HYDRAULIC EXCAVATOR
2 MAINTENANCE SECTION
INDEX 1 SPECIFICATIONS SECTION 2 MAINTENANCE SECTION 3 SYSTEM SECTION
4 DISASSEMBLY SECTION
4 DISASSEMBLY SECTION 6 ENGINE SECTION OF INSTALLING 7 PROCEDURE OPTIONS SECTION
OPT.
OF INSTALLING 7 PROCEDURE OPTIONS SECTION
5 TROUBLESHOOTING
OPT.
6 ENGINE SECTION
E / G TROUBLESHOOTING
5 TROUBLESHOOTING
DISASSEMBLING
3 SYSTEM SECTION
Book Code No. 0-1
MAINTENANCE SPECIFICATIONS
(HS Engine)
SYSTEM
1 SPECIFICATIONS SECTION
E215B model E215BLC
DISASSEMBLING
INDEX
SHOP MANUAL
E / G TROUBLESHOOTING
(HS Engine)
MAINTENANCE SPECIFICATIONS
E215B model E215BLC
SYSTEM
SHOP MANUAL
HYDRAULIC EXCAVATOR
87731203
Book Code No. 0-1
87731203
GENERAL SAFETY INFORMATION
3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:
Do not operate or perform any maintenance on this machine until all instructions found in the OPERATOR’S MANUAL and this MANUAL have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor.
(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.
(1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.
GENERAL SAFETY INFORMATION
Do not operate or perform any maintenance on this machine until all instructions found in the OPERATOR’S MANUAL and this MANUAL have been thoroughly read and understood. Improper operation or maintenance of this machine may cause accidents and could result in serious injury or death. Always keep the manual in storage. If it is missing or damaged, place an order with an authorized our Distributor for a replacement. If you have any questions, please consult an authorized our Distributor.
(4) It is very difficult to forecast every danger that may occur during operation. However, safety can be ensured by fully understanding proper operating procedures for this machine according to methods recommended by Manufacturer. (5) While operating the machine, be sure to perform work with great care, so as not to damage the machine, or allow accidents to occur. (6) Continue studying the manual until all Safety, Operation and Maintenance procedures are completely understood by all persons working with the machine.
(1) Most accidents, which occur during operation, are due to neglect of precautionary measures and safety rules. Sufficient care should be taken to avoid these accidents. Erroneous operation, lubrication or maintenance services are very dangerous and may cause injury or death of personnel. Therefore all precautionary measures, NOTES, DANGERS, WARNINGS and CAUTIONS contained in the manual and on the machine should be read and understood by all personnel before starting any work with or on the machine.
(2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.
(2) Operation, inspection, and maintenance should be carefully carried out, and safety must be given the first priority. Messages of safety are indicated with marks. The safety information contained in the manual is intended only to supplement safety codes, insurance requirements, local laws, rules and regulations.
(3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION".
(3) Messages of safety appear in the manual and on the machine : All messages of safety are identified by either word of "DANGER", "WARNING" and "CAUTION".
1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:
1) DANGER- Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury and is represented as follows:
2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:
2) WARNING- Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury and is represented as follows:
0-2
3) CAUTION- Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against possible damage to the machine and its components and is represented as follows:
0-2
SAFETY PRECAUTIONS
stands, capable of supporting the machine, before performing any disassembly.
The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.
Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death. (6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.
(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.
Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS.
(8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.
The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.
(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
(2) Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.
(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.
(3) Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys. (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.
(12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.
(5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack
0-3
SAFETY PRECAUTIONS
stands, capable of supporting the machine, before performing any disassembly.
The proper and safe lubrication and maintenance for this machine, recommended by Manufacturer, are outlined in the OPERATOR’S MANUAL for the machine. Improper performance of lubrication or maintenance procedures are dangerous and could result in injury or death. Read and understand the MANUAL before performing any lubrication or maintenance.
Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death. (6) Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly and be alert for possible pressure when disconnecting any device from a system that utilizes pressure.
The serviceman or mechanic may be unfamiliar with many of the systems on this machine. This makes it important to use caution when performing service work. A knowledge of the system and or components is important before the removal or disassembly of any component.
(7) Lower the bucket, dozer, or other attachments to the ground before performing any work on the machine. If this cannot be done, make sure the bucket, dozer, ripper or other attachment is blocked correctly to prevent it from dropping unexpectedly.
Because of the size of some of the machine components, the serviceman or mechanic should check the weights noted in this manual. Use proper lifting procedures when removing any components. Weight of components table is shown in the section ; SPECIFICATIONS.
(8) Use steps and grab handles when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face to the machine when using steps, ladders and walkways. When it is not possible to use the designed access system, provide ladders, scaffolds, or work platforms to perform safe repair operations.
The following is a list of basic precautions that must always be observed. (1) Read and understand all Warning plates and decal on the machine before Operating, Maintaining or Repairing this machine.
(9) To avoid back injury, use a hoist when lifting components which weigh 20kg (45lbs) or more. Make sure all chains, hooks, slings, etc., are in good condition and are the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation.
(2) Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when using hammers, punches or drifts on any part of the machine or attachments. Use welders gloves, hood/goggles, apron and the protective clothing appropriate to the welding job being performed. Do not wear loose fitting or torn clothing. Remove all rings from fingers, loose jewelry, confine long hair and loose clothing before working on this machinery.
(10)To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments. (11)Be careful when removing cover plates. Gradually back off the last two capscrews or nuts located at opposite ends of the cover or device and carefully pry cover loose to relieve any spring or other pressure, before removing the last two capscrews or nuts completely.
(3) Disconnect the battery and hang a "Do Not Operate" tag in the Operators Compartment. Remove ignition keys. (4) If possible, make all repairs with the machine parked on a firm level surface. Block the machine so it does not roll while working on or under the machine. Hang a "Do Not Operate" tag in the Operators Compartment.
(12)Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot.
(5) Do not work on any machine that is supported only by lift, jacks or a hoist. Always use blocks or jack
0-3
(21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
(13)Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work. (14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.
(22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.
(15)Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.
(14)Reinstall all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.
(22)Be careful when servicing or separating the tracks (crawlers). Chips can fly when removing or installing a track (crawlers) pin. Wear safety glasses and long sleeve protective clothing. Tracks (crawlers) can unroll very quickly when separated. Keep away from front and rear of machine. The machine can move unexpectedly when both tracks (crawlers) are disengaged from the sprockets. Block the machine to prevent it from moving.
(15)Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of the parent metal. Make sure to disconnect battery before any welding procedures are attempted.
(16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.
(16)Do not damage wiring during removal operations. Reinstall the wiring so it is not damaged nor will be damaged in operation of the machine by contacting sharp corners, or by rubbing against some object or hot surface. Do not connect wiring to a line containing fluid.
(17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed.
(17)Be sure all protective devices including guards and shields are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution and replace the guard or shield after repair is completed.
(18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work.
(18)The maintenance and repair work while holding the bucket raised is dangerous due to the possibility of a falling attachment. Don’t fail to lower the attachment and place the bucket to the ground before starting the work.
(19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks.
(19)Loose or damaged fuel, lubricant and hydraulic lines, tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones which have been bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Very small (pinhole) leaks can result in a high velocity oil stream that will be invisible close to the hose. This oil can penetrate the skin and cause personal injury. Use card-board or paper to locate pinhole leaks.
(20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.
(20)Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in event of a line, tube or seal failure must be installed correctly.
0-4
(21)Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing.
(13)Always use the proper tools that are in good condition and that are suited for the job at hand. Be sure you understand how to use them before performing any service work.
0-4
SYSTEM
MAINTENANCE SPECIFICATIONS
S5YN0118E01 2007-7 S5YN0225E01 2007-7 S5YN0322E01 2007-7 S5YN1122E01 2007-7 S5YN1221E01 2007-7 S5YN1318E02 2007-7 S5YN2122E01 2007-7 S5YN2223E01 2007-7 S5YN2325E01 2007-7 S5YN2425E01 2007-7 S5YN2518E02 2007-7
Title
Index No.
OUTLINE
1
SPECIFICATIONS
2
ATTACHMENT DIMENSIONS
3
TOOLS
11
STANDARD MAINTENANCE TIME SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL SYSTEM
12
HYDRAULIC SYSTEM
22
ELECTRIC SYSTEM
23
COMPONENTS SYSTEM
24
AIR-CONDITIONER SYSTEM
25
13 21
S5YN0118E01 2007-7 S5YN0225E01 2007-7 S5YN0322E01 2007-7 S5YN1122E01 2007-7 S5YN1221E01 2007-7 S5YN1318E02 2007-7 S5YN2122E01 2007-7 S5YN2223E01 2007-7 S5YN2325E01 2007-7 S5YN2425E01 2007-7 S5YN2518E02 2007-7
Title
Index No.
OUTLINE
1
SPECIFICATIONS
2
ATTACHMENT DIMENSIONS
3
TOOLS
11
STANDARD MAINTENANCE TIME SCHEDULE MAINTENANCE STANDARD AND TEST PROCEDURE MECHATRO CONTROL SYSTEM
12
HYDRAULIC SYSTEM
22
ELECTRIC SYSTEM
23
COMPONENTS SYSTEM
24
AIR-CONDITIONER SYSTEM
25
DISASSEMBLING & ASSEMBLING
31
ATTACHMENT
32
UPPER STRUCTURE
33
TRAVEL SYSTEM
34
BY ERROR CODES
46
BY TROUBLE
47
TROUBLE DIAGNOSIS MODE
48
ENGINE
51
13 21
_
E /G TROUBLESHOOTING
_
S5YN5123E01 2007-7
DISASSEMBLING & ASSEMBLING
31
ATTACHMENT
32
UPPER STRUCTURE
33
TRAVEL SYSTEM
34
BY ERROR CODES
46
BY TROUBLE
47
TROUBLE DIAGNOSIS MODE
48
S5YN3118E01 2007-7 S5YN3218E02 2007-7 S5YN3325E01 2007-7 S5YN3421E01 2007-7 S5YN4618E02 2007-7 S5YN4718E01 2007-7 S5YN4818E01 2007-7 _
ENGINE
51
S5YN5123E01 2007-7
_
_
_
_
_
_
YN11-45001~ YQ11-06001~
APPLICABLE MACHINES
0-5
DISASSEMBLING
DISASSEMBLING
S5YN3118E01 2007-7 S5YN3218E02 2007-7 S5YN3325E01 2007-7 S5YN3421E01 2007-7 S5YN4618E02 2007-7 S5YN4718E01 2007-7 S5YN4818E01 2007-7
E /G TROUBLESHOOTING
_
Book Code No. Distribution Year–Month
MAINTENANCE SPECIFICATIONS
Book Code No. Distribution Year–Month
E215B E215BLC
NHK Russia (HS Engine)
SYSTEM
E215B E215BLC
NHK Russia (HS Engine)
YN11-45001~ YQ11-06001~
APPLICABLE MACHINES
0-5
NOTE:
NOTE:
This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specification, Maintenance, System, Disassembly, Troubleshooting, Engine, and Installation Procedures for Optional Attachment.
This Manual may be properly revised due to the improvement of products, modification of specifications, etc. And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly understood, contact our distributor.
This Manual is prepared as a technical material in which the information necessary for the maintenance and repairing services of our hydraulic excavators are collected, and is categorized into 7 Chapters, Specification, Maintenance, System, Disassembly, Troubleshooting, Engine, and Installation Procedures for Optional Attachment.
This Manual may be properly revised due to the improvement of products, modification of specifications, etc. And there are cases where the system on actual machine and a part of the contents of this manual may differ due to the variations of specification by countries. For the section in which the description is hardly understood, contact our distributor.
•
The Chapter "Specification" describes the specifications for entire machine and material, which are instructive for replacement and repairing of attachments.
•
The Chapter "Specification" describes the specifications for entire machine and material, which are instructive for replacement and repairing of attachments.
•
The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjustments for entire machine.
The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are contained. Therefore, the order must be placed with respective formal number with due confirmation on the Parts Manual for applicable machine.
•
The Chapter "Maintenance" describes the material, which is helpful for maintenance service and adjustments for entire machine.
The number is assigned to every part handled in this Manual on account of the description, but the parts, which cannot be supplied as service parts are contained. Therefore, the order must be placed with respective formal number with due confirmation on the Parts Manual for applicable machine.
•
The Chapter "System" describes the operating system like hydraulic system, electric system, components, and so on.
•
The Chapter "System" describes the operating system like hydraulic system, electric system, components, and so on.
•
The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.
•
The Chapter "Disassembly" describes the removal and installing of assembly mounted on the upper structure and undercarriage, and the assembling and disassembling of the associated hydraulic equipment.
•
The Chapter "Troubleshooting" describes how to find the fault equipment.
•
The Chapter "Troubleshooting" describes how to find the fault equipment.
•
The Chapter "Engine" describes the engines making use of the "Maintenance Manual" provided by the suppliers.
•
The Chapter "Engine" describes the engines making use of the "Maintenance Manual" provided by the suppliers.
•
The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required.
•
The Chapter "Installation Procedures for Optional Attachment" describes the supplements added on request as required.
0-6
0-6
1
1.1
1
1. OUTLINE
1. OUTLINE
TABLE OF CONTENTS
TABLE OF CONTENTS
GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3
1.1
GENERAL PRECAUTIONS FOR MAKING REPAIRS ......................................................1-3
1.1.1
PREPARATION BEFORE DISASSEMBLING ..........................................................1-3
1.1.1
PREPARATION BEFORE DISASSEMBLING ..........................................................1-3
1.1.2
SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.2
SAFETY WHEN DISASSEMBLING AND ASSEMBLING ........................................1-3
1.1.3
DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.3
DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT .......................1-3
1.1.4
ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.4
ELECTRICAL EQUIPMENT .....................................................................................1-4
1.1.5
HYDRAULIC PARTS ................................................................................................1-5
1.1.5
HYDRAULIC PARTS ................................................................................................1-5
1.1.6
WELD REPAIR .........................................................................................................1-5
1.1.6
WELD REPAIR .........................................................................................................1-5
1.1.7
ENVIRONMENTAL ISSUES.....................................................................................1-5
1.1.7
ENVIRONMENTAL ISSUES.....................................................................................1-5
1.2
INTERNATIONAL UNIT SYSTEM .....................................................................................1-6
1.2
INTERNATIONAL UNIT SYSTEM .....................................................................................1-6
Book Code No. S5YN0118E01 1-1
Book Code No. S5YN0118E01 1-1
1. OUTLINE
1. OUTLINE
Issue
Date of Issue
First edition
July, 2006
SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~
n
August, 2006
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
October, 2006
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
Applicable Machines
Remarks S5YN0118E01 (ASIA, OCE) n (ASIA, OCE) n (ASIA, OCE) n
December, 2006 SK850LC: LY01-00101~
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
n
n
SK235SRLC-2 : YU05-02001~
n
March, 2007
n
April, 2007
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
n
n
SK215SRLC : LA05-02001~
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
n
n
SK460-8: LS10-02001~ SK480LC–8 : YS10-01501~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
n
August, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
1-2
n (NHK) n (North America) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (ASIA, OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
Issue
Date of Issue
Applicable Machines
K
First edition
July, 2006
SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~
K
n
August, 2006
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
October, 2006
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
K
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
K
n
n
SK235SRLC-2 : YU05-02001~
K
n
March, 2007
K
n
April, 2007
K
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
K
n
n
SK215SRLC : LA05-02001~
K
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
K
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
K
n
n
SK460-8: LS10-02001~ SK480LC–8 : YS10-01501~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
K
n
August, 2007
Remarks S5YN0118E01 (ASIA, OCE) n (ASIA, OCE) n (ASIA, OCE) n
December, 2006 SK850LC: LY01-00101~
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
1-2
n (NHK) n (North America) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (ASIA, OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
K K K K K K K K K K K K K K K K K K K K
1. OUTLINE
1.1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
1.1.1
PREPARATION BEFORE DISASSEMBLING
2) Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work. 3) Before starting inspection and maintenance stop the engine. 4) Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire.
Read Operator's Manual before disassembling
(1) Knowledge of operating procedure Read Operator’s Manual carefully to understand the operating procedure.
5) Choose a hard, lever and safe place, and put attachment on the ground without fail. 6) Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
(2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.
7) Use proper tools, and change or repair defective tools. 8) Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely.
(3) Inspecting machines Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions in work shop into account, and request to procure necessary parts in advance.
1.1.3
(4) Recording Record the following items to keep contact and prevent malfunction from recurring.
(1) Removing hydraulic equipment assy 1) Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter.
1) Inspecting date, place 2) Model name, Serial number and Record on hour meter
2) Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
3) Trouble condition, place, cause
3) Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oil quality, oil contamination and looseness.
4) Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working bench.
6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited.
1) Tools required for repair work. 2) Prepare the places to put the disassembled parts. 3) Prepare oil pans for leaking oil, etc. 1.1.2
DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT
SAFETY WHEN DISASSEMBLING AND ASSEMBLING
1. OUTLINE
1.1
GENERAL PRECAUTIONS FOR MAKING REPAIRS
1.1.1
PREPARATION BEFORE DISASSEMBLING
3) Make match mark on parts for reassembling.
(1) Safety
4) Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not.
1) Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
1-3
3) Before starting inspection and maintenance stop the engine. 4) Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure and ambulance to prepare for accidents and fire.
Read Operator's Manual before disassembling
(1) Knowledge of operating procedure Read Operator’s Manual carefully to understand the operating procedure.
5) Choose a hard, lever and safe place, and put attachment on the ground without fail. 6) Use hoist, etc. to remove parts of heavy weight (23kg [50 lb] or more).
(2) Cleaning machines Clean machines of soil, mud, and dust before carrying into the service shop. Carrying a soiled machine into the service shop, causes making less efficient work and damage of parts.
7) Use proper tools, and change or repair defective tools. 8) Machine and attachment required to work in the lifting condition should be supported with supports or blocks securely.
(3) Inspecting machines Confirm the disassembling section before starting work, determine the disassembly procedure taking the conditions in work shop into account, and request to procure necessary parts in advance.
1.1.3
(4) Recording Record the following items to keep contact and prevent malfunction from recurring.
1) Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and take out the filter.
2) Model name, Serial number and Record on hour meter
2) Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
3) Trouble condition, place, cause
3) Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
4) Visible oil leak, water leak and damage 5) Clogging of filters, oil level, oil quality, oil contamination and looseness.
4) Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting them on working bench.
6) Examine the problems on the basis of monthly operation rate with the last inspection date and records on hour meter.
(2) Disassembling hydraulic equipment
(5) Arrangement and cleaning in service shop
1) Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly prohibited.
1) Tools required for repair work. 2) Prepare the places to put the disassembled parts. 3) Prepare oil pans for leaking oil, etc. 1.1.2
DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT
(1) Removing hydraulic equipment assy
1) Inspecting date, place
2) If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training.
WARNING
2) Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work.
SAFETY WHEN DISASSEMBLING AND ASSEMBLING
2) If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified through service training. 3) Make match mark on parts for reassembling.
WARNING
(1) Safety
4) Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly are permitted or not.
1) Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
1-3
1. OUTLINE
1. OUTLINE
5) For parts which are required to use jig and tools, don’t fail to use the specified jig and tools.
5) For parts which are required to use jig and tools, don’t fail to use the specified jig and tools.
6) For parts which can not be removed in the specified procedure, never force removal. First check for the cause.
If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged.
7) The removed parts should be put in order and tagged so as to install on proper places without confusion.
3) For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely.
8) For common parts, pay attention to the quantity and places. (3) Inspecting parts
4) For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed.
1) Check that the disassembled parts are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values.
6) For parts which can not be removed in the specified procedure, never force removal. First check for the cause.
If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment may be damaged.
7) The removed parts should be put in order and tagged so as to install on proper places without confusion.
3) For air bleed of hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low idling, then bleed air until hydraulic oil is comes out. After completion of comes, tighten plug securely.
8) For common parts, pay attention to the quantity and places. (3) Inspecting parts
4) For air bleed of travel motor and hydraulic cylinder, starts engine and operate it for 10 minutes or more at no-load and low speed.
1) Check that the disassembled parts are free from adherence, interference and uneven working face. 2) Measure the wear of parts and clearance, and record the measured values.
For cylinder, don’t move it to the stroke end at beginning.
3) If an abnormality is detected, repair or replace the parts. (4) Reassembling hydraulic equipment
5) Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly.
1) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely.
6) Check hydraulic oil level. Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if the oil level is lower than the specified level. How to check oil level of hydraulic oil tank
3) Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. 4) Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling. 5) Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them.
LEVEL GAUGE Oil level of hydraulic oil tank. If the indicator is within level marks, the oil quantity is acceptable.
6) Before assembling, remove rust preventives on new parts. 1.1.4
7) Use special tools to fit bearings, bushing and oil seal.
ELECTRICAL EQUIPMENT
8) Assemble parts matching to the marks.
For cylinder, don’t move it to the stroke end at beginning.
3) If an abnormality is detected, repair or replace the parts. (4) Reassembling hydraulic equipment
5) Air in pilot circuit can be bleed out by only operating digging, swing and traveling motions thoroughly.
1) During the parts cleaning, ventilate the room. 2) Before assembly, clean parts roughly first, and then completely.
6) Check hydraulic oil level. Move attachments to hydraulic oil check position, and check hydraulic oil level of tank. Refill oil if the oil level is lower than the specified level. How to check oil level of hydraulic oil tank
3) Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them. 4) Replace the removed O-ring, back-up rings and oil seal with new ones, and apply grease oil on them before assembling. 5) Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant on them.
LEVEL GAUGE Oil level of hydraulic oil tank. If the indicator is within level marks, the oil quantity is acceptable.
6) Before assembling, remove rust preventives on new parts. 1.1.4
7) Use special tools to fit bearings, bushing and oil seal.
ELECTRICAL EQUIPMENT
8) Assemble parts matching to the marks.
9) After completion, check that there is no omission of parts.
(1) The disassembly of electrical equipment is not allowed.
(5) Installing hydraulic equipment
(2) Handle equipment with care so as not to drop it or bump it.
1) Confirm hydraulic oil and lubrication oil. 2) Air release is required in the following cases ;
(3) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire.
1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump 4. Removing and attaching swing motor 5. Removing and attaching travel motor 6. Removing and attaching hydraulic cylinder
1-4
9) After completion, check that there is no omission of parts.
(1) The disassembly of electrical equipment is not allowed.
(5) Installing hydraulic equipment
(2) Handle equipment with care so as not to drop it or bump it.
1) Confirm hydraulic oil and lubrication oil. 2) Air release is required in the following cases ;
(3) Connector should be removed by unlocking while holding the connector. Never stress in tension to the caulked section by pulling wire.
1. Change of hydraulic oil 2. Replacement of parts on suction pipe side 3. Removing and attaching hydraulic pump
(4) Check that connector is connected and locked completely.
4. Removing and attaching swing motor
(5) Engine key off before removing and connecting connector.
6. Removing and attaching hydraulic cylinder
(4) Check that connector is connected and locked completely.
5. Removing and attaching travel motor
(5) Engine key off before removing and connecting connector.
1-4
1. OUTLINE (2) Flexible hose (F hose)
(6) Engine key off before touching terminals of starter and alternator.
•
(7) Remove battery grounding terminal before beginning work close to battery and battery relay with tools.
•
(8) Wash machine with care so as not to splash water on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting.
1.1.6
•
•
• •
(3) Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don’t fail to cover the section with flame-proof clothes. 1.1.7
(2) Waste disposal The following parts follows the regulation. Waste oil, waste container and battery
When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water.
(3) Precautions for handling hydraulic oil Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it.
When it was swallowed ; Drink milk or water. When it has adhered on clothes ; Wash it immediately.
•
When it has got in eyes ; Wash eyes with water until the stimulus is gone.
•
When it was swallowed ; Don’t force him to vomit it, but immediately receive medical treatment.
•
When it has adhered on skin ; Wash with soap and water.
HYDRAULIC PARTS
(4) Others For spare parts, grease and oil, use KOBELCO genuine ones.
(1) O-ring Check that O-ring is free from flaw and has elasticity before fitting.
•
ENVIRONMENTAL ISSUES
(1) Engine should be started and operated in the place where air can be sufficiently ventilated.
When it has got in eyes ; Wash in water for 10 minutes or more immediately.
•
WELD REPAIR
(2) Remove parts which may cause fire due to the entry of spark beforehand.
When it has adhered on skin ; Wash with soap and water.
1.1.5
Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.
(1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be damaged.
Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice. •
Even if the connector and length of hose are the same, the parts differ according to the withstanding pressure. Use proper parts.
1. OUTLINE
(7) Remove battery grounding terminal before beginning work close to battery and battery relay with tools.
•
Even if the connector and length of hose are the same, the parts differ according to the withstanding pressure. Use proper parts.
•
Tighten it to the specified torque, and check that it is free from twist, over tension, interference, and oil leak.
(8) Wash machine with care so as not to splash water on electrical equipment and connector. (9) When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before connecting.
1.1.6
• •
•
• •
(2) Remove parts which may cause fire due to the entry of spark beforehand. (3) Repair attachments which are damaged, giving particular attention to the plated section of piston rod to protect it from sparks, and don’t fail to cover the section with flame-proof clothes. 1.1.7
When it has adhered on skin ; Wash with soap and water.
(2) Waste disposal The following parts follows the regulation. Waste oil, waste container and battery
When it has spilled out in large quantity ; Use sodium bicarbonate to neutralize, or wash away with water.
(3) Precautions for handling hydraulic oil Hydraulic oil may cause inflammation of eyes. Wear goggles to protect eyes on handling it.
When it was swallowed ; Drink milk or water. When it has adhered on clothes ; Wash it immediately.
•
When it has got in eyes ; Wash eyes with water until the stimulus is gone.
•
When it was swallowed ; Don’t force him to vomit it, but immediately receive medical treatment.
•
When it has adhered on skin ; Wash with soap and water.
HYDRAULIC PARTS
(4) Others For spare parts, grease and oil, use KOBELCO genuine ones.
(1) O-ring Check that O-ring is free from flaw and has elasticity before fitting.
Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O-ring.
•
Even if the size of O-ring is equal, the usage differs, for example in dynamic and static sections, the rubber hardness also differs according to the pressure force, and also the quality differs depending on the materials to be seated. So, choose proper O-ring.
•
Fit O-ring so as to be free from distortion and bend.
•
Fit O-ring so as to be free from distortion and bend.
•
Floating seal should be put in pairs.
•
Floating seal should be put in pairs.
ENVIRONMENTAL ISSUES
(1) Engine should be started and operated in the place where air can be sufficiently ventilated.
When it has got in eyes ; Wash in water for 10 minutes or more immediately.
1.1.5
WELD REPAIR
(1) The weld repair should be carried out by qualified personnel in the specified procedure after disconnecting the grounding cable of battery. If the grounding cable is not disconnected, the electrical equipment may be damaged.
Battery fluid is dangerous. The battery fluid is dilute sulfuric acid, and causes scald and loss of eyesight by adhering on eyes, skin and clothes. When the fluid has adhered on them, take an emergency measure immediately and see a doctor for medical advice.
•
1-5
(2) Flexible hose (F hose)
(6) Engine key off before touching terminals of starter and alternator.
1-5
1. OUTLINE
1.2
1. OUTLINE
INTERNATIONAL UNIT SYSTEM
Table1-4
Introduction Although this manual uses the SI units system. Outline of SI units system is described here. Given hereinunder are an excerpt of the units that are related to this manual :
QUANTITY Force
SI units
Supplemen tary units Table 1-2 Derived units
Quantity of electricity
Derived units of base units Table 1-3 Derived units bearing peculiar designations Table 1-4
Table1-1 Length Mass Time Current Thermodynamic temperature Gram molecule Luminous intensity
Electric resistance
SIGN
Meter Kilogram Second Ampere Kelvin
m kg s A K
Mol Candela
mol cd
kg • m/s
Pa
N/m2
J
N•m
watt
W
J/s
coulomb
C
A•s
V
Radian Steradian
DESIGNATION Square meter Cubic meter Meter per second Meter per second / second Kilogram per cubic meter
Table1-4
2
SI units
Supplemen tary units Table 1-2 Derived units
F
C/V
C
(t+273.15)K
lx
l m/m2
°
lux
POWER
SIGN
Giga
G
109
SIGN
Mega
M
106
rad sr
Kilo
k
103
Hecto
h
10
Deca
da
10
Deci
2
Derived units bearing peculiar designations Table 1-4
Meter Kilogram Second Ampere Kelvin
m kg s A K
Mol Candela
mol cd
DESIGNATION Radian Steradian
d
10
(3) Derived Units of Basic Units
Centi
c
10–2
Table1-3
SIGN
Milli
m
10
m2 m3 m/s m/s2 kg/m3
Micro
P
10–6
Nano
n
10–9
Pico
p
10–12
QUANTITIES Area Volume Velocity Acceleration Density
N
kg • m/s 2
Pa
N/m2
J
N•m
watt
W
J/s
coulomb
C
A•s
Electric potential difference, volt Voltage, and Electromotive force
V
W/A
Quantity of static electricity farad and Electric capacitance
F
C/V
ohm
V/A
celcius Celcius degree or temperature degree Illuminance
C
(t+273.15)K
lx
l m/m2
°
lux
(5) Prefixes of SI Table1-5 PREFIX
–1
–3
newton
Electric resistance
SIGN
DESIGNATION Square meter Cubic meter Meter per second Meter per second / second Kilogram per cubic meter
POWER
DESIGNATION
SIGN
Giga
G
109
SIGN
Mega
M
106
rad sr
Kilo
k
103
Hecto
h
102
Deca
da
10
Deci
d
10–1
Centi
c
10–2
SIGN
Milli
m
10–3
m2 m3 m/s m/s2 kg/m3
Micro
P
10–6
Nano
n
10–9
Pico
p
10–12
Table1-2 Plain angle Solid angle
1Hz=1/s
Quantity of electricity
Derived units of base units Table 1-3
(2) Supplementary Units
QUANTITIES
Hz
Power
DESIGNATION
Length Mass Time Current Thermodynamic temperature Gram molecule Luminous intensity
hertz
Energy, Work and Quantity of joule heat
(1) Basic Units
QUANTITIES
FORMULA
Pressure and pascal Stress
Table1-1 V/A
SYMBOL
Force
2. Construction of SI Unit System Base units Table 1-1
UNIT
Frequency
1. Etymology of SI Units English : International System of units
W/A
DESIGNATION
1-6
QUANTITY
Prefixes of SI (n-th power of 10, where n is an integer) Table 1- 5
PREFIX
DESIGNATION
(4) Derived Units bearing Peculiar Designations
Although this manual uses the SI units system. Outline of SI units system is described here. Given hereinunder are an excerpt of the units that are related to this manual :
SI unit system
Table1-5
Table1-3 Area Volume Velocity Acceleration Density
N
(5) Prefixes of SI
(3) Derived Units of Basic Units
QUANTITIES
newton
ohm
Illuminance
Table1-2 Plain angle Solid angle
1Hz=1/s
celcius Celcius degree or temperature degree
(2) Supplementary Units
QUANTITIES
Hz
Quantity of static electricity farad and Electric capacitance
(1) Basic Units
DESIGNATION
hertz
Electric potential difference, volt Voltage, and Electromotive force
Prefixes of SI (n-th power of 10, where n is an integer) Table 1- 5
QUANTITIES
FORMULA
Energy, Work and Quantity of joule heat Power
INTERNATIONAL UNIT SYSTEM
Introduction
SYMBOL
Pressure and pascal Stress
2. Construction of SI Unit System Base units Table 1-1
UNIT
Frequency
1. Etymology of SI Units English : International System of units
SI unit system
1.2
(4) Derived Units bearing Peculiar Designations
1-6
1. OUTLINE (6) Unit Conversion Table
1. OUTLINE (6) Unit Conversion Table
QUANTITIES
JIS
SI
Mass
kg
kg
Force
kgf
N
Torque
kgf•m
QUANTITIES
JIS
SI
Mass
kg
kg
1kgf=9.807N
Force
kgf
N
1kgf=9.807N
N•m
1kgf•m=9.807N•m
Torque
kgf•m
N•m
1kgf•m=9.807N•m
Pressure
kgf/cm
MPa
1kgf/cm =0.098MPa
Pressure
kgf/cm
MPa
1kgf/cm2=0.098MPa
Motive power
PS
kW
1PS=0.7355kW
Motive power
PS
kW
1PS=0.7355kW
Revolution
r.p.m
min–1
1r.p.m=1min–1
Revolution
r.p.m
min–1
1r.p.m=1min–1
2
REMARKS
2
1-7
2
REMARKS
1-7
1. OUTLINE
1. OUTLINE
[MEMO]
[MEMO]
1-8
1-8
2
2
2. SPECIFICATIONS
2. SPECIFICATIONS
TABLE OF CONTENTS
TABLE OF CONTENTS
2.1
NAME OF COMPONENTS................................................................................................2-3
2.1
NAME OF COMPONENTS................................................................................................2-3
2.2
GENERAL DIMENSIONS ..................................................................................................2-4
2.2
GENERAL DIMENSIONS ..................................................................................................2-4
2.2.1
E215B/E215BLC
2.2.1
[5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m (1.05cu•yd) Bucket Shoe] ....2-4
2.2.2
E215B/E215BLC
2.2.2
[5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe] ......2-4 2.2.3
E215B/E215BLC
E215B/E215BLC [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu•yd) Bucket Shoe] ....2-4
3
E215B/E215BLC [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe] ......2-4
2.2.3
[5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe] ..........2-5
E215B/E215BLC [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe] ..........2-5
2.3
WEIGHT OF COMPONENTS............................................................................................2-6
2.3
WEIGHT OF COMPONENTS............................................................................................2-6
2.4
TRANSPOTATION ............................................................................................................2-8
2.4
TRANSPOTATION ............................................................................................................2-8
2.4.1
OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.1
OVERALL DIMENSIONS OF MACHINE ON A TRAILER ........................................2-8
2.4.2
DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.4.2
DIMENSIONS OF ATTACHMENT ...........................................................................2-9
2.5
SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5
SPECIFICATIONS AND PERFORMANCE .......................................................................2-11
2.5.1
SPEED AND CLIMBING CAPABILITY .....................................................................2-11
2.5.1
SPEED AND CLIMBING CAPABILITY .....................................................................2-11
2.5.2
ENGINE ....................................................................................................................2-11
2.5.2
ENGINE ....................................................................................................................2-11
2.5.3
HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.3
HYDRAULIC COMPONENTS ..................................................................................2-11
2.5.4
WEIGHT ...................................................................................................................2-11
2.5.4
WEIGHT ...................................................................................................................2-11
2.6
TYPE OF CRAWLER.........................................................................................................2-12
2.6
TYPE OF CRAWLER.........................................................................................................2-12
2.7
TYPE OF BUCKET ............................................................................................................2-12
2.7
TYPE OF BUCKET ............................................................................................................2-12
2.8
COMBINATIONS OF ATTACHMENT................................................................................2-13
2.8
COMBINATIONS OF ATTACHMENT................................................................................2-13
2.9
ENGINE SPECIFICATIONS ..............................................................................................2-14
2.9
ENGINE SPECIFICATIONS ..............................................................................................2-14
2.9.1
SPECIFICATIONS....................................................................................................2-14
2.9.1
SPECIFICATIONS....................................................................................................2-14
2.9.2
ENGINE CHARACTERISTIC CURVE (HINO J05E-TG) ..........................................2-15
2.9.2
ENGINE CHARACTERISTIC CURVE (HINO J05E-TG) ..........................................2-15
Book Code No. S5YN0225E01 2-1
Book Code No. S5YN0225E01 2-1
2. SPECIFICATIONS
2. SPECIFICATIONS
Issue
Date of Issue
First edition
July, 2007
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
2-2
Remarks S5YN0225E01 (NHK Russia) HS Engine n (NHK Middle East) HS Engine
Issue
Date of Issue
K
First edition
July, 2007
K
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
2-2
Remarks S5YN0225E01 (NHK Russia) HS Engine n (NHK Middle East) HS Engine
K K
2. SPECIFICATIONS
2.1
NAME OF COMPONENTS
2.1
ARM CYLINDER
ARM
2. SPECIFICATIONS
NAME OF COMPONENTS ARM CYLINDER
ARM
BOOM
BOOM BOOM CYLINDER
BUCKET CYLINDER
BOOM CYLINDER
BUCKET CYLINDER
CAB
CAB
SLEWING BEARING IDLER LINK
SLEWING BEARING IDLER LINK
SLEWING MOTOR SWIVEL JOINT
SLEWING MOTOR SWIVEL JOINT
FUEL TANK
FUEL TANK
HYDRAULIC TANK BUCKET LINK
HYDRAULIC TANK BUCKET LINK
BUCKET
CONTROL VALVE
CONTROL VALVE
GUARD MUFFLER HYDRAULIC PUMP
GUARD MUFFLER HYDRAULIC PUMP
BUCKET
MONITOR PANEL
MONITOR PANEL
SHOE AND TRACK LINK
SHOE AND TRACK LINK
FRONT IDLER
FRONT IDLER ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER AIR CLEANER
TRACK GUIDE
RADIATOR AND OIL COOLER
ROTALY MULTI CONTROL VALVE (OPTION) LOWER ROLLER
BATTERY
TRAVEL MOTOR
2-3
ENGINE
IDLER ADJUST
COUNTER WEIGHT
UPPER ROLLER AIR CLEANER
TRACK GUIDE
RADIATOR AND OIL COOLER
ROTALY MULTI CONTROL VALVE (OPTION) LOWER ROLLER
BATTERY
TRAVEL MOTOR
2-3
2. SPECIFICATIONS
2. SPECIFICATIONS
2.2
GENERAL DIMENSIONS
2.2
GENERAL DIMENSIONS
2.2.1
E215B/E215BLC [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu•yd) Bucket Shoe]
2.2.1
E215B/E215BLC [5.65m (18ft-6in) Boom+2.94m (9ft-8in) Standard Arm+0.80m3 (1.05cu•yd) Bucket Shoe]
R2
75
2710 (8'11")
1315 (4'4") 43 (1.7")
R2
75
(9
')
9450 (31')
')
3030 (9'11")
600 (23.6") 4170 (13'8") [4450 (14'7")]
600 (23.6") 4170 (13'8") [4450 (14'7")]
2800 (9'2") [2990] (9'10")
4840 (15'11") [4980 (16'4")]
2800 (9'2") [2990] (9'10")
4840 (15'11") [4980 (16'4")]
Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications.
Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications.
2.2.2
2.2.2
E215B/E215BLC [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe]
Unit : mm(ft-in)
9530 (31'3")
450
*1060 (3'6")
2980 (9'9") 450
(17.1")
*1060 (3'6")
2980 (9'9")
(9
2750 (9')
3030 (9'11")
2750 (9')
0
(17.1")
9450 (31')
0
Unit : mm(ft-in)
1395 (4'7")
1395 (4'7")
2710 (8'11")
1315 (4'4") 43 (1.7")
Unit : mm(ft-in)
E215B/E215BLC [5.65m (18ft-6in)+2.4m (7ft-10in) Short Arm+0.93m3 (1.22cu•yd) Bucket Shoe]
Unit : mm(ft-in)
9530 (31'3")
3980 (13'1")
3980 (13'1")
*1060 (3'6")
*1060 (3'6")
3160 (10'4")
2750 (9')
3160 (10'4")
2750 (9')
4170 (13'8") [4450 (14'7")]
4170 (13'8") [4450 (14'7")]
4840 (15'11") [4980 (16'4")]
2-4
4840 (15'11") [4980 (16'4")]
2-4
2. SPECIFICATIONS 2.2.3
E215B/E215BLC [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe]
2. SPECIFICATIONS 2.2.3
Unit : mm(ft-in)
9520 (31'3")
E215B/E215BLC [5.65m (18ft-6in) Boom+3.5m (11ft-6in) Long Arm+0.70m3 (0.92cu•yd) Bucket Shoe]
Unit : mm(ft-in)
9520 (31'3")
*1060 (3'6")
*1060 (3'6")
3180 (10'5")
2750 (9')
3180 (10'5")
2750 (9')
4170 (13'8") [4450 (14'7")]
4170 (13'8") [4450 (14'7")]
4840 (15'11") [4980 (16'4")]
Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications.
2-5
4840 (15'11") [4980 (16'4")]
Dimensions marked * do not include the height of the shoe lug. [ ] include LC specifications.
2-5
2. SPECIFICATIONS
2. SPECIFICATIONS
2.3
2.3
WEIGHT OF COMPONENTS
WEIGHT OF COMPONENTS
Unit ; kg (lb) Model
E215B
E215BLC
Machine complete
20,200 (44,500)
20,600 (45,400)
1. Upper frame assy (Assembly of following :)
9,500 (21,000)
m
1.1 Upper frame
1,770 (3,900)
1.2 Counter weight (Semi-weighted)
Item
Unit ; kg (lb) Model
E215B
E215BLC
Machine complete
20,200 (44,500)
20,600 (45,400)
1. Upper frame assy (Assembly of following :)
9,500 (21,000)
m
m
1.1 Upper frame
1,770 (3,900)
m
4,640 (10,230)
m
1.2 Counter weight (Semi-weighted)
4,640 (10,230)
m
Item
260 (570)
m
1.3 Cab
*540 (1,190)
m
1.4 Engine
260 (570)
m
*540 (1,190)
m
1.5 Hydraulic oil tank
*150 (330)
m
1.5 Hydraulic oil tank
*150 (330)
m
1.6 Fuel tank
*110 (240)
m
1.6 Fuel tank
*110 (240)
m
1.7 Slewing motor (including reduction unit) 1.8 Control valve
*210 (460)
m
1.7 Slewing motor (including reduction unit)
*210 (460)
m
*230 (510)
m
1.8 Control valve
*230 (510)
m
1.9 Boom cylinder
*170 (375) u 2
m
1.9 Boom cylinder
*170 (375) u 2
m
70 (150)
m
1.10 Pin (for mounting boom)
70 (150)
m
1.11 Pump
*130 (290)
m
1.11 Pump
*130 (290)
m
1.12 Radiator (including intercooler)
*90 (200)
m
1.12 Radiator (including intercooler)
*90 (200)
m
2. Lower frame assy (Assembly of following :)
6,730 (14,840)
7,130 (15,720)
2. Lower frame assy (Assembly of following :)
6,730 (14,840)
7,130 (15,720)
2.1 Lower frame
2,260 (4,980)
2,420 (5,340)
2.1 Lower frame
2,260 (4,980)
2,420 (5,340)
1.3 Cab 1.4 Engine
1.10 Pin (for mounting boom)
250 (550)
m
2.2 Slewing bearing
260 (570) u 2
m
2.3 Travel motor (including reduction unit)
2.4 Upper roller
20 (44) u 2
m
2.5 Lower roller
30 (66) u 14
30 (66) u 16
2.2 Slewing bearing 2.3 Travel motor (including reduction unit)
250 (550)
m
260 (570) u 2
m
2.4 Upper roller
20 (44) u 2
m
2.5 Lower roller
30 (66) u 14
30 (66) u 16
2.6 Front idler
110 (240) u 2
m
2.6 Front idler
110 (240) u 2
m
2.7 Idler adjuster
100 (220) u 2
m
2.7 Idler adjuster
100 (220) u 2
m
50 (110) u 2
m
2.8 Sprocket
50 (110) u 2
m
*30 (66)
m
2.9 Swivel joint
*30 (66)
m
1,260 (2,780) u 2 1,470 (3,240) u 2 1,600 (3,530) u 2
1,350 (2,980) u 2 1,560 (3,440) u 2 1,700 (3,750) u 2
1,260 (2,780) u 2 1,470 (3,240) u 2 1,600 (3,530) u 2
1,350 (2,980) u 2 1,560 (3,440) u 2 1,700 (3,750) u 2
510 (1,120) u 2
540 (1,190) u 2
510 (1,120) u 2
540 (1,190) u 2
3,420 (7,540)
m
3,420 (7,540)
m
2.8 Sprocket 2.9 Swivel joint 2.10 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.5in) shoes assy 2.10.1 Track link assy 3. Attachment (Assembly of following / STD :) {5.65m (18ft-6in) Boom + 2.94m (9ft-8in) Arm + 0.80m (1cu•yd) Bucket}
2.10 Track link with 600mm (23.6in) shoes assy Track link with 700mm (27.6in) shoes assy Track link with 800mm (31.5in) shoes assy 2.10.1 Track link assy 3. Attachment (Assembly of following / STD :) {5.65m (18ft-6in) Boom + 2.94m (9ft-8in) Arm + 0.80m (1cu•yd) Bucket}
3
3
640 (1,410)
m
3.1 Bucket assy (STD)
1,050 (2,315)
m
3.2 STD Arm assy (Assembly of following :)
3.2.1 STD Arm
660 (1,455)
m
3.2.2 Bucket cylinder
*140 (310)
3.2.3 Idler link
3.1 Bucket assy (STD) 3.2 STD Arm assy (Assembly of following :)
640 (1,410)
m
1,050 (2,315)
m
3.2.1 STD Arm
660 (1,455)
m
m
3.2.2 Bucket cylinder
*140 (310)
m
20 (44) u 2
m
3.2.3 Idler link
20 (44) u 2
m
3.2.4 Bucket link
90 (198)
m
3.2.4 Bucket link
90 (198)
m
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket)
100 (220)
m
3.2.5 Pin (2pcs. for mounting bucket cylinder / 2pcs. for mounting bucket)
100 (220)
m
3.3 Boom assy (Assembly of following :)
1,730 (3,815)
m
3.3 Boom assy (Assembly of following :)
1,730 (3,815)
m
3.3.1 Boom
1,310 (2,890)
m
3.3.1 Boom
1,310 (2,890)
m
*255 (560)
m
3.3.2 Arm cylinder
*255 (560)
m
80 (180)
m
3.3.3 Pin (Mounting arm • Mounting arm cylinder)
80 (180)
m
3.3.2 Arm cylinder 3.3.3 Pin (Mounting arm • Mounting arm cylinder)
2-6
2-6
Model Item 4. Lubricant and water (Assembly of following :) 4.1 Hydraulic oil 4.2 Engine oil 4.3 Fuel 4.4 Water
Marks * show dry weight.
2. SPECIFICATIONS
2. SPECIFICATIONS
Unit ; kg (lb)
Unit ; kg (lb) Model
E215B
E215BLC
550 (1,210)
m
4. Lubricant and water (Assembly of following :)
200 (440)
m
4.1 Hydraulic oil
20 (44)
m
4.2 Engine oil
310 (680)
m
4.3 Fuel
20 (44)
m
4.4 Water
Item
Marks * show dry weight.
2-7
2-7
E215B
E215BLC
550 (1,210)
m
200 (440)
m
20 (44)
m
310 (680)
m
20 (44)
m
2. SPECIFICATIONS
2. SPECIFICATIONS
2.4
TRANSPOTATION
2.4
TRANSPOTATION
2.4.1
OVERALL DIMENSIONS OF MACHINE ON A TRAILER
2.4.1
OVERALL DIMENSIONS OF MACHINE ON A TRAILER
E215B
E215BLC
2,800 (9ft-2in)
2,990 (9ft-10in)
20,200kg (44,500 lbs)
20,600kg (45,400 lbs)
Item Width 600mm (23.6in) shoes Weight
Model
E215B
E215BLC
2,800 (9ft-2in)
2,990 (9ft-10in)
20,200kg (44,500 lbs)
20,600kg (45,400 lbs)
Item Width 600mm (23.6in) shoes Weight
Unit : mm (ft-in)
80 (3.15") 72 (2.83") [*54 (2.13")]
100 (3.94")
138 (5.43") [*145 (5.71")]
80 (3.15")
90 (3.54") [*83 (3.27")]
72 (2.83") [*54 (2.13")]
SECTION AA
* marks indicate LC specifications.
2260 (7'5")
700 (27.6")
700 (27.6")
100 (3.94")
138 (5.43") [*145 (5.71")]
9470 (31'1")
3080 (10'1")
2260 (7'5")
3780 (12'5")
9470 (31'1")
Unit : mm (ft-in)
90 (3.54") [*83 (3.27")]
SECTION AA
* marks indicate LC specifications.
2-8
3780 (12'5")
Model
(1) 5.65m (18ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m3 (1.05cu•yd) Bucket
3080 (10'1")
(1) 5.65m (18ft-6in) Boom+2.94m (9ft-8in) Arm+0.80m3 (1.05cu•yd) Bucket
2-8
2. SPECIFICATIONS 2.4.2
DIMENSIONS OF ATTACHMENT
2.4.2
(1) BOOM
Item LengthuHeightuWidth m (ft-in) LuHuW kg (lbs)
Type
5.65m (18ft-6in) Boom
Item
5.86 u 1.57 u 0.67 (19'3"u 5'2"u 2'2")
LengthuHeightuWidth m (ft-in) LuHuW
1,670 (3,680)
Weight
(2) ARM AND BUCKET
Item LengthuHeightuWidth m (ft-in) LuHuW kg (lbs)
2.4m (7ft-10in) Arm + 0.93m 3(1.22cu•yd) Bucket
2.94m (9ft-8in) Arm + 0.80m 3 (1.05cu•yd) Bucket
3.5m (11ft-6in) Arm + 0.70m 3 (0.92cu•yd) Bucket
4.75 u 0.9 u 1.33 (15'7"u2'11"u4'4")
5.29 u 0.9 u1.16 (17'4"u2'11"u4')
5.88 u 0.9 u 1.08 (19'3"u2'11"u3'7")
1,740 (3,840)
1,680 (3,700)
1,880 (4,150)
(3) Arm
5.86 u 1.57 u 0.67 (19'3"u 5'2"u 2'2")
kg (lbs)
1,670 (3,680)
Type
2.4m (7ft-10in) Arm + 0.93m 3(1.22cu•yd) Bucket
2.94m (9ft-8in) Arm + 0.80m 3 (1.05cu•yd) Bucket
3.5m (11ft-6in) Arm + 0.70m 3 (0.92cu•yd) Bucket
4.75 u 0.9 u 1.33 (15'7"u2'11"u4'4")
5.29 u 0.9 u1.16 (17'4"u2'11"u4')
5.88 u 0.9 u 1.08 (19'3"u2'11"u3'7")
1,740 (3,840)
1,680 (3,700)
1,880 (4,150)
2.4 m (7ft-10in) Arm
2.94 m (9ft-8in) Arm
3.5 m (11ft-6in) Arm
3.40 u 0.86 u 0.56 (11'2"u2'10"u1'10")
3.94 u 0.86 u 0.56 (12'11"u2'10"u1'10")
4.53 u 0.87 u 0.56 (14'10"u2'10"u1'10")
1,020 (2,250)
1,044 (2,300)
1,260 (2,780)
Item LengthuHeightuWidth m (ft-in) LuHuW Weight
kg (lbs)
(3) Arm Type
Item LengthuHeightuWidth m (ft-in) LuHuW Weight
5.65m (18ft-6in) Boom
(2) ARM AND BUCKET Type
Weight
DIMENSIONS OF ATTACHMENT
(1) BOOM Type
Weight
2. SPECIFICATIONS
kg (lbs)
2.4 m (7ft-10in) Arm
2.94 m (9ft-8in) Arm
3.5 m (11ft-6in) Arm
3.40 u 0.86 u 0.56 (11'2"u2'10"u1'10")
3.94 u 0.86 u 0.56 (12'11"u2'10"u1'10")
4.53 u 0.87 u 0.56 (14'10"u2'10"u1'10")
1,020 (2,250)
1,044 (2,300)
1,260 (2,780)
2-9
Type Item LengthuHeightuWidth m (ft-in) LuHuW Weight
kg (lbs)
2-9
2. SPECIFICATIONS
2. SPECIFICATIONS
(4) Bucket
(4) Bucket Type
LengthuHeightuWidth LuHuW
Hoe bucket 1.37 u 1.26u 0.87 m (ft-in (4'6"u4'2"u2'10")
1.37 u 1.26u 1.07 (4'6"u4'2"u3'6")
Type
1.37 u 1.26u 1.16 (4'6"u4'2"u3'10")
1.37 u 1.26u 1.33 (4'6"u4'2"u4'4")
LengthuHeightuWidth LuHuW
Hoe bucket 1.37 u 1.26u 0.87 m (ft-in (4'6"u4'2"u2'10")
1.37 u 1.26u 1.07 (4'6"u4'2"u3'6")
1.37 u 1.26u 1.16 (4'6"u4'2"u3'10")
1.37 u 1.26u 1.33 (4'6"u4'2"u4'4")
Weight
kg (lbs)
520 (1,150)
630 (1,390)
640 (1,410)
710 (1,560)
Weight
kg (lbs)
520 (1,150)
630 (1,390)
640 (1,410)
710 (1,560)
Bucket capacity
m3 cu•yd
0.51 (0.67)
0.70 (0.92)
STD 0.80 (1.05)
0.93 (1.22)
Bucket capacity
m3 cu•yd
0.51 (0.67)
0.70 (0.92)
STD 0.80 (1.05)
0.93 (1.22)
Hoe bucket
Slope finishing bucket
Hoe bucket
Slope finishing bucket
Type LengthuHeightuWidth LuHuW
m (ft-in
1.37u1.26u1.16 (4'6"u4'2"u3'10")
1.25u0.90u2.20 (4'1"u2'11"u7'3")
Weight
kg (lbs)
750 (1,650)
Bucket capacity
m cu•yd
0.80 (1.05) HD
3
Type LengthuHeightuWidth LuHuW
m (ft-in
1.37u1.26u1.16 (4'6"u4'2"u3'10")
1.25u0.90u2.20 (4'1"u2'11"u7'3")
890 (1,960)
Weight
kg (lbs)
750 (1,650)
890 (1,960)
0.82 (1.07)
Bucket capacity
m cu•yd
0.80 (1.05) HD
0.82 (1.07)
Hoe bucket
Slope finishing bucket
2-10
3
Hoe bucket
Slope finishing bucket
2-10
2. SPECIFICATIONS
2. SPECIFICATIONS
2.5
SPECIFICATIONS AND PERFORMANCE
2.5
SPECIFICATIONS AND PERFORMANCE
2.5.1
SPEED AND CLIMBING CAPABILITY
2.5.1
SPEED AND CLIMBING CAPABILITY
Area & Model
E215B
Item Swing speed
min-1 {rpm}
Travel speed (1-speed/2speed)
km/h (mile/h)
Gradeability
% (degree)
2.5.2
E215BLC 12.5 {12.5} 3.6 / 6.0 (2.2 / 3.7) 70 (35)
ENGINE HINO J05E-TG
Swing speed
min-1 {rpm}
Travel speed (1-speed/2speed)
km/h (mile/h)
Gradeability
% (degree)
Total displacement Rated output / Engine speed
12.5 {12.5} 3.6 / 6.0 (2.2 / 3.7) 70 (35)
ENGINE HINO J05E-TG Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger
Type
4 -ø112 mm u 130 mm (4.41 in u 5.12 in)
Number of cylinders—BoreuStroke
5.123 L (312.61 cu•in)
Total displacement
114 kW (155 PS) / 2,000 min-1
Maximum torque / Engine speed
E215BLC
Engine model
Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger
Number of cylinders—BoreuStroke
E215B
Item
2.5.2
Engine model Type
Area & Model
4 -ø112 mm u 130 mm (4.41 in u 5.12 in) 5.123 L (312.61 cu•in)
Rated output / Engine speed
572 N•m (422 lbf•ft)/ 1,600 min-1
114 kW (155 PS) / 2,000 min-1
Maximum torque / Engine speed
572 N•m (422 lbf•ft)/ 1,600 min-1
Starter
24 V / 5.0kW
Starter
24 V / 5.0kW
Alternator
24 V / 1.2kW
Alternator
24 V / 1.2kW
2.5.3
HYDRAULIC COMPONENTS
Hydraulic pump
2.5.3 Variable displacement axial piston pump u 2 + gear pump u 1
HYDRAULIC COMPONENTS
Hydraulic pump
Variable displacement axial piston pump u 2 + gear pump u 1
Hydraulic motor (swing)
Axial piston motor u 1
Hydraulic motor (swing)
Axial piston motor u 1
Hydraulic motor (travel)
Variable displacement axial piston motor u 2 (with counterbalance valve)
Hydraulic motor (travel)
Variable displacement axial piston motor u 2 (with counterbalance valve)
8-spool control valve u 1
Control valve Cylinder (Boom, Arm, Bucket)
2.5.4
Cylinder (Boom, Arm, Bucket)
Double action cylinder
Oil cooler
8-spool control valve u 1
Control valve
Air-cooled type
Double action cylinder
Oil cooler
WEIGHT
2.5.4
Air-cooled type WEIGHT
Unit : kg (lbs) Fully equipped weight
20,200 (44,500)
20,600 (45,400)
Upper structure
9,500 (21,000)
m
Lower machinery (600mm grouser shoe)
6,730 (14,840)
7,130 (15,720)
3,420 (7,540)
m
Attachment 5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm +0.80m3 (1.05cu•yd) Bucket
Unit : kg (lbs) Fully equipped weight
20,200 (44,500)
20,600 (45,400)
Upper structure
9,500 (21,000)
m
Lower machinery (600mm grouser shoe)
6,730 (14,840)
7,130 (15,720)
3,420 (7,540)
m
Attachment
2-11
5.65m (18 ft-6in) Boom+2.94m (9ft-8in) Arm +0.80m3 (1.05cu•yd) Bucket
2-11
2. SPECIFICATIONS
2. SPECIFICATIONS
2.6
2.6
TYPE OF CRAWLER Shape
Overall width of crawler mm (ft-in)
Shoe width mm (in)
STD
Grouser shoe
600 (23.6)
700 (27.6)
800 (31.5)
46 LINKS
TYPE OF CRAWLER
Ground pressure kPa (psi)
2,800 (9'2")
45 (6.53)
LC
2,990 (9'10")
43 (6.24)
STD
2,900 (9'6")
40 (5.80)
LC
3,090 (10'2")
38 (5.51)
STD
3,000 (9'10")
35 (5.08)
LC
3,190 (10'6")
33 (4.79)
Shape
Overall width of crawler mm (ft-in)
Shoe width mm (in)
Grouser shoe
600 (23.6)
700 (27.6)
800 (31.5)
46 LINKS
Ground pressure kPa (psi)
STD
2,800 (9'2")
45 (6.53)
LC
2,990 (9'10")
43 (6.24)
STD
2,900 (9'6")
40 (5.80)
LC
3,090 (10'2")
38 (5.51)
STD
3,000 (9'10")
35 (5.08)
LC
3,190 (10'6")
33 (4.79)
Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
Use 600mm (23.6") grouser shoes on rough ground (areas covered with rocks and gravel). If you drive or excavate with other shoes, this may cause shoe bending, shoe bolt looseness, and track assembly (link, roller, etc.)
2.7
2.7
TYPE OF BUCKET
Hoe bucket
Heaped capacity m3(cu•yd)
Struck
Outer width mm (ft-in)
Number Without side of tooth
W or W/O side cutter
Availability Weight of face kg (lbs) shovel
m3(cu•yd)
With side cutter
0.51 (0.67)
0.39 (0.51)
870 (2'10")
770 (2'6")
3
W
YES
520 (1,150)
0.70 (0.92)
0.52 (0.68)
1,080 (3'6")
980 (3'3")
5
W
YES
[STD] 0.80 (1.05)
0.59 1,160 (3'10") 1,060 (3'6") (0.77)
5
W
0.93 (1.2)
0.67 (0.88)
5
W
cutter
1,330 (4'4")
1,230 (4')
2-12
TYPE OF BUCKET
Hoe bucket
Heaped capacity m3(cu•yd)
Struck
Outer width mm (ft-in)
Number
W or W/O side cutter
Without side of tooth cutter
Availability Weight of face kg (lbs) shovel
m3(cu•yd)
With side cutter
0.51 (0.67)
0.39 (0.51)
870 (2'10")
770 (2'6")
3
W
YES
520 (1,150)
630 (1,390)
0.70 (0.92)
0.52 (0.68)
1,080 (3'6")
980 (3'3")
5
W
YES
630 (1,390)
YES
640 (1,410)
[STD] 0.80 (1.05)
0.59 1,160 (3'10") 1,060 (3'6") (0.77)
5
W
YES
640 (1,410)
YES
710 (1,560)
0.93 (1.2)
0.67 (0.88)
5
W
YES
710 (1,560)
1,330 (4'4")
1,230 (4')
2-12
2. SPECIFICATIONS
2.8
COMBINATIONS OF ATTACHMENT Bucket
2. SPECIFICATIONS
2.8
COMBINATIONS OF ATTACHMENT
Available Arm
Struck m (cu•yd)
0.39 (0.51)
0.51 (0.67)
0.39 (0.51)
0.70 (0.92)
0.52 (0.68)
0.70 (0.92)
0.52 (0.68)
[STD] 0.80 (1.05)
0.59 (0.77)
[STD] 0.80 (1.05)
0.59 (0.77)
0.93 (1.2)
0.67 (0.88)
0.93 (1.2)
0.67 (0.88)
Breaker
—
—
Breaker
—
—
Nibbler
—
—
Nibbler
—
—
Hoe bucket
•
Struck m (cu•yd)
0.51 (0.67)
Available Arm
Heaped capacity m3 (cu•yd)
Type
Heaped capacity m3 (cu•yd)
Bucket
3
2.94m (9ft-8in) Arm (STD)
3.5m (11ft-6in) Arm (Long)
2.4m (7ft-10in) Arm +Arm (Short)
Type
Hoe bucket
3
2.94m (9ft-8in) Arm (STD)
3.5m (11ft-6in) Arm (Long)
Standard combination
Standard combination
General operation : Excavation or loading of sand, gravel, and clay
General operation : Excavation or loading of sand, gravel, and clay
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Light operation : Mainly loading or loose gravel (e.g., cultivation or loading of sand or gravel)
Prohibited combination : There are problems from the view points of strength and stability.
Prohibited combination : There are problems from the view points of strength and stability.
Use the attachments recommended by NEW HOLLAND KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility
•
2.4m (7ft-10in) Arm +Arm (Short)
Use the attachments recommended by NEW HOLLAND KOBELCO. The trouble due to the use in the condition "Use not allowed" described in the above table is not included in our responsibility
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur.
If any other bucket, except for the backhoe bucket, is turned over and used for excavation, damage to the arm and bucket may occur.
2-13
2-13
2. SPECIFICATIONS
2. SPECIFICATIONS
2.9
ENGINE SPECIFICATIONS
2.9
ENGINE SPECIFICATIONS
2.9.1
SPECIFICATIONS
2.9.1
SPECIFICATIONS
Applicable machine
E215B, E215BLC
Engine model
HINO J05E-TG
Total displacement
4 u 112 u 130 (4.41 u 5.12)
cc (cu•in)
5,123 (313)
Total displacement
18.0
Compression ratio
Rated output
Number of cylinderuBoreuStroke
kW (PS) at min
114 (155) at 2,000
Rated output
N•m (lb•ft) at min-1
572 (422) at 1,600
Maximum torque
High idling
min-1
2,000 ± 30
Low idling
min
Maximum torque
Injection starting pressure Thermostat action
-1
-1
MPa (psi) Start/Full open K (°F)
Compression pressure
Valve clearance
Starter capacity Generator capacity (Alternator)
2,000 ± 30
1,000 ± 30
Low idling
min
1,000 ± 30
50 (7,250)
Injection starting pressure
Compression pressure
0.3 mm at cool
14°before top dead point
30°after bottom dead point
Exhaust valve
0.45 mm at cool
Valve clearance
54°before bottom 13°after top dead dead point point
V u kW
24 u 5.0
Starter capacity
VuA
24 u 50
Generator capacity (Alternator)
ø650 (25.6") u suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.89
Dry weight
kg (lbs)
580 (1,280)
g/kW•h (g/ps•h)
217 (160) Front / Rear and Right / Left : 35° 1,063 u 725 u 995 (3ft-5.86in u 28.5in u 39.2in)
mm (in)
Counterclockwise seeing from flywheel side
2-14
-1
MPa (psi)
50 (7,250)
Start/Full open K (°F)
350 (170) / 363 (194) 1-3-4-2
MPa (psi) at min-1
3.4~3.7 (493~537) at 280
Fuel injection timing
Intake valve
L (gal)
-1
Firing order
Close
Engine oil quantity
Dimension (LuWuH)
Thermostat action
Open
Rotating direction
18.0
min-1
Valve clearance
Allowable inclination (Limited by E/G lubrication)
5,123 (313)
High idling
Full level 18.0 (4.76) Low level 15.0 (3.96) Total 20.5 (5.42)
Fuel consumption ratio
cc (cu•in)
572 (422) at 1,600
0°
Cooling fan drive method
4 u 112 u 130 (4.41 u 5.12)
N•m (lb•ft) at min-1
3.4~3.7 (493~537) at 280
Fuel injection timing
mm (in)
114 (155) at 2,000
1-3-4-2 MPa (psi) at min-1
Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger
kW (PS) at min
350 (170) / 363 (194)
Firing order
HINO J05E-TG
Type
mm (in)
Compression ratio
E215B, E215BLC
Engine model
Water-cooled, 4 cycle 4 cylinder direct injection type diesel engine with inter cooler turbo-charger
Type Number of cylinderuBoreuStroke
Applicable machine
0° Valve clearance
Open
Close
Intake valve
0.3 mm at cool
14°before top dead point
30°after bottom dead point
Exhaust valve
0.45 mm at cool
54°before bottom 13°after top dead dead point point
V u kW
24 u 5.0
VuA
24 u 50 ø650 (25.6") u suction type 7 fans, V-belt drive, pulley ratio Crank / Fan= 0.89
Cooling fan drive method
Engine oil quantity
L (gal)
Full level 18.0 (4.76) Low level 15.0 (3.96) Total 20.5 (5.42)
Dry weight
kg (lbs)
580 (1,280)
g/kW•h (g/ps•h)
217 (160)
Fuel consumption ratio Allowable inclination (Limited by E/G lubrication) Dimension (LuWuH)
Front / Rear and Right / Left : 35° 1,063 u 725 u 995 (3ft-5.86in u 28.5in u 39.2in)
mm (in)
Rotating direction
Counterclockwise seeing from flywheel side
2-14
2. SPECIFICATIONS 2.9.2
ENGINE CHARACTERISTIC CURVE (HINO J05E-TG)
2. SPECIFICATIONS 2.9.2
FUEL CONSUMPTION RATE
SHAFT OUTPUT FUEL CONSUMPTION RATE
SHAFT OUTPUT
SHAFT TORQUE
Condition to be measured: The net value is indicated, measuring with cooling fan. marks show the rated point
SHAFT TORQUE
Condition to be measured: The net value is indicated, measuring with cooling fan. marks show the rated point
ENGINE CHARACTERISTIC CURVE (HINO J05E-TG)
ENGINE SPEED (min-1)
ENGINE SPEED (min-1)
Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 217g/kW.h X 114kW X 0.835 X 1000 29.6
. L/h
2-15
: Standard load factor (0.70~0.80) Fuel consumption in regular operation (load factor 0.70~0.80) 20.7 L/h~23.7 L/h
Fuel consumption volume Fuel consumption rate X kW X Load factor ( ) 0.835 X 1000 217g/kW.h X 114kW X 0.835 X 1000 29.6
. L/h
2-15
: Standard load factor (0.70~0.80) Fuel consumption in regular operation (load factor 0.70~0.80) 20.7 L/h~23.7 L/h
2. SPECIFICATIONS
2. SPECIFICATIONS
[MEMO]
[MEMO]
2-16
2-16
3. ATTACHMENT DIMENSIONS
3
3. ATTACHMENT DIMENSIONS
TABLE OF CONTENTS 3.1
TABLE OF CONTENTS
BOOM ................................................................................................................................3-3
3.1
BOOM ................................................................................................................................3-3
3.1.1
BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.1
BOOM DIMENSIONAL DRAWING...........................................................................3-3
3.1.2
BOOM MAINTENANCE STANDARD .......................................................................3-4
3.1.2
BOOM MAINTENANCE STANDARD .......................................................................3-4
3.2
ARM ...................................................................................................................................3-6
3.2
ARM ...................................................................................................................................3-6
3.2.1
ARM DIMENSIONAL DRAWING..............................................................................3-6
3.2.1
ARM DIMENSIONAL DRAWING..............................................................................3-6
3.2.2
ARM MAINTENANCE STANDARD ..........................................................................3-7
3.2.2
ARM MAINTENANCE STANDARD ..........................................................................3-7
3.3
BUCKET ............................................................................................................................3-10
3.3
BUCKET ............................................................................................................................3-10
3.3.1
BUCKET DIMENSIONAL DRAWING .......................................................................3-10
3.3.1
BUCKET DIMENSIONAL DRAWING .......................................................................3-10
3.3.2
BUCKET DIMENSIONAL TABLE .............................................................................3-10
3.3.2
BUCKET DIMENSIONAL TABLE .............................................................................3-10
3.3.3
LUG SECTION DIMENSIONAL DRAWING .............................................................3-11
3.3.3
LUG SECTION DIMENSIONAL DRAWING .............................................................3-11
3.3.4
BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12
3.3.4
BOSS SECTION DIMENSIONAL DRAWING...........................................................3-12
Book Code No. S5YN0322E01 3-1
Book Code No. S5YN0322E01 3-1
3
3. ATTACHMENT DIMENSIONS Issue
Date of Issue
First edition
July, 2007
n
n
3. ATTACHMENT DIMENSIONS Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
3-2
Remarks S5YN0322E01 (NHK Middle East) n (NHK Russia) HS Engine
Issue
Date of Issue
K
First edition
July, 2007
K
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
3-2
Remarks S5YN0322E01 (NHK Middle East) n (NHK Russia) HS Engine
K K
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3.1
BOOM
3.1
BOOM
3.1.1
BOOM DIMENSIONAL DRAWING
3.1.1
BOOM DIMENSIONAL DRAWING
Fig. 3-1 Boom dimensional drawing
Fig. 3-1 Boom dimensional drawing Unit : mm (ft-in)
5.65M (18ft-6in) BOOM No
STD
—
YN02B00403F1
—
NAME
A
Boom length
B
DIMENSION
Unit : mm (ft-in) 5.65M (18ft-6in) BOOM No
—
A
Boom length
Boom foot width
670 (26.4")
—
B
C
Boom end inner width
347 (13.7")
—
D
Boom end outer width
482 (19")
—
E
Height of boom cylinder rod pin
1,008.5 (3'4")
F
Height of arm cylinder (head side) pin
1,203.5 (3'11")
Distance between pins of boss
H
Distance between pins of bracket
I J
YN02B00403F1
—
DIMENSION 5,650 (18'6")
—
Boom foot width
670 (26.4")
—
C
Boom end inner width
347 (13.7")
—
D
Boom end outer width
482 (19")
—
—
E
Height of boom cylinder rod pin
1,008.5 (3'4")
—
—
F
Height of arm cylinder (head side) pin
1,203.5 (3'11")
—
R2,589 (8'6")
—
G
Distance between pins of boss
R2,829.5 (9'3")
—
H
Distance between pins of bracket
Arm cylinder (head side) inner width
126 (4.96")
—
I
Outer width of bracket on the arm cylinder (rod side) mounting
468 (18.4")
—
J
d1
Boom foot pin dia.
ø 90 (3.54")
—
d2
Boom cylinder (rod side) pin dia.
ø 85 (3.35")
d3
Pin dia. of boom end.
d4
Arm cylinder (head side) pin dia.
3-3
—
NAME
5,650 (18'6")
G
STD
R2,589 (8'6")
—
R2,829.5 (9'3")
—
Arm cylinder (head side) inner width
126 (4.96")
—
Outer width of bracket on the arm cylinder (rod side) mounting
468 (18.4")
—
d1
Boom foot pin dia.
ø 90 (3.54")
—
—
d2
Boom cylinder (rod side) pin dia.
ø 85 (3.35")
—
ø 90 (3.54")
—
d3
Pin dia. of boom end.
ø 90 (3.54")
—
ø 85 (3.35")
—
d4
Arm cylinder (head side) pin dia.
ø 85 (3.35")
—
3-3
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3.1.2
3.1.2
BOOM MAINTENANCE STANDARD
(1) Clearance of pin and bushing on boom section
BOOM MAINTENANCE STANDARD
(1) Clearance of pin and bushing on boom section
D
D
A
A
C
C
B
B
Fig. 3-2 Clearance of pin and bushing on boom section
Fig. 3-2 Clearance of pin and bushing on boom section Unit : mm (in)
Standard value Symbol
Item
A
Boom foot
B
Boom cylinder (Head side)
C
Boom cylinder (Rod side)
D
Arm cylinder (Head side)
Pin part No.
Pin dia.
Pin dia. tolerance
+ 0.020 ø 90 (+0.0008) YN02B01719P1 (3.5433) - 0.020 (-0.0008) ø 85 YN02B01720P1 (3.3465)
Bushing i.d. tolerance
Clearance Standard value
Standard value
Repaira Service Remedy ble limit level
+ 0.237 + 0.217 (+0.0085) (+0.0093) + 0.051 + 0.071 (+0.0028) (+0.0020)
+ 0.283 + 0.243 (0.011) (+0.010) + 0.085 + 0.085 (-0.0016) (+0.0033) (+0.0033) 0 - 0.040
+ 0.267 + 0.247 (+0.0097) (+0.0105) YN02B01721P1 + 0.073 + 0.020 + 0.093 (+0.0097) (+0.0037) ø 85 (+0.0008) (3.3465) - 0.020 + 0.272 + 0.252 (-0.0008) (+0.0099) (+0.0107) YN02B01722P1 + 0.077 - 0.099 (-0.0039) (+0.0030)
3-4
Unit : mm (in)
More than 2.0 (0.08)
2.5 (0.1)
Symbol
Item
A
Boom foot
B
Boom cylinder (Head side)
Replace bushing or pin C
Boom cylinder (Rod side)
D
Arm cylinder (Head side)
Pin part No.
Pin dia.
Pin dia. tolerance
+ 0.020 ø 90 (+0.0008) YN02B01719P1 (3.5433) - 0.020 (-0.0008) ø 85 YN02B01720P1 (3.3465)
Bushing i.d. tolerance
Clearance Standard value
+ 0.237 + 0.217 (+0.0085) (+0.0093) + 0.051 + 0.071 (+0.0028) (+0.0020)
+ 0.283 + 0.243 (0.011) (+0.010) + 0.085 + 0.085 (-0.0016) (+0.0033) (+0.0033) 0 - 0.040
+ 0.267 + 0.247 (+0.0097) (+0.0105) YN02B01721P1 + 0.073 + 0.020 + 0.093 (+0.0097) (+0.0037) ø 85 (+0.0008) (3.3465) - 0.020 + 0.272 + 0.252 (-0.0008) (+0.0099) (+0.0107) YN02B01722P1 + 0.077 - 0.099 (-0.0039) (+0.0030)
3-4
Repaira Service Remedy ble limit level
More than 2.0 (0.08)
2.5 (0.1)
Replace bushing or pin
3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section
D
D
3. ATTACHMENT DIMENSIONS (2) Clearance in thrust direction on the boom cylinder installation section
D
C
D
C
C
C
A
A
A
B
A
B
B
B
SECTION C-C
SECTION C-C
SECTION D-D
SECTION D-D SECTION A-A
SECTION A-A
SECTION B-B
SECTION B-B
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section
Fig. 3-3 Clearance in thrust direction on the boom cylinder installation section Unit : mm (in)
Basic size Sec.
Item No. Boom
A-A Boom foot
Boom cylinder B-B (Head side)
C-C
Boom cylinder (Rod side)
Arm cylinder D-D (Head side)
L1
Size 670 (26.4)
Upper frame
676 (26.6)
Boom cylinder
105 (4.13)
L2 Upper frame Boom cylinder Boom
L3
105 (4.13)
L3'
468 (18.4)
Arm cylinder L4 Boom
111 (4.37)
120 (4.72) 126 (4.96)
Clearance X adjusted with shim (total of both sides) Standard value
Repairable level
Service limit
0.5 (0.02) or less
Basic size Remedy
Sec.
Item
No. Length
No. Boom
831 (32.7)
A-A Boom foot
2.5 (0.10)
0.6~1.0 (0.02~0.04)
PL2
0.6~2.0 (0.02~0.08)
3.0 (0.12)
4.0 (0.16)
0.6~1.0 (0.02~0.04)
2.0 (0.08)
2.5 (0.10)
3-5
Pin length
PL1 2.0 (0.08)
Unit : mm (in)
PL3
PL4
241 (9.49)
736 (29.0)
260 (10.2)
Shim adjust ment
Boom cylinder B-B (Head side)
C-C
Boom cylinder (Rod side)
Arm cylinder D-D (Head side)
L1
Size 670 (26.4)
Upper frame
676 (26.6)
Boom cylinder
105 (4.13)
L2 Upper frame Boom cylinder Boom
L3
105 (4.13)
L3'
468 (18.4)
Arm cylinder L4 Boom
111 (4.37)
120 (4.72) 126 (4.96)
Clearance X adjusted with shim (total of both sides) Standard value
Repairable level
Service limit
0.5 (0.02) or less 2.0 (0.08)
Pin length Remedy No. Length
PL1
831 (32.7)
PL2
241 (9.49)
2.5 (0.10)
0.6~1.0 (0.02~0.04)
0.6~2.0 (0.02~0.08)
3.0 (0.12)
4.0 (0.16)
PL3
736 (29.0)
0.6~1.0 (0.02~0.04)
2.0 (0.08)
2.5 (0.10)
PL4
260 (10.2)
3-5
Shim adjust ment
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3.2
ARM
3.2
ARM
3.2.1
ARM DIMENSIONAL DRAWING
3.2.1
ARM DIMENSIONAL DRAWING
VIEW J
VIEW J
SECTION X-X
SECTION X-X
SECTION Z-Z
SECTION Y-Y
Fig. 3-4 ARM DIMENSIONAL DRAWING
2.94m (9ft-8in) ARM Code
YN12B00904F1
NAME
DIMENSION
Code
SECTION Z-Z
SECTION Y-Y
NAME
Fig. 3-4 ARM DIMENSIONAL DRAWING
Unit : mm (ft-in)
2.94m (9ft-8in) ARM
DIMENSION
Code
YN12B00904F1
NAME
Unit : mm (ft-in)
DIMENSION
Code
NAME
DIMENSION
C
Arm length
2,940 (9'8")
N
Bracket inner width
126 (4.96")
C
Arm length
2,940 (9'8")
N
Bracket inner width
126 (4.96")
D
Distance between pins of boss and bracket
R874 (34.4")
O
Bracket inner width
111 (4.37")
D
Distance between pins of boss and bracket
R874 (34.4")
O
Bracket inner width
111 (4.37")
D1 I.D of boss
ø110 (4.33")
P
Idler link dimension
630 (24.8")
D1 I.D of boss
ø110 (4.33")
P
Idler link dimension
630 (24.8")
D2 I.D of boss
ø85 (3.35")
Q
Bucket link dimension
610 (24")
D2 I.D of boss
ø85 (3.35")
Q
Bucket link dimension
610 (24")
D4 I.D of boss
ø105 (4.13")
R
Height between pins of boss and center
31 (1.22")
D4 I.D of boss
ø105 (4.13")
R
Height between pins of boss and center
31 (1.22")
E
Distance between pins of boss and bracket
R2,169 (7'1")
d1
Pin dia.
ø80 (3.15")
E
Distance between pins of boss and bracket
R2,169 (7'1")
d1
Pin dia.
ø80 (3.15")
F
Distance between pins of boss and boss
R420 (16.5")
d2
Pin dia.
ø70 (2.76")
F
Distance between pins of boss and boss
R420 (16.5")
d2
Pin dia.
ø70 (2.76")
G
Height between pins of boss and bracket
665.5 (26.2")
d3
Pin dia.
ø85 (3.35")
G
Height between pins of boss and bracket
665.5 (26.2")
d3
Pin dia.
ø85 (3.35")
H
Height between pins of boss and bracket
312 (12.3")
d4
Pin dia.
ø90 (3.54")
H
Height between pins of boss and bracket
312 (12.3")
d4
Pin dia.
ø90 (3.54")
K
Arm top end boss width
325 (12.8")
d5
Pin dia.
ø80 (3.15")
K
Arm top end boss width
325 (12.8")
d5
Pin dia.
ø80 (3.15")
L
Arm link section boss width
323 (12.7")
L
Arm link section boss width
323 (12.7")
M
Boss width
342 (13.5")
M
Boss width
342 (13.5")
3-6
3-6
3. ATTACHMENT DIMENSIONS 3.2.2
ARM MAINTENANCE STANDARD
3.2.2
(1) Clearance of pin and bushing
ARM MAINTENANCE STANDARD
(1) Clearance of pin and bushing
E
E
F
D, D'
B
3. ATTACHMENT DIMENSIONS
B
A
F
D, D'
A
C
C
G Fig. 3-5 Clearance of pin and bushing on arm section
G Fig. 3-5 Clearance of pin and bushing on arm section
Unit : mm (in) Standard dimensions No.
A
Item
Pin part No.
Pin dia.
Arm point YN12B02215P1
B
Bucket link (Bucket side)
C
Idler link (Connected part YN12B02216P1 of arm)
D
Bucket link (Idler link side)
ø80 (3.1496)
Pin dia. tolerance
–0.020 (-0.0008) –0.060 (-0.0024)
ø70 (2.7559) 0 (0) –0.040 (-0.0016)
YN12B02217P1 D'
Bucket cylinder (Rod side)
E
Bucket cylinder YN12B02218P1 (Head side)
F
Arm cylinder (Rod side)
YN02B01722P1
ø85 (3.3465)
G
Arm foot (Connected part YN12B02094P1 of boom)
ø90 (3.5433)
ø80 (3.1496)
+0.020 (+0.0008) –0.020 (-0.0008)
3-7
Clearance
Bushing i.d. tolerance
Standard value
+0.253 (+0.0100) +0.080 (+0.0031)
+0.313 (+0.0123) +0.100 (+0.0039)
+0.284 (+0.0112) +0.156 (+0.0061)
+0.364 (+0.0143) +0.0176 (+0.0069)
+0.253 (+0.0100) +0.194 (+0.0076)
+0.293 (+0.0115) +0.194 (+0.0076)
+0.232 (+0.009) +0.161 (+0.0063)
+0.272 (+0.0107) +0161 (+0.0063)
+0.278 (+0.0109) +0.141 (+0.0056)
Unit : mm (in)
+0.318 (+0.0125) +0.141 (+0.0056) +0.298 (+0.0117) +0.161 (+0.0063)
+0.252 (+0.0099) +0.079 (+0.0031)
+0.272 (+0.0107) +0.059 (+0.0023)
+0.214 (+0.008) +0.067 (+0.003)
+0.234 (+0.0090) +0.047 (+0.0020)
Repairable level
Standard dimensions Service limit
Remedy
No.
A
2.0 (0.08)
2.5 (0.01)
Item
Pin part No.
Pin dia.
Arm point YN12B02215P1
ø80 (3.1496)
B
Bucket link (Bucket side)
C
Idler link (Connected part YN12B02216P1 of arm)
ø70 (2.7559)
D
Bucket link (Idler link side)
Replace bushing or pin
Pin dia. tolerance
–0.020 (-0.0008) –0.060 (-0.0024)
0 (0) –0.040 (-0.0016)
YN12B02217P1 D'
Bucket cylinder (Rod side)
E
Bucket cylinder YN12B02218P1 (Head side)
F
Arm cylinder (Rod side)
YN02B01722P1
ø85 (3.3465)
G
Arm foot (Connected part YN12B02094P1 of boom)
ø90 (3.5433)
ø80 (3.1496)
Standard value
+0.253 (+0.0100) +0.080 (+0.0031)
+0.313 (+0.0123) +0.100 (+0.0039)
+0.284 (+0.0112) +0.156 (+0.0061)
+0.364 (+0.0143) +0.0176 (+0.0069)
+0.253 (+0.0100) +0.194 (+0.0076)
+0.293 (+0.0115) +0.194 (+0.0076)
+0.232 (+0.009) +0.161 (+0.0063)
+0.272 (+0.0107) +0161 (+0.0063)
+0.278 (+0.0109) +0.141 (+0.0056)
+0.020 (+0.0008) –0.020 (-0.0008)
3-7
Clearance
Bushing i.d. tolerance
+0.318 (+0.0125) +0.141 (+0.0056) +0.298 (+0.0117) +0.161 (+0.0063)
+0.252 (+0.0099) +0.079 (+0.0031)
+0.272 (+0.0107) +0.059 (+0.0023)
+0.214 (+0.008) +0.067 (+0.003)
+0.234 (+0.0090) +0.047 (+0.0020)
Repairable level
Service limit
2.0 (0.08)
2.5 (0.01)
Remedy
Replace bushing or pin
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
(2) Clearance of arm and cylinder installing sections in thrust direction
(2) Clearance of arm and cylinder installing sections in thrust direction
E D, D'
B C
B A
A
D, D'
F G
L1
X
PL1 SECTION A-A X2
L2
X
PL3
X
SECTION E-E
PL7 X7
L4
L1
F G
PL6 SECTION F-F
L7
L3 X
PL1 SECTION A-A X2
L2
X4' L4' PL2 SECTION B-B
D, D'
X
L6
F
E
C
G
PL5 X L5
SECTION C-C
C
B A
A
X1
L3
D, D'
B
F
E
C X1
E
G
PL5 L5
X
PL3 SECTION C-C X
SECTION E-E
PL7 X7
L4
L6
PL6 SECTION F-F
L7
X4' L4'
PL4 SECTION D-D
SECTION G-G
PL2 SECTION B-B
PL4 SECTION D-D
SECTION G-G
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
Fig. 3-6 Clearance of arm and cylinder installing sections in thrust direction
3-8
3-8
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
Unit : mm (in) Basic size Sec.
Item No. Arm
A-A Arm point
L1 Bucket Link side
B-B Bucket link
L2 Bucket
C-C
Idler link (Arm connection)
Bucket link D-D (Idler link connection)
D’-D’
E-E
Bucket link (Rod side)
Bucket cylinder (Head side)
Arm cylinder F-F (Rod side)
Arm
L3
Link side
325 (12.79)
323 (12.72)
L4’
323 (12.72) 105 (4.13)
Link side
111 (4.37)
Head side
105 (4.13)
L5 Arm
111 (4.37)
Rod side
120 (9.72)
L6 Arm
126 (4.96)
Arm
342 (13.46)
L7 Boom
Basic size Remedy
347 (13.66)
Sec.
Item No. Arm
2.0 (0.08)
PL1
A-A Arm point
—
L1 Bucket
481 (18.9)
Link side
PL2
B-B Bucket link
L2 Bucket
0.5 (0.02)
1.0 (0.04)
2.5 (0.10)
C-C
PL3
L4
Rod side
G-G Arm foot
—
327 (12.87)
Unit : mm (in)
Pin length
Standard Repairable Service limit No. Length level value
325 (12.79) 1.0 (0.04) or less 326 (12.83)
-
Rod side Link side
Size
Clearance X adjusted with shim (total of both sides)
0.6~1.0 (0.024~0.04)
427 (16.8)
2.0 (0.08)
PL4
PL5 0.6~2.0 (0.024~0.08)
3.0 (0.12)
3-9
1.0 (0.04)
(Arm connection)
Bucket link D-D (Idler link connection)
D’-D’
E-E
Bucket link (Rod side)
Bucket cylinder (Head side)
4.0 (0.16) PL6
0.5 (0.02)
235 (9.25)
Shim adjust -ment
Idler link
2.5 (0.10)
PL7
260 (10.2)
505 (19.9)
Arm cylinder F-F (Rod side)
Arm
L3
Link side
325 (12.79)
L4’
323 (12.72) 105 (4.13)
Link side
111 (4.37)
Head side
105 (4.13)
L5 Arm
111 (4.37)
Rod side
120 (9.72)
L6 Arm
126 (4.96)
Arm
342 (13.46)
L7 Boom
Remedy
PL1 481 (18.9)
—
0.5 (0.02)
1.0 (0.04)
PL2
2.5 (0.10)
PL3
L4
Rod side
G-G Arm foot
2.0 (0.08)
—
327 (12.87) 323 (12.72)
Pin length
Standard Repairable Service limit No. Length level value
325 (12.79) 1.0 (0.04) or less 326 (12.83)
-
Rod side Link side
Size
Clearance X adjusted with shim (total of both sides)
347 (13.66)
0.6~1.0 (0.024~0.04)
0.6~2.0 (0.024~0.08)
0.5 (0.02)
3-9
427 (16.8)
2.0 (0.08)
3.0 (0.12)
1.0 (0.04)
PL4
PL5
235 (9.25)
PL6
260 (10.2)
PL7
505 (19.9)
4.0 (0.16)
2.5 (0.10)
Shim adjust -ment
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3.3
BUCKET
3.3
BUCKET
3.3.1
BUCKET DIMENSIONAL DRAWING
3.3.1
BUCKET DIMENSIONAL DRAWING
(1) Hoe bucket
(1) Hoe bucket
Fig. 3-7 Bucket dimensional drawing No. A
NAME
No.
Fig. 3-7 Bucket dimensional drawing NAME
No.
Distance between pin and bracket
G
Inner width of bucket bottom
A
NAME
No.
NAME
Distance between pin and bracket
G
Inner width of bucket bottom
B
Distance between bucket pin and tooth end
H
Bucket outer width of front side
B
Distance between bucket pin and tooth end
H
Bucket outer width of front side
C
Inner width of bucket top end
I
Pitch between teeth
C
Inner width of bucket top end
I
Pitch between teeth
D
Inner width of lug
Io
Pitch between teeth
D
Inner width of lug
Io
Pitch between teeth
E
Inner width of bracket
d1
Outer dia. of bushing
E
Inner width of bracket
d1
Outer dia. of bushing
F
Outer width of side cutter
d2
Pin dia.
F
Outer width of side cutter
d2
Pin dia.
3.3.2
BUCKET DIMENSIONAL TABLE
3.3.2
BUCKET DIMENSIONAL TABLE
Unit : mm (ft-in) Type
Hoe bucket
Unit : mm (ft-in) Type
Capacity
[STD] 0.80 m3 (1.05 cu•yd)
0.51 m3 (0.67 cu•yd))
0.70 m3 (0.92 cu•yd))
0.93 m3 (1.21 cu•yd))
Part No.
YN61B00316F1
YN61B00287F1
YN61B00286F1
A
R430 (16.9")
m
m
B
R1,440 (4'9")
m
C
1,003 (3'3")
D E
Hoe bucket
Capacity
[STD] 0.80 m3 (1.05 cu•yd)
0.51 m3 (0.67 cu•yd))
0.70 m3 (0.92 cu•yd))
0.93 m3 (1.21 cu•yd))
YN61B00288F1
Part No.
YN61B00316F1
YN61B00287F1
YN61B00286F1
YN61B00288F1
m
A
R430 (16.9")
m
m
m
m
m
B
R1,440 (4'9")
m
m
m
712 (28")
925 (36.4")
1,176 (3'10")
C
1,003 (3'3")
712 (28")
925 (36.4")
1,176 (3'10")
399 (15.7")
m
m
m
D
399 (15.7")
m
m
m
327 (12.9")
m
m
m
E
327 (12.9")
m
m
m
F
1,157 (4')
868 (34.2")
1,079 (3'6")
1,330 (4'4")
F
1,157 (4')
868 (34.2")
1,079 (3'6")
1,330 (4'4")
G
863 (34")
572 (22.5")
785 (30.9")
1,036 (3'5")
G
863 (34")
572 (22.5")
785 (30.9")
1,036 (3'5")
H
1,057 (3'6")
766 (30.2")
979 (38.5")
1,230 (4')
H
1,057 (3'6")
766 (30.2")
979 (38.5")
1,230 (4')
I
224 (8.82")
300 (11.8")
203 (7.99")
266 (10.5")
I
224 (8.82")
300 (11.8")
203 (7.99")
266 (10.5")
IO
224 (8.82")
300 (11.8")
203 (7.99")
266 (10.5")
IO
224 (8.82")
300 (11.8")
203 (7.99")
266 (10.5")
d1
ø 95 (3.74")
m
m
m
d1
ø 95 (3.74")
m
m
m
d2
ø 80 (3.15")
m
m
m
d2
ø 80 (3.15")
m
m
m
3-10
3-10
3. ATTACHMENT DIMENSIONS 3.3.3
LUG SECTION DIMENSIONAL DRAWING
3. ATTACHMENT DIMENSIONS 3.3.3
LUG SECTION DIMENSIONAL DRAWING
B
X
J
A
N
X BOSS YB61B01002P1
M
N
E
H SHIM
1
Five shims are installed at shipping
3-G
B
F
D
Apply rust prevention oil
19 (0.748)
3-G
Insert this pin flush with surface
BOSS YB61B01002P1
SECTION X-X
DETAIL B
BOSS YB61B01002P1
M
28 (1.10)
Apply rust prevention oil
19 (0.748)
J
A
X 28 (1.10)
B
X
B
F
D
E
H SHIM
1
Five shims are installed at shipping
Insert this pin flush with surface
SECTION X-X
DETAIL B
Fig. 3-8 Dimension of lug section
Fig. 3-8 Dimension of lug section
N
[STD] Hoe bucket
Screw hole P.C.D
M
Boss width.
