

Bucket

Arm cylinder

Dozer blade

Turning joint

Boom Boom cylinder

Swing motor Main control valve

Cab

Pre-cleaner Muffler

Dozer cylinder Side cutter

Connecting rod

Bucket cylinder Connecting link

Counterweight Idler

Carrier roller

Track roller

Travel motor Sprocket

R55NM2SP08

1-9

2. SPECIFICATIONS 2.9m(9' 6") ONE PIECE BOOM AND 1.6m(5' 3") ARM

555M2SP02

Description

Unit

Specification

Operating weight

kg(lb)

5400(11905)

Bucket capacity(PCSA heaped), standard

m (yd³)

0.18(0.24)

3

Overall length

A

6000(19' 8")

Overall width, with 400mm shoe

B

1865( 6' 1")

Overall height

C

2550( 8' 4")

Superstructure width

D

1760( 5' 9")

Ground clearance of counterweight

E

695( 2' 3")

Engine cover height

F

1595( 5' 3")

Minimum ground clearance

G

Rear-end distance

H

1760( 5' 9")

Rear-end swing radius

H'

1770( 5' 10")

Distance between tumblers

I

1990( 6' 6")

Undercarriage length

J

2525( 8' 3")

Undercarriage width

K

1845( 6' 1")

Track gauge

L

1445( 4' 9")

Track shoe width, standard

M

400(16")

mm(ft-in)

325( 1' 1")

km/hr(mph)

2.2/4.0(1.4/2.5)

Swing speed

rpm

10.0

Gradeability

Degree(%)

35(70)

Ground pressure(400mm shoe)

kgf/cm (psi)

0.31(4.41)

Travel speed(Low/high)

2

1-10

3. WORKING RANGE 2.9m(9' 6") ONE PIECE BOOM

R55NM2SP01

1.6m(5' 3") Arm

Description Max digging reach

A

6045mm (19' 10")

Max digging reach on ground

A'

5890mm (19' 4")

Max digging depth

B

3780mm (12' 5")

Max vertical wall digging depth

C

2845mm ( 9' 4")

Max digging height

D

5525mm (18' 2")

Max dumping height Min swing radius

E

3905mm (12' 10")

Front

F

2450mm ( 8' 1")

80 Boom swing

F'

2000mm ( 6' 7") 80 50

Boom offset angle (LH/RH)

32 kN SAE

3273 kgf 7216 lbf

Bucket digging force

35 kN ISO

3573 kgf 7877 lbf 22 kN

SAE

2236 kgf 4930 lbf

Arm crowd force

22.2 kN ISO

2268 kgf 5000 lbf

1-11

4. WEIGHT R55-3

Item

kg

lb

Upperstructure assembly

2475

5460

Main frame weld assembly

650

1430

Engine assembly

250

551

Main pump assembly

34

75

Main control valve assembly

26

57

Swing motor assembly

48

106

Hydraulic oil tank assembly

104

229

Fuel tank assembly

52

115

Counterweight

221

490

Cab assembly

190

420

Lower chassis assembly

2305

5080

Lower frame weld assembly

733

1620

Swing bearing

88

190

Travel motor assembly

90

198

Turning joint

27

60

Track recoil spring and idler

63

139

Idler

46

101

Carrier roller

11

25

Track roller

11

25

Track-chain assembly(400mm tniple grouser shos)

280

617

Front attachment assembly(2.9m boom, 1.6m arm, 0.18m3 PCSA heaped bucket)

655

1440

2.9m one piece boom assembly

205

450

Dozer blade assembly

212

470

1.6m arm assembly

95

209

0.18m3 PCSA heaped bucket assembly

137

300

Boom cylinder assembly

53

117

Arm cylinder assembly

45

99

Bucket cylinder assembly

31

68

Bucket control link assembly

37

82

Dozer blade cylinder assembly

52

114

1-12

5. LIFTING CAPACITIES ROBEX 55-3 2.9m(9' 6") boom, 1.6m(5' 3") arm equipped with 0.18m3(PCSA heaped) bucket, 400m (16") triple grouser shoe and dozer blade with 221kg(490lb) counterweight.

1) Dozer blade down with 221kg CWT

·

·

: Rating over-front

: Rating over-side or 360 degree

Load radius Load point height 5.0m kg (16.0ft) lb 4.0m kg (13.0ft) lb 3.0m kg (10.0ft) lb 2.0m kg (7.0ft) lb 1.0m kg (3.0ft) lb Ground kg lb Line -1.0m kg (-3.0ft) lb -2.0m kg (-7.0ft) lb

2.0m(7.0ft)

3.0m(10.0ft)

At max. reach

4.0m(13.0ft)

5.0m(16.0ft)

Capacity

Reach m(ft)

*2160 *4760

*2160 *4760

*2030 *4480 *3010 *6640 *2490 *5490

*2030 *4480 2840 6260 *2490 *5490

*1160 *2560 *1640 *3620 *1870 *4120 *1820 *4010 *1500 *3310

*1160 *2560 1520 3350 1460 3220 1450 3200 1470 3240

*720 *1590 *750 *1650 *900 *1980 *1090 *2400 *1220 *2690 *1200 *2650

*720 *1590 *750 *1650 *900 *1980 990 2180 960 2120 950 2090

*800 *1760 *870 *1920

730 1610 710 1570

*660 *1460 *670 *1480 *690 *1520 *710 *1570 *740 *1630 *770 *1700 *780 *1720

*660 *1460 *670 *1480 640 1410 580 1280 570 1260 600 1320 700 1540

4.05 (13.3) 5.04 (16.5) 5.56 (18.2) 5.80 (19.0) 5.81 (19.1) 5.58 (18.3) 5.06 (16.6)

2) Dozer blade up with 221kg CWT Load radius Load point height 5.0m kg (16.0ft) lb 4.0m kg (13.0ft) lb 3.0m kg (10.0ft) lb 2.0m kg (7.0ft) lb 1.0m kg (3.0ft) lb Ground kg Line lb -1.0m kg (-3.0ft) lb -2.0m kg (-7.0ft) lb

Note

2.0m(7.0ft)

3.0m(10.0ft)

At max. reach

4.0m(13.0ft)

5.0m(16.0ft)

Capacity

Reach m(ft)

*2160 *4760

*2160 *4760

*2030 *4480 *3010 *6640 *2490 *5490

*2030 *4480 2600 5730 *2490 *5490

*1160 *2560 *1640 *3620 *1870 *4120 *1820 *4010 *1500 *3310

*1160 *2560 1410 3110 1360 3000 1350 2980 1360 3000

*720 *1590 *750 *1650 *900 *1980 *1090 *2400 *1220 *2690 *1200 *2650

*720 *1590 *750 *1650 *900 *1980 920 2030 890 1960 880 1940

*800 *1760 *870 *1920

680 1500 660 1460

*660 *1460 *670 *1480 *690 *1520 *710 *1570 *740 *1630 *770 *1700 *780 *1720

*660 *1460 *670 *1480 590 1300 540 1190 530 1170 560 1230 650 1430

4.05 (13.3) 5.04 (16.5) 5.56 (18.2) 5.80 (19.0) 5.81 (19.1) 5.58 (18.3) 5.06 (16.6)

1. Lifting capacity are based on SAE J1097 and ISO 10567.

2. Lifting capacity of the ROBEX series does not exceed 75% of tipping load with the machine on firm, level ground or 87% of full hydraulic capacity.

3. The load point is a hook located on the back of the bucket.

4. *indicates load limited by hydraulic capacity.

1-13

6. BUCKET SELECTION GUIDE

0.06m3 PCSA heaped bucket

0.18m3 PCSA heaped bucket

Capacity

2.9m (9’ 6”) boom

Width

PCSA heaped

CECE heaped

Without side cutter

With side cutter

Weight

0.06m3 (0.08yd3)

0.05m3 (0.07yd3)

315mm (12.4”)

360mm (14.2”)

84kg (185lb)

●

* 0.18m3 (0.24yd3)

* 0.15m3 (0.20yd3)

705mm (27.8”)

770mm (30.3”)

137kg (300lb)

■

* : Standard backhoe bucket ● Applicable for materials with density 2000 kg/m3 (3370 lb/yd3) or less ■ Applicable for materials with density 1600 kg/m3 (2700 lb/yd3) or less

1-14

1.6m (5’ 3”) arm

7. UNDER CARRIAGE 1) TRACKS X-leg type center frame is integrally welded with reinforced box-section track frames. The design includes dry tracks, lubricated rollers, idlers, sprockets, hydraulic track adjusters with shock absorbing springs and assembled track-type tractor shoes with triple grousers.

2) TYPES OF SHOES Triple grouser

Rubber

Shapes

Shoe width

mm (in)

400 (16”)

400 (16”)

Operating weight

kg (lb)

5455 (12030)

5420 (11948)

Ground pressure

kg / cm (psi)

0.31 (4.41)

0.30 (4.26)

Overall width

mm (ft-in)

1845 (6’ 1”)

1845 (6’ 1”)

2

3) NUMBER OF ROLLERS AND SHOES ON EACH SIDE Quantity

Item Carrier rollers

1 EA

Track rollers

5 EA

Track shoes (Steel)

40 EA

1-15

8. SPECIFICATIONS FOR MAJOR COMPONENTS 1) ENGINE Item

Specification

Model

Yanmar 4TNE94

Type

4-cycle

Cooling method

Water cooling

Number of cylinders and arrangement

4 cylinders in line

Firing order

1-3-4-2

Combustion chamber type

Direct injection type

Cylinder bore×stroke

94×100mm(3.70"×3.94")

Piston displacement

2776cc(169.5cu in)

Compression ratio

18 : 1

Rated gross horse power(SAE J134P)

58.5Ps at 2500rpm(43kW at 2500rpm)

Maximum torque at 1600rpm

19.4kgf·m(140lbf·ft)

Engine oil quantity

9.7ℓ(2.6U.S. gal)

Dry weight

250kg(551lb)

High idling speed

2600±50rpm

Low idling speed

1150±50rpm

Rated fuel consumption

167g/Hp·hr

Starting motor

S13-204(12V)

Alternator

LR140-714(12V-40AMP)

Battery

1×12V×100Ah

2) MAIN PUMP Item

Specification

Type

Variable displacement piston pumps

Capacity

2×21cc/rev

Rated pressure

210kgf/cm2 (2987psi)

Rated oil flow

2×52.25ℓ/min (13.8U.S. gpm/ 11.5U.K. gpm)

Rated speed

2500rpm (Clockwise viewed from shaft end)

1-16

3) GEAR PUMP Item

Specification

Type

Fixed displacement gear pump

Capacity

16.2/4.5cc/rev

Maximum pressure

21./30kgf/cm2(2987/427psi)

Rated oil flow

40/11.3ℓ/min(10.6/3.0 U.S.gpm, 8.8/2.5U.K. gpm)

4) MAIN CONTROL VALVE Item

Specification

Type

9 spool

Operating method

Hydraulic pilot system/Manual

Main relief valve pressure

210kgf/cm2(2987psi)

Overload relief valve pressure

230kgf/cm2(3271psi)

5) SWING MOTOR Item

Specification

Type

Two fixed displacement axial piston motor

Capacity

39.1cc/rev

Relief pressure

180kgf/cm2(2560psi)

Braking system

Automatic, spring applied hydraulic released

Braking torque

11.5kgf·m(83lbf·ft)

Brake release pressure

25~50kgf/cm2(356~710psi)

Reduction gear type

2 - stage planetary

Swing speed

10rpm

6) TRAVEL MOTOR Item

Specification

Type

Variable displacement axial piston motor

Relief pressure

210kgf/cm2(2987psi)

Reduction gear type

2-stage planetary

Braking system

Automatic, spring applied hydraulic released

Brake release pressure

4.6kgf/cm2(65psi)

Braking torque

8.4kgf·m(61lbf·ft)

1-17

7) REMOTE CONTROL VALVE Item

Specification

Type

Pressure reducing type

Operating pressure Single operation spool stroke

Minimum

5kgf/cm2(71psi)

Maximum

20kgf/cm2(284psi)

Lever

6.5/8.5mm(0.26/0.33in)

8) CYLINDER Specification

Item Boom cylinder

Arm cylinder

Bucket cylinder

Bore dia×Rod dia×Stroke

Ø100×Ø55×636mm

Cushion

Extend only

Bore dia×Rod dia×Stroke

Ø85×Ø50×760mm

Cushion

Retract only

Bore dia×Rod dia×Stroke

Ø80×Ø50×580mm

Cushion

-

9) SHOE Item Standard

Width

Ground pressure

Link quantity

Overall width

400mm(16")

0.31kgf/cm2(4.41psi)

40

2525mm( 8' 3")

10) BUCKET Item

Capacity

Width Tooth quantity Without side cutter With side cutter

PCSA heaped

CECE heaped

Standard

0.18m3(0.24yd3)

0.15m3(0.20yd3)

5

705mm(27.8")

770mm(30.3")

Option

0.06m (0.08yd )

0.05m (0.07yd )

3

315mm(12.4")

360mm(14.2")

3

3

3

3

1-18

9. RECOMMENDED OILS Use only oils listed below or equivalent.

Do not mix different brand oil.

Service point

Kind of fluid

Ambient temperature ° C (° F)

Capacity ℓ(U.S. gal)

-20 (-4)

-10 (14)

0 (32)

10 (50)

20 (68)

30 (86)

SAE 30 Engine oil pan

Engine oil

SAE 10W

9.7(2.6)

SAE 10W-30 SAE 15W-40

0.6(0.16)

Swing drive Gear oil Final drive

SAE 85W-140

1.7×2 (0.45×2)

ISO VG 32 Hydraulic tank

Hydraulic oil

Tank; 80(21)

ISO VG 46 ISO VG 68

ASTM D975 NO.1 Fuel tank

Diesel fuel

125(33.0) ASTM D975 NO.2

Fitting (Grease nipple)

Grease

Radiator (Reservoir tank)

Mixture of antifreeze and water 50 : 50

NLGI NO.1

As required

NLGI NO.2

Ethylene glycol base permanent type

8(2.1)

SAE : Society of Automotive Engineers API : American Petroleum Institute ISO : International Organization for Standardization NLGI : National Lubricating Grease Institute ASTM : American Society of Testing and Material

1-19

40 (104)

SECTION 2 STRUCTURE AND FUNCTION GROUP 1 HYDRAULIC CIRCUIT DIAGRAM · Machine serial No : up to #374, except #294, 315 and 355 ~ 362.

R55NM2SF11A

2-1

· Machine serial No : #375 and up to #0616, include #294, #315 and 355~362.

R55NM2SF12

2-2

1 2 3 4 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 26 29 30

Main pump Main control valve RCV lever(LH) RCV lever(RH) Travel motor Swing motor Shuttle valve Turning joint Check valve Check valve Check valve Dozer cylinder Arm cylinder Boom cylinder Bucket cylinder Hyd oil cooler Return element Suction strainer Air breather Last guard filter Filter-line Boom swing cylinder Accumulator Solenoid valve Stop valve

· Machine serial No : #0617 and up

R55NM2SF13

2-3

1 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 28 29 30

Main pump Main control valve RCV lever(LH) RCV lever(RH) RCV dozer3 Travel motor Swing motor Shuttle valve Turning joint Check valve Check valve Check valve Dozer cylinder Arm cylinder Boom cylinder Bucket cylinder Hyd oil cooler Return element Suction strainer Air breather Last guard filter Line filter Boom swing cylinder Aux. control valve Accumulator Pressure switch Solenoid valve Stop valve

GROUP 2 HYDRAULIC PUMP 1. GENERAL This is a variable displacement double-piston pump for discharge with equal displacements from one cylinder block. This pump is so compact as to appear a single pump though this is actually a double pump.

Because this pump has one swash plate, the tilting angle is the same for two pumps. Tilting of the pump changes in response to the total pressure of P1 + P2. Namely, the output is controlled to the constant value so that the relationship between the discharge pressure and flow rate Q becomes constant, (P1 + P2) * Q =Constant.

The third pump and pilot pump can be connected to the same shaft via a coupling.

R55NM2SF35

Description of the ports Port

Name

Bore

S1

Suction port

SAE 1 1/2 (Standard)

A1, A2

Discharge port

G1/2 (JIS B 2351 Type O)

A3

Discharge port

G1/2 (JIS B 2351 Type O)

A4

Discharge port

G1/4 (JIS B 2351 Type O)

A1G, A2G

Gauge port

G1/4 (JIS B 2351 Type O) Normally plugged

A3G

Gauge port

G1/2 (JIS B 2351 Type O) Normally plugged

P4G

Gauge port

G1/2 (JIS B 2351 Type O) Normally plugged

R1

Air bleeder port

With bleeder valve

2-4

2. PRINCIPAL COMPONENTS AND FUNCTIONS

R55NM2SF32

1 2 3 4

5 6 7 8

Drive shaft Hanger Rotary group Cover

Control spring Control piston Gear pump Housing

SPECIFICATIONS ● Capacity : 2×21+16+4.5 cc/rev ● Rated oil flow : 2×52.25+40+11.3 ℓ /min ● Rated pressure : 3×210+30 kg/cm2

This is a variable displacement double-piston pump for discharge with two equal displacements from one cylinder block. Because this is one rotary group, there is only one suction port.

The oil is divided into two equal flows by the control plate in the cover and directed to two discharge ports provided in the cover.

The discharge pressure directed to the control piston tilts the hanger by overcoming the spring force.

Since the piston stroke changes according to the tilting angle of the hanger, the flow can be changed.

The simultaneous tilting angle constant-output control method is employed.

The third pump and pilot pump can be connected to the same shaft via a coupling.

2-5

1) PRINCIPLE OF OPERATION (1) Function of pump

R55NM2SF31

The cylinder block is connected via spline and can rotate together with the drive shaft.

The piston assembled into the cylinder block performs reciprocal operation while following the swash plate on the hanger.

The piston moves in a direction to increase the displacement during a stroke from the lower to the upper dead points. The oil flows from the suction port via apart plate into the cylinder block(suction process).

During a stroke from the upper to the lower dead points, the piston moves in a direction to decrease the displacement. The oil is discharged to the discharge port(discharge process).

The displacement can be changed by changing the tilting of the hanger(swash plate).

The oil sucked through the port in the cylinder block is discharged from the discharge port in the port plate.

The oil sucked through the port on the outside of the cylinder block is discharged from the discharge port on the outside of the port plate.

2-6

2) CONTROL FUNCTIONS

R55NM2SF33

The discharge pressures P1 and P2 are directed to the pistons of equal area act on the hanger.

The spring is provided to act against the discharge pressure. When the oil pressure acting on the piston is less than the installation load of the spring A (outer spring), the hanger is fixed to the maximum tilting position. When the oil, pressure acting on the piston exceeds the installation load of the spring A the hanger is tilted and kept tilted at a position where the oil pressure is balanced with the spring force. (Region A in the middle of the figure above) When the oil pressure acting on the piston rises further to reduce the tilting angle, the spring B which has been inactive up to now becomes active.

To overcome the spring force of two springs, the oil pressure must be higher and the shifting line becomes more steep. (Regions A + B in the middle of the figure above) When the P3 oil pressure acts on the shift piston, the control shifting line is shifted.

2-7

3) CONTROL / ADJUSTMENT PROCEDURE (1) Loosen the hexagonal nut.

(2) Tighten or loosen the adjusting screw to set the power shifting line.

R55NM2SF34

2-8

3. ADJUSTMENT This hydraulic pump has been set and inspected according to your specified input power and control.

Readjustment of all the adjusting portions may lead to the loss of functions specified for each control and the pump proper may be excluded from the scope of guarantee. Never attempt operating the adjusting screw, etc.

4. INSTALLATION (1) Install the pump so that the input shaft becomes horizontal.

(2) Install the pump in a position lower than the lowest oil level in the tank to allow continuous flow of the oil into the pump.

(3) Since the pump is installed directly to the diesel engine, always use a flexible hose. Install the suction pipe firmly to prevent suction of an air.

(4) Use the high-pressure type flexible hoses for the discharge ports P1 and P2.

(5) After installation, fill the pump housing with the hydraulic oil.

(6) Do not direct the external drain piping from within the oil.

5. DRIVE (1) Use a flexible coupling for connection to the motor.

(2) Insert the coupling firmly onto the input shaft. Do not hammer the coupling during insertion.

(3) The input shaft must rotate clockwise when viewed from the shaft end.

6. HYDRAULIC OIL The hydraulic oil to be used must be a general petroleum, hydraulic oil or wear-resistant hydraulic oil (ISO 3448, VG 32 ~ 56 or equivalent).

The applicable viscosity range is as follows : Maximum allowable viscosity : 1000 mm2/s Minimum allowable viscosity : 10 mm2/s Recommended viscosity range : 15 ~ 150 mm2/s

7. STARTING PROCEDURE ※ Before start up, check the following points and observe the cautions : (1) Check if the tank has been washed clean.

(2) Check if the piping is clean and installed in such a manner as to prevent stress on the pump.

(3) Check if the piping is connected correctly according to the piping (circuit) diagram.

(4) Check if the joint and flange are correctly tightened.

(5) Check if the joint between the motor and pump is correctly installed.

(6) Check if the motor rotation direction agrees with the pump rotation direction.

(7) Check if the specific hydraulic oil is supplied though the filter and filled in the tank to the specified position of the oil level gallge.

(8) Check if the filter has the specified filtration accuracy (10 ㎛ or less).

(9) Check if the filter has been installed correctly relative to the flowt direction.

(10) Check if the pump housing is filled with oil.

(11) Check if the control valve is set to the bypass position.

(12) Start the motor. If necessary, carry out warm-up operation at low speed.

(13) Check, without any load on the system, if the actuator operates correctly.

2-9

(14) When the motor has reached the operation speed, check the operation while applying the load to the actuator.

(15) Check the monitoring or measuring instrument if installed.

(16) Check the noise level.

(17) Check the oil level in the tank. Supply the oil. If required.

(18) Check the setting of the pressure control valve while applying the load to the actuator.

(19) Check the parts for any leakage.

(20) Stop the motor.

(21) Retighten all the bolts and plugs even when they have proved to by free from Leakage.

(Be sure to remove the pressure from the circuit before retightening.)

(22) Check the oil level in the tank.

(23) Check if the pump and actuator function correctly.

(24) Irregular operation of the actuator indicates that an air is left still in the circuit. When the air is bleeded completely from the circuit, all the parts operates smoothly without any irregular movement and there is no bubble in the oil of the tank.

(25) Check the oil temperature.

(26) Stop the motor.

(27) Check the filter if the element is fouled.

(28) If the element is heavily fouled, carry out flashing in the circuit. ※ To prevent damage to the pump, be sure to observe the following cautions during the operation which may allow entry of the actuator, hydraulic oil change, etc : (1) After oil supply, fill the pump housing with the hydraulic oil.

(2) Start the pump with the speed of 1000 rpm or less and take care not to allow the oil level to lower below the specified level of the oil level gauge.

(3) When bleeding an air from the hydraulic circuit, keep the motor speed at 1000 rpm or less.

Operate each actuator for three or more cycles and carry out idling for 5 minutes or more.

8. MAINTENANCE The maintenance of this hydraulic pump is limited mainly to the tank, in particular, the hydraulic oil change.

Since the maintenance interval varies depending on respective operation and use conditions, the cautions described below for the users should be for reference only.

(1) Checking the filter ① Every day for the initial period after start up. ② Once a week when the operation becomes stable. ③ Once a month when the operation hours exceed about 100 hours. ※ When any part of the hydraulic system is changed (e.g., assembling of an additional part, change and repair of the piping), check the filter newly as in the case of startup.

(2) Changing the filter ① After startup ② After 500 hours of operation ③ Every 500 hours of operation after that, and each time the hydraulic oil is changed or the failure occurs. If any abnormal fouling of the filter is observed during daily check up to the first filter change after startup, find out the cause.

In this case, do not extend the check and filter change intervals to 500 hours. ※ The paper filter can not be cleaned. Change the filter as a whole.

2-10

(3) Changing the hydraulic oil ① After 2000 hours of operation. ② Every 2000 hours of operation or once a year after that.

The change interval may have to be shortened depending on the degree of fouling and the thermal load condition of the hydraulic oil.

If the hydraulic oil is not appropriate and need be changed, pay attention to the following points : • Be sure to control the oil temperature below the highest temperature and above the lowest temperature during operation in winter and summer.

• Pay attention to the following points during change of the hydraulic oil : - Change the hydraulic oil as a whole quantity.

- Do not allow dust to mix into the circuit.

- Clean the tank inside.

- Supply the oil through the filter.

(4) Checking for the oil leakage ① Daily during the initial period after startup. ② Once a week when the operation becomes stable.

(5) Checking the temperature ① Monitor the temperature continuously. ② When the viscosity is above the allowable value because of low hydraulic oil temperature, warm-up operation is necessary.

Start the motor with the speed set to about one half of the rated speed, then operate the actuator under the load for a short period.

When the oil temperature is below the allowable ambient temperature, it is necessary to preheat the oil tank before start of the motor.

Take care not to allow the hydraulic oil temperature to exceed +90 C

2-11

GROUP 3 MAIN CONTROL VALVE A. MAIN CONTROL VALVE (SC 3A, UP TO #0616) 1. DOZER MANUAL OPERATED TYPE (UP TO #0580)

R55NM2SF15

SPECIFICATIONS Type : 9 spool Main relief pressure : 210 kg/cm2 Overload relief pressure : 230 kg/cm2 1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23

Inlet body Work body assembly (Bucket) Work body assembly (Boom 1) Work body assembly (TR, R) Inlet body Work body assembly (Dozer) Work body assembly (Swivel) Work body assembly (Swing) Outlet body Work body assembly (Arm) Inlet body assembly Work body assembly (TR, L) 2-12

Work body assembly (Boom 2) Inlet body O-ring 1B G55 (Section) Relief valve assembly Bolt, L=313 Bolt, L=205 Nut, M8 Over load relief valve assembly Anti-cavitation valve assembly Plug PF 1/4 O-ring 1B P11

2. DOZER PILOT OPERATED TYPE (#0581 TO #0616)

R55NM2SF16

SPECIFICATIONS Type : 9 spool Main relief pressure : 210 kg/cm2 Overload relief pressure : 230 kg/cm2 1 2 3 4 5 6 7 8 9 10 11 12

13 14 15 16 17 18 19 20 21 22 23

Inlet body Work body assembly (Bucket) Work body assembly (Boom 1) Work body assembly (TR, R) Inlet body Work body assembly (Dozer) Work body assembly (Swivel) Work body assembly (Swing) Outlet body Work body assembly (Arm) Inlet body assembly Work body assembly (TR, L)

2-13

Work body assembly (Boom 2) Inlet body O-ring 1B G55 (Section) Relief valve assembly Bolt, L=313 Bolt, L=205 Nut, M8 Over load relief valve assembly Anti-cavitation valve assembly Plug PF 1/4 O-ring 1B P11

3. MAIN RELIEF VALVE 1 Main valve 2 Main valve spring 3 Pilot poppet 4 Pilot poppet spring 5 Sleeve 6 Locknut 7 Adjustment screw Set pressure : See hydraulic circuit diagram R55NM2SF37

4. ANTI-CAVITATION VALVE 1 2 3

Valve Valve spring Sleeve

1 2 3 4 5 6 7 8

Safety valve main valve Suction valve Sleeve Locknut Plug Safety valve pilot poppet spring Safety valve pilot poppet Safety valve main valve spring

R55NM2SF38

5. OVERLOAD RELIEF VALVE ASSEMBLY

R55NM2SF39

2-14

B. MAIN CONTROL VALVE (BCV65, #0617 AND UP) 1. STRUCTURE

R55NM2SF60

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

16 17 18 19 20 21 22 23 24 25 26 27 28 29

T-Cover Block assembly (Boom swing) Block assembly (Swing) Block assembly (Dozer) Block assembly (Inlet-P3) Block assembly (Boom2) Block assembly (Arm1) Block assembly (TR) Block assembly (Inlet-P1, P2) Block assembly (TR) Block assembly (Boom1) Block assembly (Bucket) Block assembly (Arm2) Anti-cavitation assembly Main relief v/v assembly

2-15

Overload relief v/v assembly Tie bolt Tie bolt Nut Spool assembly (Boom swing) Spool assembly (Swing) Spool assembly (Dozer) Spool assembly (Boom2) Spool assembly (Arm1) Spool assembly (TR) Spool assembly (T.S) Spool assembly (Boom1) Spool assembly (Bucket) Spool assembly (Arm2)

2. FUNCTION 1) NEUTRAL POSITION OF SPOOL

R55NM2SF36A

In neutral, spring sets the plunger at the neutral position, oil form the pump flows to the tank through the center bypass.

2-16

2) OPERATION OF PLUNGER (General)

R55NM2SF40

When the pilot pressure is applied to a the plunger moves to the left and the center bypass is shut off. At the same time, pressurized oil from the parallel passage flows into the cylinder port A via load check valve. The return oil from the cylinder port B flows into the tank.

The opposite operation is similar.

2-17

3) OPERATION OF BOOM UP (Summation)

R55NM2SF41

When the pilot pressure is applied to b boom1 & boom2 plungers move to the right, then the pressurized oil form pump P1 flows into the boom cylinder via boom1 section; the pressurized oil from pump P2 via boom2 section joins the flow from the boom1 section via check valve.

R55NM2SF42

2-18

4) OPERATION OF ARM ROLL IN/OUT (Summation)

R55NM2SF43

When the pilot pressure is applied to a arm1 & arm2 plungers move to the left, then the pressurized oil form pump P2 flows into the arm cylinder via arm1 section.

At the same time, the pressurized oil from pump P1 via arm2 section flows into the arm1 plunger through the inner parallel line of the MCV.

R55NM2SF44

2-19

5) COMBINED TRAVEL AND ARM, BOOM, BUCKET

R55NM2SF45

R55NM2SF46A

When the other actuator spool(s) is selected under straight travel operation, the straight travel spool is moved.

The hydraulic fluid from pump P1 is supplied actuator through P1 and P2 parallel pass and travel motors through orifice at side of straight travel spool.

The hydraulic oil fluid from pump P2 is supplied to travel motors(left/right).

Therefore, the other actuator operation with straight travel operation, hydraulic oil fluid from pump P1 is mainly supplied to actuator, and the hydraulic oil fluid form pump P2 is mainly supplied to travel motors(left/right).

Then the machine keeps straight travel.

2-20

GROUP 4 TRAVEL DEVICE A. TRAVEL MOTOR (GM09VL, UP TO #0697) 1. CONSTRUCTION Travel device consists travel motor and gear box.

Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.

R55NM2SF52

Port

2-21

Port size

A, B

Main port

M24

C1, C2

Drain port

M20

P2, P3

Gauge port

PT 1/8

2-speed control port

M14

D R55NM2SF55

Port name

1) BASIC STRUCTURE

R55NM2SF51

2-22

2) STRUCTURE

R55NM2SF50

2-23

19 37 2 3 9 12 22 23 4 5 7 10 31 1 6 8 11 14 15 16 17 18 20 21 24 25 26

Spindle kit Reamer bolt Expander Spindle assembly Spindle Hold flange RV gear assembly Crank shaft Spacer Taper roller bearing Needle bearing RV gear kit RV gear A RV gear B Spur gear kit Spur gear F seal kit Distance piece Floating seal Hub Input gear Cover Collar Distance piece Coupling Shaft Pin Ring Snap ring Ball bearing Snap ring Snap ring Steel ball

27 28 29 30 33 101 123 144 154 178 179 199

161 162

105 106 102 103 104 107 108 109 110 112 113 114 115 116

O-ring O-ring O-ring O-ring Hex socket plug Rear flange kit Rear flange Spool Hex socket plug Hex socket plug Orifice Filter Name plate Piston kit Piston assembly Piston Shoe Piston kit Piston assembly Piston Shoe Shaft Swash plate Cylinder block Retainer plate Thrust ball Timing plate Washer Piston Spring Spring Friction plate Mating plate

2-24

121 124 125 126 127 128 130 132 135 136 137 138 139 141 142 143 145 149 150 151 152 153 163 164 165 166 168 173 174 176 177 185

Plug Plug Spring retainer Plug Valve Spring Spring Oil seal O-ring O-ring O-ring O-ring O-ring Parallel pin Parallel pin Hex socket bolt THS snap ring Ball Bearing Ball Bearing Roller Hex socket plug Thrust plate Valve Stopper Ring Spring Steel ball O-ring O-ring Pivot Parallel pin Spring

2. FUNCTION 1) HYDRAULIC MOTOR (1) Rotary group

R55NM2SF20

The pressurized oil delivered from the hydraulic pump flows to rear flange (101) of the motor, passes through the brake valve mechanism, and is introduced into cylinder block (104) via timing plate (109). This oil constructively introduced only to one side of (Y1)-(Y2) connecting the upper and lower dead points of stroke of piston (105). The pressurized oil fed to one side in cylinder block (104) pushes each piston (105) (four or five) and generates a force (F kg = P kgf/cm2 cm2).

This force acts on swash plate (103), and is resolves into components (F2 and F3) because swash plate (103) is fixed at an angle (α) with the axis of drive shaft(102).

Radial component (F3) generates respective torques (T = F3 ri) for (Y1)-(Y2). This residual of torque (T = (F3 ri)) rotates cylinder block (104) via piston (105). Cylinder block (104) is splinecoupled with drive shaft (102). So the drive shaft (102) rotates and the torque is transmitted.

2-25

(2) Brake valve ① Brake released(Starting / Running) When the pressurized oil supplied from port A, the oil opens valve (127) and flows into port C at the suction side of hydraulic motor to rotate motor. At the same time, the pressurized oil passes through pipe line (a) from a small hole in spool (123) and flows into chamber (b).

The oil acts on the end face of spool (123) which is put in neutral position by the force of spring (128), thus causing spool (123) to side to the left. When spool (123) slides, port D on the passage at the return side of hydraulic motor, which is closed by the spool groove during stoppage, communicates with port B at the tank side and the return oil from the hydraulic motor runs into the tank. In consequence, the hydraulic motor rotates. Moreover, sliding of spool (123) causes the pressurized oil to flow into ports P and S. The pressurized oil admitted into port P activates piston (112) of the parking brake to release the parking brake force. (for details, refer to description of the parking brake.)

When the pressurized oil is supplied from port B, spool (123) move reversely and the hydraulic motor also rotates reversely.

R55NM2SF21

2-26

② Brake applied(Stopping / Stalling) When the pressurized oil supplied from port A is stopped during traveling, no hydraulic pressure is applied and spool (123) which has slide to the left will return on the right (neutral) via stopper (125) by the force of spring (128). The oil in the chamber (b) will flow to port A side through pipe line (a) in spool (123).

However, a back pressure produced by the restricting effect of pipe line (a), whereby the return speed of spool (123) is controlled.

At the same time, the hydraulic motor will rotate by the force of inertia even if the pressurized oil is stopped. Accordingly the return oil return to port B side from port D through a passage between the groove in spool (123) and rear flange (101). When spool (123) completely returns to neutral, the above mentioned passage is fully closed and the hydraulic motor stops.

As explained above, the hydraulic motor is smoothly braked and stopped by gradually controlling the return oil from the hydraulic motor by the return speed of spool (123), its shape, etc. However, the hydraulic motor will rotate by the force of inertia. This means that the hydraulic motor will. However, no oil is supplied because the pressurized oil is stopped. In consequence, cavitation occurs on the hydraulic motor, thus adversely affecting it.

R55NM2SF22

2-27

③ Braking effect on downhill travel If the machine traveling downhill with a relatively small supply of high pressure oil to its travel motors should start coasting, the same braking effect as the one described above would automatically occur.

In the coasting condition, the motor is driven, instead of driving the track, from the ground and sucks high pressure oil in.

In other words, the motor tends to draw more high pressure oil than is being supplied.

Under this condition, port A goes negative to pull oil out of chamber ⓑ through oil way ⓐ, moving back the spool(123) rather rapidly.

The clearance on the left then becomes smaller to throttle the outgoing oil more than before, thereby obstructing the pumping action of the motor.

As in stopping the machine, pressure will build up in port D to make it harder to drive the motor from the ground: This is the braking action.

R55NM2SF23

2-28

(3) Parking brake ① Running When the pressurized oil is supplied from the brake valve, the spool of brake valve in the hydraulic motor assembly actuates to open the passage to the parking brake and the pressurized oil is introduced into cylinder chamber ⓐ which is composed of the spindle of reduction gear assembly and piston(112). When the hydraulic pressure reaches 4.6kgf/cm2(0.45Mpa) or more, it overcomes the force of spring (113) and shifts piston(112). With shift of piston(112), no pressing force is applied to mating plate(116) and friction plate (115) and the movement of friction plate (115) becomes free, whereby the brake force to the cylinder in the hydraulic motor assembly is released.

R55NM2SF70

② Stopping When the pressurized oil from the brake valve is shut off and the pressure in cylinder chamber ⓐ drops 6kgf/cm 2 (0.59Mpa) or less, piston(112) will return by the force of spring(113).

Piston(112) is pushed by this force of spring(113), and mating plate(116) and friction plate(115) in free condition are pressed against the spindle of reduction gear assembly.

The friction force produced by this pressing stops rotation of the cylinder block(104) and gives a braking torque 8.4kgf·m(82.4N·m) to the hydraulic motor shaft.

Note that oil control through a proper oil passage ensures smooth operation.

R55NM2SF71

2-29

(4) High/low speed changeover mechanism ① At low speed - At pilot pressure of less than 20kgf/cm2(1.96Mpa)

R55NM2SF24

When the pilot pressure is shut off from port Ⓟ, valve(163) is pressed upward by the force of spring(166), the pressurized oil supply port Ⓒ is shut off, and oil in chamber ⓐ is released into the motor case through the valve(163). Consequently, swash plate(103) is tilted at a maximum angle(θ1) and the piston displacement of hydraulic motor becomes maximum, thus leading to low-speed operation.

② At high speed - At pilot pressure of 20kgf/cm2(1.96Mpa) or more

R55NM2SF25

When a pilot pressure supplied from port Ⓟ(At a pressure of 20kgf/cm2(1.96Mpa) or more), the pressure overcomes the force of spring(166) and valve(163) is pressed downward. The pressurized oil supply port Ⓒ is then introduced into chamber ⓐ through the valve(163). Piston (161) pushes up swash plate(103) until it touches side ⓑ of the spindle. At this time, swash plate(103) is tilted at a minimum angle(θ2) and the piston displacement of hydraulic motor becomes minimum, thus leading to high-speed operation.

2-30

2) REDUCTION GEAR (1) Function This reduction gear is composed of spur reduction gears(First reduction) and differential reduction gears(Second reduction). It decrease high rotating speed, increase output torque of a hydraulic motor and rotates a gear case.

Planetary gear mechanism

Spur gear Crank shaft

(2) Operating principle ① First reduction At the right figure, the rotating motion of hydraulic motor is transmitted to the input gear(6) of first reduction. Then three spur gears(7) engaged with the input gear(6) rotate with reducing the rotating speed. Gear ratio of first reduction is described as the following.

Shaft

Zi Zs Zi : Number of input gear teeth Zs : Number of spur gear teeth i1 = -

Input gear

25032TM11(1)

② Second reduction Three spur gears(7) are connected severally to the three crank shafts(9).

These crank shafts(9) are input of second reduction.

Differential gear mechanism Spur gear Rotation Needle bearing Eccentric Crank shaft Rotation A

B

Eccentric Eccentric motion RV gear B RV gear A 25032TM11(2)

2-31

RV gears(4), (5) are fitted up the eccentric crank shaft(9) through bearings.

According to rotating of the crank shafts(9), RV gears(4), (5) revolve (Eccentric motion) along pin-gears(17) within hub(1). As these crank shafts are supported by spindle(2), hub (1) rotates with reducing the speed. Gear ratio of second reduction is described as the following.

Combination of planetary gear mechanism and differential gear mechanism 1 22

23

24 1 2

3

Hub Pin

4

RV gear A or B Crank shaft 360 2 x 24

(Zp - ZR) Zp Zp : Number of pin ZR : Number of RV gear teeth i2 =

2 22

23 24

1 2

360 24 3 3

4 5

22

23

24 1

2

3 4

Total gear ratio of this reduction gear is described as the following. i = i1·i2 = -

Zi (Zp-ZR) · Zs Zp

Crank shaft half revolution

Crank shaft one revolution 25032TM12

2-32

B. TRAVEL MOTOR (TM07VA, #0698 AND UP) 1. CONSTRUCTION Travel device consists travel motor and gear box.

Travel motor includes brake valve, parking brake and high/low speed changeover mechanism.

R55NM2SF29

Port

R55NM2SF28

2-33

Port name

Port size

P1

Main port

PF 1/2

P2

Main port

PF 1/2

T1, T2

Drain port

PF 3/8

Ps a1,a2, a3,a4

2-speed control port

PF 1/8

Gauge port

PF 1/8

1) BASIC STRUCTURE

R55NM2SF27

2-34

2) STRUCTURE

R55NM2SF26

1 2 3 4 5 6 7 8 9 10 12 13 14 15

Rear flange Shaft Swash plate Cylinder block Piston Shoe Retainer plate Thrust ball Timing plate Washer Piston(Parking) Spring Spring Friction plate

16 18 19 20 21 22 23 24 25 26 27 28 30 32

Mating plate Valve seat Valve(T valve) Spring Plug(VP) Ring Spool Plug(Main) Spring retainer Plug Valve(Check) Spring(Main) Spring(Check) Oil seal

33 35 36 37 38 39 40 41 42 43 44 45 46 47

O-ring O-ring O-ring O-ring O-ring O-ring O-ring Parallel pin Parallel pin Socket bolt Plug(PT) Snap ring O-ring Back up ring

48 49 50 51 52 53 54 55 56 57 58 59 60 61

Back up ring Roller bearing Ball bearing Roller Plug(RO) Thrust plate Plug(NPTF) Body Spool Stopper Spring Spring Spring Piston

2-35

62 63 64 65 66 67 70 74 75 76 89 90 91 101

Shoe Valve(2speed) Ring(2speed) Ring(2speed) Spring(2speed) Steel ball Socket bolt O-ring O-ring Snap ring Name plate Rivet screw Plug(PT) Holder flange

102 103 104 105 106 107 108 109 110 111 112 113 114 115

Floating seal Nut ring Plug Housing Steel ball Plug Planetary gear(F) Thrust washer Screw Needle bearing Collar Thrust plate(F) Sun gear Snap ring

116 117 118 119 120 121 122 123 124 125 126 127

Holder Planetary gear(R) Needle bearing Inner race Spring pin Drive gear Thrust plate(R) Cover Socket bolt Angular bearing O-ring O-ring

1. FUNCTION 1) HYDRAULIC MOTOR

R55NM2SF73

The pressurized oil delivered from the hydraulic pump flows to rear flange(1) of the motor, passes through the brake valve mechanism, and is introduced into cylinder block(4) via timing plate(9).

This oil constructively introduced only to one side of (Y1)-(Y2) connecting the upper and lower dead points of stroke of piston(5). The pressurized oil fed to one side in cylinder block(4) pushes each piston(5)(four or five) and generates a force F(kgf)= P(kgf/cm2)×A(cm2).

This force acts on swash plate(3), and is resolves into components(F2 and F3) because swash plate(3) is fixed at an angle αwith the axis of drive shaft(2).

Radial component(F3) generates respective torques (T=F3×ri) for (T1)-(Y2). This residual of torque (T=S(F3×ri)) rotates cylinder block(4) via piston(5). Cylinder block(4) is spline coupled with drive shaft(2).

So the drive shaft(2) rotates and the torque is transmitted.

2-36

2) BRAKE VALVE (1) Brake released(starting/running) When the pressurized oil supplied from port Ⓐ the oil opens valve(27) and flows into port Ⓒ at the suction side of hydraulic motor to rotate motor.

At the same time, the pressurized oil passes through pipe line ⓐ from a small hole in spool(23) and flow into chamber ⓑ.

The oil acts on the end face of spool(23) which is put in neutral position by the force of spring(28), thus causing spool(23) to slide to the left. When spool(23) slides, port Ⓓ on the passage at the return side of hydraulic motor, which is closed by the spool groove during stoppage, communicates with port Ⓑ at the tank side and the return oil from the hydraulic motor runs into the tank. In consequence, the hydraulic motor rotates. Moreover, sliding of spool(23) causes the pressurized oil to R55NM2SF74 flow into ports Ⓟ and Ⓢ.

The pressurized oil admitted into port Ⓟ activates piston(12) of the parking brake to release the parking brake force (For details, refer to description of the parking brake).

On the other hand, the pressurized oil introduced into port Ⓢ flows into chamber ⓣ and presses stopper(57) against the inside of body(55) to prevent spool(58) from moving, thus disabling communication at port Ⓒ side of the hydraulic motor (Suction side and return side of hydraulic motor). When the pressurized oil is supplied from port Ⓑ spool(23) and valve(27) move reversely and the hydraulic motor also rotates reversely.

2-37

(2) Brake applied(stopping/stalling) When the pressurized oil supplied from port Ⓐ is stopped during traveling, no hydraulic pressure is applied and spool(23) which has slided to the left will return on the right(neutral) via spring retainer(25) by the force of spring(28).

The oil in chamber ⓑ will flow to port Ⓐ side through pipe line ⓐ in spool(23).

However, a back pressure produced by the restricting effect of pipe line ⓐ whereby the return speed of spool(23) is controlled.

At the same time, the hydraulic motor will rotate by the force of inertia even if the pressurized oil is stopped.

Accordingly, the return oil will return to port Ⓑ side from port Ⓓ through a passage between the groove in spool(23) and rear flange(1). When spool(23) completely returns to neutral, the above-mentioned R55NM2SF75 passage is fully closed and the hydraulic motor stops.

As explained above, the hydraulic motor is smoothly braked and stopped by gradually controlling the return oil from the hydraulic motor by the return speed of spool(23), its shape, etc.

However, the hydraulic motor will rotate by the force of inertia. This means that the hydraulic motor will suck oil functioning as a pump.

However, no oil is supplied because the pressurized oil is stopped. In consequence, cavitation occurs on the hydraulic motor, thus adversely affecting it.

At the same time, the passage closed by spool(23), whereby the return oil from the hydraulic motor is enclosed at port Ⓓ side and the pressure is increased.

This pressure slides spool(58) to the left to short-circuit port Ⓓ and Ⓒ which prevents pressure rise and cavitation (surge cut valve function and anti-cavitation valve function).

Valve(27) is activated by a slight negative pressure to open the oil passage between the oil line at port Ⓐ side and port Ⓒ at the suction side of motor, thus preventing cavitation of the hydraulic motor.

2-38

3) PARKING BRAKE (1) Running When the pressurized oil is supplied from the valve, the spool of brake valve in the hydraulic motor assembly actuates to open the passage to the parking brake and the pressurized oil is introduced into cylinder chamber ⓐ which is composed of the spindle of reduction gear assembly and piston(12).

When the hydraulic pressure reaches 9kgf/cm2(0.88Mpa) or more, it overcomes the force of spring(13) and shifts piston(12) with shift of piston(12) no pressing force is applied to mating plate(16) and friction plate(15) and the movement of friction plate(15) becomes free, whereby the brake force to the cylinder in the hydraulic motor assembly is released.

R55NM2SF76

(2) Stopping When the pressurized oil from the brake valve is shut off and the pressure in cylinder chamber ⓐ drops 9kgf/cm2(0.88Mpa) or less, piston(12) will return by the force of spring(13).

Piston(12) is pushed by this force of spring(13), and mating plate(16) and friction plate(15) in free condition are pressed against the holder flange of reduction gear assembly.

The friction force produced by this pressing stops rotation of the cylinder and gives a braking torque(8.4kgf·m(82.3 N·m)) to the hydraulic motor shaft.

Note that oil control through a proper oil passage ensures smooth operation.

R55NM2SF77

2-39

4) HIGH/LOW SPEED CHANGEOVER MECHANISM (1) At low speed-at pilot pressure of less than 10kgf/cm2(0.98Mpa)

R55NM2SF78

When no pilot pressure is supplied from port Ⓐ at a pressure of 10kgf/cm2(0.98Mpa) or less, valve(63) is pressed toward the left by the force of spring(166), the pressurized oil supply port Ⓑ is shut off, and oil in chamber Ⓒ is released into the motor case via valve(63).

Consequently, swash plate(3) is tilted at a maximum angle(θ1°) and the piston displacement of hydraulic motor becomes maximum, thus leading to low-speed rotation.

(2) At high speed-at pilot pressure of 10kgf/cm2(0.98Mpa) or more

R55NM2SF79

When a pilot pressure is supplied from port Ⓐ at a pressure of 10kgf/cm2(0.98Mpa) or more, the pressure overcomes the force of spring(66) and valve(63) is pressed toward the right. The pressurized oil at supply port Ⓑ is then introduced into chamber Ⓒ via valve(63).

Piston(61) pushes up swash plate(3) until it touches side ⓑ of the holder flange.

At this time, swash plate(3) is tilted at a minimum angle(θ2°) and the piston displacement of hydraulic motor becomes maximum, thus leading to high-speed rotation.

2-40

2. REDUCTION GEAR 1) FUNCTION The reduction gear unit consists of a combination of simple planetaly gear mechanism.

This mechanism reduce the high speed rotation from the hydraulic motor and convert it into low speed, high torque to rotate the hub(or case), which in turn rotates the sprocket.

2) OPERATING PRINCIPLE Shaft → Drive gear → Planetary Gear R → Housing → Holder → Sun gear → Planetary Gear F →Rotation of Housing

R55NM2SF72

Reduction ratio=(Housing Teeth/Drive Gear Teeth + 1) ×(Housing Teeth/Sun Gear Teeth + 1) - 1.

2-41

GROUP 5 SWING MACHINERY A. SWING MOTOR (SG015E, UP TO #1447)

R55NM2SF04

1 2 3 4 5 6 7 8 9 10 11

Inner ring Oil seal Taper roller bearing Backing spring Cam plate Return plate Lining plate Plate O-ring Piston O-ring

12 13 14 15 16 17 18 19 20 21 22

O-ring Teflon ring Piston Coned disk spring Teflon ring Bush Balance plate Spring Needle bearing Snap-ring Cylinder

2-42

23 24 25 26 27 28 29 30 31 32

Piston assembly Plug Housing Socket bolt Cover Time delay valve Parallel pin O-ring Back-up ring Relief assembly

B. SWING MOTOR (JMF39, #1448 AND UP)

R55NM2SF07

1 2 3 4 5 6 7 8 9 10 11 12

Body Oil seal Cylinder block Shaft Taper bearing Bushing Shoe plate Spring Set plate Piston shoe assy Ball guide Rear cover

13 14 15 16 17 18 19 20 21 22 23 24

Pin Shim Taper bearing Valve plate Relief valve assy Back up ring O-ring Friction plate Plate Parking piston O-ring O-ring

2-43

25 26 27 28 29 30 31 32 33 34 35 36

Plug Spring Wrench bolt Time delay valve Socket bolt O-ring Plug Name plate Rivet Plug Plug Plug

C. REDUCTION GEAR (SG015E, UP TO #0915)

R55NM2SF03

1 2 3 4 5 6

Collar Oil seal Gear case Bearing Collar Gear

7 8 9 10 11 12

Gear Bolt (M12×80L) Holder assembly Ring gear Parallel pin Holder assembly

2-44

13 14 15 16 17 18

Drain pipe Plug Oil seal Bearing Pinion shaft Level gauge

D. REDUCTION GEAR (SB50, #0916 AND UP)

R55NM2SF06

1 2 3 4 5 6 7 8 9

Case Drive shaft Ring gear Spacer Grease seal Bearing Bearing Oil seal #2 Carrier

10 11 12 13 14 15 16 17

#2 Planet gear #2 Sun gear #2 Pin assy #1 Carrier #1 Planet gear #1 Sun gear #1 Pin assy Thrust washer2

2-45

18 19 20 21 22 23 24 25

Collar Spring pin Knock pin Socket head bolt Thrust washer1 Plug Spring pin Stop ring

1. SAFETY VALVE 1) OUTLINE The safety valve portion consists of a check valve and safety valve.

2) FUNCTION When the swing is stopped, the output circuit of the motor continues to rotate because of inertia. For this reason, the pressure at the output side of the motor becomes abnormality high, and this will damage the motor. To prevent this, the oil causing the abnormal hydraulic pressure is allowed to escape from the outlet port (highpressure side) of the motor to port Mu, thereby preventing damage to the motor.

Compared with a counterbalance valve, there is no closed-in pressure generated at the outlet port side when slowing down the swing speed. This means that there is no vibration when slowing down, so the ease of swing control is improved.

R55NM2SF18

3) OPERATION (1) When starting swing When the swing control lever is operated to left swing, the pressurized oil from the pump passes through the control valves and is supplied to port MB. Because of this, the pressure at port MB rises, staring torque is generated in the motor, and the motor starts to rotate. The oil from the outlet port of the motor passes from port MA through the control valve and returns to the tank.

2-46

(2) When stopping swing • When the swing control lever is returned to neutral, no pressurized oil is supplied from the pump to port MB. The return circuit to the tank is closed by the control valve. So the oil from the outlet port of the motor increases in pressure at port MA. Resistance to the rotation of the motor is created, and the brake starts to act.

• The pressure at Port MA rises to the set pressure of safety valve A, and in this way, a high brake torque acts on the motor, and the motor stops.

• When safety valve A is being actuated, the relief oil from safety valve A and the oil from port Mu pass through check valve CB and are supplied to port MB. This prevents cavitation from forming at port MB.

R55NM2SF18A

2-47

GROUP 6 RCV LEVER 1. STRUCTURE The casing has the oil inlet port P(Primary pressure) and the oil outlet port T(Tank). In addition the secondary pressure is taken out through ports 1,2,3 and 4 provided at the bottom face.

23.3

19 Single operation

25 Simultaneous operation

Handle bending direction (No. push rod direction)

4

P 2

3 30

1 T

30

VIEW A

A

T P 1

32 Hydraulic circuit

4 25032RL01

2-48

Port

LH

RH

P

Pilot oil inlet port

Pilot oil inlet port

T

Pilot oil return port Pilot oil return port

1

Left swing port

Bucket out port

2

Arm in port

Boom down port

3

Right swing port

Bucket in port

4

Arm out port

Boom up port

Port size

PF 1/4

CROSS SECTION The construction of the pilot valve is shown in the attached cross section drawing. The casing has vertical holes in which reducing valves are assembled.

The pressure reducing section is composed of the spool(5), spring(7) for setting secondary pressure, return spring(10), stopper(9), spring seat(8) and shim(6). The spring for setting the secondary pressure has been generally so preset that the secondary pressure is 5 to 20.5kgf/cm2(Depending on the type). The spool is pushed against the push rod(14) by the return spring.

When the push rod is pushed down by tilting the handle, the spring seat comes down simultaneously and changes setting of the secondary pressure spring.

1 2 3 4 5 6 7 8 9 10

Case Plug Plug O-ring Spool Shim Spring Spring seat Stopper Spring

11 12 13 14 15 16 17 18 19 20

Plug Rod seal O-ring Push rod Plate Bushing Joint assembly Swash plate Adjusting nut Lock nut

2-49

21 22 23 24 25 26 27 28 29

O-ring Handle connector Nut Insert Boot Handle Switch assembly Screw Boot

CROSS SECTION

R55NM2SF80

2-50

2. FUNCTIONS 1) FUNDAMENTAL FUNCTIONS The pilot valve is a valve that controls the spool stroke, direction, etc of a main control valve. This function is carried out by providing the spring at one end of the main control valve spool and applying the output pressure(Secondary pressure) of the pilot valve to the other end.

For this function to be carried out satisfactorily, the pilot valve is composed of the following elements.

(1) Inlet port(P) where oil is supplied from hydraulic pump.

(2) Output ports(1, 2, 3 & 4) to apply pressure supplied from inlet port to ends of control valve spools.

(3) Tank port(T) necessary to control the above output pressure.

(4) Spool to connect output port to inlet port or tank port.

(5) Mechanical means to control output pressure, including springs that work on the above spools.

2) FUNCTIONS OF MAJOR SECTIONS The functions of the spool(5) are to receive the supply oil pressure from the hydraulic pump at its port P, and to change over oil paths to determine whether the pressure oil of port P is led to output ports 1, 2, 3 & 4 or the output port pressure oil to tank port T. The spring(7) works on this spool to determine the output pressure.

The change the deflection of this spring, the push rod(14) is inserted and can slide in the plug(11).

For the purpose of changing the displacement of the push rod through the switch plate(19) and adjusting nut(20) are provided the handle(27) that can be tilted in any direction around the fulcrum of the universal joint(18) center.

The spring(10) works on the case(1) and spring seat(8) and tries to return the push rod(14) to the zero-displacement position irrespective of the output pressure, securing its resetting to the center position.

This also has the effect of a reaction spring to give appropriate control feeling to the operator.

2-51

3) OPERATION The operation of the pilot valve will be described on the basis of the hydraulic circuit diagram shown below and the attached operation explanation drawing.

The diagram shown below is the typical application example of the pilot valve.

5

6

1 3 1 P

T

3

4

2

2-70 (55-3)

1 2

Pilot valve Pilot pump

3 4

Main pump Main control valve

2-52

5 6

Hydraulic motor Hydraulic cylinder

(1) Case where handle is in neutral position

T 7 10 P

5

3

1

25032RL03

The force of the spring(7) that determines the output pressure of the pilot valve is not applied to the spool(5). Therefore, the spool is pushed up by the spring(10) to the position of port(1, 3) in the operation explanation drawing. Then, since the output port is connected to tank port T only, the output port pressure becomes equal to tank pressure.

2-53

(2) Case where handle is tilted

15

5

T

P

3

1

25032RL04

When the push rod(14) is stroked, the spool(5) moves downwards.

Then port P is connected with port(1) and the oil supplied from the pilot pump flows through port(1) to generate the pressure.

When the pressure at port(1) increases to the value corresponding to the spring force set by tilting the handle, the hydraulic pressure force balances with the spring force. If the pressure at port(1) increases higher than the set pressure, port P is disconnected from port(1) and port T is connected with port(1). If it decreases lower than the set pressure, port P is connected with port(1) and port T is disconnected from port 1.

In this manner the secondary pressure is kept at the constant value.

Besides, in some type, when the handle is tilted more than a certain angle, the upper end of the spool contacts with the inside bottom of the push rod and the output pressure is left to be connected with port P.

2-54

GROUP 7 POWER TRAIN

R55NM2SF01

1 2 3 4 5

6

RH travel motor Engine Hydraulic pump Main control valve LH travel motor

7 8 9

2-55

4-Tandem solenoid valve (Acceleration solenoid valve) Center swivel joint Swing motor Swing circle

GROUP 8 SWING CIRCLE

R55NM2SF04

1 2 3

4 5 6

Swing circle outer race Ball bearing Swing circle inner race

2-56

Swing circle pinion lubricating Swing circle bearing lubricating Seal

GROUP 9 TRACK FRAME AND TENSION SPRING 1. STEEL SHOE

R55NM2SF08

1 2 3 4 5

6 7 8 9 10

Idler Plunger Carrier roller/Track roller Track frame Sprocket

2-57

Travel motor Track shoe Tension spring Lubricator Guard

2. RUBBER SHOE

R55NM2SF09

1 2 3 4 5

6 7 8 9 10

Idler Plunger Carrier roller/Track roller Track frame Sprocket

2-58

Travel motor Track shoe Tension spring Lubricator Spacer

SECTION 3 TESTING AND ADJUSTING Group 1 Operational Performance Test Group 2 Testing and Adjusting Hydraulic Pressure

3-1 3-21

SECTION 3 TESTING AND ADJUSTING GROUP 1 OPERATIONAL PERFORMANCE TEST 1. PURPOSE Performance tests are used to check: 1) OPERATIONAL PERFORMANCE OF A NEW MACHINE Whenever a new machine is delivered in parts and reassembled at a customer's site, it must be tested to confirm that the operational performance of the machine meets Hyundai spec.

2) OPERATIONAL PERFORMANCE OF A WORKING MACHINE With the passage of time, the machine's operational performance deteriorates, so that the machine needs to be serviced periodically to restore it to its original performance level.

Before servicing the machine, conduct performance tests to check the extent of deterioration, and to decide what kind of service needs to be done(by referring to the "Service Limits" in this manual).

R55NN7MA01

3) OPERATIONAL PERFORMANCE OF A REPAIRED MACHINE After the machine is repaired or serviced, it must be tested to confirm that its operational performance was restored by the repair and/or service work done.

3-1

2. TERMINOLOGY 1) STANDARD Specifications applied to the brand-new machine, components and parts.

R55NN7MA02A

2) SERVICE LIMIT The lowest acceptable performance level.

When the performance level of the machine falls below this level, the machine must be removed from work and repaired.

Necessary parts and components must be replaced.

R55NN7MA02B

3-2

3. OPERATION FOR PERFORMANCE TESTS 1) Observe the following rules in order to carry out performance tests accurately and safely.

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

(2) Test area ① Select a hard, flat surface. ② Secure enough space to allow the machine to run straight more than 20m, 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.

(3) 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.

7-3 (140-7)

(4) Make precise measurements 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 procured repeatedly. Use mean values of measurements if necessary.

3-3

2) ENGINE SPEED (1) Measure the engine speed at the maximum RPM. ※ The engine speed must meet standard RPM; if not, all other operational performance data will be unreliable. It is essential to perform this test first.

(2) Preparation and measurement ① Warm up the machine, until the engine coolant temperature reaches 50° C or more, and the hydraulic oil is 50±5° C. ② Set the accel lever at the maximum stroke. ③ Measure the engine RPM. (3) Evaluation The measured speeds should meet the following specifications.

Unit : t / rpm Model R55-3

Engine speed

Standard

Low idle

1100±50

High idle

2560±50

3-4

Remark

3) TRAVEL SPEED (1) Measure the time required for the excavator to travel a 20m test track.

(2) Preparation ① Adjust the tension of both tracks to be equal. ② Prepare a flat and solid test track 20m in length, with extra length of 3 to 5m on both ends for machine acceleration and deceleration. ③ Hold the bucket 0.3 to 0.5m above the ground with the arm and bucket rolled in. ④ Keep the hydraulic oil temperature at 50±5° C.

R55NN7MA03

(3) Measurement ① Measure both the low and high speeds of the machine. ② Before starting either the low or high speed tests, adjust the travel mode switch to the speed to be tested. ③ Start traveling the machine in the acceleration zone with the travel levers at full stroke. ④ Measure the time required to travel 20m. ⑤ After measuring the forward travel speed, turn the upperstructure 180°and measure the reverse travel speed. ⑥ Repeat steps ④ and ⑤ three times in each direction and calculate the average values.

R55NN7MA04

(4) Evaluation The average measured time should meet the following specifications.

Model R55-3

Travel speed

Standard

Maximum allowable

1 Speed

32.7±2.0

39.2

2 Speed

18.0±1.0

21.6

3-5

Unit : Seconds / 20m Remarks

4) TRACK REVOLUTION SPEED (1) Measure the track revolution cycle time with the track raised off ground.

(2) Preparation ① Adjust the tension of both side tracks to be equal. ② On the track to be measured, mark one shoe with chalk. 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. Place blocks under machine frame. ④ Keep the hydraulic oil temperature at 50±5° C. (3) Measurement ① Select the following switch positions. · Travel mode switch : 1 or 2 speed ② Operate the travel control lever of the raised track in full forward and reverse. ③ Rotate 1 turn, then measure time taken for next 3 revolutions. ④ Raise the other side of machine and repeat the procedure. ⑤ Repeat steps ③ and ④ three times and calculate the average values.

R55NN7MA05

(4) Evaluation The revolution cycle time of each track should meet the following specifications.

Unit : Seconds / 3 revolutions Model R55-3

Travel speed

Standard

Maximum allowable

1 Speed

27.6±2.0

33.1

2 Speed

15.5±2.0

18.6

3-6

5) TRAVEL DEVIATION (1) Measure the deviation by the tracks from a 20m straight line.

(2) Preparation ① Adjust the tension of both tracks to be equal. ② Provide a flat, solid test yard 20m in length, with extra length of 3 to 5m on both ends for machine acceleration and deceleration. ③ Hold the bucket 0.3 to 0.5m above the ground with the arm and bucket rolled in. ④ Keep the hydraulic oil temperature at 50±5° C.

R55NN7MA03

(3) Measurement ① Measure the amount of mistracking at high and low travel speeds. ② Start traveling the machine in the acceleration zone with the travel levers at full stroke. ③ Measure the distance between a straight 20m line and the track made by the machine.(Dimension a) ④ After measuring the tracking in forward travel, turn the upperstructure 180°and measure that in reverse travel. ⑤ Repeat steps ③ and ④ three times and calculate the average values.

3~5m extra length 20 M

a

3~5m extra length

7-7(2) 140-7

(4) Evaluation Mistrack should be within the following specifications.

Unit : mm / 20m Model

Standard

Maximum allowable

R55-3

200 below

240

3-7

Remarks

6) SWING SPEED (1) Measure the time required to swing three complete turns.

(2) Preparation ① Check the lubrication of the swing gear and swing bearing. ② Place the machine on flat, 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 the same as the boom foot pin. The bucket must be empty. ④ Keep the hydraulic oil temperature at 50±5° C.

R55NN7MA06A

(3) Measurement ① Operate swing control lever fully. ② Swing 1 turn and measure time taken to swing next 2 revolutions. ③ Repeat steps ① and ② three time and calculate the average values.

(4) Evaluation The time required for 2 swings should meet the following specifications.

Unit : Seconds / 2 revolutions Model

Standard

Maximum allowable

R55-3

12.0±1.0

15.6

3-8

Remark

7) SWING FUNCTION DRIFT CHECK (1) Measure the swing drift on the bearing outer circumference when stopping after a 360°full speed swing.

(2) Preparation ① Check the lubrication of the swing gear and swing bearing. ② Place the machine on flat, 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 the same as 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 360°. ⑥ Keep the hydraulic oil temperature at 50±5° C.

R55NN7MA06A

(3) Measurement ① Operate the swing control lever fully and return it to the neutral position when the mark on the upperstructure aligns with that on track frame after swinging 360° ② Measure the distance between the two marks. ③ Align the marks again, swing 360°, then test the opposite direction. ④ Repeat steps ② and ③ three times each and calculate the average values.

(4) Evaluation The measured drift angle should be within the following specifications.

R55NN7MA07

Unit : Degree Model

Standard

Maximum allowable

R55-3

40 below

50

3-9

Remarks

8) SWING BEARING PLAY (1) Measure the swing bearing play using a dial gauge to check the wear of bearing races and balls.

(2) Preparation ① Check swing bearing mounting cap screws for loosening. ② Check the lubrication of the swing bearing. Confirm that bearing rotation is smooth and without noise. ③ Install a dial gauge on the track frame as shown, using a magnetic base. ④ Position the upperstructure so that the boom aligns with the tracks facing towards the front idlers. ⑤ Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race. ⑥ Bucket should be empty.

7-10(1) 140-7

Measurement : h1

(3) Measurement ① With the arm rolled out and bucket rolled in, hold the bottom face of the bucket to the same height of the boom foot pin.

Record the dial gauge reading(h1). ② Lower the bucket to the ground and use it to raise the front idler 50cm.

Record the dial gauge reading(h2). ③ Calculate bearing play(H) from this data(h1 and h2) as follows.

H=h2-h1

R55NN7MA06

Measurement : h2

(4) Evaluation The measured drift should be within the following specifications.

R55NN7MA08

Unit : mm Model

Standard

Maximum allowable

R55-3

0.5 ~ 1.2

2.4

3-10

Remarks

9) HYDRAULIC CYLINDER CYCLE TIME (1) Measure the cycle time of the boom, standard arm, and standard bucket cylinders.

(2) Preparation ① To measure the cycle time of the boom cylinders: With the arm rolled out and the empty bucket rolled out, lower the bucket to the ground, as shown. ② To measure the cycle time of the arm cylinder.

With the empty bucket rolled in, position the arm so that it is vertical to the ground.

Lower the boom until the bucket is 0.5m above the ground. ③ To measure the cycle time of the bucket cylinder.

The empty bucket should be positioned at midstroke between roll-in and roll-out, so that the sideplate edges are vertical to the ground. ④ Keep the hydraulic oil temperature at 50±5° C. R55NN7MA10

(3) Measurement ① To measure cylinder cycle times.

- Boom cylinders.

Measure the time it takes to raise the boom, and the time it takes to lower the boom. To do so, position the boom at one stroke end then move the control lever to the other stroke end as quickly as possible.

- Arm cylinder.

Measure the time it takes to roll in the arm, and the time it takes to roll out the arm. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.

3-11

- Bucket cylinders Measure the time it takes to roll in the bucket, and the time it takes to roll out the bucket. To do so, position the bucket at one stroke end, then move the control lever to the other stroke end as quickly as possible.

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

(4) Evaluation The average measured time should meet the following specifications.

Unit : Seconds Model

R55-3

Standard

Maximum allowable

Boom raise

2.4±0.4

3.1

Boom lower

2.8±0.4

3.6

Arm in

2.9±0.4

3.8

Arm out

2.5±0.4

3.2

Bucket load

3.5±0.4

4.6

Bucket dump

2.4±0.4

3.1

Boom swing(LH)

6.8±0.4

8.8

Boom swing(RH)

5.6±0.4

7.3

Dozer up(Raise)

1.2±0.3

1.6

Dozer down(Lower)

1.2±0.3

1.6

Function

3-12

Remarks

10) DIG FUNCTION DRIFT CHECK (1) Measure dig function drift, which can be caused by oil leakage in the control valve and boom, standard arm, and standard bucket cylinders, with the loaded bucket.

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

(2) Preparation ① Load bucket fully. Instead of loading the bucket, weight(W) of the following specification can be used. · W=M3×1.5 Where : M3 = Bucket heaped capacity(m3) 1.5= Soil specific gravity ② Position the arm cylinder with the rod 20 to 30mm extended from the fully retracted position. ③ Position the bucket cylinder with the rod 20 to 30mm retracted from the fully extended position. ④ With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is the same as the boom foot pin. ⑤ Keep the hydraulic oil temperature at 50±5° C.

R55NN7MA12

(3) Measurement ① Stop the engine. ② Five minutes after the engine has been stopped, measure the changes in the positions of the boom, arm and bucket cylinders. ③ Repeat step ② three times and calculate the average values.

(4) The measured drift should be within the following specifications.

Unit : mm / 5min Model

R55-3

Drift to be measured

Standard

Maximum allowable

Boom cylinder

20 below

30

Arm cylinder

20 below

30

Bucket cylinder

20 below

30

3-13

Remarks

11) CONTROL LEVER OPERATING FORCE (1) Use a spring scale to measure the maximum resistance of each control lever at the middle of the grip.

(2) Preparation ① Keep the hydraulic oil temperature at 50±5° C. (3) Measurement ① Start the engine. ② Operate each boom, arm, bucket and swing lever at full stroke and measure the maximum operating force for each. ③ Lower the bucket to the ground to raise one track off the ground. Operate the travel lever at full stroke and measure the maximum operating force required.

When finished, lower the track and then jack-up the other track. ④ Repeat steps ② and ③ three times and calculate the average values.

(4) Evaluation The measured operating force should be within the following specifications.

Unit : kgf Model

R55-3

Kind of lever

Standard

Maximum allowable

Boom lever

1.4 or below

1.9

Arm lever

1.4 or below

1.9

Bucket lever

1.4 or below

1.9

Swing lever

1.4 or below

1.9

Travel lever

2.0 or below

2.5

3-14

Remarks

12) CONTROL LEVER STROKE (1) Measure each lever stroke at the lever top using a ruler. ※ When the lever has play, take a half of this value and add it to the measured stroke.

(2) Preparation Keep the hydraulic oil temperature at 50±5° C. (3) Measurement ① Stop the engine. ② Measure each lever stroke at the lever top from neutral to the stroke end using a ruler. ③ Repeat step ② three times and calculate the average values.

(4) Evaluation The measured drift should be within the following specifications.

Unit : mm Model

R55-3

Kind of lever

Standard

Maximum allowable

Boom lever

87±10

109

Arm lever

87±10

109

Bucket lever

87±10

109

Swing lever

87±10

109

Travel lever

86±10

105

3-15

Remarks

13) PILOT PRIMARY PRESSURE (1) Preparation ① Stop the engine. ② Push the pressure release button to bleed air. ③ Loosen and remove plug on the pilot pump delivery port(4G) and connect pressure gauge. ④ Start the engine and check for oil leakage from the port. ⑤ Keep the hydraulic oil temperature at 50±5° C. (2) Measurement ① Measure the primary pilot pressure in the H mode.

R55NN7MA14

(3) Evaluation The average measured pressure should meet the following specifications: Unit : kgf / cm2 Model

Standard

R55-3

30±5

3-16

Remarks

14) FOR TRAVEL SPEED SELECTING PRESSURE: (1) Preparation ① Stop the engine. ② Push the pressure release button to bleed air. ③ To measure the speed selecting pressure: Install a connector and pressure gauge ④ assembly to turning joint P port as shown.

Start the engine and check for on leakage from the adapter. ⑤ Keep the hydraulic oil temperature at 50±5° C. (2) Measurement ① Select the following switch positions.

Travel mode switch : 1 speed 2 speed ② Measure the travel speed selecting pressure in the Hi or Lo mode. ③ Lower the bucket to the ground to raise the track off the ground. Operate the travel lever at full stroke and measure the fast speed pressure. ④ Repeat steps ② and ③ three times and calculate the average values.

R55NN7MA15

(3) Evaluation The average measured pressure should be within the following specifications.