J
Boss outer dia.
Screw hole P.C.D
H
Boss width.
Boss width.
G
Screw dia.
Boss outer dia.
F
Boss outer dia.
Boss width.
E
Part No. of bucket
Spring pin dia.
Screw dia.
D
Capacity of bucket m3 (cu.yd)
Hole dia.
Boss outer dia.
B
Type of bucket
Lug plate thickness
Spring pin dia.
A
Unit : mm (ft-in)
Pin hole dia.
Hole dia.
Part No. of bucket
Lug plate thickness
Capacity of bucket m3 (cu.yd)
Pin hole dia.
Unit : mm (ft-in)
Type of bucket
BOSS YB61B01002P1
A
B
D
E
F
G
H
J
M
N
[STD]
0.80 (1.05)
YN61B00316F1
0.51 (0.67)
YN61B00287F1
0.70 (0.92)
YN61B00286F1
0.93 (1.21)
YN61B00288F1
80 25 95 13 180 (3.15") (0.984") (3.74") (0.512") (7.09")
3-11
M16
25 170 36 140 (0.984") (6.69") (1.42") (5.51")
Hoe bucket
0.80 (1.05)
YN61B00316F1
0.51 (0.67)
YN61B00287F1
0.70 (0.92)
YN61B00286F1
0.93 (1.21)
YN61B00288F1
80 25 95 13 180 (3.15") (0.984") (3.74") (0.512") (7.09")
3-11
M16
25 170 36 140 (0.984") (6.69") (1.42") (5.51")
3. ATTACHMENT DIMENSIONS
3. ATTACHMENT DIMENSIONS
3.3.4
3.3.4
BOSS SECTION DIMENSIONAL DRAWING
BOSS SECTION DIMENSIONAL DRAWING
A
A
H
5 (0.197")
oD
oB
oA
oC
oG
oD
oB
oC
oG
oA
H
5 (0.197")
15 (0.591")
15 (0.591")
E
E F
F
Fig. 3-9 Dimension of boss section
Fig. 3-9 Dimension of boss section Unit : mm (ft-in)
Type
Capacity of
of
bucket
bucket
m3 (cu•yd)
Part No. of
Part No.
bucket
of boss
øA
øB
øC
øD
E
F
øG
H
I
Unit : mm (ft-in) Type
Capacity of
of
bucket
bucket
m3 (cu•yd)
[STD] Hoe bucket
Part No. of
Part No.
bucket
of boss
øA
øB
øC
øD
E
F
øG
H
I
[STD]
0.80 (1.05)
YN61B00316F1
0.51 (0.67)
YN61B00287F1 YB61B01002P1
0.70(0.92)
YN61B00286F1
0.93(1.21)
YN61B00288F1
114.3
84
105.5
111.5
23
38
17
13
2.5
Hoe
(4.50")
(3.31")
(4.15")
(4.39")
(0.91")
(1.50")
(0.669")
(0.512")
(0.098")
bucket
3-12
0.80 (1.05)
YN61B00316F1
0.51 (0.67)
YN61B00287F1 YB61B01002P1
0.70(0.92)
YN61B00286F1
0.93(1.21)
YN61B00288F1
114.3
84
105.5
111.5
23
38
17
13
2.5
(4.50")
(3.31")
(4.15")
(4.39")
(0.91")
(1.50")
(0.669")
(0.512")
(0.098")
3-12
11. TOOLS
11. TOOLS
11
TABLE OF CONTENTS
11
TABLE OF CONTENTS
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-3
11.1 TIGHTENING TORQUES FOR CAPSCREWS AND NUTS ............................................11-3
11.2 SCREW SIZE...................................................................................................................11-5
11.2 SCREW SIZE...................................................................................................................11-5
11.2.1
CAPSCREW (BOLT) ..............................................................................................11-5
11.2.1
CAPSCREW (BOLT) ..............................................................................................11-5
11.2.2
CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.2
CAPSCREW (SOCKET BOLT) ..............................................................................11-5
11.2.3
SOCKET SET SCREW...........................................................................................11-5
11.2.3
SOCKET SET SCREW...........................................................................................11-5
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3 TIGHTENING TORQUE FOR HOSE AND FITTING .......................................................11-6
11.3.1
JOINT (O-RING TYPE)...........................................................................................11-6
11.3.1
JOINT (O-RING TYPE)...........................................................................................11-6
11.3.2
HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.2
HYDRAULIC HOSE (30° FLARE TYPE) ................................................................11-6
11.3.3
JOINT (ORS TYPE) ................................................................................................11-6
11.3.3
JOINT (ORS TYPE) ................................................................................................11-6
11.3.4
SPLIT FLANGE ......................................................................................................11-6
11.3.4
SPLIT FLANGE ......................................................................................................11-6
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.4 TIGHTENING TORQUES FOR NUTS AND SLEEVES...................................................11-7
11.5 PLUG ...............................................................................................................................11-8
11.5 PLUG ...............................................................................................................................11-8
11.5.1
PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.1
PLUG FOR HYDRAULIC PIPE JOINT ...................................................................11-8
11.5.2
PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.5.2
PLUG FOR HYDRAULIC EQUIPMENT .................................................................11-9
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.6 SPECIAL SPANNER FOR TUBE ....................................................................................11-11
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.7 SPECIAL TOOLS.............................................................................................................11-12
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14
11.8 APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND......11-14
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9 SUCTION STOPPER.......................................................................................................11-15
11.9.1
COMPONENTS ......................................................................................................11-15
11.9.1
COMPONENTS ......................................................................................................11-15
11.9.2
DIMENSION ...........................................................................................................11-15
11.9.2
DIMENSION ...........................................................................................................11-15
11.9.3
APPLICABLE MODEL ............................................................................................11-15
11.9.3
APPLICABLE MODEL ............................................................................................11-15
11.10 COUNTER WEIGHT LIFTING JIG ..................................................................................11-16
11.10 COUNTER WEIGHT LIFTING JIG ..................................................................................11-16
11.11 UPPER FRAME LIFTING JIG..........................................................................................11-17
11.11 UPPER FRAME LIFTING JIG..........................................................................................11-17
11.12 ENGINE MOUNTING PEDESTAL ...................................................................................11-18
11.12 ENGINE MOUNTING PEDESTAL ...................................................................................11-18
11.13 TRACK SPRING SET JIG ...............................................................................................11-19
11.13 TRACK SPRING SET JIG ...............................................................................................11-19
Book Code No. S5YN1122E01 11-1
Book Code No. S5YN1122E01 11-1
11. TOOLS
11. TOOLS
Issue
Date of Issue
First edition
July, 2007
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
11-2
Remarks S5YN1122E01 (NHK Middle East) n (NHK Russia) HS Engine
Issue
Date of Issue
K
First edition
July, 2007
K
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
11-2
Remarks S5YN1122E01 (NHK Middle East) n (NHK Russia) HS Engine
K K
11. TOOLS
11.1
TIGHTENING TORQUES FOR CAPSCREWS AND NUTS
11. TOOLS
11.1
TIGHTENING TORQUES FOR CAPSCREWS AND NUTS
Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening of bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Tables Table11-1 and Table11-2 indicate tightening torques applicable to cases where no special note is given. Overtightening of bolts may result in a twist-off and a fracture under load. Insufficient tightening may lead to a loosening or loss of bolts. Always tighten bolts to proper torques.
Table11-1 Tightening torque for metric coarse threads (not plated)
Table11-1 Tightening torque for metric coarse threads (not plated) Unit : N•m (lbf•ft)
Classification Nominal size
4.8T
7T
Unit : N•m (lbf•ft)
10.9T
Classification
No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
Nominal size
4.8T
7T
10.9T
No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
M6
P=1
4.4±0.5 (3.2±0.4)
3.7±0.4 (2.7±0.3)
9.6±1.0 (7.1±0.7)
8.1±0.8 (6.0±0.6)
17.4±1.8 (12.8±1.3)
14.7±1.5 (10.8±1.1)
M6
P=1
4.4±0.5 (3.2±0.4)
3.7±0.4 (2.7±0.3)
9.6±1.0 (7.1±0.7)
8.1±0.8 (6.0±0.6)
17.4±1.8 (12.8±1.3)
14.7±1.5 (10.8±1.1)
M8
P=1.25
10.7±1.1 (7.9±0.8)
9.0±0.9 (6.6±0.7)
23.5±2.0 (17.3±1.5)
19.6±2.0 (14.5±1.5)
42.2±3.9 (31.1±2.9)
35.3±3.9 (26.0±2.9)
M8
P=1.25
10.7±1.1 (7.9±0.8)
9.0±0.9 (6.6±0.7)
23.5±2.0 (17.3±1.5)
19.6±2.0 (14.5±1.5)
42.2±3.9 (31.1±2.9)
35.3±3.9 (26.0±2.9)
M10
P=1.5
21.6±2.0 (15.9±1.4)
17.9±1.8 (13.2±1.3)
46.1±4.9 (34.0±3.6)
39.2±3.9 (28.9±2.9)
83.4±8.8 (61.5±6.5)
70.6±6.9 (52.1±5.1)
M10
P=1.5
21.6±2.0 (15.9±1.4)
17.9±1.8 (13.2±1.3)
46.1±4.9 (34.0±3.6)
39.2±3.9 (28.9±2.9)
83.4±8.8 (61.5±6.5)
70.6±6.9 (52.1±5.1)
M12
P=1.75
36.3±3.9 (26.8±2.9)
31.4±2.9 (23.2±2.1)
79.4±7.8 (58.6±5.8)
66.7±6.9 (49.2±5.1)
143±15 (105±11)
121±12 (89.2±8.9)
M12
P=1.75
36.3±3.9 (26.8±2.9)
31.4±2.9 (23.2±2.1)
79.4±7.8 (58.6±5.8)
66.7±6.9 (49.2±5.1)
143±15 (105±11)
121±12 (89.2±8.9)
M14
P=2
57.9±5.9 (42.7±4.4)
49.0±4.9 (36.1±3.6)
126±13 (92.9±9.6)
106±10 (78.2±7.4)
226±20 (167±15)
191±19 (141±14)
M14
P=2
57.9±5.9 (42.7±4.4)
49.0±4.9 (36.1±3.6)
126±13 (92.9±9.6)
106±10 (78.2±7.4)
226±20 (167±15)
191±19 (141±14)
M16
P=2
88.3±8.8 (65.1±6.5)
74.5±6.9 (55.0±5.1)
191±20 (141±15)
161±16 (119±12)
343±39 (253±29)
284±29 (209±21)
M16
P=2
88.3±8.8 (65.1±6.5)
74.5±6.9 (55.0±5.1)
191±20 (141±15)
161±16 (119±12)
343±39 (253±29)
284±29 (209±21)
M18
P=2.5
122±12 (90.0±8.9)
103±10 (75.8±7.2)
265±29 (195±21)
226±20 (167±15)
481±49 (355±36)
402±39 (297±29)
M18
P=2.5
122±12 (90.0±8.9)
103±10 (75.8±7.2)
265±29 (195±21)
226±20 (167±15)
481±49 (355±36)
402±39 (297±29)
M20
P=2.5
172±17 (127±13)
144±14 (106±10)
373±39 (275±29)
314±29 (232±21)
667±69 (492±51)
559±59 (412±44)
M20
P=2.5
172±17 (127±13)
144±14 (106±10)
373±39 (275±29)
314±29 (232±21)
667±69 (492±51)
559±59 (412±44)
M22
P=2.5
226±20 (167±15)
192±20 (142±15)
500±49 (369±36)
422±39 (311±29)
902±88 (665±65)
755±78 (557±58)
M22
P=2.5
226±20 (167±15)
192±20 (142±15)
500±49 (369±36)
422±39 (311±29)
902±88 (665±65)
755±78 (557±58)
M24
P=3
294±29 (217±21)
235±29 (173±21)
637±69 (470±51)
520±49 (383±36)
1160±118 (856±87)
941±98 (694±72)
M24
P=3
294±29 (217±21)
235±29 (173±21)
637±69 (470±51)
520±49 (383±36)
1160±118 (856±87)
941±98 (694±72)
M27
P=3
431±39 (318±29)
353±39 (260±29)
941±98 (694±72)
765±78 (564±58)
1700±167 (1250±123)
1370±137 (1010±101)
M27
P=3
431±39 (318±29)
353±39 (260±29)
941±98 (694±72)
765±78 (564±58)
1700±167 (1250±123)
1370±137 (1010±101)
M30
P=3.5
588±59 (434±44)
490±49 (361±36)
1285±127 (948±94)
1079±108 (796±80)
2300±235 (1700±173)
1940±196 (1430±145)
M30
P=3.5
588±59 (434±44)
490±49 (361±36)
1285±127 (948±94)
1079±108 (796±80)
2300±235 (1700±173)
1940±196 (1430±145)
M33
P=3.5
794±78 (586±58)
667±69 (492±51)
1726±177 (1270±131)
1451±147 (1070±108)
3110±314 (2290±232)
2610±265 (1930±195)
M33
P=3.5
794±78 (586±58)
667±69 (492±51)
1726±177 (1270±131)
1451±147 (1070±108)
3110±314 (2290±232)
2610±265 (1930±195)
M36
P=4
1030±98 (760±72)
863±88 (637±65)
2226±226 (1640±167)
1863±186 (1370±137)
4010±402 (2960±297)
3360±333 (2480±246)
M36
P=4
1030±98 (760±72)
863±88 (637±65)
2226±226 (1640±167)
1863±186 (1370±137)
4010±402 (2960±297)
3360±333 (2480±246)
11-3
11-3
11. TOOLS
11. TOOLS Table11-2 Tightening torques for metric fine threads (not plated)
Table11-2 Tightening torques for metric fine threads (not plated)
Torque value Unit : N•m (lbf•ft) Classification Nominal size
4.8T
7T
Torque value Unit : N•m (lbf•ft)
10.9T
Classification
No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
Nominal size
4.8T
7T
10.9T
No lubrication Oil lubrication No lubrication Oil lubrication No lubrication Oil lubrication
M8
P=1.0
11.3±1.1 (8.3±0.8)
9.5±1.0 (7.0±0.7)
24.5±2.0 (18.1±1.5)
20.6±2.0 (15.2±1.5)
44.1±3.9 (32.5±2.9)
37.3±3.9 (27.5±2.9)
M8
P=1.0
11.3±1.1 (8.3±0.8)
9.5±1.0 (7.0±0.7)
24.5±2.0 (18.1±1.5)
20.6±2.0 (15.2±1.5)
44.1±3.9 (32.5±2.9)
37.3±3.9 (27.5±2.9)
M10
P=1.25
22.6±2.0 (16.7±1.5)
18.7±1.9 (13.8±1.4)
48.1±4.9 (35.5±3.6)
41.2±3.9 (30.3±2.9)
87.3±8.8 (64.4±6.5)
73.5±6.9 (54.2±5.1)
M10
P=1.25
22.6±2.0 (16.7±1.5)
18.7±1.9 (13.8±1.4)
48.1±4.9 (35.5±3.6)
41.2±3.9 (30.3±2.9)
87.3±8.8 (64.4±6.5)
73.5±6.9 (54.2±5.1)
M12
P=1.25
39.2±3.9 (28.9±2.9)
33.3±2.9 (24.6±2.1)
85.3±8.8 (62.9±6.5)
71.6±6.9 (52.8±5.1)
154±16 (114±12)
129±13 (95.2±9.6)
M12
P=1.25
39.2±3.9 (28.9±2.9)
33.3±2.9 (24.6±2.1)
85.3±8.8 (62.9±6.5)
71.6±6.9 (52.8±5.1)
154±16 (114±12)
129±13 (95.2±9.6)
M16
P=1.5
92.2±8.8 (68.0±6.5)
77.5±7.8 (57.2±5.8)
196±20 (145±15)
169±17 (125±13)
363±39 (268±29)
304±29 (224±21)
M16
P=1.5
92.2±8.8 (68.0±6.5)
77.5±7.8 (57.2±5.8)
196±20 (145±15)
169±17 (125±13)
363±39 (268±29)
304±29 (224±21)
M20
P=1.5
186±19 (137±14)
155±16 (114±12)
402±39 (297±29)
333±29 (246±21)
726±69 (535±51)
608±59 (448±44)
M20
P=1.5
186±19 (137±14)
155±16 (114±12)
402±39 (297±29)
333±29 (246±21)
726±69 (535±51)
608±59 (448±44)
M24
P=2
314±29 (232±21)
265±29 (195±21)
686±69 (506±51)
569±59 (420±44)
1240±118 (915±87)
1030±98 (760±72)
M24
P=2
314±29 (232±21)
265±29 (195±21)
686±69 (506±51)
569±59 (420±44)
1240±118 (915±87)
1030±98 (760±72)
M30
P=2
637±59 (470±44)
530±49 (391±36)
1390±137 (1030±101)
1157±118 (853±87)
2500±255 (1840±188)
2080±206 (1530±152)
M30
P=2
637±59 (470±44)
530±49 (391±36)
1390±137 (1030±101)
1157±118 (853±87)
2500±255 (1840±188)
2080±206 (1530±152)
M33
P=2
853±88 (629±65)
706±70 (521±52)
1860±186 (1370±137)
1550±155 (1140±114)
3350±334 (2470±246)
2790±275 (2060±203)
M33
P=2
853±88 (629±65)
706±70 (521±52)
1860±186 (1370±137)
1550±155 (1140±114)
3350±334 (2470±246)
2790±275 (2060±203)
M36
P=3
1070±108 (789±80)
892±88 (658±65)
2330±226 (1720±167)
1940±196 (1430±145)
4200±422 (3100±311)
3500±353 (2580±260)
M36
P=3
1070±108 (789±80)
892±88 (658±65)
2330±226 (1720±167)
1940±196 (1430±145)
4200±422 (3100±311)
3500±353 (2580±260)
11-4
11-4
11. TOOLS
11. TOOLS
11.2
SCREW SIZE
11.2
SCREW SIZE
11.2.1
CAPSCREW (BOLT)
11.2.1
CAPSCREW (BOLT)
Nominal screw size (d) M6
B mm Tool size 10
Nominal screw size (d)
B mm
Nominal screw size (d)
Tool size
M36
55
M6
d
B mm Tool size 10
Nominal screw size (d)
B mm Tool size
M36
55
M8
13
M42
65
M8
13
M42
65
M10
17
M45
70
M10
17
M45
70
M12
19
M48
75
M12
19
M48
75
(M14)
22
M56
85
(M14)
22
M56
85
B
M16
27
(M60)
90
M16
27
(M60)
90
(M18)
27
M64
95
(M18)
27
M64
95
M20
30
(M68)
100
M20
30
(M68)
100
(M22)
32
M72
105
(M22)
32
M72
105
M24
36
M76
110
M24
36
M76
110
(M27)
41
M80
115
(M27)
41
M80
115
M30
46
M30
46
11.2.2
CAPSCREW (SOCKET BOLT)
Nominal screw size (d)
B mm Tool size
Nominal screw size (d)
11.2.2 B mm
B mm Tool size
Nominal screw size (d)
B mm Tool size
(M3)
2.5
M20
17
(M3)
2.5
M20
17
(M4)
3
(M22)
17
(M4)
3
(M22)
17
(M5)
5
M24
19
(M5)
5
M24
19
M6
5
(M27)
19
M6
5
(M27)
19
M8
6
M30
22
M8
6
M30
22
M10
8
M36
27
M10
8
M36
27
M12
10
M42
32
M12
10
M42
32
M14
12
(M45)
32
M14
12
(M45)
32
M16
14
M48
36
M16
14
M48
36
(M18)
14
M52
36
(M18)
14
M52
36
11.2.3
SOCKET SET SCREW
Nominal screw size (d)
B mm Tool size
Nominal screw size (d)
11.2.3 B mm
d
Tool size
SOCKET SET SCREW
Nominal screw size (d)
B mm Tool size
Nominal screw size (d)
B mm
1.27
M8
4
M2.5
1.27
M8
4
M3
1.5
M10
5
M3
1.5
M10
5
M4
2
M12
6
M4
2
M12
6
M5
2.5
M16
8
M5
2.5
M16
8
M6
3
M20
10
M6
3
M20
10
11-5
d
Tool size
M2.5
B
B
CAPSCREW (SOCKET BOLT)
Nominal screw size (d)
Tool size
d
B
11-5
11. TOOLS
11. TOOLS
11.3
TIGHTENING TORQUE FOR HOSE AND FITTING
11.3
TIGHTENING TORQUE FOR HOSE AND FITTING
11.3.1
JOINT (O-RING TYPE)
11.3.1
JOINT (O-RING TYPE)
11.3.2
Size (PF)
Wrench (mm)
Tightening torque N•m (lbf•ft)
Size (PF)
Wrench (mm)
Tightening torque N•m (lbf•ft)
1/8
14
17±2 (13±1.5)
1/8
14
17±2 (13±1.5)
1/4
19
36±2 (27±1.5)
1/4
19
36±2 (27±1.5)
3/8
22
74±5 (55±4)
3/8
22
74±5 (55±4)
1/2
27
108±9.8 (80.0±7)
1/2
27
108±9.8 (80.0±7)
3/4
36
162±9.8 (119±7)
3/4
36
162±9.8 (119±7)
1
41
255±9.8 (188±7)
1
41
255±9.8 (188±7)
HYDRAULIC HOSE (30° FLARE TYPE)
11.3.3
11.3.2
Size (PF)
Wrench(mm)
Tightening torque N•m (lbf•ft)
1/8
17
1/4
Size (PF)
Wrench(mm)
Tightening torque N•m (lbf•ft)
15±2.0 (11±1.5)
1/8
17
15±2.0 (11±1.5)
19
29±4.9 (21±3.6)
1/4
19
29±4.9 (21±3.6)
3/8
22
49±4.9 (36±3.6)
3/8
22
49±4.9 (36±3.6)
1/2
27
78±4.9 (58±3.6)
1/2
27
78±4.9 (58±3.6)
3/4
36
118±9.8 (87±7.2)
3/4
36
118±9.8 (87±7.2)
1
41
137±15 (101±11)
1
41
137±15 (101±11)
Unified screw size
Opposing flats
Tightening Torque N•m (lbf•ft)
1-14 UNS
30, 32
137±14 (101±10)
36
177±18 (131±13)
41
206±26 (152±15)
41
206±26 (152±15)
46
206±26 (152±15)
UNION NUT
JOINT (ORS TYPE)
11.3.3
Unified screw size
Opposing flats
Tightening Torque N•m (lbf•ft)
1-14 UNS
30, 32
137±14 (101±10)
36
177±18 (131±13)
41
206±26 (152±15)
41
206±26 (152±15)
46
206±26 (152±15)
1 3 / 16-12 UN 1 7/ 16-12 UN 11.3.4
HYDRAULIC HOSE (30° FLARE TYPE)
SPLIT FLANGE
CONNECTOR
O-RING
FITTING
JOINT (ORS TYPE)
1 3 / 16-12 UN 1 7/ 16-12 UN
NUT
11.3.4
Tightening torque N•m (lbf•ft)
SPLIT FLANGE Tightening torque N•m (lbf•ft)
Standard pressure series 20.6 MPa
Bolt size
Hi pressure series 41.2 MPa
Bolt size
Size
3/4
33.9±5.6 (25±4)
M10
39.5±5.6 (29±4)
M10
Size
Standard pressure series 20.6 MPa
Bolt size
Hi pressure series 41.2 MPa
Bolt size
3/4
33.9±5.6 (25±4)
M10
39.5±5.6 (29±4)
M10
1
42.4±5.6 (31±4)
M10
62.2±5.6 (46±4)
M12
1
42.4±5.6 (31±4)
M10
62.2±5.6 (46±4)
M12
11/4
55.1±7.1 (41±5)
M10
93.3±8.4 (69±6)
M14
11/4
55.1±7.1 (41±5)
M10
93.3±8.4 (69±6)
M14
11/2
70.6±8.4 (52±6)
M12
169±11 (125±8)
M16
11/2
70.6±8.4 (52±6)
M12
169±11 (125±8)
M16
2
81.9±8.4 (60±6)
M12
282±11 (208±8)
M20
2
81.9±8.4 (60±6)
M12
282±11 (208±8)
M20
11-6
UNION NUT
11-6
CONNECTOR
O-RING
NUT
FITTING
11. TOOLS
11.4
TIGHTENING TORQUES FOR NUTS AND SLEEVES
11. TOOLS
11.4
Table11-3 indicates standard tightening torques applicable to cases where no particular note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections. Always tighten nuts and sleeves to proper torques.
TIGHTENING TORQUES FOR NUTS AND SLEEVES
Table11-3 indicates standard tightening torques applicable to cases where no particular note is given. Overtightening or undertightening of nuts and sleeves in FLARELESS JOINT may develop oil leaks through pipe connections. Always tighten nuts and sleeves to proper torques.
Table11-3
Manufacturer's name
Nippon A.M.C.
Ihara Koatu
Opposing flats (HEX) mm
Tightening torque N•m (lbf•ft)
ø10u1.5 (0.394u0.059)
19
49.0±9.8 (36±7.2)
ø15u2.0 (0.591u0.079)
27
118±12 (87±8.7)
ø18u2.5 (0.709u0.098)
32
147±15 (110±11)
ø22u3.0 (0.866u0.118)
36
ø28u4.0 (1.10u0.157) ø35u5.0 (1.38u0.197)
Tube size OD u thickness mm (in)
Working pressure MPa (psi)
29.4 (4270)
29.4 (4270)
Table11-3 Opposing flats (HEX) mm
Tightening torque N•m (lbf•ft)
ø10u1.5 (0.394u0.059)
19
49.0±9.8 (36±7.2)
ø15u2.0 (0.591u0.079)
27
118±12 (87±8.7)
ø18u2.5 (0.709u0.098)
32
147±15 (110±11)
216±22 (160±16)
ø22u3.0 (0.866u0.118)
36
216±22 (160±16)
41
275±27 (200±20)
ø28u4.0 (1.10u0.157)
41
275±27 (200±20)
55
441±44 (330±33)
ø35u5.0 (1.38u0.197)
55
441±44 (330±33)
SLEEVE
Manufacturer's name
Nippon A.M.C.
Ihara Koatu
NUT
Tube size OD u thickness mm (in)
Working pressure MPa (psi)
29.4 (4270)
29.4 (4270)
SLEEVE
NUT
B
d
B
d
d
Parts No.
Parts No.
d
Ihara Koatu
Nippon A.M.C.
Tube size ød
Opposing flats (HEX) mm
Ihara Koatu
Nippon A.M.C.
Tube size ød
Ihara Koatu
Nippon A.M.C.
Tube size ød
Opposing flats (HEX) mm
Ihara Koatu
Nippon A.M.C.
6
ZF93S06000
—
6
14
ZF93N06000
—
6
ZF93S06000
—
6
14
ZF93N06000
—
8
ZF93S08000
—
8
17
ZF93N08000
—
8
ZF93S08000
—
8
17
ZF93N08000
—
10
ZF93S10000
ZA93S10000
10
19
ZF93N10000
ZA93N10000
10
ZF93S10000
ZA93S10000
10
19
ZF93N10000
ZA93N10000
12
ZF93S12000
—
12
22
ZF93N12000
—
12
ZF93S12000
—
12
22
ZF93N12000
—
15
ZF93S15000
ZA93S15000
15
27
ZF93N15000
ZA93N15000
15
ZF93S15000
ZA93S15000
15
27
ZF93N15000
ZA93N15000
18
ZF93S18000
ZA93S18000
18
32
ZF93N18000
ZA93N18000
18
ZF93S18000
ZA93S18000
18
32
ZF93N18000
ZA93N18000
22
ZF93S22000
ZA93S22000
22
36
ZF93N22000
ZA93N22000
22
ZF93S22000
ZA93S22000
22
36
ZF93N22000
ZA93N22000
28
ZF93S28000
ZA93S28000
28
41
ZF93N28000
ZA93N28000
28
ZF93S28000
ZA93S28000
28
41
ZF93N28000
ZA93N28000
32
ZF93S32000
—
32
50
ZF93N32000
—
32
ZF93S32000
—
32
50
ZF93N32000
—
35
ZF93S35000
ZA93S35000
35
55
ZF93N35000
ZA93N35000
35
ZF93S35000
ZA93S35000
35
55
ZF93N35000
ZA93N35000
38
ZF93S38000
—
38
60
ZF93N38000
—
38
ZF93S38000
—
38
60
ZF93N38000
—
11-7
Parts No.
Parts No.
Tube size ød
11-7
11. TOOLS
11. TOOLS
11.5
PLUG
11.5
PLUG
11.5.1
PLUG FOR HYDRAULIC PIPE JOINT
11.5.1
PLUG FOR HYDRAULIC PIPE JOINT
(1) Cap nut (Joint plug)
H
T screw
Cap nut parts No.
T screw
ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000
M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5
Opposing flats
H1 14 17 17 19 24 27 32 38
H 14 17 19 22 27 32 36 41
Sleeve Type joint body
Nut
Plug parts No.
6 8 10 12 15 18 22 28
ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000
A
Applicable tube O. D : A
Sleeve Type joint body
Opposing flats
Cap nut parts No.
T screw
ZF83H06000 ZF83H08000 ZF83H10000 ZF83H12000 ZF83H15000 ZF83H18000 ZF83H22000 ZF83H28000
M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5
Applicable tube O. D : A
Plug parts No.
6 8 10 12 15 18 22 28
ZF83P06000 ZF83P08000 ZF83P10000 ZF83P12000 ZF83P15000 ZF83P18000 ZF83P22000 ZF83P28000
H1 14 17 17 19 24 27 32 38
H 14 17 19 22 27 32 36 41
Nut
(3) Nut
A
(3) Nut
d screw
H
T screw
Applicable tube O. D : A 6 8 10 12 15 18 22 28
(2) Plug (Tube plug)
A
(2) Plug (Tube plug)
H1
Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38
11-8
Nut parts No.
d screw
Opposing flats
ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000
M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5
14 17 19 22 27 32 36 41 50 55 60
d screw
A
H1
Applicable tube O. D : A 6 8 10 12 15 18 22 28
A
A
(1) Cap nut (Joint plug)
Applicable tube O. D : A 6 8 10 12 15 18 22 28 32 35 38
11-8
Nut parts No.
d screw
Opposing flats
ZF93N06000 ZF93N08000 ZF93N10000 ZF93N12000 ZF93N15000 ZF93N18000 ZF93N22000 ZF93N28000 ZF93N32000 ZF93N35000 ZF93N38000
M12 X 1.5 M14 X 1.5 M16 X 1.5 M18 X 1.5 M22 X 1.5 M26 X 1.5 M30 X 1.5 M36 X 1.5 M42 X 1.5 M45 X 1.5 M48 X 1.5
14 17 19 22 27 32 36 41 50 55 60
11. TOOLS 11.5.2
PLUG FOR HYDRAULIC EQUIPMENT
11.5.2
(1) PF screw
O-ring
B
O-ring
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29
(2) PT screw
PF screw Plug parts No. B mm O-ring parts No. Nominal O-ring 19 PF1/4 ZE72X04000 ZD12P01100 1B P11 22 PF3/8 ZE72X06000 ZD12P01400 1B P14 27 PF1/2 ZE72X08000 ZD12P01800 1B P18 36 PF3/4 ZE72X12000 ZD12P02400 1B P24 41 PF1 ZE72X16000 ZD12P02900 1B P29
PF screw
B PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2
B mm 5 6 8 10 14 17 22 22
PT screw
B PT screw Plug parts No. ZE82T02000 PT1/8 ZE82T04000 PT1/4 ZE82T06000 PT3/8 ZE82T08000 PT1/2 ZE82T12000 PT3/4 ZE82T16000 PT1 ZE82T20000 PT1 1/4 ZE82T24000 PT1 1/2
B mm 5 6 8 10 14 17 22 22
(3) Plug for (F) flare hose
PF screw
Opposing flats B
PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4
PF screw
Opposing flats E
11-9
Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6
E mm 14 17 23 27 36 40
B mm 14 17 22 27 36
F mm 19 22 27 36 41 50
PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 2444Z2728D5 PF1
Opposing flats B
60
60
PF screw Plug parts No. 2444Z2728D1 PF1/4 2444Z2728D2 PF3/8 2444Z2728D3 PF1/2 2444Z2728D4 PF3/4 2444Z2728D5 PF1
60
PF screw
60
B
(2) PT screw
(3) Plug for (F) flare hose
Opposing flats F
PLUG FOR HYDRAULIC EQUIPMENT
(1) PF screw
PF screw
PT screw
11. TOOLS
PF screw PF1/4 PF3/8 PF1/2 PF3/4 PF1 PF1 1/4
PF screw
Opposing flats F
Opposing flats E
11-9
Plug parts No. 2444Z2729D1 2444Z2729D2 2444Z2729D3 2444Z2729D4 2444Z2729D5 2444Z2729D6
E mm 14 17 23 27 36 40
B mm 14 17 22 27 36
F mm 19 22 27 36 41 50
11. TOOLS
11. TOOLS
(4) Plug for ORS joints
(4) Plug for ORS joints
Male
Male
Female
Female
(5) Plug for half clamp
(5) Plug for half clamp 4-oH
Size
Plug part No.
C mm D mm
1/2 ZE12Q08000 38.10
C
3/4 ZE12Q12000 47.63 1 D
4-oH
For standard pressure : 20.6 MPa (2990 psi)
ZE12Q16000 52.37
1 1/4 ZE12Q20000 58.72
G mm
25.53~ 25.40 31.88~ 22.23 31.75 39.75~ 26.19 39.62 44.58~ 30.18 44.45 17.48
H mm
O-ring part No.
9
45Z91D2
11
ZD12P02600
11
ZD12P03400
11
ZD12P03800
Size
Size
Plug part No.
C mm D mm
1/2 ZE13Q08000 40.49 3/4 ZE13Q12000 50.80 1
ZE13Q16000 57.15
1 1/4 ZE13Q20000 66.68
11-10
G mm
25.53~ 25.40 31.88~ 23.80 31.75 39.75~ 27.76 39.62 44.58~ 31.75 44.45 18.24
Plug part No.
C mm D mm
1/2 ZE12Q08000 38.10
C
3/4 ZE12Q12000 47.63 1 D
For high pressure : 41.2 MPa (5970 psi) G
For standard pressure : 20.6 MPa (2990 psi)
ZE12Q16000 52.37
1 1/4 ZE12Q20000 58.72
G mm
25.53~ 25.40 31.88~ 22.23 31.75 39.75~ 26.19 39.62 44.58~ 30.18 44.45 17.48
H mm
O-ring part No.
9
45Z91D2
11
ZD12P02600
11
ZD12P03400
11
ZD12P03800
H mm
O-ring part No.
9
2445Z831D1
11
ZD12P02600
13
ZD12P03400
15
ZD12P03800
For high pressure : 41.2 MPa (5970 psi) H mm
O-ring part No.
9
2445Z831D1
1/2 ZE13Q08000 40.49
11
ZD12P02600
3/4 ZE13Q12000 50.80
13
ZD12P03400
15
ZD12P03800
G
Size
1
Plug part No.
C mm D mm
ZE13Q16000 57.15
1 1/4 ZE13Q20000 66.68
11-10
G mm
25.53~ 25.40 31.88~ 23.80 31.75 39.75~ 27.76 39.62 44.58~ 31.75 44.45 18.24
11. TOOLS
11.6
SPECIAL SPANNER FOR TUBE
Applicable tube diameter mm (in)
Part No.
HEX (mm)
11. TOOLS
11.6 Drawing of a special spanner mm (in)
SPECIAL SPANNER FOR TUBE
Applicable tube diameter mm (in)
Part No.
HEX (mm)
Drawing of a special spanner mm (in)
70(2.76)
15 (0.591)
2421T160
16 (0.630)
27
70(2.76) 22 (0.866)
(0.315)
12.7
40(1.57)
(0.500
15 (0.591)
2421T160
16 (0.630)
27
)
2421T138
22(0.866)
48(1.89)
22 (0.866)
2421T130
12.7
28 (1.10)
2421T115
22(0.866)
48(1.89)
(0.500
22 (0.866)
2421T130
28 (1.10)
2421T115
)
2421T231
46
28 (1.10)
2421T231
46
32 (1.26)
2421T232
50
32 (1.26)
2421T232
50
35 (1.38)
2421T314
55
35 (1.38)
2421T314
55
11-11
11-11
(0.500
)
109(4.29) 14.5(0.571) 22 (0.866) 12.7
28 (1.10)
)
22 (0.866)
29 (1.142)
41
(0.500
70(2.76) 11.5(0.453)
12.7
60(2.36)
(0.500
12.7
23 (0.906)
36
)
22 (0.866) 12.7
)
22 (0.866)
19 (0.748)
32
109(4.29) 14.5(0.571)
29 (1.142)
41
2421T138
)
22 (0.866) 12.7
60(2.36)
(0.500
18 (0.709)
70(2.76) 11.5(0.453)
23 (0.906)
36
(0.500
70(2.76) 42(1.65) 22 (0.866)
19 (0.748)
32
12.7
40(1.57)
70(2.76) 42(1.65)
18 (0.709)
22 (0.866)
(0.315)
(0.500
)
11. TOOLS
11. TOOLS
11.7
11.7
SPECIAL TOOLS
SPECIAL TOOLS
Table11-4 No.
Tools name
1
Allen wrench Nominal B : 10, C : 11.3
Tools No.
Table11-4 Shape
Applicable
ZT22A10000
Pump suction
No.
Tools name
1
Allen wrench Nominal B : 10, C : 11.3
Tools No.
Pump suction Commercial tool length (L1) - cut length = Required length
40 (1.57") - 10 (0.39") = 30 (1.18")
2
40 (1.57") - 10 (0.39") = 30 (1.18")
Pump install
General tools
2
Spanner or socket Nominal B : 17
Pump install
General tools
CUT
3
Spanner Nominal S : 36
CUT
ZT12A36000
Swing motor A,B port
3
Spanner Nominal S : 36
ZT12A36000
Commercial tool outer width (D) - cut length = Required length
Plug PF3/4
Additional M10 X 22 threading for M10 eye bolt
ZE72X12000
PF3/4
Swing motor A,B port Commercial tool outer width (D) - cut length = Required length
81 (3.19") - 16 (0.63") = 65 (2.56")
4
Applicable
ZT22A10000
Commercial tool length (L1) - cut length = Required length
Spanner or socket Nominal B : 17
Shape
81 (3.19") - 16 (0.63") = 65 (2.56")
For slinging the swing motor
4
Plug PF3/4
Additional M10 X 22 threading for M10 eye bolt
ZE72X12000
O-ring
PF3/4
O-ring
M12 Eye bolt
ZS91C01200 or commercial equivalent
M12 Eye bolt
5
Eye bolt M12u22
ZS91C01200 or commercial equivalent
For slinging the swing motor 22
For slinging the swing motor 22
5
Eye bolt M12u22
M12
M8 Eye bolt
6
Plug (Nominal tube dia. 22) Reference Eye bolt Nut
Reference nut M8 X 18 Addtional threading for M8 Eye bolt
11-12
M12
M8 Eye bolt
ZF83P22000
ZS91C00800 ZF93N22000
For slinging the swing motor
Flare hose
6
Plug (Nominal tube dia. 22) Reference Eye bolt Nut
ZF83P22000 Reference nut
ZS91C00800 ZF93N22000
M8 X 18 Addtional threading for M8 Eye bolt
11-12
Flare hose
11. TOOLS
11. TOOLS
Table11-4
Table11-4 M8 Eye bolt
7
Plug Nominal 1-14UNS
YN01H01001P1
Eye bolt
ZS91C00800
M8 Eye bolt
M8 X 18 Additional threading HEX 27
Flare hose
7
1-14UNS
Plug Nominal 1-14UNS
YN01H01001P1
Eye bolt
ZS91C00800
M8 X 18 Additional threading HEX 27
1-14UNS
M8 Eye bolt
Plug 8
YN01H01002P1
Eye bolt
M8 Eye bolt
M8 X 18 Additional threading
Plug
Nominal 1 3/16-12UN
HEX 36
ZS91C00800
Flare hose
8
Nominal 1 3/16-12UN Eye bolt
1 3/16-12UN
YN01H01002P1
M8 X 18 Additional threading HEX 36
ZS91C00800
9
M12 Eye nut
ZE25F08000 Weld
Coupling half
For slinging the swivel joint
9
Plug PF1/2
ZE25F08000 Weld
Coupling half
Coupling half
10
PF 1/2
5.49
—
Point shape
11-13
For slinging the swivel joint
Coupling half
PF 1/2
TORX driver (with tamper proof) T30 (For M6)
Flare hose
1 3/16-12UN
M12 Eye nut
Plug PF1/2
Flare hose
For instrument panel cover (RH)
10
TORX driver (with tamper proof) T30 (For M6)
5.49
—
Point shape
11-13
For instrument panel cover (RH)
11. TOOLS
11. TOOLS
11.8
11.8
APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND
(1) For general use
(1) For general use Manufacturer
Service
Screw locking compound
Sealing compound
Features
Loctite
Three-Bond
#242
1360K
Low strength
#262
1374
Middle strength
#271
1305
High strength
#515
1215
Sealing
Use
Manufacturer
Service
Screw locking compound
Sealing compound
(2) For specific location No.
APPLICATION OF SCREW LOCKING COMPOUND AND SEALING COMPOUND
Features
Loctite
Three-Bond
#242
1360K
Low strength
#262
1374
Middle strength
#271
1305
High strength
#515
1215
Sealing
(2) For specific location
Manufacturer
Name
Equivalent
Applicable
No.
Use
Manufacturer
Name
Equivalent
(Manufacturer ; Loctite) Three-Bond
1
Sealing Loctite compound & adhesive Loctite
Anti-seizure
Cylinder
# 1215 gray
# 5699
Swing motor
# 1211 white
# 5301J
# 1303B
# 211
# 1901
Anti-seizure
Cylinder
# 1215 gray
# 5699
Swing motor
Swing motor
# 1211 white
# 5301J
Swing motor
Main pump
# 1303B
# 211
Main pump
Three-Bond
(Manufacturer ; ThreeBond) # 1344N
# 277
# 1307N
Main pump Pilot valve
(Manufacturer ; ThreeBond) Parmatex 98D
# 1121
Sumitomo Chemical Co., Cyano Bond PO-1 Ltd. Shell petroleum
(Manufacturer ; Loctite)
# 1901
# 222
Shell Alvania EP2
New Molyknock Grease 2
11-14
Applicable
1
Sealing Loctite compound & adhesive
(Manufacturer ; ThreeBond) # 222 # 277
# 1344N
Main pump
# 1307N
Pilot valve
(Manufacturer ; ThreeBond)
Hydraulic oil tank :
Loctite
Hose
Sumitomo Chemical Co., Cyano Bond PO-1 Ltd.
Parmatex 98D
# 1121
Swing bearing grease bath
Shell petroleum
Shell Alvania EP2
Hydraulic oil tank : Hose
New Molyknock Grease 2
11-14
Swing bearing grease bath
11. TOOLS
11. TOOLS
11.9
SUCTION STOPPER
11.9
SUCTION STOPPER
11.9.1
COMPONENTS
11.9.1
COMPONENTS
No.
NAME
PARTS No.
Q'TY
No.
SUCTION STOPPER ASSY 24100P978F2
NAME
PARTS No.
Q'TY
SUCTION STOPPER ASSY 24100P978F2
1
ROD
2420T4660D1
1
1
ROD
2420T4660D1
1
2
NUT
ZN16C08007
1
2
NUT
ZN16C08007
1
3
COVER
2414T2123D2
1
3
COVER
2414T2123D2
1
4
O-RING
45Z91D6
1
4
O-RING
45Z91D6
1
1 Rod
1 Rod
2 Nut
2 Nut
3 Cover
3 Cover
4 O-ring
4 O-ring
Fig. 11-1 Components of suction stopper DIMENSION
11.9.2
DIMENSION
50 (1.97")
50 (1.97")
M8 NUT
O113 (4.45")
2
M8 NUT O8 (1.315")
600 (23.6")
(0.787") 20
O100 +0.5 0 (3.94 +0.0197 ) 0
O108 (4.25") COVER
ROD
Fig. 11-2 Dimension of suction stopper
Fig. 11-2 Dimension of suction stopper
24100P978F2
24100P978F2
11-15
11-15
SK200-8
SK200-6ES
SK200-6E
SK200-6
SK235SR
SK135SR
Part No.
SK115SR
Applicable model
SK120
APPLICABLE MODEL
SK100
SK200-8
SK200-6ES
SK200-6E
SK200-6
SK235SR
SK135SR
SK115SR
SK120-3
SK100-3
SK120-2
Part No.
11.9.3
SK100-2
Applicable model
SK120
APPLICABLE MODEL
SK100
11.9.3
O108 (4.25") COVER
SK120-3
ROD
O100 +0.5 0 (3.94 +0.0197 ) 0
M8
SK100-3
M8
SK120-2
O8 (1.315")
(0.787") 20
R8
O113 (4.45")
600 (23.6")
R8
SK100-2
11.9.2
Fig. 11-1 Components of suction stopper
2
11. TOOLS
11. TOOLS
11.10
11.10
COUNTER WEIGHT LIFTING JIG
(1) Standard eye bolt
COUNTER WEIGHT LIFTING JIG
(1) Standard eye bolt
Size Part No. d L M8 15 ZS91C00800
80 (176)
Size Part No. d L M8 15 ZS91C00800
80 (176)
M10 18 ZS91C01000
150 (331)
M10 18 ZS91C01000
150 (331)
M12 22 ZS91C01200
220 (485)
M12 22 ZS91C01200
220 (485)
M16 27 ZS91C01600
450 (992)
M16 27 ZS91C01600
450 (992)
Vertical lifting load kg (lbs)
M24 38 ZS91C02400 950 (2090)
d
M30 45 ZS91C03000 1500 (3310)
M20 30 ZS91C02000 630 (1390) L
L
M20 30 ZS91C02000 630 (1390)
Vertical lifting load kg (lbs)
M24 38 ZS91C02400 950 (2090)
d
M30 45 ZS91C03000 1500 (3310)
M36 55 ZS91C03600 2300 (5070)
M36 55 ZS91C03600 2300 (5070)
M42 65 ZS91C04200 3400 (7490)
M42 65 ZS91C04200 3400 (7490)
M48 70 ZS91C04800 4500 (9920)
M48 70 ZS91C04800 4500 (9920)
Fig. 11-3 Eye bolt
Fig. 11-3 Eye bolt
11-16
11-16
11. TOOLS
11.11
UPPER FRAME LIFTING JIG
11. TOOLS
11.11
UPPER FRAME LIFTING JIG
Q'ty : 2 sets
Q'ty : 2 sets
Material : Mild steel
Material : Mild steel
Fig. 11-4 Upper frame lifting jig
Fig. 11-4 Upper frame lifting jig
11-17
11-17
11. TOOLS
11. TOOLS
11.12
11.12
ENGINE MOUNTING PEDESTAL
Material : Wood Unit ; mm (inch)
175(6.89)
375 (14.8)
3
6
6
744 (29.3)
100 (3.94)
945 (37.2)
2 X 1 piece
352 (13.9)
200(7.87)
0 R5 .0) (2 t 24 (0.95)
213(8.39) 250(9.84)
t 24 (0.95)
5 X 1 piece
945 (37.2)
200 (7.87)
352 (13.9)
55
(2.2)
145 (5.71)
6 X 5 pieces t 24 (0.95)
R5 (2. 0 0)
10(0.39)
100(3.94)
t50 (2.0)
10(0.39) 190 (7.48)
t 24 (0.95)
90 (3.5)
(2.2)
145 (5.71)
120 (4.72)
t 24 (0.95)
352 (13.9)
200 (7.87) 55
670 (26.4)
400 (15.7)
120 (4.72)
90 (3.5)
400 (15.7)
5 X 1 piece
3 X 1 piece
670 (26.4)
352 (13.9)
3 X 1 piece
t 24 (0.95)
945 (37.2)
6 X 5 pieces t 24 (0.95)
R5 (2. 0 0)
10(0.39)
100(3.94)
t50 (2.0)
Fig. 11-5 Engine stand
Fig. 11-5 Engine stand
11-18
11-18
10(0.39) 190 (7.48)
50(2.0)
750 (29.5)
352 (13.9)
25 (0.98)120 (4.72) 5(0.2)
t 50 (2.0)
1 X 1 piece
670 (26.4) 430 (16.9)
200 (7.9)
200(7.87)
213(8.39) 250(9.84)
t 50 (2.0)
0 R5 .0) (2 t 24 (0.95)
300 (11.8)
4 X 1 piece
400 (15.7)
55 (2.2)
352 (13.9)
50(2.0)
275 (10.8)
1 X 1 piece
670 (26.4) 430 (16.9)
25 (0.98)120 (4.72) 5(0.2)
6
6
300 (11.8)
4 X 1 piece
200 (7.9)
100 (3.94)
750 (29.5)
6
275 (10.8)
55 (2.2)
6
5
6
400 (15.7)
2
945 (37.2)
5
2 X 1 piece
400 (15.7) 175(6.89)
240 (9.45)
120 120 (4.72) (4.72)
2 750 (29.5)
375 (14.8)
400 (15.7) 175(6.89)
240 (9.45)
120 120 (4.72) (4.72)
175(6.89)
3
744 (29.3)
1
6
750 (29.5)
1
6
6
Material : Wood Unit ; mm (inch)
245 (9.65)
375 (14.8)
245 (9.65)
375 (14.8)
ENGINE MOUNTING PEDESTAL
11. TOOLS
TRACK SPRING SET JIG
11.13
M30
TRACK SPRING SET JIG M30
Retainer nut
Retainer nut
Retainer plate
Retainer plate
)
)
(27.6")
.6" (12
(27.6")
.6"
(12
Stand (15.0")
Stand (15.0")
11.13
11. TOOLS
Hydraulic jack
Base
Hydraulic jack
Base Fig. 11-6 Track spring set jig
Fig. 11-6 Track spring set jig
11-19
11-19
11. TOOLS
11. TOOLS
[MEMO]
[MEMO]
11-20
11-20
12. STANDARD MAINTENANCE TIME TABLE
12
12. STANDARD MAINTENANCE TIME TABLE
TABLE OF CONTENTS
TABLE OF CONTENTS
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.1 STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR ...12-4
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) ................................................................................................12-15
12.2 ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION) ................................................................................................12-15
12.2.1
MEASURING METHOD .........................................................................................12-15
12.2.1
MEASURING METHOD .........................................................................................12-15
12.2.2
WORKING CONDITION .........................................................................................12-15
12.2.2
WORKING CONDITION .........................................................................................12-15
12.2.3
STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.3
STANDARD TIME CONSTITUENT ........................................................................12-15
12.2.4
MEANING OF WORDS IN USE .............................................................................12-17
12.2.4
MEANING OF WORDS IN USE .............................................................................12-17
Book Code No. S5YN1221E01 12-1
Book Code No. S5YN1221E01 12-1
12
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE
Issue
Date of Issue
Applicable Machines
First edition
March, 2007
n
July, 2007
n
n
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
12-2
Remarks S5YN1221E01 (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
Issue
Date of Issue
Applicable Machines
K
First edition
March, 2007
K
n
July, 2007
n
K
n
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
12-2
Remarks S5YN1221E01 (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
K K K
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE
PREFACE
PREFACE
(1) Working Conditions
(1) Working Conditions
1) Workers : More than one worker shall be 1st class service technician (having five years or more of field experience and having received training in the operation).
1) Workers : More than one worker shall be 1st class service technician (having five years or more of field experience and having received training in the operation).
2) Equipment : Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities.
2) Equipment : Jigs, tools, apparatuses and testers used in field service work shall be available commercially. The maintenance plant shall be equipped with a service shop, a crane and inspection apparatuses necessary for specific self inspection activities.
3) Place : A flat land where work may be performed and to which a service car or a truck crane is accessible.
3) Place : A flat land where work may be performed and to which a service car or a truck crane is accessible.
(2) Range of standard maintenance time
(2) Range of standard maintenance time
1) Standard maintenance time=Direct maintenance timeuPreparation time
1) Standard maintenance time=Direct maintenance timeuPreparation time
2) Direct maintenance time : Net time actually spent for maintenance
2) Direct maintenance time : Net time actually spent for maintenance
3) Spare time : Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the body.
3) Spare time : Time needed to move machines for service, prepare safety operations, discuss work, and process the needs of the body.
(3) Extra time (not included in the standard service time)
(3) Extra time (not included in the standard service time)
1) Repair time : Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
1) Repair time : Machining, sheet metal, welding, melt cutting, folding and extracting bolts, servicing parts, and painting.
2) Items excluded from service time because of uncertainty in time : Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection.
2) Items excluded from service time because of uncertainty in time : Receiving a vehicle into shop, transfer, delivery, inspection on completion, investigation of causes of faults, diagnosis, and inspection.
3) Indirect time : Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
3) Indirect time : Time for ; field work, preparation of necessary parts before leaving for work, return for field work, waiting time because of user’s convenience in the field, paper work after returning to shop, and preparation of bills.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
4) Special time : Work at early morning, at midnight and on holidays are to be calculated separately.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
5) Separate calculation : The operating time for service cars, trucks with a crane and crane trucks.
(4) Applicable machine for estimation of standard maintenance time
(4) Applicable machine for estimation of standard maintenance time
1) Standard machine
1) Standard machine
2) A well maintained and controlled machine with a standard combination of attachments which is used in a general environment.
2) A well maintained and controlled machine with a standard combination of attachments which is used in a general environment.
12-3
12-3
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE
12.1
12.1
STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
(1) Standard maintenance time table
STANDARD WORKING TIME TABLE FOR THE MAINTENANCE OF EXCAVATOR
(1) Standard maintenance time table
1) Units of working time : 6 minutes = 0.1 hour
1) Units of working time : 6 minutes = 0.1 hour
2) Calculating method of standard maintenance time : Maintenance time=Working timeuNumber of workers (Working time=Maintenance timeyNumber of workers)
2) Calculating method of standard maintenance time : Maintenance time=Working timeuNumber of workers (Working time=Maintenance timeyNumber of workers)
3) When more than one operation is going on : Add each standard service time. A pure time (readily started) is given except covers easily removed by hand. Assy works include the following works marked with black dot •.
3) When more than one operation is going on : Add each standard service time. A pure time (readily started) is given except covers easily removed by hand. Assy works include the following works marked with black dot •.
4) O/H : The removing and attaching time is not included.
4) O/H : The removing and attaching time is not included.
5) Abbreviations in the table.
5) Abbreviations in the table.
A/C
: Air conditioner
C/V
: Control valve
O/H
: Over haul
A/C
ASSY
: Assembly
Cyl
: Cylinder
SOL
: Solenoid
ATT
: Attachment
E/G
: Engine
SW
: Switch
BRG
: Bearing
F hose
: Flexible hose
V
: Valve
(2) Classification of working code No.
Attachment
02 03
C/V
: Control valve
O/H
: Over haul
ASSY
: Assembly
Cyl
: Cylinder
SOL
: Solenoid
ATT
: Attachment
E/G
: Engine
SW
: Switch
BRG
: Bearing
F hose
: Flexible hose
V
: Valve
(2) Classification of working code
Group
01
: Air conditioner
Remarks
No.
Indicates installing, removing, replacement and overhaul.
Group
Remarks
01
Attachment
Indicates installing, removing, replacement and overhaul.
Cab & Guard
02
Cab & Guard
Swing frame
03
Swing frame
04
Travel system
04
Travel system
06
Electric equipments
Indicates the installing, removing and replacement of single items.
06
Electric equipments
Indicates the installing, removing and replacement of single items.
09
E/G relation
Indicates overhaul of the single engine. (Materials prepared by manufacturer )
09
E/G relation
Indicates overhaul of the single engine. (Materials prepared by manufacturer )
(3) Conditions for standard service time of the engine
(3) Conditions for standard service time of the engine
1) Tools designated by E/G maker are used
1) Tools designated by E/G maker are used
2) Genuine parts are changed
2) Genuine parts are changed
3) Correct working procedures are observed.
3) Correct working procedures are observed.
•
The time required for works specified in this Chapter shows the total time for maintenance.
12-4
•
The time required for works specified in this Chapter shows the total time for maintenance.
12-4
12. STANDARD MAINTENANCE TIME TABLE Location
Work to be done
Unit
00
Bucket relation
01
Bucket ASSY
Detach/attach
1 pc.
02
•
Preparation
1 pc.
03
• Bucket attaching pin
Detach/attach
1
04
• Bucket drive pin
Detach/attach
05
• Bucket sling and movement
06
Bucket (single)
07
Remarks
Unit : Hour
Group
Location
Work to be done
Unit
Remarks
Unit : Hour
00
Bucket relation
0.6
01
Bucket ASSY
Detach/attach
1 pc.
0.1
02
•
Preparation
1 pc.
0.1
03
• Bucket attaching pin
Detach/attach
1
1
0.1
04
• Bucket drive pin
Detach/attach
1
0.1
Preparation
1 pc.
0.2
05
• Bucket sling and movement
Preparation
1 pc.
0.2
O/H
1 pc.
2.4
06
Bucket (single)
O/H
1 pc.
• Tooth
Replace
1 pc.
0.6
07
• Tooth
Replace
1 pc.
0.6
08
• Side cutter
Replace
1 pc.
1.2
08
• Side cutter
Replace
1 pc.
1.2
09
• Bushing
Replace
1 pc.
0.6
09
• Bushing
Replace
1 pc.
0.6
10
Arm relation
10
Arm relation
11
Arm ASSY
Detach/attach
1 pc.
1.2
11
Arm ASSY
Detach/attach
1 pc.
1.2
12
• Bucket cylinder attaching and detaching position and piping
Preparation
1 pc.
0.4
12
• Bucket cylinder attaching and detaching position and piping
Preparation
1 pc.
0.4
13
• Bucket cylinder rod pin
Detach/attach
1 pc.
Include stopper pin
0.1
13
• Bucket cylinder rod pin
Detach/attach
1 pc.
Include stopper pin
0.1
14
• Bucket cylinder head pin
Detach/attach
1 pc.
Include stopper pin
0.1
14
• Bucket cylinder head pin
Detach/attach
1 pc.
Include stopper pin
0.1
15
• Bucket cylinder assy
Detach/attach
1 pc.
0.1
15
• Bucket cylinder assy
Detach/attach
1 pc.
16
• Arm cylinder rod pin
Detach/attach
1 pc.
Include stopper pin
0.1
16
• Arm cylinder rod pin
Detach/attach
1 pc.
Include stopper pin
0.1
17
• Boom top pin
Detach/attach
1 pc.
Include wire stop pin.
0.1
17
• Boom top pin
Detach/attach
1 pc.
Include wire stop pin.
0.1
18
• Arm sling and movement
Detach/attach
1 pc.
18
• Arm sling and movement
Detach/attach
1 pc.
30
Boom relation
30
Boom relation
Bucket attaching and detaching position
See 32.1.2 Include adjustment. Include stopper pin.
Not include attaching and detaching
See 32.1.3
0.2 See 32.1.4
01 Attachment
01 Attachment
Group
12. STANDARD MAINTENANCE TIME TABLE
Bucket attaching and detaching position
See 32.1.2 Include adjustment.
0.6 0.1
Include stopper pin.
Not include attaching and detaching
0.1
2.4
See 32.1.3
0.1
0.2 See 32.1.4
31
Boom ASSY
Detach/attach
1 pc.
1.4
31
Boom ASSY
Detach/attach
1 pc.
1.4
32
• Boom attaching and detaching position Preparation
1 pc.
0.1
32
• Boom attaching and detaching position Preparation
1 pc.
0.1
33
• Boom cylinder temporary slinging
Preparation
2 pcs.
0.2
33
• Boom cylinder temporary slinging
Preparation
2 pcs.
0.2
34
• Boom cylinder rod pin
Detach/attach
2
0.2
34
• Boom cylinder rod pin
Detach/attach
2
35
• Boom cylinder piping
Detach/attach
2 pc.
0.2
35
• Boom cylinder piping
Detach/attach
2 pc.
0.2
36
• Arm & bucket piping
Detach/attach
1 pc.
0.2
36
• Arm & bucket piping
Detach/attach
1 pc.
0.2
37
• Boom assy temporary slinging
Detach/attach
1 pc.
0.1
37
• Boom assy temporary slinging
Detach/attach
1 pc.
0.1
38
• Boom foot pin
Detach/attach
1
0.2
38
• Boom foot pin
Detach/attach
1
39
• Boom assy slinging
Detach/attach
1 pc.
0.2
39
• Boom assy slinging
Detach/attach
1 pc.
0.2
40
Arm cylinder attaching and detaching Detach/attach
1 pc.
0.4
40
Arm cylinder attaching and detaching Detach/attach
1 pc.
0.4
41
• Arm cylinder piping
Detach/attach
1 pc.
0.2
41
• Arm cylinder piping
Detach/attach
1 pc.
0.2
42
• Arm cylinder head pin
Detach/attach
1 pc.
0.1
42
• Arm cylinder head pin
Detach/attach
1 pc.
43
• Arm cylinder slinging
Detach/attach
1 pc.
0.1
43
• Arm cylinder slinging
Detach/attach
1 pc.
0.1
50
Boom cylinder attaching and detaching
Detach/attach
2 pcs.
0.7
50
Boom cylinder attaching and detaching
Detach/attach
2 pcs.
0.7
51
• Boom cylinder piping
Detach/attach
2
0.3
51
• Boom cylinder piping
Detach/attach
2
0.3
52
• Boom cylinder head pin
Detach/attach
2 pcs.
0.2
52
• Boom cylinder head pin
Detach/attach
2 pcs.
0.2
53
• Boom cylinder slinging
Detach/attach
2
0.2
53
• Boom cylinder slinging
Detach/attach
2
0.2
60
Bucket cylinder
O/H
1
3.6
60
Bucket cylinder
O/H
1
3.6
61
• Pin bushing
Replace
1
1.2
61
• Pin bushing
Replace
1
70
Arm cylinder
O/H
1
3.6
70
Arm cylinder
O/H
1
12-5
Include two stopper pins.
Include stopper pin.
Include stopper pin.
Include seal.
12-5
Include two stopper pins.
Include stopper pin.
Include stopper pin.
Include seal.
0.2
0.2
0.1
1.2 3.6
12. STANDARD MAINTENANCE TIME TABLE Group
• Pin bushing
Work to be done
Unit
Replace
1 set
Remarks
Unit : Hour
Group
Location • Pin bushing
Work to be done
Unit
Replace
1 set
Include seal.
1.2
71
7.0
80
Boom cylinder
O/H
2
Include seal.
1.2
81
• Pin bushing
Replace
1 set
10
Cab relation
1.4
11
Cab ASSY
Detach/attach
Remarks
Unit : Hour
Include seal.
1.2
Include seal.
1.2
Boom cylinder
O/H
2
81
• Pin bushing
Replace
1 set
10
Cab relation
11
Cab ASSY
Detach/attach
12
• Front lower glass, floor mat
Detach/attach 1 pc. each
0.1
12
• Front lower glass, floor mat
Detach/attach 1 pc. each
0.1
13
• Seat rear cover top, bottom
Detach/attach
4 places
0.2
13
• Seat rear cover top, bottom
Detach/attach
4 places
0.2
14
• Seat rear cover top, bottom
Detach/attach 1 pc. each
0.2
14
• Seat rear cover top, bottom
Detach/attach 1 pc. each
0.2
15
• Right side panel (include A/C duct) Detach/attach
3
0.3
15
• Right side panel (include A/C duct) Detach/attach
3
0.3
16
• Cable and harness (electric)
Detach/attach
6
0.2
16
• Cable and harness (electric)
Detach/attach
6
0.2
17
• Cab mounting bolt
Detach/attach
8 pcs.
0.2
17
• Cab mounting bolt
Detach/attach
8 pcs.
0.2
18
• Cab slinging
Detach/attach
3 places
0.2
18
• Cab slinging
Detach/attach
3 places
0.2
20
Guard relation
20
Guard relation
21
Bonnet assy (11)
Detach/attach
1 pc.
0.2
21
Bonnet assy (11)
Detach/attach
1 pc.
0.2
22
Guard (5)
Detach/attach
1 pc.
0.2
22
Guard (5)
Detach/attach
1 pc.
0.2
23
Guard (6)
Detach/attach
1 pc.
0.2
23
Guard (6)
Detach/attach
1 pc.
0.2
24
Guard assy (3)
Detach/attach
1 pc.
0.2
24
Guard assy (3)
Detach/attach
1 pc.
0.2
25
Stay (7)
Detach/attach
1 pc.
0.2
25
Stay (7)
Detach/attach
1 pc.
0.2
26
Guard (2)
Detach/attach
1 pc.
0.2
26
Guard (2)
Detach/attach
1 pc.
0.2
27
Panel assy (21)
Detach/attach
1 pc.
0.2
27
Panel assy (21)
Detach/attach
1 pc.
0.2
28
Panel assy (23)
Detach/attach
1 pc.
0.2
28
Panel assy (23)
Detach/attach
1 pc.
0.2
29
Panel assy (22)
Detach/attach
1 pc.
0.2
29
Panel assy (22)
Detach/attach
1 pc.
0.2
30
Guard assy (16)
Detach/attach
1 pc.
0.2
30
Guard assy (16)
Detach/attach
1 pc.
0.2
31
Guard (14)
Detach/attach
1 pc.
0.2
31
Guard (14)
Detach/attach
1 pc.
0.2
32
Guard (15)
Detach/attach
1 pc.
0.2
32
Guard (15)
Detach/attach
1 pc.
0.2
33
Guard (17)
Detach/attach
1 pc.
0.2
33
Guard (17)
Detach/attach
1 pc.
0.2
34
Pillar (11)
Detach/attach
1 pc.
0.2
34
Pillar (11)
Detach/attach
1 pc.
0.2
35
Beam (4)
Detach/attach
1 pc.
0.2
35
Beam (4)
Detach/attach
1 pc.
0.2
36
Pillar (10)
Detach/attach
1 pc.
0.2
36
Pillar (10)
Detach/attach
1 pc.
0.2
37
Pillar (12)
Detach/attach
1 pc.
0.2
37
Pillar (12)
Detach/attach
1 pc.
0.2
38
Guard assy (18)
Detach/attach
1 pc.
0.2
38
Guard assy (18)
Detach/attach
1 pc.
0.2
39
Guard assy (13)
Detach/attach
1 pc.
0.2
39
Guard assy (13)
Detach/attach
1 pc.
0.2
40
Guard (19)
Detach/attach
1 pc.
0.2
40
Guard (19)
Detach/attach
1 pc.
0.2
41
Cover (2)
Detach/attach
1 pc.
0.2
41
Cover (2)
Detach/attach
1 pc.
0.2
42
Guard assy (1)
Detach/attach
1 pc.
0.2
42
Guard assy (1)
Detach/attach
1 pc.
0.2
43
Guard assy (3)
Detach/attach
1 pc.
0.2
43
Guard assy (3)
Detach/attach
1 pc.
0.2
44
Plate (20)
Detach/attach
1 pc.
0.2
44
Plate (20)
Detach/attach
1 pc.
0.2
45
Cover assy (1)
Detach/attach
1 pc.
0.2
45
Cover assy (1)
Detach/attach
1 pc.
0.2
01
80
See 33.1.2 1 pc.
See 33.1.4
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
02 Cab & Guard
02 Cab & Guard
01
71
Location
12. STANDARD MAINTENANCE TIME TABLE
7.0
See 33.1.2 1 pc.
1.4
See 33.1.4
Note: The numbers in the parenthesis like guard (14) match the guard numbers on the upper structure.
12-6
12. STANDARD MAINTENANCE TIME TABLE Location
Work to be done
Unit
Under cover relation
51
Cover (1)
Detach/attach
1 pc.
52
Cover (2)
Detach/attach
53
Cover (3)
54
Unit : Hour
Group
See 33.1.5
Location
Work to be done
Unit
Remarks
Unit : Hour
50
Under cover relation
0.1
51
Cover (1)
Detach/attach
1 pc.
0.1
1 pc.
0.1
52
Cover (2)
Detach/attach
1 pc.
0.1
Detach/attach
1 pc.
0.1
53
Cover (3)
Detach/attach
1 pc.
0.1
Cover (4)
Detach/attach
1 pc.
0.1
54
Cover (4)
Detach/attach
1 pc.
0.1
55
Cover (5)
Detach/attach
1 pc.
0.1
55
Cover (5)
Detach/attach
1 pc.
0.1
56
Cover (6)
Detach/attach
1 pc.
0.1
56
Cover (6)
Detach/attach
1 pc.
0.1
57
Cover (7)
Detach/attach
1 pc.
0.1
57
Cover (7)
Detach/attach
1 pc.
0.1
58
Cover (8)
Detach/attach
1 pc.
0.1
58
Cover (8)
Detach/attach
1 pc.
0.1
60
Counterweight relation
60
Counterweight relation
61
Counterweight ASSY
Detach/attach
1 pc.
0.6
61
Counterweight ASSY
Detach/attach
1 pc.
0.6
62
• Counterweight lifting eye bolt
Detach/attach
1 set
0.1
62
• Counterweight lifting eye bolt
Detach/attach
1 set
0.1
63
• Counterweight temporary slinging
Preparation
1 pc.
0.2
63
• Counterweight temporary slinging
Preparation
1 pc.
0.2
64
• Counterweight mounting bolt
Detach/attach
1 pc.
0.2
64
• Counterweight mounting bolt
Detach/attach
1 pc.
0.2
65
• Counterweight slinging
Detach/attach
1 pc.
0.1
65
• Counterweight slinging
Detach/attach
1 pc.
0.1
10
Intake relation
10
Intake relation
11
Air cleaner ASSY
Detach/attach
1 pc.
0.4
11
Air cleaner ASSY
Detach/attach
1 pc.
0.4
12
• Hose (3)
Detach/attach
1
0.1
12
• Hose (3)
Detach/attach
1
0.1
13
• Air cleaner mounting bolt
Detach/attach
1 set
0.2
13
• Air cleaner mounting bolt
Detach/attach
1 set
0.2
14
• Element
Replace
1
0.1
14
• Element
Replace
1
0.1
20
Exhaust relation
20
Exhaust relation
21
Muffler ASSY
Detach/attach
1 pc.
0.4
21
Muffler ASSY
Detach/attach
1 pc.
0.4
22
• U bolt
Detach/attach
1 pc.
0.2
22
• U bolt
Detach/attach
1 pc.
0.2
23
• Clamp ASSY
Detach/attach
1 pc.
0.2
23
• Clamp ASSY
Detach/attach
1 pc.
0.2
30
Radiator relation
30
Radiator relation
31
Radiator ASSY
31
Radiator ASSY
32
• Coolant (LLC)
32
• Coolant (LLC)
33
See 33.1.11
02 Cab & Guard
50
Remarks
See 33.1.9
See 33.1.10
See 33.1.12
03 Swing frame
03 Swing frame
02 Cab & Guard
Group
12. STANDARD MAINTENANCE TIME TABLE
Detach/attach
1 pc.
4.0
Replace
1 pc.
0.3
• • Concentration of coolant
Measuring
1 pc.
0.2
33
34
• A/C condenser
Detach/attach
1 pc.
0.3
35
• Stay
Detach/attach
1 pc.
36
• Bracket
Detach/attach
37
• Sub tank hose
38
See 33.1.5
See 33.1.11
See 33.1.9
See 33.1.10
See 33.1.12 Detach/attach
1 pc.
4.0
Replace
1 pc.
0.3
• • Concentration of coolant
Measuring
1 pc.
0.2
34
• A/C condenser
Detach/attach
1 pc.
0.3
0.1
35
• Stay
Detach/attach
1 pc.
0.1
1
0.3
36
• Bracket
Detach/attach
1
0.3
Detach/attach
1 pc.
0.1
37
• Sub tank hose
Detach/attach
1 pc.
0.1
• Fan guard
Detach/attach
1 pc.
0.3
38
• Fan guard
Detach/attach
1 pc.
0.3
39
• Water hose (radiator ~ E/G)
Detach/attach
2
0.5
39
• Water hose (radiator ~ E/G)
Detach/attach
2
0.5
40
• Radiator mounting bolts removing
Detach/attach
1 set
0.2
40
• Radiator mounting bolts removing
Detach/attach
1 set
0.2
41
• Under cover
Detach/attach
1 pc.
0.1
41
• Under cover
Detach/attach
1 pc.
0.1
42
• Hydraulic oil tank suction stopper
Detach/attach
1 pc.
0.2
42
• Hydraulic oil tank suction stopper
Detach/attach
1 pc.
0.2
43
• Hydraulic oil piping
Detach/attach
1 pc.
0.6
43
• Hydraulic oil piping
Detach/attach
1 pc.
0.6
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.
12-7
Note: The numbers in the parenthesis like cover (2) match the guard numbers on the upper structure.
12-7
12. STANDARD MAINTENANCE TIME TABLE Location
Work to be done
Unit
Remarks
Unit : Hour
Group
Location
Work to be done
Unit
Remarks
Unit : Hour
44
• Inter cooler hose & tube (E/G to inter cooler)
Detach/attach
2 pcs.
0.5
44
• Inter cooler hose & tube (E/G to inter cooler)
Detach/attach
2 pcs.
0.5
45
• Radiator lifting or hoisting
Detach/attach
1 pc.
0.2
45
• Radiator lifting or hoisting
Detach/attach
1 pc.
0.2
46
• Radiator inter cooler core & oil cooler
Cleaning
1 pc.
1.0
46
• Radiator inter cooler core & oil cooler
Cleaning
1 pc.
1.0
50
Fuel relation
50
Fuel relation
51
Fuel tank ASSY
52
• Fuel
53
See 33.1.6 Detach/attach
1 pc.
1.8
51
Fuel tank ASSY
Replace
1 pc.
0.3
52
• Fuel
• Hose (water separator side)
Detach/attach
2
0.1
53
54
• Water separator
Detach/attach
1 pc.
0.1
55
• Tube (tank side)
Detach/attach
1
57
• Fuel tank installing bolts
Detach/attach
58
• Tank slinging Other necessary works
See 33.1.6 Detach/attach
1 pc.
1.8
Replace
1 pc.
0.3
• Hose (water separator side)
Detach/attach
2
0.1
54
• Water separator
Detach/attach
1 pc.
0.1
0.1
55
• Tube (tank side)
Detach/attach
1
0.1
1 pc.
0.3
57
• Fuel tank installing bolts
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.3
58
• Tank slinging
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
Other necessary works
Detach/attach
1 pc.
Removing and installing guard
0.4
60
Hydraulic oil tank relation
61
Hydraulic oil tank ASSY
Detach/attach
65
• Cover
Detach/attach
66
• Hydraulic oil
Replace
68
• Pilot drain hose
Detach/attach
1 pc.
0.2
69
• Pump suction hose
Detach/attach
1 pc.
0.5
70
• Mounting bolt
Detach/attach
1 pc.
0.2
71
• Hydraulic oil tank slinging
Detach/attach
1 pc.
0.3
72
• Return filter
Replace
1
73
• Suction filter
Cleaning
1
80
Pump relation
81
Pump ASSY
Detach/attach
1 pc.
82
• Hydraulic oil tank cover
Detach/attach
83
• Strainer & stopper
84
Removing and installing guard
0.4
60
Hydraulic oil tank relation
3.0
61
Hydraulic oil tank ASSY
Detach/attach
1 pc.
0.2
65
• Cover
Detach/attach
1 pc.
0.2
1 pc.
0.5
66
• Hydraulic oil
Replace
1 pc.
0.5
68
• Pilot drain hose
Detach/attach
1 pc.
0.2
69
• Pump suction hose
Detach/attach
1 pc.
0.5
70
• Mounting bolt
Detach/attach
1 pc.
0.2
71
• Hydraulic oil tank slinging
Detach/attach
1 pc.
0.3
0.2
72
• Return filter
Replace
1
0.2
0.2
73
• Suction filter
Cleaning
1
0.2
80
Pump relation
3.2
81
Pump ASSY
Detach/attach
1 pc.
3.2
1 pc.
0.2
82
• Hydraulic oil tank cover
Detach/attach
1 pc.
0.2
Detach/attach
1 pc.
0.3
83
• Strainer & stopper
Detach/attach
1 pc.
0.3
• Piping
Detach/attach
1 set
1.0
84
• Piping
Detach/attach
1 set
1.0
85
• Guard
Detach/attach
5 pcs.
1.0
85
• Guard
Detach/attach
5 pcs.
1.0
86
•
Detach/attach
1 pc.
0.5
86
•
Detach/attach
1 pc.
0.5
87
• Cleaning
Cleaning
1 pc.
0.1
87
• Cleaning
Cleaning
1 pc.
0.1
88
• Vent air
Adjust
1 pc.
0.1
88
• Vent air
Adjust
1 pc.
0.1
89
Pump ASSY
O/H
1 pc.
4.0
89
Pump ASSY
O/H
1 pc.
4.0
90
Swing motor unit relation
90
Swing motor unit relation
91
Swing motor ASSY
Detach/attach
1 pc.
2.4
91
Swing motor ASSY
Detach/attach
1 pc.
2.4
92
• Piping
Detach/attach
1 set
1.0
92
• Piping
Detach/attach
1 set
1.0
93
• Mounting bolt
Detach/attach
1 pc.
0.7
93
• Mounting bolt
Detach/attach
1 pc.
0.7
94
• Unit slinging
Detach/attach
1 pc.
0.5
94
• Unit slinging
Detach/attach
1 pc.
0.5
95
• Cleaning and sealant
Cleaning
1 set
0.2
95
• Cleaning and sealant
Cleaning
1 set
0.2
Pump slinging
See 33.1.7 1 pc.
See 33.1.8
See 33.1.18
12-8
03 Swing frame
03 Swing frame
Group
12. STANDARD MAINTENANCE TIME TABLE
Pump slinging
See 33.1.7 1 pc.
3.0
See 33.1.8
See 33.1.18
12-8
12. STANDARD MAINTENANCE TIME TABLE Group
Location
Work to be done
Unit
Unit : Hour
Group
Location
Work to be done
Unit
Remarks
Unit : Hour
96
Swing motor
O/H
1 pc.
3.6
96
Swing motor
O/H
1 pc.
3.6
97
Swing reduction gear
O/H
1 pc.
4.2
97
Swing reduction gear
O/H
1 pc.
4.2
100 Swivel joint relation
See 33.1.19
100 Swivel joint relation
See 33.1.19
101 Swivel joint ASSY
Detach/attach
1
2.6
101 Swivel joint ASSY
Detach/attach
1
2.6
102 • Piping (Top part only)
Detach/attach
1 set
0.5
102 • Piping (Top part only)
Detach/attach
1 set
0.5
103 • Whirl stop bolt
Detach/attach
1
0.2
103 • Whirl stop bolt
Detach/attach
1
0.2
104 • Cover
Detach/attach
1
0.4
104 • Cover
Detach/attach
1
0.4
105 • Joint & elbow
Detach/attach
1 set
0.4
105 • Joint & elbow
Detach/attach
1 set
0.4
106 • Mounting bolt
Detach/attach
1 set
0.4
106 • Mounting bolt
Detach/attach
1 set
0.4
107 • Swivel joint slinging
Detach/attach
1
0.4
107 • Swivel joint slinging
Detach/attach
1
0.4
108 • Cleaning
Cleaning
1 set
0.3
108 • Cleaning
Cleaning
1 set
0.3
109 Swivel joint
O/H
1 set
Removing and installing guard
3.6
109 Swivel joint
O/H
1 set
Removing and installing guard
3.6
Detach/attach
1 set
Lower piping
0.6
Detach/attach
1 set
Lower piping
0.6
120 Main control valve
See 33.1.15
120 Main control valve
121 Main control valve ASSY
Detach/attach
1 pc.
2.5
122 • Attach tag to port name of pipe
Preparation
1 pc.
0.6
123 • Piping
Detach/attach
1 set
1.7
124 • Bracket mounting bolt
Detach/attach
1 pc.
0.1
125 •
Valve slinging
Detach/attach
1 pc.
0.1
126 Main control valve ASSY
Detach/attach
1 set
6.0
Detach/attach
1 set
Other necessary works
Other necessary works
Guard
130 Valve relation
0.4 OPT
03 Swing frame
Other necessary works
03 Swing frame
Remarks
12. STANDARD MAINTENANCE TIME TABLE
See 33.1.15
121 Main control valve ASSY
Detach/attach
1 pc.
2.5
122 • Attach tag to port name of pipe
Preparation
1 pc.
0.6
123 • Piping
Detach/attach
1 set
1.7
124 • Bracket mounting bolt
Detach/attach
1 pc.
0.1
125 •
Valve slinging
Detach/attach
1 pc.
0.1
126 Main control valve ASSY
Detach/attach
1 set
6.0
Detach/attach
1 set
Other necessary works
Guard
130 Valve relation
0.4 OPT
131 Solenoid valve ASSY
Detach/attach
1
1.0
131 Solenoid valve ASSY
Detach/attach
1
1.0
132 • Attach tag to port name of pipe
Preparation
1
0.2
132 • Attach tag to port name of pipe
Preparation
1
0.2
133 • Piping
Detach/attach
1 set
0.5
133 • Piping
Detach/attach
1 set
0.5
134 • Mounting bolt
Detach/attach
1
0.3
134 • Mounting bolt
Detach/attach
1
0.3
140 Engine (E/G) mounting relation
See 33.1.13
141 Engine ASSY
Detach/attach
1 pc.
142 • Harness connector & grounding & cable connection
Detach/attach
143 • Fuel hose
140 Engine (E/G) mounting relation
See 33.1.13
1.8
141 Engine ASSY
Detach/attach
1 pc.
1 pc.
0.3
142 • Harness connector & grounding & cable connection
Detach/attach
1 pc.
0.3
Detach/attach
1 pc.
0.1
143 • Fuel hose
Detach/attach
1 pc.
0.1
144 • Others
Detach/attach
1 set
0.5
144 • Others
Detach/attach
1 set
0.5
145 • Mounting bolt
Detach/attach
1 pc.
0.5
145 • Mounting bolt
Detach/attach
1 pc.
0.5
146 • Engine slinging
Detach/attach
1 set
0.2
146 • Engine slinging
Detach/attach
1 set
0.2
Cleaning
1 pc.
0.3
147 • Cleaning
Cleaning
1 pc.
0.3
147 • Cleaning
12-9
After removing pump & radiator
12-9
After removing pump & radiator
1.8
12. STANDARD MAINTENANCE TIME TABLE
148 Engine
03 Swing frame
Other necessary works
Unit
Remarks
Work to be done
Unit
Remarks
O/H
1 set
Reference for engine (Chapter 51)
O/H
1 set
Reference for engine (Chapter 51)
Detach/attach
1 set
Removing and installing guard
0.6
Detach/attach
1 set
Removing and installing guard
0.6
Detach/attach
1 set
Removing and installing Counterweight
0.6
Detach/attach
1 set
Removing and installing Counterweight
0.6
Detach/attach
1 set
Removing and installing pump
3.2
Detach/attach
1 set
Removing and installing pump
3.2
Detach/attach
1 set
Removing and installing air cleaner 0.4
Detach/attach
1 set
Removing and installing air cleaner 0.4
Detach/attach
1 set
Removing and installing muffler
0.4
Detach/attach
1 set
Removing and installing muffler
0.4
Detach/attach
1 set
Removing and installing radiator
4.0
Detach/attach
1 set
Removing and installing radiator
4.0
150 Upper frame
Unit : Hour
See 33.1.20 After removing swivel joint
Detach/attach
1 pc.
152 • Mounting bolt
Detach/attach
1 set
0.4
153 • Upper frame slinging
Detach/attach
1 pc.
0.4
154 • Cleaning
Cleaning
1 pc.
0.3
155 • Sealant
Apply
1 pc.
0.2
Detach/attach
1 set
Cab
1.4
Detach/attach
1 set
Guard
Detach/attach
1 set
Detach/attach
1 set
Location
150 Upper frame
See 33.1.20 Detach/attach
1 pc.
152 • Mounting bolt
Detach/attach
1 set
0.4
153 • Upper frame slinging
Detach/attach
1 pc.
0.4
154 • Cleaning
Cleaning
1 pc.
0.3
155 • Sealant
Apply
1 pc.
0.2
Detach/attach
1 set
Cab
1.4
0.4
Detach/attach
1 set
Guard
0.4
Counterweight
0.6
Detach/attach
1 set
Counterweight
0.6
Boom
1.4
Detach/attach
1 set
Boom
1.4
Travel relation
01
Track link ASSY
Detach/attach
02
•
03
• Master pin
04
• Track link extending and winding
05
Shoe plate
10
Upper roller relation
11
Upper roller ASSY
12
Upper roller
20
Lower roller relation
21
Lower roller ASSY
22
Lower roller
30
Front idler relation
31
Front idler ASSY
Detach/attach
One side After removing track link
32
Front idler ASSY slinging
Detach/attach
33
Front idler ASSY
34
Idler ASSY
O/H
35
Idler adjuster ASSY
36
• Grease cylinder
1.3
Other necessary works
Unit : Hour
151 Upper frame ASSY
00
Track link attaching and detaching position
Group 148 Engine
151 Upper frame ASSY
Other necessary works
04 Travel system
Work to be done
03 Swing frame
Location
Other necessary works
See 34.1.2
After removing swivel joint
1.3
00
Travel relation
1.5
01
Track link ASSY
Detach/attach
Preparation One side
0.1
02
•
Preparation One side
0.1
Detach/attach
One side
0.5
03
• Master pin
Detach/attach
One side
0.5
Detach/attach
One side
0.5
04
• Track link extending and winding
Detach/attach
One side
0.5
Replace
1 pc.
0.4
05
Shoe plate
Replace
1 pc.
0.4
10
Upper roller relation
11
Upper roller ASSY
12
Upper roller
20
Lower roller relation
One side Include adjustment of tension
See 34.1.3 Detach/attach
1
O/H
1
After removing track link
0.2 1.0
See 34.1.4
04 Travel system
Group
12. STANDARD MAINTENANCE TIME TABLE
Track link attaching and detaching position
See 34.1.2 One side Include adjustment of tension
1.5
See 34.1.3 Detach/attach
1
O/H
1
After removing track link
0.2 1.0
See 34.1.4
Detach/attach
1
0.2
21
Lower roller ASSY
O/H
1
1.5
22
Lower roller
30
Front idler relation
0.6
31
Front idler ASSY
Detach/attach
One side After removing track link
0.6
One side
0.3
32
Front idler ASSY slinging
Detach/attach
One side
0.3
Detaching One side
0.3
33
Front idler ASSY
Detaching One side
0.3
One side
1.0
34
Idler ASSY
O/H
One side
1.0
O/H
One side Replace spring
2.4
35
Idler adjuster ASSY
O/H
One side Replace spring
2.4
O/H
One side
0.6
36
• Grease cylinder
O/H
One side
0.6
See 34.1.5
12-10
Detach/attach
1
0.2
O/H
1
1.5 See 34.1.5
12-10
12. STANDARD MAINTENANCE TIME TABLE Location
Work to be done
Unit
Remarks
40
Sprocket
41
Sprocket
50
Travel motor relation
51
Travel motor ASSY
Detach/attach
One side After removing track link
52
• Motor cover
Detach/attach
53
• Hydraulic piping
54
Unit : Hour
Group
See 34.1.6
Work to be done
Unit
Remarks
Unit : Hour
Sprocket
41
Sprocket
50
Travel motor relation
1.7
51
Travel motor ASSY
Detach/attach
One side After removing track link
1.7
One side
0.1
52
• Motor cover
Detach/attach
One side
0.1
Detach/attach
One side
0.9
53
• Hydraulic piping
Detach/attach
One side
0.9
• Motor mounting bolt
Detach/attach
One side
0.5
54
• Motor mounting bolt
Detach/attach
One side
0.5
55
• Motor slinging
Detach/attach
One side
0.1
55
• Motor slinging
Detach/attach
One side
0.1
56
Motor cleaning
Cleaning
One side
0.1
56
Motor cleaning
Cleaning
One side
0.1
57
Travel motor
O/H
One side
3.6
57
Travel motor
O/H
One side
3.6
58
Travel reduction gear
O/H
One side
3.6
58
Travel reduction gear
O/H
One side
3.6
60
Swivel joint relation
60
Swivel joint relation
61
Pipe on swivel joint travel side
Detach/attach
1 pc.
Include bonnet assy removing and installing.
0.6
62
Swivel joint
O/H
1 pc.
See 33.2.6
3.6
70
Swing bearing
71
Swing bearing ASSY
Detach/attach
1 pc.
72
Swing bearing mounting bolt
Detach/attach
73
Swing bearing slinging
Detach/attach
Replace
One side After removing track link
0.6
See 34.1.7
See 34.1.6 Replace
One side After removing track link
0.6
See 34.1.7
Detach/attach
1 pc.
Include bonnet assy removing and installing.
0.6
61
Pipe on swivel joint travel side
O/H
1 pc.
See 33.2.6
3.6
62
Swivel joint
70
Swing bearing
0.7
71
Swing bearing ASSY
Detach/attach
1 pc.
1 pc.
0.5
72
Swing bearing mounting bolt
Detach/attach
1 pc.
0.5
1 pc.
0.3
73
Swing bearing slinging
Detach/attach
1 pc.
0.3
See 34.1.8 After removing upper frame
Controller
See 34.1.8 After removing upper frame
0.7
Controller
C-1 Controller (KPSS)
Replace
1
0.5
C-1 Controller (KPSS)
Replace
1
0.5
C-2 Gauge cluster
Replace
1
1.0
C-2 Gauge cluster
Replace
1
1.0
C-4 Air conditioner Amplifier
Replace
1
2.0
C-4 Air conditioner Amplifier
Replace
1
2.0
D-4 Diode
Replace
1
0.3
D-5 Diode
Replace
1
0.3
D-6 Diode
Replace
1
0.3
D-9 Diode
Replace
1
0.3
D-10 Diode
Replace
1
0.3
D-12 Diode
Replace
1
0.3
Diode 06 Electric equipments
Diode 06 Electric equipments
Location
40
04 Travel system
04 Travel system
Group
12. STANDARD MAINTENANCE TIME TABLE
D-4 Diode
Replace
1
0.3
D-5 Diode
Replace
1
0.3
D-6 Diode
Replace
1
0.3
D-9 Diode
Replace
1
0.3
D-10 Diode
Replace
1
0.3
D-12 Diode
Replace
1
0.3
D-13 Diode
Replace
1
0.3
D-13 Diode
Replace
1
0.3
D-14 Diode
Replace
1
0.3
D-14 Diode
Replace
1
0.3
D-15 Diode
Replace
1
0.3
D-15 Diode
Replace
1
0.3
D-16 Diode
Replace
1
0.3
D-16 Diode
Replace
1
0.3
D-17 Diode
Replace
1
0.3
D-17 Diode
Replace
1
0.3
D-18 Diode
Replace
1
0.3
D-18 Diode
Replace
1
0.3
D-19 Diode
Replace
1
0.3
D-19 Diode
Replace
1
0.3
D-20 Diode
Replace
1
0.3
D-20 Diode
Replace
1
0.3
12-11
12-11
12. STANDARD MAINTENANCE TIME TABLE Group
Location
12. STANDARD MAINTENANCE TIME TABLE Work to be done
Unit
Remarks
Unit : Hour
Group
Work to be done
Unit
Remarks
Unit : Hour
Electric equipments
E-1 Fuse & relay box
Replace
1
0.3
E-1 Fuse & relay box
Replace
1
0.3
E-2 Alternator
Replace
1
1.0
E-2 Alternator
Replace
1
1.0
E-3 Hour meter
Replace
1
0.3
E-3 Hour meter
Replace
1
0.3
E-5 Horn (High)
Replace
1
0.3
E-5 Horn (High)
Replace
1
0.3
E-6 Horn (Low)
Replace
1
0.3
E-6 Horn (Low)
Replace
1
0.3
E-7 Tuner
Replace
1
0.3
E-7 Tuner
Replace
1
0.3
E-8 Speaker left
Replace
1
0.3
E-8 Speaker left
Replace
1
0.3
E-9 Speaker right
Replace
1
0.3
E-9 Speaker right
Replace
1
0.3
E-10 Receiver dryer
Replace
1
Include gas sealing.