Unit : kgf / cm2 Model R55-3

Travel speed mode

Standard

Maximum allowable

1 Speed

0

-

2 Speed

30±5

-

3-17

Remarks

15) SWING PARKING BRAKE RELEASING PRESSURE (1) Preparation ① Stop the engine. ② Push the pressure release button to bleed air. ③ Install a connector and pressure gauge assembly to swing motor SH port, as shown. ④ Start the engine and check for oil leakage from the adapter. ⑤ Keep the hydraulic oil temperature at 50±5° C. (2) Measurement ① Operate the swing function or arm roll in function and measure the swing brake control pressure with the brake disengaged. Release the control lever to return to neutral and measure the control pressure when the brake is applied. ② Repeat three times and calculate the average values.

R55NN7MA16

(3) Evaluation The average measured pressure should be within the following specifications.

Unit : kgf / cm2 Model R55-3

Description

Standard

Brake disengaged

30±5

Brake applied

0

3-18

Remarks

16) MAIN PUMP DELIVERY PRESSURE (1) Preparation ① Stop the engine. ② Push the pressure release button to bleed air. ③ To measure the main pump pressure.

Install a connector and pressure gauge assembly main pump gauge port(1G, 2G) as shown. ④ Start the engine and check for oil leakage from the port. ⑤ Keep the hydraulic oil temperature at 50±5° C. (2) Measurement ① Measure the main pump delivery pressure at high idle.

R55NN7MA17

(3) Evaluation The average measured pressure should meet the following specifications.

Unit : kgf / cm2 Model

Engine speed

Standard

Allowable limits

R55-3

High ilde

20±5

-

3-19

Remarks

17) SYSTEM PRESSURE REGULATOR RELIEF SETTING (1) Preparation ① Stop the engine. ② Push the pressure release button to bleed air. ③ To measure the system relief pressure.

Install a connector and pressure gauge assembly main pump gauge port, as shown. ④ Start the engine and check for oil leakage from the port. ⑤ Keep the hydraulic oil temperature at 50±5° C. (2) Measurement ① Slowly operate each control lever of boom, arm and bucket functions at full stroke over relief and measure the pressure. ② In the swing function, place bucket against an immovable object and measure the relief pressure. ③ In the travel function, lock undercarriage with an immovable object and measure the relief pressure.

R55NN7MA17

(3) Evaluation The average measured pressure should be within the following specifications.

Unit : kgf / cm2 Model

R55-3

Function to be tested

Standard

Boom, Arm, Bucket

210±10

Travel

210±10

Swing

180±10

3-20

GROUP 2 TESTING AND ADJUSTING HYDRAULIC PRESSURE 1. WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT 1) MEASURING C ★ Oil temperature when measuring : 45-55°

UP TO #0616

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping.

Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Set the safety lock lever to the lock position.

R55NM3TA02

(1) Remove pressure pick-up plug (1G), (2G), (3G) or (4G) from the circuit to be measured, then install oil pressure gauge.

UP TO #0616

R55NM3TA01

#0617 AND UP

R55NM3TA03

3-21

(2) Start the engine and measure the main relief pressure with the engine at high idling. (See Table 1) •Condition of actuator to be measured. ① For the work equipment, set each cylinder to the end of its stroke. ② For travel, fit block(1) under the track shoe grouser, or fit block(2) between the sprocket and frame to lock the track shoe.

Measure one side at a time.

R55NM3TA04

Table 1 Plug

Pump

1G

Main pump A1

2G

Main pump A2

3G 4G

Main pump A3 Main pump A3

Actuator controlled Boom cylinder Service Arm cylinder Left travel motor Bucket cylinder Boom cylinder Arm cylinder Right travel motor Boom cylinder Swing motor Pilot

★ Measure all the actuator at single pump relief. ★ The set pressure of the safety valve for the swing motor is lower than the set pressure of the main relief valve, so when the swing is relieved, it becomes the set pressure of the safety valve.

3-22

2) ADJUSTING (1) Adjust work equipment and travel circuit with the main relief valve.

Main relief valve • R1 : For boom, bucket, right travel • R2 : For blade, boom swing, arm • R3 : For service, left travel

R55NM3TA05

(2) Adjusting relief valve ① Remove cap(3), then loosen lockout(1) and turn adjustment screw(2) to adjust. ② Adjust with the adjustment screw as follows.

•To INCREASE pressure, turn CLOCKWISE •To DECREASE pressure, turn COUNTERCLOCKWISE ③ Amount of adjustment for one turn of adjustment screw : 106 kg/cm2 Lockout : 2 ± 0.5 kg·m ④ After adjusting, repeat the procedure in step 1 to check again.

R55NM3TA10

3-23

2. ADJUSTING BLADE CONTROL LEVER (up to #0580)

R55NM3TA06

1) Install cable (1).

2) Adjust cable mounts A and B to the standard dimension. ●Standard dimensions : (mm) A

154.5

B

168.5

3) Adjust stopper bolt (2) to standard dimension D. ●Standard dimensions : (mm) C,D

6.8

4) Operate the blade control lever end check the travel of the control valve spool. ●Travel of spool : 6 mm (both RAISE and LOWER)

3-24

3. BLEEDING AIR 1) BLEEDING AIR FROM CYLINDERS When installing hydraulic cylinders or hydraulic piping after they have been removed, bleed the air from the hydraulic cylinder as follows.

(1) Start the engine and run it at low idling for approx 5 min.

(2) Run engine at low idling, and raise and lower boom 4-5 times in succession. ※ Stop the piston rod approx 100mm before the end of the stroke. Do not relieve the circuit.

(3) Run the engine at full throttle and repeat step 2).

After this, run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.

(4) Carry out the procedure in steps 2) and 3) for both the arm and bucket cylinders.

2) BLEEDING AIR FROM MAIN PISTON PUMP If the oil in the hydraulic tank has been changed, or the main pump has been replaced, or the pump suction piping has been removed and installed again, bleed the air after completion of the operation.

(1) Loosen air bleed plug (1), and check that oil oozes out from the plug.

(2) When oil oozes out, tighten plug (1).

Plug : 1.75±0.25 kgm ※ Precautions when starting the engine When starting the engine after carrying out the above operating, run at low idling for 10 minutes.

R55NM3TA07

3-25

4. RELEASING REMAINING FROM HYDRAULIC CIRCUIT There is no accumulator installed, so the remaining pressure in the piping between the control valve and hydraulic cylinder or swing motor cannot be released by operating the control levers. When the above piping is removed, be careful of the following points.

1) Run the engine at low idling, operate the hydraulic cylinders as far as possible so that the pressure is not relieved at the end of the stroke, lower the work equipment to the ground, and stop the engine.

2) When removing the piping, loosen the piping sleeve nut gradually to release the pressure remaining in the piping slowly, the remove the piping after the oil stops spurting out.

PRESSURIZING HYDRAULIC TANK When hydraulic equipment or hydraulic piping has been removed, carry out the following operation after installing to pressurize the hydraulic tank.

1) Extend all the cylinders fully and remove the oil filler cap from the hydraulic tank.

Then install the cap again and pressurize the inside of the tank.

R55NM3TA08

3-26

SECTION 4 ELECTRICAL SYSTEM Group 1 Component Location Group 2 Electrical Circuit Diagram Group 3 Electrical Circuit Operation Group 4 Monitoring System

4-1 4-3 4-9 4-23

SECTION 4 ELECTRICAL SYSTEM GROUP 1 COMPONENT LOCATION 1. LOCATION 1

R55NM4EL02

1 2 3 4 5 6 7 8

9 10 11 12 13 14

Hour meter Starting switch Horn switch (-#1538) Breaker push button switch (#1539-) Fuse box Cluster Breaker switch Heater blower switch Air-con switch

15 16

4-1

Wiper & washer switch Beacon switch Speaker Cassette & radio Cigar light switch Breaker push button switch (-#1538) Horn switch (#1539-) Safety switch Controller

2. LOCATION 2

R55NM4EL03

1 2 3 4 5 6

Fuel sender Gasket Battery relay Relay board Horn Work lamp

7 8 9 10 11

Connector plate Head lamp Hydraulic temperature switch Adapter Air cleaner switch

4-2

12 13 14 15 16

Water temperature switch Connector plate Earth cable Relay Battery

GROUP 2 ELECTRICAL CIRCUIT DIAGRAM 1. ELECTRICAL CIRCUIT DIAGRAM A-1 (Machine serial No : up to #0374, Except #0294, #0315 and #0355~#0366)

R55NM4EL25

4-3

2. ELECTRICAL CIRCUIT DIAGRAM A-2 (Machine serial No : #0375 to #0860, include #0249, #0315, and #0355~#0366)

R55NM4EL24

4-4

3. ELECTRICAL CIRCUIT DIAGRAM A-3 (Machine serial No : #0861 and up)

R55NM4EL20

4-5

4. ELECTRICAL CIRCUIT DIAGRAM B-1 (Machine serial No : up to #0860)

R55NM4EL23

4-6

5. ELECTRICAL CIRCUIT DIAGRAM B-2 (Machine serial No : #0861 to #1538)

R55NM4EL22

4-7

6. ELECTRICAL CIRCUIT DIAGRAM B-3 (Machine serial No : #1539 and up)

R55NM4EL21

4-8

GROUP 3 ELECTRICAL CIRCUIT OPERATION 1. POWER CIRCUIT The negative terminal of battery is grounded to the machine chassis.

When the start switch is the OFF position, the current flows from the positive battery terminal as shown below.

1) OPERATING FLOW Battery Battery relay Fuse box [No.17]

Fusible link [CN-60A(1)] I/conn [CN-15] I/conn [CN-41(2)] I/conn [CN-40(3)] Horn switch [CS-5] I/conn [CN-11(11)] I/conn [CN-9(4)] Horn relay [CR-2(2)] Fuse box [No.16] I/conn [CN-40(2)] Start key switch [CS-2(1)] Fuse box [No.15] I/conn [CN-40(1)] I/conn [CN-91(6)] Cluster [CN-57(6)] I/conn [CN-13(7)] I/conn [CN-5(3)] Room lamp [CL-1(1)] Cassette radio [CN-27(7)] ※ I/conn : Intermediate cinnector

2) CHECKPOINT Engine

Start switch

OFF

OFF

Check point

Voltage

① - GND (Battery) ② - GND (Fusible link) ③ - GND (Fuse box)

10~12.5V

※ GND : Ground

4-9

POWER CIRCUIT

R55NM4EL04

4-10

2. STARTING CIRCUIT 1) OPERATING FLOW Battery(+) terminal Fusible link [CN-60A(1)] I/conn [CN-15(1)] I/conn [CN-41(2)] Start switch [CS-2(1)]

Fuse box [No.16]

I/conn [CN-40(2)]

(1) When start key switch is in ON position Startswitch ON [CS-2(3)] I/conn [CN-11(14)] I/conn [CN-9(8)] Battery relay [M4 terminal] Battery relay operating (All power is supplied with the electric component) Fuse box [No.11] I/conn [CN-38(1)] I/conn [CN-11(13)] I/conn [CN-3(8)] Fuel stop sol [CN-20(1)] I/conn [CN-8(10)] Timer [CN-62(4)] (Activate for 1 sec) (2) When start key switch is in START position Start switch START [CS-2(5)] I/conn [CN-12(8)] I/conn {CN-7(11)] I/conn [CN-7(1)] I/conn [CN-3(4)] Start relay [CR-23(1)]

Anti-restart relay [CR-34(1,2)]

※ I/conn : Intermediate connecter 2) CHECKPOINT Engine

Operating

Start switch

Start

Check point ① - GND (Battery) ② - GND (Start key) ③ - GND (Battery relay) ④ - GND (Start relay) ⑤ - GND (Start relay) ⑥ - GND (Start relay) ⑦ - GND (Battery relay M8)

※ GND : Ground

4-11

Voltage

10~12.5V

STARTING CIRCUIT

R55NM4EL05

4-12

3. CHARGING CIRCUIT When the starter is activated and the engine is started, the operator releases the key switch to the ON position. Charging current generated by operating alternator flows into the battery through the fusible link (CN-60B).

The current also flows from alternator to each electrical component and controller through the fuse box.

1) OPERATING FLOW (1) Warning flow Alternator "L" terminal I/conn [CN-74(2)] I/conn [CN-2(1)] I/conn [CN-12(9)] Alter voltage level input [CN-58(17)], Charging lamp output [CN-58(11)] I/conn [CN-92(3)] Cluster charging warning lamp [CN-56(7)] (2) Charging flow Alternator "B+" terminal

I/conn [CN-1(1)]

Fusible link [CN-60B]

Battery terminal [CN-39]

※ I/conn : Intermediate connector 2) CHECKPOINT Engine

Operating

Start switch

Check point

Voltage

ON

① - GND (Battery) ② - GND (Alternator "B+" terminal) ③ - GND (Alternator "IG" terminal) ④ - GND (Alternator "L" terminal) ⑤ - GND (Controller) ⑥ - GND (Controller) ⑦ - GND (Cluster)

10~14V

※ GND : Ground

4-13

CHARGING CIRCUIT

R55NM4EL06

4-14

4. HEAD AND WORK LAMP CIRCUIT 1) OPERATING FLOW Fuse box (No.2) I/conn [CN-11(3)] Fuse box (No.3) I/conn [CN-11(2)]

I/conn [CN-9(7)] I/conn [CN-9(6)]

Head light relay [CR-13(2),(1)] Work light relay [CR-3(2),(1)]

(1) Head light switch ON Head light relay [CR-13(3)] I/conn [CN-7(5)] I/conn [CN-11(5)] Cluster [CN-58(9)] ※ When Head light relay ON [CR-13(4)] I/conn [CN-8(4)] Head light [CL-3(1)] I/conn [CN-13(3)] Cigar light [CL-2] Cluster illumination lamp ON (Control of cluster inner circuit)

GND

(2) Work light switch ON Work light relay [CR-3(3)] I/conn [CN-7(6)] I/conn [CN-11(6)] Cluster [CN-58(35)] GND ※When Work light relay ON [CR-3(4)] I/conn [CN-8(5)] I/conn [CN-16] Work light [CL-5(1)] Work light [CL-6(1)] Cluster illumination lamp ON (Control of cluster inner circuit) Cluster work lamp indicator ON (Control of cluster inner circuit) ※ I/conn : Intermediate connector 2) CHECKPOINT Engine

Stop

Stop

Start switch

Check point

Voltage

ON

① - GND (Fuse box) ③ - B+ (Switch power output) ⑤ - GND (Relay input) ⑦ - GND (Relay coil) ⑨ - GND (Relay output) ⑪ - GND (Head lamp)

10~12.5V

ON

② - GND (Fuse box) ④ - B+ (Switch power output) ⑥ - GND (Relay input) ⑧ - GND (Relay coil) ⑩ - GND (Relay output) ⑫ - GND (Work lamp)

10~12.5V

※ GND : Ground

4-15

HEAD AND WORK LAMP CIRCUIT

R55NM4EL07

4-16

5. BEACON LAMP CIRCUIT 1) OPERATING FLOW Fuse box (No.12) I/conn [CN-36(11)] ※ When lamp switch ON Beacon lamp switch ON [CS-23(5)]

Beacon lamp switch [CS-23(1)] I/conn [CN-12(12)]

I/conn [CN-5(5)] Beacon lamp [CL-7]

※ I/conn : Intermediate connector 2) CHECKPOINT Engine

Operating

Start switch

ON

Check point ① - GND (Fuse box) ② - GND (Switch power input) ③ - GND (Switch power ouput) ④ - GND (Beacon lamp)

※ GND : Ground

4-17

Voltage

10~12.5V

BEACON LAMP CIRCUIT

R55NM4EL08

4-18

6. WIPER AND WASHER CIRCUIT 1) OPERATING FLOW (1) Wiper motor switch ON : 1st step Fuse box (No.1) Wiper and washer switch [CS-3(1)

(6)]

I/conn [CN-13(12)] Wiper operation [CN-21(1)]

(2) Washer switch ON : 2nd step Fuse box (No.1) Wiper and washer switch [CS-3(1) (3)] Washer tank [CN-22(2) (1)] I/conn [CN-13(9)] Washer operation I/conn [CN-13(13)] Wiper operation [CS-21(1)] (3) Auto-parking(when switch OFF) Fuse box (No.1) Wiper motor [CN21(3) (4)] I/conn [CN-13(11)] Wiper and washer switch [CS-3(8) (6)] I/conn [CN-13(12)] I/conn [CN-21(1)] Wiper motor stop ※ I/conn : Intermediate connector 2) CHECKPOINT Engine

OFF

Start switch

ON

Check point ① - GND (Fuse box) ② - GND (Switch power input) ③ - GND (Switch power output) ④ - GND (Wiper power input) ⑤ - GND (Wiper motor) ⑥ - GND (Switch power output)

※ GND : Ground

4-19

Voltage

10~12.5V

WIPER AND WASHER CIRCUIT

R55NM4EL09

4-20

ELECTRIC CIRCUIT FOR HYDRAULIC

R55NM4EL10

4-21

MONITORING CIRCUIT

R55NM4EL11

4-22

GROUP 4 MONITORING SYSTEM 1. OUTLINE Monitoring system consists of the monitor part and switch part.

The monitor part gives warnings when any abnormality occurs in the machine and informs the condition of the machine.

Various select switches built into the monitor panel, and it acts as the control portion of the machine control system.

Alternator voltage Engine oil pressure switch Engine tacho sensor Work light Air cleaner switch Hydraulic oil temp. sensor Fuel sendor Coolant temp. sensor

Monitor

Charge warning lamp Engine oil warning lamp Tachometer (or clock) Work light lamp Air cleaner warning lamp Coolant overheat warning lamp Hydraulic oil temp warning lamp Fuel gauge Fuel low level lamp Coolant temperature gauge Warming up lamp

Switch Travel speed switch Pre-heat switch Heater switch Head lamp switch Work lamp switch

Battery(B+) Battery relay

Heater signal Pre-heat signal Travel speed signal Head lamp signal Work lamp signal

Signal ground Power ground

4-23

2. CLUSTER 1) Monitor panel

Clock and tachometer

Fuel gauge Battery charging warning lamp

Engine coolant temperature gauge

Overteat warning lamp

Engine oil pressure warning lamp Warming up lamp

Working light pilot lamp Air cleaner warning lamp

Fuel low level warning lamp Engine preheating switch

Hyd oil temp warning lamp Heater switch

Buzzer stop switch Select switch Head light switch

Travel speed switch

Work light switch

R55NM4EL13

2) CLUSTER CHECK PROCEDURE (1) Start key : ON ① Check monitor initial 3 seconds a. All lamps light up. b. Buzzer sound. ② Check monitor after 3 seconds : indicate machine condition a. Tachometer : 0 rpm b. Fuel gauge : All light up below appropriate level c. Engine coolant temperature gauge : All light up below appropriate level d. Warning lamp ※ In case, the engine oil pressure lamp and battery charging lamp go on, but it is not abnormal ※ When engine coolant temperature below 50 C, the warming up lamp light up ③ Switch portion Travel speed switch : Low(turtle) (1) Start of engine ① Check machine condition a. Tachometer indicate at present rpm b. Gauge and warning lamp : indicate at present condition ※ When normal condition : All warning lamp OFF c. Travel speed : Low(turtle) ② In case of abnormal condition a. The lamp lights up and the buzzer sounds

4-24

3. CLUSTER CONNECTOR 1) CN-57 CONNECTOR Signal

No

Input/ output -

1

Null

2

Travel high / low signal

output

3

Water temp sender

Input

4

Fuel level sender

Input

5

Battery relay power

Input

6

Battery (B+)

Input

7

Null

8

Head light signal

output

9

Work light signal

output

10

Engine speed sensor

Input

11

Power ground

-

12

signal ground

-

-

2) CN-56 CONNECTOR Signal

No

Input/ output

1

Null

-

2

Null

-

3

Null

-

4

Null

-

5

Null

-

6

Null

-

7

Charge warning

Input

8

Heater signal

output

9

Null

-

10

Null

-

11

Null

-

12

Hyd. oil temp warning

Input

13

Eng. oil pressure warning

Input

14

Air cleaner warning

Input

15

Null

16

Pre heat signal

R55NM4EL12

output

4-25

4. CLUSTER FUNCTION 1) MONITOR PANEL The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal machine operation or conditions for the appropriate operation and inspection. · Gauges : Indicate operating status of the machine. · Warning lamp : Indicate abnormality of the machine(Red). · Pilot lamp : Indicate operating status of the machine(Green). ※ The monitor installed on this machine does not entirely guarantee the condition of the machine.

Daily inspection should be performed according to chapter 6, Maintenance.

Clock and tachometer Fuel gauge Battery charging warning lamp

bar rpm

TIME

Engine coolant temperature gauge Engine oil pressure warning lamp

Overteat warning lamp

Warming up lamp Engine preheating indicator lamp Working light pilot lamp

Air cleaner warning lamp

Fuel low level warning lamp

Hyd oil temp warning lamp

555M3 3-2

(1) Tachometer and clock rpm

TIME

① Tachometer displays the number of engine revolutions. ② It displays the current time by electric digital timer(LCD). ※ Refer to the select switch of the switch panel for the selection and adjustment. ③ It can be selected as tachometer or clock by select switch.

13033CD04

4-26

(2) Fuel gauge ① This gauge indicates the amount of fuel in the fuel tank.

F

E 13033CD09

② Fill the fuel when the red range illuminates. ③ The gauge indicates continuously the current fuel amount even after tum OFF the starting switch. This does not mean that the gauge is out of order. ※ If the gauge illuminates the red range even though the machine is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.

(3) Engine coolant temperature gauge

C

H 13033CD06

① This indicates the temperature of coolant. ·White range : 30-50°C (86-122°F ) ·Green range : 50-105°C (122-221°F ) ·Red range : 105°C (221°F ) above ② The green range illuminates when operating. ③ Keep idling engine at low speed until the green range illuminates, before operation of machine. ④ When the red range illuminates, turn OFF the engine, check the radiator and engine.

(4) Overteat warning lamp ① This lamp is turned ON when the temperature of coolant is over the normal temperature(110°C , 230°F). ② Check the cooling system when the lamp is ON.

13033CD09

(5) Air cleaner warning lamp ① This lamp is operated by the vacuum caused inside when the filter of air cleaner is clogged which supply air to the engine. ② Check the filter and clean or replace it when the lamp operates.

13033CD10

4-27

(6) Battery charging warning lamp ① This lamp is ON when the starting switch is ON, it is turned OFF after starting the engine. ② Check the battery charging circuit when this lamp comes ON, during engine operation.

13033CD11

(7) Hydraulic oil overheat warning lamp ① This warning lamp operates and the buzzer sounds when the temperature of hydraulic oil is over 110°C(230°F). ② Check the hydraulic oil level when the lamp is turned ON. ③ Check for debris between oil cooler and radiator.

13033CD12

(8) Engine oil pressure warning lamp ① This lamp is turned OFF after starting the engine because of pressure. ② If lamp comes ON during engine operation, shut OFF engine immediately. Check oil level.

13033CD13

(9) Fuel low level warning lamp ① This lamp is turned ON when the level of fuel is below 13ℓ (3.4U.S.gal). ② Fill the fuel when the lamp cones ON.

13033CD14

(10) Warming up lamp ① This lamp is turned ON when the coolant temperature is below 50°C(122°F). ② Warming up is needed until this lamp OFF.

13033CD15

4-28

(11) Working light lamp ① When the main light switch is turned ON second step, the working light mounted on boom is ON and indicator lamp comes ON. ② Refer to the main light switch for detail.

13033CD17

(12) Engine preheating indicator lamp ① When engine preheating switch is turned ON, indicator lamp comes ON. ② Refer to the engine preheating switch for detail.

73033CD57

4-29

1) SWITCH PANEL

bar rpm

TIME

Engine preheating switch Buzzer stop switch Select switch

Heater switch

Head light switch Work light switch

Travel speed switch

555M3 3-6

(1) Engine preheating switch

555M3 3-6A

① In case of severe cold weather, this switch is used to preheat engine before staring. ② When this switch is pressed, LED lamp is turned on for 15 seconds in sequence and LED lamp off after second blink light when the time is completed. ③ Even if LED lamp is ON, this function is stopped when starting.

(2) Heater switch ① This switch is used to operate heater. ② When this switch is pressed one time, this function is operated (LED lamp ON) and stopped (LED lamp OFF) when pressed one more time.

555M3 3-6B

4-30

(3) Alarm buzzer stop switch

M 13033CD24

① When the starting switch is turned ON first, normally the alarm buzzer sounds for 3 seconds. ② The red lamp lights ON and the buzzer sounds when the machine has a problem.

In this case, if the switch is pressed, the buzzer will be stopped.

Be sure to check machine for problems. ③ Wait until the lamp is turned OFF, if the red lamp lights ON after the buzzer stopped.

If not, stop engine and check the system which the lamp is ON.

(4) Select switch

SELECT

13033CD25

① This switch is used to select the tachometer or clock. ② The switch is pressed, each function is selected by turns. ③ The switch is pressed for 3 seconds, it is selected time adjusting function, as below. ·Hour by auto decal switch ·Minute by buzzer stop switch ④ After time set, the switch is pressed, it is returned clock.

(5) Travel speed control switch

TRAVEL SPEED

① This switch is to control the travel speed which is changed to high speed(Rabbit mark) by pressing right switch and low speed(Turtle mark) by pressing again.

13033CD26

(6) Work and head light switch ① This switch is used to operate the head light and work light. ② When these switches are pressed by turns, lights ON and OFF.

555M3 3-6C

4-31

SECTION 5 TROUBLE SHOOTING Group 1 Electrical System Group 2 Hydraulic Components

5-1 5-22

SECTION 5 TROUBLESHOOTING GROUP 1 ELECTRICAL SYSTEM WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.10 (Panel gauge) is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES YES

Check voltage between CN-57 (5) and chassis NO

Check voltage

YES between CN-

91(5) and chassis

Check voltage between CN-37 (2) and chassis

Remedy

Defective cluster Replace

Disconnection in Repair or replace wiring harness or (after clean) poor contact between CN-57(5)-CN-91(5)

Disconnection in Repair or replace wiring harness or (after clean) poor contact between CN-37(5)-CN-91(5)

NO

Voltage : 10~15V Starting switch : ON

Disconnection in Repair or replace wiring harness or (after clean) poor contact between CN-37(2)-Fusebox

NO

CHECK VOLTAGE YES

10 ~ 15V

NO

0V R55NM5TS01

5-1

BATTERY CHARGING LAMP LIGHTS UP(Engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

Check voltage YES between CN-58 (1) and chassis NO YES

YES

Check voltage between CN-12 (11) and chassis

Check voltage between CN-2 (2) and chassis

Check voltage between alternator "P" terminal and chassis

Remedy

ⓐ

Repair or Disconnection in replace wiring harness or (after clean) poor contact between CN-58(1)-CN-12(11) Repair or Disconnection in replace wiring harness or (after clean) poor contact between CN-12(11)-CN-2(2)

NO

Disconnection in wiring harness or poor contact between CN-2(2)-alternator "P" terminal

NO

Voltage : 10~15V Starting switch : ON

Repair or replace (after clean)

Defective altemator Replace

NO YES

ⓐ

Check voltage between CN-92(3) and chassis

Defective cluster

Replace

Replace NO Defective controller

CHECK VOLTAGE YES

10 ~ 15V

*5V

NO

0V

0V

R55NM5TS02

5-2

WHEN AIR CLEANER LAMP LIGHTS UP(Engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

YES

Check resistance YES between CN3(12) and chassis

Does display go off when disconnect CD-10 and connector?

Starting switch : OFF

Check resistance

YES between CN-

92(10) and chassis

Starting switch : ON Engine : start

NO

Remedy

Check air filter

Repair or replace (after clean)

Defective sensor

Replace

Disconnection in wiring harness or poor contact between CN-3 (12)-CN-92(10)

Replace

Disconnection in wiring harness or poor contact between CN-92 (10)-CN-56(14)

Repair or replace (after clean)

Defective cluster

Replace

Starting switch : OFF

NO

Check resistance between CNNO 56(14) and chassis Starting switch : OFF

Before checking, disconnect CD-10

NO

CHECK RESISTANCE YES

MAX 1Ω

NO

MIN 1MΩ

R55NM5TS03

5-3

WHEN ENGINE OIL PRESSURE LAMP LIGHTS UP(Engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

YES

YES

YES

Does display go off when disconnect CD-18 and connector?

Check resistance between CN-12 (7) and chassis

Cause

Remedy

Engine oil leakage, or defective switch

Check engine oil level or replace switch

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CD-18-CN-12(7)

Starting switch : OFF

NO Disconnection in Repair or

Starting switch : ON Engine : start

wiring harness or replace (after clean) poor contact between CN-92(9)-CN-12(7)

Check resistance YES between CN-92 (9) and chassis Starting switch : OFF

Check resistance between CN-56 NO (13) and chassis

NO

Starting switch : OFF Before checking, disconnect CD-8

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-92 (9)-CN-56(13)

Defective cluster Replace

NO

CHECK RESISTANCE YES

MAX 1Ω

NO

MIN 1MΩ R55NM5TS04

5-4

WHEN HYDRAULIC TEMPERATURE LAMP LIGHTS UP(Engine is started) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

YES

YES

Check YES resistance

Does display go off when disconnect CD-1 and connector?

between CN-12 (4) and chassis

Cause

Remedy

Hydraulic oil overheat, or defective switch

Check hydraulic oil temperature (105± 2° C) or replace switch

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CD-1-CN-12(4)

Starting switch : OFF

Starting switch : ON Engine : start

NO Disconnection in Repair or

Check YES resistance between CN-92 (8) and chassis

wiring harness or replace (after clean) poor contact between CN-92(8)-CN-12(4)

Starting switch : OFF

Check resistance NO between CN-56 (12) and chassis

NO

Starting switch : OFF Before checking, disconnect CD-1

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-92 (8)-CN-56(12)

Defective cluster Replace

NO

CHECK RESISTANCE YES

MAX 1Ω

NO

MIN 1MΩ R55NM5TS05

5-5

WHEN COOLANT TEMPERATURE GAUGE DOES NOT OPERATE (Check coolant temperature lamp ON/OFF) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

Remedy

Coolant overheat Check coolant temperature or or defective replace sender YES

Check resistance between CN-2 (5) and chassis

YES

Does display go off when disconnect CD-8 and connector?

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-2(5)-CD-8

Starting switch : OFF

NO

Starting switch : ON Engine : start

Check resistance between CN-91 (3) and chassis

YES

Starting switch : OFF

Check resistance between CN-57 NO (3) and chassis

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-91(3)-CN-2(5)

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-91(3)-CN-57(3)

NO

Starting switch : OFF Before checking, disconnect CD-1

Defective cluster Replace

NO

CHECK TABLE Temperature

C

H

Item

(50° C)

(80° C)

(100° C)

(120° C)

Unit resistance(Ω)

826

310

176

112

Tolerance

-

±12

±9

±1.2

R55NM5TS06

5-6

WHEN FUEL GAUGE DOES NOT OPERATE(Check warning lamp ON/OFF) ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

Remedy

Defective cluster Replace YES

Check

YES resistance

Check resistance between CN57(4) and hassis

between CD2(2) and chassis NO Disconnection in Repair or wiring harness or replace See : TABLE (after clean) poor contact between CD-2(2)-CN-12(3)

Check

YES resistance

between CN4(6) and chassis

Starting switch : OFF See : TABLE

ⓐ

See : TABLE

Check resistance NO between CN8(4) and chassis

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-12(3)-CN-91(4)

NO

See : TABLE

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-9(9)-CN-57(4)

NO

YES

ⓐ

Check resistance between CD-2(2) and CD-2(1) See : TABLE

NO

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CD-2(1)-chassis Defective sender Replace

CHECK TABLE

F

E

Level Item

Empty

2/6

3/6

4/6

5/6

Full

Unit resistance(Ω)

600

500

100

200

200

100

Tolerance

±5%

±5%

±5%

±5%

±5%

±5%

R55NM5TS07

5-7

WHEN SAFETY SOLENOID DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.9 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

Remedy Check hydraulic system

YES Check operation

of solenoid Defective solenoid

Safety lever : ON-OFF NO

Replace

NO

NO

Check voltage between CN-68 (1)-CN-68(2)

Check voltage between CN-8(1) and chassis

NO

Starting switch : ON Voltage : 10~15v Non-safety state

Check voltage ⓐ between CR-40(5) Disconnection in Repair or and chassis YES wiring harness or replace Non-safety state poor contact (after clean) between CR-40(5)-CN-8(1)

Non-safety state

Check voltage between CN-68(2) NO and chassis

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CN-8(1)-CN-68(2)

YES

Non-safety state

YES

NO NO

ⓐ

Check chassis contact

Repair or replace (after clean)

Defective relay

Replace

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-40(3)-CN-37(1)

Check resistance relay magnet coil and operation of relay Check voltage between CR-40 YES (3) and chassis

NO

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-40(2)-CN-13(4)

Non-safety state

Check resistance between CR-40 YES (2)-CN-13(4)

NO

Check resistance YES between CN-13 (4)-CS-4 YES

5-8

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CN-13(4)-CS-4 Defective switch

Replace

R55NM5TS08

5-9

WHEN TRAVEL SPEED 1, 2 DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.9 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified. (* Voltage of CN-57(2) ~ CN-58(12) and chassis : 5V, if not defective cluster) Cause YES

Check hydraulic system

YES Check operation of solenoid

Defective solenoid

NO

Starting switch : ON

Check voltage

NO

12(4) and chassis

YES

NO between CR-

Check voltage between CN-70 (2)-CN-70(1)

Check voltage between CN8(3) and chassis

NO

Starting switch : ON Voltage : 10~15v

Remedy

Non-safety state

Replace

ⓐ Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-12(4)-CN-8(3)

Non-safety state

Check voltage between CN-70(2) NO and chassis

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CN-8(3)-CN-70(2)

YES

Starting switch : ON

YES

NO

ⓐ

NO

Check resistance relay magnet coil and operation of relay

Repair or replace (after clean)

Defective relay

Replace

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-12(2)-CN-37(1)

Check voltage YES between CR-12 (2) and chassis Starting switch :ON

Check chassis contact

NO

Check resistance between CR-12 YES (3)-CN-58(6)

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-12(3)-CN-58(6) NO

Check voltage between (B+)YES CN-58(6) YES

5-10

Defective controller Recheck

Replace

R55NM5TS09

5-11

WHEN ENGINE DOES NOT START ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.11 and No.16 are not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

Cause YES

YES

Check woltage YES between starter magnet coil and chassis

Check operation of start motor

NO

Starting switch : start Starting switch : start

NO

Check operation NO of start relay Starting switch : start

YES

NO

Check voltage between CS-2 NO (1) and chassis Starting switch : ON

Starting switch : start

Replace

Defective start relay

Replace

Disconnection in Repair or wiring harness or replace poor contact between (after clean) CN-40(2)-CS-2(1) Replace

Repair or wiring harness or replace poor contact between (after clean) CN-20(1)-CN-38(1)

NO

Defective fuel stop solenoid

Replace

Disconnection in Repair or wiring harness or replace poor contact between (after clean) CR-34(2)-CS-2(5)

YES

Check voltage between CR-34 YES (4) and chassis

Defective magnet of start relay

YES NO Disconnection in

YES

Check voltage between CR-34 (2) and chassis

Check engine system charge (after checking specific gravity of battery) or replace.

ⓐ

Check voltage between CN-20 YES (1) and chassis

ⓐ

Defective battery

Defective start switch

Check voltage between CS-2 (5) and chassis

Remedy

Check voltage between CR-23 (1) and chassis

YES

Defective start relay

Disconnection in Repair or wiring harness or replace poor contact between (after clean) CR-23(1)-CR-34(4)

NO

Check voltage between CN-58 NO (25) and B+

NO YES

Check voltage between CR-34 YES (3) and B+

5-12

Replace

Defective controller

Replace

Defective relay

Replace

Disconnection in Repair or wiring harness or replace NO poor contact between (after clean) CR-34(3)-CN-58(25)

R55NM5TS10

5-13

WHEN STARTING SWITCH DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fusible link and the fuse No.16 are not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

NO

YES

Check voltage and specific gravity of battery

YES

Check voltage between CN-9 (8) and chassis Voltage : 10 ~ 15V

Secific gravity : MIN 1.28 Voltage : MIN 12V

NO YES

Check voltage between CS-2 (3) and chassis Voltage : 10 ~ 15V

Check resistance between CS-2 YES (1) and chassis NO

Voltage : 10 ~ 15V

Cause

Remedy

Battery capacity too low

Repair or replace (after clean)

Disconnection in Replace wiring harness or poor contact between CN-9(8)-CR-1 or defective battery relay Disconnection in Repair or wiring harness or replace (after clean) poor contact between CS-2(3)-CN-9(8)

Defective start key switch

Replace

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CS-2(1)-CN-40(2) -CN-41(2)-CN-15 (1) - fusible link

NO

5-14

R55NM5TS11

5-15

WHEN STARTING SWITCH IS TURNED ON, WIPER MOTOR DOES NOT OPERATE ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.1 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified.