1.0
E-10 Receiver dryer
Replace
1
Include gas sealing.
1.0
E-11 Air compressor
Replace
1
Include Counterweight removing and installing.
1.0
E-11 Air compressor
Replace
1
Include Counterweight removing and installing.
1.0
E-12 Battery
Replace
2
0.4
E-12 Battery
Replace
2
0.4
E-13 Travel alarm (Middle east)
Replace
1
0.3
E-13 Travel alarm (Middle east)
Replace
1
0.3
E-14 Cigarette lighter
Replace
1
0.3
E-14 Cigarette lighter
Replace
1
0.3
E-15 Fusible link
Replace
1
0.2
E-15 Fusible link
Replace
1
0.2
E-22 DC-DC converter
Replace
1
0.3
E-22 DC-DC converter
Replace
1
0.3
E-23 12V socket
Replace
1
0.3
E-23 12V socket
Replace
1
0.3
E-27 Accel redundant volume
Replace
1
0.3
E-27 Accel redundant volume
Replace
1
0.3
06 Electric equipments
06 Electric equipments
Electric equipments
Location
Light
Light
L-1 Boom work light left
Replace
1
L-2 Work light right
Replace
L-5 Room light
Bulb
0.2
L-1 Boom work light left
Replace
1
1
0.2
L-2 Work light right
Replace
1
0.2
Replace
1
0.2
L-5 Room light
Replace
1
0.2
L-6 Boom cylinder work light (right)
Replace
1
0.2
L-6 Boom cylinder work light (right)
Replace
1
0.2
L-7 Cab work light
Replace
1
0.2
L-7 Cab work light
Replace
1
0.2
Motor
Bulb
0.2
Motor
M-1 Starter motor
Replace
1
1.0
M-1 Starter motor
Replace
1
M-3 Wiper motor
Replace
1
0.5
M-3 Wiper motor
Replace
1
0.5
M-4 Washer motor
Replace
1
0.5
M-4 Washer motor
Replace
1
0.5
M-8 Grease motor (OPT)
Replace
1
0.5
M-8 Grease motor (OPT)
Replace
1
0.5
M-9 Skylight wiper motor (OPT)
Replace
1
0.5
M-9 Skylight wiper motor (OPT)
Replace
1
0.5
Replace
1
0.5
Include Counterweight removing and installing.
Proportional valve PSV-A Arm variable recirculation proportional valve
Include Counterweight removing and installing.
1.0
Proportional valve Replace
1
0.5
PSV-A Arm variable recirculation proportional valve
0.5
PSV-B
P2 bypass cut proportional valve
Replace
1
PSV-B
P2 bypass cut proportional valve
Replace
1
PSV-C
Travel straight proportional valve
Replace
1
0.5
PSV-C
Travel straight proportional valve
Replace
1
0.5
PSV-D
P1 bypass cut proportional valve
Replace
1
0.5
PSV-D
P1 bypass cut proportional valve
Replace
1
0.5
PSV-P1
P1 pump proportional valve
Replace
1
0.5
PSV-P1
P1 pump proportional valve
Replace
1
0.5
PSV-P2
P2 pump proportional valve
Replace
1
0.5
PSV-P2
P2 pump proportional valve
Replace
1
0.5
12-12
Include proportional valve block removing and installing.
12-12
Include proportional valve block removing and installing.
0.5
12. STANDARD MAINTENANCE TIME TABLE Group
Location
Work to be done
Unit
Remarks
Unit : Hour
12. STANDARD MAINTENANCE TIME TABLE Group
Work to be done
Unit
Remarks
Unit : Hour
Relay
R-1 Battery relay
Replace
1
0.3
R-1 Battery relay
Replace
1
0.3
R-2 Starter relay
Replace
1
0.3
R-2 Starter relay
Replace
1
0.3
R-3 Glow relay
Replace
1
0.3
R-3 Glow relay
Replace
1
0.3
R-4 Safety relay
Replace
1
0.1
R-4 Safety relay
Replace
1
0.1
R-5 Horn relay
Replace
1
0.1
R-5 Horn relay
Replace
1
0.1
R-6 Work light relay
Replace
1
0.1
R-6 Work light relay
Replace
1
0.1
R-8 Travel alarm relay (Middle east)
Replace
1
0.1
R-8 Travel alarm relay (Middle east)
Replace
1
0.1
R-23 Auto idle stop relay 1
Replace
1
0.1
R-23 Auto idle stop relay 1
Replace
1
0.1
R-24 Auto idle stop relay 2
Replace
1
0.1
R-24 Auto idle stop relay 2
Replace
1
0.1
R-25 E/G emergency stop relay
Replace
1
0.1
R-25 E/G emergency stop relay
Replace
1
0.1
R-26 Safety lock lever relay
Replace
1
0.1
R-26 Safety lock lever relay
Replace
1
0.1
R-28 Alternator relay
Replace
1
0.1
R-28 Alternator relay
Replace
1
0.1
R-29 Wiper motor relay (Normal rotation)
Replace
1
0.1
R-29 Wiper motor relay (Normal rotation)
Replace
1
0.1
R-30 Wiper motor relay (Reverse rotation)
Replace
1
0.1
R-30 Wiper motor relay (Reverse rotation)
Replace
1
0.1
R-31 Wiper motor relay arc prevention relay
Replace
1
0.1
R-31 Wiper motor relay arc prevention relay
Replace
1
0.1
R-32 Washer motor relay
Replace
1
0.1
R-32 Washer motor relay
Replace
1
0.1
SE-1 Pressure sensor : Bucket digging
Replace
1
0.3
Sensor
06 Electric equipments
06 Electric equipments
Relay
Location
Sensor
SE-1 Pressure sensor : Bucket digging
Replace
1
0.3
SE-2 Pressure sensor : Bucket dump
Replace
1
0.3
SE-2 Pressure sensor : Bucket dump
Replace
1
0.3
SE-3 Pressure sensor : Boom up
Replace
1
0.3
SE-3 Pressure sensor : Boom up
Replace
1
0.3
SE-4 Pressure sensor : Boom down
Replace
1
0.3
SE-4 Pressure sensor : Boom down
Replace
1
0.3
SE-5 Pressure sensor : Swing
Replace
1
0.3
SE-5 Pressure sensor : Swing
Replace
1
0.3
SE-7 Pressure sensor : Arm in
Replace
1
0.3
SE-7 Pressure sensor : Arm in
Replace
1
0.3
SE-8 Pressure sensor : Arm out
Replace
1
0.3
SE-8 Pressure sensor : Arm out
Replace
1
0.3
SE-9 Pressure sensor : Travel right
Replace
1
Include under cover removing and installing
0.5
SE-9 Pressure sensor : Travel right
Replace
1
Include under cover removing and installing
0.5
SE-10 Pressure sensor : Travel left
Replace
1
Include under cover removing and installing
0.5
SE-10 Pressure sensor : Travel left
Replace
1
Include under cover removing and installing
0.5
SE-11 Pressure sensor : P2 side OPT.
Replace
1
Include under cover removing and installing
0.5
SE-11 Pressure sensor : P2 side OPT.
Replace
1
Include under cover removing and installing
0.5
SE-13 Engine speed sensor
Replace
1
Include under cover removing and installing
0.5
SE-13 Engine speed sensor
Replace
1
Include under cover removing and installing
0.5
SE-15 Engine water temperature sensor
Replace
1
Include guard removing and installing
0.5
SE-15 Engine water temperature sensor
Replace
1
Include guard removing and installing
0.5
SE-16 Accel potentio
Replace
1
0.5
SE-16 Accel potentio
Replace
1
SE-20 Pressure sensor : P1 side : P1 side (OPT.)
Replace
1
0.5
SE-20 Pressure sensor : P1 side : P1 side (OPT.)
Replace
1
SE-22 Pressure sensor : P1 pump
Replace
1
0.5
SE-22 Pressure sensor : P1 pump
Replace
1
0.5
SE-23 Pressure sensor : P2 pump
Replace
1
0.5
SE-23 Pressure sensor : P2 pump
Replace
1
0.5
Include under cover removing and installing
Solenoid
0.5 Include under cover removing and installing
0.5
Solenoid
SV-1 Swing parking SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-1 Swing parking SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-2 Attachment boost pressure SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-2 Attachment boost pressure SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-3 2-speed travel SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-3 2-speed travel SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-4 Safety lever lock SOL
Replace
1
Include proportional valve block removing and installing.
0.5
SV-4 Safety lever lock SOL
Replace
1
Include proportional valve block removing and installing.
0.5
12-13
12-13
12. STANDARD MAINTENANCE TIME TABLE Group
Location
12. STANDARD MAINTENANCE TIME TABLE Work to be done
Unit
Remarks
Unit : Hour
Group
Work to be done
Unit
Remarks
Unit : Hour
Switch
SW-1 Key switch
Replace
1
0.3
SW-1 Key switch
Replace
1
0.3
SW-4 Swing parking release switch
Replace
1
0.3
SW-4 Swing parking release switch
Replace
1
0.3
SW-7 Engine oil pressure switch
Replace
1
0.3
SW-7 Engine oil pressure switch
Replace
1
0.3
SW-8 Clogged air filter switch
Replace
1
0.3
SW-8 Clogged air filter switch
Replace
1
0.3
SW-10
Horn switch (left)
Replace
1
0.3
SW-10
Horn switch (left)
Replace
1
0.3
SW-11
Safety lever lock switch
Replace
1
0.3
SW-11
Safety lever lock switch
Replace
1
0.3
SW-13
Travel alarm switch (For middle east)
Replace
1
0.3
SW-13
Travel alarm switch (For middle east)
Replace
1
0.3
SW-19
Wiper interlock switch
Replace
1
0.3
SW-19
Wiper interlock switch
Replace
1
0.3
SW-20
Attachment power boost switch (right)
Replace
1
0.3
SW-20
Attachment power boost switch (right)
Replace
1
0.3
SW-26
Cab work light switch
Replace
1
0.3
SW-26
Cab work light switch
Replace
1
0.3
SW-27
Engine cooling coolant level switch
Replace
1
0.3
SW-27
Engine cooling coolant level switch
Replace
1
0.3
SW-55
Boom work light switch
Replace
1
0.3
SW-55
Boom work light switch
Replace
1
0.3
12-14
06 Electric equipments
06 Electric equipments
Switch
Location
12-14
12. STANDARD MAINTENANCE TIME TABLE
12.2
ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION)
12. STANDARD MAINTENANCE TIME TABLE
12.2
ENGINE MAINTENANCE SERVICE STANDARD TIME LIST (TEMPORARY EDITION)
Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition. This standard working time is provided under the following conditions.
Preface This standard working time is based on the work time required for service of engine like disassembly, check, adjustment and assembly and so on under a following condition. This standard working time is provided under the following conditions.
12.2.1
12.2.1
MEASURING METHOD
MEASURING METHOD
(1) The time from the worker beginning working at the regular position of machine to the returning to the regular position after completion of the work is counted as working time.
(1) The time from the worker beginning working at the regular position of machine to the returning to the regular position after completion of the work is counted as working time.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(2) The measuring unit is in 0.1 minute, and then round up the fractions.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted as the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman.
(3) The work is carried out by a couple of workmen as a general rule, and the man-hour of two workers is counted as the working time. But light work which can be carried out easily by a person and the efficient is higher is counted as a workman.
12.2.2
12.2.2
12.2.2.1
WORKING CONDITION TOOLS, INSTRUMENT
12.2.2.1
WORKING CONDITION TOOLS, INSTRUMENT
(1) Hand tool ; Tools which are commercially available and each workman usually carries
(1) Hand tool ; Tools which are commercially available and each workman usually carries
(2) Common tool ; Tools which are commercially available and each workman do not usually carry but the storing place is specified
(2) Common tool ; Tools which are commercially available and each workman do not usually carry but the storing place is specified
(3) Special tool ; Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified
(3) Special tool ; Tools especially prepared by HINO Motor’s Ltd. and the storing place is specified
(4) Machine tool ; When measuring equipment and instrument are used, the time required to move parts to the specified place is included but the time waiting for tool is not included as a general rule
(4) Machine tool ; When measuring equipment and instrument are used, the time required to move parts to the specified place is included but the time waiting for tool is not included as a general rule
12.2.2.2
12.2.2.2
WORKING PROCEDURE
WORKING PROCEDURE
The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s Ltd. Service Technical Dept. Training Group.
The disassembly and assembly should be carried out according to working procedure prepared by HINO Motor’s Ltd. Service Technical Dept. Training Group.
12.2.2.3
12.2.2.3
STANDARD WORKMAN QUALIFICATION
STANDARD WORKMAN QUALIFICATION
Workmen shall basically acquire 2~3 years of maintenance experience of HINO
Workmen shall basically acquire 2~3 years of maintenance experience of HINO
12.2.3
12.2.3
12.2.3.1
STANDARD TIME CONSTITUENT STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME
12.2.3.1
STANDARD TIME CONSTITUENT STANDARD WORKING TIME = NET WORKING TIME + STANDARD TIME + STANDARD ALLOWANCE TIME
(1) Net working time The time workman works actually and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included
(1) Net working time The time workman works actually and the time required for measurement, cleaning, and so on is included, but the time required for troubleshooting is not included
(2) Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and so on, and for the work site clean-up.
(2) Standard time Time required for preparation to the beginning of work, preparation of special tool, measuring equipment, parts and so on, and for the work site clean-up.
(3) Standard allowance time Calculate the allowance time directly required for workmen from the following equation.
(3) Standard allowance time Calculate the allowance time directly required for workmen from the following equation.
Net standard time u HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on.
12-15
Net standard time u HINO allowance rate Allowance rate varies within the range of 0.15 ~ 0.75 according to the work difficulty, contents, working position and so on.
12-15
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE
12.2.3.2
12.2.3.2
12.2.3.2.1
ALLOWANCE RATE, STANDARD PREPARATION TIME HINO allowance rate (0.15~0.75)
12.2.3.2.1
ALLOWANCE RATE, STANDARD PREPARATION TIME HINO allowance rate (0.15~0.75)
(1) Basic rate : 0.10
(1) Basic rate : 0.10
(2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.10 Work while lying : 0.15
(2) Working posture allowance (Fatigue coefficient) : Take any one of the followings according to the work contents. Standing work : 0.05 Work in bent posture : 0.10 Work while lying : 0.15
(3) Difficult work allowance : 0.30
(3) Difficult work allowance : 0.30
(4) Seized rusted section (For new vehicle) : 0.50 Take any one of above (3) and (4).
(4) Seized rusted section (For new vehicle) : 0.50 Take any one of above (3) and (4).
Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15 Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2
STANDARD WORKING TIME
Min. allowance rate = Basic allowance + standing work allowance = 0.1+ 0.05 = 0.15 Max. allowance rate = Basic allowance + work allowance in lying + seized rusted section = 0.1 + 0.15 + 0.5=0.75 12.2.3.2.2
STANDARD WORKING TIME
(1) Working standard time : 3 minutes (One time for a set of works)
(1) Working standard time : 3 minutes (One time for a set of works)
(2) Special tool standard time : 3 minutes (One time for a set of works)
(2) Special tool standard time : 3 minutes (One time for a set of works)
(3) Standard time of non-portable machine : 3 minutes (For single work)
(3) Standard time of non-portable machine : 3 minutes (For single work)
(4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works)
(4) Part standard time : 6 minutes (up to 10 items), 10 minutes (10 items or more) (One time for a set of works)
(5) Test : 15 minutes (One time for a set of works)
(5) Test : 15 minutes (One time for a set of works)
(6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes (One time for a set of works)
(6) Preparation time for chain block, measuring instrument, piston, heater and so on : 3 minutes (One time for a set of works)
(7) General cleaning : 2 minutes (One time for a set of works)
(7) General cleaning : 2 minutes (One time for a set of works)
(8) Safety treatment like wheel stopper, and so on : 3 minutes
(8) Safety treatment like wheel stopper, and so on : 3 minutes
(9) Visual checks : 2 minutes
(9) Visual checks : 2 minutes
The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work.
12-16
The preparation time is classified into as described above, and only items required for the every work are selected, calculated and counted as preparation time of the work.
12-16
12. STANDARD MAINTENANCE TIME TABLE 12.2.4
MEANING OF WORDS IN USE
12. STANDARD MAINTENANCE TIME TABLE 12.2.4
MEANING OF WORDS IN USE
• Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work.
• Completed machine : When detaching, replacing and adjusting the specified parts, it means the time which is determined by addition of the preparation time, net working time and standard allowance time of the work.
• Single unit : When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed machine".
• Single unit : When detaching, replacing and adjusting the specified parts, it means the time in which the preparation time of the work is omitted and which is determined by addition and subtraction to/from the work for "Completed machine".
• Removal and installation : The work to remove specified parts from machine and to attach the parts, and then to perform necessary adjustment
• Removal and installation : The work to remove specified parts from machine and to attach the parts, and then to perform necessary adjustment
• Simultaneous replacement : The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then to perform necessary adjustment
• Simultaneous replacement : The work to remove specified parts in 2 types or more from machine and to attach the spare parts, and then to perform necessary adjustment
• Adjustment : The work to carry out necessary adjustment with the specified parts removed or attached :
• Adjustment : The work to carry out necessary adjustment with the specified parts removed or attached :
• Overhaul : The work to remove specified assembled parts from machine, disassemble and check them, and then to attach the spare parts to machine and to perform necessary adjustment
• Overhaul : The work to remove specified assembled parts from machine, disassemble and check them, and then to attach the spare parts to machine and to perform necessary adjustment
• Include : Explains the contents of work to make the specified work range clear
• Include : Explains the contents of work to make the specified work range clear
• Exclude : Shows the work which is not included in the specified primary work
• Exclude : Shows the work which is not included in the specified primary work
• Unit : Time is shown by hour.
• Unit : Time is shown by hour.
12-17
12-17
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE SK200-8
Work No.
Work
Work unit
Works 1
1
00101
Engine adjustment A set
2
00103
Engine adjustment B set
3
00111
Compression measuring
8
99012
9
99013
Replacing cylinder, block, piston, ring and liner simultaneously Replacing crank shaft, piston, ring and liner simultaneously
Completed Timing adjustment machine Valve clearance adjustment Completed machine Completed machine
A set and nozzle adjustment
SK330-8
SK200-8
Q'ty Adding hour
Work No. 1
by 1 each
Work
1
2.3
2.5
1
00101
Engine adjustment A set
—
—
2
00103
Engine adjustment B set
3.4
4.3
3
00111
Compression measuring
and battery specific gravity measurement
Single unit From engine is removed condition
27.4
31.6
8
99012
Single unit From engine is removed condition
20.8
25.8
9
99013
Replacing cylinder, block, piston, ring and liner simultaneously Replacing crank shaft, piston, ring and liner simultaneously
Completed Timing adjustment machine Valve clearance adjustment
Replacing cylinder block
Single unit
Exclude; Installing expansion plug knock
Adding hour
1
by 1 each
2.5
—
—
3.4
4.3
Single unit From engine is removed condition
27.4
31.6
Single unit From engine is removed condition
20.8
25.8
24.4
30
Completed machine Completed machine
A set and nozzle adjustment Include; Engine warm-up, valve clearance adjustment, removing air cleaner element and battery specific gravity measurement
From engine is removed condition
24.4
30
Replacing cylinder block
Single unit
pin
Include; Valve clearance adjustment Exclude; Installing expansion plug knock pin
11
00126
Replacing crank shaft
Single unit From engine is removed condition
18.4
22.8
11
00126
Replacing crank shaft
Single unit From engine is removed condition
18.4
22.8
12
00127
Replacing crank shaft main bearing
Single unit From engine is removed condition
18.4
22.8
12
00127
Replacing crank shaft main bearing
Single unit From engine is removed condition
18.4
22.8
38.5
44.3
2.3
3.1
From engine is removed condition
From engine is removed condition
Include; Adjustment of water pump, oil
Include; Adjustment of water pump, oil
pump, valve clearance, valve lapping and
15
16
00151
00152
Engine overhaul
Compression measuring
Single unit measurement/cleaning
pump, valve clearance, valve lapping and
38.5
44.3
15
00151
Engine overhaul
Single unit measurement/cleaning
Exclude; Replacing of injection pump,
Exclude; Replacing of injection pump,
electrical equipment, water pressure test,
electrical equipment, water pressure test,
clutch overhaul and valve guide
clutch overhaul and valve guide
2.3
Single unit
From piston & connecting rod are
17
00153
Replacing piston
Single unit
18
00154
Replacing piston ring
Single unit
19
00155
Replacing cylinder liner
Single unit
20
00157
Replacing connecting rod
Single unit
21
00158
Replacing piston pin bushing
Single unit condition
removed conditions From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions
16
3.1
00152
Compression measuring
Single unit
0.5
0.5
0.5
17
00153
Replacing piston
Single unit
0.2
0.2
0.2
0.2
18
00154
Replacing piston ring
Single unit
0.4
0.4
0.4
0.4
19
00155
Replacing cylinder liner
Single unit
0.3
0.3
0.3
0.3
20
00157
Replacing connecting rod
Single unit
0.4
0.4
0.4
0.4
21
00158
Replacing piston pin bushing
Single unit condition
Replacing expansion plug
41
00302
Valve clearance adjustment
42
00305
43
00306
44
00304
45
00312
46
00313
Replacing rocker arm
47
00314
Replacing rocker arm support
48
00315
Replacing rocker arm shaft
50
00322
Removal and installing cylinder head
51
00323
Replacing cylinder head
Replacing rocker chamber cover upper Replacing rocker chamber cover lower Replacing rocker chamber cover gasket Removal and installing rocker arm and support
0.4
0.4
0.4
26
00165
Replacing expansion plug
1.7
2.0
41
00302
One set
1.3
1.4
42
00305
One set Include; Removal and installing upper
—
4.3
43
00306
One set
1.3
1.4
44
00304
2.6
3.3
45
00312
2.6
3.4
46
00313
Replacing rocker arm
2.6
3.4
47
00314
Replacing rocker arm support
2.6
3.4
48
00315
Replacing rocker arm shaft
8.2
10.4
50
00322
Removal and installing cylinder head
11.5
16.9
51
00323
Replacing cylinder head
machine
Completed machine Completed machine Completed machine Completed machine Completed Excluding; Removal and installing of nozzle machine
holder or injector and injector sub harness
Completed Include; Valve lapping machine
Exclude; Replacing of valve guide
12-18
From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions From piston & connecting rod are removed conditions
0.5
0.5
0.5
0.5
0.2
0.2
0.2
0.2
0.4
0.4
0.4
0.4
0.3
0.3
0.3
0.3
0.4
0.4
0.4
0.4
0.4
0.4
0.4
0.4
Include; Reaming 0.4
Single unit Completed
removed conditions
From connecting rod is a single unit
Include; Reaming 00165
From piston & connecting rod are
0.5
From connecting rod is a single unit
26
Adding hour by 1 each
2.3
From engine is removed condition Include; Valve clearance adjustment
Works
by 1 each
Include; Engine warm-up, valve clearance adjustment, removing air cleaner element
Work unit
Adding hour
SK330-8 Q'ty
Valve clearance adjustment Replacing rocker chamber cover upper Replacing rocker chamber cover lower Replacing rocker chamber cover gasket Removal and installing rocker arm and support
Single unit Completed
1.7
2.0
One set
1.3
1.4
One set Include; Removal and installing upper
—
4.3
One set
1.3
1.4
2.6
3.3
2.6
3.4
2.6
3.4
2.6
3.4
8.2
10.4
11.5
16.9
machine
Completed machine Completed machine Completed machine Completed machine Completed Excluding; Removal and installing of nozzle machine
holder or injector and injector sub harness
Completed Include; Valve lapping machine
Exclude; Replacing of valve guide
12-18
12. STANDARD MAINTENANCE TIME TABLE SK200-8 Work No.
Work
Work unit
12. STANDARD MAINTENANCE TIME TABLE
SK330-8
SK200-8
Q'ty
Works 1
Adding hour
Work No. 1
by 1 each
Work
Work unit
1
by 1 each
Include; Valve lapping 52
00324
Overhaul of cylinder head
Completed Exclude; Replacing of valve guide, machine
water pressure test and replacing
00325
Replacing cylinder head gasket
54
00326
Replacing valve
55
00327
Replacing valve spring
57
00328
Replacing valve stem seal
61
00376
62
00377
Removal and installing camshaft housing plug
Completed machine Completed machine
Include; Valve lapping
Completed Exclude; Removal and installing of machine
cylinder head
Completed Exclude; Removal and installing of machine
cylinder head
One set
13.3
52
18.8
00324
Overhaul of cylinder head
Completed Exclude; Replacing of valve guide, machine
8.2
10.4
53
00325
Replacing cylinder head gasket
10.2
15.6
54
00326
Replacing valve
4.9
8.8
55
00327
Replacing valve spring
5.3
9.4
57
00328
Replacing valve stem seal
61
00376
62
00377
0.2
2.6
1.6
0.2
3.4
63
00352
(one piece and one set require same Single unit hour)
cylinder head, replacing valve guide,
Removal and installing camshaft housing plug
machine Completed machine machine
00355
Replacing valve guide
72
00361
Replacing expansion plug Replacing rocker arm
73
00371
(one piece and one set require same hour) Replacing rocker arm support
74
00372
(one piece and one set require same hour)
75
00373
Replacing rocker arm bushing
76
00374
Replacing valve
cylinder Single unit
machine
6.1
63
6.5
One set
00352
(one piece and one set require same Single unit
1.0
0.8
66
00355
Replacing valve guide
0.4
0.4
0.4
0.4
72
00361
Replacing expansion plug
73
0.1
00371
(one piece and one set require same
74
0.1
00372
(one piece and one set require same hour)
cylinder
cylinder
0.8
Replacing rocker arm support
Unit of 1
Unit of 1
1.0
0.1
cylinder
0.3
0.1
0.3
0.1
75
00373
Replacing rocker arm bushing
0.5
0.5
0.5
0.5
76
00374
Replacing valve
From cylinder head is removed condition Include; Valve lapping
Unit of 1 From cylinder head is removed
13.3
18.8
8.2
10.4
10.2
15.6
4.9
8.8
5.3
9.4
1.2
0.2
1.6
2.6
3.4
6.1
6.5
77
00375
Replacing valve spring
Excluding; Removal and installing of cylinder head, replacing valve guide, water pressure test and replacing
78
00330
Replacing valve stem seal
81
00406
Removal and installing supply pump
2.3
84
00411
Tightening oil pan
Single unit From engine is removed condition
0.5
85
00412
Removal and installing oil pan
Single unit From engine is removed condition
0.5
86
00413
Replacing oil pan
Single unit From engine is removed condition
0.7
87
00414
Replacing oil pan gasket
Single unit From engine is removed condition
88
00421
Replacing oil pan drain cock
89
00422
92
00443
93 94
Unit of 1 cylinder Single unit
Unit of 1 cylinder Unit of 1 cylinder Unit of 1 cylinder Unit of 1 cylinder
1.0
0.8
1.0
0.8
0.4
0.4
0.4
0.4
0.1
0.1
0.1
0.1
0.3
0.1
0.3
0.1
0.5
0.5
0.5
0.5
0.2
0.2
0.2
0.2
0.3
0.3
0.3
0.3
From cylinder head is removed condition Include; Valve lapping
Unit of 1 From cylinder head is removed
0.2
0.2
0.2
0.2
77
00375
Replacing valve spring
0.3
0.3
0.3
0.3
78
00330
Replacing valve stem seal
2.3
81
00406
Removal and installing supply pump
2.3
2.3
0.5
84
00411
Tightening oil pan
Single unit From engine is removed condition
0.5
0.5
0.5
85
00412
Removal and installing oil pan
Single unit From engine is removed condition
0.5
0.5
0.7
86
00413
Replacing oil pan
Single unit From engine is removed condition
0.7
0.7
0.7
0.7
87
00414
Replacing oil pan gasket
Single unit From engine is removed condition
0.7
0.7
Single unit From engine is removed condition
0.5
0.5
88
00421
Replacing oil pan drain cock
Single unit From engine is removed condition
0.5
0.5
Replacing oil pan drain cock gasket
Single unit From engine is removed condition
0.5
89
00422
Replacing oil pan drain cock gasket
Single unit From engine is removed condition
0.5
Replacing breather hose
Single unit From engine is removed condition
0.3
92
00443
Replacing breather hose
Single unit From engine is removed condition
0.3
00444
Replacing oil level gauge
Single unit From engine is removed condition
0.1
0.1
93
00444
Replacing oil level gauge
Single unit From engine is removed condition
0.1
0.1
00445
Replacing oil level gauge guide
Single unit From engine is removed condition
0.2
0.2
94
00445
Replacing oil level gauge guide
Single unit From engine is removed condition
0.2
0.2
cylinder condition Unit of 1 From cylinder head is removed cylinder condition One set Include; Function check
0.5 0.2
0.3
0.2
cylinder condition Unit of 1 From cylinder head is removed cylinder condition One set Include; Function check
0.5 0.2
0.3
95
00446
Replacing oil level gauge bracket
Single unit From engine is removed condition
0.2
0.2
95
00446
Replacing oil level gauge bracket
Single unit From engine is removed condition
0.2
0.2
102
00512
Replacing fly wheel housing
Single unit From engine is removed condition
3.4
3.4
102
00512
Replacing fly wheel housing
Single unit From engine is removed condition
3.4
3.4
103
00541
Replacing fly wheel housing gasket
Single unit From engine is removed condition
5.4
5.4
103
00541
Replacing fly wheel housing gasket
Single unit From engine is removed condition
5.4
5.4
104
00542
Replacing rear end plate
Single unit From engine is removed condition
5.4
5.4
104
00542
Replacing rear end plate
Single unit From engine is removed condition
5.4
5.4
105
00543
Replacing rear end plate gasket
Single unit From engine is removed condition
5.4
5.4
105
00543
Replacing rear end plate gasket
Single unit From engine is removed condition
5.4
5.4
106
00515
Replacing crank shaft rear oil seal
Single unit From engine is removed condition
5.4
5.4
106
00515
Replacing crank shaft rear oil seal
Single unit From engine is removed condition
5.4
5.4
12-19
0.2
valve seat
hour)
Unit of 1
by 1 each
Include; Valve lapping
hour)
0.1
cylinder
cylinder head
Removal and installing camshaft (with Completed machine camshaft gear)
Replacing rocker arm
Unit of 1
cylinder head
Completed Exclude; Removal and installing of
valve seat 66
Include; Valve lapping
Completed Exclude; Removal and installing of
Replacing cylinder head
water pressure test and replacing Unit of 1
Adding hour
With manifold and nozzle holder
Include; Valve lapping Excluding; Removal and installing of
water pressure test and replacing
Completed
With manifold and nozzle holder Replacing cylinder head
1
by 1 each
valve seat
1.2
Removal and installing camshaft (with Completed machine camshaft gear)
Adding hour
Include; Valve lapping
valve seat 53
Works
Adding hour
SK330-8 Q'ty
12-19
0.2
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE SK200-8
Work No.
Work
Work unit
Works 1
119
00552
Replacing crank shaft rear oil seal
Single unit From fly wheel is removed condition
SK330-8
SK200-8
Q'ty Adding hour
Work No. 1
by 1 each
Work
Work unit
Works
Adding hour
1
by 1 each
0.2
0.2
119
00552
Replacing crank shaft rear oil seal
Single unit From fly wheel is removed condition
SK330-8 Q'ty
Adding hour
1
by 1 each
by 1 each
0.2
0.2
131
00613
Replacing intake manifold
One set Include; Applying liquid gasket
2.0
2.3
131
00613
Replacing intake manifold
One set Include; Applying liquid gasket
2.0
2.3
132
00614
Replacing intake manifold gasket
One set Include; Applying liquid gasket
2.0
2.3
132
00614
Replacing intake manifold gasket
One set Include; Applying liquid gasket
2.0
2.3
One set
1.3
1.6
One set
1.3
1.6
Removal and installing intake pipe
133
00636
134
00637
Replacing intake pipe (manifold side)
135
00622
136
00623
137 138
Removal and installing intake pipe
One set
1.3
1.6
133
00636
One set
1.3
1.6
134
00637
Replacing intake pipe (manifold side)
Replacing air intake hose
One set
0.4
0.2
0.4
0.2
135
00622
Replacing air intake hose
One set
0.4
0.2
0.4
0.2
Replacing air intake pipe
One set
0.4
0.2
0.4
0.2
136
00623
Replacing air intake pipe
One set
0.4
0.2
0.4
0.2
00626
Replacing air intake pipe
One set Turbo charger to inter cooler
0.4
137
00626
Replacing air intake pipe
One set Turbo charger to inter cooler
0.4
00627
Replacing air intake pipe
One set Air cleaner to turbo charger
0.4
138
00627
Replacing air intake pipe
One set Air cleaner to turbo charger
0.4
0.2
0.4
0.2
0.3
0.2
0.3
0.2
(manifold side)
139
00675
Replacing silencer body
142
00641
Tightening exhaust manifold
143
00643
144
00644
Replacing exhaust manifold
145
00645
Replacing exhaust manifold gasket
146
00646
Replacing exhaust heat insulator
Removal and installing exhaust manifold
Completed
0.3
machine Completed machine Completed machine
With insulator and stud bolt
Completed Include; Replacing stud bolt with new machine
one and insulator (TI system)
Completed machine One side of completed machine
Removal and installing of turbo charger
0.4 0.2 0.2
0.4 0.3
0.2 0.2
(manifold side)
139
00675
Replacing silencer body Tightening exhaust manifold
0.9
1.3
142
00641
2.8
3.2
143
00643
3.0
3.4
144
00644
Replacing exhaust manifold
2.8
3.2
145
00645
Replacing exhaust manifold gasket
2.4
2.6
146
00646
Replacing exhaust heat insulator
Removal and installing exhaust manifold
Completed machine Completed machine Completed machine
With insulator and stud bolt
Completed Include; Replacing stud bolt with new machine
one and insulator (TI system)
Completed machine One side of completed machine
Removal and installing of turbo charger
0.4
0.9
1.3
2.8
3.2
3.0
3.4
2.8
3.2
2.4
2.6
147
00651
Replacing exhaust pipe
One set
0.8
0.8
147
00651
Replacing exhaust pipe
One set
0.8
0.8
148
00653
Replacing exhaust pipe gasket
One set
0.6
0.6
148
00653
Replacing exhaust pipe gasket
One set
0.6
0.6
164
00686
Removal and installing turbo charger
One set
2.9
2.5
164
00686
Removal and installing turbo charger
One set
2.9
2.5
165
00687
Replacing turbo charger
One set Include; Replacing stud bolt
2.6
2.5
165
00687
Replacing turbo charger
One set Include; Replacing stud bolt
2.6
2.5
0.9
0.9
0.4
0.4
5.4
5.4
5.4
5.4
0.7
0.7
1.0
1.0
1.0
1.0
0.2
0.2
0.1
0.1
0.2
0.2
0.1
0.1
0.4
0.4
0.4
0.4
167
00689
174
00624
188
00701
Replacing turbo charger oil return pipe Replacing air intake pipe upper (cooler to manifold)
One set
timing gear cover
190
00712
191
00713
192
00714
Replacing timing gear cover (fly wheel housing) Replacing timing gear cover gasket (fly wheel housing) Replacing timing gear cover plate (rear end plate)
0.9
0.9
167
00689
0.4
0.4
174
00624
5.4
5.4
188
00701
From engine is removed condition
5.4
5.4
189
00711
cylinder head Single unit
Single unit
Single unit
(rear end plate gasket) 193
00725
Replacing idler gear (main)
Single unit
194
00736
Replacing idler gear (sub)
Single unit
195
00726
Replacing idler gear shaft (main)
196
00737
Replacing idler gear shaft (sub)
Single unit
197
00724
Replacing crank shaft gear rear
Single unit
201
00738
Replacing cam idle gear
Single unit
Single unit
From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition
12-20
pipe Replacing air intake pipe upper (cooler to manifold)
One set
timing gear cover
0.7
0.7
190
00712
1.0
1.0
191
00713
1.0
1.0
192
00714
Replacing timing gear cover (fly wheel housing) Replacing timing gear cover gasket (fly wheel housing) Replacing timing gear cover plate (rear end plate)
lower insulator
From engine is removed condition Single unit Include; Removal and installing of
cylinder head From engine is removed condition Single unit Include; Removal and installing of
cylinder head Single unit
Single unit
Replacing timing gear cover plate gasket
Include; Removal and installing of
One set
(fly wheel housing)
From engine is removed condition Single unit Include; Removal and installing of
Replacing turbo charger oil return
Removal and installing engine and
cylinder head
Replacing timing gear cover plate gasket
lower insulator
Single unit Include; Removal and installing of
(fly wheel housing) 00711
Include; Removal and installing of
One set
Removal and installing engine and
189
Adding hour
Single unit
(rear end plate gasket) 0.2
0.2
193
00725
Replacing idler gear (main)
Single unit
0.1
0.1
194
00736
Replacing idler gear (sub)
Single unit
0.2
0.2
195
00726
Replacing idler gear shaft (main)
0.1
0.1
196
00737
Replacing idler gear shaft (sub)
Single unit
0.4
0.4
197
00724
Replacing crank shaft gear rear
Single unit
0.4
0.4
201
00738
Replacing cam idle gear
Single unit
Single unit
From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition From timing gear cover is removed condition
12-20
12. STANDARD MAINTENANCE TIME TABLE SK200-8 Work No.
Work
Work unit
1 202
00739
Replacing cam idle gear shaft
Single unit
203
00731
Replacing camshaft
Single unit
204
00732
Replacing camshaft gear
Single unit
205
00751
Replacing crank pulley
One set
206
00754
Replacing crank dumper
One set
207
00755
Replacing crank shaft front oil seal
One set
2.2
Replacing crank shaft front oil seal
condition From timing gear cover is removed condition From timing gear cover is removed condition
1
by 1 each
00731
Replacing camshaft
Single unit
0.8
0.8
204
00732
Replacing camshaft gear
Single unit
1.9
1.9
205
00751
Replacing crank pulley
One set
1.9
1.9
2.8
2.8
206
00754
Replacing crank dumper
One set
2.8
2.8
2.2
207
00755
Replacing crank shaft front oil seal
One set
2.2
2.2
One set
2.8
2.8
One set
2.8
2.8
0.3
0.3
00834
Replacing priming pump
One set
00835
Cleaning fuel feed pump strainer
One set
228
00836
Replacing through feed valve
One set
0.4
230
00838
Replacing fuel injection pipe
One set
2.5
236
00851
Replacing fuel filter assembly
One set
0.5
237
00857
Replacing fuel filter cartridge
One set
0.3
253
00875
Replacing fuel hose
One set
254
00876
Replacing fuel leakage pipe
One set
276
00912
Replacing oil filter cartridge
One set
0.4
Replacing crank shaft front oil seal
condition From timing gear cover is removed condition From timing gear cover is removed condition
0.4
0.4
0.8
0.8
0.8
0.8
One set
2.8
2.8
208
00757
One set
2.8
2.8
209
00758
0.3
0.3
211
00801
Checking injection timing
0.4
0.4
226
00834
Replacing priming pump
One set
0.4
0.4
0.4
0.4
227
00835
Cleaning fuel feed pump strainer
One set
0.4
0.4
228
00836
Replacing through feed valve
One set
0.4
230
00838
Replacing fuel injection pipe
One set
2.5
0.5
236
00851
Replacing fuel filter assembly
One set
0.5
0.5
0.3
237
00857
Replacing fuel filter cartridge
One set
0.3
0.3
0.8
0.8
253
00875
Replacing fuel hose
One set
0.8
0.8
0.8
0.8
254
00876
Replacing fuel leakage pipe
One set
0.8
0.8
0.4
276
00912
Replacing oil filter cartridge
One set
0.4
0.4
One set
0.3
0.3
One set
0.3
0.3
Completed machine
277
00907
278
00908
279
00909
Replacing oil filter safety valve
One set
280
00910
Replacing oil filter safety valve spring
One set
6.1
0.4 0.1
2.5
0.1
retainer Replacing crank shaft front oil seal retainer gasket
Replacing oil filter relief valve (oil filter
Completed machine
0.4 0.1
2.5
One set
0.3
0.3
277
00907
One set
0.3
0.3
278
00908
0.3
0.3
279
00909
Replacing oil filter safety valve
One set
0.3
0.3
0.3
0.3
280
00910
Replacing oil filter safety valve spring
One set
0.3
0.3
6.1
294
Single unit From engine is removed condition
6.1
6.1
00961(tim Removal and installing fly wheel
regulator valve) Replacing oil filter relief valve spring (oil filter regulator valve)
Adding hour by 1 each
203
227
ing gear housing
1
by 1 each
0.8
226
294
From timing gear cover is removed
Adding hour
0.8
Checking injection timing
(oil filter regulator valve)
Works
Single unit
00801
Replacing oil filter relief valve spring
Work unit
Replacing cam idle gear shaft
211
regulator valve)
by 1 each
Work
Adding hour
00739
00758
Replacing oil filter relief valve (oil filter
Work No. 1
202
209
retainer gasket
Adding hour
SK330-8 Q'ty
0.4
00757
Replacing crank shaft front oil seal
SK200-8
0.4
208
retainer
SK330-8 Q'ty
Works
From timing gear cover is removed
12. STANDARD MAINTENANCE TIME TABLE
0.1
00961(tim Removal and installing fly wheel Single unit From engine is removed condition
cover)
(timing gear cover)
295
00942
Replacing oil pump
Single unit From engine is removed condition
6.3
6.3
296
00944
Replacing oil pump gear
Single unit From engine is removed condition
6.5
297
00943
Overhaul of oil pump
Single unit From engine is removed condition
298
00946
Replacing suction strainer
299
00947
Replacing suction strainer O-ring
ing gear housing cover)
(timing gear cover)
295
00942
Replacing oil pump
Single unit From engine is removed condition
6.3
6.3
6.5
296
00944
Replacing oil pump gear
Single unit From engine is removed condition
6.5
6.5
6.5
6.5
297
00943
Overhaul of oil pump
Single unit From engine is removed condition
6.5
6.5
One set
0.1
0.1
298
00946
Replacing suction strainer
One set
0.1
0.1
One set
0.1
0.1
299
00947
Replacing suction strainer O-ring
One set
0.1
0.1
301
00951
Replacing oil pipe
One set
0.4
0.4
0.4
0.4
301
00951
Replacing oil pipe
One set
0.4
0.4
0.4
0.4
302
00954
Replacing oil hose
One set
0.4
0.4
0.4
0.4
302
00954
Replacing oil hose
One set
0.4
0.4
0.4
0.4
303
00971
Replacing cooling oil jet
0.2
0.2
0.2
0.2
0.2
0.2
0.2
0.2
327
01028
Removal and installing water pump
328
01029
Replacing water pump
329
01030
Overhaul of water pump
Single unit
330
01031
Replacing water pump pulley
Single unit
331
01032
Replacing water pump casing gasket
332
01036
333
01037
334
303
00971
Replacing cooling oil jet
One set Include; Filling engine coolant up
4.0
4.0
327
01028
Removal and installing water pump
One set Include; Filling engine coolant up
4.0
4.0
328
01029
Replacing water pump
0.8
0.8
329
01030
Overhaul of water pump
Single unit
0.6
0.6
330
01031
Replacing water pump pulley
Single unit
0.6
0.6
One set Liquid gasket
4.0
4.0
331
01032
Replacing water pump casing gasket
One set Liquid gasket
4.0
4.0
Replacing cooling fan
One set
0.9
0.9
332
01036
Replacing cooling fan
One set
0.9
0.9
Replacing fluid fan coupling
One set
0.9
0.9
333
01037
Replacing fluid fan coupling
One set
0.9
0.9
01044
Replacing thermostat casing
One set Include; Filling engine coolant up
1.3
1.3
334
01044
Replacing thermostat casing
One set Include; Filling engine coolant up
1.3
1.3
336
01046
Replacing thermostat casing cover
One set Include; Filling engine coolant up
1.0
1.0
336
01046
Replacing thermostat casing cover
One set Include; Filling engine coolant up
1.0
1.0
337
01047
One set Include; Filling engine coolant up
1.0
1.0
337
01047
One set Include; Filling engine coolant up
1.0
1.0
338
01048
1.0
1.0
338
01048
1.0
1.0
Replacing thermostat casing cover gasket Replacing thermostat
1
One set
Include; Checking for temperature at valve start opening
12-21
Replacing thermostat casing cover gasket Replacing thermostat
1 One set Include; Filling engine coolant up
4.0
4.0
One set Include; Filling engine coolant up
4.0
4.0
0.8
0.8
One set
Include; Checking for temperature at valve start opening
12-21
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE SK200-8
Work No.
Work
Work unit
Works 1
339
01049
Checking thermostat
One set
Include; Checking for temperature at valve start opening
SK330-8
SK200-8
Q'ty Adding hour
Work No. 1
by 1 each
1.0
Work
Work unit
Works
Adding hour
1
by 1 each
1.0
339
01049
Checking thermostat
One set
Include; Checking for temperature at valve start opening
SK330-8 Q'ty
Adding hour
1
by 1 each
1.0
Adding hour by 1 each
1.0
341
01053
Replacing coolant hose
One set
0.3
0.2
0.3
0.2
341
01053
Replacing coolant hose
One set
0.3
0.2
0.3
0.2
342
01054
Replacing radiator hose
One set
0.3
0.2
0.3
0.2
342
01054
Replacing radiator hose
One set
0.3
0.2
0.3
0.2
343
01071
Replacing fluid fan coupling
1
0.3
0.3
343
01071
Replacing fluid fan coupling
1
0.3
0.3
344
01072
Replacing cooling fan
1
0.3
0.3
344
01072
Replacing cooling fan
1
0.3
0.3
345
01073
Replacing water pump
1
1.7
1.7
345
01073
Replacing water pump
1
1.7
1.7
346
01074
Overhaul of water pump
1
0.8
0.8
346
01074
Overhaul of water pump
1
0.8
0.8
402
01401
Removal and installing alternator
One set
0.8
0.8
402
01401
Removal and installing alternator
One set
0.8
0.8
403
01402
Replacing alternator
One set
0.9
0.9
403
01402
Replacing alternator
One set
0.9
0.9
From cooling fan is removed condition
From cooling fan is removed condition
404
01406
Replacing alternator support bracket
One set
1.0
1.0
404
01406
Replacing alternator support bracket
One set
1.0
1.0
405
01408
Replacing V-belt
One set
0.3
0.3
405
01408
Replacing V-belt
One set
0.3
0.3
438
01801
Removal and installing supply pump
One set Include; Function check
3.0
3.0
438
01801
Removal and installing supply pump
One set Include; Function check
3.0
3.0
439
01802
Replacing supply pump
One set Include; Function check
3.0
3.0
439
01802
Replacing supply pump
One set Include; Function check
3.0
3.0
One set Include; Function check
3.8
3.8
One set Include; Function check
3.8
3.8
2.9
3.5
3.4
4.0
Removal and installing common rail 440
01830
assembly (with pressure sensor, pressure
Removal and installing common rail One set Include; Function check
3.8
440
3.8
01830
limiter) 01804
(with pressure sensor, pressure
Replacing common rail assembly One set Include; Function check
3.8
3.8
441
01804
limiter) 442
01805
443
01806
444
01807
445
01808
446
01809
447
01810
Removal and installing injector assembly Replacing injector assembly Removal and installing injector assembly Replacing injector assembly Removal and installing injector sub harness assembly Replace injector sub harness assembly
(with pressure sensor, pressure limiter)
Replacing common rail assembly 441
assembly
(with pressure sensor, pressure limiter)
Completed machine
Include; Function check
Completed Include; Function check and machine
reprogramming
One set Include; Function check One set
Include; Function check and reprogramming
2.9
3.5
442
01805
3.4
4.0
443
01806
1.9
0.2
1.9
0.2
444
01807
2.4
0.2
2.4
0.2
445
01808
One set Include; Function check
1.9
1.9
446
01809
One set Include; Function check
1.9
1.9
447
01810
Removal and installing injector assembly Replacing injector assembly Removal and installing injector assembly Replacing injector assembly Removal and installing injector sub harness assembly Replace injector sub harness assembly
Completed machine
Include; Function check
Completed Include; Function check and machine
reprogramming
One set Include; Function check One set
Include; Function check and reprogramming
1.9
0.2
1.9
0.2
2.4
0.2
2.4
0.2
One set Include; Function check
1.9
1.9
One set Include; Function check
1.9
1.9
448
01811
Removal and installing flow dumper
One set Include; Function check
1.2
0.3
1.2
0.3
448
01811
Removal and installing flow dumper
One set Include; Function check
1.2
0.3
1.2
0.3
449
01812
Replacing flow dumper
One set Include; Function check
1.2
0.3
1.2
0.3
449
01812
Replacing flow dumper
One set Include; Function check
1.2
0.3
1.2
0.3
450
01813
One set Include; Function check
1.2
1.2
450
01813
One set Include; Function check
1.2
1.2
451
01814
One set Include; Function check
1.2
1.2
451
01814
One set Include; Function check
1.2
1.2
One set Include; Function check
1.2
1.2
452
01815
Removal and installing pressure limiter Replacing pressure limiter Replacing common rail pressure sensor
One set Include; Function check
1.2
1.2
452
01815
Removal and installing pressure limiter Replacing pressure limiter Replacing common rail pressure sensor
453
01816
Replacing main engine speed sensor
One set Include; Function check
1.2
1.2
453
01816
Replacing main engine speed sensor
One set Include; Function check
1.2
1.2
454
01817
Replacing sub engine speed sensor
One set Include; Function check
1.2
1.2
454
01817
Replacing sub engine speed sensor
One set Include; Function check
1.2
1.2
455
01818
One set Include; Function check
1.2
1.2
455
01818
One set Include; Function check
1.2
1.2
456
01819
Replacing fuel temperature sensor
One set Include; Function check
1.2
1.2
456
01819
Replacing fuel temperature sensor
One set Include; Function check
1.2
1.2
457
01820
Replacing accel sensor
One set Include; Function check
1.5
1.5
457
01820
Replacing accel sensor
One set Include; Function check
1.5
1.5
460
01823
461
01824
463
01826
464
01827
Replacing coolant temperature sensor
Removal and installing pressure sensor Removal and installing pressure limiter Replacing injection pipe Replacing fuel pipe (common rail to supply pump)
1
Include; Function check
0.3
0.3
460
01823
1
Include; Function check
0.3
0.3
461
01824
One set Include; Function check
1.2
0.1
1.2
0.1
463
01826
One set Include; Function check
1.2
0.1
1.2
0.1
464
01827
Replacing coolant temperature sensor
Removal and installing pressure sensor Removal and installing pressure limiter Replacing injection pipe Replacing fuel pipe (common rail to supply pump)
1
Include; Function check
0.3
0.3
1
Include; Function check
0.3
0.3
One set Include; Function check
1.2
0.1
1.2
0.1
One set Include; Function check
1.2
0.1
1.2
0.1
465
01828
Replacing fuel leakage pipe
One set Include; Function check
1.7
1.7
465
01828
Replacing fuel leakage pipe
One set Include; Function check
1.7
1.7
469
01840
Checking leakage of pressurized fuel
One set Include; Function check
1.2
1.2
469
01840
Checking leakage of pressurized fuel
One set Include; Function check
1.2
1.2
12-22
12-22
12. STANDARD MAINTENANCE TIME TABLE SK200-8 Work No.
Work
Work unit
01901
472
01902
SK330-8
SK200-8
Q'ty
Works 1
471
12. STANDARD MAINTENANCE TIME TABLE
Adding hour
Work No. 1
by 1 each
1.2
1.2
471
01901
Replacing sub engine speed sensor
One set Include; Function check
1.2
1.2
472
01902
01903
474
01904
Replacing accel sensor
One set Include; Function check
475
01908
Removal and installing EGR valve
One set Include; Function check
sensor
One set Include; Function check
1.2
Works 1
One set Include; Function check
473
Work unit
by 1 each
Replacing main engine speed sensor Replacing coolant temperature
Work
Adding hour
SK330-8 Q'ty
Adding hour
1
by 1 each
by 1 each
Replacing main engine speed sensor
One set Include; Function check
1.2
1.2
Replacing sub engine speed sensor
One set Include; Function check
1.2
1.2
One set Include; Function check
1.2
1.2
Replacing coolant temperature
1.2
473
01903
1.5
1.5
474
01904
Replacing accel sensor
One set Include; Function check
1.5
1.5
2.1
2.5
475
01908
Removal and installing EGR valve
One set Include; Function check
2.1
2.5
sensor
476
01909
Replacing EGR valve
One set Include; Function check
2.1
2.5
476
01909
Replacing EGR valve
One set Include; Function check
2.1
2.5
479
01916
Removal and installing EGR cooler
One set
1.8
1.8
479
01916
Removal and installing EGR cooler
One set
1.8
1.8
480
01917
Replacing EGR cooler
One set
1.8
1.8
480
01917
Replacing EGR cooler
One set
1.8
1.8
One set
0.3
0.3
One set
0.3
0.3
481
01918
482
01919
Removal and installing closed ventilator Replacing closed ventilator
One set
0.3
0.3
481
01918
One set
0.3
0.3
482
01919
12-23
Removal and installing closed ventilator Replacing closed ventilator
12-23
Adding hour
12. STANDARD MAINTENANCE TIME TABLE
12. STANDARD MAINTENANCE TIME TABLE
[MEMO]
[MEMO]
12-24
12-24
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13
TABLE OF CONTENTS
13
TABLE OF CONTENTS
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.1 HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED ..........13-3
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4
13.2 PERFORMANCE INSPECTION STANDARD TABLE .....................................................13-4
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3 MEASUREMENT OF ENGINE SPEED ...........................................................................13-6
13.3.1
MEASUREMENT OF ENGINE SPEED ..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.3.1
MEASUREMENT OF ENGINE SPEED ..................................................................13-6
13.4 MEASUREMENT OF HYDRAULIC PRESSURE ............................................................13-7
13.4.1
PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.1
PREPARING TO MEASURE HYDRAULIC PRESSURE .......................................13-7
13.4.2
PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.2
PLACE TO INSTALL PRESSURE GAUGE............................................................13-7
13.4.3
PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.3
PRESSURE ADJUSTMENT POSITION.................................................................13-8
13.4.4
PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.4.4
PROCEDURE FOR ADJUSTING RELIEF VALVE.................................................13-10
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5 MEASURING TRAVEL PERFORMANCES.....................................................................13-12
13.5.1
TRAVEL SPEED.....................................................................................................13-12
13.5.1
TRAVEL SPEED.....................................................................................................13-12
13.5.2
DEVIATION OF TRAVEL .......................................................................................13-12
13.5.2
DEVIATION OF TRAVEL .......................................................................................13-12
13.5.3
PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.3
PERFORMANCES OF PARKING BRAKE .............................................................13-13
13.5.4
DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.5.4
DRAIN RATE OF TRAVEL MOTOR.......................................................................13-14
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6 MEASURING SWING PERFORMANCES.......................................................................13-15
13.6.1
SWING SPEED ......................................................................................................13-15
13.6.1
SWING SPEED ......................................................................................................13-15
13.6.2
PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.2
PERFORMANCE OF SWING BRAKE ...................................................................13-15
13.6.3
PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.3
PERFORMANCE OF SWING PARKING BRAKE ..................................................13-16
13.6.4
DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.6.4
DRAIN RATE OF SWING MOTOR ........................................................................13-17
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7 MEASURING ATTACHMENT OPERATING PERFORMANCES ....................................13-18
13.7.1
OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.1
OPERATING TIME OF CYLINDERS .....................................................................13-18
13.7.2
OIL TIGHTNESS OF CYLINDERS .........................................................................13-19
13.7.2
OIL TIGHTNESS OF CYLINDERS .........................................................................13-19
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.8 MEASURING PERFORMANCES OF SWING BEARING ...............................................13-20
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9 MECHATRO CONTROLLER...........................................................................................13-21
13.9.1
ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.1
ENGINE CONTROL INPUT / OUTPUT ..................................................................13-21
13.9.2
ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)..........13-21
13.9.2
ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT)..........13-21
13.9.3
OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER .......................................................................................................13-27
13.9.3
OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER .......................................................................................................13-27
Book Code No. S5YN1318E02 13-1
Book Code No. S5YN1318E02 13-1
13. MAINTENANCE STANDARD AND TEST PROCEDURE Issue
Date of Issue
Applicable Machines
First edition
August, 2006
Revision
February, 2007
n
March, 2007
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n E215B : YN11-45001~ E215BLC : YQ11-06001~
n
13-2
13. MAINTENANCE STANDARD AND TEST PROCEDURE Remarks
Issue
Date of Issue
Applicable Machines
S5YN1318E01 (ASIA, OCE)
K
First edition
August, 2006
S5YN1318E02 (ASIA, OCE)
K
Revision
February, 2007
K
n
March, 2007
K
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) HS Engine
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n E215B : YN11-45001~ E215BLC : YQ11-06001~
n
13-2
Remarks S5YN1318E01 (ASIA, OCE)
K
S5YN1318E02 (ASIA, OCE)
K
n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) HS Engine
K K K K
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.1
HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED
(1) Application
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.1
HOW TO USE THE MAINTENANCE STANDARD AND CAUTIONS TO BE EXERCISED
(1) Application
1) When the machine is new ; Confirm that the performances are in accordance with standard specifications as compared to the performance standards.
1) When the machine is new ; Confirm that the performances are in accordance with standard specifications as compared to the performance standards.
2) At specific self inspection ; (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
2) At specific self inspection ; (Rule by country) Use the data for the criterion, for the purpose of correction, adjustment and replacement.
3) When performances are deteriorated ; Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations.
3) When performances are deteriorated ; Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations.
4) When main components are replaced ; For example, use data to restore performances of pumps and others.
4) When main components are replaced ; For example, use data to restore performances of pumps and others.
(2) Terminology
(2) Terminology
1) Standard values ; Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes).
1) Standard values ; Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes).
2) Reference values for remedy ; Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values.
2) Reference values for remedy ; Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values.
3) Service limit ; This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes safety problems.
3) Service limit ; This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and correction are performed, replace the parts immediately. The operation over the specified values causes increase of damage and requires the down time of machine, and also causes safety problems.
(3) Cautions to be Exercised at Judgment
(3) Cautions to be Exercised at Judgment
1) Evaluation of measured data ; Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values.
1) Evaluation of measured data ; Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values.
2) Determining correction, adjustment or replacement ; Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.
2) Determining correction, adjustment or replacement ; Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels.
(4) Other Cautions to be Exercised
(4) Other Cautions to be Exercised
1) Parts liable to degrade ; Rubber products, such as, hydraulic hoses, O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
1) Parts liable to degrade ; Rubber products, such as, hydraulic hoses, O rings, and oil seals deteriorate with time ; replace them at regular intervals or at overhauls.
2) Parts requiring regular replacement ; Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly.
2) Parts requiring regular replacement ; Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly.
3) Inspection and replacement of oils and greases ; In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.
3) Inspection and replacement of oils and greases ; In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well.
13-3
13-3
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.2
13.2
PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
PERFORMANCE INSPECTION STANDARD TABLE
Unless otherwise specified, measure it on "H" mode.
B mode Hi idle A mode Hi idle Decel
Measure the engine speed at multi display on the gauge cluster.
S mode Hi idle
Boost
Arm Bucket
Travel
Swing RH LH
G pump
a4
P1
a1
P2
a2
P1
a1
P2
a2
R
a1
H R H R H RH LH FW RV FW RV
Main pump
valve pressure
ATT
Boom Over load relief valve pressure
High pressure circuit
Main relief
Pilot primary pressure circuit
PF1/4
a2 a1
°C
- 15 (5) (°F)
Sampling
—
Atmospheric temp
—
50°C~-10°C
75 (167)
+ 15 (59)
1000
+ 30
- 30
2000
+ 30
- 30
2000
+ 30
- 30
2000
+ 30
- 30
1050
+ 30
- 30
1800
+ 30
- 30
5.0 (725)
+ 0.5 (+73)
0
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
MR1 Boom up
37.8 (5480) + 1.0 (+145)
- 0.5 (-73)
MR1
37.8 (5480)
0 - 4.0 (-580)
OR4
Boom down
39.7 (5760)
0 - 5.9 (-855)
OR3
Boom up
39.7 (5760)
0 - 5.9 (-855)
OR8
Arm out
37.8 (5480)
0 - 4.0 (-580) MPa
OR7
Arm in
37.8 (5480)
0 - 4.5 (-711) (psi)
OR2
Bucket dump
39.7 (5760)
0 - 5.9 (-855)
OR1
Bucket digging
(122°F~14°F)
LOW throttle
min-1
PR1
Full throttle (HI idle)
Perform all measurement with the air-conditioner "OFF". HI idle
29.0 (4205) + 6.0 (+870)
0
OR6
Swing RH
29.0 (4205) + 6.0 (+870)
0
OR5
Swing LH
a1
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
a2
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
a2
13-4
— — — —
Simultaneous operation of travel RH and LH
Position
Size
Port
value NAS 9
Cleanliness of hydraulic oil Hydraulic oil in tank
Tolerance
Standard
or less
Unit
Hi
Lo
—
— - 5 (23)
Adjusting Point
Measuring condition
—
Sampling
—
Atmospheric temp
Hydraulic oil temperature
Tank surface
50 (122)
+ 5 (41)
Water temperature
Radiator surface
75 (167)
+ 15 (59)
1000
+ 30
- 30
2000
+ 30
- 30
2000
+ 30
- 30
2000
+ 30
- 30
1050
+ 30
- 30
1800
+ 30
- 30
5.0 (725)
+ 0.5 (+73)
0
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
MR1 Boom up
37.8 (5480) + 1.0 (+145)
- 0.5 (-73)
MR1
37.8 (5480)
0 - 4.0 (-580)
OR4
Boom down
39.7 (5760)
0 - 5.9 (-855)
OR3
Boom up
39.7 (5760)
0 - 5.9 (-855)
OR8
Arm out
37.8 (5480)
0 - 4.0 (-580) MPa
OR7
Arm in
37.8 (5480)
0 - 4.5 (-711) (psi)
OR2
Bucket dump
39.7 (5760)
0 - 5.9 (-855)
OR1
Bucket digging
H mode Lo idle H mode Hi idle B mode Hi idle A mode Hi idle Decel
Measure the engine speed at multi display on the gauge cluster.
S mode Hi idle Pilot primary pressure circuit ATT Boost Boom Arm Bucket Swing RH LH
G pump
a4
P1
a1
P2
a2
P1
a1
P2
a2
R
a1
H R H R H RH LH FW RV FW RV
PF1/4
a2 a1
°C
- 15 (5) (°F)
—
50°C~-10°C (122°F~14°F)
LOW throttle
min-1
Adjustment not required
H mode Hi idle
- 5 (23)
—
Measuring Position
Inspection Item
Main pump
H mode Lo idle
+ 5 (41)
Measuring condition
Travel
Radiator surface
—
Point
Engine speed
50 (122)
—
Adjusting
Main relief
Tank surface
Lo
valve pressure
NAS 9 or less
Unit
Hi
Over load relief valve pressure
Water temperature
value
Standard Measuring condition
Hydraulic oil temperature
Tolerance
Standard
High pressure circuit
Port
Adjustment not required
Size
Cleanliness of hydraulic oil Hydraulic oil in tank
Engine speed
Standard Measuring condition
Position
Class
Measuring Position
Inspection Item
Table13-1
Class
Table13-1
Full throttle (HI idle)
PR1
HI idle
Perform all measurement with the air-conditioner "OFF".
29.0 (4205) + 6.0 (+870)
0
OR6
Swing RH
29.0 (4205) + 6.0 (+870)
0
OR5
Swing LH
a1
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
a2
34.3 (4970) + 0.7 (+100)
- 0.5 (-73)
a2
13-4
— — — —
Simultaneous operation of travel RH and LH
13. MAINTENANCE STANDARD AND TEST PROCEDURE
1st speed
30.5 ~ 27.5
2nd speed
50.4 ~ 45.6
Up
2.5 ~ 3.1
Down
2.2 ~ 2.8
In
3.0 ~ 3.6
Out
2.3 ~ 2.9
Digging
2.2 ~ 2.8
Dumping
1.7 ~ 2.3
Operating speed
Boom Operating time of cylinder
Bucket Swing speed Travel speed Amount of travel deviation Parking brake drift
Performance
Arm
RH LH 1st speed
Iron shoe 19.5 ~ 21.5
2nd speed
Iron shoe 11.9 ~ 13.1
ATT amount of drift
Sprocket revolution (RH,LH)
min-1
sec
(At no load)
Operating time of cylinder
sec / 1 rev
Swing speed
sec / 20 m
Travel speed
mm / 20 m
Amount of travel deviation
15 degree gradient
0
mm / 5 min
Parking brake drift
55 ~ 75
degree
15 degree gradient
0
mm
Tip of the bucket tooth
160
Boom cylinder
14
Arm cylinder
11 30 ~ 50
mm / 10min (At no load) mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in advance. (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
30.5 ~ 27.5
2nd speed
50.4 ~ 45.6
Up
2.5 ~ 3.1
Down
2.2 ~ 2.8
In
3.0 ~ 3.6
Out
2.3 ~ 2.9
Digging
2.2 ~ 2.8
Dumping
1.7 ~ 2.3
Arm Bucket
0 ~ 240
Amount of horizontal play at the bucket tooth
1st speed
Boom
2nd speed
Performance of Swing Neutral position after 180° full speed swing brake Performance of Swing parking brake
4.2 ~ 5.4
Standard value
Inspection item
Performance
Sprocket revolution (RH,LH)
Unit
Operating speed
Standard value
Inspection item
13. MAINTENANCE STANDARD AND TEST PROCEDURE
RH LH 1st speed
Iron shoe 19.5 ~ 21.5
2nd speed
Iron shoe 11.9 ~ 13.1
ATT amount of drift
min-1
sec
sec / 20 m
0 ~ 240
mm / 20 m
15 degree gradient
0
mm / 5 min
55 ~ 75
degree
15 degree gradient
0
mm
Tip of the bucket tooth
160
Boom cylinder
14
Arm cylinder
11
Amount of horizontal play at the bucket tooth
30 ~ 50
(At no load)
sec / 1 rev
2nd speed
Performance of Swing Neutral position after 180° full speed swing brake Performance of Swing parking brake
4.2 ~ 5.4
Unit
mm / 10min (At no load) mm
The port relief valves No.OR1~OR8 on the control section are adjusted to the following operation numbers in advance. (1) Bucket digging, (2) Bucket dump, (3) Boom up, (4) Boom down (5) Swing left, (6) Swing right, (7) Arm in, (8) Arm out
13-5
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.3
MEASUREMENT OF ENGINE SPEED
13.3
MEASUREMENT OF ENGINE SPEED
13.3.1
MEASUREMENT OF ENGINE SPEED
13.3.1
MEASUREMENT OF ENGINE SPEED
(1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant tem-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), so confirm that the pointer indicates the temperature within the white range.
(1) Warming up of engine Start engine to raise the coolant temperature of engine to 60 to 90°C (140 to 194°F) at surface of radiator upper tank. The E/G coolant tem-perature gauge is used to measure. The range in white color shows the temperature of approx. 65 to 105°C (149 to 221°F), so confirm that the pointer indicates the temperature within the white range.
(2) Engine speed measured value through service diagnosis (See Fig. 13-2)
(2) Engine speed measured value through service diagnosis (See Fig. 13-2)
1) Turn "ON" the starter switch with the buzzer stop switch pressed.
1) Turn "ON" the starter switch with the buzzer stop switch pressed.
2) A program No. and an actual engine revolution are displayed as the No.2 Item.
2) A program No. and an actual engine revolution are displayed as the No.2 Item.
3) The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is pushed.
3) The screen advances like No.2, No.3....each time the "Wiper switch" on the gauge cluster is pushed.
4) The screen returns like No.45, No.44....each time the "Washer switch" is pushed.
4) The screen returns like No.45, No.44....each time the "Washer switch" is pushed.
5) The display does not disappear unless the starter switch is turned to"OFF".
5) The display does not disappear unless the starter switch is turned to"OFF". Fig. 13-1 Switch for E/G speed indication NO.2 ENG G-3 SPEED SET MEAS 1 MEAS 2 G-5 ENG OIL PRS. WATER TEMP. F MODE H-1 ACCEL. VOLT. POS ECU OUTPUT
Fig. 13-1 Switch for E/G speed indication NO.2 ENG G-3 SPEED SET MEAS 1 MEAS 2 G-5 ENG OIL PRS. WATER TEMP. F MODE H-1 ACCEL. VOLT. POS ECU OUTPUT
2205 2201 2201 LIVE 100 OF HM 4.2V 100% 0.5V
Fig. 13-2 Service diagnosis for E/G speed measuring (Example)
13-6
2205 2201 2201 LIVE 100 OF HM 4.2V 100% 0.5V
Fig. 13-2 Service diagnosis for E/G speed measuring (Example)
13-6
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.4
MEASUREMENT OF HYDRAULIC PRESSURE
13.4
MEASUREMENT OF HYDRAULIC PRESSURE
13.4.1
PREPARING TO MEASURE HYDRAULIC PRESSURE
13.4.1
PREPARING TO MEASURE HYDRAULIC PRESSURE
(1) Hydraulic equipment 6.9 MPa (1000psi) pressure gauge : 1unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set
a5
A3
A2 (A1)
PSV2 (PSV1)
(2) Measuring cleanliness of hydraulic oil
Dr3
(1) Hydraulic equipment 6.9 MPa (1000psi) pressure gauge : 1unit 49 MPa (7100psi) pressure gauge : 2 units Pressure measuring equipment and instrument for analysis : 1 set
A2 (A1)
PSV2 (PSV1)
(2) Measuring cleanliness of hydraulic oil
Dr3
B3
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil. 13.4.2
PLACE TO INSTALL PRESSURE GAUGE
B3 B1
a1
a2
Fig. 13-3 Gauge port on main pump
After releasing air in the hydraulic oil tank, open the cover and sample oil in the hydraulic tank, and measure with the instrument for analysis. If the measured value is higher than the standard value, replace the return filter or change the hydraulic oil. 13.4.2
PLACE TO INSTALL PRESSURE GAUGE
(1) Main circuit After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi).
(1) Main circuit After releasing the pressure in hydraulic oil tank and system, replace plugs PF1/4 of main pump gauge ports (a1) (a2) with plugs for pressure measurement, and attach pressure gauge 49 MPa (7100 psi).
(2) Pilot circuit Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi).
(2) Pilot circuit Replace pilot gauge plug (a5) with plug PF1/4 for pressure measurement, and attach pressure gauge 6.9 MPa (1000 psi).
13-7
a5
A3
13-7
B1 a1
a2
Fig. 13-3 Gauge port on main pump
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.4.3
13.4.3
PRESSURE ADJUSTMENT POSITION
(1) Main control valve
PRESSURE ADJUSTMENT POSITION
(1) Main control valve
OR8 : ARM (R)
PLUG FOR OPTIONAL RELIEF
OR8 : ARM (R)
PLUG FOR OPTIONAL RELIEF
MACHINE FRONT
MR1 : MAIN RELIEF (ATT & TRAVEL)
OR3 : BOOM (H)
OR2 : BUCKET (R)
MR1 : MAIN RELIEF (ATT & TRAVEL)
VIEW FROM THE TOP OF THE MACHINE
OR4 : BOOM (R)
MACHINE FRONT
OR3 : BOOM (H)
OR2 : BUCKET (R)
VIEW FROM THE TOP OF THE MACHINE
OR1 : BUCKET (H)
OR4 : BOOM (R)
OR1 : BUCKET (H)
MACHINE FRONT
OR7 : ARM (H)
PLUG FOR OPTIONAL RELIEF
MACHINE FRONT
OR7 : ARM (H)
PLUG FOR OPTIONAL RELIEF
VIEW FROM THE BOTTOM OF THE MACHINE
VIEW FROM THE BOTTOM OF THE MACHINE
Fig. 13-4 Relief valve position on main control valve
Fig. 13-4 Relief valve position on main control valve
13-8
13-8
13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
13. MAINTENANCE STANDARD AND TEST PROCEDURE (2) Pilot relief valve The pilot relief valve PR1 is located on the gear pump that is attached to the main pump.
A3
A3
a5
a5
Dr3 B3
PR1 ADJUST SCREW FOR PILOT RELIEF
Dr3 B3
PR1 ADJUST SCREW FOR PILOT RELIEF
Fig. 13-5 Pilot relief valve position
Fig. 13-5 Pilot relief valve position
(3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2). (See Fig. 13-3)
(3) Swing over load relief The swing motor is equipped with plugs PA,PB for pressure measurement, but the measurement is carried out using gauge ports (a1) and (a2). (See Fig. 13-3)
Fig. 13-6 Swing over load relief position
Fig. 13-6 Swing over load relief position
13-9
13-9
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.4.4
13.4.4
PROCEDURE FOR ADJUSTING RELIEF VALVE
(1) Pilot relief valve Adjust it with adjust screw (311).
PROCEDURE FOR ADJUSTING RELIEF VALVE
(1) Pilot relief valve Adjust it with adjust screw (311).
: 24 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
: 24 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
: 6 mm
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
Approx. 2.1 (305)
(2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment.
Fig. 13-7 Pilot relief valve
Fig. 13-8 Main relief valve (Travel section, ATT common section)
: 32 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) : 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
Approx. 2.1 (305)
(2) 2-stage main relief valve (Commom for travel and ATT sections) Start from the boosting side, first. Loosen nut (1), adjust the pressure with adjusting screw (2) and tighten nut (1) after completion of the adjustment on the boosting side. Then, loosen nut (3), adjust the pressure on the standard side with adjusting screw (4) and tighten nut (3) after completion of the adjustment.
: 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft) : 19 mm, Adjust screw
: 6 mm
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi)
No. of turns of adjust screw Pressure change MPa (psi) Boosting side 1 turn STD side 1 turn
Approx. 17.6 (2560) Approx. 17.6 (2560)
(3) Over load relief valve (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2).
Approx. 17.6 (2560) Approx. 17.6 (2560)
(3) Over load relief valve (Boom, bucket, arm sections) Loosen lock nut (1) and adjust it with adjust screw (2).
: 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 22 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 6 mm
Fig. 13-9 Over load relief valve (Boom, bucket, arm sections)
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
Fig. 13-8 Main relief valve (Travel section, ATT common section)
: 32 mm, Tightening torque : 27.4~31.4 N•m (20~23 lbf•ft)
: 19 mm, Adjust screw
Boosting side 1 turn STD side 1 turn
Fig. 13-7 Pilot relief valve
: 6 mm
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
Approx. 17.7 (2560)
13-10
Fig. 13-9 Over load relief valve (Boom, bucket, arm sections)
Approx. 17.7 (2560)
13-10
13. MAINTENANCE STANDARD AND TEST PROCEDURE (4) Over load relief valve (Swing) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2).
(4) Over load relief valve (Swing) When the adjustment of pressure is required, loosen lock nut (1) and adjust the pressure with cap (2).
: 30, 38 mm, Tightening torque : 118 N•m (87 lbf•ft)
: 30, 38 mm, Tightening torque : 118 N•m (87 lbf•ft) Fig. 13-10 Swing over load relief valve
: 12 mm
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
13. MAINTENANCE STANDARD AND TEST PROCEDURE
Fig. 13-10 Swing over load relief valve
: 12 mm
No. of turns of adjust screw Pressure change MPa (psi) 1 turn
Approx. 10 (1450)
(5) Travel over load relief valve This valve was adjusted by valve maker. Do not replace any inner parts except for O-ring.
Approx. 10 (1450)
(5) Travel over load relief valve This valve was adjusted by valve maker. Do not replace any inner parts except for O-ring. Fig. 13-11 Travel over load relief valve
13-11
Fig. 13-11 Travel over load relief valve
13-11
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.5
MEASURING TRAVEL PERFORMANCES
13.5
MEASURING TRAVEL PERFORMANCES
13.5.1
TRAVEL SPEED
13.5.1
TRAVEL SPEED
(1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system.
(1) Purposes Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system.
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Crawler on the right and left sides are tensioned evenly.
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Crawler on the right and left sides are tensioned evenly.
(3) Preparation Attach the reflection panel with a magnet to the travel motor cover. Swing the swing frame through 90°as shown in Fig. 13-12 and make the crawler on one side take off the ground, using the attachment.
(3) Preparation Attach the reflection panel with a magnet to the travel motor cover. Swing the swing frame through 90°as shown in Fig. 13-12 and make the crawler on one side take off the ground, using the attachment.
(4) Measurement Engine revolution; Hi idle 2-speed travel switch; 1st speed and 2nd speed Measuring points ; Right and left Method, example 1 ; Measure revolution with a stroboscope Method, example 2 ; Measure the revolutions per minute visually.
Fig. 13-12 One side lifted position
Fig. 13-13 Adhering position of reflection panel
Measurement item RH H mode 1st speed & LH H mode 2nd speed
13.5.2
Unit
Sprocket revolution Standard value
Reference value for remedy
min-1
(4) Measurement Engine revolution; Hi idle 2-speed travel switch; 1st speed and 2nd speed Measuring points ; Right and left Method, example 1 ; Measure revolution with a stroboscope Method, example 2 ; Measure the revolutions per minute visually.
Service limit
(2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution; Hi idle
BOOM FOOT PIN
ARM TOP PIN
Fig. 13-14 Travel position
13-12
Unit
Sprocket revolution RH H mode 1st speed & LH H mode 2nd speed
13.5.2
(1) Purpose Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system.
Fig. 13-13 Adhering position of reflection panel
Measurement item
30.5~27.5 23.8~21.5 19.4 or less 50.4~45.6 39.3~35.6 32.2 or less
DEVIATION OF TRAVEL
Fig. 13-12 One side lifted position
Standard value
Reference value for remedy
min-1
Service limit
30.5~27.5 23.8~21.5 19.4 or less 50.4~45.6 39.3~35.6 32.2 or less
DEVIATION OF TRAVEL
(1) Purpose Measure the amount of deviation at 20m (66ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. (2) Condition Hydraulic oil temperature ; 45~55°C (113~131°F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution; Hi idle
BOOM FOOT PIN
ARM TOP PIN
Fig. 13-14 Travel position
13-12
13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation
13. MAINTENANCE STANDARD AND TEST PROCEDURE (3) Preparation
1) Straight course more than 30m (108ft)
1) Straight course more than 30m (108ft)
2) Travel position in which the bottom of the bucket is lifted by about 30cm (1ft).
2) Travel position in which the bottom of the bucket is lifted by about 30cm (1ft).
A 20m (66ft)
(4) Measurement 1) Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding the preliminary run of 3~5m (10~16ft).
Travel deviation
13.5.3
1) Measure the max. deviation distance of the circular arc in the 20m (66ft) length, excluding the preliminary run of 3~5m (10~16ft).
Unit : mm (in) / 20m (66ft)
Measuring position
Standard value
A
240 (9.45) or less
Reference value Service limit for remedy
480 (18.9)
20m (66ft)
(4) Measurement
Fig. 13-15 Measuring method
2) Operate the travel lever at the same time.
A
Fig. 13-15 Measuring method Travel deviation
2) Operate the travel lever at the same time.
720 (28.4)
PERFORMANCES OF PARKING BRAKE
13.5.3
(1) Purpose Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope.
(2) Condition A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position
(2) Condition A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position
(3) Preparation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.
(3) Preparation Place an angle meter on the shoe plate and confirm that it makes an angle more than 15 degree. Hang a perpendicular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate.
(4) Measurement Five minutes after the engine stops, measure the movement distance of the matching mark.
Standard value
A
240 (9.45) or less
Reference value Service limit for remedy
480 (18.9)
720 (28.4)
PERFORMANCES OF PARKING BRAKE
(1) Purpose Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope.
Fig. 13-16 Parking brake operating position
Unit : mm (in) / 20m (66ft)
Measuring position
Fig. 13-16 Parking brake operating position
(4) Measurement Five minutes after the engine stops, measure the movement distance of the matching mark.
C
GUIDE FRAME
Fig. 13-17 Method of measurement Parking brake Measuring position
C
13-13
Fig. 13-17 Method of measurement
Unit : mm(in)/5min
Parking brake
Reference value Standard value Service limit for remedy
0
1 (0.04)
C
GUIDE FRAME
Measuring position
2 (0.08)
C
13-13
Unit : mm(in)/5min Reference value Standard value Service limit for remedy
0
1 (0.04)
2 (0.08)
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.5.4
13.5.4
DRAIN RATE OF TRAVEL MOTOR
(1) Purpose To measure the drain rate of the travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Engine revolution; Hi idle
90 o 10 (3.54") (0.394")
FORWARD
o 22 PIPE (0.866") RIB "A"
150 (5.91")
STOPPER "B"
(3) Preparation
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel sprockets.
40 (1.57")
o 80 (3.15")
Fig. 13-18 Location of stopper applied to travel sprocket
2) Stop the engine and release pressure from the hydraulic circuit. 3) Connect a hose with the drain port of the travel motor and take drain in a container.
DRAIN RATE OF TRAVEL MOTOR
(1) Purpose To measure the drain rate of the travel motor and to confirm the performances of the travel motor. (2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Engine revolution; Hi idle
90 o 10 (3.54") (0.394")
FORWARD
o 22 PIPE (0.866") RIB "A"
150 (5.91")
STOPPER "B"
(3) Preparation
ROTARY DIRECTION
1) Place a stopper under the RH and LH travel sprockets.
40 (1.57")
o 80 (3.15")
Fig. 13-18 Location of stopper applied to travel sprocket
2) Stop the engine and release pressure from the hydraulic circuit. 3) Connect a hose with the drain port of the travel motor and take drain in a container.
(4) Measurement ; at Travel Lock
(4) Measurement ; at Travel Lock
Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. (See Fig. 13-18)
Unless you observe the rotary force direction at travel lock, rib "A" may be broken by stopper "B" in some cases. (See Fig. 13-18)
1) Start the engine and relieve pressure at the full stroke of the travel lever.
Fig. 13-19 Method of measuring the drain rate of travel motor
2) Measure the drain rate for 30 seconds of relieving.
Travel deviation Measuring position
Drain rate
13-14
Unit : L(gal)/30sec
1) Start the engine and relieve pressure at the full stroke of the travel lever.
Fig. 13-19 Method of measuring the drain rate of travel motor
2) Measure the drain rate for 30 seconds of relieving.
Travel deviation
Reference value Standard value Service limit for remedy
9 (2.4)
16 (4.2)
Measuring position
23 (6.1)
Drain rate
13-14
Unit : L(gal)/30sec
Reference value Standard value Service limit for remedy
9 (2.4)
16 (4.2)
23 (6.1)
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.6
MEASURING SWING PERFORMANCES
13.6
MEASURING SWING PERFORMANCES
13.6.1
SWING SPEED
13.6.1
SWING SPEED
(1) Purpose Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system.
(1) Purpose Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system.
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution; Hi idle
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution; Hi idle
(3) Preparation Put the bucket empty and extend the boom, arm and bucket cylinder fully. And the machine becomes a position of minimum reach.
(3) Preparation Put the bucket empty and extend the boom, arm and bucket cylinder fully. And the machine becomes a position of minimum reach.
Fig. 13-20 Swing speed measuring position (at the min. reach)
Fig. 13-20 Swing speed measuring position (at the min. reach)
(4) Measurement Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn.
(4) Measurement Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn.
13.6.2
13.6.2
PERFORMANCE OF SWING BRAKE
(1) Purpose Confirm the braking torque performances by the swing relief valve.
Swing speed
Unit : sec/rev
Measuring Reference value Service limit Standard value position for remedy Swing speed at 4.2~5.4 7.2~ 5.4~6.9 min. reach
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution; Hi idle
ARM TOP PIN
BOOM FOOT PIN
(3) Preparation
PERFORMANCE OF SWING BRAKE
(1) Purpose Confirm the braking torque performances by the swing relief valve.
Swing speed
Unit : sec/rev
Measuring Reference value Service limit Standard value position for remedy Swing speed at 4.2~5.4 7.2~ 5.4~6.9 min. reach
(2) Conditions Hydraulic oil temperature ; 45~55°C (113~131°F) Firm, level ground Engine revolution; Hi idle
ARM TOP PIN
BOOM FOOT PIN
(3) Preparation
1) Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. 2) Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark.
13-15
Fig. 13-21 Swing brake performance measuring position
1) Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinders fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. 2) Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark.
13-15
Fig. 13-21 Swing brake performance measuring position
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(4) Measurement
MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE
1) When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops.
MATCHING MARKS ON OUTER RACE
2) Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race :
(4) Measurement
MEASURING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE
1) When operating in regular swing speed, by shifting lever to neutral position at pole position the swing operation stops.
MATCHING MARKS ON OUTER RACE
2) Calculate the swing drift angle by the following equation, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race :
MATCHING MARKS ON INNER RACE
MATCHING MARKS ON INNER RACE
Fig. 13-22 Measuring position of swing brake performances Swing brake performance Measuring position
Swing 180
13.6.3
Fig. 13-22 Measuring position of swing brake performances
Unit : degree
Swing brake performance
Reference value Standard value Service limit for remedy
75
85
Measuring position
90
PERFORMANCE OF SWING PARKING BRAKE
Swing 180
13.6.3
(1) Purpose To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor.
(2) Conditions On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin.
(2) Conditions On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Fig. 13-23 Swing parking brake performance measuring position MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE
(4) Measurement When five minutes has passed after the engine stops, measure the length of the movement of the matching marks.
MATCHING MARKS ON INNER RACE
Measuring position
C
(3) Preparation Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side. (4) Measurement When five minutes has passed after the engine stops, measure the length of the movement of the matching marks.
13-16
MATCHING MARKS ON INNER RACE
Fig. 13-24 Measuring position of swing parking brake performances
Unit : mm(in)/5min
1 (0.04)
90
MEASUREING THE LENGTH OF THE ARC OVER THE OUTER CIRCUMFERENCE OF OUTER RACE MATCHING MARKS ON OUTER RACE
Performance of swing parking brake
Reference value Standard value Service limit for remedy
0
85
Fig. 13-23 Swing parking brake performance measuring position
Fig. 13-24 Measuring position of swing parking brake performances Performance of swing parking brake
75
PERFORMANCE OF SWING PARKING BRAKE
(1) Purpose To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor.
(3) Preparation Put the angle meter on the shoe plate and make sure that the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side.
Unit : degree
Reference value Standard value Service limit for remedy
Measuring position
2 (0.08)
C
13-16
Unit : mm(in)/5min
Reference value Standard value Service limit for remedy
0
1 (0.04)
2 (0.08)
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6.4
DRAIN RATE OF SWING MOTOR
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.6.4
DRAIN RATE OF SWING MOTOR
(1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor.
(1) Purpose Measure the drain rate of the swing motor and confirm the performances of the swing motor.
(2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground Engine revolution; Hi idle
(2) Conditions Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground Engine revolution; Hi idle
(3) Preparation
(3) Preparation
1) Stop the engine.
1) Stop the engine.
2) Release pressure from inside the hydraulic circuit.
2) Release pressure from inside the hydraulic circuit.
3) Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a container.
3) Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a container.
4) Put a plug to the tank side.
4) Put a plug to the tank side.
(4) Measurement ; at Swing Lock
(4) Measurement ; at Swing Lock
Fig. 13-25
1) Start the engine and put the side faces of bucket against the inside of the right or left shoe plates. 2) Relieve the swing motor at full stroke of the swing motion.
Travel deviation Measuring position
Drain rate
3) Collect the amount of drained oil in a container for 30 seconds.
Unit : L(gal)/30sec
Reference value Standard value Service limit for remedy
2.1 (0.55)
5.2 (1.4)
6.2 (1.6)
Fig. 13-25
1) Start the engine and put the side faces of bucket against the inside of the right or left shoe plates. 2) Relieve the swing motor at full stroke of the swing motion.
Measuring position
Drain rate
3) Collect the amount of drained oil in a container for 30 seconds.
13-17
Travel deviation
13-17
Unit : L(gal)/30sec
Reference value Standard value Service limit for remedy
2.1 (0.55)
5.2 (1.4)
6.2 (1.6)
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.7
MEASURING ATTACHMENT OPERATING PERFORMANCES
13.7
MEASURING ATTACHMENT OPERATING PERFORMANCES
13.7.1
OPERATING TIME OF CYLINDERS
13.7.1
OPERATING TIME OF CYLINDERS
(1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system.
(1) Purpose Measure the operating time of the boom, arm and bucket and confirm the performances between the hydraulic pump and the cylinder of the attachment drive system.
(2) Condition Hydraulic oil temperature ; 45~55째C (113~131째F) Engine revolution; Hi idle Operating time excluding the cushion stroke
(2) Condition Hydraulic oil temperature ; 45~55째C (113~131째F) Engine revolution; Hi idle Operating time excluding the cushion stroke
Fig. 13-26 Measuring position for bucket digging and dump
Fig. 13-26 Measuring position for bucket digging and dump
(3) Preparation Firm level ground with the bucket empty
(3) Preparation Firm level ground with the bucket empty
(4) Measurement 1 ; Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest position.
(4) Measurement 1 ; Boom up and down With the boom operating lever at full stroke, measure the required operating time of the bucket between the ground surface and its highest position.
Fig. 13-27 Measuring position for boom up and down motions
When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the bucket against concrete or other solid material.
Fig. 13-27 Measuring position for boom up and down motions
When lowering the boom, allow the bucket onto a soft ground or cushioning such as rubber tires ; never put the bucket against concrete or other solid material.
Measurement 2 ; Arm in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke.
13-18
30cm (1ft)
Fig. 13-28 Measuring position for arm in and out motions Cylinder Operating time Measuring position
Unit : sec
Reference value Service limit Standard value for remedy
Measurement 2 ; Arm in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm and bucket operating levers at full stroke.
30cm (1ft)
Fig. 13-28 Measuring position for arm in and out motions Cylinder Operating time Measuring position
Unit : sec
Reference value Service limit Standard value for remedy
2.2~2.8
2.8~3.6
3.8~
2.2~2.8
2.8~3.6
3.8~
1.7~2.3
2.2~2.9
3.0~
1.7~2.3
2.2~2.9
3.0~
2.5~3.1
3.2~4.0
4.2~
2.5~3.1
3.2~4.0
4.2~
2.2~2.8
2.8~3.6
3.8~
2.2~2.8
2.8~3.6
3.8~
3.0~3.6
3.8~4.6
5.0~
3.0~3.6
3.8~4.6
5.0~
2.3~2.9
2.9~3.7
3.9~
2.3~2.9
2.9~3.7
3.9~
13-18
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2
OIL TIGHTNESS OF CYLINDERS
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.7.2
(1) Purpose Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
B BOOM FOOT PIN
C
(2) Condition Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke end so that the piston does not match a same range of the cushioning mechanism.
A ARM TOP PIN
(3) Preparation Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin. (4) Measurement Measure the items five minutes after the engine is turned off.
13-19
D
Fig. 13-29 Oil tightness of cylinder Measuring position
Unit : mm(in)/5min
Reference value Standard value Service limit for remedy
A
7 (0.28)
11 (0.43)
14 (0.55)
B
6 (0.24)
9 (0.35)
11 (0.43)
C
-
-
-
D
80 (3.1)
120 (4.7)
160 (6.3)
OIL TIGHTNESS OF CYLINDERS
(1) Purpose Confirm that the cylinder oil tight by checking the moving length of the cylinder rods.
B BOOM FOOT PIN
C
(2) Condition Hydraulic oil temperature ; 45~55째C (113~131째F) Firm, level ground After cylinders are replaced, bleed off air from the cylinders, before checking for oil tightness. Retract the arm cylinder rod 50mm (2in) from stroke end so that the piston does not match a same range of the cushioning mechanism.
A ARM TOP PIN
(3) Preparation Put the bucket empty. Extend the arm cylinder rod 50mm (2in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin. (4) Measurement Measure the items five minutes after the engine is turned off.
13-19
D
Fig. 13-29 Oil tightness of cylinder Measuring position
Unit : mm(in)/5min
Reference value Standard value Service limit for remedy
A
7 (0.28)
11 (0.43)
14 (0.55)
B
6 (0.24)
9 (0.35)
11 (0.43)
C
-
-
-
D
80 (3.1)
120 (4.7)
160 (6.3)
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.8
13.8
MEASURING PERFORMANCES OF SWING BEARING
(1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing.
LOCATION OF BEARING MOUNTING BOLTS
SWING BEARING
(2) Condition Firm, level ground The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well, not making abnormal sound during turning.
A
DIAL INDICATOR LOWER FLAME
MEASURING PERFORMANCES OF SWING BEARING
(1) Purpose Measure the gap between the lower frame and the bottom face of the swing bearing and estimate the degree of wear of the swing bearing.
SWING BEARING
(2) Condition Firm, level ground The swing bearing mounting bolts are not loosened. The swing bearing is lubricated well, not making abnormal sound during turning.
A
DIAL INDICATOR LOWER FLAME
Fig. 13-30 How to measure the axial play of swing bearing (3) Preparation
LOCATION OF BEARING MOUNTING BOLTS
Fig. 13-30 How to measure the axial play of swing bearing (3) Preparation
1) Install a dial indicator to the magnetic base and fix it to the lower frame.
1) Install a dial indicator to the magnetic base and fix it to the lower frame.
2) Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.
2) Direct the upper swing body and the lower frame toward the travel direction, bring the probe of the dial indicator in contact with the bottom surface of the outer race on the swing body side and set the reading at zero.
Fig. 13-31 Measuring position 1
(4) Measurement 1 (Measuring position 1 and 2)
Fig. 13-31 Measuring position 1
(4) Measurement 1 (Measuring position 1 and 2) BOOM FOOT PIN
ARM TOP PIN
1) Measure the displacement of the outer race in the axial direction in position 1 [The arm at 90째~110째 and the crawler front is lifted by attachment about 30cm (1ft)] and in position 2, using a dial indicator.
Fig. 13-32 Measuring position 2 Axial play of swing bearing Measuring position
A
Fig. 13-32 Measuring position 2
Unit : mm (in)
Axial play of swing bearing
Reference value Standard value Service limit for remedy
0.8~1.8 (0.03~0.07)
2.3~3.3 (0.09~0.13)
BOOM FOOT PIN
ARM TOP PIN
1) Measure the displacement of the outer race in the axial direction in position 1 [The arm at 90째~110째 and the crawler front is lifted by attachment about 30cm (1ft)] and in position 2, using a dial indicator.
Measuring position
3.6~ (0.14)
(5) Measurement 2 (Measuring position 3)
A
Unit : mm (in)
Reference value Standard value Service limit for remedy
0.8~1.8 (0.03~0.07)
2.3~3.3 (0.09~0.13)
3.6~ (0.14)
(5) Measurement 2 (Measuring position 3)
1) Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included.
BOOM FOOT PIN
ARM TOP PIN
1) Retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. Then swing the bucket right and left by man power. But in this case, the gap of the attachment is included.
Fig. 13-33 Measuring position 3 Right and left movement of the tip of bucket Measuring position
Bucket
13-20
Fig. 13-33 Measuring position 3
Unit : mm (in)
Right and left movement of the tip of bucket
Reference value Standard value Service limit for remedy
30~50 (1.18~1.97)
80 (3.15)
BOOM FOOT PIN
ARM TOP PIN
Measuring position
120 (4.72)
Bucket
13-20
Unit : mm (in)
Reference value Standard value Service limit for remedy
30~50 (1.18~1.97)
80 (3.15)
120 (4.72)
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9
MECHATRO CONTROLLER
13.9
MECHATRO CONTROLLER
13.9.1
ENGINE CONTROL INPUT / OUTPUT
13.9.1
ENGINE CONTROL INPUT / OUTPUT
E-27: EMERGENCY ACCEL
C-8: ENGINE CONTROLLER
INJECTOR E-1: FUSE&RELAY BOX
C-2: GAUGE CLUSTER
C-1: MECHATRO CONTROLLER
ACCEL POTENTIO METER
13.9.2.1
E-1: FUSE&RELAY BOX
ENGINE
ENGINE SPEED SENSOR
PUMP PROPORTIONAL VALVE
STARTER SWITCH
ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) PURPOSE OF THE ADJUSTMENT
C-1: MECHATRO CONTROLLER
ACCEL POTENTIO METER
Fig. 13-34 INPUT / OUTPUT 13.9.2
INJECTOR
C-2: GAUGE CLUSTER ENGINE SPEED SENSOR
STARTER SWITCH
E-27: EMERGENCY ACCEL
C-8: ENGINE CONTROLLER
ENGINE
PUMP PROPORTIONAL VALVE
Fig. 13-34 INPUT / OUTPUT 13.9.2 13.9.2.1
ADJUSTMENT OF MECHATRO CONTROLLER OUTPUT (A-B-C ADJUSTMENT) PURPOSE OF THE ADJUSTMENT
There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine.
There are 3 kinds of adjustment of mechatro controller as shown below; every adjustment is an essential function to ensure performance of machine.
(1) Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the acceleration command voltage output from mechatro controller to engine controller and the engine speed.
(1) Adjustment of engine ("A" adjustment) This adjustment is performed to set the relation between the acceleration command voltage output from mechatro controller to engine controller and the engine speed.
(2) Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output.
(2) Adjustment of pump ("B" adjustment) This adjustment is performed to correct the output variation by coordinating the output hydraulic pressure with engine rated output.
(3) Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
(3) Adjustment of unloading valve ("C" adjustment) This adjustment is performed to correct the open variation of unloading valve to improve the operability further.
13.9.2.2
13.9.2.2
IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;
IN CASES WHERE THE ADJUSTMENT OF MECHATRO CONTROLLER IS REQUIRED;
When the following parts are replaced or repaired, carry out the adjustment without fail.
When the following parts are replaced or repaired, carry out the adjustment without fail.
(1) Mechatro controller
(1) Mechatro controller
(2) Engine or engine controller
(2) Engine or engine controller
(3) Hydraulic pump or hydraulic pump proportional valve
(3) Hydraulic pump or hydraulic pump proportional valve
(4) Unloading proportional valve, spool of unloading valve
(4) Unloading proportional valve, spool of unloading valve
13-21
13-21
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13.9.2.3
13.9.2.3
PREPARATION
PREPARATION
(1) Raise the oil temperature to about 50째C (122째F) to warm up the engine.
(1) Raise the oil temperature to about 50째C (122째F) to warm up the engine.
(2) Turn the air-con OFF.
(2) Turn the air-con OFF.
(3) Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, A035 As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.
(3) Turn the starter key switch OFF to stop the engine. When the mechatro controller was replaced, the following error code is displayed because the adjustment data is not entered. A215, A225, A015, A025, A035 As the error codes other than those shown above may suggest failures of machine, repair the machine into the ordinary operating condition according to Error Code List.
For machines equipped with lifting magnet, turn the generator OFF.
13-22
For machines equipped with lifting magnet, turn the generator OFF.
13-22
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4
ADJUSTING PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.2.4
ADJUSTING PROCEDURE
MULTI DISPLAY
MULTI DISPLAY
WORK MODE SELECT SWITCH
BUZZER STOP SWITCH
WORK MODE SELECT SWITCH
BUZZER STOP SWITCH
WASHER SWITCH
WASHER SWITCH
WIPER SWITCH
SELECT SWITCH
WIPER SWITCH
SELECT SWITCH
Fig. 13-35 Gauge cluster
Fig. 13-35 Gauge cluster
(1) Adjustment of engine ("A" adjustment) Procedure
(1) Adjustment of engine ("A" adjustment) Procedure
1) Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)
1) Turn starter key switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selecting adjustment is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selecting adjustment is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.
3) Press selector switch on gauge cluster to display "START ENG". "Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.
3) Press selector switch on gauge cluster to display "START ENG". "Engine SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.
4) After starting engine, press selector switch on gauge cluster, and "MEMORY ENG" is displayed, the engine speed is automatically increased, and the adjustment of engine is performed. (When trying to limit engine speed, press selector switch on gauge cluster at the speed as it is, and the adjustment of engine is terminated. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)
4) After starting engine, press selector switch on gauge cluster, and "MEMORY ENG" is displayed, the engine speed is automatically increased, and the adjustment of engine is performed. (When trying to limit engine speed, press selector switch on gauge cluster at the speed as it is, and the adjustment of engine is terminated. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)
5) When normal HIGH idling speed is detected, the adjustment is completed. And "FINISH ENG" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared, and the adjustment of engine is completed. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)
13-23
FINISH ENG ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 STEP 400
2.0M
5) When normal HIGH idling speed is detected, the adjustment is completed. And "FINISH ENG" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared, and the adjustment of engine is completed. The torque adjustment and unloading adjustment required later are not performed, and default value is written.)
13-23
FINISH ENG ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 STEP 400
2.0M
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(2) Adjustment of pump ("B" adjustment) Procedure
(2) Adjustment of pump ("B" adjustment) Procedure
1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. 2) After detection of the engine rated speed, the adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.)
1) The adjustment automatically shifts from engine to pump, the speed shifts from LOW idling to HIGH idling. And "MEMORY PUMP" is displayed. And the unloading proportional valve and pump proportional valve actuate, accordingly the loading of pump is increased. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 pump "PROPO-VALVE" current (command value) are indicated. FINISH PUMP ENGINE SPEED 2000rpm PUMP PRESSURE C-1 35.0M C-2 PROPO-VALVE E-1 300mA E-2
35.0M 300mA
(3) Adjustment of unloading valve ("C" adjustment) Procedure
2) After detection of the engine rated speed, the adjustment of pump is automatically completed. And "FINISH PUMP" is displayed. (Press the buzzer stop switch on gauge cluster while this display is appeared and the adjustment is completed. The unloading adjustment required later is not performed, and default value is written.)
FINISH PUMP ENGINE SPEED 2000rpm PUMP PRESSURE C-1 35.0M C-2 PROPO-VALVE E-1 300mA E-2
35.0M 300mA
(3) Adjustment of unloading valve ("C" adjustment) Procedure
1) The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPOVALVE" voltage (command value) are indicated. 2) When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer. The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA.
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
1) The adjustment shifts from pump to unloading, and the unloading valve actuates, accordingly the pump pressure is detected. And "MEMORY UNLOAD" is displayed. The "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and P1, P2 "PROPOVALVE" voltage (command value) are indicated. 2) When the unloading valve operates to the specified value, the adjustment of unloading proportional valve is automatically terminated. And "FINISH UNLOAD" is displayed. The speed is shifted to the speed corresponding to acceleration potentiometer. The adjusting current value is indicated on the display of current of P1, P2 unloading proportional valves. The adjusting range is usually 520~635mA.
Stop the engine. (The adjusted data is automatically stored.)
Stop the engine. (The adjusted data is automatically stored.)
(4) Corrective actions taken when the adjustment can not be performed;
(4) Corrective actions taken when the adjustment can not be performed;
1) In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed. Judging condition: The read engine speed is 50rpm lower than the last value.
1) In cases where the adjustment of engine can not be performed; And ERROR ENG" is displayed. Judging condition: The read engine speed is 50rpm lower than the last value.
It is conceived that the error is caused by the speed read error, pump load applied to the engine and unusual acceleration command voltage applied to the engine controller in the course of adjustment.
It is conceived that the error is caused by the speed read error, pump load applied to the engine and unusual acceleration command voltage applied to the engine controller in the course of adjustment.
a. Checking speed sensor: Check that it is free from wrong reading of speed due to engine vibration.
a. Checking speed sensor: Check that it is free from wrong reading of speed due to engine vibration.
b. Checking load applied to pump: Check that it is free from abnormal increase of pump pressure during adjustment of engine through adjustment screen.
b. Checking load applied to pump: Check that it is free from abnormal increase of pump pressure during adjustment of engine through adjustment screen.
c. Checking acceleration command voltage: Measure the acceleration command voltage output from mechatro controller to engine controller. Check that signal is regularly input to the engine controller by actual measurement of voltage or with failure diagnosis tool of engine controller.
c. Checking acceleration command voltage: Measure the acceleration command voltage output from mechatro controller to engine controller. Check that signal is regularly input to the engine controller by actual measurement of voltage or with failure diagnosis tool of engine controller.
13-24
13-24
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed. Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less. Judging condition 2: The adjustment does not complete although the pump proportional valve current reaches to the specified value.
13. MAINTENANCE STANDARD AND TEST PROCEDURE 2) In cases where the adjustment of pump can not be performed; And "ERROR PUMP" is displayed. Judging condition 1: P1 and P2 average pump pressure at the time when the adjustment is completed is 25MPa or less. Judging condition 2: The adjustment does not complete although the pump proportional valve current reaches to the specified value.
The P1 and P2 pump pressures usually increase to 33~38MPa. When the pressure does not increase;
The P1 and P2 pump pressures usually increase to 33~38MPa. When the pressure does not increase;
a. Identify the reason why the pressure does not increase,
a. Identify the reason why the pressure does not increase,
•
Check that the relief valve operates normally.
•
Check that the relief valve operates normally.
•
Check that the hydraulic circuit is free from leak of pressure.
•
Check that the hydraulic circuit is free from leak of pressure.
•
Check that the pressure sensor functions normally. And so on.
•
Check that the pressure sensor functions normally. And so on.
b. Identify the reason why the actual flow rate does not increase,
b. Identify the reason why the actual flow rate does not increase,
•
Check that the pump proportional valve operates normally.
•
Check that the pump proportional valve operates normally.
•
Check that the pump regulator operates normally. And so on.
•
Check that the pump regulator operates normally. And so on.
3) In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Judging condition 1: The pump pressure does not increase up to the pressure in the range of the specified adjustment. Or the increased pressure is held as it is. Judging condition 2: Pressure sensor of either P1 pump or P2 pump is failed.
3) In cases where unloading valve can not be performed; And "ERROR UNLOAD" is displayed. Judging condition 1: The pump pressure does not increase up to the pressure in the range of the specified adjustment. Or the increased pressure is held as it is. Judging condition 2: Pressure sensor of either P1 pump or P2 pump is failed.
Normally the pump pressures of P1 and p2 pumps gradually increase to 10~25MPa. (It may be affected by operating oil temperature.)
Normally the pump pressures of P1 and p2 pumps gradually increase to 10~25MPa. (It may be affected by operating oil temperature.)
When the pump pressure does not increase;
When the pump pressure does not increase;
a. Identify the reason why the pressure does not increase,
a. Identify the reason why the pressure does not increase,
•
Check that the relief valve operates normally.
•
Check that the relief valve operates normally.
•
Check that the hydraulic circuit is free from leak of pressure.
•
Check that the hydraulic circuit is free from leak of pressure.
•
Check that the pressure sensor functions normally. And so on.
•
Check that the pressure sensor functions normally. And so on.
(5) Other precautions:
(5) Other precautions:
1) In the event of a failure, there is case where the adjustment may not be performed normally. First serve the machine, and perform the adjustment work.
1) In the event of a failure, there is case where the adjustment may not be performed normally. First serve the machine, and perform the adjustment work.
2) In the condition where large load is constantly applied to engine, the adjustment could not be performed normally.
2) In the condition where large load is constantly applied to engine, the adjustment could not be performed normally.
For machines equipped with lifting magnet, turn the generator OFF.
13-25
For machines equipped with lifting magnet, turn the generator OFF.
13-25
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
(6) When the adjustment of unloading valve only is performed; ("C" adjustment) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. Procedure
(6) When the adjustment of unloading valve only is performed; ("C" adjustment) In the event where only unloading valve and unloading proportional valve are replaced, perform the adjustment of unloading valve only. Procedure
1) Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)
1) Turn starter switch ON keeping the work mode selector switch on the gauge cluster pressed, and hold it for 5~10 seconds, and then release it. (If the engine is started, the following indication is not displayed. Therefore do not start the engine.)
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.
2) Keep buzzer stop switch on gauge cluster pressed for 5 seconds and release it and the screen for selection of adjustment type is displayed. And "ADJUST" is displayed. When adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated. And the lever lock solenoid is automatically released, disabling all operations.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and select "ADJUST UNLOAD". (See Fig. 13-35) Like the output adjustment, when adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.
3) Change the adjusting items with washer switch ( ) and wiper switch ( ), and select "ADJUST UNLOAD". (See Fig. 13-35) Like the output adjustment, when adjustment data is not entered in mechatro controller, "READY" is indicated. If the adjustment operation is once performed, "FIN" is indicated.
4) Press selector switch on gauge cluster to display "START ENG". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.
4) Press selector switch on gauge cluster to display "START ENG". "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "STEP" (acceleration command voltage) are indicated.
5) After starting engine, press selector switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed. "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" (acceleration command current) are indicated. 6) When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to acceleration potentiometer. The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.)
13-26
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
5) After starting engine, press selector switch on gauge cluster and "MEMORY UNLOAD" is indicated, the engine speed is automatically increased and the adjustment of unloading valve is performed. "ENGINE SPEED", P1, P2 "PUMP PRESSURE" and "PROPO-VALVE" (acceleration command current) are indicated. 6) When the unloading proportional valve operates to the specified value, the adjustment of unloading proportional valve automatically completes. "FINISH UNLOAD" is indicated. The speed is shifted to the speed corresponding to acceleration potentiometer. The value of adjusting current is indicated on the display of current of P1 and P2 unloading proportional valves. The adjusting range is usually 520~635mA. Stop the engine. (The adjusted data is automatically stored.)
13-26
MEMORY UNLOAD ENGINE SPEED 2000rpm PUMP PRESSURE C-1 2.0M C-2 2.0M PROPO-VALVE D-1 300mA D-2 300mA
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.3
OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER
(1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)
13. MAINTENANCE STANDARD AND TEST PROCEDURE 13.9.3
OPERATIONS IN THE EVENT OF A FAILURE OF EQUIPMENT OF MECHATRO CONTROLLER
(1) Engine emergency mode When the trouble occurs and the control of engine is impossible, the engine speed can be controlled by operating emergency acceleration (E-27) provided on the seat rear side. (See Fig. 13-34)
Operating procedure:
Operating procedure:
1) Set the emergency acceleration to NORMAL position.
1) Set the emergency acceleration to NORMAL position.
2) Start engine.
2) Start engine.
3) Turn the emergency acceleration to HI side and control the engine speed.
3) Turn the emergency acceleration to HI side and control the engine speed.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
4) When stopping the engine, set the emergency acceleration to NORMAL position before stopping.
Never increase the engine speed immediately after starting engine. It is dangerous. To avoid this danger, repeat the above procedure, or the engine speed does not increase. When the machine does not operate, set the emergency acceleration to NORMAL position.
Never increase the engine speed immediately after starting engine. It is dangerous. To avoid this danger, repeat the above procedure, or the engine speed does not increase. When the machine does not operate, set the emergency acceleration to NORMAL position.
(2) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of pump and the constant power control by means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition.
(2) Pump emergency mode In the event where a failure of P1 or P2 pump proportional valve represented in items of self diagnosis is indicated on multi display provided on the gauge cluster, the full power control of pump and positive control through mechatro controller are unavailable. Then the P1 and P2 pumps are automatically switched to emergency mode, making the operation with the power shift control of pump and the constant power control by means of self-pressure possible. But be careful that, at emergency mode, the accuracy of inching becomes poor, the frequency of engine down is increased, and the engine stalls in LOW speed condition.
The emergency mode should be used in only case of emergency. We recommend that the defective section is repaired by troubleshooting as early as possible.
The emergency mode should be used in only case of emergency. We recommend that the defective section is repaired by troubleshooting as early as possible.
13-27
13-27
13. MAINTENANCE STANDARD AND TEST PROCEDURE
13. MAINTENANCE STANDARD AND TEST PROCEDURE
[MEMO]
[MEMO]
13-28
13-28
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
TABLE OF CONTENTS
TABLE OF CONTENTS
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4 21.1.1
MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2
UNLOAD VALVE CONTROL..................................................................................21-6
21.1.3
21.1 SUMMARY OF MECHATRO CONTROL SYSTEM.........................................................21-4 21.1.1
MECHATRO CONTROL SYSTEM IN GENERAL ..................................................21-4
21.1.2
UNLOAD VALVE CONTROL..................................................................................21-6
POSITIVE CONTROL & P-Q CONTROL ...............................................................21-7
21.1.3
POSITIVE CONTROL & P-Q CONTROL ...............................................................21-7
21.1.4
BOOM UP CONFLUX CONTROL ..........................................................................21-9
21.1.4
BOOM UP CONFLUX CONTROL ..........................................................................21-9
21.1.5
ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10
21.1.5
ARM IN RECIRCULATION & CONFLUX CONTROL.............................................21-10
21.1.6
ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12
21.1.6
ARM-IN ANTI-CAVITATION CONTROL ................................................................21-12
21.1.7
ARM-OUT CONFLUX CONTROL ..........................................................................21-13
21.1.7
ARM-OUT CONFLUX CONTROL ..........................................................................21-13
21.1.8
BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-14
21.1.8
BUCKET DIGGING (DUMP) CONFLUX CONTROL ..............................................21-14
21.1.9
BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-15
21.1.9
BUCKET DIGGING ANTI-CAVITATION CONTROL ..............................................21-15
21
21.1.10 SWING PRIORITY CONTROL ...............................................................................21-17
21.1.10 SWING PRIORITY CONTROL ...............................................................................21-17
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-18
21.1.11 TRAVEL STRAIGHT CONTROL ............................................................................21-18
21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-20
21.1.12 PRESSURE RELEASE CONTROL ........................................................................21-20
21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-21
21.1.13 N&B SWITCH CONTROL (OPTION) .....................................................................21-21
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-22
21.1.14 OPTION CONFLUX CONTROL (OPTION) ............................................................21-22
21.2 MECHATRO CONTROLLER...........................................................................................21-23
21.2 MECHATRO CONTROLLER...........................................................................................21-23
21.2.1
SUMMARY OF MULTI DISPLAY ...........................................................................21-23
21.2.1
SUMMARY OF MULTI DISPLAY ...........................................................................21-23
21.2.2
SELF DIAGNOSIS DISPLAY..................................................................................21-28
21.2.2
SELF DIAGNOSIS DISPLAY..................................................................................21-28
21.2.3
SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-30
21.2.3
SERVICE DIAGNOSIS DISPLAY FUNCTION .......................................................21-30
21.2.4
TROUBLE HISTORY DIAGNOSIS .........................................................................21-40
21.2.4
TROUBLE HISTORY DIAGNOSIS .........................................................................21-40
21.2.5
TROUBLE DIAGNOSIS MODE ..............................................................................21-41
21.2.5
TROUBLE DIAGNOSIS MODE ..............................................................................21-41
21.2.6
SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42
21.2.6
SET PROCEDURE OF MAINTENANCE SCHEDULE ...........................................21-42
21.2.7
ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43
21.2.7
ADJUSTING PROCEDURE OF DISPLAY .............................................................21-43
21.2.8
MECHATRO CONTROL EQUIPMENT ..................................................................21-47
21.2.8
MECHATRO CONTROL EQUIPMENT ..................................................................21-47
Book Code No. S5YN2122E01 21-1
Book Code No. S5YN2122E01 21-1
21
21. MECHATRO CONTROL SYSTEM Issue
Date of Issue
First edition
July, 2007
n
n
21. MECHATRO CONTROL SYSTEM Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
21-2
Remarks S5YN2122E01 (NHK Middle East) n (NHK Russia) HS Engine
Issue
Date of Issue
K
First edition
July, 2007
K
n
n
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~ n
21-2
Remarks S5YN2122E01 (NHK Middle East) n (NHK Russia) HS Engine
K K
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
PREFACE
PREFACE
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system.
This manual explains only those related to the electro hydraulic conversion as mechatro control. This manual summarizes the mechatro system and the function of the mechatro controller related apparatuses. Regarding the conditions before and after each conversion, refer to the hydraulic system and the electric system.
21-3
21-3
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1
SUMMARY OF MECHATRO CONTROL SYSTEM
21.1
SUMMARY OF MECHATRO CONTROL SYSTEM
21.1.1
MECHATRO CONTROL SYSTEM IN GENERAL
21.1.1
MECHATRO CONTROL SYSTEM IN GENERAL
21-4
21-4
21. MECHATRO CONTROL SYSTEM
MAIN CONTROL VALVE
L1
MAIN CONTROL VALVE
SE-29
UP
REVERSE
L2 L3
(7)
DIGGING
UP
REVERSE
REVERSE
L2 L3
LEFT ARM OUT
(6)
(8)
(5)
(7)
SV-13
OPTION
TRAVEL LEFT
PL1 ATTACHMENT BOOST
TRAVEL P1 UNLOAD STRAIGHT
TRAVEL RIGHT
BOOM LOW SPEED (3)
P1 P2
(3) BOOM UP CONFLUX
FORWARD
(4)
P2 UNLOAD
DOWN FORWARD
SOL
RIGHT ARM IN
SOLENOID VALVE
PSV -A
PSV PSV PSV -D -C -B
SV -2
SV -3
SV -1
SV -4
ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX
PSV -A
(7)
PSV PSV PSV -D -C -B
SV -2
SV -3
SV -1
SAFETY LOCK LEVER
SWING PARKING BRAKE
L5
TRAVEL 1,2 SPEED
BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX
ATTACHMENT BOOST
BOOM CYLINDER BOOM DOWN RECIRCULATION BOOM CONFLUX
P2 UNLOAD
TRAVEL MOTOR 1,2 SPEED SELECT
TRAVEL STRAIGHT
TRAVEL MOTOR 1,2 SPEED SELECT
P1 UNLOAD
SWING MOTOR PARKING RELEASE
ARM IN 2 SPEED
SWING MOTOR PARKING RELEASE
SAFETY LOCK LEVER
SWING PARKING BRAKE
TRAVEL 1,2 SPEED
ATTACHMENT BOOST
P2 UNLOAD
TRAVEL STRAIGHT
P1 UNLOAD
L4
ARM IN 2 SPEED
L5
(1)
RIGHT ARM IN
L4
(2)
BUCKET
ARM 1 SPEED
SOL
SOLENOID VALVE
DUMP
(8)
ARM 2 SPEED
SWING (5)
ARM OUT
SV-13 N&B SELECTOR VALVE
(8)
OPTION
(6)
BOOM UP CONFLUX
TRAVEL LEFT
PL1 ATTACHMENT BOOST
REVERSE
LEFT ARM OUT
ARM 1 SPEED
(3)
P1 P2
(3)
P2 UNLOAD
FORWARD
(4)
SWING
(1)
DIGGING
DOWN FORWARD
TRAVEL P1 UNLOAD STRAIGHT
BUCKET
ARM 2 SPEED
(2)
TRAVEL RIGHT
DUMP
(8)
BOOM LOW SPEED
ARM OUT
SE-29
N&B SELECTOR VALVE
L1
21. MECHATRO CONTROL SYSTEM
SV -4
ARM CYLINDER ARM OUT CONFLUX ARM IN CONFLUX
(7)
ARM IN
ARM IN
L6
BUCKET CYLINDER DIGGING / DUMP CONFLUX
L7 PROPORTIONAL VALVE SOLENOID VALVE
21-5
) BLOCK
L6
BUCKET CYLINDER DIGGING / DUMP CONFLUX
L7 PROPORTIONAL VALVE SOLENOID VALVE
21-5
) BLOCK
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.2
21.1.2
P2
(LEFT)
(RIGHT)
OPTIONAL PILOT VALVE
PILOT VALVE
P2
PILOT VALVE
(LEFT)
(RIGHT)
OPTIONAL PILOT VALVE
PILOT VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
ARM 1 SPEED
OPTION
SOLENOID
P1
PILOT VALVE
PILOT VALVE FOR TRAVEL
SE-11 SE-9
N&B SELECTOR VALVE
P1
PILOT VALVE FOR TRAVEL
SE-10
UNLOAD VALVE CONTROL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
UNLOAD VALVE CONTROL
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-11 SE-10
SE-5,7,8
pi
PILOT SIGNAL PROCESS
PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SIGNAL PROCESS
PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
MECHATRO PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective low pressure sensors.
(1) On starting any one of operations, the control pilot secondary pressure switches spools and enters in respective low pressure sensors.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by mechatro controller and switches each unload spools.
(3) Each unload pressure proportional valves output pilot secondary pressure according to the command output by mechatro controller and switches each unload spools.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
(4) With this operation, the bleed opening according to lever manipulated movement is obtained, consequently the pump pressure which is used to actuate each actuators are delivered and makes each actuator start operating.
21-6
21-6
21. MECHATRO CONTROL SYSTEM
P2
SE-23
(RIGHT)
SE-9
P2
SE-22
SE-23
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P1
P1
SE-22
SE-11
PILOT VALVE
PILOT VALVE
(LEFT)
PILOT VALVE FOR TRAVEL
SE-10
P2 UNLOAD
OPTIONAL PILOT VALVE
SE-11
(LEFT)
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
POSITIVE CONTROL & P-Q CONTROL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
OPTIONAL PILOT VALVE
TRAVEL LEFT
BOOM UP CONFLUX
21.1.3
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
POSITIVE CONTROL & P-Q CONTROL
OPTION
21.1.3
21. MECHATRO CONTROL SYSTEM
(RIGHT)
PILOT VALVE
PILOT VALVE
PILOT VALVE FOR TRAVEL
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-10
SE-5,7,8
pi
PILOT SIGNAL PROCESS
SE-9
LOW LOW PRESSURE PRESSURE SENSOR SENSOR SE-1~4
SE-5,7,8
pi P2 PUMP PROPORTIONAL VALVE COMMAND
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE
pi
pi
pi
PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE COMMAND
P1 PUMP PROPORTIONAL VALVE PSV-P1
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE
PILOT SIGNAL PROCESS PILOT SECONDARY PRESSURE
SECONDARY PRESSURE
21-7
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE COMMAND
P1 PUMP PROPORTIONAL VALVE COMMAND
P1 PUMP PROPORTIONAL VALVE PSV-P1
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
21-7
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(1) Positive control
(1) Positive control
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor.
1) On starting any one of operations, pilot secondary pressure switches each spool and is input to each low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to each unload pressure proportional valve.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes the tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained.
4) With this operation, the delivery rate according to lever manipulated movement is fed to the actuator, and consequently the working speed according to the lever manipulated movement will be obtained.
(2) P-Q control
(2) P-Q control
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure).
1) The output voltage of high pressure sensor provided on each pump line is input to mechatro controller and the mechatro controller processes pilot signal and operates the command according to the input voltage (load pressure).
2) The lower value between command values calculated by positive control and operated value found by P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve as command value.
2) The lower value between command values calculated by positive control and operated value found by P-Q control {operated value found in item 1)} is selected and is output to each pump proportional valve as command value.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes tilting angle of each pump and controls the delivery rate.
3) Each pump proportional valve outputs pilot secondary pressure according to the command output by mechatro controller and changes tilting angle of each pump and controls the delivery rate.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and consequently working speed will be obtained according to lever movement.
4) With this operation, the delivery rate according to lever manipulated movement is fed to actuator and consequently working speed will be obtained according to lever movement.
PILOT PRESSURE
PILOT SIGNAL PROCESS
PUMP DELIVERY PRESSURE
21-8
P-Q CONTROL
PILOT SIGNAL PROCESS
PUMP PROPORTIONAL SECONDARY PRESSURE
PILOT SIGNAL PROCESS
POSITIVE CONTROL
PUMP PROPORTIONAL SECONDARY PRESSURE
P-Q CONTROL
PUMP PROPORTIONAL SECONDARY PRESSURE
PUMP PROPORTIONAL SECONDARY PRESSURE
POSITIVE CONTROL
PILOT PRESSURE
PILOT SIGNAL PROCESS
PUMP DELIVERY PRESSURE
21-8
21. MECHATRO CONTROL SYSTEM
P1
LOW PRESSURE SENSOR
P2
PILOT VALVE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
P1
LOW PRESSURE SENSOR
SE-3
pi
BOOM UP CONFLUX CONTROL
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL STRAIGHT P2
PILOT VALVE
TRAVEL RIGHT
P1 UNLOAD
21.1.4
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
BOOM UP CONFLUX CONTROL
OPTION
21.1.4
21. MECHATRO CONTROL SYSTEM
SE-3
PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P2 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BOOM UP PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS MECHATRO CONTROLLER BOOM UP PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P2 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux spool and is input to low pressure sensor.
(1) On starting boom up operation, boom up operating pilot pressure switches boom spool and boom up conflux spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valve.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
(4) With original hydraulic pressure command, boom main spool and boom up conflux spool are switched, and also with the command by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched and consequently the delivery oil on P1 pump side confluxes delivery oil on P2 pump side during boom up operation.
21-9
21-9
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.5
21.1.5
P2
LOW PRESSURE SENSOR SE-1~6
P1
SE-1~6
SE-7
CONTROL PROCESS FOR 2 SPEED
P1
LOW PRESSURE SENSOR SE-7
CONTROL PROCESS FOR 2 SPEED
pi
PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE
PILOT SIGNAL PROCESS
ARM IN PILOT SECONDARY PRESSURE P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM IN PILOT SECONDARY PRESSURE
PILOT SECONDARY PRESSURE
P2 PUMP PRESSURE
PILOT SECONDARY PRESSURE PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi PILOT SECONDARY PRESSURE
pi
ARM PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE PSV-P1
ARM IN PILOT SECONDARY PRESSURE P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi
P2 PUMP PROPORTIONAL VALVE PSV-P2
pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
MECHATRO CONTROLLER
21-10
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
ARM PILOT SECONDARY PRESSURE
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P2 PUMP PRESSURE
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
MECHATRO CONTROLLER
21-10
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD P2
LOW PRESSURE SENSOR
LOW PRESSURE SENSOR
TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SWING
SOLENOID
OPTION
N&B SELECTOR VALVE
ARM 1 SPEED
ARM IN RECIRCULATION & CONFLUX CONTROL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SWING
SOLENOID
OPTION
N&B SELECTOR VALVE
ARM 1 SPEED
ARM IN RECIRCULATION & CONFLUX CONTROL
21. MECHATRO CONTROL SYSTEM (1) Recirculation and conflux (Low loading)
21. MECHATRO CONTROL SYSTEM (1) Recirculation and conflux (Low loading)
1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor.
1) On starting arm-in operation, arm-in operating pilot secondary pressure is input to arm 1 spool, arm 2 spool and low pressure sensor.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the arm-in independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool.
2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload proportional valves and reverse proportional valve for arm-in 2 spool. In case of combined operation, the pilot pressure other than arm-in operation is input to low pressure sensor and the output voltage is input to mechatro controller. And the mechatro controller processes pilot signal according to the combined operation and outputs command, which is different from the arm-in independent operation, to P1 pump proportional valve, P1 unload proportional valve and reverse proportional valve for arm-in 2 spool.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve.
3) Primary pressure of reverse proportional valve for arm-in 2 spool is arm-in pilot secondary pressure and it switches arm 2 spool by proportional secondary pressure according to command. (Arm 2 spool controls recirculation rate and conflux rate.) The other proportional valves output proportional secondary pressure according to command from mechatro controller. These proportional valves change the delivery rate of P1, P2 pump, and switch P1, P2 unload valve.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation.
4) The arm 1 spool is switched according to original oil pressure command, and P1, P2 pumps, P1, P2 unload spools and arm 2 spool are switched according to the command output by mechatro controller, and consequently the return oil from the arm cylinder rod side is recirculated in P1 and P2 pumps delivery oil during arm operation.
(2) Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.
(2) Recirculation cut The voltage output by high pressure sensor on P2 side is input to mechatro controller, and when the load is raised during arm operation the mechatro controller processes pilot signal processing according to the pressure detected by high pressure sensor and outputs command to cut recirculation into reverse proportional valve for arm-in 2 spool. The reverse proportional valve for arm-in 2 spool outputs pilot secondary pressure according to the command output by mechatro controller and switches arm 2 spool to recirculation cut position, and consequently recirculation passage is blocked.
21-11
21-11
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.6
21.1.6
P2
LOW PRESSURE SENSOR SE-7
ARM IN PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P2
ARM 2 SPEED
BUCKET
BOOM
P1
ACCEL POTENTIO
pi
pi
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
P1
LOW PRESSURE SENSOR SE-7 PILOT SIGNAL PROCESS
ARM 1 SPEED
SOLENOID
OPTION
N&B SELECTOR VALVE PILOT VALVE
ACCEL POTENTIO
pi
ARM-IN ANTI-CAVITATION CONTROL
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
ARM-IN ANTI-CAVITATION CONTROL
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM IN PILOT SECONDARY PRESSURE pi REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi
ARM IN PILOT SECONDARY PRESSURE
PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL PSV-Bpi
ARM IN PILOT SECONDARY PRESSURE
pi
pi REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL COMMAND
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
pi
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor.
(1) On starting arm-in operation, arm-in operating pilot secondary pressure switches arm 1 spool and is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional valve.
(3) Low pressure sensor output voltage is input to mechatro controller, and the mechatro controller processes pilot signal processing and outputs command according to the input voltage to P2 pump proportional valve and P2 unload proportional valve.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool.
(4) And also outputs command according to input pressure output by potentiometer to reverse proportional valve for arm 2 spool.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed.
(5) Each proportional valves output pilot secondary pressure according to each command output by mechatro controller, and consequently since the reverse proportional valve for arm 2 spool is controlled to spool stroke according to engine speed and changes recirculation rate to prevent the cavitation from occurring even if pump delivery rate is low due to low engine speed.
21-12
21-12
21. MECHATRO CONTROL SYSTEM
PILOT VALVE
P2
P1
LOW PRESSURE SENSOR SE-8
pi
PILOT VALVE
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
ARM-OUT CONFLUX CONTROL
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL STRAIGHT
TRAVEL RIGHT
P1 UNLOAD
21.1.7
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
ARM-OUT CONFLUX CONTROL
OPTION
21.1.7
21. MECHATRO CONTROL SYSTEM
P1
LOW PRESSURE SENSOR SE-8 PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
ARM OUT PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
ARM OUT PILOT SECONDARY PRESSURE pi P1 PUMP PROPORTIONAL VALVE PSV-P1
ARM OUT PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE PSV-P1
ARM OUT PILOT SECONDARY PRESSURE
pi
pi P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM OUT PILOT SECONDARY PRESSURE pi
MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
P2 UNLOAD PROPORTIONAL VALVE PSV-B
ARM OUT PILOT SECONDARY PRESSURE pi P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
MECHATRO CONTROLLER ARM OUT PILOT SECONDARY PRESSURE
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor.
(1) On starting arm-out operation, arm-out operating pilot pressure switches arm 1 spool and arm 2 spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves and P1 and P2 unload proportional valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload pressure control valves.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
(4) With original hydraulic pressure command, arm 1 spool and arm 2 spool are switched and also with the command output by mechatro controller, P1 and P2 pumps and P1 and P2 unload valves are switched, and consequently the delivery oil on P2 pump side confluxes delivery oil on P1 pump side during arm-out operation.
21-13
21-13
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.8
21.1.8
P2
P1
LOW PRESSURE SENSOR SE-1(2) pi
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
ARM 1 SPEED
SWING
P2
P1
pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
PILOT VALVE
P2 PUMP PROPORTIONAL VALVE PSV-P2
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
SOLENOID
pi
PILOT SIGNAL PROCESS
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
N&B SELECTOR VALVE
LOW PRESSURE SENSOR SE-1(2)
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi
BUCKET DIGGING (DUMP) CONFLUX CONTROL
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
PILOT VALVE
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
BUCKET DIGGING (DUMP) CONFLUX CONTROL
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE
pi TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
PILOT SIGNAL PROCESS
TRAVELSTRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO
BUCKET DIGGING (DUMP) PILOT SECONDARY PRESSURE CONTROLLER pi : PROPORTIONAL VALVE
SECONDARY PRESSURE
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor.
(1) On starting bucket digging (dump) operation, bucket digging (dump) operating pilot pressure switches bucket spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(4) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
21-14
21-14
21. MECHATRO CONTROL SYSTEM
P2
P1
LOW PRESSURE SENSOR SE-1 (2)
P2
P1
PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
ACCEL POTENTIO
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
BUCKET DIGGING PILOT SECONDARY PRESSURE
PILOT SIGNAL PROCESS
BUCKET ANTI-CAVITATION PROCESS
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
BUCKET DIGGING PILOT SECONDARY PRESSURE
pi
BUCKET DIGGING PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SIGNAL PROCESS
pi ATT BOOST SOLENOID VALVE SV-2
ENGINE SPEED (COMMAND VALUE)
PILOT SIGNAL PROCESS
BUCKET ANTI-CAVITATION PROCESS
ATT BOOST SOLENOID VALVE SV-2
ENGINE SPEED (COMMAND VALUE)
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P1 PUMP PRESSURE
21-15
MECHATRO CONTROLLER pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P1 PUMP PRESSURE
21-15
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
ARM 2 SPEED
BUCKET
BUCKET DIGGING ANTI-CAVITATION CONTROL
LOW PRESSURE SENSOR SE-1 (2)
pi
ACCEL POTENTIO
BOOM
TRAVEL STRAIGHT
TRAVEL RIGHT
P1 UNLOAD
21.1.9
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
BUCKET DIGGING ANTI-CAVITATION CONTROL
OPTION
21.1.9
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor.
(1) On starting bucket digging (dump) operation, bucket digging operating pilot pressure switches bucket spool and is input to low pressure sensor.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(2) The engine speed command output by accel potentiometer is input to mechatro controller.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload proportional valves and travel straight proportional valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve.
(4) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of control valve.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(5) The tandem passage is connected to P2 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of P2 unload valve switched.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool. The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low.
(6) ATT boost solenoid valve turns the solenoid valve on according to the engine speed, and outputs secondary pressure, and actuate stroke limiter and then controls the stroke of bucket spool. The control of spool stroke makes the prevention of cavitation possible even if engine speed is low and pump delivery rate is low.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of bucket spool.
(7) When P1 pump pressure was raised at cylinder stroke end, etc. the solenoid valve is closed according to the pump pressure, and when the pump pressure is high, the boost solenoid valve does not work to control the stroke limit of bucket spool.
21-16
21-16
21. MECHATRO CONTROL SYSTEM
P2
ARM IN PILOT SECONDARY PRESSURE
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
SWING PILOT SECONDARY PRESSURE
P2
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SWING
ARM 1 SPEED
SOLENOID
pi P2 PUMP PROPORTIONAL VALVE PSV-P2 P1 PUMP PROPORTIONAL VALVE PSV-P1
TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND
TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
MECHATRO CONTROLLER
ARM IN PILOT SECONDARY PRESSURE
pi
P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi
pi
N&B SELECTOR VALVE
P1
LOW PRESSURE SENSOR
ARM IN PILOT SECONDARY PRESSURE
SWING PILOT SECONDARY PRESSURE
PILOT VALVE
P1
LOW PRESSURE SENSOR pi
SWING PRIORITY CONTROL
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
BOOM UP CONFLUX
TRAVEL LEFT
SOLENOID
P2 UNLOAD
N&B SELECTOR VALVE
21.1.10
SWING
PILOT VALVE
ARM 1 SPEED
SWING PRIORITY CONTROL
OPTION
21.1.10
21. MECHATRO CONTROL SYSTEM
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
pi
pi
SWING PILOT SECONDARY PRESSURE
P1 PUMP PROPORTIONAL VALVE PSV-P1 P2 UNLOAD PROPORTIONAL VALVE PSV-B P1 UNLOAD PROPORTIONAL VALVE PSV-D
ARM IN PILOT SECONDARY PRESSURE
SWING PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
TRAVEL STRAIGHT PROPORTIONAL VALVE COMMAND
TRAVEL STRAIGHT COMMAND PROPORTIONAL VALVE PSV-C
REVERSE PROPORTIONAL VALVE CONTROL PROCESS FOR ARM 2 SPOOL
REVERSE PROPORTIONAL VALVE FOR ARM 2 SPOOL PSV-A
MECHATRO CONTROLLER
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor.
(1) During arm-in operation, arm operating pilot secondary pressure switches arm spool and is input to low pressure sensor on starting swing operation (or arm-in operation during swing operation), and swing operation pilot secondary pressure switches swing spool and is input to low pressure sensor.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
(2) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 proportional valves, P1 and P2 unload pressure proportional valves, travel straight valve and reverse proportional valve for arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight spool, arm 2 spool.
(3) Each proportional valve outputs pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload spool, travel straight spool, arm 2 spool.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
(4) With original hydraulic pressure command, arm 1 spool and swing spool are switched and also with the command by mechatro controller, P1 and P2 unload spools, travel straight spool and arm 2 spool are switched enabling for two pump flow rates to be supplied to the arm cylinder head side, and consequently the return oil on arm cylinder rod side is recirculated into arm cylinder head side.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible.
(5) Because the return oil on the arm rod side is recirculated, the working pressure is raised and pump delivery rate is used for swing operation by priority, and operated by the recirculated oil, making the operation with minimum speed drop possible.
21-17
21-17
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.11
21.1.11
PILOT VALVE FOR TRAVEL
SE-10
SE-9
SE-11
P2
LOW PRESSURE SENSOR
(RIGHT)
PILOT VALVE FOR TRAVEL
SE-10
SE-9
SE-11
PILOT VALVE
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
pi
PILOT SECONDARY PRESSURE
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P1 PUMP PROPORTIONAL VALVE PSV-P1
P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
P2 PUMP PROPORTIONAL VALVE PSV-P2
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
P2 UNLOAD PROPORTIONAL VALVE PSV-B
PILOT SECONDARY PRESSURE pi
PILOT SIGNAL PROCESS
P1 UNLOAD PROPORTIONAL VALVE PSV-D
MECHATRO CONTROLLER
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
PILOT SECONDARY PRESSURE
21-18
P1 UNLOAD PROPORTIONAL VALVE PSV-D
MECHATRO CONTROLLER
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
TRAVEL LEFT
BOOM UP CONFLUX
P1 UNLOAD P1
PILOT SECONDARY PRESSURE
PILOT SECONDARY PRESSURE pi
21-18
SWING
pi TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
PILOT SECONDARY PRESSURE
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
P2
TRAVEL STRAIGHT SIGNAL
PILOT SIGNAL PROCESS
pi
PILOT VALVE
LOW PRESSURE SENSOR
TRAVEL STRAIGHT SIGNAL
pi
ARM 1 SPEED
SOLENOID
(LEFT) P1
N&B SELECTOR VALVE
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
OPTIONAL PILOT VALVE
TRAVEL STRAIGHT
PILOT VALVE
TRAVEL STRAIGHT CONTROL
P2 UNLOAD
(RIGHT)
TRAVEL STRAIGHT
(LEFT)
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
OPTIONAL PILOT VALVE
OPTION
TRAVEL STRAIGHT CONTROL
21. MECHATRO CONTROL SYSTEM (1) Judgment travel straight
21. MECHATRO CONTROL SYSTEM (1) Judgment travel straight
1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor on carrying out attachment system operation.
1) During travel operation (right and left), pilot pressure switches each spool and is input to low pressure sensor on carrying out attachment system operation.
2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on.
2) Mechatro controller decides as travel straight on receiving the input according to the combination shown in the table from the low pressure sensor and turns travel straight signal on.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
3) On turning travel straight signal on, the following commands are output to each proportional valve.
(2) Operation of each proportional valve (Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel straight condition.)
(2) Operation of each proportional valve (Basically attachment operation is actuated by P1 pump and travel operation is actuated by P2 pump in travel straight condition.)
1) Travel straight proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during operation.
1) Travel straight proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating (Boom, arm, bucket, swing, option) pilot pressure during operation.
2) P1 unload proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.
2) P1 unload proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.
3) P2 unload proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.
3) P2 unload proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.
4) P1 pump proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.
4) P1 pump proportional valve Outputs switching pressure according to the high priority select pressure in the attachment system operating pilot pressure during operation.
5) P2 pump proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.
5) P2 pump proportional valve Outputs switching pressure according to the high priority select in the travel operating pilot pressure during operation.
21-19
21-19
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.12
21.1.12
P2
P1
SE-23
SE-22
pi
pi
pi
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS MECHATRO CONTROLLER
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
ENGINE SPEED CONTROL
pi
pi P1 PUMP PROPORTIONAL VALVE PSV-P1
pi P2 UNLOAD PROPORTIONAL VALVE PSV-B
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
SE-22
ENGINE
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 UNLOAD PROPORTIONAL VALVE PSV-D
P1
SE-23
PRESSURE RELEASE CONTROL
ENGINE SPEED CONTROL
P1 UNLOAD P2
ENGINE
PRESSURE RELEASE CONTROL
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
TRAVEL STRAIGHT
GAUGE CLUSTER
P2 UNLOAD
SOLENOID
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
PRESSURE RELEASE CONTROL
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
PILOT VALVE
P2 UNLOAD
GAUGE CLUSTER
SWING
SOLENOID
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
PRESSURE RELEASE CONTROL
pi
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS
PILOT SIGNAL PROCESS MECHATRO CONTROLLER
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
pi : PROPORTIONAL VALVE SECONDARY PRESSURE
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster. For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(1) Change mechatro controller to "PRESSURE DRAINING MODE" by operating switch on gauge cluster. For detail of changing mode method, refer to "How to switch to "Pressure release mode"" on item 22.11.1.
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) the mechatro controller;
(2) Once mechatro controller decides it as pressure release control, regardless of each input signal (operating pilot, accel potentiometer, etc.) the mechatro controller;
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tilt angle.
1) Outputs minimum tilt angle command to P1, P2 pump proportional valves and fixes P1, P2 pump to minimum tilt angle.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes engine speed to pressure release control speed.
2) Outputs command of pressure release and outputs command of pressure release control to ECU and fixes engine speed to pressure release control speed.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and P2 unload valves to the maximum opening.
3) Outputs maximum command to P1 and P2 unload valves and each pilot secondary pressure fixes P1 and P2 unload valves to the maximum opening.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(3) Mechatro controller senses output voltage from the main pump high pressure sensor, decides the pump pressure and displays "DRAINING HYD. PRESS" or "FAIL DRAIN HYD. PRESS" on gauge cluster.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened.
(4) Each pump delivery oil is unloaded to tank passage enabling for the remained pressure (trapped pressure) to be released by operating each control lever and switching spool with the unload valve opened.
21-20
21-20
21. MECHATRO CONTROL SYSTEM
P2
P2
P1
A MODE
A MODE
B MODE
B MODE
GAUGE CLUSTER
GAUGE CLUSTER
pi
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE
ARM 1 SPEED
N&B SWITCH CONTROL (OPTION)
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX
21.1.13
P2 UNLOAD
SOLENOID
SWING
PRESSURE SENSOR N&B FOR BREAKER SELECTOR SE-29 VALVE
ARM 1 SPEED
N&B SWITCH CONTROL (OPTION)
OPTION
21.1.13
21. MECHATRO CONTROL SYSTEM
P1
pi
B MODE SWITCH
B MODE SWITCH
MECHATRO CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit
MECHATRO CONTROLLER
pi : OUTPUT OF N&B SELECTOR SOLENOID
(1) Nibbler circuit
1) Select A mode through gauge cluster.
1) Select A mode through gauge cluster.
2) Nibbler display appears on gauge cluster.
2) Nibbler display appears on gauge cluster.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main control valve.
3) The return oil from the nibbler passes through selector valve and option spool and led to tank line of main control valve.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster.
4) When selecting A mode through gauge cluster, the breaker pressure sensor has not function to output. It is in normal when there is no output from sensor in A mode, and in cases of other than above, error display is output to gauge cluster.
(2) Breaker circuit
(2) Breaker circuit
1) Select B mode through gauge cluster.
1) Select B mode through gauge cluster.
2) Breaker display appears on gauge cluster.
2) Breaker display appears on gauge cluster.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
3) The return oil from the breaker passes through selector valve and directly returns into hydraulic oil tank.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster.
4) When selecting B mode through gauge cluster, the breaker pressure sensor outputs signal. It is in normal when there is an output from sensor in B mode, and in cases of other than above, error display is output to gauge cluster.
21-21
21-21
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.1.14
21.1.14
P2
LOW PRESSURE SENSOR
LOW PRESSURE SENSOR
SE-11
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD P2
P1
SINGLE / CONFLUX SWITCH
TRAVEL STRAIGHT
BOOM UP CONFLUX
TRAVEL LEFT
SOLENOID
P2 UNLOAD
PILOT VALVE
SWING
N&B SELECTOR VALVE
ARM 1 SPEED
OPTION CONFLUX CONTROL (OPTION)
OPTION
ARM 2 SPEED
BUCKET
BOOM
TRAVEL RIGHT
P1 UNLOAD TRAVEL STRAIGHT
TRAVEL LEFT
BOOM UP CONFLUX P2 UNLOAD
SOLENOID
SWING
PILOT VALVE
ARM 1 SPEED
N&B SELECTOR VALVE
OPTION
OPTION CONFLUX CONTROL (OPTION)
P1
SINGLE / CONFLUX SWITCH
SE-11
pi
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
pi P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE
OPTION PILOT SECONDARY PRESSURE
pi
pi
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE
PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE pi PILOT SIGNAL PROCESS
OPTION PILOT SECONDARY PRESSURE
P2 PUMP PROPORTIONAL VALVE PSV-P2
P1 PUMP PROPORTIONAL VALVE PSV-P1
P2 UNLOAD PROPORTIONAL VALVE PSV-B
P1 UNLOAD PROPORTIONAL VALVE PSV-D
TRAVEL STRAIGHT PROPORTIONAL VALVE PSV-C
MECHATRO pi : PROPORTIONAL VALVE CONTROLLER SECONDARY PRESSURE
(1) Select the Conflux with the aid of Conflux/Single switch.
(1) Select the Conflux with the aid of Conflux/Single switch.
(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor.
(2) On starting option operation, option operating pilot pressure switches option spool and is input to low pressure sensor.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
(3) The output voltage of low pressure sensor is input to mechatro controller and the mechatro controller processes pilot signal and outputs command according to the input voltage to P1 and P2 pump proportional valves, P1 and P2 unload pressure proportional valves and travel straight proportional valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve.
(4) Each proportional valves output pilot proportional valve secondary pressure according to the command output by mechatro controller and changes P1 and P2 pump delivery rate and switches P1 and P2 unload valves and travel straight valve of the control valve.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
(5) The parallel passage on P2 side is connected to P1 port because of the travel straight valve switched and P1 pump delivery oil confluxes P2 pump delivery oil because of the P2 unload valve switched.
21-22
21-22
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.2
MECHATRO CONTROLLER
21.2
MECHATRO CONTROLLER
21.2.1
SUMMARY OF MULTI DISPLAY
21.2.1
SUMMARY OF MULTI DISPLAY
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
Electro-hydraulic conversion information is displayed on the multi display of the gauge cluster.
(1) Controls
(1) Controls EMERGECY ACCEL DIAL GAUGE CLUSTER
EMERGECY ACCEL DIAL
SWING PARKING BRAKE RELEASE SWITCH
SAFETY LOCK LEVER
GAUGE CLUSTER
SWING PARKING BRAKE RELEASE SWITCH
SAFETY LOCK LEVER RIGHT CONTROL LEVER WITH ATT BOOST SW.
RIGHT CONTROL LEVER WITH ATT BOOST SW. FUSE & RELAY BOX
STARTER SWITCH ACCEL DIAL
A
ACCEL DIAL
DETAIL A
A
(2) Gauge cluster
(2) Gauge cluster No. 11
22:00 H 1
2 3 10 4
9
8
5
7
6
Name
1
Engine coolant temperature gauge
2
Fuel level gauge
3
Screen change switch
4
Buzzer stop switch
5
Work mode select switch
6
Washer switch
7
Wiper switch
8
Travel high speed, low speed select switch
9
Auto accel switch
10
Select switch
11
Multi display (LCD)
21-23
FUSE & RELAY BOX
STARTER SWITCH
No. 11
22:00 H 1
2 3 10 4
9
8
5
7
6
Name
1
Engine coolant temperature gauge
2
Fuel level gauge
3
Screen change switch
4
Buzzer stop switch
5
Work mode select switch
6
Washer switch
7
Wiper switch
8
Travel high speed, low speed select switch
9
Auto accel switch
10
Select switch
11
Multi display (LCD)
21-23
DETAIL A
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(3) Screen selection by work mode select switch
(3) Screen selection by work mode select switch
Press the work mode selector switch ( ) in order, and "S" o "H" o "B" o "A" mode can be selected. Select the effective work mode according to the work condition and working target from the table shown below. For the selected work mode, refer to the table shown below.
Press the work mode selector switch ( ) in order, and "S" o "H" o "B" o "A" mode can be selected. Select the effective work mode according to the work condition and working target from the table shown below. For the selected work mode, refer to the table shown below.
• S mode: For standard excavating work
• S mode: For standard excavating work
• H mode: For heavy duty excavating work
• H mode: For heavy duty excavating work
• B mode: For works with breaker
• B mode: For works with breaker
• A mode: For demolition works with crusher (Nibbler)
• A mode: For demolition works with crusher (Nibbler)
10:25
• The initial setting (default) of work mode had been set to "S" mode at factory. As for the work mode after the engine starts, the mode that was used the last time engine was stopped is automatically set. Check that the selected mode conforms to the work before starting work.
S
10:25
• The initial setting (default) of work mode had been set to "S" mode at factory. As for the work mode after the engine starts, the mode that was used the last time engine was stopped is automatically set. Check that the selected mode conforms to the work before starting work.
• Check that the attachment in use conforms to the work mode before starting work. If not conformed, select proper mode with the work mode select switch.
• Check that the attachment in use conforms to the work mode before starting work. If not conformed, select proper mode with the work mode select switch.
• The operation under improper work mode may cause damage to machine.
• The operation under improper work mode may cause damage to machine.
Work mode
S mode
H mode
B mode
A mode
Display
10:25 10:25 10:25 10:25
Contents
Work mode
"S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.
S mode
"H mode"is suitable for heavy duty digging work which gives priority to the workload at the high speed.
H mode
For the work with breaker, select "B mode" without fail.
B mode
For the work with crusher (nibbler), select "A mode".
A mode
For the work with breaker, select "B mode" without fail. The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and breaker.
21-24
Display
10:25 10:25 10:25 10:25
S
Contents "S mode"is suitable for standard digging and loading works and is in fuel saving and is maintained well-balanced relations with workload.
"H mode"is suitable for heavy duty digging work which gives priority to the workload at the high speed.
For the work with breaker, select "B mode" without fail.
For the work with crusher (nibbler), select "A mode".
For the work with breaker, select "B mode" without fail. The work with breaker in any mode other than "B mode" may cause damage to the hydraulic equipment and breaker.
21-24
21. MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode) No.
1
Switches
2
3
21. MECHATRO CONTROL SYSTEM 1) Pump flow rate adjustment (A mode /B mode)
4
No.
1
Screen change switch
1
Screen change switch
2
Buzzer stop switch
2
Buzzer stop switch
3
KPSS work mode select switch
3
KPSS work mode select switch
4
Washer switch
4
Washer switch
5
Wiper switch
5
Wiper switch
6
Travel speed select switch
6
Travel speed select switch
7
Auto accel switch
7
Auto accel switch
8
Select switch
8
Select switch
8
7
5
6 Fig. 21-1
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial flow rate is 220L/min. The adjustment (increase or decrease) of flow rate is changeable by 10L/min step.
Main screen
Flow rate
H
Flow rate
100 L/m Enter
A
(a)
8
(b)
(d)
220 L/m
A mode Flow rate
Flow rate
10:25
100 L/m
Flow rate
H
A
Flow rate
A
Flow rate
100 L/m
Flow rate
100 L/m Enter
(b)
(c)
(d)
Flow rate
100 L/m
B
Increase/Decrease When the conflux switch is tuned on, the double flow rate is displayed.
(d)
Screen in Attachment/Breaker mode A mode Flow rate
Flow rate
100 L/m
A
Increase/Decrease
Flow rate
220 L/m
Flow rate
100 L/m Enter
(c)
(d)
100 L/m
B
Increase/Decrease When the conflux switch is tuned on, the double flow rate is displayed.
B mode
A (c)
220 L/m
B
220 L/m
B (b)
Flow rate
220 L/m
A
(a)
Increase/Decrease
Enter
B mode 220 L/m
5
6
In Breaker mode (B mode)
B Screen in Attachment/Breaker mode
7
4
Attachment mode (A mode)
In Breaker mode (B mode) Flow rate
3
Fig. 21-1
Main screen Flow rate
220 L/m
2
According to some kind of attachment, it is required to change the flow rate for service circuit. Change the flow rate in accordance with the procedure mentioned below. In this machine, last set flow rate has been stored and the initial flow rate is 220L/min. The adjustment (increase or decrease) of flow rate is changeable by 10L/min step.
Attachment mode (A mode)
10:25
1
Switches
220 L/m
B (b)
(c)
1. Turn starter key switch on and display main screen (a).
1. Turn starter key switch on and display main screen (a).
2. The display on the left lower corner of screen is changed in order of "S" o "H" o "B" o "A" each time the "MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
2. The display on the left lower corner of screen is changed in order of "S" o "H" o "B" o "A" each time the "MODE" switch (3) is pressed under the condition where main screen (a) is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
3. Select "A" and A mode screen is displayed, and select "B" and B mode screen is displayed.
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
4. Press select switch (8) in A/B mode display screens (b)/(c) and the value of flow rate reverses in black and
the screen (d) is displayed. In this condition, press FEED decreases.
(4)/
(5) and the flow rate value increases or
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
21-25
the screen (d) is displayed. In this condition, press FEED decreases.
(4)/
(5) and the flow rate value increases or
5. Select the desired setting value and then press select switch (8) and the flow rate is set to the desired value.
21-25
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(4) MAINTENANCE SCREEN DISPLAYS
(4) MAINTENANCE SCREEN DISPLAYS
This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table.
This screen displays the remaining time to the end of recommended replacement/change interval specified for filter/oil. For the initial set value of recommenced replacement/change time, see the following table.
Replacement interval
Replacement interval
Item
Default
Item
Default
Engine oil
500 Hr
Engine oil
500 Hr
Fuel filter
500 Hr
Fuel filter
500 Hr
Hydraulic oil filter Hydraulic oil
1,000 Hr MIDDLE EAST
2,000 Hr
RUSSIA
5,000 Hr
Hydraulic oil filter Hydraulic oil
1,000 Hr MIDDLE EAST
2,000 Hr
RUSSIA
5,000 Hr
This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed.
This menu is available for confirmation of the following items. The maintenance screen changes each time the screen change switch is pressed.
1. Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.
1. Remaining time display to the engine oil change This display shows the remaining time to the coming engine oil change.
492Hr
492Hr
ENGINE OIL
ENGINE OIL
H
2. Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.
H
492Hr
FUEL FILTER
2. Remaining time display to the coming fuel filter replacement This display shows the remaining time to the coming engine fuel filter replacement.
H
3. Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.
FUEL FILTER
H
992Hr
HYD. FILTER
3. Remaining time display to the coming hydraulic oil filter replacement This display shows the remaining time to the coming hydraulic oil filter replacement.
H
4. Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.
492Hr
992Hr
HYD. FILTER
H
1992Hr HYD. OIL
4. Remaining time display to the coming hydraulic oil change This display shows the remaining time to the coming hydraulic oil change.
H
1992Hr HYD. OIL
H
•
The display automatically changes to the main screen, if switch is not operated for 30 seconds.
•
The display automatically changes to the main screen, if switch is not operated for 30 seconds.
•
For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
•
For the setting procedure of maintenance time to be performed to the coming oil change in each type and filter replacement, see the 21.2.6 SET PROCEDURE OF MAINTENANCE SCHEDULE.
21-26
21-26
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(5) Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below.
(5) Gauge cluster display After key is switched on and logo mark display disappears, screen for operator is displayed on multi screen. The display functions of multi display are explained below.
CLOCK DISPLAY
CLOCK DISPLAY
SELF DIAGNOSIS / WARNING
SELF DIAGNOSIS / WARNING
MACHINE CONDITION
MACHINE CONDITION
H
H
MULTI DISPLAY INDICATIONS
MULTI DISPLAY INDICATIONS
1) Display function for operator ......... Screen usually displayed during operation
1) Display function for operator ......... Screen usually displayed during operation
1.1 Clock display function ......... Current time is displayed.
1.1 Clock display function ......... Current time is displayed.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code.
1.2 Self-diagnosis display ......... When abnormality is detected on mechatro system like sensor, proportional valve, etc., this displays error code.
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning contents with the symbol and statement. (For warning contents, see items shown below.)
1.3 Warning display ......... When machine was thrown into dangerous state, or was failed, displays warning contents with the symbol and statement. (For warning contents, see items shown below.)
1.4 Machine condition display ......... Displays machine operating condition.
1.4 Machine condition display ......... Displays machine operating condition.
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
2) Display function for maintenance ......... Displays remaining time up to replacement/change of following items. (1) Engine oil (2) Fuel filter (3) Hydraulic oil filter (4) Hydraulic oil
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.
3) Failure history display function ......... Stores abnormality occurred on mechatro system in the past and displays in order of recent occurrence.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc.
4) Mechatro adjustment display ......... Displays procedure for adjustment of mechatro system like output adjustment and unload adjustment, etc.
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller
5) Service diagnosis display ......... Displays information like pressure sensor sensed value, proportional valve command, etc. output by mechatro controller
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.
6) Failure diagnosis mode display function ......... Specifies failed section automatically for failures which are not detected by self diagnosis and displays the results.
. Warning CAUTION ATTACHMENT
. Warning
These descriptions indicate error codes. LOW ENG OIL PRESS.
W005
PREHEAT
HIGH ENG WATER TEMP.
W006
CHARGE ERROR
AUTO IDLE STOP
POWER BOOST ON
LOW ENG WATER W004 LEVEL
LOW FUEL LEVEL
WARM FINISH WARM-UP
DRAIN WATER SEPA W010 CLOGGED AIR FLTR W008
AUTO IDLE STOP
DATA
CPU COMMUNICATION ERROR
SWING BRAKE DISENGAGED
W009
LOW ENG OIL PRESS.
W005
PREHEAT
HIGH ENG WATER TEMP.
W006
CHARGE ERROR
POWER BOOST ON
LOW ENG WATER W004 LEVEL
LOW FUEL LEVEL
WARM AUTO WARMING UP
WARM FINISH WARM-UP
DRAIN WATER SEPA W010
WARM AUTO WARMING UP
CHANGE ENG OIL
CPU COMMUNICATION
CLOGGED AIR FLTR W008
CHANGE ENG OIL
W011
ENGINE STOP
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-27
CAUTION ATTACHMENT
These descriptions indicate error codes.
DATA
ERROR
SWING BRAKE DISENGAGED
W009
W011
ENGINE STOP
Error codes were stored as trouble history, and displayed on the monitor by the trouble history display function.
21-27
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.2.2
21.2.2
SELF DIAGNOSIS DISPLAY
SELF DIAGNOSIS DISPLAY
(1) Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No. and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color.
(1) Outline This function identifies abnormality of control I/O signal like pressure, proportional valve, etc. during machine operation through self diagnosis. The failed items are displayed on multi display of gauge cluster. For connector No. and pin No., refer to the section "C-1 Mechatro controller" explained later. Electric circuit diagram or harness is available to identify wire No. and wire color.
(2) I/O configuration
(2) I/O configuration
(3) Self diagnosis display items As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with the aid of error code.
(3) Self diagnosis display items As-displayed clock (Usually main screen). When error occurred, specifies failed section and the failure type with the aid of error code.
21-28
21-28
21. MECHATRO CONTROL SYSTEM
Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-29
21. MECHATRO CONTROL SYSTEM
Note) The numbers in the column of "page for reference" show the related page in Chapter 51 Engine.
21-29
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.2.3
21.2.3
SERVICE DIAGNOSIS DISPLAY FUNCTION
SERVICE DIAGNOSIS DISPLAY FUNCTION
The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc.
The current service diagnosis is displayed on multi display based on the data received from mechatro controller. This section explains the operating procedure and examples of each screen. The values in display changes according to the conditions like engine speed, attachment position, etc.
(1) Service diagnosis display screen operating procedure
(1) Service diagnosis display screen operating procedure
1)
Turn starter switch ON keeping buzzer stop switch pressed.
2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows.
1)
Turn starter switch ON keeping buzzer stop switch pressed.
2) After logo mark is displayed, the screen changes in service diagnosis mode. The service diagnosis screen "Mode No.1", "Screen No.1" is displayed first. The service diagnosis is classified into three modes, 1, 2, and 3, and the present mode is displayed in "Screen No.1". The screen number each mode can display differs. The screen number displayed by each mode is as follows.
•
Mode No.1 : Screen No.1~No.30
•
Mode No.1 : Screen No.1~No.30
•
Mode No.2 : Screen No.1, Screen No.31~No.40
•
Mode No.2 : Screen No.1, Screen No.31~No.40
•
Mode No.3 : Screen No.1, Screen No.41~No.50
•
Mode No.3 : Screen No.1, Screen No.41~No.50
3) The screen changes each time each switch is pressed from now on.
3) The screen changes each time each switch is pressed from now on.
Washer switch: Screen gains by 1 in order. (No.2oNo.3oNo.4o...)
Washer switch: Screen gains by 1 in order. (No.2oNo.3oNo.4o...)
Wiper switch: Screen loses by 1 in order. (No.24oNo.23oNo.22o...)
Wiper switch: Screen loses by 1 in order. (No.24oNo.23oNo.22o...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1. (No.1oNo.2oNo.3oNo.1o...)
Auto idling switch: Service diagnosis number advances from No.1 to No.3, and then returns to No.1. (No.1oNo.2oNo.3oNo.1o...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3oNo.2oNo.1oNo.3o...)
Travel 1, 2 speed switch: Service diagnosis number advances from No.3 to No.1, and then returns to No.3. (No.3oNo.2oNo.1oNo.3o...)
4) Turn key switch OFF and the display of service diagnosis mode is closed.
21-30
4) Turn key switch OFF and the display of service diagnosis mode is closed.
21-30
21. MECHATRO CONTROL SYSTEM (2) Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis mode No.1 No. 1
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 1
2
3
NO.2 ENG G-3 SPEED SET 2205 MEAS1 2201 MEAS2 2201 G-5 ENG PRS. LIVE WATER TEMP 100 OFF MODE HM H-1 ACCEL VOLT. 4.2V POS. 100% ECU OUTPUT 0.5V
NO.3 SOL.VALVE F-1 POWER BOOST COMP. OFF MEAS. OFF SWITCH OFF F-2 SWING-BRAKE COMP. OFF MEAS. OFF RELEASE SW OFF F-3 1/2-TRAVEL COMP. OFF MEAS. OFF SWITCH OFF
21. MECHATRO CONTROL SYSTEM (2) Service diagnosis display screen (Example) The service diagnosis display screen list is shown below. The conditions for display are H mode, engine low speed and lever to neutral position.) 1) Service diagnosis mode No.1
Contents
No. 4
P/No. indication
K-1 AIS RELAY 2 OFF K-2 SAFETY RLY OFF K-3 ENG STOP OFF KEY SWITCH OFF START SWITCH OFF CHARGE LIVE K-4 LOCK LEVER OFF SWITCH OFF
Program version indication MERIT controller program version Service diagnosis mode
5 No load setting rpm Actual rpm 1 Actual rpm 2 (Engine controller) Engine oil pressure Coolant temperaturre sensor Work mode Potentiometer voltage Voltage % indication Accel output voltage to engine controller
6 Set value in computer Measured value Switch Set value in computer Measured value Switch Set value in computer Measured value Switch
Displays
Contents
NO.4 RELAY
NO.5 PRESS.SENSOR B-1 BOOM RAISE 3.5V 2.6M B-2 BOOM LOWER 3.5V 2.6M B-3 ARM OUT 3.5V 2.6M B-4 ARM IN 3.5V 2.6M B-5 BUCKET DIG 3.5V 2.6M B-6 BUCKET DUMP 3.5V 2.6M
NO.6 PRESS.SENSOR B-7 SWING 3.5V 2.6M B-9 TRAVEL(R) 3.5V 2.6M B-10 TRAVEL(L) 3.5V 2.6M B-16 P1 OPT. 3.5V 2.6M B-17 P2 OPT. 3.5V 2.6M B-18 DOZER 1 3.5V 2.6M B-19 DOZER 2 3.5V 2.6M
21-31
No. 1
Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 1
2 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
NO.2 ENG G-3 SPEED SET 2205 MEAS1 2201 MEAS2 2201 G-5 ENG PRS. LIVE WATER TEMP 100 OFF MODE HM H-1 ACCEL VOLT. 4.2V POS. 100% ECU OUTPUT 0.5V
Contents
No. 4
P/No. indication
K-1 AIS RELAY 2 OFF K-2 SAFETY RLY OFF K-3 ENG STOP OFF KEY SWITCH OFF START SWITCH OFF CHARGE LIVE K-4 LOCK LEVER OFF SWITCH OFF
Program version indication MERIT controller program version Service diagnosis mode
5 No load setting rpm Actual rpm 1 Actual rpm 2 (Engine controller) Engine oil pressure Coolant temperaturre sensor Work mode Potentiometer voltage Voltage % indication Accel output voltage to engine controller
Sensor voltage / Pressure converted value
3 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
NO.3 SOL.VALVE F-1 POWER BOOST COMP. OFF MEAS. OFF SWITCH OFF F-2 SWING-BRAKE COMP. OFF MEAS. OFF RELEASE SW OFF F-3 1/2-TRAVEL COMP. OFF MEAS. OFF SWITCH OFF
6 Set value in computer Measured value Switch Set value in computer Measured value Switch Set value in computer Measured value Switch
Displays
Contents
NO.4 RELAY
NO.5 PRESS.SENSOR B-1 BOOM RAISE 3.5V 2.6M B-2 BOOM LOWER 3.5V 2.6M B-3 ARM OUT 3.5V 2.6M B-4 ARM IN 3.5V 2.6M B-5 BUCKET DIG 3.5V 2.6M B-6 BUCKET DUMP 3.5V 2.6M
NO.6 PRESS.SENSOR B-7 SWING 3.5V 2.6M B-9 TRAVEL(R) 3.5V 2.6M B-10 TRAVEL(L) 3.5V 2.6M B-16 P1 OPT. 3.5V 2.6M B-17 P2 OPT. 3.5V 2.6M B-18 DOZER 1 3.5V 2.6M B-19 DOZER 2 3.5V 2.6M
21-31
Indicated value Indicated value Indicated value Key switch Starter switch Alternator Indicated value Switch
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
21. MECHATRO CONTROL SYSTEM
7
8
9
10
11
NO.7 P.SENSOR PROPO-V C-1 PUMP P1 3.5V 32.6M C-2 PUMP P2 3.5V 32.6M C-3 BOOM-HEAD 3.5V 32.6M C-4 BOOM-ROD 3.5V 32.6M PROPO-VALVE E-3 OPT RELIEF 1 COMP. 600mA 14.5M MEAS. 600mA 14.5M E-4 OPT RELIEF 2 COMP. 600mA 14.5M NO.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-2 P2 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-3 S-TRAVEL COMP. 600mA 4.5M MEAS. 600mA 4.5M D-6 ARM IN-2-SPEED COMP. 600mA 4.5M MEAS. 600mA 4.5M
NO.9 PROPO-VALVE E-1 P1 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L E-2 P2 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L
NO.10 SENSOR,SWITCH H-9 FUEL LEVEL 4.5V 90 H-10 HYD.OIL TEMP 4.5V 30 GLOW OFF AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER LIVE FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW OFF HEATER OFF ENG OIL LEVEL LIVE COOLANT LEVEL LIVE NO.11 SOL.VALVE F-4 OPT SELECT COMP. OFF MEAS. OFF SPOOL POS. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP. OFF MEAS. OFF F-6 COMP. OFF MEAS. OFF
12
NO.12 POTENTIO. H-2 BOOM 3.5V 137 H-3 ARM 3.5V 137
21. MECHATRO CONTROL SYSTEM
16 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure
NO.16 PRESS.SENSOR B-11 3.5V 12.6M B-12 3.5V 12.6M B-13 3.5V 12.6M B-14 3.5V 12.6M B-15 3.5V 12.6M B-20 3.5V 12.6M
7 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
18 Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure
19 Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P1
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P2
20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch KPSS switch Command from air heater Engine oil level Coolant level
21 Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value
22 Sent value from sensor / Converted value from angle Sent value from sensor / Converted value from angle
8
NO.18 DIGITAL INPUT DI1 OFF DI2 OFF DI3 OFF DI4 OFF DI5 OFF DI6 OFF DI7 OFF DI8 OFF DI9 OFF DI10 OFF DI11 OFF DI12 OFF DI13 OFF DI14 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.19 DIGITAL INPUT DI15 OFF DI16 OFF DI17 OFF DI18 OFF DI19 OFF DI20 OFF DI21 OFF DI22 OFF DI23 OFF DI24 OFF DI25 OFF DI26 OFF DI27 OFF DI28 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.20 DIGITAL INPUT DI29 OFF DI30 OFF DI31 OFF DI32 OFF DI33 OFF DI34 OFF DI35 OFF DI36 OFF DI37 OFF DI38 OFF DI39 OFF DI40 OFF DI41 OFF DI42 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.21 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. OFF MEAS. OFF DO6 COMP. OFF MEAS. OFF DO7 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.22 DIGITAL OUTPUT DO8 COMP. OFF MEAS. OFF DO9 COMP. OFF MEAS. OFF DO10 COMP. OFF MEAS. OFF DO11 COMP. OFF MEAS. OFF DO12 COMP. OFF MEAS. OFF DO13 COMP. OFF MEAS. OFF DO14 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
21-32
See Mechatro controller connector
9
10
11
NO.7 P.SENSOR PROPO-V C-1 PUMP P1 3.5V 32.6M C-2 PUMP P2 3.5V 32.6M C-3 BOOM-HEAD 3.5V 32.6M C-4 BOOM-ROD 3.5V 32.6M PROPO-VALVE E-3 OPT RELIEF 1 COMP. 600mA 14.5M MEAS. 600mA 14.5M E-4 OPT RELIEF 2 COMP. 600mA 14.5M NO.8 PROPO-VALVE D-1 P1 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-2 P2 UN-LOAD(BP-CUT) COMP. 600mA 4.5M MEAS. 600mA 4.5M D-3 S-TRAVEL COMP. 600mA 4.5M MEAS. 600mA 4.5M D-6 ARM IN-2-SPEED COMP. 600mA 4.5M MEAS. 600mA 4.5M
NO.9 PROPO-VALVE E-1 P1 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L E-2 P2 PUMP COMP. 600mA 4.5M MEAS. 600mA 4.5M POWER SHIFT 100mA FLOW RATE 100L
NO.10 SENSOR,SWITCH H-9 FUEL LEVEL 4.5V 90 H-10 HYD.OIL TEMP 4.5V 30 GLOW OFF AIR FILTER LIVE WATER SEPA. LIVE ENG OIL FILTER LIVE FRONT WINDOW OFF DOUBLE FLOW ON KPSS SW OFF HEATER OFF ENG OIL LEVEL LIVE COOLANT LEVEL LIVE NO.11 SOL.VALVE F-4 OPT SELECT COMP. OFF MEAS. OFF SPOOL POS. NIB SELECT SWITCH NIB F-5 FAN PUMP COMP. OFF MEAS. OFF F-6 COMP. OFF MEAS. OFF
12
NO.12 POTENTIO. H-2 BOOM 3.5V 137 H-3 ARM 3.5V 137
16 Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Set value in computer / Converted value from pressure Measured value / Converted value from pressure
NO.16 PRESS.SENSOR B-11 3.5V 12.6M B-12 3.5V 12.6M B-13 3.5V 12.6M B-14 3.5V 12.6M B-15 3.5V 12.6M B-20 3.5V 12.6M
Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value Sensor voltage / Pressure converted value
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
18 Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure Set value in computer / Converted value from pressure Measured value / Converted value from pressure
19 Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P1
Set value in computer / Converted value from pressure Measured value / Converted value from pressure
Power shift Flow rate of pump P2
20 Fuel level Hydraulic oil temperature Glow switch Air filter clogging Water separator clogging Engine oil filter clogging Front window open/close switch Conflux/Single flow select switch KPSS switch Command from air heater Engine oil level Coolant level
21 Set value in computer Measured value (Feed back value) Spool position Mode of selector valve Set value in computer Measured value Set value in computer Measured value
22 Sent value from sensor / Converted value from angle Sent value from sensor / Converted value from angle
NO.18 DIGITAL INPUT DI1 OFF DI2 OFF DI3 OFF DI4 OFF DI5 OFF DI6 OFF DI7 OFF DI8 OFF DI9 OFF DI10 OFF DI11 OFF DI12 OFF DI13 OFF DI14 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.19 DIGITAL INPUT DI15 OFF DI16 OFF DI17 OFF DI18 OFF DI19 OFF DI20 OFF DI21 OFF DI22 OFF DI23 OFF DI24 OFF DI25 OFF DI26 OFF DI27 OFF DI28 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.20 DIGITAL INPUT DI29 OFF DI30 OFF DI31 OFF DI32 OFF DI33 OFF DI34 OFF DI35 OFF DI36 OFF DI37 OFF DI38 OFF DI39 OFF DI40 OFF DI41 OFF DI42 OFF
ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication ON/OFF indication
NO.21 DIGITAL OUTPUT DO1 COMP. OFF MEAS. OFF DO2 COMP. OFF MEAS. OFF DO3 COMP. OFF MEAS. OFF DO4 COMP. OFF MEAS. OFF DO5 COMP. OFF MEAS. OFF DO6 COMP. OFF MEAS. OFF DO7 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.22 DIGITAL OUTPUT DO8 COMP. OFF MEAS. OFF DO9 COMP. OFF MEAS. OFF DO10 COMP. OFF MEAS. OFF DO11 COMP. OFF MEAS. OFF DO12 COMP. OFF MEAS. OFF DO13 COMP. OFF MEAS. OFF DO14 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
21-32
See Mechatro controller connector
21. MECHATRO CONTROL SYSTEM No. 23
24
25
Displays
Contents
NO.23 DIGITAL OUTPUT DO15 COMP. OFF MEAS. OFF DO16 COMP. OFF MEAS. OFF DO17 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. OFF DO19 COMP. OFF MEAS. OFF DO20 COMP. OFF MEAS. OFF DO21 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.24 DIGITAL OUTPUT DO22 COMP. OFF MEAS. OFF DO23 COMP. OFF MEAS. OFF DO24 COMP. OFF MEAS. OFF DO25 COMP. OFF MEAS. OFF DO26 COMP. OFF MEAS. OFF DO27 COMP. OFF MEAS. OFF DO28 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.25 WIPER SYSTEM WIPER SW OFF RISEUP SW OFF REVERSE SW OFF PREVENT ARC OFF CW MOTOR RLY OFF CCW MOTOR RLY OFF WASHER SW OFF MOTOR RELAY OFF
No. 27
Displays
Contents
NO.27 MERIT SYSTEM COMMUNICATION
OFF 4
31
32
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00
No. 23
Status of communication in MERIT controller
0412051200
28
NO.28 ENG CONT. TRANS.COUNT. 100 RECEIVE COUNT. 100 DIAG STATUS 9 NUMBER OF DIAG 100 BOOST PRESS. 100 BOOST TEMP. -100 BAROMETRIC P. 100 FUEL TEMP. -100 FUEL CONS. 200 INTAKE TEMP. -100 ENG PRESS. 300 GLOW OFF ENG STOP OFF TORQUE 1000
24 Counted number of transmission error Counted number of reception error Diagnosis status Numbers of error Boost pressure Boost temperature Atmospheric pressure Fuel temperature Fuel consumption Intake air temperature Engine oil pressure Glow output from ECU Engine stop command from ECU Calculated torque of ECU
25 Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay
2) Service diagnosis mode No.2 No. 1
21. MECHATRO CONTROL SYSTEM Displays
Contents
NO.23 DIGITAL OUTPUT DO15 COMP. OFF MEAS. OFF DO16 COMP. OFF MEAS. OFF DO17 COMP. OFF MEAS. OFF DO18 COMP. OFF MEAS. OFF DO19 COMP. OFF MEAS. OFF DO20 COMP. OFF MEAS. OFF DO21 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.24 DIGITAL OUTPUT DO22 COMP. OFF MEAS. OFF DO23 COMP. OFF MEAS. OFF DO24 COMP. OFF MEAS. OFF DO25 COMP. OFF MEAS. OFF DO26 COMP. OFF MEAS. OFF DO27 COMP. OFF MEAS. OFF DO28 COMP. OFF MEAS. OFF
Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value Set value in computer Measured value
NO.25 WIPER SYSTEM WIPER SW OFF RISEUP SW OFF REVERSE SW OFF PREVENT ARC OFF CW MOTOR RLY OFF CCW MOTOR RLY OFF WASHER SW OFF MOTOR RELAY OFF
No. 27
Displays
Contents
NO.27 MERIT SYSTEM COMMUNICATION
OFF 4
Status of communication in MERIT controller
0412051200
28
NO.28 ENG CONT. TRANS.COUNT. 100 RECEIVE COUNT. 100 DIAG STATUS 9 NUMBER OF DIAG 100 BOOST PRESS. 100 BOOST TEMP. -100 BAROMETRIC P. 100 FUEL TEMP. -100 FUEL CONS. 200 INTAKE TEMP. -100 ENG PRESS. 300 GLOW OFF ENG STOP OFF TORQUE 1000
Counted number of transmission error Counted number of reception error Diagnosis status Numbers of error Boost pressure Boost temperature Atmospheric pressure Fuel temperature Fuel consumption Intake air temperature Engine oil pressure Glow output from ECU Engine stop command from ECU Calculated torque of ECU
Wiper switch Wiper rise-up switch Wiper reverse rotation switch Wiper motor ark prevention relay Wiper normal rotation relay Wiper reverse rotation relay Washer switch Washer motor relay
2) Service diagnosis mode No.2 Contents
No. 33
P/No. indication Program version indication MERIT controller program version
SERVICE DIAG 2
Service diagnosis mode
NO.31 BOOM C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA B-1 BOOM RAISE 1.9M B-2 BOOM LOWER 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current
NO.32 ARM,SWING C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA D-6 ARM-IN-2 600mA B-3 ARM OUT 13.9M B-4 ARM IN 13.9M B-1 BOOM RAISE 13.9M B-7 SWING 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current
34
35
Displays
Contents
NO.33 BUCKET C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-5 BUCKET DIG 1.9M B-6 BUCKET DUMP 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current
NO.34 TRAVEL C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-9 TRAVEL(R) 13.9M B-10 TRAVEL(L) 13.9M Pi-P1 13.9M Pi-P2 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current
NO.35 OPT C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA E-3 OPT RELIEF 600mA B-16 P1 OPT 1.9M B-17 P2 OPT 1.9M F-4 OPT SELECT NIB DOUBLE FLOW SW NIB G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current
21-33
No. 1
31
32
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00
Contents
No. 33
P/No. indication Program version indication MERIT controller program version
SERVICE DIAG 2
Service diagnosis mode
NO.31 BOOM C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA B-1 BOOM RAISE 1.9M B-2 BOOM LOWER 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Boom up pressure sensor Boom down pressure sensor Engine actual speed Power shift current
NO.32 ARM,SWING C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA D-6 ARM-IN-2 600mA B-3 ARM OUT 13.9M B-4 ARM IN 13.9M B-1 BOOM RAISE 13.9M B-7 SWING 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current Arm out pressure sensor Arm in pressure sensor Boom up pressure sensor Swing pressure sensor Engine actual speed Power shift current
34
35
Displays
Contents
NO.33 BUCKET C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-5 BUCKET DIG 1.9M B-6 BUCKET DUMP 1.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Bucket digging pressure sensor Bucket dump pressure sensor Engine actual speed Power shift current
NO.34 TRAVEL C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA B-9 TRAVEL(R) 13.9M B-10 TRAVEL(L) 13.9M Pi-P1 13.9M Pi-P2 13.9M G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Travel right pressure sensor Travel left pressure sensor Pilot pressure at travel straight (P1 side) Pilot pressure at travel straight (P2 side) Engine actual rpm Power shift current
NO.35 OPT C-1 P1-PRES 13.9M C-2 P2-PRES 13.9M E-1 P1-PSV 600mA E-2 P2-PSV 600mA D-1 P1-UL(BPC) 600mA D-2 P2-UL(BPC) 600mA D-3 S-TRAVEL 600mA E-3 OPT RELIEF 600mA B-16 P1 OPT 1.9M B-17 P2 OPT 1.9M F-4 OPT SELECT NIB DOUBLE FLOW SW NIB G-3 ENG SPEED 2205 POWER SHIFT 100mA
Pump pressure sensor Pump pressure sensor Command current Command current Command current Command current Command current Command current P1 side option pressure sensor P2 side option pressure sensor Optional selector SOL (Nibbler line) Conflux/ Single selector switch Engine actual rpm Power shift current
21-33
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
3) Service diagnosis mode No.3 No. 1
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 3
41
NO.41 ADJUSTMENT 1 ENG HI-IDLE 2205 PUMP ACT I 515mA 15mA PUMP P 35.0M ESS N 2040 UN-LOAD P1 600mA P2 600mA BOOM 137 137 ARM 137 137 OFFSET 137 137 INTER-B 137 137
3) Service diagnosis mode No.3 Contents
No. 43
P/No. indication Program version indication MERIT controller program version Service diagnosis mode
44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment
Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200
Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated starter operating time
41 Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
Displays NO.1 MAIN CONT. P/N YN22E00001F1 PROGRAM VERSION 1-VER 11.11 2-VER 00.00 SERVICE DIAG 3
All accumulated high-reach crane operating time
NO.44 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
21-34
No. 1
NO.41 ADJUSTMENT 1 ENG HI-IDLE 2205 PUMP ACT I 515mA 15mA PUMP P 35.0M ESS N 2040 UN-LOAD P1 600mA P2 600mA BOOM 137 137 ARM 137 137 OFFSET 137 137 INTER-B 137 137
Contents
No. 43
P/No. indication Program version indication MERIT controller program version Service diagnosis mode
44 Engine speed high idle Current at pump adjustment Current correction at pump adjustment Pressure at pump adjustment Engine speed sensor rpm P1 unload corrective current P2 unload corrective current Angle adjustment Angle adjustment Angle adjustment Angle adjustment
Displays NO.43 MACHINE-INFORM. HOUR METER 3550 TRIP METER 3500 OPERATION 3300 TRAVEL 300 SWING 3000 HAMMER 100 CRANE 100 STARTER 1200
Contents Hour meter of controller Trip meter of controller All accumulated operating time All accumulated traveling time All accumulated swing time All accumulated breaker operating time All accumulated high-reach crane operating time
All accumulated starter operating time
NO.44 MACHINE-INFORM. PUMP PRESS. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Pump pressure distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
WATER TEMP. TOTAL 10Hr LEVEL1 24% 22% LEVEL2 50% 50% LEVEL3 25% 25% LEVEL4 1 % 3%
Coolant temperature distribution (%) Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours Total / In the last 10 hours
21-34
21. MECHATRO CONTROL SYSTEM (3) Service diagnosis data list
21. MECHATRO CONTROL SYSTEM (3) Service diagnosis data list
Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status.
Preface and precaution The following is the data decided as normal status after service diagnosis for every operation. Use these data to decide normal/abnormal status.
•
The values in following display are reference values with standard attachment attached machine.
•
The values in following display are reference values with standard attachment attached machine.
•
The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument.
•
The value of pressure sensor is calculated taking variation into accounts. When compared to performance check reference criteria, measure it with the aid of calibrated measuring instrument.
•
The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve.
•
The current of proportional valve is not the measured value, but command value. The measured value should be confirmed by the value in the displayed value for each proportional valve.
•
The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value.
•
The current value of pump proportional valve is reference value because it varies according to pump pressure and adjusted torque value.
•
The value in display during operation shows the value in steady state, rather than, at start of operation.
•
The value in display during operation shows the value in steady state, rather than, at start of operation.
•
Check on machine after sufficiently warming up machine.
•
Check on machine after sufficiently warming up machine.
•
The value in display may differ according to software version. Contact our dealer/distributor.