YES

Check voltage NO between CS-3 (1) and chassis Voltage : 10 ~ 15V Wiper switch : ON

Remedy

Defective wiper switch

Replace

Recheck fuse NO

YES

Check voltage YES between CN-21 (1) and chassis Check operation of wiper switch

NO YES

Starting switch : ON Wiper switch : ON-OFF

Cause

Check voltage between CS-3 YES (6) and chassis

Check voltage between CN-13 (12) and chassis

NO

Voltage : 10 ~ 15V Wiper switch : ON

Defective wiper motor

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-13 (12)-CN-21(1)

Disconnection in Repair or wiring harness or replace (after clean) poor contact between CN-13 (12)-CS-3(6) Defective wiper switch

NO

5-16

Replace

Replace

R55NM5TS12

5-17

WHEN STARTING SWITCH IS TURNED ON, HEAD LAMP DOES NOT LIGHT UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.2 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified. (* Voltage of CN-57(8) ~ CN-58(3) and chassis : 5V, if not defective cluster)

YES YES

Check voltage between CL-3 (1)-CL-3(2) NO Starting switch : ON

YES

Check voltage between CL-3 (2) and chassis

Check voltage YES between CR-13 (3) and B+ Check voltage NO between CR-13 Disconnect of relay (1) and chassis termial

Starting switch : ON Headlamp switch : ON

NO

Check voltage between CR-13 NO (4) and chassis Starting switch : ON

Remedy

Defective head lamp

Replace

Check chassis contact

Repair or replace (after clean)

Defective relay

Replace

ⓐ

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-13 (1)-CN-36(2) Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-13 (4)-CL-3(2)

YES

YES

ⓐ

NO

Cause

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-13 (3)-CN-7(5) or Defective relay

Check voltage between CN-7 (5) and B+

YES

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CN-7 (5)-CR-11(5)

Check voltage NO between CN-11 (5) and B+ Starting switch : ON

YES

Check voltage between CN-58 NO (9) and B+ NO

5-18

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-11 (5)-CN-58(9) Defective controller

Replace

R55NM5TS13

5-19

WHEN STARTING SWITCH IS TURNED ON, WORK LAMP DOES NOT LIGHT UP ·Before disconnecting the connector, always turn the starting switch OFF. ·Before carrying out below procedure, check all the related connectors are properly inserted and the fuse No.3 is not blown out. ·After checking, connect the disconnected connectors again immediately unless otherwise specified. (* Voltage of CN-57(9) ~ CN-58(18) and chassis : 5V, if not defective cluster)

YES

Check voltage

YES between CL-5

(2)-CL-5(1) and CL-6(2)-CL-6(1)

NO

Starting switch : ON

YES

Check voltage between CL-5 (2) CL-6(2) and chassis

Check voltage YES between CR-3 (3) and B+ Check voltage NO between CR-3 Disconnect of relay (1) and chassis termial

Starting switch : ON Headlamp switch : ON

NO

Check voltage between CR-3 NO (4) and chassis Starting switch : ON

Remedy

Defective work lamp

Replace

Check chassis contact

Repair or replace (after clean)

Defective relay

Replace

ⓐ

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-3 (1)-CN-36(3) Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-3(4)CL-5(2), CL-6(2)

YES

YES

ⓐ

NO

Cause

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-3(3)-CN-7(6) or Defective relay

Check voltage between CN-7 (6) and B+

YES

Disconnection in wiring harness or poor contact between CN-7(6)-CR-11(6)

Check voltage NO between CN-11 (6) and B+ Starting switch : ON

YES

Check voltage between CN-58 NO (35) and B+ NO

5-20

Repair or replace (after clean)

Disconnection in Repair or wiring harness or replace poor contact (after clean) between CR-11(6)-CN-58(35) Defective controller

Replace

R55NM5TS14

5-21

GROUP 2 HYDRAULIC COMPONENTS 1. TRAVEL MOTOR Symptom

Cause

Remedy

•Main relief pressure dropped

•Replace main relief valve

•Pump failure

•Check if action other than traveling is available.

If faulty, repair

•Control valve malfunction

•Check if spool moves correctly.

Repair if necessary

•Brake valve failure *Spool stick *Check valve stick

•Replace brake valve

•Motor failure

•Replace motor •Check hydraulic oil for contamination

•Gear broken and fragment locked

•Replace reduction gear

•Overloaded

•Reduce load

•Scratch on engaging surfaces

•Correct surfaces by oil stone or sandpaper or replace

•Loosening by poor bolt tightening

•Check after retightening

Leakage from casing

•Plug loosened •Crack formed by stone

•Retighten •Replace reduction gear

Leakage from floating seal

•Sliding surfaces worn •Creep on O-ring

•Replace reduction gear •Replace floating seal

Leakage from hydraulic motor

•Bolt loosened •O-ring damaged •Sealing surface scratched

•Tighten properly •Replace O-ring •Correct by oil stone or sandpaper

•Pitting on bearing •Lack of gear oil •Hydraulic oil introduced to gear case

•Replace reduction gear •Supply gear oil properly •Check hydraulic motor, and replace oil seal

•Poor volumetric efficiency of hydraulic motor

•Replace hydraulic motor

•Increase of internal leakage of brake valve

•Replace brake valve

Pressure is not developed

Does not start

Pressure is developed

Leakage from engaging surfaces

Oil leakage

Excessive temperature on reduction gear case

Coasts on slope excessively

•Parking brake does not actuated *Spring breakage *Wear of friction plate

5-22

•Replace spring •Replace parking brake

Symptom Meanders at low pressure

Meanders

Meanders at high pressrue

Speed is poor

Pump delivery is poor

Cause •Delivery rate is different between right and left

•Repair pump

•Motor drain rate is different between right and left

•Replace motor

•Delivery rate is different between right and left

•Repair regulator of pump

•Motor drain rate is different between right and left

•Reduce motor

•Main relief pressure dropped at right or left of control

•Replace main relief valve

•Regulator operation is poor

•Repair regulator

•External leakage of pump is excessive

•Repair pump •Replace motor

External leakage of motor is excessive

Does not switch to high-speed from low-speed

Does not switch to low-speed from high-speed

Remedy

•Ball check valve (shuttle valve) failure

•Check if check valve correctly.

Repair or replace if necessary

•2-speed control valve failure

•Check if valve correctly.

Repair or replace if necessary

•Pilot pressure is lower

•Reset to correct pressure

•2-speed control piston failure

•Check if piston correctly.

Repair or replace if necessary

•Ball check valve (shuttle valve) failure

•Check if check valve correctly.

Repair or replace if necessary

•2-speed control valve failure

•Check if valve correctly.

Repair or replace if necessary

5-23

2. HYDRAULIC PUMP Symptom

Abnormal noise

Main causes

Check

Remedy

•Air sucked due to lowering of the oil level

•Check the hydraulic oil level

•Check the hydraulic oil

•Increase in the suction pressure •Check the filter element loss due to the dogged filter

•Chean or change the element

•Increase in the suction pressure •Check the hydraulic oil loss due to increase in the temperature and the type viscosity of the hydraulic oil of hydraulic oil when the temperature is low

•Ensure the correct oil temperature or replace with the appropriate oil

•Input shaft speed higher than the specified one

•Readjust the rotating speed

•Mechanical damage (Bearing, etc)

•Lowering of the input shaft speed

•Check the input shaft speed

•Replace the damaged - Check the pressure part or the pump which may cause - Set the pressure again overload - Carry out flashing in the - Measure contamination of the hydraulic oil circuit - Check if the hydraulic oil - Change the oil is emulsified due to mixing of water •Check the input shaft speed

•Readjust the rotating speed

•Abnormally high oil temperature •Check the oil temperature •Stop the operation and check again when the oil temperature has lowered •Abnormally high viscocity

Insufficient flow rate

•Check the oil temperature •Change the oil to a type and type having an appropriate viscosity

•Increase in the leakage from the •Check if this problem directional control valve and occurs in a specific actuator actuator only

•Replace the directional control valve and actuator

•Lowering of the pump displacement efficiency

•Check if this problem occurs in a specific pump only

•Replace the pump

•Loosen power setting adjusting screw

•Check locknut for looseness

•Set again and lock

•Air sucked due to lowering of the oil level

•Check the hydraulic oil level

•Add the hydraulic oil

•Increase in the suction pressure •Check the filter element loss due to the clogged filter

•Clean or replace the element

•Increase in the suction pressure •Check the hydraulic oil loss due to increase in the temperature and type viscosity of the hydraulic oil when the temperature is low

•Ensure the correct oil temperature or replace with the appropriate oil

5-24

Symptom

Main causes

Check

Remedy

•Lowering of the setting of the relief valve

•Measure the circuit pressure

•Set the relief valve again

•Increase in the leakage from the •Check the operation of •Replace the directional each actuator and check directional control valve and control valve and actuator the tank return piping for No pressure rise actuator abnormal heat generation •Lowering of the pump displacement efficiency

•Check if this problem occurs in a specific pump only

•Replace the pump

•Increase in the setting of pump power

•Check the motor sound and speed

•Set the pump power again by means of the bench test or motor

•Check the slide portions of the control device for any inclusion of foreign materials

•Repair the damaged part caused by inclusion of foreign materials or replace

•Malfunction of the control device Overload under static load

Rotating speed decreasing under dynamic load

•Mechanical damage (Bearing, etc)

•Check the housing around •Replace the damaged the bearing for abnormal part or pump heat generation and noise

•Peak pressure occurred due to deterioration of response performance of the relief valve

•Check the circuit for abnormal vibration and measure the pressure - Check if the pilot line is clogged with foreign materials - Check the slide portions of the control device for any inclusion of foreign materials

•Deterioration of response performance of the control device

•Increase in the leakage from the •Measure the actuator speed pump

Abnormal heat generation

•Replace the relief valve

- Remove the foreign materials - Repair the damaged part caused by inclusion of foreign materials or replace •Replace the pump

•Mechanical damage (Bearing, etc)

•Check the abnormal noise •Replace the damaged and the location where part or pump abnormal heat is generated

•Seizure of the slide portion

•Check the location where abnormal heat is generated

5-25

•Replace the damaged part or pump

Symptom

Main causes

Check

Remedy

•Damage to O-ring and packing

•Confirm the oil leaking point and check for abnormal pressure

•Replace the seal material

•Damage to the oil seal

•Check for damage caused by foreign materials and check for abnormal pressure

•Replace the seal material

•Worn oil seal contact of input shaft

•Check for adhesion of foreign materials and check for abnormal pressure

•Replace the input shaft or pump

•Loosen plugs

•Confirm the oil leaking point

•Retighten or replace the seal material

Oil leakage

5-26

3. MAIN CONTROL VALVE Symptom

Main causes

Remedy

•Seal is scratched or the seal lip is worn due to long use Oil leakage from •Paint adhered to the sliding portion of the spool seal spool’s seal portion

•Replace with a new one •Remove paint mechanically. However at this time, be careful not to damage the spool surface or the seal lip

•Foreign matter is bitting into the spool’s sliding surface

•Overhaul and repair or replace

•Spool is bent from externally applied pressure

•Repair or replace

•Oil is accumulating in the cover (the side with a spring or a detent) opposite the side where the spool operates

•The spool is leaking oil, so when the spool moves, oil leaks from the cover. After confirming this, replace the seal

Spool’s sliding is •Bolts used to assemble the valve were not smooth tightened excessively

•Check tightening torque (2 kg m)

•Entire valve is strained due to strain in the installation face

•Loosen the installation bolts, then cut the installation face and edge and check

•Oil film between the spool and body disappears due to abnormally high oil temperature

•Use some method to lower the oil temperature or if the relief valve is operating frequently, investigate the cause and reduce the frequency

•Could be mistaken for a great amount of leakage in the cylinder

•Check if it isn’t just the cylinder’s natural drop when the cylinder is held. If the problem is in the cylinder, disassemble and repair it

•The gap between the spool and body is large, so the amount of oil leaking from the spool is great

•Replace the spool or replace the valve block assembly

Can’t be held in the spool neutral •Spool won’t return completely to the position neutral position (Cylinder drops)

•Foreign matter is bitting into the port relief valve seat or the anti-cavitation valve seat and oil is bypassing. Or a seat is damage

5-27

•Manual operation : Check if there is something interfering with the link mechanism •Hydraulic operation : Check the pilot pressure •Disassemble and check, then overhaul or replace

Symptom

The load won’t move (Pressure won’t increase)

The load won’t move (Pressure won’t increase)

Main causes

Remedy

•Foreign matter is bitting into the relief valve seat and oil is bypassing. Or a seat is damaged

•Disassemble and check, then overhaul or replace

•The relief valve’s adjustment screw is loose •Try tightening the adjustment screw. If it is loose, correct the setting and tighten the lock nut securely •Foreign matter is bitting into the port relief •Disassemble and check, then overhaul or valve seat or the anti-cavitation valve seat replace and oil is bypassing. Or a seat is damaged •Pump is damaged and no oil is discharged

•Check if the pump is abnormal or not. If the pump is bad, replace it. Check if the cause of the abnormality is air being sucked in, deterioration of hydraulic oil or shafts not centered, etc

•The load is too heavy

•Compare with an object of the specified weight

•Mechanical resistance of connecting parts is great regardless of the hydraulic pressure in the operating unit

•Check and replenish hydraulic oil, etc, modify or repair

•A large piece of foreign matter is trapped in the circuit or a pipe is bent, causing great resistance

•Find the affected place and repair it

•Spool stroke is not the specified stroke

•Check if there is something interfering with the link mechanism. Check if a pin or a pin hole in the link connection is worn or not

5-28

SECTION 6 MAINTENANCE STANDARD Group 1 Major Components Group 2 Track and Work Equipment

6-1 6-5

SECTION 6 MAINTENANCE STANDARD GROUP 1 MAJOR COMPONENT 1. MAIN CONTROL VALVE

R55NM6MJ02

Unit : mm No

1

Criteria

Check item

Travel spool return spring

Standard size

Repair limit

Free length

Installed length

Installed load (kg)

Free length

Installed length

38.2

26.8

13.8

-

-

2

Spool return spring (Boom swing & dozer)

42

26.8

10

-

-

3

Pilot spool return spring

35.2

34.2

3.3

-

-

4

Check load valve spring

17

9.5

0.475

-

-

5

Check anti-cavitation valve spring

18.3

15.4

0.1

-

-

6

Check valve spring

17.5

13.5

0.3

-

-

6-1

Remedy

Replace

2. TURNING JOINT

R55NM6MJ03

Unit : mm No 1

Check item Clearance between hub and shaft

Criteria Standard size 80

Standard clearance Clearance limit 0.056 ~ 0.105

6-2

0.111

Remedy Replace

3. HYDRAULIC CYLINDER

R55NM6MJ01

Unit : mm No

A

B

C

Check item

Clearance between piston rod and bushing

Clearance between piston rod mounting pin and bushing

Clearance between cylinder bottom mounting pin and bushing

Remedy

Criteria Cylinder

Standard size

Boom

Tolerance Shaft

Hole

Standard Clearance clearance limit

55

-0.030 -0.070

+0.110 0

0.025 ~ 0.174

0.567

Arm

50

-0.025 -0.064

+0.110 0

0.025 ~ 0.174

0.551

Bucket

50

-0.025 -0.064

+0.110 0

Boom swing

50

Blade

50

-0.025 -0.064 -0.025 -0.064

+0.110 0 +0.110 0

0.025 ~ 0.174 0.025 ~ 0.174 0.025 ~ 0.174

Boom

50

-0.147 -0.209

+0.142 +0.080

0.227 ~ 0.351

1.0

Arm

45

-0.025 -0.087

+0.142 +0.080

0.105 ~ 0.229

1.0

Bucket

45

-0.170 -0.230

+0.142 +0.080

0.250 ~ 0.372

1.0

Boom swing

50 55

+0.142 +0.080 +0.174 +0.100

0.105 ~ 0.206 0.130 ~ 0.250

1.0

Blade

-0.025 -0.064 -0.030 -0.076

Boom

50

-0.025 -0.087

+0.142 +0.080

0.105 ~ 0.229

1.0

Arm

45

-0.025 -0.087

+0.142 +0.080

0.105 ~ 0.229

1.0

Bucket

45

-0.025 -0.064

+0.142 +0.080

0.105 ~ 0.206

1.0

Boom swing

50

-0.025 -0.064

+0.142 +0.080

0.105 ~ 0.206

1.0

Blade

55

-0.190 -0.264

+0.174 +0.100

0.290 ~ 0.438

1.0

6-3

Replace bushing

0.539 0.551 0.551

Replace bushing

1.0

Replace bushing

4. SWING CIRCLE

R55NM6MJ04

Unit : mm No

Check item

1

Clearance of bearing

Criteria Standard clearance

Clearance limit

0.05 ~ 0.2

0.4

6-4

Remedy Replace

GROUP 2 TRACK AND WORK EQUIPMENT 1. TRACK SHOE 1) STEEL SHOE SPEC

R55NM6MJ05

Unit : mm No

Check item

Criteria Standard size

Repair limit

1

Limit pitch

135

138

2

Outside diameter of bushing

35

32

3

Height of grouser

14

11

4

Height of link

67

64

5

Tightening torque

Initial tightening torque : 19±1.0kgf·m

6-5

Remedy Replace bushing and pin and link assembly Lug welding, rebuild or replace Retighten

2) RUBBER SHOE SPEC

R55NM6MJ06

Unit : mm No

Check item

Criteria Standard size

Tolerance

Repair limit

1

Link pitch

73

±1.0

70

2

Height of grouser

25

-

5

3

Width of link

55

-

70

6-6

Remedy

Replace

2. IDLER

R55NM6MJ10

Unit : mm No

Criteria

Check item

Standard size

Repair limit

Steel

384

-

Rubber

398

-

1

Outside diameter of flange

2

Outside diameter of thread

355

349

3

Width of flange

51

45

6-7

Remedy

Rebuild or replace

3. TRACK/CARRIER ROLLER

R55NM6MJ09

Unit : mm No

Criteria

Check item

Standard size

Repair limit

Steel

120

-

Rubber

130

-

1

Outside diameter of flange

2

Outside diameter of thread

100

94

3

Width of flange

51

45

6-8

Remedy

Rebuild or replace

4. TENSION CYLINDER 1) STEEL SHOE SPEC

R55NM6MJ08

Unit : mm No

Criteria

Check item

1

Vertical width of idler guide

2

Horizontal width of idler guide

Repair limit

Track frame

82

86

Rebuild

Idler support

80

76

Rebuild or replace

Track frame

220

222

Rebuild

Idler guide

218

214

Rebuild or replace

Standard size 3

Recoil spring

Remedy

Standard size

Free length 330

Installed Installed length load 295

6-9

3,600 kg

Repair limit Free length -

Installed Replace load 2,880 kg

2) RUBBER SHOE SPEC

R55NM6MJ07

Unit : mm No

Criteria

Check item

1

Vertical width of idler guide

2

Horizontal width of idler guide

Repair limit

Track frame

82

86

Idler support

80

76

Track frame

220

222

Rebuild or replace

Idler guide

218

214

Rebuild

Standard size 3

Recoil spring

Remedy

Standard size

Free length 330

Installed Installed length load 280

6-10

5,140 kg

Repair limit Free length -

Rebuild

Rebuild or replace

Installed load 4.110 kg Replace

5. SPROCKET

R55NM6MJ12

Unit : mm No 1 2 3 4

Check item Wear out of sprocket tooth lower side diameter Wear out of sprocket tooth upper side diameter Wear out of sprocket tooth upper side width Wear out of sprocket tooth lower side width

Criteria Standard size

Repair limit

418.6

412

476

-

30.5

-

42.5

36.5

6-11

Remedy

Repair or Replace

6. WORK EQUIPMENT

R55NN6MJ11-1

R55NN6MJ11

6-12

Unit : mm No

1

2 3 4 5 6 7 8

Check item Clearance between bushing (For swing frame and swing bracket) and connector pin Clearance between connector pin (For swing bracket and boom) and bushing Clearance between connector pin (For boom and arm) and bushing Clearance between link connector pin and bushing Clearance between connector pin (For link and arm) and bushing Clearance between connector pin (For bucket and arm) and bushing Clearance between connector pin (For bucket and link) and bushing Clearance between connector pin (For track frame and blade) and bushing

Criteria Tolerance

Remedy

Shaft

Hole

Standard Clearance clearance limit

100

-0.036 -0.090

+0.295 +0.237

0.273 ~ 0.385

1.0

50

-0.025 -0.064

+0.204 +0.160

0.185 ~ 0.268

1.0

50

-0.025 -0.087

+0.204 +0.160

0.185 ~ 0.291

1.0

45

-0.170 -0.230

+0.056 +0.012

0.182 ~ 0.286

1.0

45

-0.170 -0.230

+0.056 +0.012

0.182 ~ 0.286

1.0

45

-0.170 -0.230

+0.056 +0.012

0.182 ~ 0.286

1.0

45

-0.170 -0.230

+0.056 +0.012

0.182 ~ 0.286

1.0

35

-0.080 -0.119

+0.142 +0.080

0.160 ~ 0.261

1.5

Standard size

6-13

Replace with new bushing

7. WORK EQUIPMENT

R55NM7MA20

Unit : mm Pin Mark

Measuring point (Pin and Bushing)

Normal value

Recomm. service limit

Bushing Limit of use

Recomm. service limit

Limit of use

A

Boom Rear

50

49

48.5

50.5

51

B

Boom Cylinder Head

50

49

48.5

50.5

51

C

Boom Cylinder Rod

50

49

48.5

50.5

51

D

Arm Cylinder Head

45

44

43.5

45.5

46

E

Boom Front

50

49

48.5

50.5

51

F

Arm Cylinder Rod

45

44

43.5

45.5

46

G

Bucket Cylinder Head

45

44

43.5

45.5

46

H

Arm Link

45

44

43.5

45.5

46

I

Bucket and Arm Link

45

44

43.5

45.5

46

J

Bucket Cylinder Rod

45

44

43.5

45.5

46

K

Bucket Link

45

44

43.5

45.5

46

6-14

Remedy & Remark

Replace

SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Hydraulic Pump Group 2 Main Control Valve Group 3 Swing Motor Group 4 Travel Motor Group 5 Remote Control Valve Group 6 Turning Joint

7-1 7-41 7-48 7-74 7-128 7-142

SECTION 7 DISASSEMBLY AND ASSEMBLY GROUP 1 HYDRAULIC PUMP 1. NECESSARY TOOLS AND JIGS The following tools and jigs are necessary to disassemble and reassemble the pump.

1) TOOLS Name

Quantity

Size (Nominal)

Hexagonal bar spanner

One each

5, 6, 8, 10

Spanner

1

17, 24

Plastic hammer

1

Medium size

Snap ring pilers

1

For hole (Stop ring for 72)

Snap ring pilers

1

For shaft (Stop rings for 28 and 30)

Standard screw-driver

2

Medium size

Torque wrench

-

Wrench which can tighten at the specified torque

Grease

Small

-

Adhesives

Small

LOCTITE #270

2) JIGS (1) Disassembling table.

45 or more

Ø35 ~ Ø55

Ø110 or more R55NM7HP01

This is plate to stand the pump facing downward.

A square block may be used instead if the shaft end does not contact.

15

40

(2) Bearing assembling jig

Ø19 Ø25 R55NM7HP02

7-1

2. CAUTIONS DURING ASSEMBLING AND DISASSEMBLING 1) CAUTIONS FOR DISASSEMBLING · Never attempt operating the adjusting screw unless absolutely necessary.

Otherwise, the set power may be changed, affecting adversely to the system. · Take utmost care during disassembly not to knock or drop each part.

2) CAUTIONS FOR ASSEMBLING · Wash each part thoroughly · During assembling, take utmost care not to damage the part or allow foreign materials to enter. · As a rule, the O-ring and oil seal should not be reused. · In our assembly work, the torque wrench is used to control the torque.

Be sure to use the torque wrench.

7-2

3. DISASSEMBLY PROCEDURE 1) DISASSEMBLING THE GEARED PUMP ① Remove the hexagonal socket headed bolts (M10 × 25, 2 pieces) Hexagonal bar spanner (Hex. side distance : 8) ※ Be careful because the O-ring and filter are provided to the match surface of the geared pump.

R55NM7HP03

② Remove the coupling.

R55NM7HP04

2) DISASSEMBLING THE MAIN PUMP ① Remove the cover.

Remove the hexagonal socket headed bolts. (M12 × 30, 3pieces) and (M12 × 55, 1piece) Hexagonal bar spanner (Hex. side distance : 10)

R55NM7HP05

② Remove the cover in a horizontal condition.

Connect motor to work table. ※ Be careful because the control plate is provided to the backside.

When the cover is difficult to remove, knock lightly with a plastic hammer.

R55NM7HP06

7-3

③ This photo shows the state with the cover removed.

R55NM7HP07

④ Remove the O-ring from the cover.

R55NM7HP08

(1) The removal of the control spring ① Remove 2 springs(Inner and outer).

R55NM7HP09

② Remove the spring seat.

R55NM7HP10

7-4

(2) The removal of rotary group ① Lay the pump on the side and take out the rotary group from the shaft.

R55NM7HP11

② Remove the plate.

R55NM7HP12

(3) The removal of the shaft ① Remove the C-type stop ring.

(Snap ring pliers for hole)

R55NM7HP13

② Use two standard screw-drivers to remove the oil seal case.

R55NM7HP14

7-5

③ Remove the O-ring.

R55NM7HP15

④ Remove it while knocking the shaft rear and lightly with a plastic hammer.

R55NM7HP16

(4) The removal of the hanger ① Remove the hexagonal socket headed bolts (M6 × 16, 4pieces) and plate.

Hexagonal bar spanner (Hex. side distance : 5)

R55NM7HP17

② Remove the distance piece.

R55NM7HP18

7-6

③ Remove the bearing.

R55NM7HP19

④ Remove the hanger.

R55NM7HP20

(5) The removal of the cover ① Remove the control plate.

R55NM7HP21

② Remove the C-type stop ring.

R55NM7HP22

7-7

③ Remove the filter.

R55NM7HP23

(6) The removal of the control piston ① Remove the hexagonal socket headed bolts. (M8 × 25, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) The threaded portion of the bolt is coated with LOCTITE #270.

This disassembly must therefore be made only when necessary.

R55NM7HP24

② Remove the cylinder and parallel pin. ※ Be careful because 3 O-rings are provided to the cylinder.

R55NM7HP25

③ Take out the piston.

R55NM7HP26

7-8

④ Take out three caned disk springs and spring seats.

R55NM7HP27

(7) The removal of the control spring ① Remove the hexagonal socket headed bolts (M8×30, 2pieces) and remove the cover.

Hexagonal bar spanner (Hex. side distance : 6).

R55NM7HP28

② Remove othe spring seat.

R55NM7HP29

7-9

(8) The removal of the relief valve ① Remove the hexagonal nuts. ※ Since the pressure has been set, this assembly must be made only when necessary.

Spanner (Hex. side distance : 24).

R55NM7HP30

② Remove the adjusting screw. ※ Be careful because the shim is inserted.

R55NM7HP31

③ Remove the spring.

R55NM7HP32

④ Remove the spool.

R55NM7HP33

7-10

(9) Disassembly of the shaft ① Remove the bearing.

Remove the C-type stop ring.

Snap ring pliers for shaft.

R55NM7HP34

② Remove it while knocking the rear end of shaft lightly with a plastic hammer.

R55NM7HP35

7-11

3) DISASSEMBLING THE GEARED PUMP (up to #1416) (1) Disassembling the geared pump(G1).

Remove the hexagonal socket headed bolts (M8 × 40, 4pieces).

Hexagonal bar spanner (Hex. side distance : 6)

R55NMPH36

(2) Disassembling the geared pump(G1).

Remove the side plate, back-up ring, square ring and gears while pulling out the drive gear.

R55NMPH37

(3) Remove the idle gear.

R55NMPH38

(4) Disassembling the geared pump (GSP2).

Remove the hexagonal socket headed bolts (M10 × 85, 4pieces).

Spanner (Nominal : 17) The O-ring and filter are provided to the match surface of the geared pump and should be removed.

R55NMPH39

7-12

(5) Remove the front frame.

R55NMPH40

(6) Remove the intermediate frame.

R55NMPH41

(7) Remove the square ring.

R55NMPH42

(8) Remove the plate, guide and O-ring.

R55NMPH43

7-13

(9) Remove the plate.

R55NMPH44

(10) Remove the drive gear, idle gear and side plate.

R55NMPH45

7-14

4) DISASSEMBLING THE GEARED PUMP (#1417 and up) (1) Disassembling the P3 and P4 pump ① Removed hexagonal socket head bolt and nut.

Hexagonal socket wrench(8mm).

Hexagonal bar spanner(17mm).

R55NM7HP209

(2) Disassembling the geared pump (P4) ① Remove the geared pump(P4) from the center frame.

R55NM7HP208

② Pulling out the drive gear and the idle gear.

R55NM7HP207

③ Remove the O-ring from the center frame.

R55NM7HP206

7-15

(3) Disassembling the geared pump (P3) ① Remove the front cover.

R55NM7HP205

② Remove the square ring(2-pieces).

R55NM7HP204

③ Remove the plate and the guide ring(2pieces).

Remove the O-ring from guide ring.

R55NM7HP203

④ Remove the plate.

R55NM7HP202

7-16

⑤ Remove the drive and idle gear and the side plate assembly.

R55NM7HP201

7-17

4. MAINTENANCE AND SERVICE STANDARD Before inspection, wash the parts well and dry them completely.

Inspect the principal parts with care and replace them with new parts when any abnormal wear exceeding the allowable limit or damage considered harmful is found.

Replace the seal also when any remarkable deformation and damage are found.

1) PISTON ASSEMBLY AND CYLINDER BLOCK (1) Check the appearance visually.

No damage, scouring, abnormal wear (Particularly, in the slide portion) should be found.

(2) Check the clearance between the piston outside dia and cylinder block inside dia.

D-d ≤ 0.050mm

2) PISTON SHOE AND PISTON (1) Check the axial play of the piston and piston shoe. ε≤ 0.2mm

ε

R55NM7PH46

3) SHAFT (1) Check the wear amount of the oil seal mounting section.

Wear mount ≤ 0.025mm

R55NM7PH47

7-18

4) CONTROL PLATE (1) Check the slide surface for any damage.

When the damage is large, replace the plate with new one.

R55NM7PH48

5) GUIDE AND RETAINER (1) Check for scouring or stepped wear.

If this can not be corrected, replace the guide and retainer with new full-set.

(2) Fine scouring or damage can be corrected with lapping.

Carry out thorough washing after lapping.

R55NM7PH49

7-19

5. ASSEMBLING PROCEDURE 1) ASSEMBLING THE MAIN PUMP (1) Assembling the hanger.

R55NM7HP50

(2) Install the bearing.

R55NM7HP50A

(3) Install the distance piece.

Confirm that pre-load is 0.1 ± 0.2.

R55NM7HP51

(4) Fix the plate with the hexagonal socket headed bolts (M6 × 16, 4pieces).

Hexagonal bar spanner (Hex. side distance : 5) Tightening torque : 1.2 ~ 1.5kgf·m (12 ~ 15N·m)

R55NM7HP52

7-20

(5) Assembling the shaft ① Fit the shaft into the bearing(With the bearing in the bottom) by using the press machine and jig. If the press is not available, use the jig in the similar manner and drive the shaft into the bearing by knocking with a plastic hammer.

R55NM7HP53

② Install the C-type stop ring to fix the bearing.

R55NM7HP54

③ Assembling the shaft.

Assemble the shaft into the housing.

Knock the spline end lightly with a plastic hammer and fix the bearing outer ring firmly into the housing hole.

R55NM7HP55

(6) Apply grease to the O-ring for assembling.

R55NM7HP56

7-21

(7) Install the case with oil seal verically without tilting. ※ Apply grease to the oil seal lip beforehand.

R55NM7HP57

(8) Install the C-type stop ring to fix the shaft.

R55NM7HP58

(9) Assembling the rotary group.

Install 10(ten) pistons into the retainer.

R55NM7HP59

(10) Apply grease to 3 parallel pins and assemble them to the cylinder block.

R55NM7HP60

7-22

(11) Apply grease to the spherical portion of the guide.

R55NM7HP61

(12) Insert the guide between the retainer and cylinder block and assemble the piston into the hole of cylinder block.

R55NM7HP62

(13) Assembling the rotary group.

To prevent dislodgment, apply grease to the back side of the plate and assemble it to the hanger.

R55NM7HP63

(14) Assemble the rotary group along the shaft spline. ※ During assembly, apply grease to the slide surface of piston shoe and to the slide surface of the cylinder block relative to the control plate.

R55NM7HP64

7-23

(15) Assembling the control spring.

Apply grease to the spherical portion of the spring seat before assembling.

R55NM7HP65

(16) Assemble 2 springs (Inner and outer).

R55NM7HP66

(17) Assembling the cover.

Assemble the spring seats and coned disk springs (3 pieces).

R55NM7HP67

(18) Assembling the control piston.

R55NM7HP68

7-24

(19) Apply grease to the O-rings (5.28×1.78, 1piece), (7.65×1.78, 1piece) and (15.6×1.78, 1piece) and assemble them to the cylinder.

R55NM7HP69

(20) Apply grease to 3 parallel pins and assemble 3 pins into the cylinder.

R55NM7HP70

(21) Fix the cylinder with the hexagonal socket headed bolts (M8×25, 2pieces). ※ Apply LOCTITE #270 to the threaded portion of bolt.

Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5kgf·m (28 ~ 35N·m) R55NM7HP71

(22) Assembling the control spring.

Install the spring seat.

R55NM7HP72

7-25

(23) Fix the cover with the hexagonal socket headed bolts (M8×30, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5kgf·m (28 ~35N·m)

R55NM7HP73

(24) Apply grease to the back side of the control plate and assemble it to the cover while matching knock holes.

R55NM7HP74

(25) Install the O-ring.

Assemble the spring seats and coned disk springs (3pieces).

R55NM7HP75

(26) Install the filter into the cover.

R55NM7HP76

7-26

(27) Fix the filter with the C-type stop ring.

R55NM7HP77

(28) Assembling the relief valve.

Assemble the spool.

R55NM7HP78

(29) Assemble the spring.

R55NM7HP79

(30) Insert the shim into the adjusting screw.

R55NM7HP80

7-27

(31) Assemble the adjusting screw.

R55NM7HP81

(32) Tighten the hexagonal nuts.

After assembling, set the pressure and tighten the nuts.

1kgf·m(9.8N·m) Spanner (Hex. side distance : 24)

R55NM7HP82

(33) Install the cover in a parallel direction to the housing mounting surface.

R55NM7HP83

(34) Fix the cover with the hexagonal socket headed bolts (M12×30, 3pieces) and (M12×55, 1piece) Hexagonal bar spanner (Hex. side distance :10) Tightening torque : 10 ~ 12.5kgf·m (98 ~ 123N·m)

R55NM7HP84

7-28

(35) Install the O-ring into the cover.

R55NM7HP85

(36) Install the coupling to the shaft end of the main pump.

R55NM7HP86

(37) Connect the main and geared pump.

R55NM7HP87

(38) Fix the geared pump with the hexagonal socket headed bolts (M10×25, 2pieces).

Hexagonal bar spanner (Hex. side distance : 8) Tightening torque : 5.6 ~ 7.0kgf·m (55 ~ 69N·m)

R55NM7HP88

7-29

2) ASSEMBLING THE GEARED PUMP (up to #1416) (1) Assembling the geared pump(GSP2).

Assemble the square ring into the side plate.

Pay attention to the suction and discharge directions.

R55NMPH89

(2) Assemble the drive gear and idle gear to the side plate.

R55NMPH90

(3) Assemble the drive gear, idle gear and side plate.

R55NMPH91

(4) Insert the O-ring into the guide, then insert them into the plate.

R55NMPH92

7-30

(5) Assemble the plate, guide and O-ring.

R55NMPH93

(6) Assemble 2 plates. In this case, pay attention to the suction and discharge directions.

R55NMPH94

(7) Install the square ring.

R55NMPH95

(8) Install 2 parallel pins into the front frame.

R55NMPH96

7-31

(9) Assemble the front frame.

R55NMPH97

(10) Assemble the geared pump (G1) Assemble the drive gear into the housing.

R55NMPH98

(11) Assemble the idle gear.

R55NMPH99

(12) Apply grease to the square ring and backup ring to prevent dislodgment and assemble them in this order.

R55NMPH100

7-32

(13) Assemble the side plate assembled in item(12) into the housing.

R55NMPH101

(14) Install 2 parallel pins into the intermediate frame.

R55NMPH102

(15) Install O-ring into the intermediate frame.

R55NMPH103

(16) Assemble the intermediate frame.