•
The value in display may differ according to software version. Contact our dealer/distributor.
Operation No.1 : No operation H mode Hi idle
Operation No.2 : No operation S mode Hi idle
Operation No.1 : No operation H mode Hi idle
Operation No.2 : No operation S mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
350 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2030 0 mA
POWER SHIFT
1770~1830 0 mA
POWER SHIFT
1970~2030 0 mA
POWER SHIFT
1770~1830 0 mA
Operation No.3 : Boom up in full lever operation & relief H mode Hi idle
Operation No.4 : Boom up in full lever operation & in operation
Operation No.3 : Boom up in full lever operation & relief H mode Hi idle
Operation No.4 : Boom up in full lever operation & in operation
H mode Hi idle
No.31 BOOM
No.31 BOOM
No.31 BOOM
No.31 BOOM
H mode Hi idle
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
11.0~16.0 M
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
11.0~16.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
11.0~16.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
11.0~16.0 M
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
560~750 mA
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
560~750 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
560~750 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
560~750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
B-1
BOOM RAISE
3.0 M
B-1
BOOM RAISE
3.0 M
B-1
BOOM RAISE
3.0 M
B-1
BOOM RAISE
3.0 M
B-2
BOOM LOWER
0.0 M
B-2
BOOM LOWER
0.0 M
B-2
BOOM LOWER
0.0 M
B-2
BOOM LOWER
0.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-35
1970~2060 0 mA
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-35
1970~2060 0 mA
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle
Operation No.5 : Boom down in full lever operation & in operation H mode Hi idle
No.31 BOOM
No.31 BOOM
C-1
P1-PRES
12.5~16.0 M
C-1
P1-PRES
12.5~16.0 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
E-1
P1-PSV
600~617 mA
E-1
P1-PSV
600~617 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
350 mA
D-1
P1-UL(BPC)
427~477 mA
D-1
P1-UL(BPC)
427~477 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-2
BOOM LOWER
3.0 M
B-2
BOOM LOWER
3.0 M
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
1970~2060 0 mA
Operation No.6 : Arm-in in full lever operation & relief H mode Hi idle
Operation No.7 : Arm-in in full lever operation & in operation H mode Hi idle
Operation No.6 : Arm-in in full lever operation & relief H mode Hi idle
Operation No.7 : Arm-in in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
12.5~16.5 M
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
12.5~16.5 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
12.5~16.5 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
12.5~16.5 M
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
550~750 mA
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
550~750 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
550~750 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
550~750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-6
ARM-IN-2
200 mA
D-6
ARM-IN-2
400 mA
D-6
ARM-IN-2
200 mA
D-6
ARM-IN-2
400 mA
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-4
ARM IN
3.0 M
B-4
ARM IN
3.0 M
B-4
ARM IN
3.0 M
B-4
ARM IN
3.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-36
1970~2060 0 mA
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-36
1970~2060 0 mA
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
Operation No.8 : Arm-out in full lever operation & relief H mode Hi idle
Operation No.9 : Arm-out in full lever operation & in operation H mode Hi idle
Operation No.8 : Arm-out in full lever operation & relief H mode Hi idle
Operation No.9 : Arm-out in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
15.0~22.0 M
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
15.0~22.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
15.0~22.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
15.0~22.0 M
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
488~677 mA
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
488~677 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
488~677 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
488~677 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
B-3
ARM OUT
3.0 M
B-3
ARM OUT
3.0 M
B-3
ARM OUT
3.0 M
B-3
ARM OUT
3.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
B-7
SWING
0.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
1970~2060
POWER SHIFT
0 mA
1970~2060
POWER SHIFT
0 mA
1970~2060
POWER SHIFT
0 mA
1970~2060
POWER SHIFT
0 mA
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
* Measure the values after a lapse of 5 minutes or after release of low temperature mode
Operation No.10 : Swing in full lever operation & relief H mode Hi idle
Operation No.11 : Swing in full lever operation & in operation H mode Hi idle
Operation No.10 : Swing in full lever operation & relief H mode Hi idle
Operation No.11 : Swing in full lever operation & in operation H mode Hi idle
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
No.32 ARM, SWING
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
0.2~1.5 M
C-2
P2-PRES
28.0~35.8 M
C-2
P2-PRES
10.0~15.0 M
C-2
P2-PRES
28.0~35.8 M
C-2
P2-PRES
10.0~15.0 M
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-1
P1-PSV
350 mA
E-2
P2-PSV
528~750 mA
E-2
P2-PSV
750 mA
E-2
P2-PSV
528~750 mA
E-2
P2-PSV
750 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
750 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
D-6
ARM-IN-2
750 mA
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-3
ARM OUT
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-4
ARM IN
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-1
BOOM RAISE
0.0 M
B-7
SWING
3.0 M
B-7
SWING
3.0 M
B-7
SWING
3.0 M
B-7
SWING
3.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-37
1970~2060 0 mA
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-37
1970~2060 0 mA
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
Operation No.12 : Bucket digging in full lever operation & relief H mode Hi idle
Operation No.13 : Bucket digging in full lever operation & in operation H mode Hi idle
Operation No.12 : Bucket digging in full lever operation & relief H mode Hi idle
Operation No.13 : Bucket digging in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
No.33 BUCKET
No.33 BUCKET
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
4.0~8.0 M
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
4.0~8.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
4.0~8.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
4.0~8.0 M
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
650~750 mA
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
650~750 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
540~563 mA
E-2
P2-PSV
415~525 mA
E-2
P2-PSV
540~563 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
B-5
BUCKET DIG
3.0 M
B-5
BUCKET DIG
3.0 M
B-5
BUCKET DIG
3.0 M
B-5
BUCKET DIG
3.0 M
B-6
BUCKET DUMP
0.0 M
B-6
BUCKET DUMP
0.0 M
B-6
BUCKET DUMP
0.0 M
B-6
BUCKET DUMP
0.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
1970~2060
POWER SHIFT
0 mA
POWER SHIFT
1970~2060 0 mA
1970~2060
POWER SHIFT
0 mA
POWER SHIFT
1970~2060 0 mA
Operation No.14 : Bucket dump in full lever operation & relief H mode Hi idle
Operation No.15 : Bucket dump in full lever operation & in operation H mode Hi idle
Operation No.14 : Bucket dump in full lever operation & relief H mode Hi idle
Operation No.15 : Bucket dump in full lever operation & in operation H mode Hi idle
No.33 BUCKET
No.33 BUCKET
No.33 BUCKET
No.33 BUCKET
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
6.0~15.0 M
C-1
P1-PRES
33.0~35.8 M
C-1
P1-PRES
6.0~15.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
6.0~15.0 M
C-2
P2-PRES
33.0~35.8 M
C-2
P2-PRES
6.0~15.0 M
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
577~750 mA
E-1
P1-PSV
415~525 mA
E-1
P1-PSV
577~750 mA
E-2
P2-PSV
415~435 mA
E-2
P2-PSV
415~435 mA
E-2
P2-PSV
415~435 mA
E-2
P2-PSV
415~435 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
720 mA
B-5
BUCKET DIG
0.0 M
B-5
BUCKET DIG
0.0 M
B-5
BUCKET DIG
0.0 M
B-5
BUCKET DIG
0.0 M
B-6
BUCKET DUMP
3.0 M
B-6
BUCKET DUMP
3.0 M
B-6
BUCKET DUMP
3.0 M
B-6
BUCKET DUMP
3.0 M
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
G-3
ENG SPEED
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-38
1970~2060 0 mA
POWER SHIFT
1970~2060 0 mA
POWER SHIFT
21-38
1970~2060 0 mA
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
Operation No.16 : P2 side option in full lever operation & relief A mode Hi idle
Operation No.17 : P2 side option in full lever operation & relief B mode Hi idle
Operation No.16 : P2 side option in full lever operation & relief A mode Hi idle
Operation No.17 : P2 side option in full lever operation & relief B mode Hi idle
No.35 OPT
No.35 OPT
No.35 OPT
No.35 OPT
C-1
P1-PRES
22.5~26.0 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
22.5~26.0 M
C-1
P1-PRES
0.2~1.5 M
C-2
P2-PRES
22.5~26.0 M
C-2
P2-PRES
22.5~26.0 M
C-2
P2-PRES
22.5~26.0 M
C-2
P2-PRES
22.5~26.0 M
E-1
P1-PSV
459~584 mA
E-1
P1-PSV
500 mA
E-1
P1-PSV
459~584 mA
E-1
P1-PSV
500 mA
E-2
P2-PSV
459~584 mA
E-2
P2-PSV
665~750 mA
E-2
P2-PSV
459~584 mA
E-2
P2-PSV
665~750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
750 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
720 mA
D-3
S-TRAVEL
350 mA
E-3
OPT RELIEF
0 mA
E-3
OPT RELIEF
0 mA
E-3
OPT RELIEF
0 mA
E-3
OPT RELIEF
0 mA
B-16 P1 OPT
0.0 M
B-16 P1 OPT
0.0 M
B-16 P1 OPT
0.0 M
B-16 P1 OPT
0.0 M
B-17 P2 OPT
2.0~2.6 M
B-17 P2 OPT
2.0~2.6 M
B-17 P2 OPT
2.0~2.6 M
B-17 P2 OPT
2.0~2.6 M
F-4 G-3
OPT SELECT
NIB
DOUBLE FLOW SW.
ON
ENG SPEED POWER SHIFT
F-4
1970~2060
G-3
0 mA
OPT SELECT
BRK
DOUBLE FLOW SW.
OFF
ENG SPEED POWER SHIFT
1970~2060
F-4 G-3
0 mA
OPT SELECT
NIB
DOUBLE FLOW SW.
ON
ENG SPEED POWER SHIFT
F-4
1970~2060
G-3
0 mA
OPT SELECT
BRK
DOUBLE FLOW SW.
OFF
ENG SPEED POWER SHIFT
1970~2060 0 mA
* Conflux switch is ON. Relief set pressure is value of shipping.
* Conflux switch is OFF. Relief set pressure is value of shipping.
* Conflux switch is ON. Relief set pressure is value of shipping.
* Conflux switch is OFF. Relief set pressure is value of shipping.
Operation No.18 : Travel right in full lever operation & travel idling H mode Hi idle
Operation No.19 : Travel left in full lever operation & travel idling H mode Hi idle
Operation No.18 : Travel right in full lever operation & travel idling H mode Hi idle
Operation No.19 : Travel left in full lever operation & travel idling H mode Hi idle
No.34 TRAVEL
No.34 TRAVLE
No.34 TRAVEL
No.34 TRAVLE
C-1
P1-PRES
5.0~12.0 M
C-1
P1-PRES
0.2~1.5 M
C-1
P1-PRES
5.0~12.0 M
C-1
P1-PRES
0.2~1.5 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
5.0~12.0 M
C-2
P2-PRES
0.2~1.5 M
C-2
P2-PRES
5.0~12.0 M
E-1
P1-PSV
750 mA
E-1
P1-PSV
350 mA
E-1
P1-PSV
750 mA
E-1
P1-PSV
350 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
750 mA
E-2
P2-PSV
350 mA
E-2
P2-PSV
750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
750 mA
D-1
P1-UL(BPC)
360 mA
D-1
P1-UL(BPC)
750 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
360 mA
D-2
P2-UL(BPC)
750 mA
D-2
P2-UL(BPC)
360 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
D-3
S-TRAVEL
350 mA
B-9
TRAVEL(R)
2.0~2.5 M
B-9
TRAVEL(R)
0.0 M
B-9
TRAVEL(R)
2.0~2.5 M
B-9
TRAVEL(R)
0.0 M
B-10 TRAVEL(L)
0.0 M
B-10 TRAVEL(L)
2.0~2.5 M
B-10 TRAVEL(L)
0.0 M
B-10 TRAVEL(L)
2.0~2.5 M
Pi-P1
0.0 M
Pi-P1
0.0 M
Pi-P1
0.0 M
Pi-P1
0.0 M
Pi-P2
0.0 M
Pi-P2
0.0 M
Pi-P2
0.0 M
Pi-P2
0.0 M
G-3
ENG SPEED POWER SHIFT
1970~2060
G-3
0 mA
ENG SPEED POWER SHIFT
21-39
1970~2060 0 mA
G-3
ENG SPEED POWER SHIFT
1970~2060
G-3
0 mA
ENG SPEED POWER SHIFT
21-39
1970~2060 0 mA
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.2.4
21.2.4
TROUBLE HISTORY DIAGNOSIS
TROUBLE HISTORY DIAGNOSIS
The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. The warning content is record partially in "Travel history screen". The error code for self diagnosis is stored.
The items of error detected by mechatro controller self diagnosis function are stored in mechatro controller as one of history. And the errors are able to be indicated on the multi display. The warning content is record partially in "Travel history screen". The error code for self diagnosis is stored.
(1) How to display
(1) How to display
1) Turn starter switch on.
1) Turn starter switch on.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
2) Press buzzer stop switch for 10 seconds continuously 5 times and the trouble history screen is displayed.
(Example) No errors
(Example) NO ERROR
No errors
Error detected in the past
NO ERROR
Error detected in the past
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
3) Transmit trouble history data (One or many) and hour meter to gauge cluster.
•
Hour meter and 4 failure data are displayed on screen.
•
Hour meter and 4 failure data are displayed on screen.
•
In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
•
In case of more than 4 failure data, 4 data is displayed at a time for 10 seconds by turns.
4) Paging (Up and down)
4) Paging (Up and down)
•
Press washer switch ( ), and the item moves upward.
•
Press washer switch ( ), and the item moves upward.
•
Press wiper switch ( ), and the item moves downward.
•
Press wiper switch ( ), and the item moves downward.
5) Turn starter switch off, and the display is disappeared. (2) How to delete contents of trouble history
5) Turn starter switch off, and the display is disappeared. (2) How to delete contents of trouble history
1) Display trouble history screen.
1) Display trouble history screen.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
2) Press work mode change switch and buzzer stop switch simultaneously for 10 seconds or more.
3) When "NO ERROR" is displayed, the deletion is completed.
3) When "NO ERROR" is displayed, the deletion is completed.
4) Turn starter switch off.
4) Turn starter switch off.
All the stored items are erased. It is impossible to erase data partially.
All the stored items are erased. It is impossible to erase data partially.
21-40
21-40
21. MECHATRO CONTROL SYSTEM 21.2.5
TROUBLE DIAGNOSIS MODE
21. MECHATRO CONTROL SYSTEM 21.2.5
TROUBLE DIAGNOSIS MODE
The recent control system includes many electrical systems and it makes troubleshooting very difficult. The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting.
The recent control system includes many electrical systems and it makes troubleshooting very difficult. The failure diagnosis mode is used to automatically specify the failed sections for the failures which can not be detected through the use of self diagnosis function (the failure can be specified through the use of error code) like disconnection and abnormal output. This is useful to save the time for troubleshooting.
(1) Function There are two types of trouble diagnosis mode.
(1) Function There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not moved, both directional valve and proportional valve are automatically actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition or failed condition of the system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not moved, both directional valve and proportional valve are automatically actuated, the sensor detects the machine status and the mechatro controller identifies the normal condition or failed condition of the system.
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
For details of how to use, refer to "Chapter 46 TROUBLESHOOTING TROUBLE DIAGNOSIS MODE".
21-41
21-41
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21.2.6
21.2.6
SET PROCEDURE OF MAINTENANCE SCHEDULE
This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/ change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting by the following order. Screen change switch
Buzzer stop switch
Washer switch
• Engine oil : 500 Hr
• Hydraulic oil : 2,000 Hr (MIDDLE EAST) 5,000 Hr (RUSSIA)
3
4
5
Buzzer stop switch
KPSS work mode select switch Washer switch
Interval of replacement of parts is mentioned below. • Fuel filter : 500 Hr
Select switch
• Hydraulic filter : 1,000 Hr
2
Screen change switch
• Engine oil : 500 Hr
• Fuel filter : 500 Hr
1
This machine is equipped with multi-display which allows confirmation of remaining time to the coming replacement/ change time of engine oil, fuel filter, hydraulic oil filter and hydraulic oil, therefore when the remaining time reaches to Zero (0), replace or change engine oil, fuel filter, hydraulic filter, hydraulic oil, etc. and perform the initial setting by the following order.
KPSS work mode select switch
Interval of replacement of parts is mentioned below.
Procedure
SET PROCEDURE OF MAINTENANCE SCHEDULE
Operating Procedure
Auto accel switch
Travel speed select switch
Wiper switch
• Hydraulic oil : 2,000 Hr (MIDDLE EAST) 5,000 Hr (RUSSIA)
Display on Multidisplay After several seconds, display is changed to clock autmatically.
Turn starter key switch on.
Press " " switch press once display change switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press " " switch press once select switch once and the display for the engine oil change reverses. When required to adjust the interval to the coming change time by 10 hours, press " " switch and the time to the coming engine oil change is added. Press " " switch and the time to the coming engine oil change is reduced. When desired to return to the initial set time, press " " buzzer stop switch once. Press " " select switch once and the set time is stored.
10:25 H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
Press screen change switch once more.
Press select switch once more.
Replacing interval is changed with each pressing of switch.
To set the desired interval, press the select switch
Select switch
• Hydraulic filter : 1,000 Hr
Procedure
10:25
1
Operating Procedure
ENGINE OIL
2
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
500 Hr ENGINE OIL
H
3
4
5
Travel speed select switch
Wiper switch
Display on Multidisplay After several seconds, display is changed to clock autmatically.
Turn starter key switch on.
H
250 Hr
Auto accel switch
Press " " switch press once display change switch on the switch panel once. And the clock display changes to the display of remaining time for coming engine oil change. Press " " switch press once select switch once and the display for the engine oil change reverses. When required to adjust the interval to the coming change time by 10 hours, press " " switch and the time to the coming engine oil change is added. Press " " switch and the time to the coming engine oil change is reduced. When desired to return to the initial set time, press " " buzzer stop switch once. Press " " select switch once and the set time is stored.
10:25 H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
Press screen change switch once more.
Press select switch once more.
Replacing interval is changed with each pressing of switch.
To set the desired interval, press the select switch
10:25 H
250 Hr ENGINE OIL
H
250 Hr ENGINE OIL
500 Hr ENGINE OIL
500 Hr ENGINE OIL
H
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
1. After displaying the display for setting by pressing the display change switch, set the respective maintenance time for fuel filter, hydraulic oil filter and hydraulic oil while repeating the procedure 2 to 5.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound.
2. The engine oil change time is displayed on the multi-display by 500 hours as a warning, but the buzzer does not sound.
21-42
21-42
21. MECHATRO CONTROL SYSTEM 21.2.7
ADJUSTING PROCEDURE OF DISPLAY
21.2.7
(1) For operator
ADJUSTING PROCEDURE OF DISPLAY
(1) For operator
1) Auto idling stop No.
21. MECHATRO CONTROL SYSTEM
1
Switchs
2
3
1) Auto idling stop
4
No.
1
Switchs
1
Screen change switch
1
Screen change switch
2
Buzzer stop switch
2
Buzzer stop switch
3
KPSS work mode select switch
3
KPSS work mode select switch
4
Washer switch
4
Washer switch
5
Wiper switch
5
Wiper switch
6
Travel speed select switch
6
Travel speed select switch
7
Auto accel switch
7
Auto accel switch
8
Select switch
8
Select switch
Main screen
10:25
8
7
5
6 Fig. 21-2
Main screen
SWITCH STATUS CLOCK/CONTRAST
10:25
H (a)
8
2
3
7
4
5
6 Fig. 21-2
SWITCH STATUS CLOCK/CONTRAST
H (b) (d)
AUTO IDLE STOP OFF
AUTO WARM-UP
OFF FEED
(a)
AUTO IDLING STOP
(b) (d)
AUTO IDLE STOP ON
FEED
AUTO IDLE STOP OFF
AUTO WARM-UP
OFF
FEED
FEED
(c)
AUTO IDLING STOP AUTO IDLE STOP ON
FEED
FEED
(c)
(e)
(e)
AUTO IDLE STOP OFF
AUTO IDLE STOP ON
OFF ON
AUTO IDLE STOP OFF
OFF ON
AUTO IDLE STOP ON
OFF ON
OFF ON
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
1. Press select switch (8) in main screen (a) for operator and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
2. Press select switch (8) again and display "AUTO WARM-UP OFF" screen (c).
3. In operation of FEED
(4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
3. In operation of FEED
(4), the "AUTO IDLE STOP OFF" screen (d) is displayed.
4. In operation of FEED (e) is displayed.
(4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
4. In operation of FEED (e) is displayed.
(4), the color of "OFF" portion reverses and the "AUTO IDLE STOP OFF" screen
5. Switch from "OFF" to "ON" in operation of FEED
(4) and set it by pressing selector switch (8).
5. Switch from "OFF" to "ON" in operation of FEED
(4) and set it by pressing selector switch (8).
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
6. When auto idling is functioning, the "AUTO IDLE STOP" is displayed on the multi-display.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
7. Turn starter key switch off once and store the auto idling stop setting as a memory.
21-43
21-43
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
2) Clock Adjustment Switches No.
2) Clock Adjustment Switches
Switches
1
2
3
No.
4
Switches
1
1
Screen Change Switch
1
Screen Change Switch
2
Buzzer Stop Switch
2
Buzzer Stop Switch
3
KPSS Work Mode Select Switch
3
KPSS Work Mode Select Switch
4
Washer Switch
4
Washer Switch
5
Wiper Switch
5
Wiper Switch
6
Travel Speed Select Switch
6
Travel Speed Select Switch
7
Auto Accel Switch
7
Auto Accel Switch
8
Select Switch
8
Select Switch
Main screen
10:25
8
7
5
6 (a)
SWITCH STATUS CLOCK/CONTRAST
Main screen
13:15
H
H
(a)
10:25
(d)
Select Year/Month/Day/Hour/Minute
(a) SWITCH STATUS CLOCK/CONTRAST
(c)
Y M D H M 06 04 01 13 15
5
6
13:15
(b)
(e)
ADJUST CLOCK ADJ CONTRAST
7
4
H
(a)
SWITCH STATUS CLOCK/CONTRAST
3
H
(b)
(c)
8
2
Enter
(d)
SWITCH STATUS CLOCK/CONTRAST
(e)
ADJUST CLOCK ADJ CONTRAST
Increase/Decrese
Y M D H M 06 04 01 13 15
Select Year/Month/Day/Hour/Minute
Enter
Increase/Decrese
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
1. Turn starter key switch on and display main screen (a) for operator, and then press select switch (8) and display "SWITCH STATUS CLOCK/CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
2. In operations of FEED (4) and FEED (5), move cursor to "CLOCK/CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK" and then press select switch (8) and the "ADJUST CLOCK" screen (e) is displayed.
4. Select any of "Y•M•D•H•M" in operation of FEED
4. Select any of "Y•M•D•H•M" in operation of FEED
of FEED
(4) and FEED
(4) and FEED
(5) and vary the values in operations
(5).
of FEED
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is completed, and then the screen returns to main screen (a).
21-44
(4) and FEED
(4) and FEED
(5) and vary the values in operations
(5).
5. After adjustment, press select switch (8) and the adjusted values are stored as memory and time setting is completed, and then the screen returns to main screen (a).
21-44
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
3) Contrast Adjustment Switches No.
3) Contrast Adjustment Switches
Switches
1
2
3
No.
4
Switches
1
Screen Change Switch
1
Screen Change Switch
2
Buzzer Stop Switch
2
Buzzer Stop Switch
3
KPSS Work Mode Select Switch
3
KPSS Work Mode Select Switch
4
Washer Switch
4
Washer Switch
5
Wiper Switch
5
Wiper Switch
6
Travel Speed Select Switch
6
Travel Speed Select Switch
7
Auto Accel Switch
7
Auto Accel Switch
8
Select Switch
8
Select Switch
Main screen
10:25
8
7
5
6
Main screen
SWITCH STATUS CLOCK/CONTRAST
10:25
H
1
8
2
3
4
7
5
6
SWITCH STATUS CLOCK/CONTRAST
H
(a)
(b)
(c) SWITCH STATUS CLOCK/CONTRAST
(a)
(d)
(c)
(a)
ADJUST CLOCK ADJ CONTRAST
(b)
10:25
SWITCH STATUS CLOCK/CONTRAST
(d)
(a)
ADJUST CLOCK ADJ CONTRAST
10:25
H
(e) ADJUST CLOCK ADJ CONTRAST
H
(f)
(e) Enter
ADJ CONTRAST 55555
Adjustable range 11111~99999 (Default 55555)
ADJUST CLOCK ADJ CONTRAST
(f)
Adjustable range 11111~99999 (Default 55555)
Increase/Decrease
Enter
ADJ CONTRAST 55555
Increase/Decrease
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH STATUS CLOCK CONTRAST" select screen (b).
1. Turn starter key switch on and display main screen (a), and press select switch (8) and display "SWITCH STATUS CLOCK CONTRAST" select screen (b).
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
2. In operations of FEED (4) and FEED (5), move cursor to "SWITCH STATUS CLOCK CONTRAST" screen (c) and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (d) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
3. In operations of FEED (4) and FEED (5), move cursor to "ADJUST CLOCK ADJ CONTRAST" and then press select switch (8) and the "ADJUST CLOCK ADJ CONTRAST" screen (e) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
4. Press select switch (8) and the "ADJ CONTRAST 55555" screen (f) is displayed.
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED The available setting range is in 9 steps from "11111" to "99999". [Example] 11111 (faint) o 99999 (clear) * The initial set value is 55555.
(5).
5. Vary the values by pressing the desired figure in operations of FEED (4) and FEED The available setting range is in 9 steps from "11111" to "99999". [Example] 11111 (faint) o 99999 (clear) * The initial set value is 55555.
(5).
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to main screen (a).
6. Press select switch (8) and the adjusted values are stored as a memory and the contrast adjustment is completed, and then the screen returns to main screen (a).
21-45
21-45
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(2) Function for service Following items are provided for adjustment of service function.
(2) Function for service Following items are provided for adjustment of service function.
Item Language
CONTENTS Language selection
Item Language
CONTENTS Language selection
Rise-up wiper
Wiper control change (When cab is changed)
Rise-up wiper
Wiper control change (When cab is changed)
Idle stop
ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
Idle stop
ON/OFF of auto idle stop (ON/OFF of adjustment for user) and time adjust
P1 option pressure sensor
ON/OFF of self diagnosis for P1 option pressure sensor
P1 option pressure sensor
ON/OFF of self diagnosis for P1 option pressure sensor
P2 option pressure sensor
ON/OFF of self diagnosis for P2 option pressure sensor
P2 option pressure sensor
ON/OFF of self diagnosis for P2 option pressure sensor
Swing alarm
ON/OFF of swing alarm (ON/OFF of adjustment for user)
Swing alarm
ON/OFF of swing alarm (ON/OFF of adjustment for user)
Left pedal for rotation of option attachment
Does left rotation pedal use? (Unload valve does not actuate because P4 pump is equipped in EU.)
Left pedal for rotation of option attachment
Does left rotation pedal use? (Unload valve does not actuate because P4 pump is equipped in EU.)
Setting of optional equipment
Optional flow rate limitation, relief pressure limitation, combination of return selector adjustment)
Setting of optional equipment
Optional flow rate limitation, relief pressure limitation, combination of return selector adjustment)
Engine speed
ON/OFF of engine rpm display
Engine speed
ON/OFF of engine rpm display
Auto acceleration
Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Auto acceleration
Adjustment the type of the engine speed of auto deceleration runs up abruptly.
Change of starter mode
Change of start mode
Change of starter mode
Change of start mode
Low temperature mode forcible release
Low temperature mode release
Low temperature mode forcible release
Low temperature mode release
Cylinders calibration
Injection adjust mode of engine
Cylinders calibration
Injection adjust mode of engine
Pressure release
For pressure release
Pressure release
For pressure release
21-46
21-46
21. MECHATRO CONTROL SYSTEM 21.2.8
MECHATRO CONTROL EQUIPMENT
21. MECHATRO CONTROL SYSTEM 21.2.8
(1) C-1 Mechatro controller
MECHATRO CONTROL EQUIPMENT
(1) C-1 Mechatro controller
1) Outside view
1) Outside view 2 1
10
6
4 2 1 8
2
1
16
26
26
34
34 27
22
CN105
18
CN102
16 12 CN103
28
2 1
10
16
CN101
9
2 1
22
27
CN104
CN101
CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21
CN105
9
21
6
2 1
22
18
CN102
4 2 1 8
16 12 CN103
2
28
10
22
16
24
8
17
12
17
7
28 10 22 13 19 20 15 16
2) List of connectors
CN106 CN107 CN108 CN109 21 7 2 16 21 9 21 7 21
8
10
31
22
16
24
8
17
12
17
7
28 10 22 13 19 20 15 16
2) List of connectors
Pin No.
Port name
CN101
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 30 31 32 33 34
GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36
22
CN104
21
31
Connector No.
1
Function
Input/putput
Boom up
Input
Boom down
Input
Arm in
Input
Arm out
Input
Bucket digging
Input
Bucket dump
Input
Gauge cluster
Transmission
Down load
Transmission
E/G ECU E/G ECU Spare Safety relay Spare Rotary light (yellow) Rotary light (green) Heavy lift
21-47
Reception
Reception
Output Output Output Output Output Input
Signal level
Connector No.
Pin No.
Port name
0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN
CN101
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 30 31 32 33 34
GA A1 +5VA +5VA A2 GA GA A3 +5VA +5VA A4 GA GA A5 +5VA +5VA A6 GA TXD1 RXD1 GP SHG1 TXD3 RXD3 DL GP CANH1 CANL1 DO 20 DO 21 DO 22 DO 23 DO 24 DI 36
Function
Input/putput
Boom up
Input
Boom down
Input
Arm in
Input
Arm out
Input
Bucket digging
Input
Bucket dump
Input
Gauge cluster
Transmission
Down load
Transmission
E/G ECU E/G ECU Spare Safety relay Spare Rotary light (yellow) Rotary light (green) Heavy lift
21-47
Reception
Reception
Output Output Output Output Output Input
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V RS232C communication RS232C communication 0V Shield GND RS232C communication RS232C communication EARTH / OPEN(5V 0V CAN communication CAN communication EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN EARTH/OPEN
8
21. MECHATRO CONTROL SYSTEM Connector No. CN102
Connector No. CN103
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA
21. MECHATRO CONTROL SYSTEM Function
Input/putput
Travel right
Input
Travel left
Input
Accelation
Input
P1 option
Input
P2 option
Input
Spare
Input
Spare
Input
Spare
Input Function
Input/putput
Swing
Input
P1 pump
Input
P2 pump
Input
Boom angle
Input
Arm angle
Input
Reserved
21-48
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
Connector No. CN102
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
Connector No. CN103
GND / OPEN
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name GA A8 +5VA +5VA A9 GA GA A10 +5VA +5VA A13 GA GA A14 +5VA +5VA A27 GA GA A28 +5VA D1 37
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Port name GA A +5VA +5VA A11 GA GA A12 +5VA +5VA A15 GA GA A16 +5VA
Function
Input/putput
Travel right
Input
Travel left
Input
Accelation
Input
P1 option
Input
P2 option
Input
Spare
Input
Spare
Input
Spare
Input Function
Input/putput
Swing
Input
P1 pump
Input
P2 pump
Input
Boom angle
Input
Arm angle
Input
Reserved
21-48
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
GND / OPEN
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V
21. MECHATRO CONTROL SYSTEM Connector No. CN104
Connector No. CN105
Pin No. 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
Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1
Pin No. 1 2
Port name +24V +24V
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 30 31
+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V
Function
Input/putput
Boom head
Input
Boom rod
Input
Extra pressure source
Input
Spare
Input
Spare
Input
Fuel level
Input
Spare
Input
Selector detection
Input
Spare
Input
Spare
Input
Cab slow up and down
Input
Function Battery relay output side Battery relay output side (sensor analog output) Battery relay output side
Input/putput
Output Swing P/B select valve Output Travel 1,2 speed select valve Output Attachment boost select valve Output Battery (-) Battery (-) OPT changeable relief 1 Output P1 unload Output Travel 1,2 speed select valve
P2 unload
Output
Travel straight
Output
Arm in
Output
P1 pump
Output
Battery (-) OPT changeable relief 1 P2 pump
Output Output
Cab slow stop valve
Output
Boom cushion
Output
Arm cushion
Output
Battery direct connection
21-49
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5 4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V
21. MECHATRO CONTROL SYSTEM Connector No. CN104
Connector No. CN105
Pin No. 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
Port name GA A17 +5VA +5VA A18 GA GA A19 +5VA +5VA A20 GA A21 GA A22 GP A23 GA GA A24 +5VA +5VA A25 GA GA A26 +5VA DI 1
Pin No. 1 2
Port name +24V +24V
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 30 31
+24V DO 7 DO 8 DO 9 DO 11 GND GND D10+ D1+ D1D2+ D2D3+ D3D4+ D4D5+ D5GND D10D6+ D6D7+ D7D8+ D8D9+ D9+24V
Function
Input/putput
Boom head
Input
Boom rod
Input
Extra pressure source
Input
Spare
Input
Spare
Input
Fuel level
Input
Spare
Input
Selector detection
Input
Spare
Input
Spare
Input
Cab slow up and down
Input
Function Battery relay output side Battery relay output side (sensor analog output) Battery relay output side
Input/putput
Output Swing P/B select valve Output Travel 1,2 speed select valve Output Attachment boost select valve Output Battery (-) Battery (-) OPT changeable relief 1 Output P1 unload Output Travel 1,2 speed select valve
P2 unload
Output
Travel straight
Output
Arm in
Output
P1 pump
Output
Battery (-) OPT changeable relief 1 P2 pump
Output Output
Cab slow stop valve
Output
Boom cushion
Output
Arm cushion
Output
Battery direct connection
21-49
Signal level 0V 0.5~4.5V Power output 5V Power output 5V 0.5 4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V Power output 5V 0.5~4.5V 0V 0V 0.5~4.5V Power output 5V GND / OPEN Signal level 20~32V 20~32V 20~32V 24V/OPEN 24V/OPEN 24V/OPEN 24V/OPEN 0V 0V +0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA -0~800mA +0~800mA 20~32V
21. MECHATRO CONTROL SYSTEM Connector No. CN106
Connector No. CN107
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41
21. MECHATRO CONTROL SYSTEM Function
Input/putput
Battery relay secondary side
0
Accel motor A phase (spare) Accel motor A phase (spare) Accel motor B phase (spare) Accel motor B phase (spare)
Oil level (spare)
Output Output Output Output 0
OPT changeable relief 2
Output
Spare
Output
Spare
Output
Spare
Output
Battery (-) Spare
Output
E/G speed sensor
Input
Proportional vlave expand unit
Function Key switch (GLOW) Water separetor E/G oil pressure Air filter Stroke end check Spare E/G coolant level Spare Spare ECU main relay Spare Hand control nibbler Quick coupler Extra pressure Spare Spare Reserved
21-50
Input/putput
Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
Signal level 20~32V Shield GND +24V 1.5A +24V 1.5A +24V 1.5A +24V 1.5A
Connector No. CN106
+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN
Connector No. CN107
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Port name +24V SHGF F1+ F1F2+ F2OIL OILG D11+ D11D12+ D12D13+ D13D14+ D14GND D12+ D12E1+ E1SHG3 CANH2 CANL2
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Port name DI 3 DI 8 DI 9 DI 10 DI 11 DI 12 DI 13 DI 14 DI 15 DI 20 DI 28 DI 32 DI 38 DI 39 DI 40 DI 41
Function
Input/putput
Battery relay secondary side
0
Accel motor A phase (spare) Accel motor A phase (spare) Accel motor B phase (spare) Accel motor B phase (spare)
Oil level (spare)
Output Output Output Output 0
OPT changeable relief 2
Output
Spare
Output
Spare
Output
Spare
Output
Battery (-) Spare
Output
E/G speed sensor
Input
Proportional vlave expand unit
Function Key switch (GLOW) Water separetor E/G oil pressure Air filter Stroke end check Spare E/G coolant level Spare Spare ECU main relay Spare Hand control nibbler Quick coupler Extra pressure Spare Spare Reserved
21-50
Input/putput
Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
Signal level 20~32V Shield GND +24V 1.5A +24V 1.5A +24V 1.5A +24V 1.5A
+0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA +0~800mA -0~800mA 0V +0~800mA -0~800mA XX~XXVp-p 0V Shiled GND CAN communication CAN communication Signal level +24V/OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN EARTH / OPEN
21. MECHATRO CONTROL SYSTEM Connector No. CN108
Pin No. 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
Connector No. CN109
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24 DI DI DI DI DI
25 26 27 29 30
GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10
Function Key switch (ON) Spare Swing P/B release E/G start High reach hoisting at fixed position
Wiper rise up Wiper reverse ATT boost Nibbler open check SW Elevator cab up check Spare Lever lock Hand control rotation / clamp open or close Front window open or close Hand control breaker Conflux/single select Overload select High reach (hoist at travel) Reserved Charge Spare Spare Reserved Accel signal 1
Input/putput
Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
Input Input Input Reserved
Accel signal 2
Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Bucket move limitation Reserved Rotary light (RH) Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Extra pressure release Reserved IT controller
Input/putput
Output Output Output Output Output Output Output Output Output Output Output Output Output Output
Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN
21-51
Connector No. CN108
GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
0~5V 0V 0~5V 0V Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN 0V
Tranmission RS232C communication
Pin No. 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
~12V / 12V~ +24V / OPEN +24V / OPEN
Reception RS232C communication RS232C communication RS232C communication Shiled GND Cab up and down switching valve 24V/OPEN SV Spare Spare
21. MECHATRO CONTROL SYSTEM
Connector No. CN109
Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Port name DI 2 DI 4 DI 5 DI 6 DI 7 DI 16 DI 17 DI 18 DI 19 DI 21 DI 22 DI 23 DI 24 DI DI DI DI DI
25 26 27 29 30
GP DI 33 DI 34 DI 35 H1+ H2H2+ H2Port name DO 1 DO 2 DO 3 DO 4 DO 5 DO 6 DO 12 DO 13 DO 14 DO 15 DO 16 DO 17 DO 18 DO 19 GP TXD2 RXD2 RTS CTS SHG2 DO 10
Function Key switch (ON) Spare Swing P/B release E/G start High reach hoisting at fixed position
Wiper rise up Wiper reverse ATT boost Nibbler open check SW Elevator cab up check Spare Lever lock Hand control rotation / clamp open or close Front window open or close Hand control breaker Conflux/single select Overload select High reach (hoist at travel) Reserved Charge Spare Spare Reserved Accel signal 1
Input/putput
Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
Input Input Input Reserved
~12V / 12V~ +24V / OPEN +24V / OPEN
Input/putput
Signal level GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN
Accel signal 2
Function Wiper arc prevention Wiper normal moving Wiper reserve moving Washer motor Bucket move limitation Reserved Rotary light (RH) Swing flasher (RH) Swing flasher (LH) Travel alarm Auto idle stop relay Engine stop Lever lock Extra pressure release Reserved IT controller
Signal level +24V / OPEN +24V / OPEN GND / OPEN +24V / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN GND / OPEN +24V / OPEN +24V / OPEN +24V / OPEN
Output Output Output Output Output Output Output Output Output Output Output Output Output Output
0~5V 0V 0~5V 0V
0V
Tranmission RS232C communication
Reception RS232C communication RS232C communication RS232C communication Shiled GND Cab up and down switching valve 24V/OPEN SV Spare Spare
21-51
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
(2) Gauge cluster (symbol C-2)
(2) Gauge cluster (symbol C-2)
1) General view
1) General view
MULTI DISPLAY LCD
MULTI DISPLAY LCD
COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE
COOLANT TEMPERATURE GAUGE FUEL LEVEL GAUGE
MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2
SCREEN CHANGE SWITCH ETC. BUZZER STOP SWITCH
SCREEN CHANGE SWITCH ETC.
WORK MODE SWIHCH
BUZZER STOP SWITCH
2) Connector CN-600 (Harness side) No.
Item name
1
Gauge cluster o Mechatro controller (RS232C communication)
2
Mechatro controller o Gauge cluster (RS232C communication)
3 4
MATED SIDE AMP 040 HOUSING : 174044-2 TERMINAL : 173681-2
WORK MODE SWIHCH
2) Connector CN-600 (Harness side) Wire color
No.
White
5
Item name GND source (+24V Battery direct connection)
Wire color Yellow / Black
No.
Item name
1
Gauge cluster o Mechatro controller (RS232C communication)
Wire color
No.
Item name
Wire color
White
5
GND source (+24V Battery direct connection)
Red
6
GND
Black
Yellow / Black
Red
6
GND
Black
2
Mechatro controller o Gauge cluster (RS232C communication)
Reserved
—
7
Source (+24V starter switch ON)
White
3
Reserved
—
7
Source (+24V starter switch ON)
White
Reserved
—
8
GND (RS232C communication)
Black
4
Reserved
—
8
GND (RS232C communication)
Black
3) Function
3) Function
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer.
a. It processes signals by communication between the gauge cluster and the mechatro controller, displays them in lamps, displays them in LCDs and actuates the buzzer.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro controller through the communication port.
b. It outputs coolant temperature signals, fuel level signals and panel switch signals to the mechatro controller through the communication port.
4) Summary of display and drive item No.
4) Summary of display and drive item
Item
Remarks
No.
Item
Remarks
1
Monitar display
LCD dot 120u168
1
Monitar display
LCD dot 120u168
2
Gauge display (Coolant temp., Fuel level)
Stepping motor
2
Gauge display (Coolant temp., Fuel level)
Stepping motor
3
—
4
Buzzer
3
—
4
Buzzer
5
Screen change switch
5
Screen change switch
6
Buzzer stop switch
6
Buzzer stop switch
7
Work mode select switch
7
Work mode select switch
8
Back light
8
Back light
Piezo-electricity type
LED
21-52
Piezo-electricity type
LED
21-52
21. MECHATRO CONTROL SYSTEM (3) Relay & fuse box (symbol E-1)
21. MECHATRO CONTROL SYSTEM (3) Relay & fuse box (symbol E-1)
1) General view
1) General view
(Overhead view of box)
LABEL
(Overhead view of box)
INSIDE
LABEL
INSIDE
Note) These circles indicate the parts which are used in standard specification 14
1
1
14
1
12
1
10
1
3
20
CN2-1
13
26
1
13
9
1
12
CN3-2
16
8
24
12 CN8
26
13
17
CN3-1
1
20
CN2-2
2
1 CN9
2
17
11
22
1
7
CN5
9
15
20
6
12
1 CN2-3 3
1
2
6
3
1
3
2
6
2
6
1
3
1
3
2
4
2 1
13
26
1
13
6
14
1
12
20
CN4-1
17
11
22
1
7
CN10
CN8
26
13
9
1
12
CN3-2
16
8
24
12 1
2
CN2-2
17
CN3-1
CN13 6
20
CN2-1
CN15
3 CN12
CN1 2
6
1
2
1
1
10
CN5
15
1
3
2
1 CN9
2
9
20
6
12
1 CN2-3 3
1
6
2
6
1
3
1
3
2
6
2
6
1
3
1
3
2
2
CN15
3 CN12
CN1 2
3
2
CN14
CN4-2
1 CN17
CN16
2
CN14
CN4-2
14
1
3
CN17
CN16 CN4-1
1
Note) These circles indicate the parts which are used in standard specification
CN13 6
4
2 1
6 2
CN10
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF CONNECTORS (Seen from backside)
LOCATION OF RELAY & FUSE
LOCATION OF RELAY & FUSE
LABEL OF RELAY & FUSE BOX
LABEL OF RELAY & FUSE BOX No. CODE IN CIRCUIT
21-53
PARTS NAME
No. CODE IN CIRCUIT
21-53
PARTS NAME
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
2) Circuit diagram
2) Circuit diagram
21-54
21-54
21. MECHATRO CONTROL SYSTEM
21-55
21. MECHATRO CONTROL SYSTEM
21-55
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
21-56
21-56
21. MECHATRO CONTROL SYSTEM (4) High pressure sensor : YN52S00048P1 ECONOSEAL SERIES MARK 3POLES CAP MATING HOUSING174357-2
21. MECHATRO CONTROL SYSTEM (4) High pressure sensor : YN52S00048P1
SPECIFICATION :
(+)>
PRESSURE RANGE : 0
50 MPa (0
7110 psi)
ECONOSEAL SERIES MARK 3POLES CAP MATING HOUSING174357-2
SPECIFICATION :
(+)>
PRESSURE RANGE : 0
POWER SOURCE VOLTAGE : 5.0+0.5V DC OUTPUT : 1/10Vs-9/10Vs
COMMON
(Vs=5V DC 0.5
OUTPUT (+)
INSURANCE RESISTANCE : 100M
POWER SOURCE (+) HOUSING TERMINAL
TERMINALS AT 50V DC MEGGER)
TERMINALS AT 50V DC MEGGER)
(Ex. Construction of internal controller)
PIPE
COVER
CASING
FLEXIBLE BOARD
PF 3/8 Tightening torgue 73.5N.m (54.2lbf.ft)
STRUCTURE
(5) Low pressure sensor : LC52S00019P1
ELECTRIC CONNECTING DIAGRAM
DIE
(Ex. Construction of internal controller)
DIAPHRAGM PIPE
O-RING P14 JIS B2401 CLASS1B
THREAD
THREAD
STRUCTURE
(5) Low pressure sensor : LC52S00019P1
AMP MQS CONNECTOR 3 POLE (B TYPE) OPPOSITE CONNECTOR (FEMALE) HOUSING 2-967642-1 TERMINAL (GOLD PLATED) 965906-5
A
CONDENSER
CIRCUIT
DIAPHRAGM
O-RING P14 JIS B2401 CLASS1B PF 3/8 Tightening torgue 73.5N.m (54.2lbf.ft)
(BETWEEN CASING AND ALL IN/OUT
TERMINAL
CASING
CIRCUIT
AMP MQS CONNECTOR 3 POLE (B TYPE) OPPOSITE CONNECTOR (FEMALE) HOUSING 2-967642-1 TERMINAL (GOLD PLATED) 965906-5
A
CONNECTOR TERMINAL POSITION TERMINAL No. 1 COM 2 OUT PUT (+) 3 POWER (+)
CONNECTOR TERMINAL POSITION TERMINAL No. 1 COM 2 OUT PUT (+) 3 POWER (+)
VIEW A 19
OR MORE
HOUSING
ELECTRIC CONNECTING DIAGRAM
DIE
4.5V DC)
INSURANCE RESISTANCE : 100M
POWER SOURCE (+)
PLASTIC POTTING
COVER
FLEXIBLE BOARD
(Vs=5V DC 0.5
(BETWEEN CASING AND ALL IN/OUT
CONDENSER
PLASTIC POTTING
OUTPUT : 1/10Vs-9/10Vs
OUTPUT (+)
OR MORE
7110 psi)
POWER SOURCE VOLTAGE : 5.0+0.5V DC COMMON
4.5V DC)
50 MPa (0
VIEW A
21.9 HEX
19
21.9 HEX
O-RING P11
O-RING P11
PF1/4 Tightening torgue 34.3N.m (25.3lbf.ft)
PF1/4 Tightening torgue 34.3N.m (25.3lbf.ft)
SPECIFICATION :
DETAIL OF SENSOR CONNECTOR
PRESSURE RANGE : 0
SPECIFICATION :
DETAIL OF SENSOR CONNECTOR
3.0 MPa (0
448 psi)
PRESSURE RANGE : 0
RATED VOLTAGE : 5.0+0.5V DC INSURANCE RESISTANCE : 100M
21-57
3.0 MPa (0
448 psi)
RATED VOLTAGE : 5.0+0.5V DC OR MORE
INSURANCE RESISTANCE : 100M
OR MORE
(BETWEEN BODY AND EACH TERMINAL AT
(BETWEEN BODY AND EACH TERMINAL AT
50V DC MEGGER)
50V DC MEGGER)
21-57
21. MECHATRO CONTROL SYSTEM
21. MECHATRO CONTROL SYSTEM
[MEMO]
[MEMO]
21-58
21-58
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
TABLE OF CONTENTS
TABLE OF CONTENTS
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3
24.1 HYDRAULIC COMPONENTS .........................................................................................24-3
24.1.1
HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.1
HYDRAULIC PUMP • REGULATOR ......................................................................24-3
24.1.2
CONTROL VALVE..................................................................................................24-21
24.1.2
CONTROL VALVE..................................................................................................24-21
24.1.3
PILOT VALVE (ATT)...............................................................................................24-59
24.1.3
PILOT VALVE (ATT)...............................................................................................24-59
24.1.4
PILOT VALVE (TRAVEL) .......................................................................................24-63
24.1.4
PILOT VALVE (TRAVEL) .......................................................................................24-63
24.1.5
SWING MOTOR UNIT ............................................................................................24-65
24.1.5
SWING MOTOR UNIT ............................................................................................24-65
24.1.6
TRAVEL MOTOR ...................................................................................................24-75
24.1.6
TRAVEL MOTOR ...................................................................................................24-75
24.1.7
SWIVEL JOINT.......................................................................................................24-89
24.1.7
SWIVEL JOINT.......................................................................................................24-89
24.1.8
CYLINDER..............................................................................................................24-91
24.1.8
CYLINDER..............................................................................................................24-91
24.2 ELECTRIC EQUIPMENT.................................................................................................24-97
24
24.2 ELECTRIC EQUIPMENT.................................................................................................24-97
24.2.1
ELECTRIC EQUIPMENT LIST ...............................................................................24-97
24.2.1
ELECTRIC EQUIPMENT LIST ...............................................................................24-97
24.2.2
SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-100
24.2.2
SPECIFICATION OF ELECTRIC EQIUPMENTS...................................................24-100
Book Code No. S5YN2425E01 24-1
Book Code No. S5YN2425E01 24-1
24
24. COMPONENTS SYSTEM Issue
Date of Issue
First edition
July, 2007
24. COMPONENTS SYSTEM Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~
24-2
Remarks S5YN2425E01 (NHK Russia) HS Engine
K
Issue
Date of Issue
First edition
July, 2007
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~
24-2
Remarks S5YN2425E01 (NHK Russia) HS Engine
K
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1
HYDRAULIC COMPONENTS
24.1
HYDRAULIC COMPONENTS
24.1.1
HYDRAULIC PUMP • REGULATOR
24.1.1
HYDRAULIC PUMP • REGULATOR
24.1.1.1
SUMMARY
24.1.1.1
(1) Outside view and Hydraulic port
SUMMARY
(1) Outside view and Hydraulic port 5
5
EYE BOLT (M10)
a3
EYE BOLT (M10)
a3
PSV2
Dr
2X4-M12 Depth 22
A3
A1
B3
MIN. FLOW 2 RATE ADJUSTING SCREW
VIEW 4
PSV2
MIN. FLOW 2 RATE ADJUSTING SCREW
a3 PH1 PH2 a1
3
a2
PSV2 MIN. FLOW RATE ADJUSTING SCREW
a3 PH1 PH2
PH2 PH1
a4
a1
a1 a2 B3
4
PSV2
2
PH2 PH1
a4
VIEW
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2 PSV1
4
MIN. FLOW RATE ADJUSTING SCREW
A2
a4
PSV1
PSV2 2
A1
B3
MAX. FLOW RATE ADJUSTING SCREW
PH1 PH2 PSV1
4
2X4-M12 Depth 22
A3
A2
a4
PSV1
PSV2
Dr
3
a2
B3
a1 a2 B3
B3 B1
B1 Dr
B1
A1
Dr
A3 Dr3 a5
A2
A1
5 1
Dr3
B1
A3 Dr3 a5
A2
5
A2
1
Dr3
Hydraulic ports
Hydraulic ports Parts
No. 1
Main pump assy
Q'TY
Code
1
A1,2
Ports name
A2
Size
Parts
No.
Q'TY
Code
Ports name
Size
Delivery port
SAE 6000psi 1"
1
Main pump assy
1
A1,2
Delivery port
SAE 6000psi 1"
SAE 2500psi 2 1/2"
2
Regulator assy
2
B1
Suction port
SAE 2500psi 2 1/2"
PF3/4-20
3
Gear pump assy (for pilot)
1
Dr
Drain port
2
Regulator assy
2
B1
Suction port
3
Gear pump assy (for pilot)
1
Dr
Drain port
4
Solenoid proportional reducing valve
2
PSV1,2 Servo assist port
PF1/4-13
4
Solenoid proportional reducing valve
2
PSV1,2 Servo assist port
PF1/4-13
5
PTO unit (OPT.)
1
PH1,2 Pressure sensor port
PF3/8-17
5
PTO unit (OPT.)
1
PH1,2 Pressure sensor port
PF3/8-17
a1~a4 Gauge port
PF1/4-15
a1~a4 Gauge port
PF1/4-15
a5
Gauge port
PF1/4-14
a5
Gauge port
PF1/4-14
A3
Delivery port of gear pump
PF1/2-19
A3
Delivery port of gear pump
PF1/2-19
B3
Suction port of gear pump
PF3/4-20.5
B3
Suction port of gear pump
PF3/4-20.5
Dr3
Drain port of gear pump
PF3/8-15
Dr3
Drain port of gear pump
PF3/8-15
Fig. 24-1 Hydraulic pump • regulator
Fig. 24-1 Hydraulic pump • regulator
24-3
24-3
PF3/4-20
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(2) Hydraulic circuit diagram
(2) Hydraulic circuit diagram
(KDRDE5K)
PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (FRONT) (REAR) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
(KDRDE5K) Solenoid proportional reducing valve (PSV-2)
Solenoid proportional reducing valve (PSV-1)
Regulator
Regulator
Regulator
a4
Dr Engine
Main pump
Solenoid proportional reducing valve (PSV-2)
Solenoid proportional reducing valve (PSV-1)
Regulator
a3
a5 B1
B3
Dr3
PSV1 a1 A1 PH1 PH2 A2 a2 PSV2 (FRONT) (REAR) (KR3G-YTOK-HV) (KR3G-YTOK-HV) (KDRDE5K)
a4
Dr
a3 Engine
Gear pump for pilot
Main pump
A3
a5 B1
B3
PTO gear case (OPT.)
Fig. 24-2 Hydraulic circuit diagram of pump
(3) Specifications
(3) Specifications
Item Parts No.
Main pump
Gear pump
Pump assy
YN10V00036F1
-
Single Pump
YN10V00043F1
YN10V00014F3
K3V112DTP1K9R-YT0K-HV
ZX10LGRZ2-07G
cm3
110 X 2
10
min-1(Clockwise seen from shaft end)
2000
Pump model Max.displacement capacity
Pressure
Rated Rated ATT boost pressure
Max. flow Max. input horse power Max. input torque
Regulator
Weight
A3
PTO gear case (OPT.)
Fig. 24-2 Hydraulic circuit diagram of pump
Revolution
Dr3
Gear pump for pilot
Parts No.
37.8 (5480)
Main pump
Gear pump
Pump assy
YN10V00036F1
-
Single Pump
YN10V00043F1
YN10V00014F3
K3V112DTP1K9R-YT0K-HV
ZX10LGRZ2-07G
cm3
110 X 2
10
min-1(Clockwise seen from shaft end)
2000
Pump model Max.displacement capacity Revolution
34.3 (4980)
MPa (psi)
Item
5.0 (725)
Pressure
Rated Rated ATT boost pressure
L/min (gal/min)
220 (58) X 2 at 7.8MPa (1130 psi)
21 (5.5)
Max. flow
kW (PS) N.m (lbf.ft)
114 (155)
3.4 (4.6)
Max. input horse power
544 (401)
14.7 (10.8)
Max. input torque
34.3 (4980)
MPa (psi)
37.8 (5480)
L/min (gal/min)
220 (58) X 2 at 7.8MPa (1130 psi)
21 (5.5)
kW (PS) N.m (lbf.ft)
114 (155)
3.4 (4.6)
544 (401)
14.7 (10.8)
Part No.
YN10V01009F1
Part No.
YN10V01009F1
Model
KR3G-YTOK-HV
Model
KR3G-YTOK-HV
Control function
Electric flow control, positive flow control,
Regulator
total power control at emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/30C50)
kg (lb)
141 (310)
24-4
Weight
5.0 (725)
Control function
Electric flow control, positive flow control, total power control at emergency mode and power shift control
Others
With solenoid proportional reducing valve (KDRDE5K-31/30C50)
kg (lb)
141 (310)
24-4
24. COMPONENTS SYSTEM 24.1.1.2
HYDRAULIC PUMP
24.1.1.2.1
24.1.1.2
CONSTRUCTION
953 806
CONSTRUCTION
(1) Main pump
789 532 Apply adhesive (Three Bond No.1305N) 724 A 214 548 531 702 792 534 535 732
901 808 954
717
151
152
211
886 717
261
261
406
406
824
824
774
774
111
111 B
953 806
789 532 Apply adhesive (Three Bond No.1305N) 724 A 214 548 531 702 792 534 535 732
B
901 808 954
B
127
127
123
123 04
710 212
717
151
152
211
B
04
710 212
401 251 490
271
153 156 157
Tightening torque Item number
Thread size
401 406 407 414 466 467 468 490 531,532 806 808
M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20
No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313
HYDRAULIC PUMP
24.1.1.2.1
(1) Main pump 886 717
24. COMPONENTS SYSTEM
468 728
313 124 710 116 467 466 312 885 314 141 727 725
Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 8.8 (6.5) 240 (177) 130 (96) 240 (177)
546
414
725 727
407
271
401 251 490
113 05
326
325 VIEW A
SECTION B-B
SECTION B-B (OPT.)
No. Q'ty No. Parts Q'ty Parts Parts 724 O-ring ; 1B P8 1 314 Valve plate (L) 1 Drive shaft (F) 725 O-ring ; 1B P11 1 325 Sensor block 1 Drive shaft (R) 727 O-ring ; 1B P14 1 326 Cover 1 Gear #1 728 O-ring ; 1B P24 8 401 Socket bolt ; M20X210 2 Roller bearing 732 O-ring ; 1B P18 4 406 Socket bolt ; M8X20 2 Needle bearing 774 Oil seal 3 407 Socket bolt ; M6X55 3 Bearing spacer 789 Back up ring ; P18 4 414 Socket bolt ; M10X20 2 Cylinder block 792 Back up ring ; G35 2 466 VP plug ; PF1/4 18 Piston 806 Nut ; M16 2 467 VP plug ; PF3/8 18 Shoe 808 Nut ; M20 4 468 VP plug ; PF3/4 2 Retainer plate 824 Snap ring 32 490 Plug ; NPTF1/16 2 Spherical bushing 885 Valve plate pin 2 531 Tilting pin ; M24X2 18 Cylinder spring 886 Spring pin 2 532 Servo piston ; M24X2 2 Shoe plate 901 Eye bolt ; M10 2 534 Stopper(L) 2 Swash plate 953 Socket screw ; M16X35 2 535 Stopper(S) 2 Tilting bushing 954 Set screw ; M20 2 546 Spacer 2 Swash plate support 04 Gear pump 2 548 Feed back pin 1 Seal cover (F) 05 PTO unit 2 702 O-ring ; 1B G35 2 Pump casing 2 710 O-ring ; 1B G95 1 Valve block 4 717 O-ring ; 1B G145 1 Valve plate (R) The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Q'ty 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1
271
153 156 157
Tightening torque Item number
Thread size
401 406 407 414 466 467 468 490 531,532 806 808
M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20
No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313
468 728
313 124 710 116 467 466 312 885 314 141 727 725
Tightening torque N.m (lbf.ft) 430 29 12 57 36 74 170 8.8 240 130 240
(317) (21) (8.9) (42) (27) (55) (125) (6.5) (177) (96) (177)
546
414
725 727
407
271
113 05
326
325 VIEW A
SECTION B-B
SECTION B-B (OPT.)
No. Q'ty No. Parts Q'ty Parts Parts 724 O-ring ; 1B P8 1 314 Valve plate (L) 1 Drive shaft (F) 725 O-ring ; 1B P11 1 325 Sensor block 1 Drive shaft (R) 727 O-ring ; 1B P14 1 326 Cover 1 Gear #1 728 O-ring ; 1B P24 8 401 Socket bolt ; M20X210 2 Roller bearing 732 O-ring ; 1B P18 4 406 Socket bolt ; M8X20 2 Needle bearing 774 Oil seal 3 407 Socket bolt ; M6X55 3 Bearing spacer 789 Back up ring ; P18 4 414 Socket bolt ; M10X20 2 Cylinder block 792 Back up ring ; G35 2 466 VP plug ; PF1/4 18 Piston 806 Nut ; M16 2 467 VP plug ; PF3/8 18 Shoe 808 Nut ; M20 4 468 VP plug ; PF3/4 2 Retainer plate 824 Snap ring 32 490 Plug ; NPTF1/16 2 Spherical bushing 885 Valve plate pin 2 531 Tilting pin ; M24X2 18 Cylinder spring 886 Spring pin 2 532 Servo piston ; M24X2 2 Shoe plate 901 Eye bolt ; M10 2 534 Stopper(L) 2 Swash plate 953 Socket screw ; M16X35 2 535 Stopper(S) 2 Tilting bushing 954 Set screw ; M20 2 546 Spacer 2 Swash plate support 04 Gear pump 2 548 Feed back pin 1 Seal cover (F) 05 PTO unit 2 702 O-ring ; 1B G35 2 Pump casing 2 710 O-ring ; 1B G95 1 Valve block 4 717 O-ring ; 1B G145 1 Valve plate (R) The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
Fig. 24-3
Fig. 24-3
24-5
24-5
Q'ty 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(2) Gear pump (For pilot)
(2) Gear pump (For pilot)
700
354
351
Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)
700
433
354
351
434
Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)
433
434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft)
Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft)
311
311
312
312 732 307
710
435
361
No.
353
Parts
310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)
Q’ty
732 307
850 308 309
434
No.
Parts
466 725
355 710
Q’ty
435
361
No.
353
Parts
850
310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)
Q’ty
308 309
434
No.
Parts
466 725
355
Q’ty
307 Poppet
1
361 Front case
1
307 Poppet
1
361 Front case
1
308 Seat
1
433 Flange socket; M8u40
2
308 Seat
1
433 Flange socket; M8u40
2
309 Ring
1
434 Flange socket; M8u55
2
309 Ring
1
434 Flange socket; M8u55
2
310 Spring
1
435 Flange socket; M8u20
4
310 Spring
1
435 Flange socket; M8u20
4
311 Adjust screw
1
466 VP plug ; PF1/4
1
311 Adjust screw
1
466 VP plug ; PF1/4
1
312 Lock nut ; M14u1.5
1
700 Ring
1
312 Lock nut ; M14u1.5
1
700 Ring
1
351 Gear case
1
710 O-ring ; 1B G95
1
351 Gear case
1
710 O-ring ; 1B G95
1
353 Drive gear
1
725 O-ring ; 1B P11
1
353 Drive gear
1
725 O-ring ; 1B P11
1
354 Driven gear
1
732 O-ring ; 1B P16
1
354 Driven gear
1
732 O-ring ; 1B P16
1
355 Filter
1
850 Locking ring
1
355 Filter
1
850 Locking ring
1
24-6
24-6
24. COMPONENTS SYSTEM (3) PTO gear case (OPT.)
125 711 118
24. COMPONENTS SYSTEM (3) PTO gear case (OPT.)
825
125 711 118
468 728
710
117
825
468 728
710
117
126 326 115 128 826
126 326 115 128 826
262
414
262
414
435
886 885
No.
Parts
435
886 885
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
115 Idle shaft
1
435 Flange socket ; M10u20
4
115 Idle shaft
1
435 Flange socket ; M10u20
4
117 2nd gear
1
468 VP plug ; PF3/4
1
117 2nd gear
1
468 VP plug ; PF3/4
1
118 3rd gear
1
710 O-ring ; 1B G80
1
118 3rd gear
1
710 O-ring ; 1B G80
1
125 Ball bearing
2
711 O-ring ; 1B G85
1
125 Ball bearing
2
711 O-ring ; 1B G85
1
126 Roller bearing
1
728 O-ring ; 1B P24
1
126 Roller bearing
1
728 O-ring ; 1B P24
1
128 Bearing spacer
2
825 Snap ring
1
128 Bearing spacer
2
825 Snap ring
1
262 Cover
2
826 Snap ring
1
262 Cover
2
826 Snap ring
1
326 Gear case
1
885 Sprig pin
1
326 Gear case
1
885 Sprig pin
1
414 Capscrew ; M10u20
4
886 Pin
2
414 Capscrew ; M10u20
4
886 Pin
2
24-7
24-7
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.1.2.2
24.1.1.2.2
OPERATION
The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft. The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery ; and the PTO group (OPT) that transmits the drive power to the auxiliary pump.
REGULATOR
116 111
(1) Rotary group The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156), and cylinder spring (157). The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure. Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance. The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed against valve plate (313) by the action of cylinder spring (157).
PTO GEAR CASE (OPT) AUXILIARY PUMP (OPT)
Fig. 24-4 Construction of hydraulic pump
124
OPERATION
The pump assy is equipped with two pumps arranged on the same axis that are connected with gear (116) and distribute the rotating power to the gear trains on a different axis. Thus the engine rotation is transmitted to front shaft (111) that drives the two pumps and, at the same time, drives the auxiliary pump (OPT) arranged on another shaft. The pump assy consists largely of the rotary group, the main part of the pump that makes rotary on; the swash plate group that changes the delivery rate; the valve block group that selects between oil suction and delivery ; and the PTO group (OPT) that transmits the drive power to the auxiliary pump.
REGULATOR
116 111
(1) Rotary group The rotary group consists of shaft(111), cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156), and cylinder spring (157). The shaft is supported by bearings (123) and (124) at its both ends. The shoe, which is caulked to the piston, forms a spherical joint and relieves it of thrust force that is generated by load pressure. Further, the piston is provided with a pocket so it moves lightly on shoe plate (211), taking hydraulic balance. The sub group of the piston-shoe is pressed against the shoe plate by the cylinder spring, via the retainer plate and the spherical bushing, so that it moves smoothly over the shoe plate. The cylinder block (141) is also pressed against valve plate (313) by the action of cylinder spring (157).
PTO GEAR CASE (OPT) AUXILIARY PUMP (OPT)
Fig. 24-4 Construction of hydraulic pump
313
124
312
312 111
124 314 141
211
151 . 153 152
156
313
111
116
124 314 141
157
211
151 . 153 152
156
116
157
Fig. 24-5 Rotary group
Fig. 24-5 Rotary group
24-8
24-8
24. COMPONENTS SYSTEM (1) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).
532 531
214 211 212
251
Fig. 24-6 Swash plate group
(2) Valve block group The valve block group consists of valve block (312), valve plates (313 or 314), and valve plate pin (885). The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.
313 312
116 141
111
314 885
24. COMPONENTS SYSTEM (1) Swash plate group The swash plate group consists of swash plate (212), shoe plate (211), swash plate support (251), tilting bushing (214), tilting pin (531), and servo piston (532). The swash plate is the cylindrical part that is formed on the opposite side of the shoe sliding surface and is supported by the swash plate support. The hydraulic force controlled by the regulator flows into the hydraulic chamber that is provided on both sides of the servo piston. This moves the servo piston to the right and left. The result is that the swash plate swings on the swash plate support via the spherical part of the tilting pin and changes the tilting angle (a).
532 531 212
251
Fig. 24-6 Swash plate group
(2) Valve block group The valve block group consists of valve block (312), valve plates (313 or 314), and valve plate pin (885). The valve plates having two crescent-shaped ports are installed to valve block (312) to feed oil and recycle it from cylinder block (141). The oil switched over by the valve plate is connected with the external pipe by way of the valve block.
313 312
116 141
Fig. 24-7 Valve block group (3) PTO group (OPT) The PTO group is composed of 1st gear (116), 2nd gear (117) and 3rd gear (118). The 2nd and the 3rd gear are supported by bearings (125) and (126) respectively and installed to the valve block. Now, if the shaft is driven by the engine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder block. If we keep an eye on a single piston, it makes a motion away from the valve plate (oil suction process) in the first 180째and a motion toward the valve plate (oil delivery process) in the remaining 180째. If the swash plate is not inclined (zero tilting angle), the piston does not stroke i.e. delivers no oil. The shaft rotation is taken up by the 1st gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear.
117 126
118 125
125
Fig. 24-8 PTO group
24-9
214 211
111
314 885
Fig. 24-7 Valve block group (3) PTO group (OPT) The PTO group is composed of 1st gear (116), 2nd gear (117) and 3rd gear (118). The 2nd and the 3rd gear are supported by bearings (125) and (126) respectively and installed to the valve block. Now, if the shaft is driven by the engine, the cylinder block rotates together by the spline linkage. If the swash plate is inclined, the pistons arranged in the cylinder block make reciprocating motion with respect to the cylinder while rotating with the cylinder block. If we keep an eye on a single piston, it makes a motion away from the valve plate (oil suction process) in the first 180째and a motion toward the valve plate (oil delivery process) in the remaining 180째. If the swash plate is not inclined (zero tilting angle), the piston does not stroke i.e. delivers no oil. The shaft rotation is taken up by the 1st gear (116) and transmitted to the 2nd gear (117) and the 3rd gear (118), in that order, to drive the gear pump that is linked to the 3rd gear.
117 126
118 125
125
Fig. 24-8 PTO group
24-9
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.1.3
24.1.1.3
REGULATOR
24.1.1.3.1
CONSTRUCTION PSV
413
24.1.1.3.1 PSV
B
418
PSV
PSV
B
439
D 439
438
725 656
a3
643
438
924 708
VIEW C
646 645
644
728
438
722
836
651
652
924
D 543 755 545 541 724
SECTION B-B 654
a3
643
801
466, 755
641 655
730
656
D B
438
725
730
418 079
757
D
543 755 545 541 724
CONSTRUCTION
413
079
757
722
REGULATOR
801
466, 755
B
708
VIEW C
646 645
644
SECTION B-B
601
641 655
654
836
651
652
601
624
624
734 612
897
876
874
858
755 A
412
814
614
631
734
629
653
615
630 628
612
897
876
874
858
755 A
412
627
C
613 875 A
629
653
615
814
614
631
630 628 627
C
613 898
802
875 A
732 611
898
802
732 611
753 733
753 733
622
621
625
623
626 887
763
756
622
621
625
623
SECTION A-A
543
545
541
466 755
496
755
SECTION E-E
At normal
E
E
SECTION D-D
763
756
At start and emergency mode
Tightening torque 642
626 887
SECTION A-A
At start and emergency mode
662
728
Item No.
Thread size
412,413 438,439 418 466 496 630 801 802
M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10
Tightening torque N.m 29 12 6.9 36 8.8 160 16 19
Tightening torque 662 543
545
541
466 755
496
755
SECTION E-E
642 At normal
E
E
SECTION D-D
Fig. 24-9
Fig. 24-9
24-10
24-10
Item No.
Thread size
412,413 438,439 418 466 496 630 801 802
M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10
Tightening torque N.m 29 12 6.9 36 8.8 160 16 19
24. COMPONENTS SYSTEM
No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627
Parts Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjusting plug Compensating piston Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)
Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730
Parts Adjusting screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjusting stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
24-11
Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1
No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079
Parts O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 5X19L Pin ; 11.5X11.8L Socket screw ; M8X20 Sub-check valve
Q'ty 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1 Solenoid proportional reducing valve
24. COMPONENTS SYSTEM
No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627
Parts Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjusting plug Compensating piston Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)
Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730
Parts Adjusting screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjusting stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22
The codes in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible.
24-11
Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1
No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079
Parts O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 5X19L Pin ; 11.5X11.8L Socket screw ; M8X20 Sub-check valve
Q'ty 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1 Solenoid proportional reducing valve
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.1.3.2
24.1.1.3.2
OPERATION
OPERATION
(1) Control function Control function …… Electric flow control. •Positive flow control. •Total horsepower control. Emergency mode control. •Hydraulic positive control. •Hydraulic total horsepower control
(1) Control function Control function …… Electric flow control. •Positive flow control. •Total horsepower control. Emergency mode control. •Hydraulic positive control. •Hydraulic total horsepower control
(2) Summary The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control mechanism as mentioned below:
(2) Summary The regulator KR3G-YTOK for the in-line type axial piston pump K3V series is composed of the control mechanism as mentioned below:
1) Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power.
1) Electric flow control and positive flow control The tilting angle of the pump (delivery rate) is controlled by controlling the current command value of the solenoid proportional reducing valve attached to the regulator. The regulator makes positive flow control (positive control) that increases the delivery rate as the secondary pressure of the solenoid proportional reducing valve rises. Since this function permits the output power of the pump to be varied, it is possible to attain optimum power according to the operating condition. Also, since the pump delivers only the necessary oil flow, the machine does not consume excessive power.
2) Constant power control at emergency mode When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode). In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value. In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is also constant.) This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power control is not worked. With this mechanism, it is possible to obtain proper power for the working condition. This regulator is made up of the above two kinds of control system, but when both controls are actuated together, the low tilt angle (low delivery rate) command precede on mechanical operation described later.
2) Constant power control at emergency mode When the electromagnetic proportional pressure-reducing valve cannot output the secondary pressure due to the trouble, the spool for emergency mode is switched automatically, and the control is switched from electric control to hydraulic control (emergency mode). In emergency mode, the power shift command pressure Pf shifts the power set value. The power shift pressure (secondary pressure of electromagnetic proportional pressure-reducing valve) is led to power control section of regulator on each pump through pump inside passage and shifts respective control to the same power set value. In the power shifted condition, as self pump delivery pressure Pd1 rises, the pump tilt angle (delivery rate) is automatically reduced; consequently the input torque is controlled to the constant value or less. (When the speed is constant, the input power is also constant.) This pump is controlled by Pd1 only regardless of another delivery pressure. Condition where the power is controlled, the regulator of each pump is controlled to the different tilt angle (delivery rate). Consequently in the condition where the power is controlled, the overloading of engine is automatically prevented regardless of the loading of pump 2. And in normal condition, because the power shift pressure is 0MPa, the power control is not worked. With this mechanism, it is possible to obtain proper power for the working condition. This regulator is made up of the above two kinds of control system, but when both controls are actuated together, the low tilt angle (low delivery rate) command precede on mechanical operation described later. (3) Explanation of operation 1) Flow rate electrical control The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in right figure.
Delivery flow rate Q
1) Flow rate electrical control The pump delivery rate is controlled according to the command current value corresponding to the movement of control devices. This relation is shown in right figure.
Command current I
Command current I
Fig. 24-10
24-12
Delivery flow rate Q
(3) Explanation of operation
Fig. 24-10
24-12
24. COMPONENTS SYSTEM a. Flow rate increase (See Fig. 24-11) As the command current value I rises, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646). The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (C) fulcrum in the same arrow direction as (B). Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL connected to tank port is open and the pressure in servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pd1 in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulcrums with the movement of the servo piston towards (E), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
24-13
CL port : Connect with large diameter chamber of servo piston
652
B 876
D
875 611 643
A C 532
E
Psv A
(KDRDE5K)
Pd1
CL port a3
Hydraulic circuit diagram B
Fig. 24-11
646 613 F 897
24. COMPONENTS SYSTEM a. Flow rate increase (See Fig. 24-11) As the command current value I rises, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve rises, and by pressing pilot piston (643) in (A) direction it stops at the position the secondary pressure P2 balances the pilot spring force (646). The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (B) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (C) fulcrum in the same arrow direction as (B). Consequently the spool (652) connected to feedback lever moves towards (D). When the spool moves towards (D), the port CL connected to tank port is open and the pressure in servo piston large bore diameter chamber is released, consequently the servo piston (532) moves towards (E) according to delivery pressure Pd1 in small bore diameter piston chamber, resulting in the rise of flow rate. Since the feed back lever is connected to the servo piston and spool, the feed back lever rotates at (F) fulcrums with the movement of the servo piston towards (E), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
24-13
CL port : Connect with large diameter chamber of servo piston
652
B 876
D
875 611 643
A C 532
E
Psv A
(KDRDE5K)
Pd1
CL port a3
Hydraulic circuit diagram B
Fig. 24-11
646 613 F 897
24. COMPONENTS SYSTEM
b. Flow rate decrease (See Fig. 24-12) As the command current value I is reduced, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum in the same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and port CL. The servo piston small bore diameter chamber constantly receives delivery the pressure Pd1, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L) fulcrum with the movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
2) Power control (In emergency mode) When the load pressure rises, the pump tilt angle is reduced preventing the overloading of engine as shown in Fig. 24-13. The operation of power control is the same as the flow rate control, and is explained below.
Delivery flow rate Q
2) Power control (In emergency mode) When the load pressure rises, the pump tilt angle is reduced preventing the overloading of engine as shown in Fig. 24-13. The operation of power control is the same as the flow rate control, and is explained below.
Fig. 24-12
b. Flow rate decrease (See Fig. 24-12) As the command current value I is reduced, the secondary pressure P2 of electromagnetic proportional pressure-reducing valve is reduced, and by pressing pilot piston (643) in (G) direction it stops at the position the pilot spring force (646) balances the secondary pressure P2. The movement of pilot piston is transferred to lever 2 (613) through pin (875), and rotates at (H) fulcrum in arrow direction. Furthermore the lever 2 movement is transferred to feedback lever (611) through pin (897) and rotates at (I) fulcrum in the same arrow direction as (H). Consequently the spool (652) connected to the feedback lever moves towards (J). When the spool moves towards (J), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and port CL. The servo piston small bore diameter chamber constantly receives delivery the pressure Pd1, consequently the servo piston moves towards (K) according to the difference of area resulting in the reduction of tilt angle, and finally the flow rate is reduced. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (L) fulcrum with the movement of servo piston towards (K), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
Delivery output (Pd1)
Delivery output (Pd1)
Fig. 24-13
24-14
Fig. 24-12
Delivery flow rate Q
24. COMPONENTS SYSTEM
Fig. 24-13
24-14
24. COMPONENTS SYSTEM a. Overload prevention operation (See Fig. 24-14) Because the delivery pressure Pd1 acts on the compensating rod stepped section with the rise of self pump delivery pressure Pd1 the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring (625) and inner spring (626). The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (N) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and CL port. Since the delivery pressure Pd1 is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tilt angle, consequently the flow rate is also reduced. Since the feed back lever is connected with servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (Q), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
24-15
Fig. 24-14
24. COMPONENTS SYSTEM a. Overload prevention operation (See Fig. 24-14) Because the delivery pressure Pd1 acts on the compensating rod stepped section with the rise of self pump delivery pressure Pd1 the compensating rod (623) is pushed towards (M), and moves to the position the delivery pressure Pd1 balances the spring force of outer spring (625) and inner spring (626). The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (N) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (O) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected with feedback lever moves towards (P). When the spool moves towards (P), the delivery pressure Pd1 is led in servo piston large bore diameter chamber through spool and CL port. Since the delivery pressure Pd1 is constantly led to servo piston large bore diameter chamber, the servo piston moves towards (Q) according to the difference of area, resulting in the reduction of tilt angle, consequently the flow rate is also reduced. Since the feed back lever is connected with servo piston and spool, the feed back lever rotates at (R) fulcrum with the movement of the servo piston towards (Q), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely.
24-15
Fig. 24-14
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
b. Flow rate recovery operation (See Fig. 24-15) Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) and inner spring (626) with reduction of self pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (T) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V). As the spool moves towards (V), CL port is open and connected to tank port, the pressure of servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pd1 in small bore diameter chamber, and consequently the flow rate is raised. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 3) Priority mechanism of low tilt angle (low flow rate) command As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side where larger tilt angle command is given is free without contact with pin (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow rate control and power control has a priority.
24-16
625 897 876 612 626 X T
S
CL port : Connect with large diameter chamber of servo piston
G
652 H J 875
V
623 611
621 U
W
532 (KDRDE5K)
Psv A
Pd1 CL port a3
Hydraulic circuit daigram
Fig. 24-15
B
b. Flow rate recovery operation (See Fig. 24-15) Because the compensating rod (623) is pushed towards (S) with the force of outer spring (625) and inner spring (626) with reduction of self pump delivery pressure Pd1, and moves to the position the spring force of outer spring (625) and inner spring (626) balances the delivery pressure Pd1. The movement of compensating rod is transferred to lever 1 (612) through pin (875), and rotates at (T) fulcrum in arrow direction. Furthermore the lever 1 (612) movement is transferred to feedback lever (611) through pin (897) and rotates at (T) fulcrum in the same arrow direction as (N). Consequently the spool (652) connected to feedback lever moves towards (V). As the spool moves towards (V), CL port is open and connected to tank port, the pressure of servo piston large bore diameter chamber is released and the servo piston (532) moves towards (W) with delivery pressure Pd1 in small bore diameter chamber, and consequently the flow rate is raised. Since the feed back lever is connected to servo piston and spool, the feed back lever rotates at (X) fulcrum with the movement of the servo piston towards (W), consequently the spool is returned to the original position. With this movement, the opening of spool sleeve gradually closes, and the servo piston stops at the position the opening closes completely. 3) Priority mechanism of low tilt angle (low flow rate) command As the said explanation, the tilting commands of flow rate control and power control are transferred to feedback lever (611) and spool (652) through the large bore section of lever 1 (612) and lever 2 (613), but because the pin (dia 5) is extruded in large bore (dia 9), pin (897) on the side where making tilt angle smaller contacts with it, consequently the bore (dia 9) of lever on the side where larger tilt angle command is given is free without contact with pin (897). In this mechanical selecting manner, the command on the side of low tilt angle of the flow rate control and power control has a priority.
24-16
625 897 876 612 626 X T
S
CL port : Connect with large diameter chamber of servo piston
G
652 H J 875
V
623 611
621 U
W
532 (KDRDE5K)
Psv A
Pd1 CL port a3
Hydraulic circuit daigram
Fig. 24-15
B
Fig. 24-16
ADJUSTING THE REGULATOR
24.1.1.3.3
(1) Adjusting the maximum flow (See Fig. 24-3) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated in Fig. 24-17. Only the maximum flow varies, but other control characteristics remain unchanged.
(1) Adjusting the maximum flow (See Fig. 24-3) Adjust the maximum flow by loosening nut (808) and by tightening set screw (954) (or loosening it). Tightening set screw (954) decreases the delivery rate, as indicated in Fig. 24-17. Only the maximum flow varies, but other control characteristics remain unchanged.
1/4
Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)
Input current I (Pilot pressure Pi)
No change
Fig. 24-17 Adjusting the max. delivery flow
5.8 (1.5)
(2) Adjusting the minimum flow (See Fig. 24-3) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated in Fig. 24-18. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action).
Adjust screw no.
953
No. of turns for tightening
1/4
Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)
Input current I (Pilot pressure Pi)
Fig. 24-18 Adjusting the min. delivery flow
No change
Adjust screw no.
954
No. of turns for tightening
1/4
Pilot pressure Pi (Input current I) Min. increase in delivery flow L/min (gal/min)
953
No. of turns for tightening
1/4
Min. increase in delivery flow L/min (gal/min)
24-17
Fig. 24-17 Adjusting the max. delivery flow
5.8 (1.5)
Adjust screw no. Pilot pressure Pi (Input current I)
4.6 (1.2)
Fig. 24-16
Input current I (Pilot pressure Pi)
No change
(2) Adjusting the minimum flow (See Fig. 24-3) Adjust the minimum flow by loosening nut (806) and by tightening socket screw (953) (or loosening it). Tightening socket screw increases the delivery rate, as indicated in Fig. 24-18. Other control characteristics remain unchanged in the same way as maximum flow adjustment, care should be used of the fact that overtightening may increase a required power at the maximum delivery pressure (at relieving action).
Delivery flow rate Q
No. of turns for tightening
Delivery flow rate Q
The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control) control characteristics, flow control characteristics using the adjust screw.
954
Delivery pressure (Pd1)
ADJUSTING THE REGULATOR
The regulator may be adjusted in terms of maximum flow, minimum flow, horsepower (at emergency mode control) control characteristics, flow control characteristics using the adjust screw.
Adjust screw no.
Delivery flow rate Q
4) Power shift control As shown in Fig. 24-16, the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently like the overloading prevention operation of power control, the pump tilt angle becomes smaller and the power setting value is reduced. Conversely, if the power shift pressure Pf is reduced, the power set value is raised. The power shift pressure Pf of this pump is ordinary set to 0MPa, but in emergency mode, the power shift pressure Pf is raised to 4.9MPa.
Delivery flow rate Q
24.1.1.3.3
Delivery pressure (Pd1)
24. COMPONENTS SYSTEM
Delivery flow rate Q
4) Power shift control As shown in Fig. 24-16, the pump set power is controlled according to the movement of control by power shift pressure Pf. As power pressure Pf rises, the compensating rod (623) moves rightward through pin (898) and compensating piston (621). Consequently like the overloading prevention operation of power control, the pump tilt angle becomes smaller and the power setting value is reduced. Conversely, if the power shift pressure Pf is reduced, the power set value is raised. The power shift pressure Pf of this pump is ordinary set to 0MPa, but in emergency mode, the power shift pressure Pf is raised to 4.9MPa.
Delivery flow rate Q
24. COMPONENTS SYSTEM
Input current I (Pilot pressure Pi)
Fig. 24-18 Adjusting the min. delivery flow
No change 4.6 (1.2)
24-17
(3) Adjusting the input horsepower (At emergency mode) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will by halved when only one pump is loaded.
(3) Adjusting the input horsepower (At emergency mode) Since the regulator is of total horsepower control type, turn the adjust screws of both the front (No.1) and rear (No.2) pumps when changing horsepower set values. Adjust the horsepower settings of both pumps to a same level. The pressure change values by adjustment are based on two pumps pressurized at the same time, and the values will by halved when only one pump is loaded.
1) Adjusting the Outer Spring (See Fig. 24-9) (At emergency mode) Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in Fig. 24-19. Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by NX1.48 turns at first.
1) Adjusting the Outer Spring (See Fig. 24-9) (At emergency mode) Adjust it by loosening lock nut (630) and by tightening adjust screw (628) (or loosening it). Tightening the adjust screw shifts the control chart to the right and increases the input horsepower, as indicated in Fig. 24-19. Since turning the adjust screw C (628) by N turns changes the setting of the inner spring (626), return the adjust screw C (627) by NX1.48 turns at first.
No. of turns for tightening
1/4
Adjust screw no.
628
No. of turns for tightening
1/4
Increase delivery pressure MPa (psi) 2.06 (299)
Increase delivery pressure MPa (psi) 2.06 (299)
Increase in input torque N.m (lbf.ft)
Increase in input torque N.m (lbf.ft)
50 (36.9)
627
No. of turns for tightening
1/4
Increase inflow L/min (gal/min)
Delivery pressre (Pd1)
12 (3.2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3) (4) Adjusting the flow control characteristics (See Fig. 24-9) Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown in Fig. 24-21.
Adjust screw no.
924
No. of turns for tightening
1/4
Increase Pilot pressure MPa (psi)
0.18 (26)
Decrease in delivery flow L/min (gal/min)
18.5 (4.9)
Fig. 24-20 Adjusting the input horsepower (2)
Input current I (Pilot pressure Pi)
Fig. 24-21 Adjusting the flow control characteristics
24-18
Adjust screw no.
627
No. of turns for tightening
1/4
Increase inflow L/min (gal/min)
Delivery pressre (Pd1)
12 (3.2)
Increase in input torque N.m (lbf.ft) 58.7 (43.3) (4) Adjusting the flow control characteristics (See Fig. 24-9) Adjust them by loosening nut (801) and socket bolt (924) (or loosening it). Socket bolt causes the control chart to move to the right as shown in Fig. 24-21.
Delivery flow rate Q
Adjust screw no.
2) Adjusting the Inner Spring (See Fig. 24-9) (At emergency mode) Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the adjust screw increases the flow and then the input horsepower, as indicated in Fig. 24-20. And the input torque raises.
Delivery flow rate Q
2) Adjusting the Inner Spring (See Fig. 24-9) (At emergency mode) Adjust it by loosening nut (802) and by adjust screw (C) (627) (or loosening it). Tightening the adjust screw increases the flow and then the input horsepower, as indicated in Fig. 24-20. And the input torque raises.
50 (36.9)
Adjust screw no.
924
No. of turns for tightening
1/4
Increase Pilot pressure MPa (psi)
0.18 (26)
Decrease in delivery flow L/min (gal/min)
18.5 (4.9)
Delivery flow rate Q
628
Delivery pressure (Pd1)
Fig. 24-19 Adjusting the input horsepower (1)
Fig. 24-20 Adjusting the input horsepower (2)
Delivery flow rate Q
Adjust screw no.
Delivery pressure (Pd1)
Fig. 24-19 Adjusting the input horsepower (1)
Delivery flow rate Q
24. COMPONENTS SYSTEM
Delivery flow rate Q
24. COMPONENTS SYSTEM
Input current I (Pilot pressure Pi)
Fig. 24-21 Adjusting the flow control characteristics
24-18
24. COMPONENTS SYSTEM 24.1.1.3.4
CAUSES OF FAULT RESULTING FROM REGULATOR
24. COMPONENTS SYSTEM 24.1.1.3.4
CAUSES OF FAULT RESULTING FROM REGULATOR
When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-II"
When trouble due to this regulator occurs, disassemble and inspect it referring to "Chapter YN33-II"
(1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3).
(1) When the engine is overloaded, Load every unit of pump, and check on pumps on the right and left sides for possible damages. When pumps on both sides are failed, check on them for the following failures 1), 2). When pump on the one side is failed, start checking from para. 3).
1) Check that the power shift command current I is normal.
1) Check that the power shift command current I is normal.
2) The power shift pressure is low.
2) The power shift pressure is low.
•
Check the dither of amp.
•
Check the dither of amp.
•
Replace solenoid proportional reducing valve.
•
Replace solenoid proportional reducing valve.
3) Stick of compensating piston (621) and compensating rod (623) •
3) Stick of compensating piston (621) and compensating rod (623)
Disassemble and clean it.
•
4) Stick of pin (898) •
Disassemble and clean it.
4) Stick of pin (898)
Disassemble and clean it.
•
(2) The max. flow rate is not delivered.
Disassemble and clean it.
(2) The max. flow rate is not delivered.
1) Check that pilot differential pressure Pi is normal.
1) Check that pilot differential pressure Pi is normal.
2) Stick of pilot piston (643)
2) Stick of pilot piston (643)
•
Disassemble and clean it.
•
3) Stick of spool (652) •
3) Stick of spool (652)
Disassemble and clean it.
•
4) Stick of pin (898) •
Disassemble and clean it. Disassemble and clean it.
4) Stick of pin (898)
Disassemble and clean it.
•
Note : When the damage of part is severe, replace the part with new one.
24-19
Disassemble and clean it.
Note : When the damage of part is severe, replace the part with new one.
24-19
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.1.4
24.1.1.4
CONTROL CURVE OF PUMP
250
Q
[1] 99kW H mode at traveling or optional working [2] 83kW H mode at operating attachment [3] 75kW S mode at operating attachment
2000min-1: (H mode) 1800min-1: (S mode)
200
[2]
250 ;2000 min-1
Input revolution Input horse power ;114 kW Input torque ;544 N.m
Q
[1] 99kW H mode at traveling or optional working [2] 83kW H mode at operating attachment [3] 75kW S mode at operating attachment
2000min-1: (H mode) 1800min-1: (S mode)
200
Reference value in ( )
[1]
CONTROL CURVE OF PUMP
[2]
Reference value in ( )
[1]
Two pumps are loaded at the same time Delivery flow rate Q [ L/min ]
Two pumps are loaded at the same time Delivery flow rate Q [ L/min ]
Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m
150
150
[3]
100
[3]
100
50
50 Min.Flow(at 2000min-1)
10
15 20 Delivery pressure Pd
250
300mA
30
35
40 [MPa]
Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m
200
Delivery flow rate Q [ L/min ]
1471
m
981
od
e
I-Q Curve Pd=7.8MPa at Qmax 490 Min.Flow(at 2000min-1) 400mA 30L
0
5
10
0
1
2
15 20 Delivery pressure Pd 3 4 [MPa] Pilot pressure Pi
24-20
25
30
25
35
40 [MPa]
30
35
40 [MPa]
[4] 91kW : At emergency mode
Input revolution ;2000 min-1 Input horse power ;114 kW Input torque ;544 N.m
718mA 220L
Reference value in ( ) Two pumps are loaded at the same time Pf:Power shift pressure (Reference value) [4]
150
(P At f=4 em .9M er Pa ge ) nc y
100
1471
m
981
od
e
I-Q Curve Pd=7.8MPa at Qmax 490
50
Input torque Tin N.m
50
Tin
15 20 Delivery pressure Pd
200
[4]
100
10
300mA
Two pumps are loaded at the same time Pf:Power shift pressure (Reference value) (P At f=4 em .9M er Pa ge ) nc y
5
Q 2000min-1
Reference value in ( )
150
0 250
[4] 91kW : At emergency mode
718mA 220L
Q 2000min-1
25
Input torque Tin N.m
5
Delivery flow rate Q [ L/min ]
0
Min.Flow(at 2000min-1)
Min.Flow(at 2000min-1) 400mA 30L
Tin 0
5
10
0
1
2
15 20 Delivery pressure Pd 3 4 [MPa] Pilot pressure Pi
24-20
25
30
35
40 [MPa]
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM 24.1.2 24.1.2.1 24.1.2.1.1
24.1.2
CONTROL VALVE SPECIFICATIONS
24.1.2.1
OUTSIDE VIEW
24.1.2.1.1
CONTROL VALVE SPECIFICATIONS OUTSIDE VIEW
PTb
PTb
PBL
PBL
CT2
P2
CT2
P2
CP2
CP2
CT1
CT1 P1
P1
PAL
Pcb
CT1 PTb
CMR1 CMR2 Br 1
PAb
Bb (ROD)
PAc
Ac
CP1
Ab (HEAD)
LCb CRb Bc
(HEAD)
PAa2
Ar
(ROD)
LCc PCAP2 LCAT2
Travel right Boom Bucket
PAr
PAr
PB1 PBs
PBb PBb PCc
PC
PBc
Arm 2
PAL
PCb
PCb
PBa2
MU
PBa1 Pss
PBa2
PAo
PAL PB1
CT2
Travel left
AL
Boom conflux
PAo
Arm 1
As
PLc2
CRa Ba
Option
P2 unload PCa
Travel straight PBr
Ao
CMR1 CMR2 Br
LCs
1
PAs
Aa (HEAD)
PAa1
PAb
LCo
PBo
Bo
Bb (ROD)
PAc
Ac
CP1
PAa2
Ab (HEAD)
(ROD)
LCc PCAP2 LCAT2
Boom Bucket
PAr
PAr
PBs PBb PCc
PC
PBa2
MU
(P3)
PBp1
PAo
PAL PB1
PBa2 PBp1
PBp2
As
Swing
PBs
PAo
Arm 1
PLc2
CRa Ba
Option
P2 unload PCa
Bs
CCb
Pss PBa1
PBL
BL CP2
Boom conflux
LCs
PAs
Aa (HEAD)
PAa1
LCa
(ROD) Ao
LCo
PBo
Bo
PAo PBp2 PAa2
PAa2
Arm 2 Bucket (P4)
Boom Travel right
PAa2
AL
(P2)
PAo
(P3)
CT2
Travel left
PBp1 PBp2
(P2) PBa2
PBa1 Pss
PBa2
PBp1 PBp2 (P3)
PB1
PBb
PBc
Arm 2
PAL
PCb
PCb
Travel right
T1
T2
P1 unload
Ar
LCb CRb Bc
(HEAD)
LCa
(ROD)
PL
Bs
CCb
Pss PBa1
PBL
BL CP2
Swing
PBs
PTb
USE FOR YN30V00101 F1
PBr
PL
USE FOR YN30V00101 F1
Travel straight
CT1
T1
T2
P1 unload
PAL
Pcb
PBo
A
Travel straight
PBo PAc PAb PBr
PAa1
Option
Arm 2
Arm 1
Bucket
PAa
Swing PCa
(P4)
(P3)
Boom Travel right
P2 unload (T3)
PTb
PBL
Travel left PAa2
VIEW A
PBo
A
Fig. 24-22 Outside view
Fig. 24-22 Outside view
24-21
24-21
Travel straight
Option
PBo PAc PAb PBr
PAa1
Arm 1 PAa
Swing PCa
P2 unload (T3)
PTb
PBL
VIEW A
Travel left
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.2.1.2
24.1.2.1.2
PORTS
Port size
Tightening torque
Ports
PF3/4
150~180 N•m (111~133 lbf•ft)
MU
Description
(T3)
Pluged
PF1/2
98~120 N•m (72~89 lbf•ft)
(P3)
Pluged
(P4)
Pluged
PF3/8
69~78 N•m (51~58 lbf•ft)
PAa1
Arm 1 (in) pilot port
PBa1
34~39 N•m (25~29 lbf•ft)
M10
49~65 N•m (36~48 lbf•ft)
Ports
150~180 N•m (111~133 lbf•ft)
MU
Description
(T3)
Pluged
(P3)
Pluged
(P4)
Pluged
PF3/8
69~78 N•m (51~58 lbf•ft)
PAa1
Arm 1 (in) pilot port
Arm 1 (out) pilot port
PBa1
Arm 1 (out) pilot port
PAb
Boom (up) pilot port
PAb
Boom (up) pilot port
PBb
Boom (down) pilot port
PBb
Boom (down) pilot port
PAc
Bucket (digging) pilot port
PAc
Bucket (digging) pilot port
PBc
Bucket (dump) pilot port
PBc
Bucket (dump) pilot port
PAL
Travel left (forward) pilot port
PAL
Travel left (forward) pilot port
PBL
Travel left (reverse) pilot port
PBL
Travel left (reverse) pilot port
PAr
Travel right (forward) pilot port
PAr
Travel right (forward) pilot port
PBr
Travel right (reverse) pilot port
PBr
Travel right (reverse) pilot port
PAs
Swing (right) pilot port
PAs
Swing (right) pilot port
PBs
Swing (left) pilot port
PBs
Swing (left) pilot port
PAa2
Arm 2 (in) pilot port
PAa2
Arm 2 (in) pilot port
PBa2
Arm 2 (out) pilot port
PBa2
Arm 2 (out) pilot port
Option pilot port
PAo
PBo
Option pilot port
PBo
Option pilot port
DR
Drain port
DR
Drain port
Pss
Swing pilot high pressure select port
Pss
Swing pilot high pressure select port
PF1/4
34~39 N•m (25~29 lbf•ft)
Option pilot port
PLc2
Lock valve select pilot port
PLc2
Lock valve select pilot port
PBp1
Bypass cut valve (P1 side) pilot port
PBp1
Bypass cut valve (P1 side) pilot port
PBp2
Bypass cut valve (P2 side) pilot port
PBp2
Bypass cut valve (P2 side) pilot port
PB1
83~110N•m (61~81 lbf•ft)
Tightening torque
PF3/4
98~120 N•m (72~89 lbf•ft)
PL
M12
Port size
PF1/2
PAo
PF1/4
PORTS
Attachment boost port
PL
Boom (up) conflux pilot port
PB1
Attachment boost port Boom (up) conflux pilot port
PTb
Travel straight pilot port
PTb
Travel straight pilot port
PCa
Unload valve (P2 side) pilot port
PCa
Unload valve (P2 side) pilot port
PCb
Unload valve (P1 side) pilot port
PCb
Unload valve (P1 side) pilot port
PCc
Bucket (digging) stroke limiter pilot port
PCc
Bucket (digging) stroke limiter pilot port
P1
Pump port (P1 side)
P1
Pump port (P1 side)
P2
Pump port (P2 side)
P2
Pump port (P2 side)
T1
Tank port 1
T1
Tank port 1
T2
Tank port 2
T2
Tank port 2
Ar
Right travel motor port (forward)
Ar
Right travel motor port (forward)
Br
Right travel motor port (reverse)
Br
Right travel motor port (reverse)
AL
Left travel motor port (forward)
AL
Left travel motor port (forward)
BL
Left travel motor port (reverse)
BL
Left travel motor port (reverse)
As
Swing motor port (right)
As
Swing motor port (right)
Bs
Swing motor port (left)
Bs
Swing motor port (left)
Ab
Boom cylinder head side port (up)
Ab
Boom cylinder head side port (up)
Bb
Boom cylinder rod side port (down)
Bb
Boom cylinder rod side port (down)
Aa
Arm cylinder head side port (in)
Aa
Arm cylinder head side port (in)
Ba
Arm cylinder rod side port (out)
Ba
Arm cylinder rod side port (out)
Ac
Bucket cylinder head side port (digging)
Ac
Bucket cylinder head side port (digging)
Bc
Bucket cylinder rod side port (dump)
Bc
Bucket cylinder rod side port (dump)
24-22
M12
M10
83~110N•m (61~81 lbf•ft)
49~65 N•m (36~48 lbf•ft)
24-22
24. COMPONENTS SYSTEM Port size
24.1.2.1.3
Tightening torque
Ports
Description
24. COMPONENTS SYSTEM Port size
Tightening torque
Ports
Description
Ao
Optional pilot port
Ao
Optional pilot port
Bo
Optional pilot port
Bo
Optional pilot port
SPECIFICATIONS
24.1.2.1.3
Item
Specifications
SPECIFICATIONS Item
Specifications
Model
KMX15YD/B44001
Model
KMX15YD/B44001
Maximum flow rate [L/min (gal/min)]
220 (58)u2
Maximum flow rate [L/min (gal/min)]
220 (58)u2
Maximum set pressure [MPa (psi)]
37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Maximum set pressure [MPa (psi)]
37.8 (5480) (Pump port)/ 39.7 (5760) (Actuator port)
Main relief valve set pressure [MPa (psi)] When power boost pressure
Std 34.3 (4970) [at 70u2L/min (18.5u2gal/min)] 37.8 (5480) [at 60u2L/min (15.9u2gal/min)]
Main relief valve set pressure [MPa (psi)] When power boost pressure
Std 34.3 (4970) [at 70u2L/min (18.5u2gal/min)] 37.8 (5480) [at 60u2L/min (15.9u2gal/min)]
Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]
39.7 (5760) [at 30L/min (8gal/min)]
Overload relief valve set pressure (Boom head, Bucket head, Arm rod) [MPa (psi)]
39.7 (5760) [at 30L/min (8gal/min)]
Overload relief valve set pressure (Boom rod, Bucket rod, Arm head) [MPa (psi)]
37.8 (5480) [at 30L/min (8gal/min)]
Overload relief valve set pressure (Boom rod, Bucket rod, Arm head) [MPa (psi)]
37.8 (5480) [at 30L/min (8gal/min)]
24-23
24-23
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.2.2
24.1.2.2
CONSTRUCTION
24.1.2.2.1
(1) Control valve
CONSTRUCTION AND OPERATION CONSTRUCTION
(1) Control valve J
J 164
154
T2
T2
T1
PBL
PCa
YS1
PAs
PCa
YBG1
PB1
PBs
P2-20
PBs
PBL
J
P2-20
YBG1
PB1
PAL
T1
YT1
J
101
P2
PAs
YS1
YT1
PAL
164
154
101
P2
Pss
Pss
PAa1
PBo
YP1
PAo
163
PBa1
PAo
(P4)
163
162 163 169 155 162 SECTION A-A 154
164
PAa1
YA1
YA1
PBa1
PBo
YP1
24.1.2.2.1
CONSTRUCTION AND OPERATION
(P4)
162 163 169 155 162 SECTION A-A 154
P1
164
102
973
PCb
973 PCb
PTb P1-20
P1-20
973
973
973
973
PAr
PBr
YT1
YT1
PBr
102
973
973
PTb
P1
PAr
973
973 PBb
PAb
973
973
PBc PCc
973 PBa2
974
973
PAa2
YAG 1
YAG 1
PAa2
PBc PCc YK1
974
974
974
162
(P3)
162 169 155 163
162
PBb
973
973 PAc
YK1
PAc
YB1
YB1
PAb
162
(P3)
162 169 155 163
SECTION B-B
SECTION B-B
Fig. 24-23 Section (1/6)
Fig. 24-23 Section (1/6)
24-24
24-24
162
PBa2
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM A
A
B
B
H
T2
273x10 P1 unload
Travel right D
H
PB1
C
Boom conflux (P2 unload)
978x2
977
D
PB1
978x2
D
Boom
Swing PBb
E
Pss
PBa1
Bucket F
Option
G
F Arm 2
G
(P3)
Arm 1
PBp1
G
G K
B
(P3)
A
PBp1
Option
MU
K PBp2
PBp1
A
PBp1
274x4
275x4 (P4)
212
PAo
PBa2
PBp2
(P3)
K PBp2
B
PAo
PBa2
PAo PA
PBa2
MU
PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2
273x10
PBo
273x10
E
Pss
PBa1
F
PA PAo
K
PBb
PCc
Bucket F
Arm 2
Swing
E
Arm 1 PBa2
Boom conflux (P2 unload)
PBs
Boom PCc
H
C PAr
PBs
E
273x10 Travel left
(Travel straight)
Travel right D
PAL
PCb
P1 unload C
PAr
T2
273x10
USE FOR YN30V00101F1
977
H
Travel left
(Travel straight) USE FOR YN30V00101F1
C
PAL
PCb
273x10
PAa2
273x10
PBo
273x10
Fig. 24-24 Section (2/6)
Fig. 24-24 Section (2/6)
24-25
24-25
213
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
Fig. 24-25 Section (3/6)
Fig. 24-25 Section (3/6)
24-26
24-26
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM Swing 203 333 331 336 322 321 603 331 211 261 266 160 160 514 524 556 164 511 521 551 164
204
PBs
Boom
333
Pss
331 336 AbR
322 321
266
As
CRb Ab
LCs
LCb
Bb
Bs
331 261 303 161 162 163 511 523 556 164
Swing 203 333 331 336 322 321 603 331 211 261 266 160 160 514 524 556 164 511 521 551 164
204
PBs
Boom
333
Pss
331 336 AbR
322 321
266
As
CRb Ab
LCs
LCb
Bb
162
Bs
266 264 206
PAb
205
160
BbR
164 551 209 216 333 331 336 322 321 602
PAs
Arm 1
PBa1
PBc
BaR
BcR
304 CRar
Bc
551 164
Ba LCc
LCa
160 514 524
205
160
BbR
209 216 333 331 336 322 321 602
PAs
SECTION E-E Bucket
PCc
201 333 331 336 322 321 603 331 261 211
Arm 1
PBa1
PBc
BaR
BcR
331 261 304
556 164 511 521
511 521
551 164
551 164
CRar
Bc
Ac
Ba LCc
LCa
160 514 524 556 164 511 521 551 164
Ac
162
162
Aa
161
Aa
161
264 603 205
162
264 206
PAb
Bucket 201 333 331 336 322 321 603 331 261 211
556 164
266
164 551
331 261
511 521
301 264 602
SECTION E-E
PCc
163 511 523
161
161 301 264 602
331 261 303 161 162
PAc AcR
PAa1
SECTION F-F
AaR
302 264
264 603
205 605
205
PAc AcR
302 264
PAa1
SECTION F-F
Fig. 24-26 Section (4/6)
Fig. 24-26 Section (4/6)
24-27
24-27
AaR
205 605
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM 201 333 331 340 328 321
Arm 2
Option
PBa2
201 333
PAo
331 336
331 261
324 AoR
323 604 331
MU
308
261 311
162 162 162 511 521 551 164 515 521
Ao
511 521
LCAT2 LCo LCAP2
551
551 164
164
201 333 331 340 328 321
Arm 2
Option
PBa2
201 333
PAo
331 336
331 261
324 AoR
323 604 331
MU
308
261 311
162 162 162 511 521 551 164 515 521
Ao
511 521
LCAT2 LCo LCAP2
551 164 Bo
Bo
162
162
161
161
604 264
BoR
264
PBo
PAa2
205
205
SECTION G-G
604 264
BoR
264
PBo
PAa2
205
205
SECTION G-G
T2
T2
161 P1
511 521
551 164
P1
T1
163
CT1
551 164
161
163 162
511 521
T1
163
CT1
551 164
163 162
511 521
P2
511 521
P2 CT2
CT2
551
551
164
164
SECTION H-H
SECTION H-H
Fig. 24-27 Section (5/6)
Fig. 24-27 Section (5/6)
24-28
24-28
24. COMPONENTS SYSTEM
PBp1
207
PBp1
PBp2
606
160
24. COMPONENTS SYSTEM
606
207
606
160
278x5
266
278x5
266
264
264
264
264
527
528 T2
517
163
527
528 T2
T1
517
518
SECTION J-J
PBp2
606
163
T1
518
SECTION J-J SECTION K-K
SECTION K-K
Fig. 24-28 Section (6/6)
Fig. 24-28 Section (6/6)
24-29
24-29
24. COMPONENTS SYSTEM Tightening torque N•m (lbf•ft)
No.
24. COMPONENTS SYSTEM
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
101 Casing A
1
321 Spring
5
101 Casing A
1
321 Spring
5
102 Casing B
1
322 Spring
4
102 Casing B
1
322 Spring
4
220~250 (162~184)
154 Plug PF3/4
3
323 Spring
3
220~250 (162~184)
154 Plug PF3/4
3
323 Spring
3
110~130 (81~96)
155 Plug PF1/2
2
324 Spring
3
110~130 (81~96)
155 Plug PF1/2
2
324 Spring
3
20~24 (15~18)
159 Plug PT1/4 MEC (Pre-coat bolt)
1
325 Spring
1
20~24 (15~18)
159 Plug PT1/4 MEC (Pre-coat bolt)
1
325 Spring
1
7.8~9.8 (5.8~7.2)
160 Plug PT1/16 MEC (Pre-coat bolt)
5
326 Spring
1
7.8~9.8 (5.8~7.2)
160 Plug PT1/16 MEC (Pre-coat bolt)
5
326 Spring
1
161 O-ring
7
327 Spring
3
161 O-ring
7
327 Spring
3
162 O-ring
15
328 Spring
1
162 O-ring
15
328 Spring
1
163 O-ring
11
329 Spring
3
163 O-ring
11
329 Spring
3
164 O-ring
19
331 Spring seat
24
164 O-ring
19
331 Spring seat
24
169 O-ring
2
333 Spacer bolt
12
169 O-ring
2
333 Spacer bolt
12
201 Cover
5
336 Stopper
10
201 Cover
5
336 Stopper
10
202 Cover
4
339 Stopper
1
202 Cover
4
339 Stopper
1
203 Cover
1
340 Stopper
1
203 Cover
1
340 Stopper
1
204 Sub cover
1
511 Poppet
11
204 Sub cover
1
511 Poppet
11
205 Cover
7
512 Poppet
2
205 Cover
7
512 Poppet
2
206 Cover
1
514 Poppet
2
206 Cover
1
514 Poppet
2
207 Back pressure check valve cover
1
515 Poppet
1
207 Back pressure check valve cover
1
515 Poppet
1
209 Cover
1
517 Poppet
1
209 Cover
1
517 Poppet
1
211 Lock valve selector sub
2
518 Poppet
1
211 Lock valve selector sub
2
518 Poppet
1
212 Plate
1
521 Spring
11
212 Plate
1
521 Spring
11
213 Plate
1
522 Spring
2
213 Plate
1
522 Spring
2
216 Piston
1
523 Spring
1
216 Piston
1
523 Spring
1
261 O-ring
12
524 Spring
2
261 O-ring
12
524 Spring
2
264 O-ring
10
527 Spring
1
264 O-ring
10
527 Spring
1
266 O-ring
4
528 Spring
1
266 O-ring
4
528 Spring
1
25~34 (18~25)
273 Socket bolt
40
230~260 (170~192)
551 Plug
13
25~34 (18~25)
273 Socket bolt
40
230~260 (170~192)
551 Plug
13
98~120 (72~89)
274 Socket bolt
4
130~150 (96~111)
552 Plug
2
98~120 (72~89)
274 Socket bolt
4
130~150 (96~111)
552 Plug
2
98~120 (72~89)
275 Socket bolt
4
230~260 (170~192)
556 Plug
3
98~120 (72~89)
275 Socket bolt
4
230~260 (170~192)
556 Plug
3
25~34 (18~25)
278 Socket bolt
5
562 O-ring
2
25~34 (18~25)
278 Socket bolt
5
562 O-ring
2
301 Boom spool sub
1
69~78 (51~58)
601 Main relief valve
1
301 Boom spool sub
1
69~78 (51~58)
601 Main relief valve
1
302 Arm 1 spool
1
69~78 (51~58)
602 Port relief valve
2
302 Arm 1 spool
1
69~78 (51~58)
602 Port relief valve
2
303 Swing spool
1
69~78 (51~58)
603 Port relief valve
3
303 Swing spool
1
69~78 (51~58)
603 Port relief valve
3
304 Bucket spool
1
69~78 (51~58)
604 Relief valve plug assy
2
304 Bucket spool
1
69~78 (51~58)
604 Relief valve plug assy
2
305 Boom conflux spool
1
69~78 (51~58)
605 Overload relief valve
1
305 Boom conflux spool
1
69~78 (51~58)
605 Overload relief valve
1
306 Travel spool
2
98~120 (72~89)
606 Bypass cut valve
2
306 Travel spool
2
98~120 (72~89)
606 Bypass cut valve
2
307 Travel straight spool
1
140~180 (103~133)
973 Socket bolt
8
307 Travel straight spool
1
140~180 (103~133)
973 Socket bolt
8
308 Arm 2 spool sub
1
140~180 (103~133)
974 Socket bolt
2
308 Arm 2 spool sub
1
140~180 (103~133)
974 Socket bolt
2
309 P1 unload spool
1
977 Name plate
1
309 P1 unload spool
1
977 Name plate
1
310 P2 unload spool
1
978 Rivet
2
310 P2 unload spool
1
978 Rivet
2
311 Option spool
1
311 Option spool
1
9.8~14 (7.2~10.3)
24-30
16~18 (11.8~13.3) Loctite #262
9.8~14 (7.2~10.3)
24-30
16~18 (11.8~13.3) Loctite #262
24. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601)
24. COMPONENTS SYSTEM (2) Main relief valve (Two step relief) (601)
Fig. 24-29 Main relief valve (Two step relief) Tightening torque N•m (lbf•ft) 69~78 (51~58)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Fig. 24-29 Main relief valve (Two step relief) Parts
Q’ty
Tightening torque N•m (lbf•ft) 69~78 (51~58)
103 Plug ; M27
1
562 Back up ring
1
104 Adjust screw
1
611 Poppet
121 C-ring
1
122 Spacer
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
103 Plug ; M27
1
562 Back up ring
1
1
104 Adjust screw
1
611 Poppet
1
613 Stopper
1
121 C-ring
1
613 Stopper
1
1
614 Piston
1
122 Spacer
1
614 Piston
1
123 C-ring
1
621 Spring
1
123 C-ring
1
621 Spring
1
124 Filter stopper
1
652 Adjust screw
1
124 Filter stopper
1
652 Adjust screw
1
125 Filter
1
661 O-ring
1
125 Filter
1
661 O-ring
1
163 O-ring
1
663 O-ring
1
163 O-ring
1
663 O-ring
1
512 Plunger
1
664 O-ring
1
512 Plunger
1
664 O-ring
1
521 Spring
1
28~31 (21~23)
671 Lock nut ; M14
1
521 Spring
1
28~31 (21~23)
671 Lock nut ; M14
1
541 Seat
1
46~52 (34~38)
673 Lock nut ; M24
1
541 Seat
1
46~52 (34~38)
673 Lock nut ; M24
1
561 O-ring
1
1
561 O-ring
1
24-31
24-31
1
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(3) Over load relief valve (602,603,605)
(3) Over load relief valve (602,603,605)
Fig. 24-30 Over load relief valve Tightening torque N•m (lbf•ft)
No.
Parts
Tightening torque N•m (lbf•ft)
Q’ty
Fig. 24-30 Over load relief valve
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Tightening torque N•m (lbf•ft)
Q’ty
No.
Parts
Q’ty
69~78 (51~58)
101 Body ; M27
1
541 Seat
1
69~78 (51~58)
101 Body ; M27
1
541 Seat
1
69~78 (51~58)
102 Plug ; M27
1
561 O-ring
1
69~78 (51~58)
102 Plug ; M27
1
561 O-ring
1
161 O-ring
1
562 Backup ring
1
161 O-ring
1
562 Backup ring
1
162 O-ring
1
563 O-ring
1
162 O-ring
1
563 O-ring
1
123 C-ring
1
564 Backup ring
1
123 C-ring
1
564 Backup ring
1
124 Filter stopper
1
611 Poppet
1
124 Filter stopper
1
611 Poppet
1
125 Filter
1
612 Spring seat
1
125 Filter
1
612 Spring seat
1
301 Piston
1
621 Spring
1
301 Piston
1
621 Spring
1
511 Plunger
1
651 Adjust screw
1
511 Plunger
1
651 Adjust screw
1
521 Spring
1
661 O-ring
1
521 Spring
1
661 O-ring
1
522 Spring
1
671 Lock nut ; M14
1
522 Spring
1
671 Lock nut ; M14
1
28~31 (21~23)
24-32
28~31 (21~23)
24-32
24. COMPONENTS SYSTEM (4) Arm 2 spool (308)
351
24. COMPONENTS SYSTEM (4) Arm 2 spool (308)
317 340 361 371 350
308
371 361 340 319
351
Fig. 24-31 Arm 2 spool Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Fig. 24-31 Arm 2 spool
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
308 Spool
1
16~18 (33~35) Loctite #638
350 Plug
1
308 Spool
1
16~18 (33~35) Loctite #638
350 Plug
1
317 Plunger
1
16~18 (33~35) Loctite #638
351 Plug
1
317 Plunger
1
16~18 (33~35) Loctite #638
351 Plug
1
319 Plunger
1
361 O-ring
2
319 Plunger
1
361 O-ring
2
340 Spring
2
371 Buckup ring
2
340 Spring
2
371 Buckup ring
2
(5) Boom spool (301)
(5) Boom spool (301)
301
317
340
361 371 350
301
Fig. 24-32 Boom spool Tightening torque N•m (lbf•ft)
317 340 361 371 350
308
371 361 340 319
No.
Parts
Q’ty
301 Spool
1
317 Plunger 340 Spring
Tightening torque N•m (lbf•ft) 16~18 (12~13) Loctite #638
340
361 371 350
Fig. 24-32 Boom spool
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
350 Plug
1
301 Spool
1
1
361 O-ring
1
317 Plunger
1
371 Buckup ring
1
340 Spring
24-33
317
Tightening torque N•m (lbf•ft) 16~18 (12~13) Loctite #638
No.
Parts
Q’ty
350 Plug
1
1
361 O-ring
1
1
371 Buckup ring
1
24-33
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(6) Lock valve selector (211)
(6) Lock valve selector (211)
Fig. 24-33 Lock valve selector Tightening torque N•m (lbf•ft)
Fig. 24-33 Lock valve selector
Q’ty
Tightening torque N•m (lbf•ft)
No.
101 Casing
1
10~14 (7.4~10.3)
171 Socket bolt
3
161 O-ring
4
49~59 (36~44)
201 Plug
164 O-ring
1
166 O-ring 167 O-ring
No.
Parts
Tightening torque N•m (lbf•ft)
Q’ty
Tightening torque N•m (lbf•ft)
No.
101 Casing
1
10~14 (7.4~10.3)
171 Socket bolt
3
1
161 O-ring
4
49~59 (36~44)
201 Plug
1
321 Spring
1
164 O-ring
1
321 Spring
1
1
511 Spool
1
166 O-ring
1
511 Spool
1
1
541 Sleeve
1
167 O-ring
1
541 Sleeve
1
24-34
Parts
Q’ty
No.
Parts
24-34
Parts
Q’ty
24. COMPONENTS SYSTEM (7) Bypass cut valve (606)
24. COMPONENTS SYSTEM (7) Bypass cut valve (606)
Fig. 24-34 Bypass cut valve Tightening torque N•m (lbf•ft) 98~120 (72~89)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
Fig. 24-34 Bypass cut valve No.
Parts
Q’ty
Tightening torque N•m (lbf•ft) 98~120 (72~89)
101 Plug
1
301 Plunger
1
102 O-ring
1
302 Spring
201 Poppet
1
202 Spring
1
69~78 (51~58)
24-35
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
101 Plug
1
301 Plunger
1
1
102 O-ring
1
302 Spring
1
401 Plug
1
201 Poppet
1
401 Plug
1
402 O-ring
1
202 Spring
1
402 O-ring
1
69~78 (51~58)
24-35
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(8) Swing shuttle valve cover (204)
(8) Swing shuttle valve cover (204)
Fig. 24-35 Swing shuttle valve cover Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
166 O-ring
1
202 Cover
1
541 Steel ball
1
Tightening torque N•m (lbf•ft)
Fig. 24-35 Swing shuttle valve cover
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
542 Seat
1
166 O-ring
1
25~29 (18~21)
554 Plug
1
202 Cover
1
7.9~9.8 (5.9~7.2)
555 Plug
1
541 Steel ball
1
24-36
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
542 Seat
1
25~29 (18~21)
554 Plug
1
7.9~9.8 (5.9~7.2)
555 Plug
1
24-36
24. COMPONENTS SYSTEM (9) Boost check valve (517)
24. COMPONENTS SYSTEM (9) Boost check valve (517)
104
104
107
107
102
102
101
101
Fig. 24-36 Boost check valve Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
101 Poppet
1
102 Poppet
1
Tightening torque N•m (lbf•ft) 20~29 (15~21) Loctite #262
24-37
Fig. 24-36 Boost check valve
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
104 Plug
1
101 Poppet
1
107 Spring
1
102 Poppet
1
Tightening torque N•m (lbf•ft) 20~29 (15~21) Loctite #262
24-37
No.
Parts
Q’ty
104 Plug
1
107 Spring
1
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.2.2.2
24.1.2.2.2
HYDRAULIC CIRCUIT DIAGRAM P1
T1
T2
HYDRAULIC CIRCUIT DIAGRAM P1
P2
CMR1 PL PTb
CMR2
PCb
PAL
CT2
Travel right
Travel left
AL BL
CP2
(T3)
CT1
PAr
PCa CP1
Br Ar PBr
T2
P2
PAL
CT2
Boom conflux P2 unload
Travel right
PAs
CP2
(T3) PCa
CP1 PB1 PBs
Dr
LCs
LCb
Swing
Boom
Pss
PAb
PAs
As Bs (ROD) Bb CRb
(ROD) Bb CRb
(HEAD) Ab
Arm 1
PAa1
PBb Aa (HEAD)
CRa
Aa (HEAD)
LCc
Bucket
PAc
(ROD) Bc (HEAD) Ac
PLc2
PAc
CRa
(ROD) Bc (HEAD) Ac
Ba (ROD)
Arm 2
Arm 1
PBb LCc
PCc PBc
PBa1
LCa
(HEAD) Ab PAa1
Bucket
Swing
As Bs
PBa1
LCa
Boom conflux P2 unload
CCb
Pss
PAb
Travel left
AL BL
CT1
PAr Br Ar PBr
PBs LCs
PBL
PCb
P1 unload
CCb
LCb
CMR2
Travel straight
PB1
Dr
Boom
PL PTb
PBL
Travel straight P1 unload
T1
CMR1
Ba (ROD) PCc PBc
LCAT2 LCo
LCAP2 PAa2
PAo
Option
Arm 2
LCAT2 LCo
LCAP2 PAa2
PAo
Ao Bo PBo
PBa2 MU PBp1
PBp2
(P3)
(P4)
PLc2
Ao Bo PBo
PBa2 MU PBp1
PBp2
(P3)
(P4)
Fig. 24-37 Hydraulic circuit diagram
Fig. 24-37 Hydraulic circuit diagram
24-38
24-38
Option
24. COMPONENTS SYSTEM 24.1.2.2.3
OPERATION
24. COMPONENTS SYSTEM 24.1.2.2.3
OPERATION
(1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
(1) In neutral position The hydraulic oil delivered by hydraulic pump P1 enters port P1 of control valve, and passes through unloading valve P1 (309), low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the operation of unloading valve is impossible due to failure of electric control system, because the by-pass cut valve (606) located on the downstream of center by-pass passage (52) opens, the hydraulic oil through hydraulic pump P1 port passes through travel straight spool (306), and then flows though the center by-pass passage (52) which passes through travel right, boom, bucket and arm 2 and the by-pass cut valve (606) on P1 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The hydraulic oil delivered by hydraulic pump P2 passes through unloading valve P2 (310), low pressure circuit (D) and boost check valve (517) and returns to the hydraulic tank through tank port T1 similarly to the hydraulic oil from hydraulic pump P1. And when the operation of unloading valve is impossible, because the by-pass cut valve (606) located on the downstream of center by-pass passage (55) opens, the hydraulic oil through hydraulic pump P2 port passes through main passage, and then flows though the center by-pass passage (55) which passes through travel left, swing, arm 1 and option and the by-pass cut valve (606) on P2 side, and flows into low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
Fig. 24-38 In neutral position
Fig. 24-38 In neutral position
24-39
24-39
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(2) Actuation in travel operation
(2) Actuation in travel operation
1) In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.
1) In travel independent operation On starting travel operation (forward) started, the hydraulic oil delivered by hydraulic pump P1 is fed into travel right motor, and the hydraulic oil delivered by hydraulic pump P2 is fed into travel left motor. The pilot pressure enters ports PAr and PAL, and the right and left travel spools (306) move rightward the force of springs (323)(324) and the secondary pressure of solenoid proportional valves [X1] and [X2] acts on ports PCb and PCa and switches unloading spools (309) (310). The hydraulic oil delivered by hydraulic pump P1 passes through travel straight spool (307) and flows into main circuit, and flows through between the perimeter of right travel spool (306) and casing and is fed into A side of right travel motor through port Ar. The hydraulic oil delivered by hydraulic pump P2 flows through between the perimeter of left travel spool (306) and casing and is fed into A side of left travel motor through port Ar similarly to the stream of hydraulic oil delivered by hydraulic pump P1. But in the meantime, the return oil from the B sides of left and right travel operations passes through between the perimeter of right and left travel spools (306) and casing through ports Br and BL and flows into low pressure circuit (D), boost check valve (517), and then returns to the hydraulic tank through tank port T1. On traveling reverse (at the time when the pilot pressure actuates on ports PBr and PBL of control valve), the actuation is similar to that in forward travel operation.
Fig. 24-39 In left reverse travel (at PBL is pressurized)
Fig. 24-39 In left reverse travel (at PBL is pressurized)
24-40
24-40
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.
2) In travel straight operation When actuator other than travel operation and the travel operation are operated simultaneously in the said item 1) "In travel independent operation" the pilot signal from the outside acts on port PTb and the travel straight spool (307) moves upward. With this operation, the hydraulic oil delivered by hydraulic pump P1 mainly flows from P2 to A and is used for each actuator, and the hydraulic oil delivered by hydraulic pump P2 mainly flows from P2 to B and into main passage, and is used for right and left travel operations as hydraulic oil realizing the actuator and travel simultaneous operation. (Travel straight function) At circuit (I) position, a part of hydraulic oil delivered by hydraulic oil P1 passes through circular notch on travel straight spool (307) and enters from P1 to B enabling the hydraulic oil to be supplied from actuator side to travel side. And at circuit (II) position, the circular notch on travel straight spool (307) closes and the pump line on the travel sides is independent from pump line on actuator.
Fig. 24-40 Movement of travel straight spool
Fig. 24-40 Movement of travel straight spool
24-41
24-41
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(3) Actuation in bucket operation
(3) Actuation in bucket operation
1) In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON)
1) In bucket digging operation On starting bucket digging operation, the pilot pressure enters port PAc, bucket spool (304) moves leftward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ac). In the meantime, the return oil from bucket cylinder rod side (R) passes through between the perimeter of bucket spool (304) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1. And when the flow rate of hydraulic oil delivered by hydraulic pump P1 with engine running in low idling is low, the pilot signal from the outside enters port PCc and piston (216) moves rightward. With this actuation, the maximum leftward stroke of bucket spool (304) is limited, consequently the area of passage between the perimeter of bucket spool (304) and casing minimizes. Consequently the flow rate of return oil from bucket cylinder rod side (R) reduces and bucket cylinder moving speed is limited preventing cavitation which may be occurred on bucket cylinder head side (H). (Stroke limiter ON)
53
53
216
216
PAc
PCc
PCc
PBc
Bc 321 322
PAc
304
(D)
Bc
Ac
LCc
321 322
511
(R)
PBc
(H)
304
(D)
Ac
LCc 511
(R)
(H)
Fig. 24-41 In bucket digging operation (Stroke limiter ON)
Fig. 24-41 In bucket digging operation (Stroke limiter ON)
24-42
24-42
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517). Downstream of boost check valve
2) In bucket dumping operation On starting bucket dumping operation, the pilot pressure enters port PBc and bucket spool (304) moves rightward the force of springs (321)(322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCb and switches unloading spool (309). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCc (511), and flows through between the perimeter of bucket spool (304) and casing through U-shaped passage, and supplied to bucket cylinder rod side (R) through port (Bc). In the meantime, the return oil from bucket cylinder head side (H) passes through between the perimeter of bucket spool (304) and casing and flows through low pressure circuit (D), and returns to the hydraulic tank through tank port T1. The return oil does not pass through boost check valve (517). Downstream of boost check valve
Fig. 24-42 In bucket dumping operation
Fig. 24-42 In bucket dumping operation
24-43
24-43
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(4) Boom
(4) Boom
1) In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309). And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spools (310). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab). In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.
1) In boom up operation On starting boom up operation, the pilot pressure enters port PAb and boom spool (301) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [XI] acts on port PCa and switches unloading spool (309). And the pilot pressure enters port PB1 and boom conflux spool (305) is switched against the force of springs (325) (326) and the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spools (310). The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and supplied to bucket cylinder head side (H) through port (Ab). In the meantime, the return oil from boom cylinder rod side (R) passes through between the perimeter of boom spool (301) and casing, flows through low pressure circuit (D) and boost check valve (517), and returns to the hydraulic tank through tank port T1.
Fig. 24-43 In boom up operation (Boom spool)
Fig. 24-43 In boom up operation (Boom spool)
24-44
24-44
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.
2) In boom up conflux operation The hydraulic oil delivered by hydraulic pump P2 passes through travel left spool and enters parallel passage (56), and pushes and opens load check valve CP2, and flows through between the perimeter of boom conflux spool (305) and casing from the A side of U-shaped passage, and pushes and opens conflux check valve CCb (511) and enters port Ab through conflux passage inside of casing and confluents the hydraulic oil from the hydraulic pump P1 side.
Fig. 24-44 In boom up conflux operation (Boom conflux spool)
Fig. 24-44 In boom up conflux operation (Boom conflux spool)
24-45
24-45
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
3) In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)
3) In boom down operation On starting boom down operation, the pilot pressure enters port PBb and boom spool (301) moves leftward against the force of springs (321) (322) and the secondary pressure of solenoid proportional valve [X1] acts on PCb and switches unloading spool (309). And simultaneously the spool of lock valve selector (211) is switched, and the poppet (514) is released because the spring chamber of lock valve poppet CRb (514) is connected to the drain circuit. The hydraulic oil delivered by hydraulic pump P1 flows into parallel passage (53), and pushes and opens load check valve LCb (511), and flows through between the perimeter of boom spool (301) and casing through U-shaped passage, and is supplied to boom cylinder rod side (R) through port (Bb). In the meantime, the return oil from boom cylinder head side (H) enters the control valve through port (Ab). Because the retention of lock valve poppet CRb (514) which is located on this side of boom spool (301) is released, the lock valve poppet (514) pushes and opens. And then the return oil enters BH chamber and passes through between the perimeter of boom spool (301) and casing, and flows through low pressure circuit (D) and boost check valve (517), and the returns to the hydraulic tank through tank port T1. And a part of the return oil flows into the inside of boom spool (301) through circular notch of boom spool (301). Since the return oil contains sufficient pressure with the self weight of boom, arm, etc. the return oil passes through inside passage of boom spool (301) and pushes and opens poppet (317) leftward as shown in the figure and flows through the circular notch, and then supplied to boom cylinder rod (R) side again through port Bb. (Boom recirculation function)
Fig. 24-45 In boom down operation
Fig. 24-45 In boom down operation
24-46
24-46
24. COMPONENTS SYSTEM (5) Arm operation
24. COMPONENTS SYSTEM (5) Arm operation
1) In arm out operation On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R). In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing. The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing through boost check valve (517).
1) In arm out operation On starting arm out operation, the pilot pressure enters ports PBa1 and PBa2, and arm 1 spool (302) moves rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). And the pilot pressure also enters PBa2, and arm 2 spool (308) is switched against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into AR chamber through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters U-shaped passage, and pushes and opens load check valve LCAP2 (515) provided with orifice, and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing, and enters AR chamber through casing inside passage (RR) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil opens lock valve poppet CRar (514) and is supplied to arm cylinder rod side (R). In the meantime, the return oil from arm cylinder head side (H) flows through between the perimeter of arm 1 spool (302) and casing and passes though low pressure circuit (D’) and casing inside passage (HH) and then flows into low pressure circuit (D’) through between the perimeter of arm 2 spool (308) and casing. The return oil in low pressure circuit (D’) returns to hydraulic tank through tank port T1 without passing through boost check valve (517).
Fig. 24-46 In arm out operation
Fig. 24-46 In arm out operation
24-47
24-47
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters Ushaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1. (R) AR 322 321 chamber 514 211 CRar 511 LCa Ba
(H)
2) In arm in operation (At light load: arm recirculation function) On starting arm in operation, the pilot pressure enters ports PAa1 and PLc2, and arm 1 spool (302) moves leftward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, since the spool of lock valve selector (211) is switched, the spring chamber of lock valve poppet CRar (514) is connected to the drain circuit and the retention of poppet (514) is released. And the pilot pressure enters PAa2 through solenoid proportional valve [XR], and arm2 spool (308) moves leftward against the force of springs (321) (328) and the secondary pressure of solenoid proportional valve [X1] acts on port PCb and switches unloading spools (309). But in light load operation, because the solenoid proportional valve [XR] actuates and arm 2 spool (308) stays in the position of circuit (I). The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCa (511), and flows into port (Aa) through between the perimeter of arm 1 spool (302) and casing through U-shaped passage. In the meantime, the hydraulic oil delivered by hydraulic pump P1 flows through center by-pass passage (52) and pushes and opens load check valve LCAT2 (511) and enters Ushaped passage, and also the oil from parallel passage (53) pushes and opens load check valve LCAP2 (515) provided with orifice and flows into U-shaped passage. And then the hydraulic oil flows through between the perimeter of arm 2 spool (308) and casing from U-shaped passage and enters port (Aa) through casing inside passage (HH) and confluences the hydraulic oil from hydraulic pump P2 side. The conflux hydraulic oil is supplied to arm cylinder head side (H) through port (Aa). In the meantime, the return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR), but because arm 2 spool (308) does not connect to low pressure passage (D) at circuit (I), the entire flow rate flows into arm 1 spool (302). The return oil from chamber AR passes through the perimeter of arm 1 spool (302) and casing, and flows through casing inside passage (RH) and is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In light load operation, since the return oil contains higher pressure than that of arm cylinder head side (H) with the self weight of arm, etc. the hydraulic oil inside of arm 2 spool (308) passes through check valve (317) and flows into casing inside passage (HH) and the supplied to arm cylinder head side (H) again. (Arm recirculation function) And a part of the return oil which was led to arm 2 spool (308) passes through check valve (319), and flows through boost check valve (517) through load pressure circuit (D) and returns to the hydraulic tank through tank port T1. (R) AR 322 321 chamber 514 211 CRar 511 LCa Ba
302
Aa
56 PAa1 Arm 1
Arm 2
RH
Aa
PBa1 LCAT2
LCAP2 P1
(a)
PBa2 53 MU
PAa1 Arm 1
To arm 1 spool Aa (HEAD) Ba (ROD) To pilot cut valve
(D) Arm 2
308319(D)511 LCAT2 LCAP2
RH (a)
PBa2 53 MU
328 321
LCAT2
LCAP2 P1 PBa2 Dr
PAa2 Dr
HH
PAa2 [XR]
Circuit (I) 317 515
RR 52
P1 (D') (D)
(D')
PBa2 Dr
PAa2 Dr
HH
PAa2 [XR]
328 321
P1 (D') (D)
(D') RR 52
302
56
PBa1
(D)
(H)
To arm 1 spool Aa (HEAD) Ba (ROD) To pilot cut valve
Circuit (I)
308319(D)511 LCAT2 LCAP2
317 515
Fig. 24-47 In arm in operation (At light load: arm recirculation function)
Fig. 24-47 In arm in operation (At light load: arm recirculation function)
24-48
24-48
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
3) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (รกU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.
3) In arm in operation (In heavy load operation) The arm recirculation function is effective in actuating arm cylinder quickly in light load operation, but in heavy load operation (work required large power); the function causes the power loss. This control valve selects the presence of recirculation function in light and heavy load operation with solenoid proportional valve [XR]. (Variable recirculation function) The flow path of hydraulic oil in heavy load operation, the path on the supply side to arm cylinder is the same as that in light load operation, differs from that of return oil. In heavy load operation, solenoid proportional valve [XR] actuates and arm 2 spool (308) is positioned to circuit (II). The return oil from arm cylinder rod side (R) enters the control valve through port (Ba). Because the retention of lock valve poppet CRar (514) which is located on this side of arm 1 spool (302) is released, the return oil pushes and opens lock valve poppet CRar (514) and enters AR chamber. The return oil in AR chamber is led to arm 2 spool (308) through arm 1 spool (302) and casing inside passage (RR). But because arm 2 spool (308) is connected to low pressure passage (D) at circuit (รกU), almost all the return oil passes through between the perimeter of arm 2 spool (308) and casing and flows through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through tank port T1. The return oil from AR chamber passes through between the perimeter of arm 1 spool (302) and casing and flows through casing inside passage (RH) and then is led to the inside of arm 2 spool (308) through circular notch (a) of arm 2 spool (308). In heavy load operation, since the pressure on arm cylinder head side (H) is higher than the rod side, the hydraulic oil in arm 2 spool (308) does not flow into casing inside passage (HH), but flows through check valve (319) and passes through boost check valve (517) through low pressure (D) and returns to the hydraulic tank through port T1.
(R) AR 322 321 chamber 514 211 CRar 511 LCa Ba
(H)
(R) AR 322 321 chamber 514 211 CRar 511 LCa Ba
302
Aa
56 PAa1
Arm 1 RH
LCAT2
LCAP2 P1
PAa1
Arm 1
To arm 1 spool Aa (HEAD)
PAa2 [XR] Ba
(D) RR 52 Arm 2
308 (D) 319 511 LCAT2 LCAP2
515
321
To arm 1 spool Aa (HEAD)
(ROD) To pilot cut valve
Circuit (II)
308 (D) 319 511 LCAT2 LCAP2
LCAP2 P1 PBa2 Dr
PAa2 [XR] Ba
MU 328
LCAT2
PAa2 Dr
HH
53
Circuit (II)
(D') (D)
(a)
To pilot cut valve
317
RH
PBa2
(ROD)
MU
P1
(D')
PBa2 Dr
(a) 53
321
(D') (D) PAa2 Dr
HH
PBa2
328
Aa
PBa1
P1
(D')
Arm 2
302
56
PBa1
(D) RR 52
(H)
515
317
Fig. 24-48 In arm in operation (In heavy load operation)
Fig. 24-48 In arm in operation (In heavy load operation)
24-49
24-49
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(6) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
(6) Swing operation On starting swing operation, the pilot pressure enters ports PAs or PBs, and swing spool (303) moves leftward or rightward against the force of springs (321) (322), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). At the same time, in the event that the pilot pressure acts on port PAs, the pilot pressure flows through shuttle valve inside of cover (204) through the inside passage and then is led to port Pss. When the pilot pressure acts on port PBs, the pilot pressure also flows through shuttle valve inside of cover (204) and then is led to port Pss. The hydraulic oil delivered by hydraulic pump P2 flows into parallel passage (56), pushes and opens load check valve LCs (511) and flows through between the perimeter of swing spool (303) and casing through U-shaped passage and is supplied to swing motor A side or B side through port (As) or (Bs). In the meantime, the return oil from swing motor A side or B side passes through between the perimeter of swing spool (303) and casing through port (Bs) or (As) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1.
Fig. 24-49 Swing operation
Fig. 24-49 Swing operation
24-50
24-50
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(7) Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above.
(7) Spool actuation for operation in option This spool is used to control the attachment in option like Nibbler (Crusher), etc. Where the pilot pressure acts on port PAo on operating the attachment in option, the pilot pressure enters ports PAo, and option spool (311) moves against the force of springs (323) (324), and simultaneously the secondary pressure of solenoid proportional valve [X2] acts on port PCa and switches unloading spool (310). The hydraulic oil delivered by hydraulic pump P2 flows through parallel passage (56) and pushes and opens load check valve LCo (511), and flows through between the perimeter of option spool (311) and casing through U-shaped passage and is supplied to actuator for attachment through port (Ao). In the meantime, the return oil from actuator for attachment swing passes through between the perimeter of option spool (311) and casing through port (Bo) and flows through low pressure circuit (D) and boost check valve (517), and then returns to the hydraulic tank through tank port T1. The operation where the pilot pressure acts on PBo port is the same as the above.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.
* The oil passage is branched toward the end side of control valve at the mid course from option spool (311) to port Ao, but when N&B (Nibbler and Breaker) selector valve is provided on the end side of control valve, this oil passage is used as passage to connect to N&B selector valve.
Fig. 24-50 Spool actuation for operation in option
Fig. 24-50 Spool actuation for operation in option
24-51
24-51
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(8) Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder.
(8) Lock valve operation The lock valve is housed in between each port of the control valve connected to arm cylinder rod side (R) and arm cylinder head side (H) and the arm spool and boom spool, and reduces the leaking due to holding pressure caused by each cylinder.
1) At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the Fig. 24-51 and restricts the leaking to the minimum.
1) At boom spool neutral position (Arm spool makes the same operation.) When boom spool (301) is set to neutral position, spool (511) of lock valve selector is held on the left side as shown in the figure. At this position, passages Sa and Sb are connected each other at the inside of bushing (541) and on the perimeter of spool (511). Therefore in spring chamber (RH) of lock valve poppet, the holding pressure receiving from boom cylinder head side (H) passes from passage Sa to bushing (541) spool (511) and is connected through passage Sb, consequently the lock valve poppet (514) is kept pressed the lower side as shown in the Fig. 24-51 and restricts the leaking to the minimum.
Fig. 24-51 Lock valve operation (At boom spool neutral position)
Fig. 24-51 Lock valve operation (At boom spool neutral position)
24-52
24-52
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) In boom down operation ((In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (321). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the Fig. 24-52 is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm-in operation, the operation is the same.
2) In boom down operation ((In arm in operation) Pilot pressure PBb for boom down operation acts on port PLc of lock valve selector, and the spool (511) moves rightward as shown in the Fig. 25-52. After the spool (511) was moved, orifice (a) of bushing (541) first closes and then passages Sa and Sb are blocked, and therefore the holding pressure receiving from boom cylinder head side (H) does not act on spring chamber (RH) of lock valve poppet (514). And after spool (511) was moved, the inside of bushing (541) is connected from port Dr to passage DR through spring chamber (321). With this actuation, spring chamber (RH) of lock valve poppet (514) is connected from orifice (b) of bushing (541) to drain passage Dr through passage Sb, and the force which pushes lock valve poppet (514) down as shown in the Fig. 24-52 is released. And since lock valve poppet (514) receives holding pressure from boom cylinder head side (H) to the pressure receiving section in ring type which is made up of guide diameter and seat diameter of lock valve poppet (514), lock valve poppet (514) is pushed upward and is open. The said operation, in boom down operation, is performed before making the opening (meter out opening) which is used to return the return oil from the boom cylinder head side of boom spool (301) to the tank open, the operation has no effect on the operability of boom down operation. In case of arm-in operation, the operation is the same.
Return oil from boom cylinder head
RH CHAMBER 514
Return oil from boom cylinder head
Lock valve selector BH CHAMBER
511
541
514
Lock valve selector BH CHAMBER
Sb CRb
RH CHAMBER 511
541
Sb PLc
Ab
CRb
Dr
(a)
A
(b)
PLc Sa Sb
A Sa
PLc
Ab
Dr
(a)
321 Dr
A
321
PLc Sa Sb
A
SECTION A-A
(b)
Sa
SECTION A-A
321
322
PBb
Dr
322
PBb
(D) 301
321 Dr
(D) Dr
301
Fig. 24-52 Lock valve selector operation (At boom down operation)
Fig. 24-52 Lock valve selector operation (At boom down operation)
24-53
24-53
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(9) By-pass cut valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D).
(9) By-pass cut valve This by-pass cut valve is located on the most downstream of center by-pass passage (52) on P1 side and center by-pass passage (55) on P2 side. And this by-pass cut valve controls the flow rate of hydraulic oil from each center by-pass passage to low pressure passage (D).
1) In normal operation On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot ports PBp1 and PBp2 of by-pass cut valve (606). This secondary pressure is the same as that actting on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310). The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101). The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52) and low pressure passage (D). Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
1) In normal operation On starting the engine, the secondary pressure of solenoid proportional valves [X1] and [X2] act on pilot ports PBp1 and PBp2 of by-pass cut valve (606). This secondary pressure is the same as that actting on pilot port PCb of P1 unloading spool (309) and pilot port PCa of P2 unloading spool (310). The following explains the by-pass cut valve on P1 side, the operation of by-pass cut valve on P2 side is the same. The secondary pressure of solenoid proportional valve [X1] enters PBp1 and plunger (301) moves downward against the force of spring (302). The taper section at the top end of plunger (301) is seated on the seat of plug (101), shutting off the spring chamber of poppet (201) and spring chamber (b) of plug (101). The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are disconnected, spring chamber (a) of poppet (201) is the same pressure as center by-pass passage (52) and poppet (201) is pushed the seat section of casing shutting off center by-pass passage (52) and low pressure passage (D). Consequently, in normal operation, center by-pass passage (52) is always disconnected from low pressure passage (D) and the hydraulic oil delivered by hydraulic pump P1 does not flow through center by-pass passage (52), but returns to the hydraulic tank through P1 unloading spool (309).
[X1]
[X1]
PBp1
PBp1
302
301
302
301
(b)
(b)
(C) Dr
(C) Dr 101
201 (a)
(D)
52
101
201 (a)
(D)
52
Fig. 24-53 By-pass cut valve (In normal operation)
Fig. 24-53 By-pass cut valve (In normal operation)
24-54
24-54
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) At the time when failure occurred When the electric system is failed and consequently the secondary pressure of solenoid proportional valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other. The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve (606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.
2) At the time when failure occurred When the electric system is failed and consequently the secondary pressure of solenoid proportional valves [X1] and [X2] is not produced, plunger (301) is moved upward by the force of spring (302). Since the taper section at the top end of plunger (301) is lifted up from the seat section of plug (101), spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other. The hydraulic oil from center by-pass passage (52) passes through the orifice of poppet (201) and enters spring chamber (a) of poppet (201). Because spring chamber (a) of poppet (201) and spring chamber (b) of plug (101) are connected each other, the hydraulic oil in spring chamber (a) of poppet (201) passes through from seat section of plug (101) to spring chamber (b) and flows into passage (Dr) through passage (c). Consequently the pressure in spring chamber (a) of poppet (201) lowers, poppet (201) receives the pressure of center by-pass passage (52) and is lifted up against the force of spring (202), and the hydraulic oil from center by-pass passage (52) flows into low pressure passage (D) through poppet (201) of by-pass cut valve (606). Therefore when the electric system is failed, P1 unloading spool (309) is shifted to the neutral position and the passage to low pressure passage (D) is cut off, but because center by-pass passage (52) is connected to low pressure passage (D) through by-pass cut valve (606), the abnormal rise of the pump pressure is prevented.
PBp1
PBp1
302
301
302
301
(b)
(C)
(b)
(C)
Dr
Dr 101
201
101
201
(a)
(a)
(D)
(D) 202
52
202
52
Fig. 24-54 By-pass cut valve (In condition of failure)
Fig. 24-54 By-pass cut valve (In condition of failure)
24-55
24-55
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(10)Boost check valve, By-pass check valve
(10)Boost check valve, By-pass check valve
1) Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage.
1) Boost check valve The boost check valve is located between low pressure passage (D) and tank port T1 and generates boost pressure necessary for the low pressure passage.
a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage. But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1.
a. In normal operation The hydraulic oil from low pressure passage (D) moves the boost check valve (517) upward against the force of spring (527), and returns to the hydraulic tank through tank port T1. At this time, the pressure generated by spring (527) is used as the boost pressure for the low pressure passage. But the return oil used for the arm out and bucket dumping operation does not pass through boost check valve (517), but returns from low pressure passage (D’) to hydraulic tank through tank port T1.
b. In make up operation When supplying to make up the flow rate through low pressure passage (D) after the swing operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D). When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient flow rate.
b. In make up operation When supplying to make up the flow rate through low pressure passage (D) after the swing operation is suspended, if the hydraulic oil quantity in low pressure passage (D) is not enough, the deficient hydraulic oil is made up from hydraulic tank into low pressure passage (D). When the deficient hydraulic oil in low pressure passage (D) is not sufficient, the pressure of low pressure passage (D) is lowered. If the pressure of low pressure passage (D) is lowered to the pressure at tank port T1, poppet (102) housed in boost check valve (517) receives the pressure at tank port T1 on the receiving section in ring type which is made up of guide diameter and seat diameter of poppet (102), and is pushed upward and opens, and the hydraulic oil flows from the hydraulic tank to low pressure passage (D) to make up the deficient flow rate.
Fig. 24-55 Boost check valve operation
Fig. 24-55 Boost check valve operation
24-56
24-56
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
2) By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.
2) By-pass check valve Even if the pressure at tank port T1 goes up due to the sudden change of return flow rate, the by-pass check valve actuates and prevents the pressure at tank port T1 from going up higher than the specified pressure, and consequently the oil cooler and filter located between tank port T1 and the hydraulic tank are protected from possible damage. When the pressure at tank port T1 goes up to the pressure added by spring (528), by-pass check valve (518) is pushed and opens against the force of spring (528), and the hydraulic oil in tank port T1 directly returns to the hydraulic tank through tank port T2.
527
527
528 (D')
T2
518
528 (D')
T2
T1 102
102
517
(D)
518 T1
517
(D)
Fig. 24-56 By-pass check valve operation
Fig. 24-56 By-pass check valve operation
24-57
24-57
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
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This page is blank for editing convenience.
24-58
24-58
24. COMPONENTS SYSTEM PILOT VALVE (ATT) OUTLINE
PILOT VALVE (ATT)
24.1.3.1
(1) Outside view
OUTLINE
(1) Outside view
Single operating angle Single operating angle (Port 2, 4) (Port 1, 3)
5-PF3/8 T=49.0 (36.1)
The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) when the lever is installed by means of spanner or the like. Then tighten the mating lock nut to 41 + 3 N.m (302.2 lbf.ft).
Single operating angle Single operating angle (Port 2, 4) (Port 1, 3) The adjust nut (opposing flats : 22) : Fix adjust nut (opposing flats : 22) when the lever is installed by means of spanner or the like. Then tighten the mating lock nut to 41 + 3 N.m (302.2 lbf.ft).
PF1/4 T=29.4 (21.7)
VIEW A
T=Tightening torque : N.m (lbf.ft)
PF1/4 T=29.4 (21.7)
VIEW A
YN30V00111F1
Part No.
Max. primary pressure
6.9 MPa (1000 psi)
Max. primary pressure
Approx. 1.9 kg (4.2 lbs)
Weight
SECONDARY PRESSURE
(145)1.0
1.0(0.74) 0.94(0.69)
(87)0.6
0 1.1 2 4 6 7 PUSH ROD STROKE (mm) 0
0
2.29(1.69)
2.0(1.5)
SECONDARY PRESSURE
1.0(0.74)
(145)1.0
5 10 15 19 Operating angle (deg.)
0.94(0.69)
(87)0.6
0
0 P
1
SINGLE OPERATING TORQUE
(290)2.0
0
3.0(2.2)
1.1
2 4 6 8 PUSH ROD STROKE (mm) 5 10 15 20 Operating angle (deg.)
9.4
25
0
PORT 2, 4
(580)4.0 Secondary pressure [MPa (psi)]
2.0(1.5)
(464)3.2
(435)3.0
Operation torque [N.m (lbf.ft)]
2.21(1.63)
(290)2.0
0
Secondary pressure [MPa (psi)]
3.0(2.2)
SINGLE OPERATING TORQUE
4.0(3.0)
(580)4.0
Operation torque [N.m (lbf.ft)]
Secondary pressure [MPa (psi)]
(464)3.2
PORT 1, 3 4.0(3.0)
(464)3.2
(435)3.0
3.0(2.2)
SINGLE OPERATING TORQUE
2.21(1.63)
(290)2.0
2.0(1.5)
SECONDARY PRESSURE
(145)1.0
1.0(0.74) 0.94(0.69)
(87)0.6
0
0 1.1 2 4 6 7 PUSH ROD STROKE (mm) 0
24-59
1
2.29(1.69)
2.0(1.5)
(290)2.0
SECONDARY PRESSURE
1.0(0.74)
(145)1.0
0.94(0.69)
(87)0.6
0
0
T
3 2 HYDRAULIC SYMBOL
24-59
3.0(2.2)
SINGLE OPERATING TORQUE
0 P
4
(464)3.2
(435)3.0
5 10 15 19 Operating angle (deg.)
T
3 2 HYDRAULIC SYMBOL
0
4.0(3.0)
(580)4.0
Operation torque [N.m (lbf.ft)]
PORT 2, 4 4.0(3.0)
(435)3.0
Approx. 1.9 kg (4.2 lbs)
Weight
A
PORT 1, 3 (580)4.0
20 L/min (5.3gal/min)
Rated flow
A
6.9 MPa (1000 psi) 5.0 MPa (725 psi)
Primary pressure
20 L/min (5.3gal/min)
Rated flow
Refer to the curve below
Operating torque
5.0 MPa (725 psi)
Primary pressure
PV48K2004
Model
Refer to the curve below
Operating torque
T=Tightening torque : N.m (lbf.ft)
YN30V00111F1
Part No.
PV48K2004
Model
5-PF3/8 T=49.0 (36.1)
Secondary pressure [MPa (psi)]
24.1.3.1
24.1.3
Operation torque [N.m (lbf.ft)]
24.1.3
24. COMPONENTS SYSTEM
4
1.1
2 4 6 8 PUSH ROD STROKE (mm) 5 10 15 20 Operating angle (deg.)
9.4
25
0
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.3.2
24.1.3.2
CONSTRUCTION
CONSTRUCTION
Apply Loctite #277
501
Apply Loctite #277
312
312
302
302
301
Apply grease on top section
212
Apply grease on rotating and sliding sections. Be careful the assembling direction
501 Apply grease on top section
212
213
151
*246
*218-2
211
214
211
214
*218-1
*218-1
216-2
216-1
216-2
216-1
241-2
241-1
241-2
241-1
201-2 Secondary pressure adjusting shim
201-2
201-1
217
Secondary pressure adjusting shim
221
101
201-1
217
221
101
PORT 1,3
PORT 2,4
No.
Name
Q’ty
Tightening torque N•m (lbf•ft)
PORT 1,3
PORT 2,4
Fig. 24-57 Pilot valve (ATT) Tightening torque N•m (lbf•ft)
Apply grease on rotating and sliding sections. Be careful the assembling direction
213
151
*246
*218-2
301
Fig. 24-57 Pilot valve (ATT)
No.
Name
Q’ty
Tightening torque N•m (lbf•ft)
No.
Name
Q’ty
Tightening torque N•m (lbf•ft)
No.
Name
Q’ty
101
Casing
1
*218-1 Seat
2
101
Casing
1
*218-1 Seat
2
151
Plate
1
*218-2 Seat
2
151
Plate
1
*218-2 Seat
2
201-1 Spool
2
201-2 Spool
221
Spring
4
201-1 Spool
2
2
241-1 Spring
2
201-2 Spool
221
Spring
4
2
241-1 Spring
2
211
Plug
4
241-2 Spring
2
211
Plug
4
241-2 Spring
2
212
Push rod
4
*246
Spring
4
212
Push rod
4
*246
Spring
4
213
Seal
4
301
Joint : M14
1
213
Seal
4
301
Joint : M14
1
214
O-ring : 1B P20
4
302
Circular plate
1
214
O-ring : 1B P20
4
302
Circular plate
1
312
Adjust nut : M14
1
216-1 Spring seat
2
312
Adjust nut : M14
1
501
Boots
1
216-2 Spring seat
2
501
Boots
1
216-1 Spring seat
2
216-2 Spring seat
2
217
Washer 2 (Shim)
47.1 (34.7) 68.6 (50.6)
4
Note) The parts marked * may not be equipped depending on valve type.
24-60
217
Washer 2 (Shim)
47.1 (34.7) 68.6 (50.6)
4
Note) The parts marked * may not be equipped depending on valve type.
24-60
24. COMPONENTS SYSTEM 24.1.3.3
OPERATION
24. COMPONENTS SYSTEM 24.1.3.3
(1) Lever in neutral (See Fig. 24-58) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)]. The output ports (2,4) connect with the T port. The result is that the output pressure is equal to the tank pressure.
OPERATION
(1) Lever in neutral (See Fig. 24-58) The action of spring (509) (for secondary pressure setting) that determines the output pressure of the pilot valve does not act upon spool (201). Therefore, spool (201) (for return) is pushed up by spring (221) [spring seat (216)]. The output ports (2,4) connect with the T port. The result is that the output pressure is equal to the tank pressure.
216 509
509
221
221
201
201 PORT (2,4)
PORT (1,3)
PORT (2,4)
Fig. 24-58 Lever in neutral (2) When the pilot lever is tilted (See Fig. 24-59 ) When the lever is tilted and the push rod (511) strokes, the spool (201) [spring seat (216)] moves downward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 ,4 to produce a pressure.
PORT (1,3)
Fig. 24-58 Lever in neutral (2) When the pilot lever is tilted (See Fig. 24-59 ) When the lever is tilted and the push rod (511) strokes, the spool (201) [spring seat (216)] moves downward to make the port P to connect with the port 2, 4, with the result that the oil of the pilot pump flows to the port 2 ,4 to produce a pressure.
Fig. 24-59 When the lever is tilted (3) Lever held (See Fig. 24-60) When the pressure at ports (2,4) rises to a level equivalent to the action of spring (509) that is set by tilting the lever, the hydraulic pressure balances the spring action. When the pressure of ports (2,4) rises above a set value, ports (2,4) and the P port close while ports (2,4) and the T port open. When the pressure at ports (2,4) falls below a set value, ports (2,4) and the P port open while ports (2,4) and the T port close. Thus the secondary pressure is kept constant.
Fig. 24-59 When the lever is tilted (3) Lever held (See Fig. 24-60) When the pressure at ports (2,4) rises to a level equivalent to the action of spring (509) that is set by tilting the lever, the hydraulic pressure balances the spring action. When the pressure of ports (2,4) rises above a set value, ports (2,4) and the P port close while ports (2,4) and the T port open. When the pressure at ports (2,4) falls below a set value, ports (2,4) and the P port open while ports (2,4) and the T port close. Thus the secondary pressure is kept constant.
Fig. 24-60 When the lever is held
24-61
216
Fig. 24-60 When the lever is held
24-61
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(4) Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod. This keeps the output pressure connected with the P port pressure. Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port.
(4) Operation in the area where the tilting angle of the lever is large. (varies with the model) If the lever is inclined beyond a certain angle on certain models, the top end of the spool contacts the bottom of the bore of the push rod. This keeps the output pressure connected with the P port pressure. Furthermore, on a model in which a spring seat and a spring are built in the push rod, the bottom of the bore of the push rod contacts the spring if the lever is turned beyond a certain angle. This causes the secondary pressure gradient to change by the spring action. Thereafter, the bottom of the bore of the push rod contacts the top end of the spring seat, keeping the output pressure connected with the P port.
24-62
24-62
24. COMPONENTS SYSTEM 24.1.4
PILOT VALVE (TRAVEL)
24.1.4.1
24.1.4
OUTLINE
OUTLINE
(1) Outside view
Port size
Tightening torque Port name N.m (lbf.ft)
PF3/8
30 (22)
PF1/4 16.7 (12.3)
Function
Port size
LH travel forward port
1
LH travel forward port
LH travel reverse port
2
LH travel reverse port
3
RH travel forward port
3
RH travel forward port
4
RH travel reverse port
4
RH travel reverse port
T
Tank port
T
Tank port
5
LH travel pressure sensor port
5
LH travel pressure sensor port
6
RH travel pressure sensor port
6
RH travel pressure sensor port
P
Pilot primary pressure port
P
Pilot primary pressure port
PF3/8
PF1/4 16.7 (12.3)
T
P
Specifications
Item
YN30V00105F1
YN30V00105F1
6TH6NRZ
Type
6TH6NRZ
Primary pressure
4.9MPa (711psi)
Primary pressure
4.9MPa (711psi)
Secondary pressure
0.54~2.35MPa (78~341 psi)
Secondary pressure
0.54~2.35MPa (78~341 psi)
Rated flow
25 L/min (6.6 gal/min)
Rated flow
25 L/min (6.6 gal/min)
Approx. 8kg (18 lbs)
Weight
Approx. 8kg (18 lbs)
Weight
1
(3) Performance characteristics Secondary pressure [MPa (psi)]
5
2 3 Hydraulic symbol
6
4
1
(3) Performance characteristics Secondary pressure [MPa (psi)]
Secondary pressure
2.35 + 0.15 (340 + 22)
2.35 + 0.15 (340 + 22)
0.54 + 0.1 (78 + 15) 0
0.54 + 0.1 (78 + 15) 0
1 30' 2 30'
11 30' 12 30'
Pedal angle (degree)
(4.7 + 0.5) 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9)
Operating torque
Operating torque Control diagram
[N.m (lbf.ft)]
24-63
T
Specifications
Part No.
[N.m (lbf.ft)]
30 (22)
(2) Specifications
Item
Operating torque
Function
2
P
(4.7 + 0.5) 6.4 + 0.64 7.7 + 0.77 (5.7 + 0.6) 12.7 + 1.27 (9.4 + 0.9)
Tightening torque Port name N.m (lbf.ft)
1
(2) Specifications
Type
PILOT VALVE (TRAVEL)
24.1.4.1
(1) Outside view
Part No.
24. COMPONENTS SYSTEM
1 30' 2 30'
Secondary pressure
11 30' 12 30'
Pedal angle (degree)
Operating torque Control diagram
24-63
5
2 3 Hydraulic symbol
6
4
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.4.2
24.1.4.2
Construction and operation
The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve. The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6). Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger (5). The dumper system is made up of plunger (8), orifice (9) and return spring (10). In stationary condition, the pedal is held in neutral position by return spring (10). In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for dumper system. The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the flow rate of hydraulic oil led through orifice (9).] Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3) first moves the control spool (2) downwards, and then closes the passage between control port and the return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it starts retaining the condition. The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring (3).
Construction and operation
The hydraulic remote control valve in TH6NR type is operated with directly-operated pressure-reducing valve. The pilot control equipment TH6NR in double foot pedal type is made up of the actuating section which is equipped with 2 foot supports (1), 4 pressure-reducing valves (11), 4 damper system (12) and body (6). Every pressure-reducing valve is made up of control spool (2), control spring (3), return spring (4) and plunger (5). The dumper system is made up of plunger (8), orifice (9) and return spring (10). In stationary condition, the pedal is held in neutral position by return spring (10). In operation, the foot pedal pushes the plunger (5) used for pressure-reducing valve and plunger (8) used for dumper system. The hydraulic oil fed into damper chamber is restricted in the orifice (9) by the pressure corresponding to the operating speed. [Similarly, when the foot pedal returns to the neutral position with the return spring, the hydraulic oil trapped in the damper chamber is forced out. Consequently the return speed is controlled by the flow rate of hydraulic oil led through orifice (9).] Simultaneously, the plunger (5) is pushed against return spring (4) and control spring (3). The control spring (3) first moves the control spool (2) downwards, and then closes the passage between control port and the return pipe to tank port (T). At the same time, the control port is connected to passage (7). When the control spool reaches to the position the force of control spring (3) balances the pressure of control port (1 or 2), it starts retaining the condition. The pressure of control port is proportional to the stroke of plunger (5) and the position of pedal (1) according to the mutual relations between the control spool (2) and control spring (3). The closed circuit pressure control makes proportional control of selector valve and high responsibility of hydraulic pump and motor possible in relation with the characteristics of foot pedal (1) position and control spring (3).
1
1
5
5
3
3 8
3 11
10 12
4
8
3 11
12
4
10
10
2
2 9
9 9
7
6
2 control ports 1-3
10
P line
control ports 2-4 T line
24-64
9 7
6
2 control ports 1-3
P line
control ports 2-4 T line
24-64
24. COMPONENTS SYSTEM 24.1.5 24.1.5.1
SWING MOTOR UNIT
24.1.5
SPECIFICATION
24.1.5.1
(1) General view Port size
Tightening torque N.m (lbf.ft)
A,B
Main port
PF3/4
167 (123)
DB
Drain port
PF3/8
74 (55)
M
Make-up port
PF3/4
167 (123)
PA,PB Pressure measuring port PF1/4 PG
SWING MOTOR UNIT SPECIFICATION
(1) General view
Port name
Symbol
24. COMPONENTS SYSTEM
36 (27)
Parking brake release port PF1/4
36 (27)
L
Gear oil level gauge
PT1/2
65 (48)
IP
Gear oil filling port
PT3/4
98 (72)
M
PB
L
THREAD FOR EYE BOLT 2-M10 DEPTH 18 RELIEF VALVE (B PORT SIDE)
B
(SH)
Port size
Tightening torque N.m (lbf.ft)
A,B
Main port
PF3/4
167 (123)
DB
Drain port
PF3/8
74 (55)
M
Make-up port
PF3/4
167 (123)
PA,PB Pressure measuring port PF1/4 PG IP
PG
36 (27)
Parking brake release port PF1/4
36 (27)
L
Gear oil level gauge
PT1/2
65 (48)
IP
Gear oil filling port
PT3/4
98 (72)
PB A,(B)
PG
IP PG RELIEF VALVE (A PORT SIDE)
DB
PA
PA ANTI-REACTION VALVE BLOCK M DB
DB
THREAD FOR EYE BOLT 2-M10 DEPTH 18
(SH)
A
PB A,(B)
PG
IP FILLING PORT PT3/4
L
RELIEF VALVE (B PORT SIDE)
B
DB
PA
M
PB
RELIEF VALVE (A PORT SIDE)
A
PG
Port name
Symbol
PG
PA ANTI-REACTION VALVE BLOCK M DB
IP FILLING PORT PT3/4
DB
M PA
M
PB
A
Grease fitting
B
PA
PB
A
Hydraulic diagram
Grease fitting
B
Hydraulic diagram
24-65
24-65
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(2) Specifications
(2) Specifications
Swing motor unit part No.
YN15V00036F2
Type
129.2 (7.88)
Working pressure
MPa (psi)
32.4 (4700)
Max. flow
L/min (gal/min)
220 (58)
Braking torque
N•m (lbf•ft)
655 (483)
Release pressure
MPa (psi)
2.5~5.0 (362~725)
Relief set pressure
MPa (psi)
Weight
kg (lbs)
Reduction unit
Hydraulic motor assy weight
3
M5X130CHB-10A-41C/295
Part No. Hydraulic motor
cm (in )
AntiType reaction valve Weight block
Total weight
YN15V00035F1 3
YN15V00036F2
Type
129.2 (7.88)
Working pressure
MPa (psi)
32.4 (4700)
Max. flow
L/min (gal/min)
220 (58)
Braking torque
N•m (lbf•ft)
655 (483)
Release pressure
MPa (psi)
2.5~5.0 (362~725)
29 (4205)
Relief set pressure
MPa (psi)
29 (4205)
49 (108)
Weight
kg (lbs)
49 (108)
2KAR6P72/240-712 kg (lbs)
2.5 (5.5)
kg (lbs)
51.5 (114)
Displacement
YN15V00035F1 cm (in )
AntiType reaction valve Weight block Hydraulic motor assy weight
3
3
2KAR6P72/240-712 kg (lbs)
2.5 (5.5)
kg (lbs)
51.5 (114)
Part No.
YN32W00022F1
Part No.
YN32W00022F1
Speed reduction type
Planetary 2-stage
Speed reduction type
Planetary 2-stage
Reduction ratio
15.38
Lubicate oil Lubicate oil volume
Gear oil SAE90 (API class GL-4 grade) L (gal)
3 (0.8)
Grease
Extreme pressure lithum base #2 grease
Grease volume
kg (lbs)
Approx. 1 (2.2)
Weight
kg (lbs)
145 (320)
kg (lbs)
Approx. 197 (434)
24-66
Reduction unit
Hydraulic motor
Part No. Displacement
Swing motor unit part No.
M5X130CHB-10A-41C/295
Total weight
Reduction ratio
15.38
Lubicate oil Lubicate oil volume
Gear oil SAE90 (API class GL-4 grade) L (gal)
3 (0.8)
Grease
Extreme pressure lithum base #2 grease
Grease volume
kg (lbs)
Approx. 1 (2.2)
Weight
kg (lbs)
145 (320)
kg (lbs)
Approx. 197 (434)
24-66
24. COMPONENTS SYSTEM 24.1.5.2
CONSTRUCTION
24. COMPONENTS SYSTEM 24.1.5.2
(1) Swing motor
CONSTRUCTION
(1) Swing motor 993
993
VALVE CASING SECTION
VALVE CASING SECTION
702 712
ANTI CAVITATION PLUNGER
Arrangement of brake spring
351 355
488
ANTI-REACTION VALVE BLOCK
401
052 151 303 162 171 161 985
163 A
985
444
984
131
Arrangement of brake spring
351
051 RELIEF VALVE
469
051-1
712
ANTI CAVITATION PLUNGER
355
051 RELIEF VALVE
469 488
702 712
051-1 ANTI-REACTION VALVE BLOCK
401
052 151 303 162 171 161 985
451
163
712
A
472
985
444
984
131
451
A
472
390 391 VIEW I
702
A
390 391 VIEW I
702
707
707
706
706 100
100
980
980 743 742
111
743
400-2 121 994
123 122
114 124 443
491
101
301
742
400-1 052
111
400-2 121
400 SECTION A-A
994
123 122
114 124 443
24-67
400-1
491
101
24-67
301
052
400 SECTION A-A
24. COMPONENTS SYSTEM Tightening torque No. N•m (lbf•ft) 177 (130)
24. COMPONENTS SYSTEM
Parts
051 Relief valve ; M33-P1.5 051-1 O-ring ; 1B G30
29 (21)
Tightening torque No. N•m (lbf•ft)
2
69 (51)
400
Parts Anti-reaction valve ; M22P1.5
Q’ty 2
Tightening torque No. N•m (lbf•ft) 177 (130)
400-1 O-ring ; 1B P20
2
052 Anti-reaction valve sub
1
400-2 Backup ring
2
Casing for anti-reaction valve
1
401 Socket bolt ; M20u45
4
100
431 (318)
Parts
051 Relief valve ; M33-P1.5
2
100
36 (27)
Q’ty
051-1 O-ring ; 1B G30
Q’ty
Tightening torque No. N•m (lbf•ft)
2
69 (51)
400
Parts Anti-reaction valve ; M22P1.5
Q’ty 2
2
400-1 O-ring ; 1B P20
2
052 Anti-reaction valve sub
1
400-2 Backup ring
2
Casing for anti-reaction valve
1
431 (318)
401 Socket bolt ; M20u45
4
101 Drive shaft
1
443 Roller bearing
1
101 Drive shaft
1
443 Roller bearing
1
111 Cylinder
1
444 Roller bearing
1
111 Cylinder
1
444 Roller bearing
1
114 Spring plate
1
451 Pin
2
114 Spring plate
1
451 Pin
2
121 Piston
9
469 ROMH plug; M30-P1.5
2
121 Piston
9
469 ROMH plug; M30-P1.5
2
122 Shoe
9
472 O-ring ; W1516,WG40
1
122 Shoe
9
472 O-ring ; W1516,WG40
1
123 Set plate
1
488 O-ring ; 1B P28
2
123 Set plate
1
488 O-ring ; 1B P28
2
124 Shoe plate
1
491 Oil seal
1
124 Shoe plate
1
491 Oil seal
1
131 Valve plate
1
702 Brake piston
1
131 Valve plate
1
702 Brake piston
1
151 Plug ; PF1/4
2
706 O-ring ; W1516,WG38
1
151 Plug ; PF1/4
2
706 O-ring ; W1516,WG38
1
161 O-ring ; 1B P11
2
707 O-ring ; W1516,WG41
1
161 O-ring ; 1B P11
2
707 O-ring ; W1516,WG41
1
162 O-ring ; 1B P12
2
712 Brake spring
18
162 O-ring ; 1B P12
2
712 Brake spring
18
163 O-ring ; 1B P6
2
742 Friction plate
3
163 O-ring ; 1B P6
2
742 Friction plate
3
171 Socket bolt ; M8u55
4
743 Separator plate
4
171 Socket bolt ; M8u55
4
743 Separator plate
4
301 Casing
1
0.9 (0.66)
980 Plug ; PF1/4
1
301 Casing
1
0.9 (0.66)
980 Plug ; PF1/4
1
303 Valve casing
1
1.7 (1.2)
984 Plug ; PF3/8
1
303 Valve casing
1
1.7 (1.2)
984 Plug ; PF3/8
1
351 Plunger
2
4.4 (3.2)
985 Plug ; PF3/4
3
351 Plunger
2
4.4 (3.2)
985 Plug ; PF3/4
3
355 Spring
2
65 (48)
993 Plug ; PT1/2
1
355 Spring
2
65 (48)
993 Plug ; PT1/2
1
390 Name plate
1
98 (72)
994 Plug ; PT3/4
1
390 Name plate
1
98 (72)
994 Plug ; PT3/4
1
391 Rivet
2
391 Rivet
2
24-68
334 (246)
36 (27)
29 (21)
24-68
334 (246)
24. COMPONENTS SYSTEM (2) Swing reduction unit
24. COMPONENTS SYSTEM (2) Swing reduction unit
Punch here 2 portions near hole to prevent item 22 (spring pin) coming out.
Be careful about installation direction of retaining ring.
Apply Three Bond #1360 or equivalent.
OIL FILLING PORT PT3/4
Apply Three Bond #1360 or equivalent.
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515.
Punch here 2 portions near hole to prevent item 22 (spring pin) coming out.
Be careful about installation direction of retaining ring.
LEVEL PORT PT1/2
Apply Loctite #515.
SURFACE OF LUBE OIL
SURFACE OF LUBE OIL
Be careful about installation direction of spring pin.
Be careful about installation direction of spring pin.
VIEW (II) (4 places) Apply Loctite #515.
VIEW (II) (4 places) Apply Loctite #515.
Be careful about installation direction of retaining ring.
Be careful about installation direction of retaining ring.
Drive this spring pin into 1mm lower than the surface of spider.
Apply Loctite #515.
Drive this spring pin into 1mm lower than the surface of spider.
Apply Loctite #515.
Install the filling port of this fitting toward motor side.
Install the filling port of this fitting toward motor side.
Tightening torque 69.1+4.4 N.m (51.0+3.2 lbf.ft) Apply seal tape or Loctite #577.
Tightening torque 69.1+4.4 N.m (51.0+3.2 lbf.ft) Apply seal tape or Loctite #577.
Fill up this space with grease.
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts
Fill up this space with grease.
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
1
Pinion shaft
1
17
Needle bearing
4
1
Pinion shaft
1
17
Needle bearing
4
2
#1 sungear
1
18
Washer
8
2
#1 sungear
1
18
Washer
8
3
#1 pinion
3
19
Retaining ring
1
3
#1 pinion
3
19
Retaining ring
1
4
#2 sungear
1
20
Retaining ring
1
4
#2 sungear
1
20
Retaining ring
1
5
#2 pinion
4
21
Sleeve
1
5
#2 pinion
4
21
Sleeve
1
6
Ring gear
1
22
Spring pin
4
6
Ring gear
1
22
Spring pin
4
7
Spider assy
1
23
Capscrew ; M14X135
11
7
Spider assy
1
23
Capscrew ; M14X135
11
8
Spider
1
24
Cap
2
8
Spider
1
24
Cap
2
9
Shaft
4
25
Tube L=112
1
9
Shaft
4
25
Tube L=112
1
10
Spherical bearing
1
26
Elbow
1
10
Spherical bearing
1
26
Elbow
1
11
Spherical bearing
1
27
Plug
1
11
Spherical bearing
1
27
Plug
1
12
Oil seal
1
28
Retaining ring
3
12
Oil seal
1
28
Retaining ring
3
13
Housing
1
30
Oil seal
1
13
Housing
1
30
Oil seal
1
15
Thrust Washer
6
31
Grease fitting
1
15
Thrust Washer
6
31
Grease fitting
1
16
Needle bearing
3
32
Relief fitting
1
16
Needle bearing
3
32
Relief fitting
1
24-69
181 (134)
69.1 (51)
24-69
181 (134)
69.1 (51)
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.5.3
24.1.5.3
24.1.5.3.1
OPERATION OPERATION OF HYDRAULIC MOTOR
24.1.5.3.1
If the high pressure oil flows into the cylinder through the inlet port (a) of valve plate (131), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction. The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft. The force F2 is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn so as to produce a rotating moment. The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil. If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction. Theoretical output torque T can be given by the following equation.
OPERATION OPERATION OF HYDRAULIC MOTOR
If the high pressure oil flows into the cylinder through the inlet port (a) of valve plate (131), as shown on the figure on the right, the hydraulic pressure acts upon piston (121) and creates force F in the axial direction. The force F may be divided into force F1 vertical to shoe plate (124) via shoe (122) and force F2 at right angles with the shaft. The force F2 is transmitted to cylinder block (111) via pistons (121) and causes drive shaft to turn so as to produce a rotating moment. The cylinder block (111) has nine pistons equally arranged. Rotating torque is transmitted to drive shaft by turns by pistons connected to inlet port of high pressure oil. If the oil supply and discharge directions are reversed, the drive shaft rotates in the opposite direction. Theoretical output torque T can be given by the following equation.
Fig. 24-61 Operation of hydraulic motor 24.1.5.3.2
VALVE CASING SECTION
Fig. 24-61 Operation of hydraulic motor 24.1.5.3.2
(1) (1)Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. The system has check plunger(351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.
VALVE CASING SECTION
(1) (1)Operation of anti-cavitation check plunger Since the system using this type of motor is not equipped with a valve having a counterbalance function, the motor is rotated beyond the oil feed rate in some cases. The system has check plunger(351) and sucks in deficient oil, in order to prevent cavitation from occurring due to oil deficiency.
Fig. 24-62 Operation of anti-cavitation check plunger
24-70
Fig. 24-62 Operation of anti-cavitation check plunger
24-70
24. COMPONENTS SYSTEM (2) Operation of relief valve
24. COMPONENTS SYSTEM (2) Operation of relief valve
1) Consider where the relief valve is pressurized. The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in Fig. 2463. The relief valve begins to operates when the hydraulic pressure that is determined by the product of the pressure-receiving area A1 of plunger(301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of the plunger(301) and the pressure Pg of chamber g. Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321) increases by this movement of the piston. As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. This process is explained in the following in the relationships between the movements of the components shown in (2) to (4) of Fig. 2464~Fig. 24-66and the relief pressure : a. Condition shown in Fig. 24-64. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301). The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1. This relationship is expressed as : P1uA1=FSP1+Pg1uA2 where FSP1 : primary set load value of spring (321) b. Condition shown in Fig. 24-65. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left. On that occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber. The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.
Fig. 24-63 Functional explanation of relief valve (1)
Fig. 24-64 Functional explanation of relief valve (2)
P R
Fig. 24-65 Functional explanation of relief valve (3)
P R
Fig. 24-66 Functional explanation of relief valve (4)
24-71
Fig. 24-67 Pressure boost characteristics
1) Consider where the relief valve is pressurized. The pressure at the P, R ports is equal to the tank pressure at the beginning, as shown in Fig. 2463. The relief valve begins to operates when the hydraulic pressure that is determined by the product of the pressure-receiving area A1 of plunger(301) and the pressure P balances the hydraulic pressure that is determined by the product of the pressure-receiving area A2 of the plunger(301) and the pressure Pg of chamber g. Thereafter, the pressure of chamber g rises and the piston 1 (302) begins to stroke. The load to spring (321) increases by this movement of the piston. As the result, the relief pressure P is raised and controlled in the pressure boost time t1 from P1 till Ps. This process is explained in the following in the relationships between the movements of the components shown in (2) to (4) of Fig. 2464~Fig. 24-66and the relief pressure : a. Condition shown in Fig. 24-64. If the P port of the relief valve is pressurized, pressure is built up in chamber g via the restrictor m of plunger (301). The hydraulic pressure acting on plunger (301) increases and when it balances the load Fsp of spring (321), the relief valve performs relieving action by the pressure P1. This relationship is expressed as : P1uA1=FSP1+Pg1uA2 where FSP1 : primary set load value of spring (321) b. Condition shown in Fig. 24-65. The pressure of chamber g acts upon the pressure-receiving area A3-A4 of piston 1 (302). When the hydraulic pressure rises above the load of spring (321), the piston 1 begins to move to the left. On that occasion, since the machine turns to the left while discharging the oil of chamber h arranged between piston 1 and adjust plug (401) into chamber g via orifice n provided in piston 1 (302), chamber h serves as a dumping chamber. The load of the spring increases slowly till piston 1 reaches the end of the adjust plug. The relief pressure P rises smoothly.
Fig. 24-63 Functional explanation of relief valve (1)
Fig. 24-64 Functional explanation of relief valve (2)
P R
Fig. 24-65 Functional explanation of relief valve (3)
P R
Fig. 24-66 Functional explanation of relief valve (4)
24-71
Fig. 24-67 Pressure boost characteristics
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
c. Condition shown in Fig. 24-66. The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes 1 to 3 above, the relief pressure changes as shown in Fig. 24-67.
c. Condition shown in Fig. 24-66. The machine does not travel to the left further when piston 1 (302) arrives at the end of adjust plug (401). Therefore, the relief valve keeps its normal relieving action whereby the relief pressure is held at P2. In the processes 1 to 3 above, the relief pressure changes as shown in Fig. 24-67.
2) Function when the relief valve pressure is reduced Let us consider the pressure of the P port is reduced. When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of Fig. 24-63.
2) Function when the relief valve pressure is reduced Let us consider the pressure of the P port is reduced. When the pressure at port P is reduced to zero, the pressure of chamber g falls to the tank pressure level. The result is that the plunger (301) which is now open moves to the left and is seated on seat (341). At the same time, the piston 1 (302) moves to the right by the action of spring (321) and returns to the condition of Fig. 24-63.
(3) Operation of anti-reaction valve
(3) Operation of anti-reaction valve
Fig. 24-68 Hydraulic circuit diagram for antireaction valve. 1) Neutral condition : Fig. 24-68 illustrates the relationship between the neutral condition of the anti-reaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side.
Fig. 24-68 Hydraulic circuit diagram for antireaction valve. 1) Neutral condition : Fig. 24-68 illustrates the relationship between the neutral condition of the anti-reaction valve and the hydraulic circuits. Now, let us consider a braking condition in which brake pressure generates on the AM port side.
L
L
k 322
k
313
321
311
322
Fig. 24-69 Neutral condition 2) When brake pressure occurs : If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left. Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left.
24-72
m
n
L
313
321
321
311
Fig. 24-69 Neutral condition
P=PS
322
313
311
Fig. 24-70 When brake pressure occurs
2) When brake pressure occurs : If pressure (P) generates at the AM port, it passes through the passage L, the hole on the shaft of seat (313) and the passage m of plunger (311) and is led to the n chamber. When the pressure P rises above a value (Ps) set by spring (321), plunger (311) compresses spring (321) and shifts it to the left. Seat (313) compresses weak spring (322) as pushed by plunger (311) and moves to the left.