R55NMPH104

7-33

(17) Fix the intermediate frame with the hexagonal socket headed bolts(M8×40, 4pieces).

Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 29N·m(3kgf·m)

R55NMPH105

(18) Install 2 parallel pins into the intermediate frame.

R55NMPH106

(19) Install the coupling to the shaft end on the GSP2 side.

R55NMPH107

(20) Connect the GSP2 and G1.

R55NMPH108

7-34

(21) Fix the GSP2 and G1 with the hexagonal bolts (M10×95, 4pieces).

Spanner (Nominal : 17) Tightening torque : 59N·m(6kgf·m)

R55NMPH109

(22) Install the O-ring and filter into the front frame.

R55NMPH110

7-35

4) REASSEMBLING THE GEARED PUMP (#1417 and up) (1) Reassembling the geared pump (P3) ① Insert the square ring into the side plate. ※ Becareful to suction and discharge side.

R55NM7HP210

② Assemble the side plate to the drive and idle gear.

R55NM7HP211

③ Assemble the gear assembly into the gear casing.

R55NM7HP212

④ Assemble the O-ring to the guide ring and assemble them to the plate.

R55NM7HP213

7-36

⑤ Assemble the guide ring assembly to the gear casing.

R55NM7HP214

⑥ Assemble the plate to the gear casing. ※ Becareful to suction and discharge side.

R55NM7HP215

⑦ Assemble the square ring(2 piece) to the gear casing.

R55NM7HP216

⑧ Insert pin to the front cover.

R55NM7HP217

7-37

⑨ Assemble the front cover to the gear casing.

R55NM7HP218

(2) Reassembling the geared pump (P4) ① Insert the drive gear into the gear casing.

R55NM7HP219

② Insert the idle gear to into the gear casing.

R55NM7HP220

③ Insert the pins (2-pieces) to the center frame.

R55NM7HP221

7-38

④ Assemble the O-ring to the center frame.

R55NM7HP222

⑤ Assemble the center frame sub-assemble to the gear casing sub-assembly.

R55NM7HP223

(3) Reassembling the P3 and P4 pumps ① Insert the pins (2-pieces) into the center frame.

R55NM7HP224

② Insert coupling to the P3 geared pump.

R55NM7HP225

7-39

③ Assemble the P3 and P4 geared pumps.

R55NM7HP226

④ Assemble the hexagonal socket bolts and nuts. · Size : M10×135L, 4pieces · Allen wrench : 8mm · Spanner : 17mm · Tightening torque : 580kgf·cm(56.9N·m)

R55NM7HP227

⑤ Assemble the O-ring to the front cover.

R55NM7HP228

7-40

SECTION 7 DISASSEMBLY AND ASSEMBLY Group 1 Hydraulic Pump Group 2 Main Control Valve Group 3 Swing Motor Group 4 Travel Motor Group 5 Remote Control Valve Group 6 Turning Joint

7-1 7-41 7-48 7-74 7-128 7-142

SECTION 7 DISASSEMBLY AND ASSEMBLY GROUP 1 HYDRAULIC PUMP 1. NECESSARY TOOLS AND JIGS The following tools and jigs are necessary to disassemble and reassemble the pump.

1) TOOLS Name

Quantity

Size (Nominal)

Hexagonal bar spanner

One each

5, 6, 8, 10

Spanner

1

17, 24

Plastic hammer

1

Medium size

Snap ring pilers

1

For hole (Stop ring for 72)

Snap ring pilers

1

For shaft (Stop rings for 28 and 30)

Standard screw-driver

2

Medium size

Torque wrench

-

Wrench which can tighten at the specified torque

Grease

Small

-

Adhesives

Small

LOCTITE #270

2) JIGS (1) Disassembling table.

45 or more

Ø35 ~ Ø55

Ø110 or more R55NM7HP01

This is plate to stand the pump facing downward.

A square block may be used instead if the shaft end does not contact.

15

40

(2) Bearing assembling jig

Ø19 Ø25 R55NM7HP02

7-1

2. CAUTIONS DURING ASSEMBLING AND DISASSEMBLING 1) CAUTIONS FOR DISASSEMBLING · Never attempt operating the adjusting screw unless absolutely necessary.

Otherwise, the set power may be changed, affecting adversely to the system. · Take utmost care during disassembly not to knock or drop each part.

2) CAUTIONS FOR ASSEMBLING · Wash each part thoroughly · During assembling, take utmost care not to damage the part or allow foreign materials to enter. · As a rule, the O-ring and oil seal should not be reused. · In our assembly work, the torque wrench is used to control the torque.

Be sure to use the torque wrench.

7-2

3. DISASSEMBLY PROCEDURE 1) DISASSEMBLING THE GEARED PUMP ① Remove the hexagonal socket headed bolts (M10 × 25, 2 pieces) Hexagonal bar spanner (Hex. side distance : 8) ※ Be careful because the O-ring and filter are provided to the match surface of the geared pump.

R55NM7HP03

② Remove the coupling.

R55NM7HP04

2) DISASSEMBLING THE MAIN PUMP ① Remove the cover.

Remove the hexagonal socket headed bolts. (M12 × 30, 3pieces) and (M12 × 55, 1piece) Hexagonal bar spanner (Hex. side distance : 10)

R55NM7HP05

② Remove the cover in a horizontal condition.

Connect motor to work table. ※ Be careful because the control plate is provided to the backside.

When the cover is difficult to remove, knock lightly with a plastic hammer.

R55NM7HP06

7-3

③ This photo shows the state with the cover removed.

R55NM7HP07

④ Remove the O-ring from the cover.

R55NM7HP08

(1) The removal of the control spring ① Remove 2 springs(Inner and outer).

R55NM7HP09

② Remove the spring seat.

R55NM7HP10

7-4

(2) The removal of rotary group ① Lay the pump on the side and take out the rotary group from the shaft.

R55NM7HP11

② Remove the plate.

R55NM7HP12

(3) The removal of the shaft ① Remove the C-type stop ring.

(Snap ring pliers for hole)

R55NM7HP13

② Use two standard screw-drivers to remove the oil seal case.

R55NM7HP14

7-5

③ Remove the O-ring.

R55NM7HP15

④ Remove it while knocking the shaft rear and lightly with a plastic hammer.

R55NM7HP16

(4) The removal of the hanger ① Remove the hexagonal socket headed bolts (M6 × 16, 4pieces) and plate.

Hexagonal bar spanner (Hex. side distance : 5)

R55NM7HP17

② Remove the distance piece.

R55NM7HP18

7-6

③ Remove the bearing.

R55NM7HP19

④ Remove the hanger.

R55NM7HP20

(5) The removal of the cover ① Remove the control plate.

R55NM7HP21

② Remove the C-type stop ring.

R55NM7HP22

7-7

③ Remove the filter.

R55NM7HP23

(6) The removal of the control piston ① Remove the hexagonal socket headed bolts. (M8 × 25, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) The threaded portion of the bolt is coated with LOCTITE #270.

This disassembly must therefore be made only when necessary.

R55NM7HP24

② Remove the cylinder and parallel pin. ※ Be careful because 3 O-rings are provided to the cylinder.

R55NM7HP25

③ Take out the piston.

R55NM7HP26

7-8

④ Take out three caned disk springs and spring seats.

R55NM7HP27

(7) The removal of the control spring ① Remove the hexagonal socket headed bolts (M8×30, 2pieces) and remove the cover.

Hexagonal bar spanner (Hex. side distance : 6).

R55NM7HP28

② Remove othe spring seat.

R55NM7HP29

7-9

(8) The removal of the relief valve ① Remove the hexagonal nuts. ※ Since the pressure has been set, this assembly must be made only when necessary.

Spanner (Hex. side distance : 24).

R55NM7HP30

② Remove the adjusting screw. ※ Be careful because the shim is inserted.

R55NM7HP31

③ Remove the spring.

R55NM7HP32

④ Remove the spool.

R55NM7HP33

7-10

(9) Disassembly of the shaft ① Remove the bearing.

Remove the C-type stop ring.

Snap ring pliers for shaft.

R55NM7HP34

② Remove it while knocking the rear end of shaft lightly with a plastic hammer.

R55NM7HP35

7-11

3) DISASSEMBLING THE GEARED PUMP (up to #1416) (1) Disassembling the geared pump(G1).

Remove the hexagonal socket headed bolts (M8 × 40, 4pieces).

Hexagonal bar spanner (Hex. side distance : 6)

R55NMPH36

(2) Disassembling the geared pump(G1).

Remove the side plate, back-up ring, square ring and gears while pulling out the drive gear.

R55NMPH37

(3) Remove the idle gear.

R55NMPH38

(4) Disassembling the geared pump (GSP2).

Remove the hexagonal socket headed bolts (M10 × 85, 4pieces).

Spanner (Nominal : 17) The O-ring and filter are provided to the match surface of the geared pump and should be removed.

R55NMPH39

7-12

(5) Remove the front frame.

R55NMPH40

(6) Remove the intermediate frame.

R55NMPH41

(7) Remove the square ring.

R55NMPH42

(8) Remove the plate, guide and O-ring.

R55NMPH43

7-13

(9) Remove the plate.

R55NMPH44

(10) Remove the drive gear, idle gear and side plate.

R55NMPH45

7-14

4) DISASSEMBLING THE GEARED PUMP (#1417 and up) (1) Disassembling the P3 and P4 pump ① Removed hexagonal socket head bolt and nut.

Hexagonal socket wrench(8mm).

Hexagonal bar spanner(17mm).

R55NM7HP209

(2) Disassembling the geared pump (P4) ① Remove the geared pump(P4) from the center frame.

R55NM7HP208

② Pulling out the drive gear and the idle gear.

R55NM7HP207

③ Remove the O-ring from the center frame.

R55NM7HP206

7-15

(3) Disassembling the geared pump (P3) ① Remove the front cover.

R55NM7HP205

② Remove the square ring(2-pieces).

R55NM7HP204

③ Remove the plate and the guide ring(2pieces).

Remove the O-ring from guide ring.

R55NM7HP203

④ Remove the plate.

R55NM7HP202

7-16

⑤ Remove the drive and idle gear and the side plate assembly.

R55NM7HP201

7-17

4. MAINTENANCE AND SERVICE STANDARD Before inspection, wash the parts well and dry them completely.

Inspect the principal parts with care and replace them with new parts when any abnormal wear exceeding the allowable limit or damage considered harmful is found.

Replace the seal also when any remarkable deformation and damage are found.

1) PISTON ASSEMBLY AND CYLINDER BLOCK (1) Check the appearance visually.

No damage, scouring, abnormal wear (Particularly, in the slide portion) should be found.

(2) Check the clearance between the piston outside dia and cylinder block inside dia.

D-d ≤ 0.050mm

2) PISTON SHOE AND PISTON (1) Check the axial play of the piston and piston shoe. ε≤ 0.2mm

ε

R55NM7PH46

3) SHAFT (1) Check the wear amount of the oil seal mounting section.

Wear mount ≤ 0.025mm

R55NM7PH47

7-18

4) CONTROL PLATE (1) Check the slide surface for any damage.

When the damage is large, replace the plate with new one.

R55NM7PH48

5) GUIDE AND RETAINER (1) Check for scouring or stepped wear.

If this can not be corrected, replace the guide and retainer with new full-set.

(2) Fine scouring or damage can be corrected with lapping.

Carry out thorough washing after lapping.

R55NM7PH49

7-19

5. ASSEMBLING PROCEDURE 1) ASSEMBLING THE MAIN PUMP (1) Assembling the hanger.

R55NM7HP50

(2) Install the bearing.

R55NM7HP50A

(3) Install the distance piece.

Confirm that pre-load is 0.1 ± 0.2.

R55NM7HP51

(4) Fix the plate with the hexagonal socket headed bolts (M6 × 16, 4pieces).

Hexagonal bar spanner (Hex. side distance : 5) Tightening torque : 1.2 ~ 1.5kgf·m (12 ~ 15N·m)

R55NM7HP52

7-20

(5) Assembling the shaft ① Fit the shaft into the bearing(With the bearing in the bottom) by using the press machine and jig. If the press is not available, use the jig in the similar manner and drive the shaft into the bearing by knocking with a plastic hammer.

R55NM7HP53

② Install the C-type stop ring to fix the bearing.

R55NM7HP54

③ Assembling the shaft.

Assemble the shaft into the housing.

Knock the spline end lightly with a plastic hammer and fix the bearing outer ring firmly into the housing hole.

R55NM7HP55

(6) Apply grease to the O-ring for assembling.

R55NM7HP56

7-21

(7) Install the case with oil seal verically without tilting. ※ Apply grease to the oil seal lip beforehand.

R55NM7HP57

(8) Install the C-type stop ring to fix the shaft.

R55NM7HP58

(9) Assembling the rotary group.

Install 10(ten) pistons into the retainer.

R55NM7HP59

(10) Apply grease to 3 parallel pins and assemble them to the cylinder block.

R55NM7HP60

7-22

(11) Apply grease to the spherical portion of the guide.

R55NM7HP61

(12) Insert the guide between the retainer and cylinder block and assemble the piston into the hole of cylinder block.

R55NM7HP62

(13) Assembling the rotary group.

To prevent dislodgment, apply grease to the back side of the plate and assemble it to the hanger.

R55NM7HP63

(14) Assemble the rotary group along the shaft spline. ※ During assembly, apply grease to the slide surface of piston shoe and to the slide surface of the cylinder block relative to the control plate.

R55NM7HP64

7-23

(15) Assembling the control spring.

Apply grease to the spherical portion of the spring seat before assembling.

R55NM7HP65

(16) Assemble 2 springs (Inner and outer).

R55NM7HP66

(17) Assembling the cover.

Assemble the spring seats and coned disk springs (3 pieces).

R55NM7HP67

(18) Assembling the control piston.

R55NM7HP68

7-24

(19) Apply grease to the O-rings (5.28×1.78, 1piece), (7.65×1.78, 1piece) and (15.6×1.78, 1piece) and assemble them to the cylinder.

R55NM7HP69

(20) Apply grease to 3 parallel pins and assemble 3 pins into the cylinder.

R55NM7HP70

(21) Fix the cylinder with the hexagonal socket headed bolts (M8×25, 2pieces). ※ Apply LOCTITE #270 to the threaded portion of bolt.

Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5kgf·m (28 ~ 35N·m) R55NM7HP71

(22) Assembling the control spring.

Install the spring seat.

R55NM7HP72

7-25

(23) Fix the cover with the hexagonal socket headed bolts (M8×30, 2pieces) Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 2.9 ~ 3.5kgf·m (28 ~35N·m)

R55NM7HP73

(24) Apply grease to the back side of the control plate and assemble it to the cover while matching knock holes.

R55NM7HP74

(25) Install the O-ring.

Assemble the spring seats and coned disk springs (3pieces).

R55NM7HP75

(26) Install the filter into the cover.

R55NM7HP76

7-26

(27) Fix the filter with the C-type stop ring.

R55NM7HP77

(28) Assembling the relief valve.

Assemble the spool.

R55NM7HP78

(29) Assemble the spring.

R55NM7HP79

(30) Insert the shim into the adjusting screw.

R55NM7HP80

7-27

(31) Assemble the adjusting screw.

R55NM7HP81

(32) Tighten the hexagonal nuts.

After assembling, set the pressure and tighten the nuts.

1kgf·m(9.8N·m) Spanner (Hex. side distance : 24)

R55NM7HP82

(33) Install the cover in a parallel direction to the housing mounting surface.

R55NM7HP83

(34) Fix the cover with the hexagonal socket headed bolts (M12×30, 3pieces) and (M12×55, 1piece) Hexagonal bar spanner (Hex. side distance :10) Tightening torque : 10 ~ 12.5kgf·m (98 ~ 123N·m)

R55NM7HP84

7-28

(35) Install the O-ring into the cover.

R55NM7HP85

(36) Install the coupling to the shaft end of the main pump.

R55NM7HP86

(37) Connect the main and geared pump.

R55NM7HP87

(38) Fix the geared pump with the hexagonal socket headed bolts (M10×25, 2pieces).

Hexagonal bar spanner (Hex. side distance : 8) Tightening torque : 5.6 ~ 7.0kgf·m (55 ~ 69N·m)

R55NM7HP88

7-29

2) ASSEMBLING THE GEARED PUMP (up to #1416) (1) Assembling the geared pump(GSP2).

Assemble the square ring into the side plate.

Pay attention to the suction and discharge directions.

R55NMPH89

(2) Assemble the drive gear and idle gear to the side plate.

R55NMPH90

(3) Assemble the drive gear, idle gear and side plate.

R55NMPH91

(4) Insert the O-ring into the guide, then insert them into the plate.

R55NMPH92

7-30

(5) Assemble the plate, guide and O-ring.

R55NMPH93

(6) Assemble 2 plates. In this case, pay attention to the suction and discharge directions.

R55NMPH94

(7) Install the square ring.

R55NMPH95

(8) Install 2 parallel pins into the front frame.

R55NMPH96

7-31

(9) Assemble the front frame.

R55NMPH97

(10) Assemble the geared pump (G1) Assemble the drive gear into the housing.

R55NMPH98

(11) Assemble the idle gear.

R55NMPH99

(12) Apply grease to the square ring and backup ring to prevent dislodgment and assemble them in this order.

R55NMPH100

7-32

(13) Assemble the side plate assembled in item(12) into the housing.

R55NMPH101

(14) Install 2 parallel pins into the intermediate frame.

R55NMPH102

(15) Install O-ring into the intermediate frame.

R55NMPH103

(16) Assemble the intermediate frame.

R55NMPH104

7-33

(17) Fix the intermediate frame with the hexagonal socket headed bolts(M8×40, 4pieces).

Hexagonal bar spanner (Hex. side distance : 6) Tightening torque : 29N·m(3kgf·m)

R55NMPH105

(18) Install 2 parallel pins into the intermediate frame.

R55NMPH106

(19) Install the coupling to the shaft end on the GSP2 side.

R55NMPH107

(20) Connect the GSP2 and G1.

R55NMPH108

7-34

(21) Fix the GSP2 and G1 with the hexagonal bolts (M10×95, 4pieces).

Spanner (Nominal : 17) Tightening torque : 59N·m(6kgf·m)

R55NMPH109

(22) Install the O-ring and filter into the front frame.

R55NMPH110

7-35

4) REASSEMBLING THE GEARED PUMP (#1417 and up) (1) Reassembling the geared pump (P3) ① Insert the square ring into the side plate. ※ Becareful to suction and discharge side.

R55NM7HP210

② Assemble the side plate to the drive and idle gear.

R55NM7HP211

③ Assemble the gear assembly into the gear casing.

R55NM7HP212

④ Assemble the O-ring to the guide ring and assemble them to the plate.

R55NM7HP213

7-36

⑤ Assemble the guide ring assembly to the gear casing.

R55NM7HP214

⑥ Assemble the plate to the gear casing. ※ Becareful to suction and discharge side.

R55NM7HP215

⑦ Assemble the square ring(2 piece) to the gear casing.

R55NM7HP216

⑧ Insert pin to the front cover.

R55NM7HP217

7-37

⑨ Assemble the front cover to the gear casing.

R55NM7HP218

(2) Reassembling the geared pump (P4) ① Insert the drive gear into the gear casing.

R55NM7HP219

② Insert the idle gear to into the gear casing.

R55NM7HP220

③ Insert the pins (2-pieces) to the center frame.

R55NM7HP221

7-38

④ Assemble the O-ring to the center frame.

R55NM7HP222

⑤ Assemble the center frame sub-assemble to the gear casing sub-assembly.

R55NM7HP223

(3) Reassembling the P3 and P4 pumps ① Insert the pins (2-pieces) into the center frame.

R55NM7HP224

② Insert coupling to the P3 geared pump.

R55NM7HP225

7-39

③ Assemble the P3 and P4 geared pumps.

R55NM7HP226

④ Assemble the hexagonal socket bolts and nuts. · Size : M10×135L, 4pieces · Allen wrench : 8mm · Spanner : 17mm · Tightening torque : 580kgf·cm(56.9N·m)

R55NM7HP227

⑤ Assemble the O-ring to the front cover.

R55NM7HP228

7-40

GROUP 2 MAIN CONTROL VALVE A. MAIN CONTROL VALVE (SC3A, UP TO #0616) 1. TOOLS FOR DISASSEMBLY AND ASSEMBLY Tool name “L” type wrench

Spanner

Size (mm)

Q’ty (EA)

5

1

Socket bolt M6

6

1

Socket bolt M8

13

1

Nut M8

21

1

Lock nut, Check valve plug

30

1

Relief valve

Less than 10×250

1

Handling of relief valve

1

Set screw

1

Spring and set screw

Rod

Use for

1) DISASSEMBLY Remove piping and lever cable link parts, fix cylinder port of valve on the work table to the upper direction, loosen cap bolt in spring and then remove cap.

(1) Disassembly of spool Insert Ø7 rod into the link hole of each spool, loosen and remove bolt on end point of valve rod, press and remove spring, spacer, oil seal and then disassembly spool.

At this time, oil seal and spool are disassembled together.

The oil seal of opposite side is removed after loosening 2 bolt and pressing oil seal.

Loosen this and then others will be removed.

R55NM7MCV00-1

This is removed on condition of set. ※ Because spool and valve body are assembled at regular interval, mark position to be reassembled and then reassemble according to original position.

7-41

(2) Disassembly of main relief valve Separate the plug assembly from the housing assembly.

R55NM7MCV51

※ If there is a damage on relief valve, replace valve assembly.

If it is used again, clean the disassembled parts from plug assembly and replace O-ring newly.

(3) Load check valve Loosen check valve and remove it.

Check if there are dirt, oil and any damage between seat and check valve, then replace if any problems.

If it is used again, clean the disassembled parts from check valve and replace O-ring newly.

(4) Disassembly of section assembly Loosen nuts of valve housing, remove 4 bolts, then disassemble each section.

If it is used again, clean the disassembled parts from section assembly and replace O-ring newly.

R55NM7MCV02

R55NM7MCV01

7-42

2) REASSEMBLY (1) Reassembly of valve housing Install O-ring to each valve body, assemble in sequence. ※ Do not apply grease to O-ring, Tighten with regular torque by wrench. · Tightening torque : 2kgf·m(19.6N·m) (2) Spool assembly Assemble spool in body. Insert Ø7 rod into the link hole of each spool, install oil seal and spacer.

After inserting valve assembly, check if it moves by pressing spring supporter, then tighten it with regular torque. ·Tightening torque : 2 ~ 2.5kgf·m(16.6 ~ 24.5N·m) Tighten socket bolt after inserting rectum spring cap. ·Tightening torque : 1kgf·m(9.8N·m) Remove Ø7 rod of the spool link hole, insert oil seal and seal supporter, then tighten socket bolt. ·Tightening torque : 1kgf·m(9.8N·m) (3) Load check valve Install check valve and spring in valve body, install O-ring in check valve, then tighten it. ※ Apply grease to O-ring.

(4) Relief valve assembly Install relief valve assembly to body. ·Tightening torque : 6.5kgf·m(63.7N·m) ※ Apply grease to O-ring.

(5) Overload valve assembly and anti-cavitation valve assembly Install each valve assembly to body. ·Tightening torque : 6.5kgf·m(63.7N·m) ※ Apply grease to O-ring.

(6) Install control valve assembly to machine, connect piping and control link.

7-43

2. ADJUSTING THE MAIN RELIEF VALVE PRESSURE 1) Install pressure gauge to pressure sensor port.

2) Operate the control valve’s cylinder spool over its full stroke, then read the value indicated by the pressure gauge.

3) Turn the set screw while watching the pressure gauge to adjust. ·Turn it to the right to increase the set pressure. ·Turn it to the left to decrease the set pressure.

R55NM7MCV50

4) After completing the pressure adjustment, tighten the lock nut while holding the set screw.

Operate the relief valve again and check if the pressure is stabilized.

7-44

B. MAIN CONTROL VALVE (#0617 AND UP) 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine.

(2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.

(3) Loosen the breather slowly to release the pressure inside the hydraulic tank.

Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.

13031GE18

(4) Remove bolts and disconnect pipe.

(5) Disconnect pilot line hoses.

(6) Disconnect pilot piping.

(7) Sling the control valve assembly and remove the control valve mounting bolt. ·Weight : 45kg(99lb) (8) Remove the control valve assembly. ※ When removing the control valve assembly, check that all the piping have been disconnected.

2) INSTALL (1) Carry out installation in the reverse order to removal.

(2) Bleed the air from below items. ① Cylinder(Boom, arm, bucket) ② Swing motor ③ Travel motor ※ See each item removal and install.

(3) Confirm the hydraulic oil level and recheck the hydraulic oil leak or not.

7-45

2. DISASSEMBLY AND ASSEMBLY 1) PRECAUTION (1) Disassembly ① Handle the components carefully not to drop them or bump them with each other as they are made with precision. ② Do not force the work by hitting or twisting as burred or damaged component may not be assembled or result in oil leakage or low performance. ③ When disassembled, tag the components for identification so that they can be reassembled correctly. ④ Once disassembled, O-rings and backup rings are not to be used again.(Remove them using a wire with its end made like a shoehorn. Be careful not to damaged the slot.) ⑤ If the components are left disassembled or half-disassembled, they may get rust from moisture or dust. If the work has to be interrupted, take measures to prevent rust and dust.

(2) Assembly ① Take the same precautions as for disassembly. ② When assembling the components, remove any metal chips or foreign objects and check them for any burrs or dents. Remove burrs and dents with oilstone, if any. ③ O-rings and backup rings are to be replaced with new ones, as a rule. ④ When installing O-rings and backup rings, be careful not to damage them.(Apply a little amount of grease for smoothness.) ⑤ Tighten the bolts and caps with specified torque.(See Disassembly/Assembly.)

7-46

2) PLUNGER (1) Main plunger ① Loosen socket bolt(3), to remove cover(2), and O-ring(4). ·Tightening torque : 1.2kgf·m(8.7lbf·ft) ·Socket bolt : 5mm ※ Install cover(2) after making sure that Oring is placed on the edge of the valve hole.

R55NM7MCV10

② Pull the plunger(1) out while holding the spring. ※ Do not pull it out violently, but draw it out gently while making sure of its contact with HG hole.

R55NM7MCV11

③ Place the plunger between holders and loosen plunger cap(3) by using a vise. ·Plunger cap : 5mm ·Tightening torque : 0.5kgf·m(8.7lbf·ft) ·Loctite

R55NM7MCV12

④ Main relief assembly(P1, P2, P3 port) Relief assy is assembled into a single block as a cartridge. Do not disassemble the relief assembly as a rule.

R55NM7MCV13

7-47

GROUP 2 MAIN CONTROL VALVE A. MAIN CONTROL VALVE (SC3A, UP TO #0616) 1. TOOLS FOR DISASSEMBLY AND ASSEMBLY Tool name “L” type wrench

Spanner

Size (mm)

Q’ty (EA)

5

1

Socket bolt M6

6

1

Socket bolt M8

13

1

Nut M8

21

1

Lock nut, Check valve plug

30

1

Relief valve

Less than 10×250

1

Handling of relief valve

1

Set screw

1

Spring and set screw

Rod

Use for

1) DISASSEMBLY Remove piping and lever cable link parts, fix cylinder port of valve on the work table to the upper direction, loosen cap bolt in spring and then remove cap.

(1) Disassembly of spool Insert Ø7 rod into the link hole of each spool, loosen and remove bolt on end point of valve rod, press and remove spring, spacer, oil seal and then disassembly spool.

At this time, oil seal and spool are disassembled together.

The oil seal of opposite side is removed after loosening 2 bolt and pressing oil seal.

Loosen this and then others will be removed.

R55NM7MCV00-1

This is removed on condition of set. ※ Because spool and valve body are assembled at regular interval, mark position to be reassembled and then reassemble according to original position.

7-41

(2) Disassembly of main relief valve Separate the plug assembly from the housing assembly.

R55NM7MCV51

※ If there is a damage on relief valve, replace valve assembly.

If it is used again, clean the disassembled parts from plug assembly and replace O-ring newly.

(3) Load check valve Loosen check valve and remove it.

Check if there are dirt, oil and any damage between seat and check valve, then replace if any problems.

If it is used again, clean the disassembled parts from check valve and replace O-ring newly.

(4) Disassembly of section assembly Loosen nuts of valve housing, remove 4 bolts, then disassemble each section.

If it is used again, clean the disassembled parts from section assembly and replace O-ring newly.

R55NM7MCV02

R55NM7MCV01

7-42

2) REASSEMBLY (1) Reassembly of valve housing Install O-ring to each valve body, assemble in sequence. ※ Do not apply grease to O-ring, Tighten with regular torque by wrench. · Tightening torque : 2kgf·m(19.6N·m) (2) Spool assembly Assemble spool in body. Insert Ø7 rod into the link hole of each spool, install oil seal and spacer.

After inserting valve assembly, check if it moves by pressing spring supporter, then tighten it with regular torque. ·Tightening torque : 2 ~ 2.5kgf·m(16.6 ~ 24.5N·m) Tighten socket bolt after inserting rectum spring cap. ·Tightening torque : 1kgf·m(9.8N·m) Remove Ø7 rod of the spool link hole, insert oil seal and seal supporter, then tighten socket bolt. ·Tightening torque : 1kgf·m(9.8N·m) (3) Load check valve Install check valve and spring in valve body, install O-ring in check valve, then tighten it. ※ Apply grease to O-ring.

(4) Relief valve assembly Install relief valve assembly to body. ·Tightening torque : 6.5kgf·m(63.7N·m) ※ Apply grease to O-ring.

(5) Overload valve assembly and anti-cavitation valve assembly Install each valve assembly to body. ·Tightening torque : 6.5kgf·m(63.7N·m) ※ Apply grease to O-ring.

(6) Install control valve assembly to machine, connect piping and control link.

7-43

2. ADJUSTING THE MAIN RELIEF VALVE PRESSURE 1) Install pressure gauge to pressure sensor port.

2) Operate the control valve’s cylinder spool over its full stroke, then read the value indicated by the pressure gauge.

3) Turn the set screw while watching the pressure gauge to adjust. ·Turn it to the right to increase the set pressure. ·Turn it to the left to decrease the set pressure.

R55NM7MCV50

4) After completing the pressure adjustment, tighten the lock nut while holding the set screw.

Operate the relief valve again and check if the pressure is stabilized.

7-44

B. MAIN CONTROL VALVE (#0617 AND UP) 1. REMOVAL AND INSTALL OF MOTOR 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine.

(2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.

(3) Loosen the breather slowly to release the pressure inside the hydraulic tank.

Escaping fluid under pressure can penetrate the skin causing serious injury. ※ When pipes and hoses are disconnected, the oil inside the piping will flow out, so catch it in oil pan.

13031GE18

(4) Remove bolts and disconnect pipe.

(5) Disconnect pilot line hoses.

(6) Disconnect pilot piping.

(7) Sling the control valve assembly and remove the control valve mounting bolt. ·Weight : 45kg(99lb) (8) Remove the control valve assembly. ※ When removing the control valve assembly, check that all the piping have been disconnected.

2) INSTALL (1) Carry out installation in the reverse order to removal.

(2) Bleed the air from below items. ① Cylinder(Boom, arm, bucket) ② Swing motor ③ Travel motor ※ See each item removal and install.

(3) Confirm the hydraulic oil level and recheck the hydraulic oil leak or not.

7-45

2. DISASSEMBLY AND ASSEMBLY 1) PRECAUTION (1) Disassembly ① Handle the components carefully not to drop them or bump them with each other as they are made with precision. ② Do not force the work by hitting or twisting as burred or damaged component may not be assembled or result in oil leakage or low performance. ③ When disassembled, tag the components for identification so that they can be reassembled correctly. ④ Once disassembled, O-rings and backup rings are not to be used again.(Remove them using a wire with its end made like a shoehorn. Be careful not to damaged the slot.) ⑤ If the components are left disassembled or half-disassembled, they may get rust from moisture or dust. If the work has to be interrupted, take measures to prevent rust and dust.

(2) Assembly ① Take the same precautions as for disassembly. ② When assembling the components, remove any metal chips or foreign objects and check them for any burrs or dents. Remove burrs and dents with oilstone, if any. ③ O-rings and backup rings are to be replaced with new ones, as a rule. ④ When installing O-rings and backup rings, be careful not to damage them.(Apply a little amount of grease for smoothness.) ⑤ Tighten the bolts and caps with specified torque.(See Disassembly/Assembly.)

7-46

2) PLUNGER (1) Main plunger ① Loosen socket bolt(3), to remove cover(2), and O-ring(4). ·Tightening torque : 1.2kgf·m(8.7lbf·ft) ·Socket bolt : 5mm ※ Install cover(2) after making sure that Oring is placed on the edge of the valve hole.

R55NM7MCV10

② Pull the plunger(1) out while holding the spring. ※ Do not pull it out violently, but draw it out gently while making sure of its contact with HG hole.

R55NM7MCV11

③ Place the plunger between holders and loosen plunger cap(3) by using a vise. ·Plunger cap : 5mm ·Tightening torque : 0.5kgf·m(8.7lbf·ft) ·Loctite

R55NM7MCV12

④ Main relief assembly(P1, P2, P3 port) Relief assy is assembled into a single block as a cartridge. Do not disassemble the relief assembly as a rule.

R55NM7MCV13

7-47

GROUP 3 SWING MOTOR 1. SWING MOTOR 1) DISASSEMBLY (1) Remove the relief valve and hydraulic timer. The relief valve and bypass valve disassembled to be reassembled to the original position.

25038SM02(1)

(2) Mark “I” on the assembly position of motor.

To mark “I” on the assembly position of cover & housing is convenient for reassembly

25038SM02(3)

(3) Removal of bolt.

Remove cover & housing and then remove bypass valve assembly.

25038SM02(4)

(4) Lift cover and then remove it.

25038SM03(1)

7-48

(5) Remove the snap ring and then remove the inlet parts of needle bearing.

25038SM03(2)

(6) Remove O-ring.

25038SM03(3)

(7) Remove balance plate.

25038SM03(4)

(8) Remove bushing and dish spring attached to teffron ring.

25038SM04(1)

7-49

(9) Remove the spring from the piston for brake the inlet parts of needle bearing.

Mark to recognize assembly position of spring.

25038SM04(2)

(10) Removal of the piston for brake.

It is difficult for piston th be removed from housing due to resistance, so it is necessary to use tap hole on the piston as shown on the picture.

25038SM04(3)

(11) Remove friction plate and opposite plate.

25038SM05(1)

(12) Removal of cylinder assembly.

Remove cylinder assembly from housing.

Wrap the edge of cylinder in a smooth texture to prevent a damage.

25038SM05(2)

7-50

(13) Remove the outlet parts of taper roller bearing from housing.

25038SM05(3)

(14) Removal of oil seal.

Tap screw driver or hammer on the seal of housing.

Don’t use oil seal again.

25038SM05(4)

7-51

(15) Disassembly of cylinder assembly ① Remove inlet parts of taper roller bearing.

SM16 (250-3)

② Remove cam plate, piston plate and return plate from cylinder all together.

SM17 (250-3)

③ Make cam plate slide to edge of piston assembly and then remove cam plate.

SM18 (250-3)

④ Remove cam spring from cylinder.

SM19 (250-3)

7-52

2) ASSEMBLY (1) Preparation for assembly Carry out followings before assembly. ① Check if there is a damage to each of the disassembled parts due to disassembly, remove a damage by use of a light sandpaper, clean each of the disassembled parts and apply clean hydraulic oil to them. ② Replace with a new seal. ③ When use sandpaper, sand paper (#2000) to be used for piston assembly, balance plate and cam plate.

SM20 (250-3)

SM21 (250-3)

SM22 (250-3)

7-53

(2) Cylinder assembly ① Install cap spring after applying grease oil to edge of cylinder contacted to cap spring.

SM23 (250-3)

② Insert piston assembly into the hole of return plate.

SM24 (250-3)

③ Install piston assembly and return plate in cylinder. At this time, after applying grease oil to hole of cylinder piston, insert piston assembly into the same hole located in before disassembly.

SM25 (250-3)

④ After applying oil to shoe edge of piston assembly, install cam plate.

SM26 (250-3)

7-54

⑤ Install inlet parts of tape roller bearing.

SM27 (250-3)

⑥ Spray loctote 515 to inlet parts of cylinder.

SM28 (250-3)

⑦ Install inlet parts of cylinder.

SM29 (250-3)

7-55

(3) Assembly of oil seal.

Install oil seal after spraying 3-bond “KK 1211” to seal.

At this time, apply grease oil to seal lip.

SM30 (250-3)

(4) Install outlets of taper roller bearing.

25038SM05(3)

(5) Assembly of cylinder assembly Install cylinder assembly in housing.

At this time, use seal shelter for cylinder spring part.

SM32 (250-3)

(6) Install friction plate, opposite plate.

Apply oil to each of both side.

25038SM05(1)

7-56

(7) Install O-ring in housing and piston.

Apply grease oil to O-ring.

25038SM06(1)

(8) Assembly of brake piston.