24-72
m
n
P=PS L
322
313
321
311
Fig. 24-70 When brake pressure occurs
24. COMPONENTS SYSTEM 3) At anti-reaction action When inertia load stops moving (point Y Fig. 2472), brake pressure (P) tries to fall. When P<Ps, plunger (311) moves toward the right return side by the action of spring (321). Seat (313) tries to move to the right by the action of spring (322), but since chamber p provides damping action by orifice g, the return of the seat makes a time delay with regard to the return of the plunger. Consequently, seat t opens. This makes a passage connecting the AM port and BM ports or both ports of the hydraulic motor by way of otorok. The result is that the pressures at the AM and BM ports become equal (Pb), falling into the condition at point Z in Fig. 24-72. This prevents the hydraulic motor from swing shock by the closing pressure of the AM port. 24.1.5.3.3
p
t
P<PS L k 322 313
r
g
321
311
Fig. 24-71 At anti-reaction action P
Y
PS PB
X
Z
T
Fig. 24-72 Pressure change diagram of antireaction operation
OPERATION OF BRAKE SECTION
24. COMPONENTS SYSTEM 3) At anti-reaction action When inertia load stops moving (point Y Fig. 2472), brake pressure (P) tries to fall. When P<Ps, plunger (311) moves toward the right return side by the action of spring (321). Seat (313) tries to move to the right by the action of spring (322), but since chamber p provides damping action by orifice g, the return of the seat makes a time delay with regard to the return of the plunger. Consequently, seat t opens. This makes a passage connecting the AM port and BM ports or both ports of the hydraulic motor by way of otorok. The result is that the pressures at the AM and BM ports become equal (Pb), falling into the condition at point Z in Fig. 24-72. This prevents the hydraulic motor from swing shock by the closing pressure of the AM port. 24.1.5.3.3
The cylinder (111) is jointed by drive shaft (101) and a spline. Separator plate (743) is fixed in its circumferential direction by circular grooves provided in casing (301). Now, if the friction plate (742) splined to the outer circumference of the cylinder is pressed against casing (301) via separator plate (743) and brake piston (702) by the action of brake spring (712), frictional force is created between friction plate (742) and casing (301) and between separator plate (743) and brake piston (702). The frictional force bounds the drive shaft to brake the motor. In the meantime, when brake release pressure applied to the oil chamber formed between brake piston (702) and casing (301) overcomes the spring force, the brake is released as brake piston (702) moves till friction plate (742) is separated from casing (301).
712
702 712
743
702
742
111
301
24-73
743
742
301
101
Fig. 24-73 Operation of swing brake
p
t
P<PS L k 322 313
r
g
321
311
Fig. 24-71 At anti-reaction action P
Y
PS PB
X
Z
T
Fig. 24-72 Pressure change diagram of antireaction operation
OPERATION OF BRAKE SECTION
The cylinder (111) is jointed by drive shaft (101) and a spline. Separator plate (743) is fixed in its circumferential direction by circular grooves provided in casing (301). Now, if the friction plate (742) splined to the outer circumference of the cylinder is pressed against casing (301) via separator plate (743) and brake piston (702) by the action of brake spring (712), frictional force is created between friction plate (742) and casing (301) and between separator plate (743) and brake piston (702). The frictional force bounds the drive shaft to brake the motor. In the meantime, when brake release pressure applied to the oil chamber formed between brake piston (702) and casing (301) overcomes the spring force, the brake is released as brake piston (702) moves till friction plate (742) is separated from casing (301).
712
702 712
743
702
742
111
301
24-73
743
742
301
101
Fig. 24-73 Operation of swing brake
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.5.3.4
24.1.5.3.4
SWING REDUCTION UNIT
SWING REDUCTION UNIT
The swing reduction unit is used to reduce the rotating speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque). This swing speed reduction unit is equipped with planetary speed reducing mechanism. The planetary mechanism is made up of sun gear, planetary pinion, planetary shaft, spider and ring gear, as shown in Fig. 24-74.
The swing reduction unit is used to reduce the rotating speed which is transmitted by the hydraulic motor and to convert it to the strong turning force (torque). This swing speed reduction unit is equipped with planetary speed reducing mechanism. The planetary mechanism is made up of sun gear, planetary pinion, planetary shaft, spider and ring gear, as shown in Fig. 24-74.
For the operation of the 1st stage planetary, the hydraulic motor rotates #1 sun gear (2). Sun gear (2) is engaged with planetary pinion (3) and rotates, but since ring gear (6) is fixed, planetary pinion (3) revolves about sun gear (2) with the planetary shaft and spider (7).
For the operation of the 1st stage planetary, the hydraulic motor rotates #1 sun gear (2). Sun gear (2) is engaged with planetary pinion (3) and rotates, but since ring gear (6) is fixed, planetary pinion (3) revolves about sun gear (2) with the planetary shaft and spider (7).
Fig. 24-74 Planetary mechanism
The role of spider is to hold the planetary pinion and planetary shaft and transmits the power from the planetary pinion to the spider through the planetary shaft. The #1 spider (7) is linked with #2 sun gear (4) by the involute spline, and transmits the power to the 2nd stage planetary mechanism. For the operation of the 2nd stage planetary, the power is transmitted to sun gear (4)oplanetary pinion (5)ospider (8) similarly to the 1st stage. The #2 spider (8) is linked with pinion shaft (1) by the involute spline, and pinion shaft (1) is engaged with the swing gear fixed on the undercarriage (lower frame) and rotates.
The role of spider is to hold the planetary pinion and planetary shaft and transmits the power from the planetary pinion to the spider through the planetary shaft. The #1 spider (7) is linked with #2 sun gear (4) by the involute spline, and transmits the power to the 2nd stage planetary mechanism. For the operation of the 2nd stage planetary, the power is transmitted to sun gear (4)oplanetary pinion (5)ospider (8) similarly to the 1st stage. The #2 spider (8) is linked with pinion shaft (1) by the involute spline, and pinion shaft (1) is engaged with the swing gear fixed on the undercarriage (lower frame) and rotates.
Fig. 24-75 Function of reduction unit
24-74
Fig. 24-74 Planetary mechanism
Fig. 24-75 Function of reduction unit
24-74
24. COMPONENTS SYSTEM 24.1.6 24.1.6.1
TRAVEL MOTOR
24.1.6
SPECIFICATIONS
24.1.6.1.1
24. COMPONENTS SYSTEM
24.1.6.1
General view
TRAVEL MOTOR SPECIFICATIONS
24.1.6.1.1
General view
[A] PF 1 O-ring port
[A] PF 1 O-ring port
[D] PF 1/2 O-ring port
[B] PF 1 O-ring port
[P] PF 1/4 O-ring port
24.1.6.1.2
[D] PF 1/2 O-ring port
SPECIFICATIONS
24.1.6.1.2
Model
GM38VB
Item N.m (lbf.ft)
Rated output torque
min-1
Working revolution Reduction ratio Max. displacement
cm3/rev. (cu.in/rev)
Hydraulic Max. revolution motor
[B] PF 1 O-ring port
[P] PF 1/4 O-ring port
SPECIFICATIONS
Model
20100 / 34200 (14800 / 25200)
Rated output torque
48.2 / 29.6
Working revolution
1 / 55.617
Reduction ratio
78.8 / 130.8 (4.81 / 7.98)
Max. displacement
min-1
2680 / 1648
Hydraulic Max. revolution
Max. pressure
MPa (psi)
34.3 (4970)
motor
2 speed chamber pilot pressure
MPa (psi)
2.94~5.88 (426~853)
N.m (lbf.ft)
470 (347)
Parking
Breke torque
MPa (psi)
1.49 (216)
brake
Release pressure
Parking
Breke torque
brake
Release pressure
24-75
GM38VB
Item N.m (lbf.ft) min-1
20100 / 34200 (14800 / 25200) 48.2 / 29.6 1 / 55.617
cm3/rev. (cu.in/rev)
78.8 / 130.8 (4.81 / 7.98)
min-1
2680 / 1648
Max. pressure
MPa (psi)
34.3 (4970)
2 speed chamber pilot pressure
MPa (psi)
2.94~5.88 (426~853)
N.m (lbf.ft)
470 (347)
MPa (psi)
1.49 (216)
24-75
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.6.2
24.1.6.2
CONSTRUCTION
A
CONSTRUCTION
A
A
A
B
B
SECTION B-B
SECTION B-B
B
C
B
C
SECTION C-C
C
C
SECTION C-C SECTION A-A
24-76
SECTION A-A
24-76
24. COMPONENTS SYSTEM No.
Parts
Q’ty
No.
Parts Piston assy
Q’ty
1
Hub
1
1
3
Carrier [1]
1
161 •Piston
1
4
Sun gear[1]
1
163 •Seal
1
5
Planetary gear[1]
3
162 Steel ball
1
6
Carrier pin [1]
3
102 Shaft
1
7
Carrier [2]
1
8
Sun gear[2]
1
9
Planetary gear[2]
3
10 Carier pin[2]
No.
Parts
Q’ty
Rear flange assy
24. COMPONENTS SYSTEM No.
Parts
Q’ty
No.
Parts
1
Hub
1
3
Carrier [1]
1
161 •Piston
1
4
Sun gear[1]
1
163 •Seal
1
1
5
Planetary gear[1]
3
162 Steel ball
1
323 ••Spool
1
6
Carrier pin [1]
3
102 Shaft
1
326 ••Plug
2
7
Carrier [2]
1
1
327 ••Valve
2
8
Sun gear[2]
1
103 •Swash plate
1
328 ••Spring
2
9
Planetary gear[2]
3
3
167 •Pivot
2
331 ••O-ring
2
10 Carier pin[2]
11 Thrust washer[1]
6
107 Retainer plate
1
324 •Plug
2
12 Thrust washer[2]
6
108 Thrust ball
1
325 •Spring retainer
13 Thrust plate
1
109 Timing plate
1
14 Cover
1
112 Piston
15 Cupling
1
16 Parallel pin [1]
301 •Rear flange •Spool assy
1
Piston assy
Q’ty 1
No.
Parts
Q’ty
Rear flange assy 301 •Rear flange •Spool assy
1 1
323 ••Spool
1
326 ••Plug
2
1
327 ••Valve
2
103 •Swash plate
1
328 ••Spring
2
3
167 •Pivot
2
331 ••O-ring
2
11 Thrust washer[1]
6
107 Retainer plate
1
324 •Plug
2
2
12 Thrust washer[2]
6
108 Thrust ball
1
325 •Spring retainer
2
329 •O-ring
2
13 Thrust plate
1
109 Timing plate
1
329 •O-ring
2
1
330 •Spring
2
14 Cover
1
112 Piston
1
330 •Spring
2
113 Spring
8
363 •Spool
1
15 Cupling
1
113 Spring
8
363 •Spool
1
3
114 Spring
9
364 •Connector
1
16 Parallel pin [1]
3
114 Spring
9
364 •Connector
1
17 Parallel pin [2]
3
115 Friction plate
3
365 •Pin
1
17 Parallel pin [2]
3
115 Friction plate
3
365 •Pin
1
22 Lock washer
2
116 Separator plate
4
366 •Spring
1
22 Lock washer
2
116 Separator plate
4
366 •Spring
1
23 Shim
1
119 Shim
1~2
367 •Spring retainer
1
23 Shim
1
119 Shim
1~2
367 •Spring retainer
1
24 Angular bearing
2
132 Oil seal
1
368 •G (PF) 1/4 plug
2
24 Angular bearing
2
132 Oil seal
1
368 •G (PF) 1/4 plug
2
Swash plate kit
Swash plate kit
27
Needle-roller bearing with cage
3
133 C-ring for hose
1
369 •O-ring
2
27
Needle-roller bearing with cage
3
133 C-ring for hose
1
369 •O-ring
2
28
Needle-roller bearing with cage
3
135 D-ring
1
370 •G (PF) 3/8 plug
1
28
Needle-roller bearing with cage
3
135 D-ring
1
370 •G (PF) 3/8 plug
1
29 Floating seal
1
139 D-ring
1
371 •O-ring
2
29 Floating seal
1
139 D-ring
1
371 •O-ring
2
30 Plug
3
149 Tapered-roller bearing
1
372 •Orifice
2
30 Plug
3
149 Tapered-roller bearing
1
372 •Orifice
2
31 O-ring
3
150 Tapered-roller bearing
1
373 •Orifice spring
2
31 O-ring
3
150 Tapered-roller bearing
1
373 •Orifice spring
2
35 Socket bolt
18
374 •G (PF) 1/8 plug
5
35 Socket bolt
18
374 •G (PF) 1/8 plug
5
36 C-ring for hole
1
375 •O-ring
6
36 C-ring for hole
1
375 •O-ring
6
Relief valve assy 201 •Valve seat
2
376 •M6 orifice
3
Relief valve assy 201 •Valve seat
2
376 •M6 orifice
3
101 Spindle
1
202 •Valve
1
377 •Check valve
3
101 Spindle
1
202 •Valve
1
377 •Check valve
3
137 Socket plug
1
203 •Sleeve
1
378 •Check valve spring
3
137 Socket plug
1
203 •Sleeve
1
378 •Check valve spring
3
138 Expander
1
204 •Plug
1
379 •O-ring
1
138 Expander
1
204 •Plug
1
379 •O-ring
1
205 •Spring retainer
1
380 •O-ring
1
205 •Spring retainer
1
380 •O-ring
1
Piston kit
1
206 •Piston
1
341 •Parallel pin
1
Piston kit
1
206 •Piston
1
341 •Parallel pin
1
•Piston kit
9
207 •Spring
1
343 •Socket bolt
8
•Piston kit
9
207 •Spring
1
343 •Socket bolt
8
105 ••Piston
1
208 •Piston seal
1
345 •Socket plug
15
105 ••Piston
1
208 •Piston seal
1
345 •Socket plug
15
106 ••Shoe
1
209 •Piston seal
1
106 ••Shoe
1
209 •Piston seal
1
104 Cylinder block
1
210 •O-ring
1
104 Cylinder block
1
210 •O-ring
1
399 Name plate
1
24-77
399 Name plate
1
24-77
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.6.3
24.1.6.3
24.1.6.3.1
OPERATION HYDRAULIC MOTOR SECTION (BRAKE VALVE, PARKING BRAKE, HIGH-LOW 2 SPEED CHANGE MECHANISM)
(1) Function
24.1.6.3.1
OPERATION HYDRAULIC MOTOR SECTION (BRAKE VALVE, PARKING BRAKE, HIGH-LOW 2 SPEED CHANGE MECHANISM)
(1) Function
1) Function of hydraulic motor This hydraulic motor is swash plate type axial piston motor and functions to convert the force of oil pressure from the pump to rotary motions.
1) Function of hydraulic motor This hydraulic motor is swash plate type axial piston motor and functions to convert the force of oil pressure from the pump to rotary motions.
2) Function of brake valve
2) Function of brake valve
a. When trying to stop travel motor, this brake valve controls the force of inertia meant to rotate the travel motor with the inertia of body so as to stop the rotation with smooth braking.
a. When trying to stop travel motor, this brake valve controls the force of inertia meant to rotate the travel motor with the inertia of body so as to stop the rotation with smooth braking.
b. Function like check valve used to prevent cavitation of hydraulic motor.
b. Function like check valve used to prevent cavitation of hydraulic motor.
c. This brake valve opens the port used to releases the force of parking brake when the travel motor is operated and closes it when the travel motor stops.
c. This brake valve opens the port used to releases the force of parking brake when the travel motor is operated and closes it when the travel motor stops.
3) Function of parking brake This parking brake functions to prevent power shovel from runaway at the time when parking or stopping on slope and from slipping with the friction disk type braking mechanism, and is integrated into hydraulic motor section.
3) Function of parking brake This parking brake functions to prevent power shovel from runaway at the time when parking or stopping on slope and from slipping with the friction disk type braking mechanism, and is integrated into hydraulic motor section.
4) Function of high and low 2 speed change mechanism This mechanism varies the tilt angle of swash plate with functions of selector valve and control piston, and changes the speed in 2 steps, high speed-low torque rotation and low speed-high torque rotation.
4) Function of high and low 2 speed change mechanism This mechanism varies the tilt angle of swash plate with functions of selector valve and control piston, and changes the speed in 2 steps, high speed-low torque rotation and low speed-high torque rotation.
(2) Working principle and explanation of functions
(2) Working principle and explanation of functions
1) Hydraulic motor The hydraulic oil delivered by hydraulic pump enters rear flange (301) of GM motor, passes through brake valve and is led to the inside of cylinder block (104) through timing plate (109). This hydraulic oil flows through only one side of [Y1-Y2] linked from the upper dead point to the lower dead point after piston (105) stroke. The hydraulic oil flowed into one side of the cylinder block pushes each piston (4 or 5 pieces) and produces force (F kg=P MPauA cm2 ). This force acts on swash plate (103), and is separated into (F2, F3) because the swash plate is fixed having angle (a degree) to motor shaft (102) line. The radial force of the separated force (F3) generates torque (T= F3uri) to [Y1-Y2]. This combined force [T= (F3uri)] makes the cylinder block rotate using the piston as turning effort. This cylinder block transmits torque by making the motor shaft rotate because the motor shaft and spline are linked each other.
24-78
1) Hydraulic motor The hydraulic oil delivered by hydraulic pump enters rear flange (301) of GM motor, passes through brake valve and is led to the inside of cylinder block (104) through timing plate (109). This hydraulic oil flows through only one side of [Y1-Y2] linked from the upper dead point to the lower dead point after piston (105) stroke. The hydraulic oil flowed into one side of the cylinder block pushes each piston (4 or 5 pieces) and produces force (F kg=P MPauA cm2 ). This force acts on swash plate (103), and is separated into (F2, F3) because the swash plate is fixed having angle (a degree) to motor shaft (102) line. The radial force of the separated force (F3) generates torque (T= F3uri) to [Y1-Y2]. This combined force [T= (F3uri)] makes the cylinder block rotate using the piston as turning effort. This cylinder block transmits torque by making the motor shaft rotate because the motor shaft and spline are linked each other.
24-78
24. COMPONENTS SYSTEM 2) Brake valve
24. COMPONENTS SYSTEM 2) Brake valve
a. When starting operation and in operation When the hydraulic oil is supplied from the control valve to port A, the hydraulic oil opens valve (327) and enters port P2 on the suction side of hydraulic motor and tries to rotate the hydraulic motor. And simultaneously the hydraulic oil pushes and opens orifice (372) located on section X-X through passage (a) and enters chamber (e). This hydraulic oil acts on the end face of spool assembly (323A) and generates force, and slides the spool on the neutral condition slide rightward with the force of spring (330). At this time the hydraulic oil pushed out of chamber (f) passes through passage b1 and is discharged into port B through the orifice of throttle valve located on section Y-Y. Because the hydraulic oil flows through the orifice, the damper functions resulting in slow movement of spool assembly and consequently the shock caused when starting is reduced. When spool assembly slides, passage g is formed between rear flange (301) and spool assembly with the spool groove. Port PS located on the passage on the return side of hydraulic motor and port B on the other side are connected to this passage and consequently because the return oil returns to the control valve enabling the hydraulic motor to rotate. And because the spool assembly slides, the hydraulic oil enters port C1 through passage c. The hydraulic oil entered in port C1 actuates piston (112) of parking brake and releases parking brake force. (For details, see 24.1.6.3.1 (2)-3.) In the event that the hydraulic oil is supplied to port B, the right valve in pair opens, and the spool assembly moves leftward resulting in reverse rotation of hydraulic motor.
24-79
a. When starting operation and in operation When the hydraulic oil is supplied from the control valve to port A, the hydraulic oil opens valve (327) and enters port P2 on the suction side of hydraulic motor and tries to rotate the hydraulic motor. And simultaneously the hydraulic oil pushes and opens orifice (372) located on section X-X through passage (a) and enters chamber (e). This hydraulic oil acts on the end face of spool assembly (323A) and generates force, and slides the spool on the neutral condition slide rightward with the force of spring (330). At this time the hydraulic oil pushed out of chamber (f) passes through passage b1 and is discharged into port B through the orifice of throttle valve located on section Y-Y. Because the hydraulic oil flows through the orifice, the damper functions resulting in slow movement of spool assembly and consequently the shock caused when starting is reduced. When spool assembly slides, passage g is formed between rear flange (301) and spool assembly with the spool groove. Port PS located on the passage on the return side of hydraulic motor and port B on the other side are connected to this passage and consequently because the return oil returns to the control valve enabling the hydraulic motor to rotate. And because the spool assembly slides, the hydraulic oil enters port C1 through passage c. The hydraulic oil entered in port C1 actuates piston (112) of parking brake and releases parking brake force. (For details, see 24.1.6.3.1 (2)-3.) In the event that the hydraulic oil is supplied to port B, the right valve in pair opens, and the spool assembly moves leftward resulting in reverse rotation of hydraulic motor.
24-79
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
b. When slowing down the speed and in traveling down on slope On reducing the oil flow rate supplied from control valve to port A to slow down the travel speed, the pressure at port A and port P2 lowers because the force of inertia is applied to the hydraulic motor. Consequently the hydraulic pressure which is used to push spool assembly (323A) in chamber (e) is cancelled, and the spool assembly which has been shifted rightward tries to return to the neutral position with the force of spring (330). At this time passage g is restricted and the flow rate from port P3 to port B is limited. With this actuation, the pressure is generated on port P3 and the pressure gives the braking force to the hydraulic motor which is tried to continue rotating with the force of inertia to slow down the speed. When reaching to the target speed, the pressure at port A and port P2 rises and the spool assembly slides rightward to the former position and restores the operation in the former state. And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is discharged into port A side through passage b2. At the same time, the hydraulic oil passes through passage b and pushes and opens orifice (372) located on the section Y-Y and is supplied to chamber (f) to prevent cavitation generating in chamber (f). On traveling on slope, the force acts on hydraulic motor to increase the speed from the outside. Consequently the pressure at port A and port P2 lowers, like the actuation when slowing down the speed, the hydraulic pressure in chamber (e) is cancelled, and the spool assembly which has been shifted rightward tries to return to the neutral position. At this time passage g is restricted to limit the flow rate from port P3 to port B, and the pressure is generated on port P3 and the braking force is supplied to the hydraulic motor. This braking force resists the external force used to increase the speed of hydraulic motor, and prevents self traveling of hydraulic motor. And also in cases where hydraulic oil is supplied to port B, because the spool assembly which has been pushed leftward tries to return to the neutral position, the braking force is supplied to the hydraulic motor to prevent the speed from slowing down and self traveling.
24-80
b. When slowing down the speed and in traveling down on slope On reducing the oil flow rate supplied from control valve to port A to slow down the travel speed, the pressure at port A and port P2 lowers because the force of inertia is applied to the hydraulic motor. Consequently the hydraulic pressure which is used to push spool assembly (323A) in chamber (e) is cancelled, and the spool assembly which has been shifted rightward tries to return to the neutral position with the force of spring (330). At this time passage g is restricted and the flow rate from port P3 to port B is limited. With this actuation, the pressure is generated on port P3 and the pressure gives the braking force to the hydraulic motor which is tried to continue rotating with the force of inertia to slow down the speed. When reaching to the target speed, the pressure at port A and port P2 rises and the spool assembly slides rightward to the former position and restores the operation in the former state. And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is discharged into port A side through passage b2. At the same time, the hydraulic oil passes through passage b and pushes and opens orifice (372) located on the section Y-Y and is supplied to chamber (f) to prevent cavitation generating in chamber (f). On traveling on slope, the force acts on hydraulic motor to increase the speed from the outside. Consequently the pressure at port A and port P2 lowers, like the actuation when slowing down the speed, the hydraulic pressure in chamber (e) is cancelled, and the spool assembly which has been shifted rightward tries to return to the neutral position. At this time passage g is restricted to limit the flow rate from port P3 to port B, and the pressure is generated on port P3 and the braking force is supplied to the hydraulic motor. This braking force resists the external force used to increase the speed of hydraulic motor, and prevents self traveling of hydraulic motor. And also in cases where hydraulic oil is supplied to port B, because the spool assembly which has been pushed leftward tries to return to the neutral position, the braking force is supplied to the hydraulic motor to prevent the speed from slowing down and self traveling.
24-80
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
c. When parking and stopping When the hydraulic oil supplied from control valve to port A is cut off to stop operating, the pressure at port A and port P2 lowers. Consequently because the hydraulic pressure which has pushed spool assembly (323A) is cancelled, the spool assembly which has been shifted rightward returns to the neutral position with the force of spring (330). At this time passage g is closed and the flow rate from port P3 to port B is cut off. With this actuation, the pressure is generated on port P3 and gives the braking force to the hydraulic motor which is tried to continue rotating with the force of inertia to reduce the speed and to stop operating. Because relief valve (202A) is provided on between port P3 and port P2 and restricts the pressure generated on port P3, the hydraulic motor is protected from being broken by excess pressure and the shock caused by stopping motion is reduced. And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is discharged into port A side through passage b2. At the same time, the hydraulic oil passes through passage b and pushes and opens throttle valve (372) located on the section Y-Y and is supplied to chamber (f) to prevent cavitation generating in chamber (f). And when the spool assembly returns to the neutral position, port C1 and drain port D are connected with the passage provided on the spool assembly, and the hydraulic oil which is used to slide piston (112) of parking brake is discharged to drain port D through passage c. With this operation, the released parking brake actuates again and gets back the braking force.
c. When parking and stopping When the hydraulic oil supplied from control valve to port A is cut off to stop operating, the pressure at port A and port P2 lowers. Consequently because the hydraulic pressure which has pushed spool assembly (323A) is cancelled, the spool assembly which has been shifted rightward returns to the neutral position with the force of spring (330). At this time passage g is closed and the flow rate from port P3 to port B is cut off. With this actuation, the pressure is generated on port P3 and gives the braking force to the hydraulic motor which is tried to continue rotating with the force of inertia to reduce the speed and to stop operating. Because relief valve (202A) is provided on between port P3 and port P2 and restricts the pressure generated on port P3, the hydraulic motor is protected from being broken by excess pressure and the shock caused by stopping motion is reduced. And when the spool assembly tries to return to the neutral position, the hydraulic oil in chamber (e) is discharged into port A side through passage b2. At the same time, the hydraulic oil passes through passage b and pushes and opens throttle valve (372) located on the section Y-Y and is supplied to chamber (f) to prevent cavitation generating in chamber (f). And when the spool assembly returns to the neutral position, port C1 and drain port D are connected with the passage provided on the spool assembly, and the hydraulic oil which is used to slide piston (112) of parking brake is discharged to drain port D through passage c. With this operation, the released parking brake actuates again and gets back the braking force.
X
Y
X
Y
SECTION Y-Y
X
Y
24-81
SECTION Y-Y
X
Y
24-81
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
3) Parking brake
3) Parking brake
a. When starting operating and in operation The hydraulic oil is supplied from the brake valve to port C1 when starting operating and then flows into cylinder chamber (a), which is made up of spindle (101) and piston (112). When the pressure in cylinder chamber (a) increases until the force reaches over the force of spring (113), the piston moves toward rear flange (301) side. With the movement of this piston, the piston pushing force the separator plate (116) and the friction plate (115) is cancelled, consequently the movement of friction plate fitted on cylinder block (104) of hydraulic motor is in a free state and the braking force to the cylinder block is released.
24-82
a. When starting operating and in operation The hydraulic oil is supplied from the brake valve to port C1 when starting operating and then flows into cylinder chamber (a), which is made up of spindle (101) and piston (112). When the pressure in cylinder chamber (a) increases until the force reaches over the force of spring (113), the piston moves toward rear flange (301) side. With the movement of this piston, the piston pushing force the separator plate (116) and the friction plate (115) is cancelled, consequently the movement of friction plate fitted on cylinder block (104) of hydraulic motor is in a free state and the braking force to the cylinder block is released.
24-82
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
b. When parking and stopping When spool assembly (202) of brake valve returns to the neutral position after stopping the operation, port C1 is connected to the drain and the pressure in cylinder chamber (a) lowers. When the pressure in cylinder chamber (a) reduces lower than the force of spring (113), piston (112) is pushed back by the force of spring and pushes separator plate (116) and friction plate (115) in free state to spindle (101), and consequently frictional force is generated between the separator plate and friction plate and fixes cylinder block (104) which is linked to the friction plate with spline. With this operation, and also in cases where the force (torque) for rotation is applied to the traveling motor used for parking on slope and digging work from the outside, the motor is prevented rotating.
b. When parking and stopping When spool assembly (202) of brake valve returns to the neutral position after stopping the operation, port C1 is connected to the drain and the pressure in cylinder chamber (a) lowers. When the pressure in cylinder chamber (a) reduces lower than the force of spring (113), piston (112) is pushed back by the force of spring and pushes separator plate (116) and friction plate (115) in free state to spindle (101), and consequently frictional force is generated between the separator plate and friction plate and fixes cylinder block (104) which is linked to the friction plate with spline. With this operation, and also in cases where the force (torque) for rotation is applied to the traveling motor used for parking on slope and digging work from the outside, the motor is prevented rotating.
The torque of parking brake is set to 60% of output force of motor, if the external torque over the parking braking torque is applied to, the motor rotates.
The torque of parking brake is set to 60% of output force of motor, if the external torque over the parking braking torque is applied to, the motor rotates.
24-83
24-83
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
4) Explanation of auto 2-speed change mechanism a. In low speed operation When the pilot pressure is not supplied through port P, spool (383) is pushed rightward by the force of spring (366) and the hydraulic oil is blocked at port P1 and the hydraulic oil in chamber (h) is bled into drain port D through spool. Consequently swash plate (103) turns into the maximum tilt angle 1, and the cylinder capacity of hydraulic motor reaches to the maximum and the speed changes in the low speed operation.
24-84
4) Explanation of auto 2-speed change mechanism a. In low speed operation When the pilot pressure is not supplied through port P, spool (383) is pushed rightward by the force of spring (366) and the hydraulic oil is blocked at port P1 and the hydraulic oil in chamber (h) is bled into drain port D through spool. Consequently swash plate (103) turns into the maximum tilt angle 1, and the cylinder capacity of hydraulic motor reaches to the maximum and the speed changes in the low speed operation.
24-84
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
b. In high speed operation When the pilot pressure is supplied through port P, the force overcomes the force of spring (366) and the hydraulic oil pressure supplied into chamber (k) inside of spool through port A (or port B) and port C1 and spool (363) is pushed leftward. Consequently the hydraulic oil which is the highest of oil pressures at port P, P2 and P3 is led from port P1 to chamber (h) through the spool and port C1. Piston (161) is then pushed and held by the hydraulic pressure which has been led into chamber (h) until swash plate (103) strikes stopper face m provided on spindle (101). At this time the swash plate turns into the minimum tilt angle, 2, and the cylinder capacity of hydraulic motor reaches to the minimum and the speed changes in the high speed operation.
b. In high speed operation When the pilot pressure is supplied through port P, the force overcomes the force of spring (366) and the hydraulic oil pressure supplied into chamber (k) inside of spool through port A (or port B) and port C1 and spool (363) is pushed leftward. Consequently the hydraulic oil which is the highest of oil pressures at port P, P2 and P3 is led from port P1 to chamber (h) through the spool and port C1. Piston (161) is then pushed and held by the hydraulic pressure which has been led into chamber (h) until swash plate (103) strikes stopper face m provided on spindle (101). At this time the swash plate turns into the minimum tilt angle, 2, and the cylinder capacity of hydraulic motor reaches to the minimum and the speed changes in the high speed operation.
24-85
24-85
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
c. Auto change to low speed operation while operating it at high speed As the load increases during high speed operation, the hydraulic pressure at port A (or port B) increases, and the spool slides rightward when the force in combination of the force of spring (366) and the force in chamber (k) inside of spool (363) overcomes the pressure at port P. Consequently the hydraulic oil in chamber (h) which has pushed the swash plate to face m is fed into drain port D through spool (363). At this time the swash plate strikes spindle face n and turns into the maximum tilt angle 1, and the speed changes in low speed operation. And when the load lowers and the hydraulic pressure at port A (or port B) lowers, the cylinder capacity turns into the minimum and the high speed operation is restored by the operation in previous item "b. In high speed operation".
24-86
c. Auto change to low speed operation while operating it at high speed As the load increases during high speed operation, the hydraulic pressure at port A (or port B) increases, and the spool slides rightward when the force in combination of the force of spring (366) and the force in chamber (k) inside of spool (363) overcomes the pressure at port P. Consequently the hydraulic oil in chamber (h) which has pushed the swash plate to face m is fed into drain port D through spool (363). At this time the swash plate strikes spindle face n and turns into the maximum tilt angle 1, and the speed changes in low speed operation. And when the load lowers and the hydraulic pressure at port A (or port B) lowers, the cylinder capacity turns into the minimum and the high speed operation is restored by the operation in previous item "b. In high speed operation".
24-86
24. COMPONENTS SYSTEM 24.1.6.3.2
Reduction unit
24. COMPONENTS SYSTEM 24.1.6.3.2
Reduction unit
(1) Function This reduction unit is made up of 2 step planetary gearing (epicycle gear, sun and planet gear) mechanism and functions to reduce the high speed rotation supplied from hydraulic motor, to convert it into the low speed high torque and to obtain hub (1) (casing) rotation.
(1) Function This reduction unit is made up of 2 step planetary gearing (epicycle gear, sun and planet gear) mechanism and functions to reduce the high speed rotation supplied from hydraulic motor, to convert it into the low speed high torque and to obtain hub (1) (casing) rotation.
(2) Explanation of actuation The hydraulic motor axis rotation motion is transmitted to sun gear 1 (4) located on the 1st stage which is linked to shaft (102) with spline. At this time planetary gear 1 (5) on the 2nd stage stays in mesh with sun gear 1 (4), and planetary gear 1 (5) is engaged with hub (1) rotating on its axis and starts revolving. This revolution makes carrier (3) fixed to planetary gear 1 (5) and sun gear 2 (8) on the 2nd stage linked with the carrier rotate. This rotation is transmitted to hub (1) (ring gear) through planetary gear 2 (9) on the 2nd stage fixed on the column of spindle, and turns into output rotation motion of the reduction unit. (The rotation is transmitted by planetary gear1 (5) on the 1st stage, too.)
(2) Explanation of actuation The hydraulic motor axis rotation motion is transmitted to sun gear 1 (4) located on the 1st stage which is linked to shaft (102) with spline. At this time planetary gear 1 (5) on the 2nd stage stays in mesh with sun gear 1 (4), and planetary gear 1 (5) is engaged with hub (1) rotating on its axis and starts revolving. This revolution makes carrier (3) fixed to planetary gear 1 (5) and sun gear 2 (8) on the 2nd stage linked with the carrier rotate. This rotation is transmitted to hub (1) (ring gear) through planetary gear 2 (9) on the 2nd stage fixed on the column of spindle, and turns into output rotation motion of the reduction unit. (The rotation is transmitted by planetary gear1 (5) on the 1st stage, too.)
Column
Planetary gear 2
Planetary gear 1 Sun gear1
Shaft
Input
Out put Spindle
Column
Planetary gear 2
Planetary gear 1 Sun gear1
Shaft
Input
Out put Spindle
Sun gear 2
Sun gear 2 Carrier
Hub (Ring gear)
24-87
Carrier
Hub (Ring gear)
24-87
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
This page is blank for editing convenience.
This page is blank for editing convenience.
24-88
24-88
24. COMPONENTS SYSTEM 24.1.7
SWIVEL JOINT
24.1.7.1
24. COMPONENTS SYSTEM 24.1.7
GENERAL VIEW
SWIVEL JOINT
24.1.7.1
GENERAL VIEW
Fig. 24-76 General view of swivel joint
24.1.7.2
Fig. 24-76 General view of swivel joint
SPECIFICATIONS
24.1.7.2
SPECIFICATIONS
Item
Specifications
Item
Specifications
Assy parts No.
YN55V00053F1
Assy parts No.
YN55V00053F1
High pressure ports A, B, C, D
Working pressure Max. impact pressure Rated flow
34.3 MPa (4970 psi) 51.5 MPa (7470 psi) 255 L/min (67 gal/min)
High pressure ports A, B, C, D
Working pressure Max. impact pressure Rated flow
34.3 MPa (4970 psi) 51.5 MPa (7470 psi) 255 L/min (67 gal/min)
Low pressure ports E
Working pressure Rated flow
0.5 MPa (73 psi) 50 L/min (13 gal/min)
Low pressure ports E
Working pressure Rated flow
0.5 MPa (73 psi) 50 L/min (13 gal/min)
Low pressure ports F
Working pressure Rated flow
5 MPa (725 psi) 30 L/min (8 gal/min)
Low pressure ports F
Working pressure Rated flow
5 MPa (725 psi) 30 L/min (8 gal/min)
Revolution speed
15 min-1 (15 rpm)
A, B, C, D (Body) A, B, C, D (Stem) E F
Ports size
PF1 PF3/4 PF1/2 PF1/4
Revolution speed
15 min-1 (15 rpm)
A, B, C, D (Body) A, B, C, D (Stem) E F
Ports size
PF1 PF3/4 PF1/2 PF1/4
Length : L
368 mm (14.5")
Length : L
368 mm (14.5")
Weight
25 kg (245 lbs)
Weight
25 kg (245 lbs)
24-89
24-89
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.7.3
24.1.7.3
CONSTRUCTION
CONSTRUCTION
Fig. 24-77 Construction No.
Name
Q’ty
No.
Fig. 24-77 Construction Name
Q’ty
No.
Name
Q’ty
No.
Name
Q’ty
1
Body
1
7
O-ring(G95 1A)
1
1
Body
1
7
O-ring(G95 1A)
1
2
Stem
1
8
Capscrew (M8u20)
2
2
Stem
1
8
Capscrew (M8u20)
2
3
Thrust plate
1
9
Capscrew (M8u30)
3
3
Thrust plate
1
9
Capscrew (M8u30)
3
4
Cover
1
12
Plug
1
4
Cover
1
12
Plug
1
5
Seal
5
13
O-ring
1
5
Seal
5
13
O-ring
1
6
Seal
1
6
Seal
1
24.1.7.4
OPERATION
24.1.7.4
OPERATION
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal assy (6) and O-ring (7) that prevent external leaks. Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove. The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem (2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
The swivel joint consists mainly of body (1) and stem (2) that rotate mutually, thrust plate (3) preventing both components from falling off, cover (4) closing one side of body (1), seal (5) that partitions off the circuits and seal assy (6) and O-ring (7) that prevent external leaks. Four ports for the travel main circuits are provided on body (1) and stem (2). Further, four oil passing grooves are arranged in the inner surface of body (1), with seal (5) fixed above and below the circumferential groove. The body (1) and the stem (2) rotate mutually. The oil flowing in from body (1) or stem (2) keeps on flowing to stem (2) or body (1) past the circumferential groove between body (1) and stem (2) ; the oil flow is never shut off because of rotation. Further, an oil groove for lubrication that connects with the drain port is provided, in order to prevent the body (1) from seizure with the stem (2). This construction keeps on connecting the circuits between the swing bodies by means of a swivel joint.
24-90
24-90
24. COMPONENTS SYSTEM 24.1.8
CYLINDER
24.1.8.1
24. COMPONENTS SYSTEM 24.1.8
SPECIFICATIONS
CYLINDER
24.1.8.1
(1) General view
SPECIFICATIONS
(1) General view
ul
F
de
en
xt ly e
gth
n d le
ully
F
ed
act
r ret
B
th
g len
A de
en
ext ully
F
Part No. and Manufacturing No. Stamp position
n d le
F
B
e act
etr
r ully
gth
gth
n d le
A
Part No. and Manufacturing No. Stamp position
Fig. 24-78 General view of cylinder
Fig. 24-78 General view of cylinder
(2) Specifications
(2) Specifications Unit : mm (ft-in)
Use
Part No. of cylinder assy
Cylinder bore / Rod Dia.
Stroke
Center distance of pins Full extend B / Full retract A
Boom
YN01V00151F1
ø120 / ø85 (4.72" / 3.34")
1,355 (4-5)
3,199 / 1,844 (10-6 / 6-1)
Arm
YN01V00175F2
ø135 / ø95 (5.32" / 3.74")
1,558 (5-1)
3,637/ 2,079 (11-11 / 6-10)
Bucket
YN01V00153F2
ø120 / ø80 (4.72" / 3.15")
1,080 (3-7)
2,675 / 1,595 (8-9 / 5-3)
24-91
Cushion With cushion on rod side R-50 With cushion on both sides H-40,R-60 With cushion on rod side R-50
Unit : mm (ft-in)
Use
Part No. of cylinder assy
Cylinder bore / Rod Dia.
Stroke
Center distance of pins Full extend B / Full retract A
166 (366)
Boom
YN01V00151F1
ø120 / ø85 (4.72" / 3.34")
1,355 (4-5)
3,199 / 1,844 (10-6 / 6-1)
249 (549)
Arm
YN01V00175F2
ø135 / ø95 (5.32" / 3.74")
1,558 (5-1)
3,637/ 2,079 (11-11 / 6-10)
149 (329)
Bucket
YN01V00153F2
ø120 / ø80 (4.72" / 3.15")
1,080 (3-7)
2,675 / 1,595 (8-9 / 5-3)
Dry weight kg (lbs)
24-91
Cushion With cushion on rod side R-50 With cushion on both sides H-40,R-60 With cushion on rod side R-50
Dry weight kg (lbs) 166 (366) 249 (549) 149 (329)
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.1.8.2
24.1.8.2
CONSTRUCTION AND FUNCTION
24.1.8.2.1
CONSTRUCTION
CONSTRUCTION AND FUNCTION
24.1.8.2.1
(1) Boom cylinder
CONSTRUCTION
(1) Boom cylinder T= Tightening torque ; N.m (lbf.ft)
22
23
T=267 (197)
12
22
T= Tightening torque ; N.m (lbf.ft) 22
23
23
T=267 (197)
12
22
23 B 105 0 -0.5
105 0 -0.5
105 0 -0.5
105 0 -0.5
B
PS1/8
PS1/8
PT1/4
PT1/4
With hole (1 place)
DETAIL B
DETAIL C
With hole (1 place)
DETAIL B
DETAIL C
T=5460 (4027)
9
8
7
6
3
4
11
5
10
2
1
13
14
16
17
18
19
15
20
T=5460 (4027)
9
21
8
7
6
C
3
10
2
Slit
1
13
14
16
17
18
19
15
20
21
Slit
Orientation of cut off part of cushion bearing (13)
Fig. 24-79 Construction of boom cylinder
Fig. 24-79 Construction of boom cylinder
P/No YN01V00151F1 Parts
11
5
C
Orientation of cut off part of cushion bearing (13)
No.
4
P/No YN01V00151F1 Q’ty
No.
1
Cylinder tube
1
9
2
Piston rod
1
3
Rod cover
4
Parts Wiper ring
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
1
17 Buckup ring
2
1
Cylinder tube
1
9
10 O-ring
1
18 Slide ring
2
2
Piston rod
1
1
11 Buckup ring
1
19 Slide ring
2
3
Rod cover
Bushing
1
12 Socket bolt; M16u75
12
20 Set screw; M12
1
4
5
Snap ring
1
13 Cushion bearing
1
21 Steel ball
1
6
Buffer ring
1
14 Cushion seal
1
22 Pin bushing
7
U-ring
1
15 Piston
1
23 Wiper ring
8
Buckup ring
1
16 Seal ring
1
24-92
Parts Wiper ring
Q’ty
No.
Parts
Q’ty
1
17 Buckup ring
2
10 O-ring
1
18 Slide ring
2
1
11 Buckup ring
1
19 Slide ring
2
Bushing
1
12 Socket bolt; M16u75
12
20 Set screw; M12
1
5
Snap ring
1
13 Cushion bearing
1
21 Steel ball
1
2
6
Buffer ring
1
14 Cushion seal
1
22 Pin bushing
2
4
7
U-ring
1
15 Piston
1
23 Wiper ring
4
8
Buckup ring
1
16 Seal ring
1
24-92
24. COMPONENTS SYSTEM (2) Arm cylinder
(2) Arm cylinder T= Tightening torque ; N.m (lbf.ft)
T=367 (271)
12
26
27
24. COMPONENTS SYSTEM
27
26
12
26
27
T= Tightening torque ; N.m (lbf.ft)
T=367 (271)
27
26
B 120 0 -0.5
120 0 -0.5
120 0 -0.5
120 0 -0.5
B
PT1/4
PT1/4
PS1/8
PS1/8
With hole (1 place)
DETAIL B 9
8
7
6
3
4
5
11
10
2
1
DETAIL C 13
14
T=7890 (5820)
16
17
18
19
15
20
With hole (1 place)
DETAIL B
T=56.9 (42)
9
21
8
7
6
C
3
4
5
11
10
2
1
DETAIL C 13
14
T=7890 (5820)
16
17
18
19
Slit
21
Slit
Orientation of cut off part of cushion bearing (13)
25 23 22 24
25 23 22 24
Slit
Slit
Fig. 24-80 Construction of arm cylinder
Fig. 24-80 Construction of arm cylinder
P/No YN01V00175F2
Parts
20
C Orientation of cut off part of cushion bearing (13)
No.
15
T=56.9 (42)
P/No YN01V00175F2
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
1
Cylinder tube
1
10 O-ring
1
19 Slide ring
2
1
Cylinder tube
1
10 O-ring
1
19 Slide ring
2
2
Piston rod
1
11 Buckup ring
1
20 Set screw; M12
1
2
Piston rod
1
11 Buckup ring
1
20 Set screw; M12
1
3
Rod cover
1
12 Socket bolt; M18u80
12
21 Steel ball
1
3
Rod cover
1
12 Socket bolt; M18u80
12
21 Steel ball
1
4
Bushing
1
13 Cushion bearing
1
22 Cushion bearing
1
4
Bushing
1
13 Cushion bearing
1
22 Cushion bearing
1
5
Snap ring
1
14 Cushion seal
1
23 Cushion seal
1
5
Snap ring
1
14 Cushion seal
1
23 Cushion seal
1
6
Buffer ring
1
15 Piston
1
24 Stopper
2
6
Buffer ring
1
15 Piston
1
24 Stopper
2
7
U-ring
1
16 Seal ring
1
25 Snap ring
1
7
U-ring
1
16 Seal ring
1
25 Snap ring
1
8
Buckup ring
1
17 Buckup ring
2
26 Pin bushing
4
8
Buckup ring
1
17 Buckup ring
2
26 Pin bushing
4
9
Wiper ring
1
18 Slide ring
2
27 Wiper ring
4
9
Wiper ring
1
18 Slide ring
2
27 Wiper ring
4
24-93
24-93
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
(3) Bucket cylinder
(3) Bucket cylinder T= Tightening torque ; N.m (lbf.ft)
21
22
12
T=267 (197)
21
T= Tightening torque ; N.m (lbf.ft) 21
22
22
12
T=267 (197)
21
22 B 105 0 -0.5
105 0 -0.5
105 0 -0.5
105 0 -0.5
B
PS1/8
PS1/8
PS1/8
PS1/8
With hole (1 place)
DETAIL B
DETAIL C
T=6200 (4573)
9
8
7
6
3
4
5
11
10
2
1
13
With hole (1 place)
DETAIL B
15
16
17
18
14
T=6200 (4573)
T=56.9 (42)
19
9
20
8
7
6
3
C
4
5
11
10
2
13
15
16
17
18
14
19
20
Orientation of cut off part of cushion bearing (13)
Fig. 24-81 Construction of bucket cylinder
Fig. 24-81 Construction of bucket cylinder
P/No YN01V00153F2
Parts
1
T=56.9 (42)
C Orientation of cut off part of cushion bearing (13)
No.
DETAIL C
P/No YN01V00153F2
Q’ty
No.
1
Cylinder tube
1
9
2
Piston rod
1
3
Rod cover
4
Parts Wiper ring
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
1
17 Slide ring
2
1
Cylinder tube
1
9
10 O-ring
1
18 Slide ring
2
2
Piston rod
1
1
11 Buckup ring
1
19 Set screw; M12
1
3
Rod cover
Bushing
1
12 Socket bolt; M16u75
12
20 Steel ball
1
4
5
Snap ring
1
13 Cushion bearing
1
21 Pin bushing
4
6
Buffer ring
1
14 Piston
1
22 Wiper ring
4
7
U-ring
1
15 Seal ring
8
Buckup ring
1
16 Buckup ring
24-94
Parts Wiper ring
Q’ty
No.
Parts
Q’ty
1
17 Slide ring
2
10 O-ring
1
18 Slide ring
2
1
11 Buckup ring
1
19 Set screw; M12
1
Bushing
1
12 Socket bolt; M16u75
12
20 Steel ball
1
5
Snap ring
1
13 Cushion bearing
1
21 Pin bushing
4
6
Buffer ring
1
14 Piston
1
22 Wiper ring
4
1
7
U-ring
1
15 Seal ring
1
2
8
Buckup ring
1
16 Buckup ring
2
24-94
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-79) By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts. In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy (1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between piston rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy (1) and cylinder head (3)
HYDRAULIC CYLINDER CONSTRUCTION (See Fig. 24-79) By construction the hydraulic cylinder consists mainly of cylinder tube assy (1), piston rod assy (2) that takes out the motion of pistons reciprocating in the cylinder tube assy, and cylinder head (3) that serves as both a lid and a guide. Cylinder tube assy (1) is equipped with a pin mount (clevis) that connects piston rod assy (2) with other parts. In addition to these main components, seal ring (16) and back-up ring (17) are located between cylinder tube assy (1) and piston rod assy (2); buffer ring (6), U-ring (7) back-up ring (8) and wiper ring (9) are located between piston rod assy (2) and cylinder head (3); and an O-ring (10) and a back-up ring (11) are placed between cylinder tube assy (1) and cylinder head (3)
24.1.8.2.2
24.1.8.2.2
OPERATION
If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn causes the piston rod (2) to extend and retract.
Cushion bearing (13) Piston (15)
Rod (2) Head side
(1) Operation of cylinder with cushion 1) Cushion on rod side The cushion mechanism is provided to prevent the generation of shock when the moving speed of piston (15) is not reduced and strikes cylinder head (3). An oil in chamber "A" returns to the tank by passing through passage "B" at a fixed flow rate in a intermediate stroke state (Fig. 24-82) of pressing head side. Next, in a state of just before stroke end (Fig. 24-83), cushion ring (13) plunges into passage "B". At this time, an oil in chamber "A" passes clearance "D" and mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.
Chamber "A" Passege "B" Tank
Cushion stroke
OPERATION
If pressurized oil is fed alternatively to the oil inlet and outlet provided in the cylinder, force acts on the piston which in turn causes the piston rod (2) to extend and retract.
Rod side
Fig. 24-82 Cushion mechanism on the rod side
Fig. 24-83 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-84) This construction is similar to the one of cushion on rod side. In a state of intermediate stroke pressing rod side, an oil in chamber "A" returns to tank by passing through passage "B" at a fixed flow rate. Next, in a state of just before stroke end, cushion bearing (22) plunges into passage "B". At this time, the oil in chamber "A" flows only through clearance "D" and mouth gap "C" of cushion seal (23). So the returning oil volume drops suddenly and the piston movement slows down.
1) Cushion on rod side The cushion mechanism is provided to prevent the generation of shock when the moving speed of piston (15) is not reduced and strikes cylinder head (3). An oil in chamber "A" returns to the tank by passing through passage "B" at a fixed flow rate in a intermediate stroke state (Fig. 24-82) of pressing head side. Next, in a state of just before stroke end (Fig. 24-83), cushion ring (13) plunges into passage "B". At this time, an oil in chamber "A" passes clearance "D" and mouth gap "C", an oil flow volume returning to tank suddenly drops and the piston part movement slows down.
Chamber "A" Passege "B" Tank Rod (2)
Cushion stroke
Rod side
Rod cover (3)
Fig. 24-82 Cushion mechanism on the rod side
Fig. 24-83 Cushioning action on the rod side
2) Cushion on head side (See Fig. 24-84) This construction is similar to the one of cushion on rod side. In a state of intermediate stroke pressing rod side, an oil in chamber "A" returns to tank by passing through passage "B" at a fixed flow rate. Next, in a state of just before stroke end, cushion bearing (22) plunges into passage "B". At this time, the oil in chamber "A" flows only through clearance "D" and mouth gap "C" of cushion seal (23). So the returning oil volume drops suddenly and the piston movement slows down.
Fig. 24-84 Cushion mechanism on the head side
24-95
Piston (15)
Head side
(1) Operation of cylinder with cushion Rod cover (3)
Cushion bearing (13)
Fig. 24-84 Cushion mechanism on the head side
24-95
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
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24-96
24-96
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.2
ELECTRIC EQUIPMENT
24.2
ELECTRIC EQUIPMENT
24.2.1
ELECTRIC EQUIPMENT LIST
24.2.1
ELECTRIC EQUIPMENT LIST
Code
Name
Parts No. YN22E00214F1
C - 2 Gauge cluster
YN59S00021F2
C - 4 Air-con controler (including panel)
YN20M01468P1
C - 5 Engine coolant level controller
VHS834701230
C - 8 Engine controller
Parts No.
C - 2 Gauge cluster
YN59S00021F2
C - 4 Air-con controler (including panel)
YN20M01468P1
C - 5 Engine coolant level controller
VHS834701230
VH89661E0010
C - 8 Engine controller
VH89661E0010
D - 4 Diode
Harness accessory
D - 4 Diode
Harness accessory
D - 5 Diode
Accessory of relay box
D - 5 Diode
Accessory of relay box
n
D - 6 Diode
n
D - 9 Diode
n
D - 9 Diode
n
D - 10 Diode
n
D - 10 Diode
n
D - 12 Diode
n
D - 12 Diode
n
D - 13 Diode
n
D - 13 Diode
n
D - 14 Diode
n
D - 14 Diode
n
D - 16 Diode
n
D - 16 Diode
n
D - 17 Diode
n
D - 17 Diode
n
(D) Diode
D - 6 Diode
Harness accessory
D - 25 Diode
Harness accessory
E - 1 Fuse and Relay box
YN24E00016F2
E - 1 Fuse and Relay box
YN24E00016F2
E - 2 Alternator
VH270402192A
E - 2 Alternator
VH270402192A
E - 3 Hour meter
YT58S00006P1
E - 3 Hour meter
YT58S00006P1
E - 5 Horn high
LC53S00001D1
E - 5 Horn high
LC53S00001D1
E - 6 Horn low
LC53S00001D2
E - 6 Horn low
LC53S00001D2
E - 7 Tuner
—
E - 8 Speaker left
YN54S00006P1 n
E - 9 Speaker right E - 10 Receiver dryer
YN54S00041P1
E - 11 Air-con compressor
YX91V00001F1
E - 12 Battery
YN72S00016P1
E - 13 Travel alarm (For Middle east)
(E) Electric fittings
(E) Electric fittings
Name
YN22E00214F1
D - 25 Diode
(L) Light
Code C - 1 Mechatro controller
(C) Controller
C - 1 Mechatro controller
Group
E - 7 Tuner
—
E - 8 Speaker left
YN54S00006P1 n
E - 9 Speaker right E - 10 Receiver dryer
YN54S00041P1
E - 11 Air-con compressor
YX91V00001F1
E - 12 Battery
YN72S00016P1
YN53S00004F1
E - 13 Travel alarm (For Middle east)
YN53S00004F1
E - 14 Cigaratte lighter
YN81S00003P1
E - 14 Cigaratte lighter
YN81S00003P1
E - 15 Fusible link
LC13E01175S002
E - 15 Fusible link
LC13E01175S002
E - 22 DC-DC converter
YT77S00001P1
E - 22 DC-DC converter
YT77S00001P1
E - 23 12V socket
YN81S01002P1
E - 23 12V socket
YN81S01002P1
E - 27 Accel redundant volume
YN52S00052P1
E - 27 Accel redundant volume
YN52S00052P1
L - 1 Boom work light (LH)
YW80S00001F1
L - 2 Deck work light (RH)
YT80S00002F2
L - 5 Room light
YT80S00001P1
L - 6 Boom work light (RH)
YW80S00001F1
L - 7 Cab work light
—
24-97
(L) Light
(D) Diode
(C) Controller
Group
L - 1 Boom work light (LH)
YW80S00001F1
L - 2 Deck work light (RH)
YT80S00002F2
L - 5 Room light
YT80S00001P1
L - 6 Boom work light (RH)
YW80S00001F1
L - 7 Cab work light
—
24-97
Name
Parts No.
M - 1 Starter motor
VHS281002894A
M - 3 Wiper motor
YN53C00012F2
M - 4 Washer motor
YN54C00001F1
PSV - A
Arm 2 speed inverse propo. valve
PSV - B P2 unload propo. valve PSV - C Travel straight propo. valve
YN35V00049F1 (YN35V00047F1) Solenoid valve assy
P1 pump propo. valve
PSV - P2
P2 pump propo. valve
(YN10V00023F1) Pump
YN35V00052F1 n
Code
Name
Parts No.
M - 1 Starter motor
VHS281002894A
M - 3 Wiper motor
YN53C00012F2
M - 4 Washer motor
YN54C00001F1
PSV - A
Arm 2 speed inverse propo. valve
PSV - B P2 unload propo. valve PSV - C Travel straight propo. valve
YN35V00049F1 (YN35V00047F1) Solenoid valve assy
P1 pump propo. valve
PSV - P2
P2 pump propo. valve
n n
PSV - D P1 unload propo. valve PSV - P1
YN35V00048F1
(YN10V00023F1) Pump
YN35V00052F1 n
R - 1 Battery relay
YN24S00008F1
R - 1 Battery relay
YN24S00008F1
R - 2 Starter relay
VHS283001271A
R - 2 Starter relay
VHS283001271A
R - 3 Glow relay
VHS286201420A
R - 3 Glow relay
VHS286201420A
R - 4 Safety relay
YN24S00010P1
R - 4 Safety relay
YN24S00010P1
n
R - 5 Horn relay
n
R - 6 Working light relay
n
R - 6 Working light relay
n
R - 8 Travel alarm relay
n
R - 8 Travel alarm relay
n
R - 9 Cab working light relay
n
R - 9 Cab working light relay
n
R - 23 Auto idle stop relay 1
YN24S00010P1
R - 24 Auto idle stop relay 2
n
R - 25 Engine emergency stop relay
(R) Reray
R - 5 Horn relay
R - 23 Auto idle stop relay 1
YN24S00010P1
R - 24 Auto idle stop relay 2
n
n
R - 25 Engine emergency stop relay
n
R - 26 Lever lock relay
n
R - 26 Lever lock relay
n
R - 28 Alternator relay
n
R - 28 Alternator relay
n
R - 29 Wiper motor relay (Normal rotation)
YN24S00012P2
R - 29 Wiper motor relay (Normal rotation)
YN24S00012P2
R - 30 Wiper motor relay (Reverse rotation)
n
R - 30 Wiper motor relay (Reverse rotation)
n
R - 31 Wiper motor relay (Arc prevention)
n
R - 31 Wiper motor relay (Arc prevention)
n
R - 32 Washer motor relay
n
R - 32 Washer motor relay
n
SE - 1 Pressure sensor : Bucket digging
(SE) Sensor
n n
PSV - D P1 unload propo. valve PSV - P1
YN35V00048F1
Group (M) Motor
Code
LC52S00019P1
SE - 1 Pressure sensor : Bucket digging
LC52S00019P1
SE - 2 Pressure sensor : Bucket dump
n
SE - 2 Pressure sensor : Bucket dump
n
SE - 3 Pressure sensor : Boom up
n
SE - 3 Pressure sensor : Boom up
n
SE - 4 Pressure sensor : Boom down
n
SE - 4 Pressure sensor : Boom down
n
SE - 5 Pressure sensor : Swing
n
SE - 5 Pressure sensor : Swing
n
SE - 7 Pressure sensor : Arm in
n
SE - 7 Pressure sensor : Arm in
n
SE - 8 Pressure sensor : Arm out
n
SE - 8 Pressure sensor : Arm out
n
SE - 9 Pressure sensor : Travel RH
n
SE - 9 Pressure sensor : Travel RH
n
SE - 10 Pressure sensor : Travel LH
n
SE - 10 Pressure sensor : Travel LH
n
SE - 11 Pressure sensor : P2 OPT.
n
SE - 11 Pressure sensor : P2 OPT.
n
(SE) Sensor
(R) Reray
(P) Proportional solenoid valve
(M) Motor
Group
24. COMPONENTS SYSTEM
(P) Proportional solenoid valve
24. COMPONENTS SYSTEM
SE - 13 E/G speed sensor
VHS894101290A
SE - 13 E/G speed sensor
VHS894101290A
SE - 15 Fuel sensor
YN52S00045F1
SE - 15 Fuel sensor
YN52S00045F1
SE - 16 Accel potentiometer
YN52S00032P1
SE - 16 Accel potentiometer
YN52S00032P1
SE - 20 Pressure sensor : P1 OPT.
LC52S00019P1
SE - 20 Pressure sensor : P1 OPT.
LC52S00019P1
SE - 22 Pressure sensor : Pump P1
YN52S00048P1
SE - 22 Pressure sensor : Pump P1
YN52S00048P1
n
SE - 23 Pressure sensor : Pump P2
24-98
n
SE - 23 Pressure sensor : Pump P2
24-98
24. COMPONENTS SYSTEM Name
Parts No. YN35V00051F1
SV - 1 Swing parking brake SOL. SV - 2 Power boost SOL SV - 3 Two speed select SOL
(YN35V00047F1) Solenoid valve assy
YN35V00050F1 n n
SV - 4 Safety lock lever SOL
Group (SV) Solenoid
Code
Code
Name
Parts No. YN35V00051F1
SV - 1 Swing parking brake SOL. SV - 2 Power boost SOL SV - 3 Two speed select SOL
(YN35V00047F1) Solenoid valve assy
YN35V00050F1 n n
SV - 4 Safety lock lever SOL
SW - 1 Key switch
YN50S00026F1
SW - 1 Key switch
YN50S00026F1
SW - 4 Swing parking brake release switch
YN50S00047P1
SW - 4 Swing parking brake release switch
YN50S00047P1
SW - 5 Horn switch (RH)
YN50E00017P1
SW - 5 Horn switch (RH)
YN50E00017P1
SW - 7 E/G oil pressure switch
VHS835301471D
SW - 7 E/G oil pressure switch
VHS835301471D
SW - 8 Air filter clogging switch
YR11P00008S005
SW - 8 Air filter clogging switch
YR11P00008S005
SW - 10 Horn switch (LH)
YN50E00017P1
SW - 10 Horn switch (LH)
YN50E00017P1
SW - 11 Safety lock lever switch
YN50S00041F1
SW - 11 Safety lock lever switch
YN50S00041F1
SW - 13 Travel alarm switch (For Middle east)
YN50S00040DF
SW - 13 Travel alarm switch (For Middle east)
YN50S00040DF
SW - 15 Conflux/single select switch
YN50S00040DD
SW - 15 Conflux/single select switch
YN50S00040DD
SW - 17 Skylight wiper switch
YN50S00040D9
SW - 17 Skylight wiper switch
YN50S00040D9
SW - 19 Wiper interlock switch
YT50S00004P1
SW - 19 Wiper interlock switch
YT50S00004P1
SW - 20 Power boost switch (RH)
YN50E00017P1
SW - 20 Power boost switch (RH)
YN50E00017P1
n
SW - 21 Power boost switch (LH)
(SW) Switch
(SW) Switch
(SV) Solenoid
Group
24. COMPONENTS SYSTEM
n
SW - 21 Power boost switch (LH)
SW - 26 Cab work light switch
YN50S00040D4
SW - 26 Cab work light switch
YN50S00040D4
SW - 27 Coolant level switch
VHS834601510A
SW - 27 Coolant level switch
VHS834601510A
SW - 28 Water separator switch
VHS233002800A
SW - 28 Water separator switch
VHS233002800A
SW - 55 Boom work light switch
YN50S00040D1
SW - 55 Boom work light switch
YN50S00040D1
24-99
24-99
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
24.2.2
24.2.2
SPECIFICATION OF ELECTRIC EQIUPMENTS
File No. Name of part Part No. Use Applicable Machine C-1 Controller YN22E00214F1 Mechatro controller
Specification
Maker Rated voltage Weight
Description
Sinko Electric Co. Ltd DC24V 4.2 kg (9.3 lbs)
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
C-2 Controller YN59S00021F2 Gauge cluster
SPECIFICATION OF ELECTRIC EQIUPMENTS
File No. Name of part Part No. Use Applicable Machine C-1 Controller YN22E00214F1 Mechatro controller
Specification
Maker Rated voltage
Description
Sinko Electric Co. Ltd DC24V
Weight
4.2 kg (9.3 lbs)
Maker
Nippon seiki Co., Ltd
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Maker Rated voltage Insulation
Nippon seiki Co., Ltd DC24V More than 3M at 500V megger
C-2 Controller YN59S00021F2 Gauge cluster
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
C-4
C-4
Controller
Controller
YN20M01468P1
YN20M01468P1
Air-con Controller
Air-con Controller
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24-100
Rated voltage Insulation
DC24V More than 3M at 500V megger
24-100
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine C-5 Controller VHS834701230
Specification
Rated voltage Maker's (Hino) P/No.
Description
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine C-5
DC24V
Controller
S8347-01230
VHS834701230
Controller
Controller
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Rated voltage Maker's (Hino) P/No.
Description
DC24V S8347-01230
Hino P/No. : 82580-8050A (YAZAKI : 7382-1680) Hino P/No. : 82580-8870A (YAZAKI : 7283-1080)
Measurement circuit
Pin arrangement
C-8 Controller
Hino P/No. : 82580-8050A (YAZAKI : 7382-1680) Hino P/No. : 82580-8870A (YAZAKI : 7283-1080)
Measurement circuit
C-8 Controller
Maker's P/No.
89661-E0010 SOFTWARE P/No.89663-E0750
VH89661E0010
Engine controller
Rated voltage
24V (DC)
Engine controller
Rated voltage
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Working voltage
16~32V (DC)
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Working voltage
VH89661E0010
Pin arrangement
Operating voltage (at starter ON) Back-up source (reference value)
9~32V (DC) 5mA MAX (BAT=24V)
Maker's P/No.
Operating voltage (at starter ON) Back-up source (reference value)
89661-E0010 SOFTWARE P/No.89663-E0750 24V (DC) 16~32V (DC) 9~32V (DC) 5mA MAX (BAT=24V)
Connector 167 pins Male
24-101
Connector 167 pins Male
24-101
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine E-1 Fuse & Relay box
24. COMPONENTS SYSTEM
Specification
Description
File No. Name of part Part No. Use Applicable Machine E-1
Fuse capacity and circuit
Fuse & Relay box
YN24E00016F2
YN24E00016F2
Fuse & Relay
Fuse & Relay
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Description
Fuse capacity and circuit
Front side of machine
E-2
Front side of machine
E-2 M6 B terminal
Alternator VH270402192A
VH270402192A
Generator
Generator
YN11 - 45001 ~ YQ11 - 06001 ~
YN11 - 45001 ~ YQ11 - 06001 ~
Terminal arrangement VIEW A
E-3 Hour meter YT58S00006P1
Movement Operating voltage
4 pin connector (Water proof) Hino P/No. 82560-2390 (Eqivalent to sumitomo 6188-0631 )
Terminal arrangement VIEW A
Connector Hino P/No. 82560-8640 (Eqivalent to sumitomo 6189-0351)
Quarts 10~80VC
Service meter YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
M6 B terminal
Alternator
E-3 Hour meter GM terminal : 2962447 GM connector : 2962448
YT58S00006P1
Movement Operating voltage
4 pin connector (Water proof) Hino P/No. 82560-2390 (Eqivalent to sumitomo 6188-0631 ) Connector Hino P/No. 82560-8640 (Eqivalent to sumitomo 6189-0351)
Quarts 10~80VC
Service meter YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24-102
24-102
GM terminal : 2962447 GM connector : 2962448
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine E - 5, 6 Horn LC53S0001D1 (High) LC53S0001D2 (Low) Warning sound YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Rated voltage Operating voltage range
Sound level Basic frequency
File No. Name of part Part No. Use Applicable Machine
Description
Bottom L : Low sound
Type
H : High sound STAMP
DC24V
24. COMPONENTS SYSTEM
DC20~30V 113+5dB(A)/2m 420+20Hz high sound 350+20Hz low sound
E - 5, 6 Horn LC53S0001D1 (High) LC53S0001D2 (Low) Warning sound
Insulation resistance More than 3M /DC500V
o 8.5
E - 8, 9
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Speaker
Speaker YN54S00006P1
Radio
Radio
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Receiver dryer YN54S00041P1 Air-con YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Description
Bottom L : Low sound
Type Rated voltage Operating voltage range
Sound level Basic frequency
H : High sound STAMP
DC24V DC20~30V 113+5dB(A)/2m 420+20Hz high sound 350+20Hz low sound
Insulation resistance More than 3M /DC500V
o 8.5
E - 8, 9
YN54S00006P1
E - 10
Specification
Maker Airtight test pressure
3.5MPa (508 psi)
Pressure proof test pressure
5.3MPa (769 psi)
Breaking test pressure Desiccant moisture adsorption capability
9.8MPa (1420 psi)
Refrigerant Inner volume/Desiccant
E - 10
Sanden Corp.
Receiver dryer YN54S00041P1 Outlet (To unit)
17% or over than the weight of desiccant (Include initial absorption 2%)
HFC-134a 578cm3/300g
24-103
Inlet (From condenser)
Air-con YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Maker Airtight test pressure
Sanden Corp. 3.5MPa (508 psi)
Pressure proof test pressure
5.3MPa (769 psi)
Breaking test pressure Desiccant moisture adsorption capability
9.8MPa (1420 psi)
Refrigerant Inner volume/Desiccant
Outlet (To unit)
17% or over than the weight of desiccant (Include initial absorption 2%)
HFC-134a 578cm3/300g
24-103
Inlet (From condenser)
24. COMPONENTS SYSTEM
E - 11
Air-con compressor
Air-con compressor
YX91V00001F1
YX91V00001F1
Air-con
Air-con
YX03 - 01601 ~ YX04 - 01773 ~ YX05 - 02001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YX03 - 01601 ~ YX04 - 01773 ~ YX05 - 02001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
112Ah
Power
Approx. 33kg (72.8 lbs) Negative terminal
17.9 (0.705")
500 (19.69")
24-104
Voltage Capacity (5HR) Weight (Incl. fluid)
145F51 12V 112Ah Approx. 33kg (72.8 lbs) Negative terminal
19.5 (0.768")
17.9 (0.705")
180 (7.09")
502 (19.76")
179 (7.05")
500 (19.69")
24-104
Positive terminal
19.5 (0.768")
180 (7.09")
255 (10")
502 (19.76")
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Positive terminal
Type
17 (0.67")
Weight (Incl. fluid)
Taper
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Capacity (5HR)
YN72S00016P1
17 (0.67")
Power
Battery
12V
Taper
YN72S00016P1
Voltage
E - 12
145F51
255 (10")
Battery
Type
210 (8.27")
E - 12
Description
179 (7.05")
17 (0.67")
E - 11
Specification
Taper
Description
Taper
Specification
File No. Name of part Part No. Use Applicable Machine
210 (8.27")
File No. Name of part Part No. Use Applicable Machine
17 (0.67")
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine E - 13 Alarm YN53S00004F1
Specification
Model Rated voltage
Description
BA3111A DC 12V~36V
Travel alarm (Middle east)
Housing : 174354-2 Terminal : 171661-1
GND AV 0.5 Black
File No. Name of part Part No. Use Applicable Machine E - 13 Alarm
Power AV 0.5 Red / Green AMP Econoseal J series Mark II water-proof Harness seal : 172888-2 Retainer : 1-174355-1
VIEW A
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24. COMPONENTS SYSTEM
YN53S00004F1
Vinyl tube
Cigarette lighter
Cigarette lighter
YN81S00003P1
YN81S00003P1
Cigarette lighter
Cigarette lighter
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
E - 15
E - 15
Fusible link
Fusible link
LC13E01175S002
LC13E01175S002
Fuse
Fuse
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YT77S00001P1 DC24VoDC12V YN11 - 45001 ~ YQ11 - 06001 ~
E - 22
DC 24V
Input voltage Output voltage
DC 12V
Output current
2.5A Max
Ground
Negative
DC-DC converter YT77S00001P1 DC24VoDC12V YV WG
YB OL B
Fix the wire with tape HOUSING YAZAKI 7122-2262 TERMINAL YAZAKI 7114-2020 VIEW A
24-105
Rated voltage
A
YN11 - 45001 ~ YQ11 - 06001 ~
Description
BA3111A DC 12V~36V Housing : 174354-2 Terminal : 171661-1
GND AV 0.5 Black Power AV 0.5 Red / Green AMP Econoseal J series Mark II water-proof Harness seal : 172888-2 Retainer : 1-174355-1
VIEW A
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
E - 14
E - 22
Model
Travel alarm (Middle east)
E - 14
DC-DC converter
Specification
Vinyl tube
DC 24V
Input voltage Output voltage
DC 12V
Output current
2.5A Max
Ground
Negative
YV WG
YB OL B
Fix the wire with tape HOUSING YAZAKI 7122-2262 TERMINAL YAZAKI 7114-2020 VIEW A
24-105
A
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
File No. Name of part Part No. Use Applicable Machine E - 23 12V socket YN81S00001P1 Power socket
Specification
File No. Name of part Part No. Use Applicable Machine
Description
Power supply
For 12V
Max. current
Less than 10A
E - 23 12V socket YN81S00001P1
Insulation resistance More than 10M /500v megger
YN11 - 45001 ~ YQ11 - 06001 ~
Power socket
Specification
Power supply
For 12V
Max. current
Less than 10A
Insulation resistance More than 10M /500v megger
YN11 - 45001 ~ YQ11 - 06001 ~
GROUND TERMINAL
GROUND TERMINAL
Open and shut direction
POSITIVE TERMINAL
Accel redundant volume YN52S00052P1
Rated voltage
980-10760
E - 27
Resistance 2
DC 5V
Accel redundant volume
Resistance 2 TOCOS Parts E-27 RA30YME20FB202
YN52S00052P1
Accel redundant volume
Clip Adhesive
Dial
PVC tube (Black)
Dial
Light (Halogen)
YW80S00001F1
YW80S00001F1
Boom work light (LH, RH)
Boom work light (LH, RH)
LC08 - 06201 ~ YC08 - 03001 ~ LC09 - 06201 ~ YC09 - 03701 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
LC08 - 06201 ~ YC08 - 03001 ~ LC09 - 06201 ~ YC09 - 03701 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Deck work light
Effective area of lens
Adhesive
VIEW I
Light (Halogen)
Bulb
Clip
Fix this resistance with tape
L - 1, 6
Type
After soldering, insulate this part with heat shrinkable tube
HOUSING : 172131-5 TERMINAL : 170340-1
L - 1, 6
YT80S00002F2
Resistance 2
DC 5V
Resistance 2 TOCOS Parts E-27 RA30YME20FB202
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
After soldering, insulate this part with heat shrinkable tube
Fix this resistance with tape
Light (Halogen)
Rated voltage
Accel redundant volume
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
L-2
Open and shut direction
POSITIVE TERMINAL
980-10760
E - 27
Description
BL84-200 DC 24V,70W 71cm2
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
L-2 Light (Halogen) YT80S00002F2 Deck work light
Type Bulb Effective area of lens
PVC tube (Black)
VIEW I
BL84-200 DC 24V,70W 71cm2
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24-106
HOUSING : 172131-5 TERMINAL : 170340-1
24-106
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine L-5 Light YT80S00001P1
Specification
Bulb
File No. Name of part Part No. Use Applicable Machine
Description
24V,5W
Note) Equivalent to 2456Z322F1
L-5
Body
Lens
24. COMPONENTS SYSTEM
Light YT80S00001P1
Room light
Room light
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
M-1 Motor VHS281002894A Starter motor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Bulb
SECTION A-A
Rated output
DC 24V, 15kW
Yazaki P/No. Terminal : 7114-6047 Connector : 7282-3013-30 (Black) Hino P/No. : 82580-6720 Mating connector Hino P/No. : 82580-6730
Pinion gear
Switch A
Door
B Terminal : M8X1.25
M-1 Motor VHS281002894A Starter motor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Bulb
24V,5W
Bulb
SECTION A-A
Rated output
DC 24V, 15kW
Yazaki P/No. Terminal : 7114-6047 Connector : 7282-3013-30 (Black) Hino P/No. : 82580-6720 Mating connector Hino P/No. : 82580-6730
Motor YN53C00012F2 Wiper motor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Denso corp. P/No. Rated voltage
24V
YN53C00012F2
Controller Wiper motor
M-3 Motor
Applox. 80
Swing angle
24V
Wiper motor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN54C00001F1
Controller Wiper motor
Window washer YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Wiper sw OFF-Stop ON-Start
Stop signal
Electric diagram
DC 24V
Injection flow
600cc (0.16 gal) / min or more
Injection pressure
24V
Reverse signal
Rated voltage Capacity
Applox. 80
Swing angle
Electric diagram
M-4
24V
Rated voltage
Reverse signal
Motor (Reservoir)
159800-5710 (Motor only)
Denso corp. P/No.
Wiper sw OFF-Stop ON-Start
Stop signal
Pinion gear
VIEW A
159800-5710 (Motor only)
1.5L (0.4 gal) 88.3 kPa (12.8 psi) or more
24-107
M-4 Motor (Reservoir) YN54C00001F1 Window washer YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Body
Lens
Note) Equivalent to 2456Z322F1
VIEW A
M-3
Description
Rated voltage
DC 24V
Injection flow
600cc (0.16 gal) / min or more
Capacity Injection pressure
1.5L (0.4 gal) 88.3 kPa (12.8 psi) or more
24-107
Switch A
Door
B Terminal : M8X1.25
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
File No. Name of part Part No. Use Applicable Machine R-1 Relay YN24S00008F1 Battery relay YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Description
At start 24V2000A(0.1 sec) Rated voltage / current At charge 28V120A(Continuous)
0.4A or less / 24V
Exciting current Closed circuit voltage
16V or less
Open circuit voltage
7V or less
YN24S00008F1
HOUSING AMP 174359-2 RETAINER AMP 1-174360-7 TERMINAL AMP 171661-1 WIRE PROOF PLUG AMP 172888-2
Terminal B
AVS 1.25G
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Terminal B
Specification
Description
At start 24V2000A(0.1 sec) Rated voltage / current At charge 28V120A(Continuous)
0.4A or less / 24V
Exciting current Closed circuit voltage
16V or less
Open circuit voltage
7V or less
I Terminal B
F HOUSING YAZAKI 7123-4220-30 F TERMINAL YAZAKI 7116-3251 REAR HOLDER YAZAKI 7157-6801-30 WIRE PROOF PLUG 7157-3580-60
Terminal A Terminal B
F TERMINAL YAZAKI
Terminal B
AVS 1.25G
H coil
Circuit diagram
I Terminal B
F HOUSING YAZAKI 7123-4220-30 F TERMINAL YAZAKI 7116-3251 REAR HOLDER YAZAKI 7157-6801-30 WIRE PROOF PLUG 7157-3580-60
P coil
Relay VHS283001271A Starter relay YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
DC24V
Rated time
30 sec
Exciting current
3A or more (at 20
F TERMINAL YAZAKI
Terminal L
WIRE PROOF PLUG 7157-3580-60
Terminal B
AVS 1.25L
Fusible link assy B
18 o4 MAX )
Length of coupler harness (From outlet to coupler) L=215mm Vynil tube (Red)
1M or more Black
Blue Vynil tube (Red) Terminal C
R-2 Relay VHS283001271A Starter relay
Min operating voltage DC18V or less (at 20 ) Insulation resistance
F HOUSING YAZAKI o 9 X 30L Heart shrinkage tube 7123-4210-30
Bracket groud
o 7.0 X 150L Fusible link assy A Corrugete tube (Black)
S2830-01271A
Rated voltage
Terminal L
o 7.0 X 150L Corrugete tube (Black)
Fusible link assy B
Hino P/No.
Terminal B
AVS 1.25B 7116-3251* GND wire
z
WIRE PROOF PLUG 7157-3580-60
Bracket groud
GND terminal
VIEW Z
Flowing direction of main current
o 7.0 X 150L Corrugete tube (Black)
R-2
HOUSING AMP 174359-2 RETAINER AMP 1-174360-7 TERMINAL AMP 171661-1 WIRE PROOF PLUG AMP 172888-2
Insulation resistance 3M or more/500V megger
Terminal B
AVS 1.25L
Terminal A
VIEW I
Terminal L
F HOUSING YAZAKI o 9 X 30L Heart shrinkage tube 7123-4210-30
Terminal L
Terminal A
VIEW A Lock section
37.2N {8.4 lb} or more
Contact pressure
AVS 1.25B 7116-3251* GND wire
z
Circuit diagram
GND terminal
VIEW Z
H coil
Battery relay
VIEW I
Flowing direction of main current
P coil
Relay
Terminal A
Insulation resistance 3M or more/500V megger
Terminal A Terminal B
R-1
Terminal A
VIEW A Lock section
37.2N {8.4 lb} or more
Contact pressure
File No. Name of part Part No. Use Applicable Machine
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Hino P/No.
S2830-01271A
Rated voltage
DC24V
Rated time
30 sec
Exciting current
3A or more (at 20
18 o4 MAX )
Length of coupler harness (From outlet to coupler) L=215mm Vynil tube (Red)
Min operating voltage DC18V or less (at 20 ) Insulation resistance
1M or more Black
Blue Vynil tube (Red) Terminal C
M6 Terminal B
Electric diagram
o 7.0 X 150L Fusible link assy A Corrugete tube (Black)
M6 Terminal B
Electric diagram E (AVX 0.85mm2 Black)
E (AVX 0.85mm2 Black)
E (AVX 0.85mm2 Blue)
E (AVX 0.85mm2 Blue) Tape
Tape
M6
24-108
M6
24-108
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine R-3 Relay VHS286201420A Glow relay YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Hino P/No.
Description
Relay
DC 24V
Rated load
VHS286201420A
100A flow
Glow relay
DC 18V or less
Min. operating voltage
File No. Name of part Part No. Use Applicable Machine R-3
S2862-01420A
Rated voltage
24. COMPONENTS SYSTEM
S terminal
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Hino P/No.
Description
S2862-01420A
Rated voltage
DC 24V
Rated load
100A flow DC 18V or less
Min. operating voltage
S terminal Name plate (Red)
Name plate (Red)
F terminal
SW terminal
Electric diagram
R - 4,5,6,8,9,23,24,25, 26,28 Relay YN24S00010P1 Safety relay Horn realy Work light relay
Connector 090 II Non water-proof male 2P blue Hino P/No. 82580-7320A Yazaki P/No. 7282-1020-90
Relay
Micro relay A
Rated voltage Contact
Electric diagram
R - 4,5,6,8,9,23,24,25, 26,28
V23074-A2002-A403
Type
SW terminal
Mating connector 090 II Non water-proof female 2P Hino P/No. 82580-7330A Yazaki P/No. 7383-1020-**
Tyco Electronics
Maker Maker's p/No.
L terminal
F terminal
YN24S00010P1
DC 24V
Safety relay
1C
Horn realy Work light relay
* Accessory of relay box
Travel alarm relay
V23074-A2002-A403 Micro relay A
Type Rated voltage Contact
DC 24V 1C
* Accessory of relay box
Travel alarm relay
Cab working light relay
Cab working light relay
Auto idle stop relay 1, 2
Auto idle stop relay 1, 2
Engine emergency stop relay
Mating connector 090 II Non water-proof female 2P Hino P/No. 82580-7330A Yazaki P/No. 7383-1020-**
Tyco Electronics
Maker Maker's p/No.
L terminal
Connector 090 II Non water-proof male 2P blue Hino P/No. 82580-7320A Yazaki P/No. 7282-1020-90
Pin assignment
Engine emergency stop relay
Lever lock relay
Lever lock relay
Alternator relay
Alternator relay
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Pin assignment
Terminal arrangement
24-109
Terminal arrangement
24-109
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
File No. Name of part Part No. Use Applicable Machine R - 29,30,31,32 Relay YN24S00012P2 Wiper motor relay Washer motor relay
YN11 - 45001 ~ YQ11 - 06001 ~
Specification
Maker's P/No.
Description
R - 29,30,31,32
V23134-A0053-C643
Relay
Relay
Parts name
YN24S00012P2
DV 24V
Rated voltage
Wiper motor relay
1C
Contact
File No. Name of part Part No. Use Applicable Machine
Washer motor relay
* Accessory of relay box
YN11 - 45001 ~ YQ11 - 06001 ~
Pin assignment
SE - 1 ~ 5, 7 ~ 11,20
SE - 1 ~ 5, 7 ~ 11,20
Pressure sensor (Low pressure)
Pressure sensor (Low pressure)
LC52S00019P1
LC52S00019P1
Bucket dig and dump,
Bucket dig and dump,
Boom up and down,
Boom up and down,
Swing,
Swing,
Arm in and out,
Arm in and out,
Travel RH and LH and other
Travel RH and LH and other
YN11 - 45001 ~ YQ11 - 06001 ~
YN11 - 45001 ~ YQ11 - 06001 ~
SE - 13 Speed sensor VHS894101290A
Output voltage Clearance
1.0mm
E/G speed sensor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ M16 x 1
SE - 13
2.8V or more
Hex. : 17
Speed sensor Sumitomo : 090-II (4P : B) P/No. : 6188-0265 Hino. P/No. Sensor side : 82580-6120A (B) Harness side : 82580-6130A (B)
VHS894101290A
Specification
Maker's P/No.
Description
V23134-A0053-C643 Relay
Parts name
DV 24V
Rated voltage
1C
Contact * Accessory of relay box
Pin assignment
Output voltage
2.8V or more
Clearance
1.0mm
E/G speed sensor YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ M16 x 1
Hex. : 17
Hex. : 22 Tightening torque : 47N.m (34.7 lbf.ft)
Hex. : 22 Tightening torque : 47N.m (34.7 lbf.ft)
24-110
24-110
Sumitomo : 090-II (4P : B) P/No. : 6188-0265 Hino. P/No. Sensor side : 82580-6120A (B) Harness side : 82580-6130A (B)
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine SE - 15 Fuel sending unit YN52S00045F1 Fuel level YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Description
File No. Name of part Part No. Use Applicable Machine SE - 15
Float operation
Fuel sending unit
Resistance
Float
24. COMPONENTS SYSTEM
YN52S00045F1
+0.1
10 -0.6
FULL 3/4
(19)
1/2
32+5
1/4
(49.5)
EMPTY
85 +10 0
Fuel level YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Machine side controller
Specification
Float operation Resistance
Float 3/4
(19)
1/2
32+5
1/4
(49.5)
EMPTY
85 +10 0
Machine side controller
YN52S00032P1 Accel dial YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ SE - 22, 23 Pressure sensor (High pressure) YN52S00048P1 P1 pump P2 pump YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Float
VIEW A
Electric diagram
Potentio meter
+0.1
10 -0.6
FULL
Float
SE - 16
Description
SE - 16
Total resistance value
Potentio meter
Effective electric angle
YN52S00032P1
Number of notches
Accel dial
Source voltage Notch part Potentio Bracket
3MA JM II + AMP HOUSING : 174359-2 TERMINAL : 171661-1
Dial
Pressure range
0~50MPa (7250 psi)
Max. allowable press.
120MPa (17400 psi)
Operating source voltage
5+0.5V DC
Electric diagram
(Arrangement)
24-111
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~ SE - 22, 23 Pressure sensor (High pressure) YN52S00048P1
100M or more/DC50V megger Insulation resistance (Between casing and terminal)
P3/8 Tightening torque O ring P14 : 73.5 N.m JIS B2401 (54.2 lbf.ft)
VIEW A
Electric diagram
P1 pump P2 pump
Source (+) Output (+) Common (+)
Econo seal J series (Mark II (+) 3 pole
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Total resistance value Effective electric angle
Number of notches Source voltage Notch part Potentio Bracket
3MA JM II + AMP HOUSING : 174359-2 TERMINAL : 171661-1
Dial
Pressure range
0~50MPa (7250 psi)
Max. allowable press.