After applying oil to outside of cylinder, install it in housing.

25038SM06(2)

(9) Assembly of spring (for brake) Install spring in piston for brake.

25038SM04(2)

(10) Install dish spring and bushing which teffron ring is attached in bushing hole of cover.

SM38 (250-3)

7-57

(11) Assembly of balance plate Install balance plate in cover. ※ Be careful to be installed in correct position.

25038SM07(2)

(12) Install inlet parts of needle bearing, snap ring.

25038SM08(1)

(13) Install O-ring in cover after applying grease oil to O-ring.

SM41 (250-3)

(14) To prevent oil in cover bolt hole from flowing outside, apply 3-bond “KK 1211”.

25038SM08(2)

7-58

(15) Install cover in housing.

Assemble housing and cover according to marking “I” before disassembly.

25038SM03(1)

(16) Bolt tightening torque ·Connecting cover and housing : 10.5kgf·m(103N·m) ·Bypass valve : 4kgf·m(39.2N·m)

25038SM02(4)

(17) Install relief valve assembly in cover, then install hydraulic timer. ·Tightening torque for relief valve assembly : 4kgf·m(39.2N·m) ·Tightening torque for hydraulic timer : 1.2kgf·m(11.8N·m)

25038SM09(2)

(18) Make sure that shaft is turned more than one revolution.

If it is not turned, disassemble again and adjust. At this time, the drain port to be opened. ·Torque : 2 ~ 3kgf·m(19.6 ~ 29.4N·m)

SM47 (250-3)

7-59

2. SWING MOTOR REDUCER A. REDUCTION GEAR (SG015E, UP TO #0915) 1) STRUCTURE

R55NM2SF03

1 2 3 4 5 7 8 9 10 11 12 13 14

Pinion shaft Collar Taper roller bearing Friction plate Gear case Oil seal Taper roller bearing Parallel pin Ring gear Gear Piston assembly Sun gear Socket bolt

16 17 18 19 20 21 22 23 24 25 26 27

7-60

Collar Plug Shaft assembly Bypass valve assembly Shaft O-ring Gear Holder Needle bearing Thrust plate Gear Oil seal

2) DISASSEMBLY (1) Remove sun gear and 1st step holder assembly.

(2) Remove sun gear and 2nd step holder assembly.

(3) Removal of 2nd step holder assembly.

Install spring pin into the shaft inside by using hammer. ※ Spring pin not to be used again.

Fixing gear by hands, remove shaft from holder.

R55NM7SM01

R55NM7SM02

(4) Removal of ring gear.

Remove ring gear from gear case.

Because liquid packing (3-bond “KK 1215”, black) is applied to the edge of contact between ring gear and gear case to prevent the leakage of gear oil, remove ring gear by using the contact part of gear case.

(5) Removal of collar.

Remove the collar from shaft by using hammer and driver.

R55NM7SM03

(6) Removal of shaft assembly.

Put the support (300mm height) to the flange part of gear case in order to get the position of removal, press flange part by hydraulic machine, then remove shaft, collar, taper roller bearing.

Oil seal not to be used again. ※ Don’t disassemble more than the above if there is not any abnormality in bearing, etc.

R55NM7SM04

7-61

3) ASSEMBLY (1) Preparation for assembly.

Carry out followings before assembly. ① Check if there is a damage to each of the disassembled parts due to disassembly, remove a damage by use of a light sandpaper, clean each of the disassembled parts and apply clean hydraulic oil to them. ② Replace with a new seal.

(2) Apply grease oil to the roller part of taper roller bearing.

R55NM7SM05

(3) Install oil seal after spraying 3-bond “KK 1211” to seal. At this time, apply grease oil to seal lip.

R55NM7SM06

(4) Assembly of pinion shaft assembly Use seal protector for spline part to prevent damage of seal lip.

Put the output shaft of gear case to the upper direction, then install pinion shaft in gear case.

R55NM7SM07

7-62

(5) Installation of taper roller bearing Put output shaft of gear case to the lower direction, install roller bearing in shaft on condition of environmental temperature 50° C

R55NM7SM08

(6) Assembly of collar Adjust the thickness of collar so that a gap between collar and groove of shaft become ± 0.06.

(7) Installation of ring gear Remove the pin and edge touched each other between gear case and ring gear.

Apply liquid packing (3-bond “KK 1215”) to inlet side of bolt hole.

Install ring gear.

R55NM7SM09

R55NM7SM10

7-63

(8) Assembly of holder assembly Install thrust plate and gear in which needle bearing is inserted in holder, then install it in shaft.

At this time, apply gear oil to inside of gear, inside & outside of bushing and outside of shaft.

R55NM7SM11

Install spring pin by using a hammer.

Hit a hammer on the pin to the gear direction.

R55NM7SM12

(9) Assembly of gear and holder assembly Install holder assembly into the inside of ring gear, tum holder assembly slowly so that spline of pinion shaft can be installed on it.

Install gear slowly.

R55NM7SM13

7-64

(10) Assembly of sun gear and 1st step holder assembly Install holder assembly into the inside of ring gear, turn slowly holder assembly so that teeth side of gear installed in teeth side of holder assembly.

Fit sun gear in gear slowly.

R55NM7SM14

(11) Check if output shaft is turned smoothly by turning 1st step holder assembly by hand.

7-65

B. REDUCTION GEAR (SB50, #0916 AND UP) 1) STRUCTURE

R55NM2SF06

1 2 3 4 5 6 7 8 9

Case Drive shaft Ring gear Spacer Grease seal Bearing Bearing Oil seal #2 Carrier

10 11 12 13 14 15 16 17

#2 Planet gear #2 Sun gear #2 Pin assy #1 Carrier #1 Planet gear #1 Sun gear #1 Pin assy Thrust washer2

7-66

18 19 20 21 22 23 24 25

Collar Spring pin Knock pin Socket head bolt Thrust washer1 Plug Spring pin Stop ring

2) DISASSEMBLY (1) Remove the plug as shown on picture and drain out gear oil.

R55NM7RG01

(2) Remove the socket bolt.

R55NM7RG02

(3) Lift out the hydraulic motor.

(4) Remove the No.1 sun gear.

R55NM7RG03

7-67

(5) Remove the No.1 carrier sub-assembly using the jig.

R55NM7RG04

(6) Remove the No.2 sun gear. ※ Pay attention to ensure the gear is not damaged during disassembling.

R55NM7RG05

(7) Remove the No.2 carrier sub assembly.

R55NM7RG09

7-68

(8) Remove the ring gear by the removal groove between the ring gear and casing by using jig.

Full out the knock pin.

Do nat need to remove the knock pin if it is not worn or damaged.

R55NM7RG06

(9) Put it on the working table with the drive shaft up.

R55NM7RG07

(10) Disassemble the drive shaft by using jig.

R55NM7RG08

7-69

3) ASSEMBLING SWING REDUCTION GEAR (1) Place the case on the reversing machine having the flange side of the case up.

R55NM7RG12

(2) Install shaft assembly into case. ※ Be sure to clean the case before install, using washing machine with the temperature of 80°C ※ Do not install shaft assembly by force.

R55NM7RG08

(3) Reverse case and press to insert oil seal by using pressing jig after spreading grease oil around the outside ring of the seal and bearing.

Coat grease oil slightly on the lip surface to prevent any scratch when installing. ※ Be sure to check by eye that the oil seal is seated completely after being installed.

R55NM7RG07

7-70

(4) Assemble collar and check that the collar is correctly inserted by pushing drive shaft.

R55NM7RG10

(5) Clean the assembling surface of case and spread packing liquid(TH1105) as shown in figure.

R55NM7RG11

(6) Place ring gear on the case by matching it with knock pin hole.

(7) Insert 2 knock pins by using jig. ※ Be sure to check the hole location of oil gage before inserting.

R55NM7RG06

7-71

(8) Assemble ring gear with case by screwing socket bolt(M12). ※ Spread loctite 262 on socket bolt when installing.

R55NM7RG02

(9) Screw drain plug into drain port after winding sealing tape.

R55NM7RG01

(10) Mount No.2 carrier assembly in the case sub assembly and install bolts into 2 TAP holes(M6) as shown in figure. ※ Turn the carrier slowly by hand to adjust the matching holes when assembling.

R55NM7RG09

7-72

(11) Install No.2 sun gear. ※ Be sure to check the direction of sun gear when assembling.

R55NM7RG05

(12) Mount No.1 carrier assembly in the case sub assembly and install bolts into 2 TAP holes(M6) as shown in figure. ※ Turn the carrier slowly by hand to adjust the matching holes when assembling.

R55NM7RG04

(13) Assemble No.1 sun gear.

R55NM7RG03

7-73

GROUP 3 SWING MOTOR 1. SWING MOTOR 1) DISASSEMBLY (1) Remove the relief valve and hydraulic timer. The relief valve and bypass valve disassembled to be reassembled to the original position.

25038SM02(1)

(2) Mark “I” on the assembly position of motor.

To mark “I” on the assembly position of cover & housing is convenient for reassembly

25038SM02(3)

(3) Removal of bolt.

Remove cover & housing and then remove bypass valve assembly.

25038SM02(4)

(4) Lift cover and then remove it.

25038SM03(1)

7-48

(5) Remove the snap ring and then remove the inlet parts of needle bearing.

25038SM03(2)

(6) Remove O-ring.

25038SM03(3)

(7) Remove balance plate.

25038SM03(4)

(8) Remove bushing and dish spring attached to teffron ring.

25038SM04(1)

7-49

(9) Remove the spring from the piston for brake the inlet parts of needle bearing.

Mark to recognize assembly position of spring.

25038SM04(2)

(10) Removal of the piston for brake.

It is difficult for piston th be removed from housing due to resistance, so it is necessary to use tap hole on the piston as shown on the picture.

25038SM04(3)

(11) Remove friction plate and opposite plate.

25038SM05(1)

(12) Removal of cylinder assembly.

Remove cylinder assembly from housing.

Wrap the edge of cylinder in a smooth texture to prevent a damage.

25038SM05(2)

7-50

(13) Remove the outlet parts of taper roller bearing from housing.

25038SM05(3)

(14) Removal of oil seal.

Tap screw driver or hammer on the seal of housing.

Don’t use oil seal again.

25038SM05(4)

7-51

(15) Disassembly of cylinder assembly ① Remove inlet parts of taper roller bearing.

SM16 (250-3)

② Remove cam plate, piston plate and return plate from cylinder all together.

SM17 (250-3)

③ Make cam plate slide to edge of piston assembly and then remove cam plate.

SM18 (250-3)

④ Remove cam spring from cylinder.

SM19 (250-3)

7-52

2) ASSEMBLY (1) Preparation for assembly Carry out followings before assembly. ① Check if there is a damage to each of the disassembled parts due to disassembly, remove a damage by use of a light sandpaper, clean each of the disassembled parts and apply clean hydraulic oil to them. ② Replace with a new seal. ③ When use sandpaper, sand paper (#2000) to be used for piston assembly, balance plate and cam plate.

SM20 (250-3)

SM21 (250-3)

SM22 (250-3)

7-53

(2) Cylinder assembly ① Install cap spring after applying grease oil to edge of cylinder contacted to cap spring.

SM23 (250-3)

② Insert piston assembly into the hole of return plate.

SM24 (250-3)

③ Install piston assembly and return plate in cylinder. At this time, after applying grease oil to hole of cylinder piston, insert piston assembly into the same hole located in before disassembly.

SM25 (250-3)

④ After applying oil to shoe edge of piston assembly, install cam plate.

SM26 (250-3)

7-54

⑤ Install inlet parts of tape roller bearing.

SM27 (250-3)

⑥ Spray loctote 515 to inlet parts of cylinder.

SM28 (250-3)

⑦ Install inlet parts of cylinder.

SM29 (250-3)

7-55

(3) Assembly of oil seal.

Install oil seal after spraying 3-bond “KK 1211” to seal.

At this time, apply grease oil to seal lip.

SM30 (250-3)

(4) Install outlets of taper roller bearing.

25038SM05(3)

(5) Assembly of cylinder assembly Install cylinder assembly in housing.

At this time, use seal shelter for cylinder spring part.

SM32 (250-3)

(6) Install friction plate, opposite plate.

Apply oil to each of both side.

25038SM05(1)

7-56

(7) Install O-ring in housing and piston.

Apply grease oil to O-ring.

25038SM06(1)

(8) Assembly of brake piston.

After applying oil to outside of cylinder, install it in housing.

25038SM06(2)

(9) Assembly of spring (for brake) Install spring in piston for brake.

25038SM04(2)

(10) Install dish spring and bushing which teffron ring is attached in bushing hole of cover.

SM38 (250-3)

7-57

(11) Assembly of balance plate Install balance plate in cover. ※ Be careful to be installed in correct position.

25038SM07(2)

(12) Install inlet parts of needle bearing, snap ring.

25038SM08(1)

(13) Install O-ring in cover after applying grease oil to O-ring.

SM41 (250-3)

(14) To prevent oil in cover bolt hole from flowing outside, apply 3-bond “KK 1211”.

25038SM08(2)

7-58

(15) Install cover in housing.

Assemble housing and cover according to marking “I” before disassembly.

25038SM03(1)

(16) Bolt tightening torque ·Connecting cover and housing : 10.5kgf·m(103N·m) ·Bypass valve : 4kgf·m(39.2N·m)

25038SM02(4)

(17) Install relief valve assembly in cover, then install hydraulic timer. ·Tightening torque for relief valve assembly : 4kgf·m(39.2N·m) ·Tightening torque for hydraulic timer : 1.2kgf·m(11.8N·m)

25038SM09(2)

(18) Make sure that shaft is turned more than one revolution.

If it is not turned, disassemble again and adjust. At this time, the drain port to be opened. ·Torque : 2 ~ 3kgf·m(19.6 ~ 29.4N·m)

SM47 (250-3)

7-59

2. SWING MOTOR REDUCER A. REDUCTION GEAR (SG015E, UP TO #0915) 1) STRUCTURE

R55NM2SF03

1 2 3 4 5 7 8 9 10 11 12 13 14

Pinion shaft Collar Taper roller bearing Friction plate Gear case Oil seal Taper roller bearing Parallel pin Ring gear Gear Piston assembly Sun gear Socket bolt

16 17 18 19 20 21 22 23 24 25 26 27

7-60

Collar Plug Shaft assembly Bypass valve assembly Shaft O-ring Gear Holder Needle bearing Thrust plate Gear Oil seal

2) DISASSEMBLY (1) Remove sun gear and 1st step holder assembly.

(2) Remove sun gear and 2nd step holder assembly.

(3) Removal of 2nd step holder assembly.

Install spring pin into the shaft inside by using hammer. ※ Spring pin not to be used again.

Fixing gear by hands, remove shaft from holder.

R55NM7SM01

R55NM7SM02

(4) Removal of ring gear.

Remove ring gear from gear case.

Because liquid packing (3-bond “KK 1215”, black) is applied to the edge of contact between ring gear and gear case to prevent the leakage of gear oil, remove ring gear by using the contact part of gear case.

(5) Removal of collar.

Remove the collar from shaft by using hammer and driver.

R55NM7SM03

(6) Removal of shaft assembly.

Put the support (300mm height) to the flange part of gear case in order to get the position of removal, press flange part by hydraulic machine, then remove shaft, collar, taper roller bearing.

Oil seal not to be used again. ※ Don’t disassemble more than the above if there is not any abnormality in bearing, etc.

R55NM7SM04

7-61

3) ASSEMBLY (1) Preparation for assembly.

Carry out followings before assembly. ① Check if there is a damage to each of the disassembled parts due to disassembly, remove a damage by use of a light sandpaper, clean each of the disassembled parts and apply clean hydraulic oil to them. ② Replace with a new seal.

(2) Apply grease oil to the roller part of taper roller bearing.

R55NM7SM05

(3) Install oil seal after spraying 3-bond “KK 1211” to seal. At this time, apply grease oil to seal lip.

R55NM7SM06

(4) Assembly of pinion shaft assembly Use seal protector for spline part to prevent damage of seal lip.

Put the output shaft of gear case to the upper direction, then install pinion shaft in gear case.

R55NM7SM07

7-62

(5) Installation of taper roller bearing Put output shaft of gear case to the lower direction, install roller bearing in shaft on condition of environmental temperature 50° C

R55NM7SM08

(6) Assembly of collar Adjust the thickness of collar so that a gap between collar and groove of shaft become ± 0.06.

(7) Installation of ring gear Remove the pin and edge touched each other between gear case and ring gear.

Apply liquid packing (3-bond “KK 1215”) to inlet side of bolt hole.

Install ring gear.

R55NM7SM09

R55NM7SM10

7-63

(8) Assembly of holder assembly Install thrust plate and gear in which needle bearing is inserted in holder, then install it in shaft.

At this time, apply gear oil to inside of gear, inside & outside of bushing and outside of shaft.

R55NM7SM11

Install spring pin by using a hammer.

Hit a hammer on the pin to the gear direction.

R55NM7SM12

(9) Assembly of gear and holder assembly Install holder assembly into the inside of ring gear, tum holder assembly slowly so that spline of pinion shaft can be installed on it.

Install gear slowly.

R55NM7SM13

7-64

(10) Assembly of sun gear and 1st step holder assembly Install holder assembly into the inside of ring gear, turn slowly holder assembly so that teeth side of gear installed in teeth side of holder assembly.

Fit sun gear in gear slowly.

R55NM7SM14

(11) Check if output shaft is turned smoothly by turning 1st step holder assembly by hand.

7-65

B. REDUCTION GEAR (SB50, #0916 AND UP) 1) STRUCTURE

R55NM2SF06

1 2 3 4 5 6 7 8 9

Case Drive shaft Ring gear Spacer Grease seal Bearing Bearing Oil seal #2 Carrier

10 11 12 13 14 15 16 17

#2 Planet gear #2 Sun gear #2 Pin assy #1 Carrier #1 Planet gear #1 Sun gear #1 Pin assy Thrust washer2

7-66

18 19 20 21 22 23 24 25

Collar Spring pin Knock pin Socket head bolt Thrust washer1 Plug Spring pin Stop ring

2) DISASSEMBLY (1) Remove the plug as shown on picture and drain out gear oil.

R55NM7RG01

(2) Remove the socket bolt.

R55NM7RG02

(3) Lift out the hydraulic motor.

(4) Remove the No.1 sun gear.

R55NM7RG03

7-67

(5) Remove the No.1 carrier sub-assembly using the jig.

R55NM7RG04

(6) Remove the No.2 sun gear. ※ Pay attention to ensure the gear is not damaged during disassembling.

R55NM7RG05

(7) Remove the No.2 carrier sub assembly.

R55NM7RG09

7-68

(8) Remove the ring gear by the removal groove between the ring gear and casing by using jig.

Full out the knock pin.

Do nat need to remove the knock pin if it is not worn or damaged.

R55NM7RG06

(9) Put it on the working table with the drive shaft up.

R55NM7RG07

(10) Disassemble the drive shaft by using jig.

R55NM7RG08

7-69

3) ASSEMBLING SWING REDUCTION GEAR (1) Place the case on the reversing machine having the flange side of the case up.

R55NM7RG12

(2) Install shaft assembly into case. ※ Be sure to clean the case before install, using washing machine with the temperature of 80°C ※ Do not install shaft assembly by force.

R55NM7RG08

(3) Reverse case and press to insert oil seal by using pressing jig after spreading grease oil around the outside ring of the seal and bearing.

Coat grease oil slightly on the lip surface to prevent any scratch when installing. ※ Be sure to check by eye that the oil seal is seated completely after being installed.

R55NM7RG07

7-70

(4) Assemble collar and check that the collar is correctly inserted by pushing drive shaft.

R55NM7RG10

(5) Clean the assembling surface of case and spread packing liquid(TH1105) as shown in figure.

R55NM7RG11

(6) Place ring gear on the case by matching it with knock pin hole.

(7) Insert 2 knock pins by using jig. ※ Be sure to check the hole location of oil gage before inserting.

R55NM7RG06

7-71

(8) Assemble ring gear with case by screwing socket bolt(M12). ※ Spread loctite 262 on socket bolt when installing.

R55NM7RG02

(9) Screw drain plug into drain port after winding sealing tape.

R55NM7RG01

(10) Mount No.2 carrier assembly in the case sub assembly and install bolts into 2 TAP holes(M6) as shown in figure. ※ Turn the carrier slowly by hand to adjust the matching holes when assembling.

R55NM7RG09

7-72

(11) Install No.2 sun gear. ※ Be sure to check the direction of sun gear when assembling.

R55NM7RG05

(12) Mount No.1 carrier assembly in the case sub assembly and install bolts into 2 TAP holes(M6) as shown in figure. ※ Turn the carrier slowly by hand to adjust the matching holes when assembling.

R55NM7RG04

(13) Assemble No.1 sun gear.

R55NM7RG03

7-73

GROUP 4 TRAVEL MOTOR A. TRAVEL MOTOR (GM09VL, UP TO #0698) 1. PRECAUTIONS FOR OPERATION 1) METHOD OF INSTALLATION A : Installation part for machine B : Installation part for sprocket B

A

R55NN7TM01-1

·Tightening torque for installation bolt Quantity

Dimension

Tightening torque

Installation bolt for machine

12

M16 (P2.0)

25.7±4.0 kg·m

Installation bolt for sprocket

12

M14 (P2.0)

16.6±2.5 kg·m

2) CHANGE OF GEAR OIL (1) Make oil filing port and oil drain port be vertical position on horizontal place.

(2) Change oil after loosening both port plug and draining gear oil.

For supplement, loosen the plug of oil filling port.

(3) Fill amount of gear oil at oil filling port until oil is overflowed.

(4) Wash the plug and reinstall it with sealing tape. ·Oil capacity : Each 0.45 U.S.gal ·Service interval : Every 1000 hr (Initial service : 500 hr)

R55NN7TM01-2

7-74

2. TOOLS FOR DISASSEMBLY AND ASSEMBLY 1) STANDARD TOOLS Serial No. of applied item (See page 2-23, 24 in this manual)

Tool name

Size & type

Quantity (EA)

126,143,121,152,33

Torque wrench

Dial type, #1800

1

19,124

Torque wrench

Dial type, #5600

1

152

Hexagon wrench

Nominal 6 mm

1

33,143

Hexagon wrench

Nominal 8 mm

1

126

Hexagon wrench

Nominal 10 mm

1

33,143

Hexagon socket

Nominal 8 mm

1

126

Hexagon socket

Nominal 10 mm

1

19

Hexagon socket

Nominal 27 mm

1

124

Socket, Adapter

Nominal 36 mm

1

19

Extension bar

Nominal 27 mm

1

1,11,21,132,165

Hand hammer

Nominal 12 mm

1

8,10,102,112

Plastic hammer

79.25 U.S.gal

1

24,25

Snap ring plier

For shaft

1

20,145

Snap ring plier

For hole

1

1

Center punch

Ø 9.5 × 100

1

21

Pin punch

Ø 4 × 100

1

For washing

Washing brush

1

For washing

Wire washing brush

1

For washing

Paint marker

17

Metal net gasket

2

149

Leather gloves

1 Pair

11

Vinyl sheets

For filling oil

Oil pot with handle

2

33

Sealing tape

1

21

Gear puller

1 Set

Hanger for 1,2

Shackle, wire rope

1 Set

White color

500 × 500 × 1.0

7-75

1

1

2) TOOLS (1) Work table This is used for safe assembly and disassembly of track motor.

R55NM7TM02

(2) Clamp This is used for connecting hub and spindle together.

R55NM7TM03

(3) Retainer ( I ) This is used for installing coil spring (114), washer (110) and snap ring (145), used for removing coil spring (114) from cylinder block.

R55NM7TM04

(4) Retainer ( II ) This is used for removing ball bearing from shaft, used for pressing bearing.

R55NM7TM05

7-76

(5) Retainer ( III ) This is used for installing oil seal in the hole of spindle.

R55NM7TM06

(6) Retainer ( IV ) This is used for installing RV gear sub assembly in spindle.

R55NM7TM07

(7) Tool for adjusting bearing This is used for adjusting an interval of shaft between flange and ball bearing when installing ball bearing in hub.

R55NM7TM08

(8) Steel bar This is used for removing ring from hub.

R55NM7TM09

7-77

(9) Aluminum rod This is used for removing oil seal from spindle.

R55NM7TM10

(10) PT eye bolt This is used for lifting cover from hub by crane and wire rope..

R55NM7TM11

(11) Long eye bolt This is used for lifting motor, spindle and hub.

A Hub

M 14

Spring

M16

GM motor

M14

A R55NM7TM12

(12) Flat bar and steel pipe This is used for removing inlet parts of ball bearing from spindle, used for removing timing belt from rear flange.

R55NM7TM13

7-78

(13) Punch This is used for removing ring from rear flange.

R55NM7TM14

(14) Steel bar This is used for removing ring from rear flange.

1.6

150

R55NM7TM15

7-79

3) PREPARATIONS Item No

Description

Tool name

For disassembling and assembling work

Standard work table

Motor and items to be washed

Washing sink

104, 149

Press machine

Q’ty 1

For initial washing and final washing

2

Capacity : 200 kgf

1

149

Heating vessel

1

Electric drill

Capacity : 500×500×500 Heating temperature : 100° C more Hand drilling machine, Ø5

1

Drill

Diameter : 2mm

Motor

Crane

1

3

Lathe

1

1 1 1

1

Grinder Items to be dried

Compressed air

3 - 5 kgf/cm

1

2

4) TOOLS FOR ADJUSTING Item No

Name

Size

20 (For adjusting thickness of snap ring) 20 (For adjusting thickness of snap ring) 21 (For adjusting pre-pressure of snap ring)

Gauge for adjusting thickness Micrometer for adjusting outside Micrometer for adjusting depth

Q’ty

Adjustment range : 0.04 ~ 0.3mm

2

Adjustment range : 0 ~ 25mm Minimum scale : 0.01 Adjustment range : 0 ~ 25mm Minimum scale : 0.01

1 1

5) TIGHTENING TORQUE Item No

Name

Size

Contact width (mm)

Tightening torque (kgf·cm)

19

Rimmer bolt

M20 P2.5

22

4200

33

Socket plug

PT 3/8

8

400

124

Plug

M30 P1.5

36

3600

126

Plug

M24 P1.5

20

1300

143

Socket bolt

M10 P1.5

8

590

146

Socket bolt

PT 1/8

3

125

121

Plug

M20

26

600

152

Socket plug

PT 1/4

6

300

160

Plug

M30 P1.5

36

3600

170

Socket plug

P1.25

6

300

6) WEIGHT TABLE Item No Motor

Item description

Weight (kg)

Assembly

90

1

Hub

21.75

2

Spindle

26.65

101

Rear flange sub assembly

11.85

7-80

3. DISASSEMBLY 1) PREPARATION FOR DISASSEMBLY (1) Prepare work table and work bench ① Prepare useful work table ② Prepare wide and robust work bench that parts don’t move under working (2) Preparation of tool and matters ① Prepare standard tool and matters for work 2) GENERAL PRECAUTIONS (1) Read this manual thoroughly before disassemble motor (2) Be care to deal with inlet parts of motor because they are precisely machined (3) Be care not to get rusty on the surface of disassembled parts

7-81

3) DISASSEMBLY (1) Washing GM motor ① Enclose oil port of rear flange. ② Install 2(two) eye-bolts in the tapped holes of spindle so that they can be parallel each other.

R55NM7TM16

③ Wash each part of motor with brush when washing in the washing sink.

Remove matters between hub and spindle.

R55NM7TM17

(2) Installation of motor ① Install motor in work table.

Fit the bolt hole of hub to the hole of work table when installing motor in work table.

R55NM7TM18

② Tighten 2(two) socket bolt in order to connect motor to work table.

R55NM7TM19

7-82

(3) Drain of gear oil ① Turn the motor to be upper direction. ② Loosen 3(three) plug with socket wrench.

At this time, leave 1-2 thread of plug in the cover.

R55NM7TM20

③ Turn the work table in order that rear flange can be upper direction. ④ Remove 3(three) plug, put the vessel for draining gear oil.

R55NM7TM21

(4) The removal of cover ① Turn the work table in order that motor cover can be upper direction. ② Mark paint on contact point between hub and cover in order to reassemble again.

R55NM7TM22

③ Finding the split gap of ring, punch marking for drilling at the point of inside 20mm from front edge of ring and 7mm from end edge.

R55NM7TM23

7-83

④ Drill Ø2 hole at the punch marking by use of electric drilling machine.

Remove chip after piercing hub.

R55NM7TM24

⑤ Insert steel bar in the hole of drill, push it in order that ring can be rised on the cover.

R55NM7TM25

⑥ After taking hold of edge of ring, remove the ring from groove.

R55NM7TM26

⑦ Tighten PT I type bolt in the hole of plug on the cover. ⑧ Remove the cover by use of crane.

R55NM7TM27

7-84

⑨ Remove O-ring from the cover.

Do not use the removed O-ring again.

R55NM7TM28

(5) Removal of input gear ① Remove snap-ring from shaft.

R55NM7TM29

② Remove input-gear from shaft. ③ Remove shaft from coupling. ④ Remove steel-ball from shaft. ⑤ Remove coupling from shaft.

R55NM7TM30

(6) Removal of rear flange ① Turn the work table in order that rear flange can be upper direction. ② Loosen right / left plug and plug.

This is only required for disassembling inlet parts of rear flange.

R55NM7TM31

7-85

③ Loosen right and left plug.

This is required disassembling the inlet parts of rear flange.

R55NM7TM32

④ Loosen socket bolt from rear flange, then remove housing.

At this time, O-ring is removed with housing.

⑤ Loosen the socket bolt to protect the rear flange from spindle.

R55NM7TM33

⑥ Loosen rear flange from spindle on the cover.

Taking out rear flange, be care not to damage the timing plate.

R55NM7TM34

7-86

⑦ Remove spring of parking brake. ⑧ Remove parallel pin from spindle.

R55NM7TM35

⑨ Remove O-ring from spindle.

Do not use it again.

R55NM7TM36

(7) The removal of inlet parts from rear flange ① Put the rear flange on the work table, at this time, let the inside of rear flange be upper direction. ② Remove timing plate from rear flange.

When it is difficult for the timing plate to be removed due to the adhesion of oil between rear flange and it, insert the plane bar in the groove of rear flange and then remove timing plate.

R55NM7TM37

③ Remove parallel pin from rear flange.

R55NM7TM38

7-87

④ Remove ball bearing.

R55NM7TM39

(8) Removal of brake valve ① Remove 2(two) plug from rear flange.

R55NM7TM40

② Remove coil spring and stopper from rear flange. ③ Remove spool from rear flange.

When removing spool, if spool shaft of rear flange is to the lower direction, spool become fall down.

Therefore, take hold of spool, then remove it again.

R55NM7TM41

④ Remove 2(two) plug from rear flange.

R55NM7TM42

7-88

⑤ After removing plug, remove spring and valve.

R55NM7TM43

⑥ Remove O-ring from plug.

Do not use it again.

R55NM7TM44

⑦ Remove O-ring from plug.

Do not use it again.

R55NM7TM45

(9) Disassembly of valve ① Remove plug from housing.

R55NM7TM200

7-89

② Remove spring and stopper from housing.

R55NM7TM201

③ Remove spool from housing.

Because housing and spool are composd of one set, if there is a damage in any part of them, replace it together.

R55NM7TM202

④ Remove O-ring from plug.

Do not use it again.

R55NM7TM203

(10) Disassembly of pilot valve ① Apply a sharp-point punch at the notch of ring, hit a hammer on the punch to remove ring.

R55NM7TM46

7-90

② After removing ring, lift rear flange and take the hole of that to the lower direction, then stopper, spring and valve are removed from rear flange. In spite of using the above method, if they were not removed, remove them by use of compressed air .

Do not use removed ring again.

Unless pilot valve is not replaced, don’t remove ring.

R55NM7TM47

(11) Disassembly of plug ① Do not disassemble plug except necessary case. If plug is closed by dust and etc, remove them by washing.

Be careful that steel sphere is not removed.

(12) Disassembly of parking brake ① Remove piston by pouring compressed air into the hole parking brake, at this time, be care not to pouring air suddenly.

For operator’s safe, install cover for protector on piston.

R55NM7TM48

② Remove O-ring from piston.

Do not use removed ring again.

R55NM7TM49

7-91

(13) Disassemble of hydraulic motor ① Turn the motor to 90° C direction, drain hydraulic oil.

R55NM7TM50

② Take hold of cylinder block, pull motor shaft slowly, then remove it.

Before pull it, turn cylinder block 2-3 times in order that shoe is not removed from inside sliding edge of swash plate, then remove friction plate and other plate.

R55NM7TM51

③ Take hold of retainer plate by both hands, remove piston kit and retainer plate.

Because piston and shoe are not disassembled without a damage of any part among them, if replacement is required, replace them together.

R55NM7TM52

④ Remove 9(nine) piston sub assembly from retainer plate.

R55NM7TM53

7-92

⑤ Remove thrust ball from cylinder block.

R55NM7TM54

⑥ Remove 3(three) parallel pin from cylinder block.

R55NM7TM55

(14) Removal of spring from cylinder block ① Put cylinder block on the press machine as shown on drawing. ② Pressing retainer on washer, remove snap ring from cylinder block by snap ring plyer. ·Before pressing spring, put cylinder block, retainer and presser absorber on a straight line to prevent a damage. ·To prevent a damage of cylinder block, envelop the surface of that with vinyl.

R55NM7TM56

Press Retainer(I) Washer

Snap ring Spring Cylinder block

R55NM7TM57

7-93

③ Remove snap-ring, washer, spring from cylinder block.

R55NM7TM58

(15) Removal of motor shaft ① Remove swash plate from motor shaft.

R55NM7TM59

② Remove shaft and ball bearing from spindle. ·If hit a plastic hammer on the shaft end point of reducer gear, they will be removed easily. ③ Remove thrust plate from swash plate ·In case that they’re not removed due to the oil between swash plate and thrust plate, remove them by inserting a small bar.

R55NM7TM60

④ Remove 2(two) pivot and parallel pin. ⑤ Remove piston assembly from spindle by pouring compressed air into the hole of spindle.

Piston assembly is composed of piston and shoe. ·Pressure of compressed air : 3-5kg/cm2 ·Because piston and shoe are not disassembled without a damage of any part among them, if replacement is required, replace them together.

R55NM7TM61

7-94

(16) Removal of bearing from motor shaft ① Put retainer on work table of presser, install shaft in retainer. ② Pressing shaft end point by press machine, remove ball bearing from shaft. ·Use the above method only when replacement is required.

Press

Retainer(II)

R55NM7TM62

(17) Removal of spur gear ① Turn the motor in order that the side of spur gear is to the upper direction. ② Remove the snap ring from crank shaft.

R55NM7TM63

③ Remove spur gear from each crank shaft.

R55NM7TM64

④ Remove distance piece from each shaft.

R55NM7TM65

7-95

(18) Removal of hold flange ① Turn the motor in order that the side of spindle is to the upper direction. ② Fix hub and spindle to be parallel by use of 2(two) clamp. ·Hub to be fixed between spindle and hold by clamp.

R55NM7TM66

③ Turn the motor in order that hold flange is to the upper direction. ④ Remove 3(three) snap ring from each hole.

R55NM7TM67

⑤ Mark hold flange and each snap ring with paint for reassembly.

R55NM7TM68

⑥ Loosen 3(three) reamer bolt supporting hold flange of spindle. ·Tightening torque : 42 ± 6.5kgf·m (411.8 ± 63.7N·m)

R55NM7TM69

7-96

⑦ Remove the hold flange from spindle. ⑧ Mark hold flange and spindle with paint for reassembly. ·If replacement is required, replace assembly composed of spindle and hold flange.

R55NM7TM70

(19) Removal of clamp ① Turn the motor to be the lower direction. ② Remove 2(two) clamp in order to remove spindle from hub.

R55NM7TM71

(20) Removal of spindle ① Tighten 2(two) eye type bolt into the hole of spindle. ② Remove spindle from hub by use of crane, at this time, remove roller bearing and seals together.

R55NM7TM72

③ Remove distance piece from hub.

Do not use O-ring again.

R55NM7TM73

7-97

④ Remove O-ring from hub.

Do not use O-ring again.

R55NM7TM74

(21) Removal of ball bearing, RV gear assembly and pin ① Remove ball bearing from hub.

At this time, remove RV gear assembly, crank shaft, taper roller bearing, needle roller bearing, spacer and pin in sequence. ·When removing ball bearing from hub, install rubber mat on the work table to prevent a damage of each item. ② Do not disassemble RV gear assembly, if disassemble it, quality assurance is not applied to.

Hammer Pin punch

Pin Ball bearing

R55NM7TM75

R55NM7TM73

(22) Removal of ball bearing and collar ① Turn the motor to the lower direction. ② Remove ball bearing and collar from hub. ·When removing ball bearing and collar from hub, install the rubber mat to prevent a damage.

Hammer Pin punch Collar Ball bearing

R55NM7TM76

7-98

(23) Disassembly of fittings for spindle ① Remove oil seal from spindle.

Do not use removed oil seal again.

Oil seal Spindle

R55NM7TM77

② Remove floating seal from spindle.

R55NM7TM78

③ Remove the outlets of 3(three) tape roller bearing from spindle.

When it is difficult to remove tape roller bearing due to oil, remove oil by inserting aluminum bar into the hole of spindle.

R55NM7TM79

(24) Disassembly of bolt flange ① Remove outlets of tape roller bearing.

R55NM7TM80

7-99

(25) Washing of parts ① Remove hub, spindle, cover and rear flange. ② Wash hub, cover, spindle and rear flange in container for washing and remove dust on the surface. ③ Make clean inlet parts by use of oil. ·After removing sufficiently dust of each part to prevent a damage, wash each part.

R55NM7TM81

(26) Finish for washing ① Apply oil to the each part for finishing wash.

Put each part into container for washing, rotating it slowly, make clean inside of them.

R55NM7TM82

② Remove dust with soft brush, apply oil to them.

R55NM7TM83

7-100

4) REASSEMBLY Follow the procedure used to disassemble in the reverse order when reassembling it.

(1) General cautions ① Follow cautions for disassembly. ② Remove dust from all disassembled parts, use sand paper and oil stone in order to remove burrs and sharp edges of them. ③ Replace O-ring, oil seal, floating seal, etc with new one. ④ Apply a thin coat of grease to the seals before fitting them. ⑤ Apply a thin coat of grease to the parts of motor and to each side of valve. ⑥ Follow regular tightening torque. ⑦ Enclose all ports of motor after assembling it completely.

7-101

B. TRAVEL MOTOR (TM07VA, #0698 AND UP) 1. DISASSEMBLY 1) GENERAL PRECAUTIONS (1) Before disassembling the TM motors, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively.

(2) To disassemble the motor, use the disassembling procedures described in section 2-2, and select a clean place.

(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect the surface of the motor to be serviced.

(4) During disassembly, give a match mark to the mating surfaces of each part.

(5) Arrange removed parts in order so that they will not become damaged or missing during disassembly.

(6) Once seals have been disassembled, they should be replaced even if damage is not observed.

Have replacement seals ready on hand before starting your disassembling job.

7-102

2) SPECIAL TOOLS (1) Inversion working bench.

R55NM7TM152

(2) Retainer (I).

R55NM7TM151

(3) Retainer (II).

R55NM7TM150

(4) Aluminum rod.

R55NM7TM149

7-103

(5) Retainer (I).

R55NM7TM148

(6) Retainer (II).

R55NM7TM146

(7) Aluminum rod.

R55NM7TM147

7-104

3) REAR FLANGE (1) Loosen the four hex.(hexagon) socket head bolts(70) and remove the S.C.V valve body(55) from the rear flange(1).

(2) Remove the two O-rings(40), (46) from the rear flange(1).

R55NM7TM120

(3) Remove the hex. socket head bolts(43).

R55NM7TM119

(4) Remove the rear flange(1) from the holder flange(10).

R55NM7TM121

(5) Remove the timing plate(9), the two pins(41), the eight springs(13), the ball bearing(50), and O-ring(126) from the rear flange(1) and holder flange(101).

R55NM7TM122

7-105

4) BRAKE VALVE (1) To remove the spool ① Remove the two plugs(24) from the rear flange(1).

Remove the O-ring(36) from the plug(24).

R55NM7TM110

② Remove the two springs(28), the two spring retainers(25), and the spool(23) from the rear flange(1). ※ Be careful not to damage the outer surface of the rear flange(1).

R55NM7TM108

(2) To remove the check valves ① Remove the two plugs(26) from the rear flange(1).

R55NM7TM101

② Remove the two springs(30) and the two valves(27) from the rear flange(1). ※ Be careful not to damage the seat section of valves(27) or rear flange(1). ③ Remove the O-ring(34) from the plug(26).

R55NM7TM136

7-106

(3) To remove the T-valve(19) from the rear flange(1) ① Press and hold down the valve seat(18) using a steel bar, and in that state, as shown in the diagram at right, press the notch in the ring(22) using a sharp pointed steel bar. This deforms the ring(22), disengaging it from the ring groove in the rear flange(1). The ring(22) can now be removed from the rear flange(1).

R55NM7TM210

R55NM7TM212

② After filling up the hole section of the valve seat(18), inject compressed air from the parking brake access hole and remove the valve seat(18). ③ Holding the rear flange(1) by hand and lightly shaking it with its hole section facing downward allows the T-valve(19) and the spring(20) to be removed or using tweezers or any other such tool, remove the T-valve(19) and the spring(20) from the rear flange(1)

R55NM7TM211

④ Remove the O-ring(33) from the valve seat(18).

7-107

(4) To remove the valve(63) from the rear flange(1) ① Press and hold down the stopper(64) using a steel bar, and in that state, as shown in the diagram at right, press the notch in the ring(65) using a sharp pointed steel bar.

This deforms the ring(65), disengaging it from the ring groove in the rear flange(1).

The ring(65) can now be removed from the rear flange(1)

R55NM7TM104

R55NM7TM212

② Make the hole section of the removed ring(65) face downward, and lift the rear flange(1). This allows the stopper(64), the spring(166) and the valve(63) from the rear flange(1).

R55NM7TM106

(5) To disassemble the internal parts of the body kit ① Remove the plug(24) from the body(55). ② Remove the O-ring(36) from the plug(24).

R55NM7TM124

7-108

③ Remove the springs(58), (59), the stopper(57) and the spool(56), in that order, from the body(55). ※ Be careful not to damage the other surface of the spool(56) and the sliding surface of the rear flange.

R55NM7TM112

5) HYDRAULIC MOTOR (1) To remove the parking brake parts ① Remove the piston(12) by injecting compressed air from the parking brake access hole in the holder flange(101). ※ Take care that abrupt injection of compressed air may cause the piston(12) to pop out.

R55NM7TM127

② Remove the O-rings(35), (39) from the piston(12).

R55NM7TM129

7-109

(2) To remove the internal parts of the motor ① Lay the TM motor body on the side. ② Drain out the oil from the TM motor. ③ Hold the cylinder block(4) with both hands, and remove it from the holder flange(101) ※ Before removal, hold the cylinder block(4) with both hands and turn it two to three times in a clockwise and a counterclockwise direction alternately to detach the shoe(6) from the swash plate(3). ※ Becareful that if an attempt is made to remove the cylinder block(4) without detaching the shoe(6) from the swash plate(3), then the piston, shoe and other parts that are connected to the cylinder block may come loose and fall into the spindle.

R55NM7TM131

④ Remove the four mating plates(16) and three friction plates(15) that are mounted on the outer surface of the removed cylinder block(4). ⑤ Remove the piston assy piston(5), shoe(6), retainer plate(7), thrust ball(8), and three rollers(51) from the removed cylinder block(4).

R55NM7TM132

⑥ Remove the swash plate(3) from the holder flange(101). ⑦ Remove the two steel balls(67) from the holder flange(101). ⑧ Remove the speed selector piston assy piston(61) and shoe(62) from the holder flange(101) by feeding compressed air(3 to 5kgf/cm2) from the access hole in holder flange(101).

7-110

(3) To disassembly the inside of the cylinder block(4) ① Place the cylinder block(4) on a press working bench, and then while pressing and holding down a retainer(I) against the washer(10), remove the snap ring(45) using snap ring pliers. ※ Press load : 120 kgf or more. ※ Protect the sliding surface of the cylinder block withe a vinyl sheet.

R55NM7TM133

② Remove the snap ring(45) the washer(10), the spring(14), and the washer(10), in that oder, from the cylinder block(4).

R55NM7TM137

(4) To remove the shaft(2) and the roller bearing(49) ① Remove the shaft(2) from the holder flange(101).

At this time, the roller bearing(49) can also be removed in conjunction with the shaft(2).

The oil seal(32), however, cannot be removed.

R55NM7TM118

7-111

6) REDUCTION GEAR (1) Remove the plugs(10) from the cover(123).

(2) Loosen the socket bolts(124) and remove the cover(123) from the housing(105).

R55NM7TM103

(3) Remove the thrust plate(R)(122) and the drive gear(121).

R55NM7TM105

(4) Remove the planetary gear(R)(117), the needle bearing(118), the inner race(119) and the holder(116).

R55NM7TM123

(5) Remove the sun gear(114), the screw(110), the thrust plate(F)(113) and the needle bearing(111).

R55NM7TM125

7-112

(6) Remove the collar(112) and the thrust washer(109).

R55NM7TM126

(7) Remove the plugs(124).

R55NM7TM128

(8) Remove the nut ring(103).

R55NM7TM130

(9) Remove the holder flange(101) from the housing(105).

R55NM7TM116

7-113

(10) Remove the plug(104) and steel ball(106) (104ea).

R55NM7TM113

(11) Remove the floating seal(102) and angular bearing(125).

R55NM7TM109

(12) Remove the floating seal(102) from the holder flange(1).

R55NM7TM134

(13) Remove the snap ring(76).

(14) Remove the oil seal(32).

R55NM7TM135

7-114

2. REASSEMBLY 1) GENERAL PRECAUTIONS (1) Reassemble in a work area that is clean and free from dust and grit.

(2) Handle parts with bare hands to keep them free or linty contaminants.

(3) Repair or replace the damage parts.

Each parts must be free of burrs its corners.

(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.

Provide the new parts.

(5) Wash all parts thoroughly in a suitable solvent.

Dry thoroughly with compressed air Do not use the cloths.

(6) When reassembling oil motor components of TM motor, be sure to coat the sliding parts of the motor and valve with fresh hydraulic oil.(NAS class 9 or above).

(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

2) TIGHTENING TORQUE TABLE Item No

Parts name

Size

Tightening torque kgf·cm

lbf·in

21

Plug

PF 3/8

600

520.8

24

Plug

M30 P1.5

3600

3125

26

Plug

M24 P1.5

1300

1128

43

Hex. socket bolt

M10 P1.5

590

512

44, 107

Hex. socket plug

PT 1/8

125

108.5

52

Hex. socket plug

PF 1/4

300

260

54

Hex. socket plug

NPTF 1/16

100

86.8

70

Hex. socket bolt

M8

300

260

91

Hex. socket plug

PT 1/4

300

260

103

Nut ring

M165×P2

1800

1562

104

Hex. socket plug

PT 3/8

350

304

110

Screw

M6

83

72

124

Hex. socket bolt

M8

300

260

7-115

3) REDUCTION GEAR (1) Mount end of the floating seal(102) in the holder flange(101).

R55NM7TM107

(2) Press angular bearing(125) into the housing(105).

R55NM7TM109

(3) Insert the steel balls(106)(104ea) into the housing(105).

R55NM7TM111

(4) Place seal taper around plug(104) and tighten it up.

R55NM7TM113

7-116

(5) Mount another end of floating seal(102) into the housing(105).

R55NM7TM115

(6) Fit the holder flange(101) into the housing(105).

R55NM7TM116

(7) Tighten the nut ring(103) and the plugs(104) to the required torque using a torque wrench. ※ Tightening torque : 350kgf·cm(2531lbf·ft)

R55NM7TM130

(8) Mount the thrust washer(109) and the collar(112).

R55NM7TM126

7-117

(9) Fit the needle bearing(111) and place the thrust plate(F)(113). Tighten the screw (110) to required torque using torque wrench. ※ Tightening torque : 83kgf·cm(72lbf·in)

R55NM7TM125

(10) Fit holder ass’y sun gear(114), needle bearing(118) and planetary gear(R)(117).

R55NM7TM138

(11) Attach the drive gear(121) and place thrust plate(R)(122).

R55NM7TM103

(12) Fit the cover(123) to the housing(105).

(13) Tighten socket bolts(124) to the required torque using a torque wrench. ※ Tightening torque : 125kgf·m(904lbf·ft)

R55NM7TM140

7-118

4) BRAKE VALVE (1) To remount the check valve ① Fit the O-ring(37) on the plug(26). ② Insert the spring(30) and the valve(27) into the plug(26), and then grease the spring(30) and the valve(30) and handlock the former. ※ Tightening torque : 26±4kgf·m (188±28.9lbf·ft) ③ Insert the plug(26) in conjunction with the spring(30) and the valve(30) into the rear flange(1), and tighten the plug to the required torque. ※ Tightening torque : 26±4kgf·m (188±28.9lbf·ft)

R55NM7TM136

(2) To remount the spool ① Insert the spool(23) into the rear flange(1).

R55NM7TM108

② Attach the O-ring(36) to the plug(24). ③ Install spring retainer(25) and the spring(28) into both plugs(24), and tighten the plugs(24) into the rear flange(1) at the required torque. ※ Required torque : 45±9kgf·m (32.5±65lbf·ft)

R55NM7TM110

7-119

(3) To reassemble the surge cut off valve ① Apply a working fluid to the spool(56), and insert it into the body(55). ※ Damage to the hole section of the body or the outer surface of the spool may cause internal leakage to occur after reassembling, and TM motor performance to deteriorate.

R55NM7TM112

② Fit the O-ring(36) to the plug(24). ③ Install the spring retainer(25) and the springs(58), (59) into the plug(24). ④ Tighten the plug(24) into the body(55) at the required torque.

R55NM7TM114

(4) To remount the parking brake valve ① Mount the O-ring(33) on the valve seat(18). ② Insert the valve(19), the spring(20), and the valve seat(18), in that order, into the rear flange(1).

③ Slightly bend a new ring and place it in the new ring into the ring groove of the rear flange.

R55NM7TM117

7-120

(5) To remount the valve(63) ① Holding the rear flange(1) with its surface contacting the holder flange(101) upward, place the rear flange on a working bench. ② Insert the valve(63) into the rear flange(1). ③ Fit the spring(66) into the valve(63), and mount the stopper(64) on it.

R55NM7TM143

④ Slightly bench a new ring(65) and insert it into the rear flange(1) from the top of the stopper(64).

Then, fit the new ring into the ring groove of the rear flange.

R55NM7TM142

5) HYDRAULIC MOTOR (1) To remount the shaft(2) ① Fit the oil seal(32), the snap ring(45) and roller bearing(49) in that oder, into the holder flange(101). ② Insert the shaft(2) into the roller bearing(49).

R55NM7TM118

(2) To reassemble the piston ass’y(61), (62) ① Mount the piston ass’y(61), (62) in the piston hole of the holder flange(101).

7-121

(3) To reassemble the steel balls(67) ① Mount the two steel balls(67) in the steel ball hole of the holder flange(101).

(4) To reassemble cylinder block section ① Insert washer(10), spring(14), washer(10) and the snap ring(45) in that order, into the shaft bore of cylinder block(4).

R55NM7TM137

② Set cylinder block in the press in other to compress the spring(14).

Place retainer(I) on the washer(10) and push down this tool with the press until the snap ring groove becomes cleared.

Fit snap ring(45) into the groove.

R55NM7TM133

(5) Piston motor sub-assembly ① Fit 3-rollers(51) into the pin holes of cylinder block(4), and then, put thrust ball(8) on it. ② Insert piston assembly into retainer plate(7). ③ Mount the piston assembly into the cylinder block(4). After mounting, immerse the entire them in a working fluid.

R55NM7TM144

7-122

④ Fit the sping(60) into the piston(62). ⑤ Insert the piston(62) and steel balls(68) into the hole of the holder flange(101).

R55NM7TM139

⑥ Mount the swash plate(3) on the steel balls(68).

R55NM7TM145

⑦ Fit the cylinder block & piston into the shaft(5).

R55NM7TM131

(6) To reassemble the parking brake section ① Fit the mating plate(16) first and then the friction plate(15), one by one, into the grooves of the outer surface of the cylinder block(4). ※ This order of fitting must be strictly observed.

R55NM7TM141

7-123

② Fit the O-rings(39), (35) in the O-ring grooves of the piston(12). ③ Mount the piston(12) in the holder flange(101).

R55NM7TM129

④ Fit the O-ring(75) and the O-ring(126) in the O-ring groove of the holder flange(101). ⑤ Fill the holder flange(101) with a working fluid quantity required : 1.2 liters

(7) To mount the rear flange(1) back in the holder flange(101) ① Mount the ball bearing(50) in the rear flange(1). ② Fit the two dowel pins(41) into the pin holes of the rear flange(1). ③ Using the dowel pins(41) as a guide, mount the timing plate(9) in the rear flange(1).

At this time, apply grease to the contact surface of the timing plate(9) and the rear flange(1). ④ Arrange the eight springs(113) correctly in the spring mounting hole of the rear flange(1). ⑤ Fit the two dowel pins(42) into the holder flange(101).

R55NM7TM122

7-124

⑥ Mount the rear flange(1) on the holder flange(101).

At this time, the two dowel pins that have been fitted into the holder flange(101) must be aligned with the pin holes.

R55NM7TM121

⑦ Tighten the eight hex. socket head bolts into the holder flange(101) at the required torque. · Tightening torque : 25.7±4kgf·m (185.9±29lbf·ft)

R55NM7TM119

(8) To mount the surge cut off valve ass’y back in the rear flange(1) ① Fit the two O-rings(40), (46) in the rear flange(1). ② Assemble the body(55) of the surge cut off valve, which was mounted previously in procedure 4), into the rear flange(1).

Then, tighten the four hex. socket bolts(70) into the rear flange(1) at the required torque. · Tightening torque : 3±0.5kgf·m (21.7±3.6lbf·ft)

R55NM7TM120

7-125

3. TESTING The motor case must be filled up with a working fluid before starting performance verification tests.

After completion of TM motor servicing, the performance verification tests listed below must be performed.

1) WHEN A TESTING APPARATUS IS AVAILABLE : ※ If internal parts have been replaced, carry out running in operation, followed by performance tests.

(1) Conditions for running-in operation ① 10 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ② 20 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ③ 20 rpm, 100kgf/cm2, two minutes, clockwise/counterclockwise rotation.

(2) Condition for performance tests ① Working fluid : ISO VG #46 wear-resistant type. ② Lubricating oil : Gear oil. ③ Temperatures : Ambient temperature ---- Room temperature.

Working fluid temperature ---- 50±5 °C Casing temperature of ---- 40 to 80 °C reducer section Drainage pressure : 0.8kgf/cm2 or less

(3) Efficiency tests (for the first speed) Volume efficiency 90% or more

External drainage amount (Referential data)

Machine efficiency 83% or more

Remarks

83% or more

(4) Second speed volume efficiency verification tests Second speed selection Differential pressure : 100kgf/cm2 Revolutions : 20 rpm

Volume efficiency 96% or more

(5) Second speed operation tests During the no-load tests under the running-in operating conditions for (3) and (4) above, make sure that the motor will change from the low speed over to the high speed when fluid pressures of 20kgf/cm2 or more are applied from the second-speed selector pilot port (D-port).

Also, ensure that the motor changes over to the low speed at fluid pressures of 10kgf/cm2 or less.

7-126

2) WHEN FIELD PERFORMANCE VERIFICATION TESTS ARE TO BE CONDUCTED WITHOUT USING A TESTING APPARATUS ※ Install the TM motor in the vehicle and provide piping, and then without mounting a crawler, carry out running-in operation, followed by performance tests.

(1) Condition for running-in operation ① 10 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ② 20 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation.

(2) Condition for performance tests ① Temperature : Working fluid temperature ---- 50±5 °C Casing temperature of the ---- 40 to 80 °C reducer section

(3) No load driving pressure (Differential pressure) First speed Second speed

10 rpm

20kgf/cm2

20 rpm

30kgf/cm2

10 rpm

0.8 ℓ/min below

(4) Motor drainage amount measurement Both first and second speeds

7-127

GROUP 4 TRAVEL MOTOR A. TRAVEL MOTOR (GM09VL, UP TO #0698) 1. PRECAUTIONS FOR OPERATION 1) METHOD OF INSTALLATION A : Installation part for machine B : Installation part for sprocket B

A

R55NN7TM01-1

·Tightening torque for installation bolt Quantity

Dimension

Tightening torque

Installation bolt for machine

12

M16 (P2.0)

25.7±4.0 kg·m

Installation bolt for sprocket

12

M14 (P2.0)

16.6±2.5 kg·m

2) CHANGE OF GEAR OIL (1) Make oil filing port and oil drain port be vertical position on horizontal place.

(2) Change oil after loosening both port plug and draining gear oil.

For supplement, loosen the plug of oil filling port.

(3) Fill amount of gear oil at oil filling port until oil is overflowed.

(4) Wash the plug and reinstall it with sealing tape. ·Oil capacity : Each 0.45 U.S.gal ·Service interval : Every 1000 hr (Initial service : 500 hr)

R55NN7TM01-2

7-74

2. TOOLS FOR DISASSEMBLY AND ASSEMBLY 1) STANDARD TOOLS Serial No. of applied item (See page 2-23, 24 in this manual)

Tool name

Size & type

Quantity (EA)

126,143,121,152,33

Torque wrench

Dial type, #1800

1

19,124

Torque wrench

Dial type, #5600

1

152

Hexagon wrench

Nominal 6 mm

1

33,143

Hexagon wrench

Nominal 8 mm

1

126

Hexagon wrench

Nominal 10 mm

1

33,143

Hexagon socket

Nominal 8 mm

1

126

Hexagon socket

Nominal 10 mm

1

19

Hexagon socket

Nominal 27 mm

1

124

Socket, Adapter

Nominal 36 mm

1

19

Extension bar

Nominal 27 mm

1

1,11,21,132,165

Hand hammer

Nominal 12 mm

1

8,10,102,112

Plastic hammer

79.25 U.S.gal

1

24,25

Snap ring plier

For shaft

1

20,145

Snap ring plier

For hole

1

1

Center punch

Ø 9.5 × 100

1

21

Pin punch

Ø 4 × 100

1

For washing

Washing brush

1

For washing

Wire washing brush

1

For washing

Paint marker

17

Metal net gasket

2

149

Leather gloves

1 Pair

11

Vinyl sheets

For filling oil

Oil pot with handle

2

33

Sealing tape

1

21

Gear puller

1 Set

Hanger for 1,2

Shackle, wire rope

1 Set

White color

500 × 500 × 1.0

7-75

1

1

2) TOOLS (1) Work table This is used for safe assembly and disassembly of track motor.

R55NM7TM02

(2) Clamp This is used for connecting hub and spindle together.

R55NM7TM03

(3) Retainer ( I ) This is used for installing coil spring (114), washer (110) and snap ring (145), used for removing coil spring (114) from cylinder block.

R55NM7TM04

(4) Retainer ( II ) This is used for removing ball bearing from shaft, used for pressing bearing.

R55NM7TM05

7-76

(5) Retainer ( III ) This is used for installing oil seal in the hole of spindle.

R55NM7TM06

(6) Retainer ( IV ) This is used for installing RV gear sub assembly in spindle.

R55NM7TM07

(7) Tool for adjusting bearing This is used for adjusting an interval of shaft between flange and ball bearing when installing ball bearing in hub.

R55NM7TM08

(8) Steel bar This is used for removing ring from hub.

R55NM7TM09

7-77

(9) Aluminum rod This is used for removing oil seal from spindle.

R55NM7TM10

(10) PT eye bolt This is used for lifting cover from hub by crane and wire rope..

R55NM7TM11

(11) Long eye bolt This is used for lifting motor, spindle and hub.

A Hub

M 14

Spring

M16

GM motor

M14

A R55NM7TM12

(12) Flat bar and steel pipe This is used for removing inlet parts of ball bearing from spindle, used for removing timing belt from rear flange.

R55NM7TM13

7-78

(13) Punch This is used for removing ring from rear flange.

R55NM7TM14

(14) Steel bar This is used for removing ring from rear flange.

1.6

150

R55NM7TM15

7-79

3) PREPARATIONS Item No

Description

Tool name

For disassembling and assembling work

Standard work table

Motor and items to be washed

Washing sink

104, 149

Press machine

Q’ty 1

For initial washing and final washing

2

Capacity : 200 kgf

1

149

Heating vessel

1

Electric drill

Capacity : 500×500×500 Heating temperature : 100° C more Hand drilling machine, Ø5

1

Drill

Diameter : 2mm

Motor

Crane

1

3

Lathe

1

1 1 1

1

Grinder Items to be dried

Compressed air

3 - 5 kgf/cm

1

2

4) TOOLS FOR ADJUSTING Item No

Name

Size

20 (For adjusting thickness of snap ring) 20 (For adjusting thickness of snap ring) 21 (For adjusting pre-pressure of snap ring)

Gauge for adjusting thickness Micrometer for adjusting outside Micrometer for adjusting depth

Q’ty

Adjustment range : 0.04 ~ 0.3mm

2

Adjustment range : 0 ~ 25mm Minimum scale : 0.01 Adjustment range : 0 ~ 25mm Minimum scale : 0.01

1 1

5) TIGHTENING TORQUE Item No

Name

Size

Contact width (mm)

Tightening torque (kgf·cm)

19

Rimmer bolt

M20 P2.5

22

4200

33

Socket plug

PT 3/8

8

400

124

Plug

M30 P1.5

36

3600

126

Plug

M24 P1.5

20

1300

143

Socket bolt

M10 P1.5

8

590

146

Socket bolt

PT 1/8

3

125

121

Plug

M20

26

600

152

Socket plug

PT 1/4

6

300

160

Plug

M30 P1.5

36

3600

170

Socket plug

P1.25

6

300

6) WEIGHT TABLE Item No Motor

Item description

Weight (kg)

Assembly

90

1

Hub

21.75

2

Spindle

26.65

101

Rear flange sub assembly

11.85

7-80

3. DISASSEMBLY 1) PREPARATION FOR DISASSEMBLY (1) Prepare work table and work bench ① Prepare useful work table ② Prepare wide and robust work bench that parts don’t move under working (2) Preparation of tool and matters ① Prepare standard tool and matters for work 2) GENERAL PRECAUTIONS (1) Read this manual thoroughly before disassemble motor (2) Be care to deal with inlet parts of motor because they are precisely machined (3) Be care not to get rusty on the surface of disassembled parts

7-81

3) DISASSEMBLY (1) Washing GM motor ① Enclose oil port of rear flange. ② Install 2(two) eye-bolts in the tapped holes of spindle so that they can be parallel each other.

R55NM7TM16

③ Wash each part of motor with brush when washing in the washing sink.

Remove matters between hub and spindle.

R55NM7TM17

(2) Installation of motor ① Install motor in work table.

Fit the bolt hole of hub to the hole of work table when installing motor in work table.

R55NM7TM18

② Tighten 2(two) socket bolt in order to connect motor to work table.

R55NM7TM19

7-82

(3) Drain of gear oil ① Turn the motor to be upper direction. ② Loosen 3(three) plug with socket wrench.

At this time, leave 1-2 thread of plug in the cover.

R55NM7TM20

③ Turn the work table in order that rear flange can be upper direction. ④ Remove 3(three) plug, put the vessel for draining gear oil.

R55NM7TM21

(4) The removal of cover ① Turn the work table in order that motor cover can be upper direction. ② Mark paint on contact point between hub and cover in order to reassemble again.

R55NM7TM22

③ Finding the split gap of ring, punch marking for drilling at the point of inside 20mm from front edge of ring and 7mm from end edge.

R55NM7TM23

7-83

④ Drill Ø2 hole at the punch marking by use of electric drilling machine.

Remove chip after piercing hub.

R55NM7TM24

⑤ Insert steel bar in the hole of drill, push it in order that ring can be rised on the cover.

R55NM7TM25

⑥ After taking hold of edge of ring, remove the ring from groove.

R55NM7TM26

⑦ Tighten PT I type bolt in the hole of plug on the cover. ⑧ Remove the cover by use of crane.

R55NM7TM27

7-84

⑨ Remove O-ring from the cover.

Do not use the removed O-ring again.

R55NM7TM28

(5) Removal of input gear ① Remove snap-ring from shaft.

R55NM7TM29

② Remove input-gear from shaft. ③ Remove shaft from coupling. ④ Remove steel-ball from shaft. ⑤ Remove coupling from shaft.

R55NM7TM30

(6) Removal of rear flange ① Turn the work table in order that rear flange can be upper direction. ② Loosen right / left plug and plug.

This is only required for disassembling inlet parts of rear flange.

R55NM7TM31

7-85

③ Loosen right and left plug.

This is required disassembling the inlet parts of rear flange.

R55NM7TM32

④ Loosen socket bolt from rear flange, then remove housing.

At this time, O-ring is removed with housing.

⑤ Loosen the socket bolt to protect the rear flange from spindle.

R55NM7TM33

⑥ Loosen rear flange from spindle on the cover.

Taking out rear flange, be care not to damage the timing plate.

R55NM7TM34

7-86

⑦ Remove spring of parking brake. ⑧ Remove parallel pin from spindle.

R55NM7TM35

⑨ Remove O-ring from spindle.

Do not use it again.

R55NM7TM36

(7) The removal of inlet parts from rear flange ① Put the rear flange on the work table, at this time, let the inside of rear flange be upper direction. ② Remove timing plate from rear flange.

When it is difficult for the timing plate to be removed due to the adhesion of oil between rear flange and it, insert the plane bar in the groove of rear flange and then remove timing plate.

R55NM7TM37

③ Remove parallel pin from rear flange.

R55NM7TM38

7-87

④ Remove ball bearing.

R55NM7TM39

(8) Removal of brake valve ① Remove 2(two) plug from rear flange.

R55NM7TM40

② Remove coil spring and stopper from rear flange. ③ Remove spool from rear flange.

When removing spool, if spool shaft of rear flange is to the lower direction, spool become fall down.

Therefore, take hold of spool, then remove it again.

R55NM7TM41

④ Remove 2(two) plug from rear flange.

R55NM7TM42

7-88

⑤ After removing plug, remove spring and valve.

R55NM7TM43

⑥ Remove O-ring from plug.

Do not use it again.

R55NM7TM44

⑦ Remove O-ring from plug.

Do not use it again.

R55NM7TM45

(9) Disassembly of valve ① Remove plug from housing.

R55NM7TM200

7-89

② Remove spring and stopper from housing.

R55NM7TM201

③ Remove spool from housing.

Because housing and spool are composd of one set, if there is a damage in any part of them, replace it together.

R55NM7TM202

④ Remove O-ring from plug.

Do not use it again.

R55NM7TM203

(10) Disassembly of pilot valve ① Apply a sharp-point punch at the notch of ring, hit a hammer on the punch to remove ring.

R55NM7TM46

7-90

② After removing ring, lift rear flange and take the hole of that to the lower direction, then stopper, spring and valve are removed from rear flange. In spite of using the above method, if they were not removed, remove them by use of compressed air .

Do not use removed ring again.

Unless pilot valve is not replaced, don’t remove ring.

R55NM7TM47

(11) Disassembly of plug ① Do not disassemble plug except necessary case. If plug is closed by dust and etc, remove them by washing.

Be careful that steel sphere is not removed.

(12) Disassembly of parking brake ① Remove piston by pouring compressed air into the hole parking brake, at this time, be care not to pouring air suddenly.

For operator’s safe, install cover for protector on piston.

R55NM7TM48

② Remove O-ring from piston.

Do not use removed ring again.

R55NM7TM49

7-91

(13) Disassemble of hydraulic motor ① Turn the motor to 90° C direction, drain hydraulic oil.

R55NM7TM50

② Take hold of cylinder block, pull motor shaft slowly, then remove it.

Before pull it, turn cylinder block 2-3 times in order that shoe is not removed from inside sliding edge of swash plate, then remove friction plate and other plate.

R55NM7TM51

③ Take hold of retainer plate by both hands, remove piston kit and retainer plate.

Because piston and shoe are not disassembled without a damage of any part among them, if replacement is required, replace them together.

R55NM7TM52

④ Remove 9(nine) piston sub assembly from retainer plate.

R55NM7TM53

7-92

⑤ Remove thrust ball from cylinder block.

R55NM7TM54

⑥ Remove 3(three) parallel pin from cylinder block.

R55NM7TM55

(14) Removal of spring from cylinder block ① Put cylinder block on the press machine as shown on drawing. ② Pressing retainer on washer, remove snap ring from cylinder block by snap ring plyer. ·Before pressing spring, put cylinder block, retainer and presser absorber on a straight line to prevent a damage. ·To prevent a damage of cylinder block, envelop the surface of that with vinyl.

R55NM7TM56

Press Retainer(I) Washer

Snap ring Spring Cylinder block

R55NM7TM57

7-93

③ Remove snap-ring, washer, spring from cylinder block.

R55NM7TM58

(15) Removal of motor shaft ① Remove swash plate from motor shaft.

R55NM7TM59

② Remove shaft and ball bearing from spindle. ·If hit a plastic hammer on the shaft end point of reducer gear, they will be removed easily. ③ Remove thrust plate from swash plate ·In case that they’re not removed due to the oil between swash plate and thrust plate, remove them by inserting a small bar.

R55NM7TM60

④ Remove 2(two) pivot and parallel pin. ⑤ Remove piston assembly from spindle by pouring compressed air into the hole of spindle.

Piston assembly is composed of piston and shoe. ·Pressure of compressed air : 3-5kg/cm2 ·Because piston and shoe are not disassembled without a damage of any part among them, if replacement is required, replace them together.

R55NM7TM61

7-94

(16) Removal of bearing from motor shaft ① Put retainer on work table of presser, install shaft in retainer. ② Pressing shaft end point by press machine, remove ball bearing from shaft. ·Use the above method only when replacement is required.

Press

Retainer(II)

R55NM7TM62

(17) Removal of spur gear ① Turn the motor in order that the side of spur gear is to the upper direction. ② Remove the snap ring from crank shaft.

R55NM7TM63

③ Remove spur gear from each crank shaft.

R55NM7TM64

④ Remove distance piece from each shaft.

R55NM7TM65

7-95

(18) Removal of hold flange ① Turn the motor in order that the side of spindle is to the upper direction. ② Fix hub and spindle to be parallel by use of 2(two) clamp. ·Hub to be fixed between spindle and hold by clamp.

R55NM7TM66

③ Turn the motor in order that hold flange is to the upper direction. ④ Remove 3(three) snap ring from each hole.

R55NM7TM67

⑤ Mark hold flange and each snap ring with paint for reassembly.

R55NM7TM68

⑥ Loosen 3(three) reamer bolt supporting hold flange of spindle. ·Tightening torque : 42 ± 6.5kgf·m (411.8 ± 63.7N·m)

R55NM7TM69

7-96

⑦ Remove the hold flange from spindle. ⑧ Mark hold flange and spindle with paint for reassembly. ·If replacement is required, replace assembly composed of spindle and hold flange.

R55NM7TM70

(19) Removal of clamp ① Turn the motor to be the lower direction. ② Remove 2(two) clamp in order to remove spindle from hub.

R55NM7TM71

(20) Removal of spindle ① Tighten 2(two) eye type bolt into the hole of spindle. ② Remove spindle from hub by use of crane, at this time, remove roller bearing and seals together.

R55NM7TM72

③ Remove distance piece from hub.

Do not use O-ring again.

R55NM7TM73

7-97

④ Remove O-ring from hub.

Do not use O-ring again.

R55NM7TM74

(21) Removal of ball bearing, RV gear assembly and pin ① Remove ball bearing from hub.

At this time, remove RV gear assembly, crank shaft, taper roller bearing, needle roller bearing, spacer and pin in sequence. ·When removing ball bearing from hub, install rubber mat on the work table to prevent a damage of each item. ② Do not disassemble RV gear assembly, if disassemble it, quality assurance is not applied to.

Hammer Pin punch

Pin Ball bearing

R55NM7TM75

R55NM7TM73

(22) Removal of ball bearing and collar ① Turn the motor to the lower direction. ② Remove ball bearing and collar from hub. ·When removing ball bearing and collar from hub, install the rubber mat to prevent a damage.

Hammer Pin punch Collar Ball bearing

R55NM7TM76

7-98

(23) Disassembly of fittings for spindle ① Remove oil seal from spindle.

Do not use removed oil seal again.

Oil seal Spindle

R55NM7TM77

② Remove floating seal from spindle.

R55NM7TM78

③ Remove the outlets of 3(three) tape roller bearing from spindle.

When it is difficult to remove tape roller bearing due to oil, remove oil by inserting aluminum bar into the hole of spindle.

R55NM7TM79

(24) Disassembly of bolt flange ① Remove outlets of tape roller bearing.

R55NM7TM80

7-99

(25) Washing of parts ① Remove hub, spindle, cover and rear flange. ② Wash hub, cover, spindle and rear flange in container for washing and remove dust on the surface. ③ Make clean inlet parts by use of oil. ·After removing sufficiently dust of each part to prevent a damage, wash each part.

R55NM7TM81

(26) Finish for washing ① Apply oil to the each part for finishing wash.

Put each part into container for washing, rotating it slowly, make clean inside of them.

R55NM7TM82

② Remove dust with soft brush, apply oil to them.

R55NM7TM83

7-100

4) REASSEMBLY Follow the procedure used to disassemble in the reverse order when reassembling it.

(1) General cautions ① Follow cautions for disassembly. ② Remove dust from all disassembled parts, use sand paper and oil stone in order to remove burrs and sharp edges of them. ③ Replace O-ring, oil seal, floating seal, etc with new one. ④ Apply a thin coat of grease to the seals before fitting them. ⑤ Apply a thin coat of grease to the parts of motor and to each side of valve. ⑥ Follow regular tightening torque. ⑦ Enclose all ports of motor after assembling it completely.

7-101

B. TRAVEL MOTOR (TM07VA, #0698 AND UP) 1. DISASSEMBLY 1) GENERAL PRECAUTIONS (1) Before disassembling the TM motors, check the items to be inspected and, for remedy against trouble, closely examine the nature of the trouble, so that the motor can be disassembled effectively.

(2) To disassemble the motor, use the disassembling procedures described in section 2-2, and select a clean place.

(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect the surface of the motor to be serviced.

(4) During disassembly, give a match mark to the mating surfaces of each part.

(5) Arrange removed parts in order so that they will not become damaged or missing during disassembly.

(6) Once seals have been disassembled, they should be replaced even if damage is not observed.

Have replacement seals ready on hand before starting your disassembling job.

7-102

2) SPECIAL TOOLS (1) Inversion working bench.

R55NM7TM152

(2) Retainer (I).

R55NM7TM151

(3) Retainer (II).

R55NM7TM150

(4) Aluminum rod.

R55NM7TM149

7-103

(5) Retainer (I).

R55NM7TM148

(6) Retainer (II).

R55NM7TM146

(7) Aluminum rod.

R55NM7TM147

7-104

3) REAR FLANGE (1) Loosen the four hex.(hexagon) socket head bolts(70) and remove the S.C.V valve body(55) from the rear flange(1).

(2) Remove the two O-rings(40), (46) from the rear flange(1).

R55NM7TM120

(3) Remove the hex. socket head bolts(43).

R55NM7TM119

(4) Remove the rear flange(1) from the holder flange(10).

R55NM7TM121

(5) Remove the timing plate(9), the two pins(41), the eight springs(13), the ball bearing(50), and O-ring(126) from the rear flange(1) and holder flange(101).

R55NM7TM122

7-105

4) BRAKE VALVE (1) To remove the spool ① Remove the two plugs(24) from the rear flange(1).

Remove the O-ring(36) from the plug(24).

R55NM7TM110

② Remove the two springs(28), the two spring retainers(25), and the spool(23) from the rear flange(1). ※ Be careful not to damage the outer surface of the rear flange(1).

R55NM7TM108

(2) To remove the check valves ① Remove the two plugs(26) from the rear flange(1).

R55NM7TM101

② Remove the two springs(30) and the two valves(27) from the rear flange(1). ※ Be careful not to damage the seat section of valves(27) or rear flange(1). ③ Remove the O-ring(34) from the plug(26).

R55NM7TM136

7-106

(3) To remove the T-valve(19) from the rear flange(1) ① Press and hold down the valve seat(18) using a steel bar, and in that state, as shown in the diagram at right, press the notch in the ring(22) using a sharp pointed steel bar. This deforms the ring(22), disengaging it from the ring groove in the rear flange(1). The ring(22) can now be removed from the rear flange(1).

R55NM7TM210

R55NM7TM212

② After filling up the hole section of the valve seat(18), inject compressed air from the parking brake access hole and remove the valve seat(18). ③ Holding the rear flange(1) by hand and lightly shaking it with its hole section facing downward allows the T-valve(19) and the spring(20) to be removed or using tweezers or any other such tool, remove the T-valve(19) and the spring(20) from the rear flange(1)

R55NM7TM211

④ Remove the O-ring(33) from the valve seat(18).

7-107

(4) To remove the valve(63) from the rear flange(1) ① Press and hold down the stopper(64) using a steel bar, and in that state, as shown in the diagram at right, press the notch in the ring(65) using a sharp pointed steel bar.

This deforms the ring(65), disengaging it from the ring groove in the rear flange(1).

The ring(65) can now be removed from the rear flange(1)

R55NM7TM104

R55NM7TM212

② Make the hole section of the removed ring(65) face downward, and lift the rear flange(1). This allows the stopper(64), the spring(166) and the valve(63) from the rear flange(1).

R55NM7TM106

(5) To disassemble the internal parts of the body kit ① Remove the plug(24) from the body(55). ② Remove the O-ring(36) from the plug(24).

R55NM7TM124

7-108

③ Remove the springs(58), (59), the stopper(57) and the spool(56), in that order, from the body(55). ※ Be careful not to damage the other surface of the spool(56) and the sliding surface of the rear flange.

R55NM7TM112

5) HYDRAULIC MOTOR (1) To remove the parking brake parts ① Remove the piston(12) by injecting compressed air from the parking brake access hole in the holder flange(101). ※ Take care that abrupt injection of compressed air may cause the piston(12) to pop out.

R55NM7TM127

② Remove the O-rings(35), (39) from the piston(12).

R55NM7TM129

7-109

(2) To remove the internal parts of the motor ① Lay the TM motor body on the side. ② Drain out the oil from the TM motor. ③ Hold the cylinder block(4) with both hands, and remove it from the holder flange(101) ※ Before removal, hold the cylinder block(4) with both hands and turn it two to three times in a clockwise and a counterclockwise direction alternately to detach the shoe(6) from the swash plate(3). ※ Becareful that if an attempt is made to remove the cylinder block(4) without detaching the shoe(6) from the swash plate(3), then the piston, shoe and other parts that are connected to the cylinder block may come loose and fall into the spindle.

R55NM7TM131

④ Remove the four mating plates(16) and three friction plates(15) that are mounted on the outer surface of the removed cylinder block(4). ⑤ Remove the piston assy piston(5), shoe(6), retainer plate(7), thrust ball(8), and three rollers(51) from the removed cylinder block(4).

R55NM7TM132

⑥ Remove the swash plate(3) from the holder flange(101). ⑦ Remove the two steel balls(67) from the holder flange(101). ⑧ Remove the speed selector piston assy piston(61) and shoe(62) from the holder flange(101) by feeding compressed air(3 to 5kgf/cm2) from the access hole in holder flange(101).

7-110

(3) To disassembly the inside of the cylinder block(4) ① Place the cylinder block(4) on a press working bench, and then while pressing and holding down a retainer(I) against the washer(10), remove the snap ring(45) using snap ring pliers. ※ Press load : 120 kgf or more. ※ Protect the sliding surface of the cylinder block withe a vinyl sheet.

R55NM7TM133

② Remove the snap ring(45) the washer(10), the spring(14), and the washer(10), in that oder, from the cylinder block(4).

R55NM7TM137

(4) To remove the shaft(2) and the roller bearing(49) ① Remove the shaft(2) from the holder flange(101).

At this time, the roller bearing(49) can also be removed in conjunction with the shaft(2).

The oil seal(32), however, cannot be removed.

R55NM7TM118

7-111

6) REDUCTION GEAR (1) Remove the plugs(10) from the cover(123).

(2) Loosen the socket bolts(124) and remove the cover(123) from the housing(105).

R55NM7TM103

(3) Remove the thrust plate(R)(122) and the drive gear(121).

R55NM7TM105

(4) Remove the planetary gear(R)(117), the needle bearing(118), the inner race(119) and the holder(116).

R55NM7TM123

(5) Remove the sun gear(114), the screw(110), the thrust plate(F)(113) and the needle bearing(111).

R55NM7TM125

7-112

(6) Remove the collar(112) and the thrust washer(109).

R55NM7TM126

(7) Remove the plugs(124).

R55NM7TM128

(8) Remove the nut ring(103).

R55NM7TM130

(9) Remove the holder flange(101) from the housing(105).

R55NM7TM116

7-113

(10) Remove the plug(104) and steel ball(106) (104ea).

R55NM7TM113

(11) Remove the floating seal(102) and angular bearing(125).

R55NM7TM109

(12) Remove the floating seal(102) from the holder flange(1).

R55NM7TM134

(13) Remove the snap ring(76).

(14) Remove the oil seal(32).

R55NM7TM135

7-114

2. REASSEMBLY 1) GENERAL PRECAUTIONS (1) Reassemble in a work area that is clean and free from dust and grit.

(2) Handle parts with bare hands to keep them free or linty contaminants.

(3) Repair or replace the damage parts.

Each parts must be free of burrs its corners.

(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.

Provide the new parts.

(5) Wash all parts thoroughly in a suitable solvent.

Dry thoroughly with compressed air Do not use the cloths.

(6) When reassembling oil motor components of TM motor, be sure to coat the sliding parts of the motor and valve with fresh hydraulic oil.(NAS class 9 or above).

(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

2) TIGHTENING TORQUE TABLE Item No

Parts name

Size

Tightening torque kgf·cm

lbf·in

21

Plug

PF 3/8

600

520.8

24

Plug

M30 P1.5

3600

3125

26

Plug

M24 P1.5

1300

1128

43

Hex. socket bolt

M10 P1.5

590

512

44, 107

Hex. socket plug

PT 1/8

125

108.5

52

Hex. socket plug

PF 1/4

300

260

54

Hex. socket plug

NPTF 1/16

100

86.8

70

Hex. socket bolt

M8

300

260

91

Hex. socket plug

PT 1/4

300

260

103

Nut ring

M165×P2

1800

1562

104

Hex. socket plug

PT 3/8

350

304

110

Screw

M6

83

72

124

Hex. socket bolt

M8

300

260

7-115

3) REDUCTION GEAR (1) Mount end of the floating seal(102) in the holder flange(101).

R55NM7TM107

(2) Press angular bearing(125) into the housing(105).

R55NM7TM109

(3) Insert the steel balls(106)(104ea) into the housing(105).

R55NM7TM111

(4) Place seal taper around plug(104) and tighten it up.

R55NM7TM113

7-116

(5) Mount another end of floating seal(102) into the housing(105).

R55NM7TM115

(6) Fit the holder flange(101) into the housing(105).

R55NM7TM116

(7) Tighten the nut ring(103) and the plugs(104) to the required torque using a torque wrench. ※ Tightening torque : 350kgf·cm(2531lbf·ft)

R55NM7TM130

(8) Mount the thrust washer(109) and the collar(112).

R55NM7TM126

7-117

(9) Fit the needle bearing(111) and place the thrust plate(F)(113). Tighten the screw (110) to required torque using torque wrench. ※ Tightening torque : 83kgf·cm(72lbf·in)

R55NM7TM125

(10) Fit holder ass’y sun gear(114), needle bearing(118) and planetary gear(R)(117).

R55NM7TM138

(11) Attach the drive gear(121) and place thrust plate(R)(122).

R55NM7TM103

(12) Fit the cover(123) to the housing(105).

(13) Tighten socket bolts(124) to the required torque using a torque wrench. ※ Tightening torque : 125kgf·m(904lbf·ft)

R55NM7TM140

7-118

4) BRAKE VALVE (1) To remount the check valve ① Fit the O-ring(37) on the plug(26). ② Insert the spring(30) and the valve(27) into the plug(26), and then grease the spring(30) and the valve(30) and handlock the former. ※ Tightening torque : 26±4kgf·m (188±28.9lbf·ft) ③ Insert the plug(26) in conjunction with the spring(30) and the valve(30) into the rear flange(1), and tighten the plug to the required torque. ※ Tightening torque : 26±4kgf·m (188±28.9lbf·ft)

R55NM7TM136

(2) To remount the spool ① Insert the spool(23) into the rear flange(1).

R55NM7TM108

② Attach the O-ring(36) to the plug(24). ③ Install spring retainer(25) and the spring(28) into both plugs(24), and tighten the plugs(24) into the rear flange(1) at the required torque. ※ Required torque : 45±9kgf·m (32.5±65lbf·ft)

R55NM7TM110

7-119

(3) To reassemble the surge cut off valve ① Apply a working fluid to the spool(56), and insert it into the body(55). ※ Damage to the hole section of the body or the outer surface of the spool may cause internal leakage to occur after reassembling, and TM motor performance to deteriorate.

R55NM7TM112

② Fit the O-ring(36) to the plug(24). ③ Install the spring retainer(25) and the springs(58), (59) into the plug(24). ④ Tighten the plug(24) into the body(55) at the required torque.

R55NM7TM114

(4) To remount the parking brake valve ① Mount the O-ring(33) on the valve seat(18). ② Insert the valve(19), the spring(20), and the valve seat(18), in that order, into the rear flange(1).

③ Slightly bend a new ring and place it in the new ring into the ring groove of the rear flange.

R55NM7TM117

7-120

(5) To remount the valve(63) ① Holding the rear flange(1) with its surface contacting the holder flange(101) upward, place the rear flange on a working bench. ② Insert the valve(63) into the rear flange(1). ③ Fit the spring(66) into the valve(63), and mount the stopper(64) on it.

R55NM7TM143

④ Slightly bench a new ring(65) and insert it into the rear flange(1) from the top of the stopper(64).

Then, fit the new ring into the ring groove of the rear flange.

R55NM7TM142

5) HYDRAULIC MOTOR (1) To remount the shaft(2) ① Fit the oil seal(32), the snap ring(45) and roller bearing(49) in that oder, into the holder flange(101). ② Insert the shaft(2) into the roller bearing(49).

R55NM7TM118

(2) To reassemble the piston ass’y(61), (62) ① Mount the piston ass’y(61), (62) in the piston hole of the holder flange(101).

7-121

(3) To reassemble the steel balls(67) ① Mount the two steel balls(67) in the steel ball hole of the holder flange(101).

(4) To reassemble cylinder block section ① Insert washer(10), spring(14), washer(10) and the snap ring(45) in that order, into the shaft bore of cylinder block(4).

R55NM7TM137

② Set cylinder block in the press in other to compress the spring(14).

Place retainer(I) on the washer(10) and push down this tool with the press until the snap ring groove becomes cleared.

Fit snap ring(45) into the groove.

R55NM7TM133

(5) Piston motor sub-assembly ① Fit 3-rollers(51) into the pin holes of cylinder block(4), and then, put thrust ball(8) on it. ② Insert piston assembly into retainer plate(7). ③ Mount the piston assembly into the cylinder block(4). After mounting, immerse the entire them in a working fluid.

R55NM7TM144

7-122

④ Fit the sping(60) into the piston(62). ⑤ Insert the piston(62) and steel balls(68) into the hole of the holder flange(101).

R55NM7TM139

⑥ Mount the swash plate(3) on the steel balls(68).

R55NM7TM145

⑦ Fit the cylinder block & piston into the shaft(5).

R55NM7TM131

(6) To reassemble the parking brake section ① Fit the mating plate(16) first and then the friction plate(15), one by one, into the grooves of the outer surface of the cylinder block(4). ※ This order of fitting must be strictly observed.

R55NM7TM141

7-123

② Fit the O-rings(39), (35) in the O-ring grooves of the piston(12). ③ Mount the piston(12) in the holder flange(101).

R55NM7TM129

④ Fit the O-ring(75) and the O-ring(126) in the O-ring groove of the holder flange(101). ⑤ Fill the holder flange(101) with a working fluid quantity required : 1.2 liters

(7) To mount the rear flange(1) back in the holder flange(101) ① Mount the ball bearing(50) in the rear flange(1). ② Fit the two dowel pins(41) into the pin holes of the rear flange(1). ③ Using the dowel pins(41) as a guide, mount the timing plate(9) in the rear flange(1).

At this time, apply grease to the contact surface of the timing plate(9) and the rear flange(1). ④ Arrange the eight springs(113) correctly in the spring mounting hole of the rear flange(1). ⑤ Fit the two dowel pins(42) into the holder flange(101).

R55NM7TM122

7-124

⑥ Mount the rear flange(1) on the holder flange(101).

At this time, the two dowel pins that have been fitted into the holder flange(101) must be aligned with the pin holes.

R55NM7TM121

⑦ Tighten the eight hex. socket head bolts into the holder flange(101) at the required torque. · Tightening torque : 25.7±4kgf·m (185.9±29lbf·ft)

R55NM7TM119

(8) To mount the surge cut off valve ass’y back in the rear flange(1) ① Fit the two O-rings(40), (46) in the rear flange(1). ② Assemble the body(55) of the surge cut off valve, which was mounted previously in procedure 4), into the rear flange(1).

Then, tighten the four hex. socket bolts(70) into the rear flange(1) at the required torque. · Tightening torque : 3±0.5kgf·m (21.7±3.6lbf·ft)

R55NM7TM120

7-125

3. TESTING The motor case must be filled up with a working fluid before starting performance verification tests.

After completion of TM motor servicing, the performance verification tests listed below must be performed.

1) WHEN A TESTING APPARATUS IS AVAILABLE : ※ If internal parts have been replaced, carry out running in operation, followed by performance tests.

(1) Conditions for running-in operation ① 10 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ② 20 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ③ 20 rpm, 100kgf/cm2, two minutes, clockwise/counterclockwise rotation.

(2) Condition for performance tests ① Working fluid : ISO VG #46 wear-resistant type. ② Lubricating oil : Gear oil. ③ Temperatures : Ambient temperature ---- Room temperature.

Working fluid temperature ---- 50±5 °C Casing temperature of ---- 40 to 80 °C reducer section Drainage pressure : 0.8kgf/cm2 or less

(3) Efficiency tests (for the first speed) Volume efficiency 90% or more

External drainage amount (Referential data)

Machine efficiency 83% or more

Remarks

83% or more

(4) Second speed volume efficiency verification tests Second speed selection Differential pressure : 100kgf/cm2 Revolutions : 20 rpm

Volume efficiency 96% or more

(5) Second speed operation tests During the no-load tests under the running-in operating conditions for (3) and (4) above, make sure that the motor will change from the low speed over to the high speed when fluid pressures of 20kgf/cm2 or more are applied from the second-speed selector pilot port (D-port).

Also, ensure that the motor changes over to the low speed at fluid pressures of 10kgf/cm2 or less.

7-126

2) WHEN FIELD PERFORMANCE VERIFICATION TESTS ARE TO BE CONDUCTED WITHOUT USING A TESTING APPARATUS ※ Install the TM motor in the vehicle and provide piping, and then without mounting a crawler, carry out running-in operation, followed by performance tests.

(1) Condition for running-in operation ① 10 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation. ② 20 rpm, no-load pressure, one minute, clockwise/counterclockwise rotation.

(2) Condition for performance tests ① Temperature : Working fluid temperature ---- 50±5 °C Casing temperature of the ---- 40 to 80 °C reducer section

(3) No load driving pressure (Differential pressure) First speed Second speed

10 rpm

20kgf/cm2

20 rpm

30kgf/cm2

10 rpm

0.8 ℓ/min below

(4) Motor drainage amount measurement Both first and second speeds

7-127

GROUP 5 REMOTE CONTROL VALVE 1. REMOVAL AND INSTALL 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine.

(2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.

(3) Loosen the breather slowly to release the pressure inside the hydraulic tank.

Escaping fluid under pressure can penetrate the skin causing serious injury.

13031GE18

1

(4) Loosen the socket bolt(2).

2

(5) Remove the cover of the console box.

(6) Disconnect pilot line hoses(3).

3

(7) Remove the pilot valve assembly(1). ※ When removing the pilot valve assembly, check that all the hoses have been disconnected.

21078DA06

2) INSTALL (1) Carry out installation in the reverse order to removal.

(2) Confirm the hydraulic oil level and check the hydraulic oil leak or not.

7-128

2. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE

R55NM2SF80

1 2 3 4 5 6 7 8 9 10

Case Plug Plug O-ring Spool Shim Spring Spring seat Stopper Spring

11 12 13 14 15 16 17 18 19 20

Plug Rod seal O-ring Push rod Plate Bushing Joint assembly Swash plate Adjusting nut Lock nut

7-129

21 22 23 24 25 26 27 28 29

O-ring Handle connector Nut Insert Boot Handle Switch assembly Screw Boot

2) TOOLS AND TIGHTENING TORQUE (1) Tools Tool name

Remark

Allen wrench

B

6 22

Spanner

27

(+) Driver

Length 150

(-) Driver

Width 4~5

Torque wrench

Capable of tightening with the specified torques

(2) Tightening torque Part name

Item

Size

Plug

2

Joint

Torque kgf·m

lbf·ft

PT 1/8

3.0

21.7

18

M14

3.5

25.3

Swash plate

19

M14

5.0±0.35

36.2±2.5

Adjusting nut

20

M14

5.0±0.35

36.2±2.5

Lock nut

21

M14

5.0±0.35

36.2±2.5

Screw

29

M 3

0.05

0.36

7-130

3) DISASSEMBLY (1) Clean pilot valve with kerosene. ※ Put blind plugs into all ports (2) Fix pilot valve in a vise with copper(or lead) sheets.

(3) Remove end of boot(26) from case(1) and take it out upwards.

1408DA62

※ For valve with switch, remove cord also through hole of casing.

1408DA63

(4) Loosen lock nut(21) and adjusting nut(20) with spanners on them respectively, and take out handle section as one body.

1408DA64

(5) Remove the boot(29)

1408DA61

7-131

(6) Loosen adjusting nut(20) and plate(19) with spanners on them respectively, and remove them.

RE04 (140-7)

RE05 (140-7)

(7) Turn joint anticlockwise to loosen it, utilizing jig(Special tool). ※ When return spring(10) is strong in force, plate(16), plug(11) and push rod(14, 15) will come up on loosening joint.

Pay attention to this.

RE06 (140-7)

RE07 (140-7)

7-132

(8) Remove plate(16).

RE08 (140-7)

(9) When return spring(10) is weak in force, plug(11) stays in casing because of sliding resistance of O-ring. ※ Take it out with minus screwdriver.

Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading. ※ During taking out, plug may jump up due to return spring(10) force.

Pay attention to this.

RE09 (140-7)

(10) Remove reducing valve subassembly and return spring(10) out of casing. ※ Record relative position of reducing valve subassembly and return springs.

RE10 (140-7)

(11) Loosen hexagon socket head plug(2) with hexagon socket screw key.

RE11 (140-7)

7-133

(12) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench.

Push down spring seat(8, 31) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. ※ Pay attention not to damage spool surface. ※ Record original position of spring seat(8, 31). ※ Do not push down spring seat more than 6mm.

RE14 (140-7)

(13) Separate spool(5), spring seat(8, 31), spring(7, 30) and shim(6) individually. ※ Until being assembled, they should be handled as one subassembly group.

RE15 (140-7)

(14) Take push rod(14, 15) out of plug(11).

RE16 (140-7)

(15) Remove O-ring(13) and seal(12) from plug(11).

Use small minus screwdriver or so on to remove this seal.

RE17 (140-7)

7-134

RE18 (140-7)

(16) Remove lock nut(21) and then boot(26).

RE19 (140-7)

25038RL02(4)

7-135

(17) Cleaning of parts ① Put all parts in rough cleaning vessel filled with kerosene and clean them (Rough cleaning). ※ If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil. ※ If this kerosene is polluted, parts will be damaged and functions of reassembled valve will be degraded.

Therefore, control cleanliness of kerosene fully. ② Put parts in final cleaning vessel filled with kerosene, turning it slowly to clean them even to their insides(Finish cleaning). ※ Do not dry parts with compressed air, since they will be damaged and/or rusted by dust and moisture in air.

(18) Rust prevention of parts Apply rust-preventives to all parts. ※ If left as they after being cleaned, they will be rusted and will not display their functions fully after being reassembled.

7-136

4) ASSEMBLY (1) Tighten hexagon socket head plug(2) to the specified torque. ※ Tighten two bolts alternately and slowly.

RE29 (140-7)

(2) Put shim(6), springs(7, 30) and spring seat(8, 31) onto spool(5) in this order.

RE30 (140-7)

(3) Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(9) on spring seat without piling them on. ※ Assemble stopper(9) so that its sharp edge side will be caught by head of spool.

Do not push down spring seat more than 6mm.

RE31 (140-7)

(4) Assemble spring(10) into casing.

Assemble reducing valve subassembly into casing. ※ Assemble them to their original positions.

RE32 (140-7)

7-137

(5) Assemble O-ring(13) onto plug(11).

RE33 (140-7)

(6) Assemble seal(12) to plug(11). ※ Assemble seal in such lip direction as shown below.

RE34 (140-7)

(7) Assemble push rod(14, 15) to plug(11). ※ Apply working oil on push-rod surface.

RE35 (140-7)

(8) Assemble plug subassembly to casing. ※ When return spring is weak in force, subassembly stops due to resistance of O-ring.

RE36 (140-7)

7-138

(9) When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(16), and tighten joint(18) temporarily.

RE37 (140-7)

(10) Fit plate(16).

(11) Tighten joint(18) with the specified torque to casing, utilizing jig.

RE38 (140-7)

(12) Assemble plate(19) to joint(18). ※ Screw it to position that it contacts with 4 push rods evenly. ※ Do not screw it over.

RE39 (140-7)

(13) Assemble adjusting nut(20), apply spanner to width across flat of plate(19) to fix it, and tighten adjusting nut to the specified torque. ※ During tightening, do not change position of disk.

RE40 (140-7)

7-139

(14) Fit boot(29) to plate.

1408DA61

(15) Fit boot(26) and lock nut(21), and handle subassembly is assembled completely.

25038RL02(4)

RE48 (140-7)

(16) Pull out cord and tube through adjusting nut hole provided in direction 60°to 120° from casing hole.

1408DA66

7-140

(17) Assemble bushing(17) to plate and pass cord and tube through it. ※ Provide margin necessary to operation.

1408DA67

(18) Determine handle direction, tighten lock nut(21) to specified torque to fix handle.

1408DA68

(19) Apply grease to rotating section of joint and contacting faces of disk and push rod.

1408DA69

(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all ports and then put blind plugs in ports.

25038RL04

7-141

GROUP 5 REMOTE CONTROL VALVE 1. REMOVAL AND INSTALL 1) REMOVAL (1) Lower the work equipment to the ground and stop the engine.

(2) Operate the control levers and pedals several times to release the remaining pressure in the hydraulic piping.

(3) Loosen the breather slowly to release the pressure inside the hydraulic tank.

Escaping fluid under pressure can penetrate the skin causing serious injury.

13031GE18

1

(4) Loosen the socket bolt(2).

2

(5) Remove the cover of the console box.

(6) Disconnect pilot line hoses(3).

3

(7) Remove the pilot valve assembly(1). ※ When removing the pilot valve assembly, check that all the hoses have been disconnected.

21078DA06

2) INSTALL (1) Carry out installation in the reverse order to removal.

(2) Confirm the hydraulic oil level and check the hydraulic oil leak or not.

7-128

2. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE

R55NM2SF80

1 2 3 4 5 6 7 8 9 10

Case Plug Plug O-ring Spool Shim Spring Spring seat Stopper Spring

11 12 13 14 15 16 17 18 19 20

Plug Rod seal O-ring Push rod Plate Bushing Joint assembly Swash plate Adjusting nut Lock nut

7-129

21 22 23 24 25 26 27 28 29

O-ring Handle connector Nut Insert Boot Handle Switch assembly Screw Boot

2) TOOLS AND TIGHTENING TORQUE (1) Tools Tool name

Remark

Allen wrench

B

6 22

Spanner

27

(+) Driver

Length 150

(-) Driver

Width 4~5

Torque wrench

Capable of tightening with the specified torques

(2) Tightening torque Part name

Item

Size

Plug

2

Joint

Torque kgf·m

lbf·ft

PT 1/8

3.0

21.7

18

M14

3.5

25.3

Swash plate

19

M14

5.0±0.35

36.2±2.5

Adjusting nut

20

M14

5.0±0.35

36.2±2.5

Lock nut

21

M14

5.0±0.35

36.2±2.5

Screw

29

M 3

0.05

0.36

7-130

3) DISASSEMBLY (1) Clean pilot valve with kerosene. ※ Put blind plugs into all ports (2) Fix pilot valve in a vise with copper(or lead) sheets.

(3) Remove end of boot(26) from case(1) and take it out upwards.

1408DA62

※ For valve with switch, remove cord also through hole of casing.

1408DA63

(4) Loosen lock nut(21) and adjusting nut(20) with spanners on them respectively, and take out handle section as one body.

1408DA64

(5) Remove the boot(29)

1408DA61

7-131

(6) Loosen adjusting nut(20) and plate(19) with spanners on them respectively, and remove them.

RE04 (140-7)

RE05 (140-7)

(7) Turn joint anticlockwise to loosen it, utilizing jig(Special tool). ※ When return spring(10) is strong in force, plate(16), plug(11) and push rod(14, 15) will come up on loosening joint.

Pay attention to this.

RE06 (140-7)

RE07 (140-7)

7-132

(8) Remove plate(16).

RE08 (140-7)

(9) When return spring(10) is weak in force, plug(11) stays in casing because of sliding resistance of O-ring. ※ Take it out with minus screwdriver.

Take it out, utilizing external periphery groove of plug and paying attention not to damage it by partial loading. ※ During taking out, plug may jump up due to return spring(10) force.

Pay attention to this.

RE09 (140-7)

(10) Remove reducing valve subassembly and return spring(10) out of casing. ※ Record relative position of reducing valve subassembly and return springs.

RE10 (140-7)

(11) Loosen hexagon socket head plug(2) with hexagon socket screw key.

RE11 (140-7)

7-133

(12) For disassembling reducing valve section, stand it vertically with spool(5) bottom placed on flat workbench.

Push down spring seat(8, 31) and remove two pieces of semicircular stopper(9) with tip of small minus screwdriver. ※ Pay attention not to damage spool surface. ※ Record original position of spring seat(8, 31). ※ Do not push down spring seat more than 6mm.

RE14 (140-7)

(13) Separate spool(5), spring seat(8, 31), spring(7, 30) and shim(6) individually. ※ Until being assembled, they should be handled as one subassembly group.

RE15 (140-7)

(14) Take push rod(14, 15) out of plug(11).

RE16 (140-7)

(15) Remove O-ring(13) and seal(12) from plug(11).

Use small minus screwdriver or so on to remove this seal.

RE17 (140-7)

7-134

RE18 (140-7)

(16) Remove lock nut(21) and then boot(26).

RE19 (140-7)

25038RL02(4)

7-135

(17) Cleaning of parts ① Put all parts in rough cleaning vessel filled with kerosene and clean them (Rough cleaning). ※ If dirty part is cleaned with kerosene just after putting it in vessel, it may be damaged. Leave it in kerosene for a while to loosen dust and dirty oil. ※ If this kerosene is polluted, parts will be damaged and functions of reassembled valve will be degraded.

Therefore, control cleanliness of kerosene fully. ② Put parts in final cleaning vessel filled with kerosene, turning it slowly to clean them even to their insides(Finish cleaning). ※ Do not dry parts with compressed air, since they will be damaged and/or rusted by dust and moisture in air.

(18) Rust prevention of parts Apply rust-preventives to all parts. ※ If left as they after being cleaned, they will be rusted and will not display their functions fully after being reassembled.

7-136

4) ASSEMBLY (1) Tighten hexagon socket head plug(2) to the specified torque. ※ Tighten two bolts alternately and slowly.

RE29 (140-7)

(2) Put shim(6), springs(7, 30) and spring seat(8, 31) onto spool(5) in this order.

RE30 (140-7)

(3) Stand spool vertically with its bottom placed on flat workbench, and with spring seat pushed down, put two pieces of semicircular stopper(9) on spring seat without piling them on. ※ Assemble stopper(9) so that its sharp edge side will be caught by head of spool.

Do not push down spring seat more than 6mm.

RE31 (140-7)

(4) Assemble spring(10) into casing.

Assemble reducing valve subassembly into casing. ※ Assemble them to their original positions.

RE32 (140-7)

7-137

(5) Assemble O-ring(13) onto plug(11).

RE33 (140-7)

(6) Assemble seal(12) to plug(11). ※ Assemble seal in such lip direction as shown below.

RE34 (140-7)

(7) Assemble push rod(14, 15) to plug(11). ※ Apply working oil on push-rod surface.

RE35 (140-7)

(8) Assemble plug subassembly to casing. ※ When return spring is weak in force, subassembly stops due to resistance of O-ring.

RE36 (140-7)

7-138

(9) When return spring is strong in force, assemble 4 sets at the same time, utilizing plate(16), and tighten joint(18) temporarily.

RE37 (140-7)

(10) Fit plate(16).

(11) Tighten joint(18) with the specified torque to casing, utilizing jig.

RE38 (140-7)

(12) Assemble plate(19) to joint(18). ※ Screw it to position that it contacts with 4 push rods evenly. ※ Do not screw it over.

RE39 (140-7)

(13) Assemble adjusting nut(20), apply spanner to width across flat of plate(19) to fix it, and tighten adjusting nut to the specified torque. ※ During tightening, do not change position of disk.

RE40 (140-7)

7-139

(14) Fit boot(29) to plate.

1408DA61

(15) Fit boot(26) and lock nut(21), and handle subassembly is assembled completely.

25038RL02(4)

RE48 (140-7)

(16) Pull out cord and tube through adjusting nut hole provided in direction 60°to 120° from casing hole.

1408DA66

7-140

(17) Assemble bushing(17) to plate and pass cord and tube through it. ※ Provide margin necessary to operation.

1408DA67

(18) Determine handle direction, tighten lock nut(21) to specified torque to fix handle.

1408DA68

(19) Apply grease to rotating section of joint and contacting faces of disk and push rod.

1408DA69

(20) Assemble lower end of bellows to casing.

(21) Inject volatile rust-preventives through all ports and then put blind plugs in ports.

25038RL04

7-141

GROUP 6 TURNING JOINT 1. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE

R55NM7TJ01

1 2 3 4 5

Hub Shaft Cover Oil seal Ring

6 7 8 9

Slipper seal O-ring Retainer ring Retainer ring

7-142

10 11 12 13

Plug Plug Hexagon bolt Spring washer

2) DISASSEMBLY ※ Before the disassembly, clean the turning joint.

(1) Remove bolts(12), washer(13) and cover(3).

R55NM7TJ02

(2) Remove O-ring(7).

(3) Remove retainer ring(9) and spacer(4).

R55NM7TJ03

(4) Place hub(1) on a V-block and by using a wood buffer at the shaft end, hit out shaft(2) to about 1/2 from the body with a hammer. ※ Take care not to damage the shaft(2) when remove hub(1) or rest it sideway. ※ Put a fitting mark on hub(1) and shaft(2).

Wooden block

Secure with hand

V block Work bench 8-141(3) 210-7

(5) Remove eight slipper seals(6) and oil seal(4), retainer ring(9) from hub(1).

R55NM7TJ04

7-143

3) ASSEMBLY ※ Clean all parts. ※ As a general rule, replace oil seals and Oring. ※ Coat the sliding surfaces of all parts with engine oil or grease before installing.

(1) Fix eight slipper seal(6) and oil seal(4), retainer ring(9) to hub(1).

R55NM7TJ04

(2) Set shaft(2) on block, tap hub(1) with a plastic hammer to install.

2

1

21078DA13

(3) Fit spacer(4) and retainer ring(9) to shaft(2).

6 10 12

(4) Fit O-ring(7) to hub(1).

4 5

21078DA11

7-144

(5) Install cover(3) to body(1) and tighten bolts(12).

R55NM7TJ02

7-145

GROUP 6 TURNING JOINT 1. DISASSEMBLY AND ASSEMBLY 1) STRUCTURE

R55NM7TJ01

1 2 3 4 5

Hub Shaft Cover Oil seal Ring

6 7 8 9

Slipper seal O-ring Retainer ring Retainer ring

7-142

10 11 12 13

Plug Plug Hexagon bolt Spring washer

2) DISASSEMBLY ※ Before the disassembly, clean the turning joint.

(1) Remove bolts(12), washer(13) and cover(3).

R55NM7TJ02

(2) Remove O-ring(7).

(3) Remove retainer ring(9) and spacer(4).

R55NM7TJ03

(4) Place hub(1) on a V-block and by using a wood buffer at the shaft end, hit out shaft(2) to about 1/2 from the body with a hammer. ※ Take care not to damage the shaft(2) when remove hub(1) or rest it sideway. ※ Put a fitting mark on hub(1) and shaft(2).

Wooden block

Secure with hand

V block Work bench 8-141(3) 210-7

(5) Remove eight slipper seals(6) and oil seal(4), retainer ring(9) from hub(1).

R55NM7TJ04

7-143

3) ASSEMBLY ※ Clean all parts. ※ As a general rule, replace oil seals and Oring. ※ Coat the sliding surfaces of all parts with engine oil or grease before installing.

(1) Fix eight slipper seal(6) and oil seal(4), retainer ring(9) to hub(1).

R55NM7TJ04

(2) Set shaft(2) on block, tap hub(1) with a plastic hammer to install.

2

1

21078DA13

(3) Fit spacer(4) and retainer ring(9) to shaft(2).

6 10 12

(4) Fit O-ring(7) to hub(1).

4 5

21078DA11

7-144

(5) Install cover(3) to body(1) and tighten bolts(12).

R55NM7TJ02

7-145