120MPa (17400 psi)
Operating source voltage
5+0.5V DC
Electric diagram
(Arrangement)
100M or more/DC50V megger Insulation resistance (Between casing and terminal)
P3/8 Tightening torque O ring P14 : 73.5 N.m JIS B2401 (54.2 lbf.ft)
24-111
Source (+) Output (+) Common (+)
Econo seal J series (Mark II (+) 3 pole
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
Specification
File No. Name of part Part No. Use Applicable Machine
Description
PSV - A, B, C, D
PSV - A, B, C, D
Proportional solenoid valve
Proportional solenoid valve
Hydraulic solenoid valve Hydraulic symbol A5 to A8
Hydraulic solenoid valve Hydraulic symbol A5 to A8
(YN35V00047F1) YN35V00048F1 YN35V00049F1
(YN35V00047F1) YN35V00048F1 YN35V00049F1
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
PSV - P1, P2 Solenoid YN35V00052F1 Pump P1, P2 proportional valve YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SV - 1, 2, 3, 4 Solenoid directional valve (8 spool) assy Hydraulic symbol A1 to A4 (YN35V00047F1) YN35V00050F1 YN35V00051F1
Type Max. feed press Rated feed press Allowable back press Control pressure range
Rated voltage
Solenoid directional pressure
O-ring 1B P20
PSV - P1, P2 AMP MARK II HOUSING : 174354-2 TERMINAL : 173706-1 HEX 10 T=7.4N.m (5.5lbf.ft)
Solenoid
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Pump P1, P2 proportional valve YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Solenoid directional valve (8 spool) assy
Rated voltage DC 24V
TERMINAL 173706-1
YN35V00052F1
SV - 1, 2, 3, 4
5.0 MPa (725 psi)
Solenoid proportional Dither current 100Hz,200mA P-P valve Coil resistance 17.5 (at 20C) AMP MARK II HOUSING 174354-2 Connector specification
Seal nut
Solenoid
P1, P2, T, A1, A8 port PF3/8 A2~A7 port PF1/4 AMP MARK II
Hydraulic symbol A1 to A4 (YN35V00047F1) YN35V00050F1 YN35V00051F1
Type Max. feed press Rated feed press Allowable back press Control pressure range
Rated voltage
Sleeve
Rated pressure Solenoid directional pressure
O-ring 1B P20
Lever lock
Swing parking
Travel 1,2 speed
Attachment boost
P2 unload
KDRDE-5K 13.7MPa (1987 psi) Spring 5.0MPa (725 psi) Orifice Spool 1MPa (145 psi) 0~2.7MPa (392 psi) DC 24V
AMP MARK II HOUSING : 174354-2 TERMINAL : 173706-1 HEX 10 T=7.4N.m (5.5lbf.ft)
Solenoid
5.0 MPa (725 psi) Rated voltage DC 24V
Solenoid proportional Dither current 100Hz,200mA P-P valve Coil resistance 17.5 (at 20C) AMP MARK II HOUSING 174354-2 Connector specification TERMINAL 173706-1
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24-112
Travel straight
Arm 2 speed
Lever lock
Swing parking
Travel 1,2 speed
Attachment boost
P2 unload
Travel straight
P1 unload
KDRDE-5K 13.7MPa (1987 psi) Spring 5.0MPa (725 psi) Orifice Spool 1MPa (145 psi) 0~2.7MPa (392 psi) DC 24V
Sleeve
Rated pressure
Description
HYDRAULIC SYMBOL
Arm 2 speed
HYDRAULIC SYMBOL
Specification
P1 unload
File No. Name of part Part No. Use Applicable Machine
24-112
P1, P2, T, A1, A8 port PF3/8 A2~A7 port PF1/4 AMP MARK II
Seal nut
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine
Specification
Switch YN50S00026F1 Starter switch
Switch
Connection
YN50S00026F1
Terminal Position
Auto return
Switch YN50S00047P1 Swing parking brake release YN11 - 45001 ~ YQ11 - 06001 ~
VIEW A
Type
ST110D
Rated
DC30V, 10A
Terminal arrangement
Starter switch
SW - 4 Insulation tape R B W
Switch YN50S00047P1
Insulation resistance Vinyl tube
T No. Contact construction : Position Swing parking release
Red (2)
Swing parking brake release YAZAKI 7122-2237 7114-2020
YN11 - 45001 ~ YQ11 - 06001 ~
Switch
Switch
YN03M01861F1 (Right grip) YN03M01862F1 (Left grip)
YN03M01861F1 (Right grip) YN03M01862F1 (Left grip)
Horn, ATT Power boost
Horn, ATT Power boost
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
E/G oil pressure switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Working pressure Rating Insulation resistance
Terminal Position
Auto return VIEW A
Type
ST110D
Rated
DC30V, 10A
Terminal arrangement
Insulation tape R B W
Insulation resistance Vinyl tube
T No. Contact construction : Position Swing parking release
Red (2)
White (3)
SW - 5, 10, 20, 21
VHS835301471D
Connection
Blue (1)
SW - 5, 10, 20, 21
Type
Auto return
YAZAKI 7122-2237 7114-2020
Normal White (3)
Switch
Description
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Normal
SW - 7
Specification
SW - 1
Auto return
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SW - 4
File No. Name of part Part No. Use Applicable Machine
Description
SW - 1
24. COMPONENTS SYSTEM
SW - 7
Normal close
Switch
39.2~58.8kPa (5.7~8.5psi)
VHS835301471D
DC 24V/12W More than 100M / DC500V megger
24-113
090 II Water proof connector Color : Black Hino P/No. : 82580-6830 Yazaki P/No. : 7383-1114
E/G oil pressure switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Type Working pressure Rating Insulation resistance
Blue (1)
Normal close 39.2~58.8kPa (5.7~8.5psi) DC 24V/12W More than 100M / DC500V megger
24-113
090 II Water proof connector Color : Black Hino P/No. : 82580-6830 Yazaki P/No. : 7383-1114
24. COMPONENTS SYSTEM
24. COMPONENTS SYSTEM
File No. Name of part Part No. Use Applicable Machine
Specification
Description
SW - 8
File No. Name of part Part No. Use Applicable Machine
Switch
Switch YR11P00008S005
Air cleaner Clogging switch
Air cleaner Clogging switch
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YT02 - 04001 ~ YT03 - 05293 ~ YT04 - 07001 ~ YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SW - 11
SW - 11
Switch
Switch
YN50S00041F1
YN50S00041F1
Lock lever
Lock lever
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Switch YN50S00040DF Travel alarm (Middle east) YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SW - 15 Switch YN50S00040DD Conflux / single flow switching (OPT) YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Description
SW - 8
YR11P00008S005
SW - 13
Specification
Rated voltage
SW - 13
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
Switch YN50S00040DF UP
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Terminal connector Connector Position
Rated voltage
Travel alarm (Middle east)
SW - 15
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
Switch YN50S00040DD UP
Conflux / single flow switching (OPT) YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Terminal connector Connector Position
24-114
Rated voltage
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
UP
Terminal connector Connector Position
Rated voltage
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger Terminal connector Connector Position
24-114
UP
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine SW - 17 Switch YN50S00040D9 Roof window wiper switch (OPT) YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Specification
Rated voltage
Description
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine SW - 17
DC 24V
Switch
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
YN50S00040D9 UP
Roof window wiper switch (OPT) YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Terminal connector Connector Position
SW - 19
SW - 19
Switch
Switch
YT50S00004P1
YT50S00004P1
Wiper inter lock
Wiper inter lock
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SW - 26 Switch YN50S00040D4 Cab work light switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
SW - 27 Switch VHS834601510A
Rated voltage
SW - 26
DC 24V
Switch
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
YN50S00040D4 UP
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Terminal connector Connector Position
Purpose Working temperature
Cab work light switch
SW - 27
Coolant level detection -40
Switch
~130
VHS834601510A Hino P/No. : 82580-71708 Sumitomo P/No. : 6188-0110
Coolant level switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Electrode side CONNECTOR Housing side (To ground)
M18, P=1.5
24-115
Mating connector Hino P/No. : 82580-71808 Sumitomo P/No. : 6189-0189
Specification
Rated voltage
Description
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
UP
Terminal connector Connector Position
Rated voltage
DC 24V
Single pole single throw Type (alternate) More than 1M / Insulation resistance DC500V megger
UP
Terminal connector Connector Position
Purpose Working temperature
Coolant level detection -40
~130 Hino P/No. : 82580-71708 Sumitomo P/No. : 6188-0110
Coolant level switch YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Electrode side CONNECTOR Housing side (To ground)
M18, P=1.5
24-115
Mating connector Hino P/No. : 82580-71808 Sumitomo P/No. : 6189-0189
24. COMPONENTS SYSTEM File No. Name of part Part No. Use Applicable Machine
24. COMPONENTS SYSTEM
Specification
Description
SW - 28
File No. Name of part Part No. Use Applicable Machine
Specification
Description
SW - 28
Switch
Switch
VHS233002800A
VHS233002800A
Fuel filter
Fuel filter
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
Fuel inlet
Fuel outlet
Fuel inlet
Deposit container
Deposit container
Drain
Drain Water proof connector Yazaki 7383-7028-40
SW - 55
Water proof connector Yazaki 7383-7028-40
SW - 55
Switch
Switch
YN50S00040D1
YN50S00040D1
Boom work light switch
Boom work light switch
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
YN11 - 45001 ~ YQ11 - 06001 ~ LC10 - 07001 ~ YC10 - 03501 ~
24-116
Fuel outlet
24-116
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
TABLE OF CONTENTS
TABLE OF CONTENTS
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3
25.1 BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER).........................25-3
25.1.1
AIR CYCLE.............................................................................................................25-3
25.1.1
AIR CYCLE.............................................................................................................25-3
25.1.2
AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.1.2
AUTO AIR CONDITIONER SYSTEM OUTLINE ....................................................25-4
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2 COMPONENT AND CONSTRUCTION ...........................................................................25-5
25.2.1
COMPONENT ........................................................................................................25-5
25.2.1
COMPONENT ........................................................................................................25-5
25.2.2
CONSTRUCTION ...................................................................................................25-6
25.2.2
CONSTRUCTION ...................................................................................................25-6
25.3 PIPING.............................................................................................................................25-9 25.3.1
AIR CONDITIONER................................................................................................25-9
25.3.2
AIR DRYER ASSY..................................................................................................25-11
25.4 FUNCTION ......................................................................................................................25-12
25.3 PIPING.............................................................................................................................25-9
25
25.3.1
AIR CONDITIONER................................................................................................25-9
25.3.2
AIR DRYER ASSY..................................................................................................25-11
25.4 FUNCTION ......................................................................................................................25-12
25.4.1
MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.1
MECHANISM OF COOLING CIRCUIT...................................................................25-12
25.4.2
COOLING CIRCUIT................................................................................................25-14
25.4.2
COOLING CIRCUIT................................................................................................25-14
25.4.3
COMPONENT PARTS ...........................................................................................25-15
25.4.3
COMPONENT PARTS ...........................................................................................25-15
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5 DISASSEMBLY AND ASSEMBLY...................................................................................25-19
25.5.1
PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.1
PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-19
25.5.2
DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.5.2
DISASSEMBLY AND ASSEMBLY OF UNIT ..........................................................25-20
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6 CHARGING REFRIGERANT...........................................................................................25-24
25.6.1
PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.1
PRECAUTIONS TO BE EXERCISED IN OPERATION .........................................25-24
25.6.2
OPERATING PROCEDURE...................................................................................25-25
25.6.2
OPERATING PROCEDURE...................................................................................25-25
25.6.3
CHARGING PROCEDURE ....................................................................................25-26
25.6.3
CHARGING PROCEDURE ....................................................................................25-26
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7 ELECTRIC CIRCUIT........................................................................................................25-32
25.7.1
WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.1
WIRING DIAGRAM AND CONNECTORS .............................................................25-32
25.7.2
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
..........25-34
25.7.2
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
..........25-34
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.8 TROUBLESHOOTING.....................................................................................................25-37
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9 SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL ..............................................25-44
25.9.1
POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.1
POSITION OF INDICATION FOR FAILURE. .........................................................25-44
25.9.2
EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.2
EXPLANATION OF INDICATION FOR FAILURE. .................................................25-44
25.9.3
EXPLANATION OF MONITOR MODE ...................................................................25-46
25.9.3
EXPLANATION OF MONITOR MODE ...................................................................25-46
Book Code No. S5YN2518E02 25-1
Book Code No. S5YN2518E02 25-1
25
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Issue
Date of Issue
Applicable Machines
First edition
August, 2006
Revision
February, 2007
n
March, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n
n
25-2
Remarks
Issue
Date of Issue
Applicable Machines
S5YN2518E01 (ASIA, OCE)
K
First edition
August, 2006
S5YN2518E02 (ASIA, OCE)
K
Revision
February, 2007
K
n
March, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
n (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n
n
25-2
Remarks S5YN2518E01 (ASIA, OCE)
K
S5YN2518E02 (ASIA, OCE)
K
n (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
K K K
25. AIR-CONDITIONER SYSTEM
25.1
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)
25. AIR-CONDITIONER SYSTEM
25.1
BASIC SYSTEM OF AIR CONDITIONER (HVAC AIR CONDITIONER)
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside / outside air switching unit. And this unit changes hot air to cool air.
Air-conditioner is the unit which places evaporator and heater core parallel, and unifies a blower fan and an inside / outside air switching unit. And this unit changes hot air to cool air.
25.1.1
25.1.1
AIR CYCLE
AIR CYCLE
•
Heater Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille through duct.
•
Heater Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with hot air (heating) at the heater core of air-con unit, and then the heated air blows off from grille through duct.
•
Cooler Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows off from grille through duct.
•
Cooler Inside air or outside air is taken in through intake port and the air is passing through filter and heat exchange is performed with cold air (dehumidifying and cooling) at the evaporator of air-con unit, and then the cooled air blows off from grille through duct.
•
Heater system The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in the heater core of air-con unit and then heat exchange is performed. The intake air is heated and the heated air blows off from the grille provided on the inside of cab. The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation is controlled by air mixing damper on the air-con unit.
•
Heater system The heater recycles (circulates) the cooling water in the engine, and the hot water delivered by the engine flows in the heater core of air-con unit and then heat exchange is performed. The intake air is heated and the heated air blows off from the grille provided on the inside of cab. The blow off air temperature is controlled by the temperature control switch on the control panel, and the operation is controlled by air mixing damper on the air-con unit.
25-3
25-3
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.1.2
25.1.2
AUTO AIR CONDITIONER SYSTEM OUTLINE AIR CONDITIONER CONTROL PANEL
AUTO AIR CONDITIONER SYSTEM OUTLINE AIR CONDITIONER CONTROL PANEL
COMPRESSOR
COMPRESSOR DRIVE SOURCE
SOLAR RADIATION SENSOR
AIR OUTLET SWITCHING SIGNAL
COMPRESSOR DRIVE SOURCE
SOLAR RADIATION SENSOR REFRIGERANT PRESSURE SWITCH
AIR MIXED DAMPER SIGNAL AIR-CON
COMPRESSOR
BLOWER REVOLUTION SIGNAL
AIR-CON AIR OUTLET SWITCHING SIGNAL
CONTROLLER
VENT
EVAPORATION SENSOR
MOTOR ACTUATOR
VENT INNER AIR
MOTOR BLOWER ACTUATOR CONTROLLER
25-4
OUTER AIR INTAKE INNER AIR
MOTOR ACTUATOR
AIR CONDITIONER UNIT
FACE
FOOT
INNER AIR AND OUTER AIR SWITCHING SIGNAL
OUTER AIR INTAKE
MOTOR ACTUATOR
AIR CONDITIONER UNIT
INNER AIR SENSOR
INNER AIR AND OUTER AIR SWITCHING SIGNAL
MOTOR ACTUATOR
BLOWER REVOLUTION SIGNAL
CONTROLLER
INNER AIR SENSOR EVAPORATION SENSOR
REFRIGERANT PRESSURE SWITCH
AIR MIXED DAMPER SIGNAL
FACE
FOOT
MOTOR BLOWER ACTUATOR CONTROLLER
25-4
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.2
COMPONENT AND CONSTRUCTION
25.2
COMPONENT AND CONSTRUCTION
25.2.1
COMPONENT
25.2.1
COMPONENT
27
30
33
27
30
33
27-1
27-1
40
40
32
32 39
39 27-3
27-3
27-4
27-2
27-2
35
35 35-6
35-7
35-1 35-5
35-2
35-8
35-8
34
35-9
35-10
A/C ASSY
No.
1
33
Pulley
1
27–1 Air-conditioner unit
1
34
Condenser
27–2 Hose
2
35
Air dryer assy
27–3 Clamp
2
27–4 Filter
Air-conditioner assy
Fig. 25-1 Air-conditioner group
(12)
Q’ty
27
Parts
Parts
Q’ty
Q’ty
No.
35–7 L hose
1
27
1
35–8 L hose : Ø 15.5
1
1
35–9 S tube : Ø 16
35–1 Receiver dryer
1
35–10 L tube : Ø 8.5
1
35–2 Bracket
1
39 40
30
Panel assy
1
35–5 S hose : Ø 24.5
1
32
Compressor
1
35–6 D hose
1
25-5
35-9
35-10
Fig. 25-1 Air-conditioner group
No.
35-5
35-2
34
YN20M00104F1
35-6
35-7
35-1
A/C ASSY
27-4
No.
Parts
YN20M00104F1 Parts
(12)
Q’ty
No.
1
33
Pulley
1
35–7 L hose
1
27–1 Air-conditioner unit
1
34
Condenser
1
35–8 L hose : Ø 15.5
1
1
27–2 Hose
2
35
Air dryer assy
1
35–9 S tube : Ø 16
1
1
27–3 Clamp
2
35–1 Receiver dryer
1
35–10 L tube : Ø 8.5
1
Filter
1
27–4 Filter
1
35–2 Bracket
1
39
Filter
1
Solar radiation sensor
1
40
Solar radiation sensor
1
Air-conditioner assy
Parts
Q’ty
30
Panel assy
1
35–5 S hose : Ø 24.5
1
32
Compressor
1
35–6 D hose
1
25-5
No.
Parts
Q’ty
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.2.2
25.2.2
CONSTRUCTION
(1) Air conditioner unit
CONSTRUCTION
(1) Air conditioner unit 49 47
48 46
42
46
44 31
31
42
45
1
1
31
31
1
3
45
A
43
32
44
41
50
1
3
47
48
41
50
1
49
1
A
43
32
1
1 39
39
37
38
37
38
36
36
40
B
40
B
2
33
2
33
Fig. 25-2 Air conditioner unit (1/2)
Fig. 25-2 Air conditioner unit (1/2)
25-6
25-6
25. AIR-CONDITIONER SYSTEM
14 6
1
1
1
14
16
31
6
5 31 3
1
1
1
4
28
A
1
1
1
20
20
26
13 60
1
1
27
26
C
13 60
11
29
11
29 23 22 24
21 24 51
9
83 54 63 78
82
24
79
51
9
C
23
84
83 54 63
61
78
82 79
C
23
84
1
E
E
17
18
D 10
23 22 24
21
1
31
62
D
E
1
12
3
7
27
31
31
1
1
4
1
17
15
1
7
C
31
1
D
28
16
5
62
1
A
1
1
1
15 1
E
25. AIR-CONDITIONER SYSTEM
B
31
18
D 10
19 1
12
25
3
31
B 19 1
25
3
77
77
Fig. 25-3 Air conditioner unit (2/2)
Fig. 25-3 Air conditioner unit (2/2)
25-7
25-7
61
25. AIR-CONDITIONER SYSTEM No.
Parts
25. AIR-CONDITIONER SYSTEM
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
1
Screw M5u16
23
21
Expansion valve
1
44
MA mode lever
1
1
Screw M5u16
23
21
Expansion valve
1
44
MA mode lever
1
2
Main harness
1
22
O-ring
1
45
Foot lever
1
2
Main harness
1
22
O-ring
1
45
Foot lever
1
3
MA air mix
3
23
O-ring
1
46
Face lever cam
1
3
MA air mix
3
23
O-ring
1
46
Face lever cam
1
4
Blower controller
1
24
Screw M5u40
2
47
Vent lever cam
1
4
Blower controller
1
24
Screw M5u40
2
47
Vent lever cam
1
5
Upper casing
1
25
Thermistor
1
48
Face rod
1
5
Upper casing
1
25
Thermistor
1
48
Face rod
1
6
Air mix door
1
26
Thermistor holder
1
49
Vent rod
1
6
Air mix door
1
26
Thermistor holder
1
49
Vent rod
1
7
Air mix lever
1
27
Heater core
1
50
Foot rod
1
7
Air mix lever
1
27
Heater core
1
50
Foot rod
1
8
Lower casing
1
28
Pipe holder
1
51
Plate
1
8
Lower casing
1
28
Pipe holder
1
51
Plate
1
9
Air mix door sub
1
29
Thermistor
1
54
Screw
1
9
Air mix door sub
1
29
Thermistor
1
54
Screw
1
10
Air mix lever sub
1
31
Screw M4u30
9
60
Casing packing A
1
10
Air mix lever sub
1
31
Screw M4u30
9
60
Casing packing A
1
11
Blower
1
32
Upper casing
1
61
Casing packing B
1
11
Blower
1
32
Upper casing
1
61
Casing packing B
1
12
Lever MA air mix
1
33
Lower casing
1
63
O-ring
1
12
Lever MA air mix
1
33
Lower casing
1
63
O-ring
1
13
Intake door
1
36
Foot door
1
77
Packing
1
13
Intake door
1
36
Foot door
1
77
Packing
1
14
MA intake lever
1
37
Vent door
1
78
Tube
1
14
MA intake lever
1
37
Vent door
1
78
Tube
1
15
Intake lever
1
38
Face door
1
79
Tube
1
15
Intake lever
1
38
Face door
1
79
Tube
1
16
Intake rod
1
39
KK box upper packing
1
82
Tube
1
16
Intake rod
1
39
KK box upper packing
1
82
Tube
1
17
Air mix rod
1
40
KK-box lower packing
1
83
Bracket
1
17
Air mix rod
1
40
KK-box lower packing
1
83
Bracket
1
18
Air mix rod sub
1
41
Vent lever
1
84
Lower casing
1
18
Air mix rod sub
1
41
Vent lever
1
84
Lower casing
1
19
Relay
2
42
Face lever
1
19
Relay
2
42
Face lever
1
20
Evaporator
1
43
Foot joint lever
1
20
Evaporator
1
43
Foot joint lever
1
(2) Receiver dryer
(2) Receiver dryer
REFRIGERANT INLET
REFRIGERANT INLET
2 REFRIGERANT OUTLET
1
2-M6
2 REFRIGERANT OUTLET
1 No
Q'TY
No
PRESSURE SWITCH
1
1
1
SIGHT GLASS
1
3
PRESSURE SWITCH
2
SIGHT GLASS
1
DESICCANT
1
4
3
DESICCANT
1
4
SUCTION PIPE
1
4
SUCTION PIPE
1
5
FILTER
1
5
FILTER
1
6
RECEIVER TANK
1
6
RECEIVER TANK
1
1 3
2
4
3
5
NAME
2-M6
5
NAME
6
6
Fig. 25-4 Receiver dryer
Fig. 25-4 Receiver dryer
25-8
25-8
Q'TY
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.3
PIPING
25.3
PIPING
25.3.1
AIR CONDITIONER
25.3.1
AIR CONDITIONER
30
30 40
27
40
NOTE 1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings. 2. Refrigerant volume : 900 50g 3. T : Tightening torque N.m(lbf.ft)
8
8
8
27
8
8
8
58 25 6 24
8
NOTE 1. Apply oil for refrigerant R134a to the O-rings of all air-conditioner hose fittings. 2. Refrigerant volume : 900 50g 3. T : Tightening torque N.m(lbf.ft) 58 25 6 24
8 6 24
8
6 24
5
8
5
1
1
A
A
12
55
2 6 24
39 JAM NUT FOR TENSION PULLEY T=46.1(33)
6 24
25
18 20
39 JAM NUT FOR TENSION PULLEY T=46.1(33)
10 11 16
3 6 59 25 49 25
23
9 10
32
15
35
52 53
A
1
5 25
25 49 25
23
35
52 53
7
13
25
3 6
12 14
5 25 25
17
25
3 6
12
56 57
14
23 34
56 57
1
50
8
17
9 10
32
15
25 25
56 57
9 10
33
25
8
21
L
25
50
13
7
10 11 16
59
9 10
33
22 25
5
3 6
L
A
18 20
8 51
2
21
25
4
22 25
5
13
INITIAL BELT TENSION When the belt is pushed by the force of 28N, adjust the deflection of L part to be 6mm.
54
4 8 51
2
25
2
13
INITIAL BELT TENSION When the belt is pushed by the force of 28N, adjust the deflection of L part to be 6mm.
54
12
55
23 34
56 57
Fig. 25-5
Fig. 25-5
25-9
25-9
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Air conditioner
Air conditioner
Tightening torque N•m (lbf•ft)
YN20M00104F1 No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
YN20M00104F1 No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
1
Hose : L = 3550
1
24 Clip
3
1
Hose : L = 3550
1
24 Clip
3
2
Hose : L = 2950
1
25 Clip
15
2
Hose : L = 2950
1
25 Clip
15
3
Bracket
2
27 Air conditioner assy
1
3
Bracket
2
27 Air conditioner assy
1
4
V-belt
1
30 Panel
1
4
V-belt
1
30 Panel
1
5
Clip
4
32 Compressor assy
1
5
Clip
4
32 Compressor assy
1
6
Sems bolt : M10u25
5
33 Pulley assy
1
6
Sems bolt : M10u25
5
33 Pulley assy
1
7
Sems bolt : M6u20
2
34 Condenser
1
7
Sems bolt : M6u20
2
34 Condenser
1
8
Sems bolt : M8u20
9
35 Air dryer assy
1
8
Sems bolt : M8u20
9
35 Air dryer assy
1
9
Capscrew : M8u100
4
39 Filter
1
9
Capscrew : M8u100
4
39 Filter
1
10 Washer
6
40 Solar radiation sensor
1
10 Washer
6
40 Solar radiation sensor
1
11 Capscrew : M8u25
2
49 Clip
1
11 Capscrew : M8u25
2
49 Clip
1
12 Tube for heater : L = 2400
1
50 Connector
1
12 Tube for heater : L = 2400
1
50 Connector
1
13 Tube for heater : L = 1500
1
51 Bracket
1
13 Tube for heater : L = 1500
1
51 Bracket
1
14 Tube for D hose : L = 2350
1
52 Clip
1
14 Tube for D hose : L = 2350
1
52 Clip
1
15 Tube for S hose : L = 2050
1
53 Sems bolt : M10u20
1
15 Tube for S hose : L = 2050
1
53 Sems bolt : M10u20
1
16 Bracket
1
54 Grommet
1
16 Bracket
1
54 Grommet
1
17 Tube for L hose : L = 1800
1
55 Grommet
1
17 Tube for L hose : L = 1800
1
55 Grommet
1
18 hose : L = 90
1
56 Capscrew : M6u50
4
18 hose : L = 90
1
56 Capscrew : M6u50
4
20 Clip
2
57 Washer
4
20 Clip
2
57 Washer
4
21 Bracket
1
58 Tube for L hose
1
21 Bracket
1
58 Tube for L hose
1
46.1 (34.0)
22 Sems bolt : M10u40
2
59 Clip
1
46.1 (34.0)
22 Sems bolt : M10u40
2
59 Clip
1
23.5 (17.3)
23 Sems bolt : M8u25
4
23.5 (17.3)
23 Sems bolt : M8u25
4
3.92~4.9 (2.9~3.6)
23.5 (17.3)
UNIT CONNECTION TUBE ASSY UNIT CONNECTION BOLT
4.4 (3.2)
COMPRESSOR CONNECTION BOLT
23.5 (17.3)
UNIT CONNECTION TUBE ASSY UNIT CONNECTION BOLT
S TUBE (9)
27 AIR CONDITIONER ASSY
3.92~4.9 (2.9~3.6)
D HOSE (6)
S
27 AIR CONDITIONER ASSY
D
RECEIVER CONNECTION BOLT
L TUBE (10)
25-10
32 COMPRESSOR ASSY RECEIVER CONNECTION BOLT
S HOSE (5) L TUBE (10)
L HOSE (7)
35 RECEIVER DRYER Note : Numbers in ( ) shows the number in Fig. 25-6.
D HOSE (6)
S
32 COMPRESSOR ASSY
L HOSE (8)
COMPRESSOR CONNECTION BOLT
S TUBE (9)
D
S HOSE (5)
4.4 (3.2)
34 CONDENSER
RECEIVER DRYER MOUNTING BRACKET
L HOSE (8)
L HOSE (7)
35 RECEIVER DRYER Note : Numbers in ( ) shows the number in Fig. 25-6.
25-10
34 CONDENSER
RECEIVER DRYER MOUNTING BRACKET
25. AIR-CONDITIONER SYSTEM 25.3.2
AIR DRYER ASSY
25. AIR-CONDITIONER SYSTEM 25.3.2
AIR DRYER ASSY
Fig. 25-6
Air dryer assy Tightening torque N•m (lbf•ft)
YN96V00024F1 No.
Parts
Fig. 25-6
Air dryer assy
(02)
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
YN96V00024F1 No.
Parts
(02)
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
1
Receiver dryer
1
6
D hose
1
1
Receiver dryer
1
6
D hose
1
2
Bracket
1
7
L hose
1
2
Bracket
1
7
L hose
1
3
Capscrew
2
8
L hose
1
3
Capscrew
2
8
L hose
1
4
Capscrew
2
9
S tube
1
4
Capscrew
2
9
S tube
1
5
S hose
1
10 L tube
1
5
S hose
1
10 L tube
1
25-11
25-11
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.4
FUNCTION
25.4
FUNCTION
25.4.1
MECHANISM OF COOLING CIRCUIT
25.4.1
MECHANISM OF COOLING CIRCUIT
(2) Mechanism of Cooling In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle). 1) Kind of Refrigerant Many kinds of refrigerants that change in that way are available, but the following requirements are needed for use in such applications: •
Latent heat of vaporization (heat of vaporization) is large.
•
It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
•
Item
HFC-134a (R134a)
CH2FCF3 Chemical formula 102.03 Molecular weight -26.19 (-15.14 ) Boiling point 101.14 (214.05 ) Critical temperature 4.065 MPa (41.45kgf/cm2 1) Critical pressure 511 kg/m3 (31.9lb/ft3) Critical density Density of saturated 1206 kg/m3 (75.3lb/ft3) liquid[25 (77.0 )] Specific volume of saturated 0.0310 m3/kg (0.496ft3/lb) vapor [25 (77.0 )] Latent heat of 197.5 KJ/kg {47.19kcal/kg} vaporization [0 (32 )] Flammability Nonflammable Ozone destruction 0 coefficient 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2 (145psi)
(2) Mechanism of Cooling In the cooling process, the refrigerant that flows through the cooling circuit changes its phases from liquid to gas and vice versa during which process heat is transferred from the low temperature part (compartment) to the high temperature part (outside of the vehicle). 1) Kind of Refrigerant Many kinds of refrigerants that change in that way are available, but the following requirements are needed for use in such applications: •
Latent heat of vaporization (heat of vaporization) is large.
•
It is easy to liquefy (condense). (It dose not require very high pressure for condensation.)
It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down an object.)
•
It is easy to gasify (evaporate). (It evaporates sufficiently at not too low pressure, i.e. cools down an object.)
•
It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss resulting from it must be held down to a minimum.)
•
It has small specific heat. (Since the refrigerant itself is cooled by the expansion valve, the loss resulting from it must be held down to a minimum.)
•
It has a high critical temperature and a low solidification point.
•
It has a high critical temperature and a low solidification point.
•
It is stable chemically and does not corrode and permeate into the circuit parts.
•
It is stable chemically and does not corrode and permeate into the circuit parts.
•
It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal conductivity and electric insulation.
•
It is free from toxicity, objectionable odor, flammability and explosiveness and excels in thermal conductivity and electric insulation.
•
It has small specific volume.
•
It has small specific volume.
•
It is easy to find out leakage. Out of refrigerants meeting the abovementioned requirements, ones having characteristics that suit the intended cooling unit are chosen and used. If a refrigerant other that those designated is used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used may be broken. Therefore, always use a designated refrigerant for the cooling unit. Table shows the principal characteristics of the R134a refrigerant that is used in this machine.
•
It is easy to find out leakage. Out of refrigerants meeting the abovementioned requirements, ones having characteristics that suit the intended cooling unit are chosen and used. If a refrigerant other that those designated is used, sufficient refrigeration will not be performed or the equipment in which the refrigerant is used may be broken. Therefore, always use a designated refrigerant for the cooling unit. Table shows the principal characteristics of the R134a refrigerant that is used in this machine.
25-12
25-12
Item
HFC-134a (R134a)
CH2FCF3 Chemical formula 102.03 Molecular weight -26.19 (-15.14 ) Boiling point 101.14 (214.05 ) Critical temperature 4.065 MPa (41.45kgf/cm2 1) Critical pressure 511 kg/m3 (31.9lb/ft3) Critical density Density of saturated 1206 kg/m3 (75.3lb/ft3) liquid[25 (77.0 )] Specific volume of saturated 0.0310 m3/kg (0.496ft3/lb) vapor [25 (77.0 )] Latent heat of 197.5 KJ/kg {47.19kcal/kg} vaporization [0 (32 )] Flammability Nonflammable Ozone destruction 0 coefficient 1 : 1MPa (mega pascal) equals 10.1972kgf/cm2 (145psi)
25. AIR-CONDITIONER SYSTEM (3) Characteristics of Refrigerant (Fig. 25-7) In general, the fluid (general term of gas and liquid) has the following qualities: 1) As a gas under certain pressure is cooled down, it begins to condensate at a certain temperature to take a liquid state. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure. The temperature determined by a given pressure is called saturation temperature.
PRESSURE MPa(psi)
R134a
4(580) 3(435)
LIQUID
2(290)
GAS
1(145) 0.5(75)
2) Inversely to 1) above, the pressure at which a gas condenses for a temperature is determined. This pressure is called saturation pressure. Fig. 25-7 illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side of the curve in Fig. 25-7 the refrigerant take a gaseous state, while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid state. Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of the compartment down to 25°C (77°F), the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. It can be seen from Fig. 25-7 that R134a under a pressure above the atmospheric pressure is capable of cooling the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the refrigerant is cooled and condensed by the outer air exceeding 35°C (95°F). Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen from Fig. 25-7.
25-13
0
0 (32)
15 18 35 50 (59)(64) (95) (122)
TEMPERATURE [ ( )] 100 (212.0)
Fig. 25-7 Pressure-temperature characteristics of R134a
25. AIR-CONDITIONER SYSTEM (3) Characteristics of Refrigerant (Fig. 25-7) In general, the fluid (general term of gas and liquid) has the following qualities: 1) As a gas under certain pressure is cooled down, it begins to condensate at a certain temperature to take a liquid state. The temperature at which condensation begins is unique to each substance (fluid) at a given pressure. The temperature determined by a given pressure is called saturation temperature.
PRESSURE MPa(psi)
R134a
4(580) 3(435)
LIQUID
2(290)
GAS
1(145) 0.5(75)
2) Inversely to 1) above, the pressure at which a gas condenses for a temperature is determined. This pressure is called saturation pressure. Fig. 25-7 illustrates the relationships between the saturation temperature and the saturation pressure in the case of refrigerant R134a used in the air-conditioner. At the temperature and the pressure on the lower righthand side of the curve in Fig. 25-7 the refrigerant take a gaseous state, while at the temperature and the pressure on the upper lefthand side of the curve, the refrigerant takes a liquid state. Let us think of a case where an air-conditioner is operated in the midst of summer. As the refrigerant evaporates, it absorbs evaporation heat from the air of the compartment. In order to cool the inside of the compartment down to 25°C (77°F), the refrigerant must transform (evaporate) from a liquid to a gaseous state at a lower temperature. It can be seen from Fig. 25-7 that R134a under a pressure above the atmospheric pressure is capable of cooling the inside of the compartment sufficiently. (If a refrigerant that requires a pressure below the atmospheric pressure to cool it to a required temperature is used, air is mixed into the circuits, thereby deteriorating the performance of the cooling unit.) In the process in which gaseous refrigerant is brought back to a liquid state, the refrigerant is cooled and condensed by the outer air exceeding 35°C (95°F). Accordingly the refrigerant is capable of condensing at a pressure exceeding 1 MPa (145psi), as seen from Fig. 25-7.
25-13
0
0 (32)
15 18 35 50 (59)(64) (95) (122)
TEMPERATURE [ ( )] 100 (212.0)
Fig. 25-7 Pressure-temperature characteristics of R134a
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.4.2
25.4.2
COOLING CIRCUIT
Fig. 25-8 illustrates the cooling circuit of the car airconditioner. In this circuit diagram, the portion that cools the air of the compartment is the evaporator. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. Since the part at which vaporization of the refrigerant takes place is the evaporator, cooled air is constantly delivered to the circumference of the evaporator by the blower fan. In the meantime, liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator, when "cooling" effect is attained. For instance, in order to cool the air to 15°C (59°F), the refrigerant can not absorb evaporation heat from the air unless it evaporates at a temperature lower that 15°C (59°F). For that purpose, it can be seen from Fig. 25-7 that the pressure of the refrigerant in the evaporator must be less than 0.51 MPa (74psi). Furthermore, the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor. Consequently, the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.e. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. The feed rate of the refrigerant is controlled by the expansion valve, but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. The compressor acts as a pump that allows the refrigerant to circulate. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state.
25-14
INSIDE OF COMPARTMENT(CAB)
EVAPORATOR
BLOWER
S
EXPANSION VALVE
INSIDE OF ENGINE D ROOM
COMPRESSOR
COOLING FAN
RECEIVER DRYER CONDENSER
Fig. 25-8 Construction of cooling circuit
COOLING CIRCUIT
Fig. 25-8 illustrates the cooling circuit of the car airconditioner. In this circuit diagram, the portion that cools the air of the compartment is the evaporator. The object air is cooled off by utilizing the fact that the refrigerant takes heat off the surrounding area as evaporation heat as it evaporates in the cooling circuit. Since the part at which vaporization of the refrigerant takes place is the evaporator, cooled air is constantly delivered to the circumference of the evaporator by the blower fan. In the meantime, liquid refrigerant (slightly wet vaporized refrigerant) is fed into the evaporator, when "cooling" effect is attained. For instance, in order to cool the air to 15°C (59°F), the refrigerant can not absorb evaporation heat from the air unless it evaporates at a temperature lower that 15°C (59°F). For that purpose, it can be seen from Fig. 25-7 that the pressure of the refrigerant in the evaporator must be less than 0.51 MPa (74psi). Furthermore, the cooling effect deteriorates unless the feed rate of the refrigerant is controlled so that all of the refrigerant supplied to the evaporator vaporizes and turns into dry vapor. Consequently, the cooling circuit is so constructed that the evaporator can cool down an object (air in this case) sufficiently (i.e. so as to decrease the pressure in the evaporator) and that an adequate amount of refrigerant can be fed to the evaporator. The feed rate of the refrigerant is controlled by the expansion valve, but the pressure in the evaporator is held low by the throttling action of the expansion valve and the suction action of the compressor. The compressor acts as a pump that allows the refrigerant to circulate. The compressive action of the compressor and the heat exchange (heat radiation) action of the condenser transform the refrigerant in a dry vapor state back to a liquid state.
25-14
INSIDE OF COMPARTMENT(CAB)
EVAPORATOR
BLOWER
S
EXPANSION VALVE
INSIDE OF ENGINE D ROOM
COMPRESSOR
COOLING FAN
RECEIVER DRYER CONDENSER
Fig. 25-8 Construction of cooling circuit
25. AIR-CONDITIONER SYSTEM 25.4.3
COMPONENT PARTS
25. AIR-CONDITIONER SYSTEM 25.4.3
(1) Evaporator (See Fig. 25-9.) The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature, low-pressure liquid-state refrigerant. Therefore, it is necessary that satisfactory heat transfer between the object and the refrigerant take place in the evaporator. To that end, the evaporator is equipped with fins on the air side in order to increase the heat transfer area of the air side and thereby perform excellent thermal transfer between the refrigerant and the air. The humidity in the air condenses as the air cools down and adheres to the outside of the evaporator as water drops. The cooling effect deteriorates if the water drops freeze. Therefore, how to discharge water is an important point. The amount of refrigerant supplied to the evaporator is controlled by the expansion valve which is described in the following. In order to attain proper control, it is necessary to reduce the pressure drop of the refrigerant of the evaporator. Accordingly, reducing the pressure drop is one element that makes the evaporator attain its full performances. (2) Expansion Valve In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature liquid refrigerant must be fed to the evaporator. If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the compressor valves. The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time.
25-15
EVAPORATOR
O-RING
EXPANSION VALVE
SOCKET BOLT M5X40(2 PCS.)
Fig. 25-9
COMPONENT PARTS
(1) Evaporator (See Fig. 25-9.) The evaporator is an important heat exchanger that absorbs the heat of the compartment air (object) by the utilization of the latent vaporization heat of the low-temperature, low-pressure liquid-state refrigerant. Therefore, it is necessary that satisfactory heat transfer between the object and the refrigerant take place in the evaporator. To that end, the evaporator is equipped with fins on the air side in order to increase the heat transfer area of the air side and thereby perform excellent thermal transfer between the refrigerant and the air. The humidity in the air condenses as the air cools down and adheres to the outside of the evaporator as water drops. The cooling effect deteriorates if the water drops freeze. Therefore, how to discharge water is an important point. The amount of refrigerant supplied to the evaporator is controlled by the expansion valve which is described in the following. In order to attain proper control, it is necessary to reduce the pressure drop of the refrigerant of the evaporator. Accordingly, reducing the pressure drop is one element that makes the evaporator attain its full performances. (2) Expansion Valve In order for the evaporator to fulfill its performances, a proper amount of low-pressure low-temperature liquid refrigerant must be fed to the evaporator. If the feed rate is too low, the refrigerant completes vaporization early in the evaporator which results in deterioration of the cooling effect. If the feed rate is too high, unvaporized liquid refrigerant returns to the compressor (liquid back). This not only deteriorates the cooling effect, but also damages the compressor valves. The expansion valve feeds the flowing highpressure high-temperature liquid refrigerant to the evaporator as low-pressure low-temperature liquid refrigerant (damp vapor of low dryness). The expansion valve controls the feed rate of the refrigerant at the same time.
25-15
EVAPORATOR
O-RING
EXPANSION VALVE
SOCKET BOLT M5X40(2 PCS.)
Fig. 25-9
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Fig. 25-10 shows how the block type expansion valve is constructed. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated state. The pressure in the diaphragm changes according to the temperature detected by the sensor. The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). On that occasion, part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. The result is that low-pressure low-temperature damp refrigerant vapor is fed to the evaporator. The opening of the valve is determined by the equilibrium between the pressure (low) of the evaporator side, the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the thermowell). The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly overheated (3~8 degrees C) and goes out of the evaporator. This action is carried out by sensing the refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and consequently controlling the feed rate of the refrigerant. This means that if the refrigerant pressure drop in the evaporator is excessive, it is difficult to control the overheating or the feed rate of the refrigerant. For this reason, the smaller the pressure drop of the evaporator, the better. The expansion valve senses the pressure and the temperature at the outlet of the evaporator and controls the overheating of the refrigerant and the refrigerant supply to the evaporator more securely. The air-conditioner of this machine adopts a block type expansion valve.
25-16
DIAPHRAGM
EVAPORATOR SIDE
REFRIGERANT OUTLET SHAFT
REFRIGERANT INLET BALL VALVE SPRING
Fig. 25-10 Block type expansion valve
Fig. 25-11 Expansion valve outside view
Fig. 25-10 shows how the block type expansion valve is constructed. The temperature sensing part is provided in the shaft of the expansion valve to directly detect the refrigerant temperature at the outlet of the evaporator. The diaphragm contains R134a in saturated state. The pressure in the diaphragm changes according to the temperature detected by the sensor. The change in the pressure causes the force acting upon the diaphragm to vary accordingly. The high-pressure high-temperature liquid refrigerant that is fed from the receiver side reduces the pressure abruptly as it passes through the valve (throttling action). On that occasion, part of the refrigerant evaporates by the very heat of the refrigerant and cooled off. The result is that low-pressure low-temperature damp refrigerant vapor is fed to the evaporator. The opening of the valve is determined by the equilibrium between the pressure (low) of the evaporator side, the action of the adjust spring and the pressing force of the diaphragm (the temperature of the refrigerant at the outlet of the evaporator to be sensed by the thermowell). The feed rate is controlled automatically so that under the pressure in the evaporator, the refrigerant is properly overheated (3~8 degrees C) and goes out of the evaporator. This action is carried out by sensing the refrigerant temperature at the outlet of the evaporator as against the inlet pressure of the evaporator and consequently controlling the feed rate of the refrigerant. This means that if the refrigerant pressure drop in the evaporator is excessive, it is difficult to control the overheating or the feed rate of the refrigerant. For this reason, the smaller the pressure drop of the evaporator, the better. The expansion valve senses the pressure and the temperature at the outlet of the evaporator and controls the overheating of the refrigerant and the refrigerant supply to the evaporator more securely. The air-conditioner of this machine adopts a block type expansion valve.
25-16
DIAPHRAGM
EVAPORATOR SIDE
REFRIGERANT OUTLET SHAFT
REFRIGERANT INLET BALL VALVE SPRING
Fig. 25-10 Block type expansion valve
Fig. 25-11 Expansion valve outside view
25. AIR-CONDITIONER SYSTEM (3) Compressor (See Fig. 25-12.)
(3) Compressor (See Fig. 25-12.)
D HOSE
The compressor performs the following three functions in the cooling circuit:
25. AIR-CONDITIONER SYSTEM D HOSE
The compressor performs the following three functions in the cooling circuit:
1) Suction action
S HOSE
2) Pumping action 3) Compressive action
1) Suction action
S HOSE
2) Pumping action 3) Compressive action
1) The suction action, as combined with the throttling action, works to decrease the refrigerant pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to perform cooling effect.
1) The suction action, as combined with the throttling action, works to decrease the refrigerant pressure in the evaporator. This permits the refrigerant to vaporize at low temperature in order to perform cooling effect.
2) The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables enables continuous cooling.
2) The pumping action serves to cause all the refrigerant to circulate in the cooling circuit. This enables enables continuous cooling.
3) The compressive action, as combined with the action of the condenser which is mentioned hereunder, transforms vaporized refrigerant back to a liquid state again. The saturation temperature gets higher as the pressure increases. For instance, it becomes possible to cool down the refrigerant by the use of an outer air of 35째C (95째F) and liquefy it. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high pressure vapor refrigerant. The condenser then serves to cool down the refrigerant. However, since the compressive action takes place only for a short period, the refrigerant hardly exchanges heat with outer air. That is to say, it takes a near form of thermally insulated compression, so that the refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser.
Fig. 25-12
(4) Condenser ( See Fig. 25-13.) This is a heat exchanger that cools the vaporized refrigerant at high temperature and high pressure by the use of outer air and condenses the refrigerant. The direction in which heat moves is from the refrigerant to air, the opposite to the case of the evaporator. Fins are equipped on the outer air side to improve thermal transfer. If the refrigerant is not cooled well by the condenser, the air in the compartment can not be cooled sufficiently by the evaporator. For that purpose, it is necessary to secure ventilation required for the cooling of the refrigerant.
3) The compressive action, as combined with the action of the condenser which is mentioned hereunder, transforms vaporized refrigerant back to a liquid state again. The saturation temperature gets higher as the pressure increases. For instance, it becomes possible to cool down the refrigerant by the use of an outer air of 35째C (95째F) and liquefy it. The compressive action of the compressor works to turn low pressure vaporized refrigerant to high pressure vapor refrigerant. The condenser then serves to cool down the refrigerant. However, since the compressive action takes place only for a short period, the refrigerant hardly exchanges heat with outer air. That is to say, it takes a near form of thermally insulated compression, so that the refrigerant discharged by the compressor turns into high-temperature high-pressure vapor and is delivered to the condenser. (4) Condenser ( See Fig. 25-13.) This is a heat exchanger that cools the vaporized refrigerant at high temperature and high pressure by the use of outer air and condenses the refrigerant. The direction in which heat moves is from the refrigerant to air, the opposite to the case of the evaporator. Fins are equipped on the outer air side to improve thermal transfer. If the refrigerant is not cooled well by the condenser, the air in the compartment can not be cooled sufficiently by the evaporator. For that purpose, it is necessary to secure ventilation required for the cooling of the refrigerant.
Fig. 25-13 Condenser
25-17
Fig. 25-12
Fig. 25-13 Condenser
25-17
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
(5) Receiver dryer ( See Fig. 25-14.) 1) Receiver Tank On the air-conditioner, the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to vary. It is the receiver tank that receives the variations. When the cooling circuit does not need much refrigerant, the receiver tank stores extra refrigerant temporarily and supplies it when the cooling circuit needs much refrigerant. The receiver tank also stores an extra amount of refrigerant to be used for filling balance and supplement small amounts of leakage of the refrigerant through penetration into rubber hoses.
SIGHT GLASS
REFRIGERANT INLET
REFRIGERANT OUTLET
PRESSURE SWITCH
2) Dryer If water is mixed in the cooling circuit, it deteriorates the compressor valves and oil, corrodes the metallic parts of the circuit or clogs the circuit as the water freezes in the expansion valve. It is desirable that the amount of water mixed in the refrigerant should be held below a concentration of 30ppm. The air-conditioner uses a molecular sieve as desiccant suited for the circuit, in order to absorb water content that intrudes into the circuit when the dryer is installed or when refrigerant is charged.
DESICCANT SUCTION PIPE
FILTER
3) Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined, the only means of confirming the inside of the circuit visually.
RECEIVER TANK
(5) Receiver dryer ( See Fig. 25-14.) 1) Receiver Tank On the air-conditioner, the revolution of the compressor varies greatly which causes the proper flow of refrigerant in the cooling circuit to vary. It is the receiver tank that receives the variations. When the cooling circuit does not need much refrigerant, the receiver tank stores extra refrigerant temporarily and supplies it when the cooling circuit needs much refrigerant. The receiver tank also stores an extra amount of refrigerant to be used for filling balance and supplement small amounts of leakage of the refrigerant through penetration into rubber hoses.
PRESSURE SWITCH
DESICCANT SUCTION PIPE
FILTER
3) Sight Glass This is a inspection window with which the refrigerant level in the circuit is determined, the only means of confirming the inside of the circuit visually. 4) Filter
5) Pressure Switch This machine employs pressure switches of high/low pressure type. The pressure switch protects the circuit by cutting off the power supply to the compressor when high pressure increases abnormally high [more than 3.14MPa (460psi) ]. The pressure switch also detects the leakage of refrigerant by cutting the power supply to the compressor when the pressure of the circuit falls below 0.2MPa (28psi).
5) Pressure Switch This machine employs pressure switches of high/low pressure type. The pressure switch protects the circuit by cutting off the power supply to the compressor when high pressure increases abnormally high [more than 3.14MPa (460psi) ]. The pressure switch also detects the leakage of refrigerant by cutting the power supply to the compressor when the pressure of the circuit falls below 0.2MPa (28psi).
25-18
REFRIGERANT OUTLET
2) Dryer If water is mixed in the cooling circuit, it deteriorates the compressor valves and oil, corrodes the metallic parts of the circuit or clogs the circuit as the water freezes in the expansion valve. It is desirable that the amount of water mixed in the refrigerant should be held below a concentration of 30ppm. The air-conditioner uses a molecular sieve as desiccant suited for the circuit, in order to absorb water content that intrudes into the circuit when the dryer is installed or when refrigerant is charged.
4) Filter
Fig. 25-14
SIGHT GLASS
REFRIGERANT INLET
25-18
RECEIVER TANK
Fig. 25-14
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.5
DISASSEMBLY AND ASSEMBLY
25.5
DISASSEMBLY AND ASSEMBLY
25.5.1
PRECAUTIONS TO BE EXERCISED IN OPERATION
25.5.1
PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Special Refrigerator Oil This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other than SP20 may not be used. Since SP20 tends to absorb moisture and may corrode paint and resin, the following points must be noted: 1) Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor, just before connecting pipes. If you have removed a pipe joint for repair, put a cap to both ports immediately.) 2) Use care so SP20 does not adhere to the painted surface and resin parts. In case SP20 has adhered to such surfaces, wipe it off immediately.
Unit : N.m (lbf.ft) PIPE FASTENING PART
TIGHTENING TORQUE
D hose and compressor (M8 bolt)
19.6~24.5 (14~18)
D hose and condenser
19.6~24.5 (14~18)
L hose and condenser
11.8~14.7 (8.7~11)
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7) L hose and air-conditioner unit
11.8~14.7 (8.7~11)
S hose and air-conditioner unit
29.4~34.3 (22~25)
Expansion valve
1.96~2.45 (1.4~1.8) Unit : N.m (lbf.ft)
(2) The receiver dryer is filled with desiccant to absorb moisture in the circuit. Therefore, remove the valve at the pipe port immediately before connecting pipes. (3) Tightening Torque 1) Pipe Joints When connecting pipe joints, coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table, using a double spanner. 2) Screws and Bolts Fasten to the tightening torque indicated in the table
SCREW SIZE
TIGHTENING TORQUE
N4,T4 machine screw, M4
0.78~1.18 (0.58~0.87)
N5,T5 machine screw, M5
1.96~2.45 (1.4~1.8)
M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7) M6 (except mounting part of L hose joint)
9.8~11.8 (7.2~8.7)
M8 (mounting part of S,D hose joints)
19.6~24.5 (14~18)
M8 (mounting part of A/C unit)
9.8~11.8 (7.2~8.7)
M8 (other than those mentioned above) 11.8~15.7 (8.7~12) M10
REPLACED PARTS
(4) Amount of Oil for Compressor The compressor SD7H (HD type) is filled with 135cc (8.2cuâ&#x20AC;˘in) of oil. If the oil volume is small, seizure at high revolution and shortening of service life will occur. If the oil volume is large, the cooling ability will be deteriorated. Once the air-conditioner is operated, part of the oil is dispersed in the refrigeration circuit. Therefore, when replacing the parts in right Table, adjust the oil level to that of table.
39.2~53.9 (29~40)
AMOUNT TO BE FILLED IN
EVAPORATOR
40 cc (2.4cu.in)
CONDENSER
40 cc (2.4cu.in)
COMPRESSOR
Drain out the volume of oil left in the compressor to be replaced, from the new compressor.
RECEIVER DRYER
20 cc (1.2cu.in)
HOSES
20 cc (1.2cu.in)
(1) Special Refrigerator Oil This air-conditioner uses special refrigerator oil SP20 for use with new refrigerant R134a. Oils other than SP20 may not be used. Since SP20 tends to absorb moisture and may corrode paint and resin, the following points must be noted: 1) Do not keep open all pipe connections on a new compressor and the component parts of the installed refrigeration circuit (Remove valves and caps at the pipe openings of the compressor, just before connecting pipes. If you have removed a pipe joint for repair, put a cap to both ports immediately.) 2) Use care so SP20 does not adhere to the painted surface and resin parts. In case SP20 has adhered to such surfaces, wipe it off immediately.
PIPE FASTENING PART
TIGHTENING TORQUE
D hose and compressor (M8 bolt)
19.6~24.5 (14~18)
D hose and condenser
19.6~24.5 (14~18)
L hose and condenser
11.8~14.7 (8.7~11)
L hose and receiver dryer (M6 bolt) 7.8~11.8 (5.8~8.7) L hose and air-conditioner unit
11.8~14.7 (8.7~11)
S hose and air-conditioner unit
29.4~34.3 (22~25)
Expansion valve
1.96~2.45 (1.4~1.8) Unit : N.m (lbf.ft)
(2) The receiver dryer is filled with desiccant to absorb moisture in the circuit. Therefore, remove the valve at the pipe port immediately before connecting pipes. (3) Tightening Torque 1) Pipe Joints When connecting pipe joints, coat the O-ring with special oil (SP20) and fasten to the tightening torque indicated in the table, using a double spanner. 2) Screws and Bolts Fasten to the tightening torque indicated in the table
SCREW SIZE
TIGHTENING TORQUE
N4,T4 machine screw, M4
0.78~1.18 (0.58~0.87)
N5,T5 machine screw, M5
1.96~2.45 (1.4~1.8)
M6 (mounting part of L hose joint) 7.85~11.8 (5.8~8.7) M6 (except mounting part of L hose joint)
9.8~11.8 (7.2~8.7)
M8 (mounting part of S,D hose joints)
19.6~24.5 (14~18)
M8 (mounting part of A/C unit)
9.8~11.8 (7.2~8.7)
M8 (other than those mentioned above) 11.8~15.7 (8.7~12) M10
REPLACED PARTS
(4) Amount of Oil for Compressor The compressor SD7H (HD type) is filled with 135cc (8.2cuâ&#x20AC;˘in) of oil. If the oil volume is small, seizure at high revolution and shortening of service life will occur. If the oil volume is large, the cooling ability will be deteriorated. Once the air-conditioner is operated, part of the oil is dispersed in the refrigeration circuit. Therefore, when replacing the parts in right Table, adjust the oil level to that of table.
(5) Before performing operation, stop the engine and turn off all power supplies to the equipment related to the air-conditioner.
(5) Before performing operation, stop the engine and turn off all power supplies to the equipment related to the air-conditioner.
(6) After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner.
(6) After the operation is over, confirm that all faults have been repaired completely, by operating the air-conditioner.
25-19
Unit : N.m (lbf.ft)
25-19
39.2~53.9 (29~40)
AMOUNT TO BE FILLED IN
EVAPORATOR
40 cc (2.4cu.in)
CONDENSER
40 cc (2.4cu.in)
COMPRESSOR
Drain out the volume of oil left in the compressor to be replaced, from the new compressor.
RECEIVER DRYER
20 cc (1.2cu.in)
HOSES
20 cc (1.2cu.in)
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.5.2
25.5.2
DISASSEMBLY AND ASSEMBLY OF UNIT
(1) Removing inner air filter Slide the inner air filter leftward and remove it from the unit.
DISASSEMBLY AND ASSEMBLY OF UNIT
(1) Removing inner air filter Slide the inner air filter leftward and remove it from the unit.
Fig. 25-15 (2) Removing selector box Remove 6 plus screws, remove connector connected to the mode actuator on mode selector box, and separate the mode selector box from the unit.
MODE ACTUATOR
Fig. 25-15
PLUS SCREW
MAIN HARNESS
CONNECTOR SELECTOR BOX
(3) Removing main harness Pull out 3 harness clamps from the unit, and disconnect all connected connectors and remove harness on the body from the unit.
Fig. 25-16 AIR MIX LEVER
PLUS SCREW
MAIN HARNESS
Fig. 25-16
(4) Removing upper unit case
AIR MIX LEVER
1) Remove air MIX rod and air MIX rod sub from air MIX lever.
2) Remove 12 plus screws which are used to install the upper and lower unit casings. Pull out the upper unit casing upward giving attention to the thermistor harness so as not to be caught by the casing.
2) Remove 12 plus screws which are used to install the upper and lower unit casings. Pull out the upper unit casing upward giving attention to the thermistor harness so as not to be caught by the casing.
PLUS SCREW
UPPER UNIT CASING
AIR MIX ROD SUB
AIR MIX ROD SUB
AIR MIX ROD SUB
AIR MIX ROD SUB
LOWER UNIT CASING
LOWER UNIT CASING
Fig. 25-17
25-20
PLUS SCREW
UNIT
1) Remove air MIX rod and air MIX rod sub from air MIX lever.
UPPER UNIT CASING
MODE ACTUATOR
CONNECTOR SELECTOR BOX
(3) Removing main harness Pull out 3 harness clamps from the unit, and disconnect all connected connectors and remove harness on the body from the unit.
UNIT
(4) Removing upper unit case
(2) Removing selector box Remove 6 plus screws, remove connector connected to the mode actuator on mode selector box, and separate the mode selector box from the unit.
Fig. 25-17
25-20
25. AIR-CONDITIONER SYSTEM (5) Replacing blower controller
UPPER UNIT CASING
25. AIR-CONDITIONER SYSTEM (5) Replacing blower controller
1) Remove 2 plus screws and remove the blower controller from the upper unit casing.
1) Remove 2 plus screws and remove the blower controller from the upper unit casing.
2) Install new blower controller by the reverse procedure of removal.
2) Install new blower controller by the reverse procedure of removal.
* Do not disassemble the blower controller.
* Do not disassemble the blower controller.
PLUS SCREW
UPPER UNIT CASING
PLUS SCREW
BLOWER CONTROLLER
Fig. 25-18 (6) Removing heater core
Fig. 25-18 PIPE CLAMP
HEATER CORE
1) After draining the coolant, remove heater hose from the heater core.
PLUS SCREW EVAPORATOR ASSY
2) Remove 1 plus screw, and remove pipe clamp which is used to secure the heater core and then remove the heater core from the lower unit casing.
BLOWER CONTROLLER
BLOWER MOTOR
3) Install it by the reverse procedure of removal.
(6) Removing heater core
PIPE CLAMP
HEATER CORE
1) After draining the coolant, remove heater hose from the heater core.
PLUS SCREW EVAPORATOR ASSY
2) Remove 1 plus screw, and remove pipe clamp which is used to secure the heater core and then remove the heater core from the lower unit casing.
BLOWER MOTOR
3) Install it by the reverse procedure of removal.
(7) Replacing blower motor
(7) Replacing blower motor
1) Disconnect connector which is connected to the blower motor and remove the blower motor from the lower unit casing.
1) Disconnect connector which is connected to the blower motor and remove the blower motor from the lower unit casing.
* Do not remove the fan from the blower motor.
* Do not remove the fan from the blower motor. LOWER UNIT CASING
2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
LOWER UNIT CASING
2) Install it by the reverse procedure of removal.
Fig. 25-19
(8) Replacing evaporator and expansion valve
1) Take the evaporator with expansion valve off from the lower casing.
EVAPORATOR
2) Remove evaporator sensor with sensor holder from the removed evaporator.
EVAPORATOR
2) Remove evaporator sensor with sensor holder from the removed evaporator.
SENSOR HOLDER
3) Insert the sensor holder into the new evaporator at the position shown in Fig. 25-20 and install the evaporator sensor again.
1) Take the evaporator with expansion valve off from the lower casing.
SENSOR HOLDER
3) Insert the sensor holder into the new evaporator at the position shown in Fig. 25-20 and install the evaporator sensor again.
105mm (4.1 inch)
11TH ROWS OF FIN
11TH ROWS OF FIN
EVAPORATION SENSOR
EVAPORATION SENSOR
Fig. 25-20
25-21
105mm (4.1 inch)
Fig. 25-20
25-21
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
4) Remove 2 socket bolts M5u40 with Allen wrench (4mm) and remove the expansion valve from the evaporator.
EVAPORATOR
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to new evaporator.
A
* When assembling again, fit O-ring paying attention so as not to be caught with others. (Socket bolt M5u40 (2 pcs.) Tightening torque : 6.9N•m (5.1lbf•ft)
SOCKET BOLT M5X40(2 PCS.)
Fig. 25-21 VENT ROD
1) Replacing mode actuator
FACE ROD
a) Remove connector connected to the motor actuator.
MA MODE LEVER PLUS SCREW 3PCS.
b) Remove FACE rod and VENT rod which is used to connect MA mode lever and mode cam from the holder.
5) Fit O-ring (NF O-ring 5/8 and 1/2 one each) to new evaporator.
A
O-RING
* Do not apply undue force to pipe of evaporator outlet. This undue stress causes the leak of refrigerant from "A" part of evaporator. Moreover, when tube (78), (79) (see Fig. 25-3) connected with expansion valve is disconnected from expansion valve, similar careful work is necessary.
EXPANSION VALVE
(9) Replacing motor actuator
CONNECTOR MODE ACTUATOR
FACE ROD
a) Remove connector connected to the motor actuator.
MA MODE LEVER PLUS SCREW 3PCS.
b) Remove FACE rod and VENT rod which is used to connect MA mode lever and mode cam from the holder.
2) Replacing air mixing actuator MA AIR MIX LEVER
b) Remove rod air MIX which is used to connect the motor actuator and the lever MA air MIX.
MA AIR MIX LEVER
c) Remove 3 plus screws and remove the motor actuator with MA lever air MIX from the unit.
c) Remove 3 plus screws and remove the motor actuator with MA lever air MIX from the unit.
d) Remove the MA lever air MIX from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
d) Remove the MA lever air MIX from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
AIR MIX ACTUATOR
PLUS SCREW 3PCS.
Fig. 25-23
25-22
Fig. 25-22
AIR MIX ROD
a) Remove connector connected to the motor actuator. b) Remove rod air MIX which is used to connect the motor actuator and the lever MA air MIX.
CONNECTOR
CONNECTOR MODE ACTUATOR
d) Remove the lever MA mode from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
a) Remove connector connected to the motor actuator.
Fig. 25-21 VENT ROD
d) Remove the lever MA mode from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
AIR MIX ROD
SOCKET BOLT M5X40(2 PCS.)
1) Replacing mode actuator
c) Remove 3 plus screws and remove the motor actuator with lever MA mode from the unit. Fig. 25-22
EXPANSION VALVE
(9) Replacing motor actuator
c) Remove 3 plus screws and remove the motor actuator with lever MA mode from the unit.
2) Replacing air mixing actuator
EVAPORATOR
* When assembling again, fit O-ring paying attention so as not to be caught with others. (Socket bolt M5u40 (2 pcs.) Tightening torque : 6.9N•m (5.1lbf•ft)
O-RING
* Do not apply undue force to pipe of evaporator outlet. This undue stress causes the leak of refrigerant from "A" part of evaporator. Moreover, when tube (78), (79) (see Fig. 25-3) connected with expansion valve is disconnected from expansion valve, similar careful work is necessary.
4) Remove 2 socket bolts M5u40 with Allen wrench (4mm) and remove the expansion valve from the evaporator.
CONNECTOR
AIR MIX ACTUATOR
PLUS SCREW 3PCS.
Fig. 25-23
25-22
25. AIR-CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator
25. AIR-CONDITIONER SYSTEM 3) Replacing inner and outer air switching actuator
a) Disconnect connector connected to the motor actuator.
a) Disconnect connector connected to the motor actuator.
b) Remove intake rod from MA intake lever.
b) Remove intake rod from MA intake lever.
c) Remove 3 plus screws and remove the motor actuator with MA intake lever from the unit.
c) Remove 3 plus screws and remove the motor actuator with MA intake lever from the unit.
d) Remove the MA intake lever from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
d) Remove the MA intake lever from the removed motor actuator, and install it on new motor actuator by the reverse procedure of removal.
Fig. 25-24
25-23
Fig. 25-24
25-23
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.6
CHARGING REFRIGERANT
25.6
CHARGING REFRIGERANT
25.6.1
PRECAUTIONS TO BE EXERCISED IN OPERATION
25.6.1
PRECAUTIONS TO BE EXERCISED IN OPERATION
(1) Always assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar with how work is done for handling refrigerant.
(1) Always assign a person in charge of handling refrigerant. Refrigerant charge operation involves dangers as it handles high pressure gas. Always assign a person familiar with how work is done for handling refrigerant.
•
Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
•
Wear protective goggles. (You may lose your sight if the refrigerant gets in your eyes.)
•
The refrigerant in liquid state is at very low temperature [approx. -26 C (-15 F)]. Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
•
The refrigerant in liquid state is at very low temperature [approx. -26°C (-15°F)]. Therefore, handle it with care. (You may get a frostbite if the refrigerant is sprayed over your skin.)
°
°
(2) Storage and Transportation
(2) Storage and Transportation
1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises. The can may blast as the result. It is for this reason why the can temperature must be kept below 40°C (104°F).
1) Keep the service can (hereinafter called can) less than 40°C (104°F). Since high pressure gas of R134a is filled in the can in a saturated liguefied state, the pressure in the can increases sharply as temperature rises. The can may blast as the result. It is for this reason why the can temperature must be kept below 40°C (104°F).
2) For storage, choose a cold dark place not exposed to direct sunlight.
2) For storage, choose a cold dark place not exposed to direct sunlight.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
3) If the can is placed near a fire source, it is subject to radiation heat and gets hot. This causes the inside pressure to rise and may cause the can to blow out. Do not bring the can close to a fire.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into account.
4) The inside of the closed compartment gets very hot as the radiation heat of the sunlight enters the compartment. The areas of the compartment which are exposed to direct sunlight may rise to a dangerous temperature level. Do not bring the can into the compartment. Also, the inside of the trunk room may rise to a dangerous temperature level even in the summer time. Use sufficient care, therefore, taking the above into account.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
5) Note that if the can has scratches, dents and distortion, the strength of the can will deteriorate.
1. Do not drop or knock on the can.
1. Do not drop or knock on the can.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
2. When transporting, loading or unloading cans and packages containing cans, do not throw or drop them.
6) Store cans beyond the reach of children.
6) Store cans beyond the reach of children.
(3) Charging
(3) Charging
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
1) When warming the can in which refrigerant is charged, do not fail to open the service can valve and the low pressure valve of the gauge manifold and warm the can in warm water of 40°C (104°F or below (to an extent that you do not feel hot when you put your hand in the water.) If the can is put in hot water or heated by a direct fire, the pressure of the can may rise sharply, thereby blowing off the can.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge manifold in any case.
2) When charging refrigerant while running the engine, do not open the high pressure valve (HI) of the gauge manifold in any case.
(4) Others
(4) Others
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the airconditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the airconditioner correctly and speedily. Pay full attention to the entry of water and dust.
Reuse of service cans is prohibited by law; never use them again. Do not allow foreign matter to enter the airconditioner circuit. Air, water and dust are detrimental to the refrigeration cycle. Install the components of the airconditioner correctly and speedily. Pay full attention to the entry of water and dust.
•
Be careful about overcharge of gas.
•
Be careful about overcharge of gas.
•
Fasten pipes to a specified torque.
•
Fasten pipes to a specified torque.
25-24
25-24
25. AIR-CONDITIONER SYSTEM 25.6.2
OPERATING PROCEDURE
25.6.2
(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge operation".
OPERATING PROCEDURE
(1) Refrigerant charge into the air-conditioner consists mainly of "vacuum making operation", and "gas charge operation".
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus eliminated.
1) The "vacuum making operation" consists of removing water in the air-conditioner circuit. If only a little water remains in the circuit, the small holes of the expansion valve are frozen during operation. This causes the circuit to clog up or rust, resulting in a variety of malfunctions. Therefore, before filling refrigerant in the circuit, make vacuum and allow the water in the circuit to boil and vaporize. Water in the circuit is thus eliminated.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not only depends upon the cooling performances of the air-conditioner, but also affects the service life of the component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the lubricating oil of the compressor and causes seizure of the moving parts of the compressor. The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in this manual.
2) The "gas charging operation" consists of filling refrigerant in the circuit after forming vacuum. Filling gas not only depends upon the cooling performances of the air-conditioner, but also affects the service life of the component parts of the circuit. Extreme overcharge will make the circuit pressure extremely high and causes the cooling performance to deteriorate. On the contrary, undercharge causes poor circulation of the lubricating oil of the compressor and causes seizure of the moving parts of the compressor. The gas filling operation involves handling of high pressure gas; filling gas according to incorrect operation procedure is dangerous. Fill refrigerant correctly following the operation procedures and cautions stated in this manual.
(2) Operation Chart
(2) Operation Chart
Refrigerant filling operation
Vacuum making operation
More than 30 min. Begin vacuum making
More than 30 min. Fill in refrigerant
Check air-tightness
Check for gas leak
Fill in refrigerant
Charge refrigerant gas to a gauge pressure of 0.1MPa (14 psi)
Check and correct joints (3) Tools No.
Parts
Gauge manifold
Begin vacuum making
Gauge indicates abnormality
Check for gas leak
Fill in refrigerant
Charge refrigerant gas to a gauge pressure of 0.1MPa (14 psi)
(3) Tools Q’ty
Sketch
Service
No.
Parts
4 Quick joint
Q’ty 1
1 5 T joint
1
Sketch
Service Low pressure side For service can valve
No.
1
Parts
Gauge manifold
Q’ty
3
1
Sketch
Service
No.
Parts
Q’ty
Sketch
Service
4 Quick joint
1
Low pressure side
5 T joint
1
For service can valve
2
For service can
1
For vacuum pump
1
Red :
high pressure side
3 Quick joint
Fill in refrigerant
Check air-tightness
Check and correct joints
Red :
Charging 2 hose
Leave it as it is, for five minutes.
Stop vacuum making
Lower than -750mmHg
Gauge indicates abnormality
Refrigerant filling operation
Vacuum making operation
Leave it as it is, for five minutes.
Stop vacuum making
Lower than -750mmHg
1
25. AIR-CONDITIONER SYSTEM
Blue : low pressure side
high pressure side
Service can 6 valve
2
For service can
Charging 2 hose
3
Blue : low pressure side
Yellow :
Yellow :
vacuum pump side
vacuum pump side
High pressure side
Vacuum 7 pump adapter
25-25
1
For vacuum pump
3 Quick joint
1
High pressure side
6
Service can valve
Vacuum 7 pump adapter
25-25
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.6.3
25.6.3
CHARGING PROCEDURE
25.6.3.1
VACUUM MAKING OPERATION
CHARGING PROCEDURE
25.6.3.1
(1) Connecting gauge manifold (See Fig. 25-25) 1) Close the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold.
HIGH PRESSURE GAUGE GAUGE MANIFOLD HIGH PRESSURE VALVE(CLOSED) RED
LOW PRESSURE GAUGE
2) Connect the charging hoses (red and blue) with the service valves of the compressor. Red hose : High pressure side (HI) of the gauge manifoldohigh pressure side (DIS) of compressor
(CLOSED)LOW PRESSURE VALVE BLUE HIGH PRESSURE SIDE DIS
Blue hose : Low pressure side (LO) of gauge manifoldolow pressure side (SUC) of compressor
VACUUM MAKING OPERATION
(1) Connecting gauge manifold (See Fig. 25-25) 1) Close the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold. 2) Connect the charging hoses (red and blue) with the service valves of the compressor. Red hose : High pressure side (HI) of the gauge manifoldohigh pressure side (DIS) of compressor
YELLOW LOW PRESSURE SIDE SUC
Blue hose : Low pressure side (LO) of gauge manifoldolow pressure side (SUC) of compressor
25-26
LOW PRESSURE SIDE SUC
Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them. Put the hose in firmly till a clicking sound is heard. 3) Connect the center valve of the gauge manifold with the charging hose of the vacuum pump.
Fig. 25-26 Connecting gauge manifold Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
YELLOW
Fig. 25-25 •
3) Connect the center valve of the gauge manifold with the charging hose of the vacuum pump.
BLUE
COMPRESSOR VACUUM PUMP(STOP)
Fig. 25-25 Do not mistake the high pressure hose for the low pressure hose in any circumstances when connecting them. Put the hose in firmly till a clicking sound is heard.
(CLOSED)LOW PRESSURE VALVE
HIGH PRESSURE SIDE DIS
COMPRESSOR VACUUM PUMP(STOP)
•
HIGH PRESSURE GAUGE GAUGE MANIFOLD HIGH PRESSURE VALVE(CLOSED) RED
LOW PRESSURE GAUGE
Fig. 25-26 Connecting gauge manifold Some kinds of gauge manifolds are not equipped with an open/close valve in the center.
25-26
25. AIR-CONDITIONER SYSTEM (2) Vacuum making (See Fig. 25-27)
(CLOSE) LOW PRESSURE VALVE(OPEN) HIGH PRESSURE VALVE(OPEN) More than (CLOSE) 30 min
1) Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold. 2) Turn on the switch of the vacuum pump and make vacuum for more than 30 minutes.
GAUGE MANIFOLD
3) When vacuum making for a specified duration is over (degree of vacuum : less than - 750 mmHg), close the high pressure valve and the low pressure valve of the gauge manifold. 4) Then turn off the vacuum pump. (3) Air-tightness Check Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for more than five minutes and make sure that the gauge indication does not return toward 0.
If the gauge indication swings toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again and make sure of no leakage.
25-27
25. AIR-CONDITIONER SYSTEM (2) Vacuum making (See Fig. 25-27)
(CLOSE) LOW PRESSURE VALVE(OPEN) HIGH PRESSURE VALVE(OPEN) More than (CLOSE) 30 min
1) Open the high pressure valve (HI) and the low pressure valve (LO) of the gauge manifold. 2) Turn on the switch of the vacuum pump and make vacuum for more than 30 minutes.
GAUGE MANIFOLD
3) When vacuum making for a specified duration is over (degree of vacuum : less than - 750 mmHg), close the high pressure valve and the low pressure valve of the gauge manifold.
DIS
4) Then turn off the vacuum pump.
SUC
Fig. 25-27 Vacuum making operation
(3) Air-tightness Check Close the high pressure valve and the low pressure valve of the gauge manifold, leave it as it is for more than five minutes and make sure that the gauge indication does not return toward 0.
If the gauge indication swings toward 0, there is somewhere that is leaking. Retighten pipe joints, make vacuum again and make sure of no leakage.
25-27
DIS
SUC
Fig. 25-27 Vacuum making operation
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.6.3.2
25.6.3.2
GAS CHARGING OPERATION
GAS CHARGING OPERATION
(1) Charging from high pressure side (See Fig. 25-28.)
(1) Charging from high pressure side (See Fig. 25-28.)
1) After making vacuum repeatedly, change the charging hose (yellow) of the gauge manifold from the vacuum pump to the service can.
1) After making vacuum repeatedly, change the charging hose (yellow) of the gauge manifold from the vacuum pump to the service can.
2) Air purge Open the service can valve. (However, close the high and low pressure valves of the gauge manifold.) Then push the gas valve of the side service port on the low pressure side of the gauge manifold, using a screw driver, in order to let out the air in the charging hose by the pressure of the refrigerant. (See Fig. 25-28.) (The operation ends when a hissing sound is heard.)
2) Air purge Open the service can valve. (However, close the high and low pressure valves of the gauge manifold.) Then push the gas valve of the side service port on the low pressure side of the gauge manifold, using a screw driver, in order to let out the air in the charging hose by the pressure of the refrigerant. (See Fig. 25-28.) (The operation ends when a hissing sound is heard.)
AIR PURGE
CLOSE
SCREW DRIVER YELLOW BLUE
OPEN SERVICE CAN VALVE
RED
AIR PURGE SCREW DRIVER
YELLOW BLUE
Fig. 25-28 Gas charging operation 3) Open the high pressure valve of the gauge manifold and charge in refrigerant. [Charge in gaseous refrigerant to a gauge pressure of 0.1MPa (14psi).] After charging, close the high pressure valve of the gauge manifold and the service and valve. (See Fig. 25-29.)
•
LOW PRESSURE VALVE(CLOSE) BLUE
Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which causes the service can and the hoses to rupture. This is very dangerous.)
(2) Checking for gas leak Check for gas leak in the cycle, using a gas leak detector (electric type). Retighten and correct leaking points.
•
Always use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)
25-28
SERVICE CAN VALVE (OPEN) (CLOSE) CHARGE
3) Open the high pressure valve of the gauge manifold and charge in refrigerant. [Charge in gaseous refrigerant to a gauge pressure of 0.1MPa (14psi).] After charging, close the high pressure valve of the gauge manifold and the service and valve. (See Fig. 25-29.)
LOW PRESSURE VALVE(CLOSE) BLUE
RED
•
SUC
Do not run the compressor during this work, (Otherwise the refrigerant flow in reverse direction which causes the service can and the hoses to rupture. This is very dangerous.)
(2) Checking for gas leak Check for gas leak in the cycle, using a gas leak detector (electric type). Retighten and correct leaking points.
•
HIGH PRESSURE VALVE (OPEN) (CLOSE) RED FILL IN 1~1.5 CANS OF REFRIGERANT
DIS
YELLOW
Fig. 25-29 Gas charging operation (High pressure side)
OPEN SERVICE CAN VALVE
Fig. 25-28 Gas charging operation
HIGH PRESSURE VALVE (OPEN) (CLOSE) RED FILL IN 1~1.5 CANS OF REFRIGERANT
DIS
CLOSE
Always use the leak tester for R134a. (Do not use one for flon gas service as it provides poor sensitivity.)
25-28
SERVICE CAN VALVE (OPEN) (CLOSE) CHARGE
YELLOW
SUC
Fig. 25-29 Gas charging operation (High pressure side)
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
(3) Charging from low pressure side (See Fig. 25-30)
(3) Charging from low pressure side (See Fig. 25-30)
1) Make sure that the high-pressure and lowpressure valves of the gauge manifold and the service can valve are closed.
1) Make sure that the high-pressure and lowpressure valves of the gauge manifold and the service can valve are closed.
LOW PRESSURE VALVE OPEN CLOSE
2) Start the engine and run the revolution to 1500±100rpm and fully close the cab door and the windows.
HIGH PRESSURE VALVE(CLOSE) RED (CLOSE SECURELY)
WHEN AIR BUBBLES IN THE SIGHT GLASS DISAPPEAR
3) Turn on the air-conditioner switch, set the fan switch to Max and the temperature control switch to cool Max.
DIS
2) Start the engine and run the revolution to 1500±100rpm and fully close the cab door and the windows.
YELLOW
SERVICE CAN VALVE(OPEN)
COMPRESSOR OPERATION
6) When refrigerant charge is over, close the low pressure valve of the gauge manifold and the service can valve.
• •
5) Open the low pressure valve of the gauge manifold and the service can valve and fill in refrigerant till air bubbles of the sight glass of the receiver go away. (See Fig. 25-30) [Total amount of gas to be charged : 900g±50g (2.0±0.11 lbs)]
SIGHT GLASS
6) When refrigerant charge is over, close the low pressure valve of the gauge manifold and the service can valve.
• Fig. 25-31 Receiver dryer
Never place the service can upside down. (The compressor valve may be scored because the refrigerant is sucked in a liquid state.)
25-29
SERVICE CAN VALVE(OPEN) SUC SERVICE CAN (DO NOT TURN IT OVER)
Fig. 25-30 Gas charging operation (Low pressure side)
RECEIVER DRYER
Do not open the high pressure valve of the gauge manifold in any circumstances.
YELLOW BLUE
COMPRESSOR OPERATION
SERVICE CAN (DO NOT TURN IT OVER)
Fig. 25-30 Gas charging operation (Low pressure side) 5) Open the low pressure valve of the gauge manifold and the service can valve and fill in refrigerant till air bubbles of the sight glass of the receiver go away. (See Fig. 25-30) [Total amount of gas to be charged : 900g±50g (2.0±0.11 lbs)]
DIS
4) When charging gas, set the discharge pressure of the compressor to 1.4~1.6 MPa (200~230psi).
SUC
HIGH PRESSURE VALVE(CLOSE) RED (CLOSE SECURELY)
WHEN AIR BUBBLES IN THE SIGHT GLASS DISAPPEAR
3) Turn on the air-conditioner switch, set the fan switch to Max and the temperature control switch to cool Max.
BLUE
4) When charging gas, set the discharge pressure of the compressor to 1.4~1.6 MPa (200~230psi).
LOW PRESSURE VALVE OPEN CLOSE
•
SIGHT GLASS
RECEIVER DRYER
Do not open the high pressure valve of the gauge manifold in any circumstances.
Fig. 25-31 Receiver dryer
Never place the service can upside down. (The compressor valve may be scored because the refrigerant is sucked in a liquid state.)
25-29
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
(4) Criterion for checking the amount of refrigerant filled in
(4) Criterion for checking the amount of refrigerant filled in
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
JUDGMENT OF REFRIGERANT LEVEL THROUGH THE SIGHT GLASS OF RECEIVER DRYER
PROPER LEVEL
After A/C is turned on, only a little bubbles are seen and thereafter light milky white is seen.
PROPER LEVEL
After A/C is turned on, only a little bubbles are seen and thereafter light milky white is seen.
OVERCHARGE
After A/C is turned on, no air bubbles are seen.
OVERCHARGE
After A/C is turned on, no air bubbles are seen.
UNDERCHARGE
After A/C is turned on, continuous air bubbles are seen.
UNDERCHARGE
After A/C is turned on, continuous air bubbles are seen.
•
If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
•
If the air-conditioner is run with poor refrigerant R134a, it has adverse effect on the compressor.
•
If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the circuit pressure gets abnormally high : Always keep a proper level.
•
If the refrigerant is charged too much (overcharged), the cooling performance is deteriorated. Moreover, the circuit pressure gets abnormally high : Always keep a proper level.
(5) Removing Gauge Manifold When the refrigerant level has been checked, disconnect the charging hoses from the compressor in the following manner :
(5) Removing Gauge Manifold When the refrigerant level has been checked, disconnect the charging hoses from the compressor in the following manner :
1. Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the service valve of the compressor so the refrigerant does not leak out and loosen the nut. As soon as the nut has been removed, disconnect the charging hose from the service valve.
1. Press the "L" shape metal fitting of the charging hose (blue) on the low pressure side against the service valve of the compressor so the refrigerant does not leak out and loosen the nut. As soon as the nut has been removed, disconnect the charging hose from the service valve.
2. Leave the high pressure side as it is till the high pressure gauge reading falls. [below 1MPa (140psi)].
2. Leave the high pressure side as it is till the high pressure gauge reading falls. [below 1MPa (140psi)].
3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side.
3. Disconnect the charge hose (red) on the high pressure side the same way as on the low pressure side.
25-30
25-30
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
This page is blank for editing convenience.
This page is blank for editing convenience.
25-31
25-31
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.7
ELECTRIC CIRCUIT
25.7
ELECTRIC CIRCUIT
25.7.1
WIRING DIAGRAM AND CONNECTORS
25.7.1
WIRING DIAGRAM AND CONNECTORS
JAE : JAPAN AVIATION ELECTRONICS INDUSTRY, LTD. JAE HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000
JAE HOUSING : IL-AG5-22D-S3C1 TERMINAL : IL-AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7122-6060 REAR HOLDER : 7157-6260-30 TERMINAL : 7114-2871
MAKER : YAZAKI CORP. HOUSING No. : 7123-6060-40 TERMINAL : 7116-2871
NIPPON AMP KK 170889-1 170003-5
MAKER : YAZAKI CORP. 7120-8019 CP3.96MA
NIPPON AMP KK 170889-1 170003-5
PRESSURE SWITCH (RECEIVER DRYER)
MAKER : SUMITOMO HOUSING No. : 6189-0094 HARNESS SEAL : 7160-8234 TERMINAL : 1500-0110
MAKER : YAZAKI CORP. HOUSING No. : 7123-6020 TERMINAL : 7116-2871
MAKER : YAZAKI CORP. HOUSING No. : 7122-6060 REAR HOLDER : 7157-6260-30 TERMINAL : 7114-2871
MAKER : YAZAKI CORP. HOUSING No. : 7123-6060-40 TERMINAL : 7116-2871
MAKER : YAZAKI CORP. 7120-8019 CP3.96MA FUSE 20A
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
JAE : JAPAN AVIATION ELECTRONICS INDUSTRY, LTD. JAE HOUSING : IL-AG5-14D-S3C1 TERMINAL : IL-AG5-C1-5000
JAE HOUSING : IL-AG5-22D-S3C1 TERMINAL : IL-AG5-C1-5000
MAIN KEY SW
LIGHT SWITCH
FUSE 5A
FUSE 15A
PRESSURE SWITCH (RECEIVER DRYER)
MAKER : SUMITOMO HOUSING No. : 6189-0094 HARNESS SEAL : 7160-8234 TERMINAL : 1500-0110 FUSE 20A
POWER SUPPLY FOR NIGHT LIGHTING A/C MAIN POWER POWER SUPPLY FOR COMPRESSOR CLUTCH
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
MAKER : YAZAKI CORP. HOUSING No. : 7123-6020 TERMINAL : 7116-2871
MAIN KEY SW
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
FUSE BOX
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2237 TERMINAL : 17111
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
NIPPON AMP KK 174056-2 TERMINAL : 175062-1
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
MACHINE SIDE WIRING (PARTS) G
L
Br Lg O
LIGHT PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
A/C MAIN POWER POWER SUPPLY FOR COMPRESSOR CLUTCH
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111
FUSE BOX
MAKER : YAZAKI CORP. HOUSING No. : 7123-2228 TERMINAL : 17111 COMPRESSOR
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
NOTE) 1. THe double chain lines indicate the wiring on the excavator side. 2. The connector colors indicate the cord colors seen from the connecting part. P W B R Y
POWER SUPPLY FOR NIGHT LIGHTING
FUSE 5A
COMPRESSOR
NIPPON AMP KK 174056-2 TERMINAL : 175062-1
FUSE 5A
FUSE 15A
FUSE 5A MAKER : YAZAKI CORP. HOUSING No. : 7123-2237 TERMINAL : 17111
LIGHT SWITCH
JAE IL-AG5-7S-S3C1 TERMINAL : AG5-C1-5000
MAKER : YAZAKI CORP. HOUSING No. : 7123-2249 TERMINAL : 17111
NOTE) 1. THe double chain lines indicate the wiring on the excavator side. 2. The connector colors indicate the cord colors seen from the connecting part. P W B R Y
MACHINE SIDE WIRING (PARTS) G
L
Br Lg O
LIGHT PINK WHITE BLACK RED YELLOW GREEN BLUE BROWN GREEN ORANGE
Fig. 25-32 Electric diagram (1/2)
Fig. 25-32 Electric diagram (1/2)
25-32
25-32
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
CCU (OPERATION PANEL + CONTROLLER)
CCU (OPERATION PANEL + CONTROLLER)
EVA SENSOR
EVA SENSOR
AIR INLET SENSOR
AIR INLET SENSOR
SUN SENSOR
SUN SENSOR
MOTOR ACTUATER (FOR AIR MIX)
MOTOR ACTUATER (FOR AIR MIX)
MOTOR ACTUATER (FOR MODE)
BLOWER OFF RELAY
BLOWER MOTOR
MOTOR ACTUATER (FOR MODE)
BLOWER OFF RELAY
BLOWER MOTOR
BLOWER AMP
BLOWER AMP
MOTOR ACTUATER (REC/FRESH) COMPRESSOR RELAY
AIR CONDITIONER SIDE WIRING (PARTS)
MOTOR ACTUATER (REC/FRESH) COMPRESSOR RELAY
AIR CONDITIONER SIDE WIRING (PARTS)
IN THE CAB
IN THE CAB
Fig. 25-33 Electric diagram (2/2)
Fig. 25-33 Electric diagram (2/2)
25-33
25-33
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.7.2
25.7.2
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit The control unit is integrated into control panel, and processes the signal input by each sensor, etc. and the signal input by each switch through control panel with the function of the built-in micro computer, and comprehensively controls each actuator (Inner and outer air flow select, air mix), fan motor and compressor on the output side. And the self-diagnosis performance is provided to facilitate the trouble shooting.
Fig. 25-34
(2) Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit. TERMINAL NO. 1 2 3
STRUCTURE AND OPERATION OF EACH FUNCTIONAL PARTS AND THE INSPECTION
(1) Control panel and control unit The control unit is integrated into control panel, and processes the signal input by each sensor, etc. and the signal input by each switch through control panel with the function of the built-in micro computer, and comprehensively controls each actuator (Inner and outer air flow select, air mix), fan motor and compressor on the output side. And the self-diagnosis performance is provided to facilitate the trouble shooting. (2) Blower controller (TKS-B215A1) The power transistor shifts the fan motor into variable speed with base current from the control unit. TERMINAL NO. 1 2 3
CONTINUITY CONTINUED
TESTER
Fig. 25-34
CONTINUITY CONTINUED
TESTER
NOT CONTINUED CONTINUED(DIODE PARALLEL AND FORWARD DIRECTION FLOW)
NOT CONTINUED CONTINUED(DIODE PARALLEL AND FORWARD DIRECTION FLOW)
In normal operation 1. Disconnect the connector of blower amplifier. 2. Check continuity between terminals on the blower amplifier side.
In normal operation 1. Disconnect the connector of blower amplifier. 2. Check continuity between terminals on the blower amplifier side. Fig. 25-35
* The installing position is provided on the left side of air-con unit.
25-34
Fig. 25-35 * The installing position is provided on the left side of air-con unit.
25-34
25. AIR-CONDITIONER SYSTEM (3) Relay Four-electrode relay is used for the blower OFF relay and compressor relay.
25. AIR-CONDITIONER SYSTEM (3) Relay Four-electrode relay is used for the blower OFF relay and compressor relay.
1) Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running.
1) Blower OFF relay The blower OFF relay turns on after receiving the signal from the control amplifier. When the blower OFF relay turns on, the source voltage is supplied to the blower motor and the blower motor starts running.
2) Compressor relay The relay ONâ&#x20AC;&#x201D;OFF is tripped by the control amplifier and electronic thermostat control.
2) Compressor relay The relay ONâ&#x20AC;&#x201D;OFF is tripped by the control amplifier and electronic thermostat control.
Fig. 25-36
3) Relay inspecting items 1. Relay (24-4PE)
Fig. 25-36
3) Relay inspecting items 1. Relay (24-4PE)
2. Coil resistance: 320 3. Specified voltage: DC20V~30V 4. Be careful about the coil side of relay because this relay has polarity. 5. Inspection: Inspect the continuity between 3 and 4 according to the conditions mentioned below. 20~30V applied between terminals 1-2: Continued 20~30V not applied between terminals 1-2: Not continued
2. Coil resistance: 320 3. Specified voltage: DC20V~30V 4. Be careful about the coil side of relay because this relay has polarity. 5. Inspection: Inspect the continuity between 3 and 4 according to the conditions mentioned below. 20~30V applied between terminals 1-2: Continued 20~30V not applied between terminals 1-2: Not continued
(4) Air mix actuator Air mix actuator is installed at the center of air-con unit, and opens and closes air mix damper through the link. The air mix actuator contains potentiometer which is switched by being coupled to the shaft of actuator.
(4) Air mix actuator Air mix actuator is installed at the center of air-con unit, and opens and closes air mix damper through the link. The air mix actuator contains potentiometer which is switched by being coupled to the shaft of actuator.
When the target air mix door position is determined through the temperature control switch, the control unit reads the level of potentiometer of the actuator, and determines the rotating direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of control unit turns OFF, the motor stops rotating.
25-35
CONTROL AMPLIFIER LIMITER COOL POTENTIO 5V POTENTIO POTENTIO GND
HOT
Fig. 25-37
MOTOR ACTUATOR
When the target air mix door position is determined through the temperature control switch, the control unit reads the level of potentiometer of the actuator, and determines the rotating direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the contact point is moved, and when the contact point is detached or the output signal of control unit turns OFF, the motor stops rotating.
25-35
CONTROL AMPLIFIER LIMITER COOL POTENTIO 5V POTENTIO POTENTIO GND
HOT
Fig. 25-37
MOTOR ACTUATOR
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
(5) The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the link.
(5) The actuator for inner and outer The actuator for inner and outer air flow select is installed on the blower intake unit, and opens and closes inner and outer air damper through the link.
The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator. When the inner and outer damper position is set by the inner and outer switch on the control panel, the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the position detection switch also rotates and makes it stop at the set position of the inner and outer air damper.
The actuator for inner and outer air flow select contains position detection switch which is switched with the movement of shaft of the actuator. When the inner and outer damper position is set by the inner and outer switch on the control panel, the control unit reads the signal of the position detection switch in the actuator and determines the rotation direction of motor in either normal rotation or reverse rotation. Then as the motor rotates, the position detection switch also rotates and makes it stop at the set position of the inner and outer air damper.
AMPLIFIER
MOTOR ACTUATOR
INNER AIR SIDE OUTER AIR SIDE LIMITER
Fig. 25-38
(6) Evaporator sensor This sensor is used to control the evaporator outlet temperature with the compressor ON-OFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control. â&#x20AC;˘ Evaporator sensor inspecting items (Specification) Terminal resistance : at 25 degree C : 2.2k
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH
â&#x20AC;˘ Evaporator sensor inspecting items (Specification) Terminal resistance :
OUTER AIR SIDE LIMITER
Fig. 25-38
Fig. 25-39
at 0 degree C : 7.2 k (7) Dual pressure switch This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure at the time when abnormal pressure was generated on the high pressure side.
Fig. 25-40
SPECIFICATION OF DUAL PRESSURE SWITCH
0.59MPa(86psi)
0.02MPa(2.9psi)
ON OFF
INNER AIR SIDE
at 25 degree C : 2.2k
(7) Dual pressure switch This dual pressure switch is attached on L-hose and is used to turn OFF the compressor, and employs dual type (for high and low pressure control) to protect the cooler cycle from possible failure at the time when abnormal pressure was generated on the high pressure side.
0.02MPa(2.9psi)
MOTOR ACTUATOR
(6) Evaporator sensor This sensor is used to control the evaporator outlet temperature with the compressor ON-OFF to protect the evaporator from freezing, and this evaporator sensor functions as a sensor of this control.
Fig. 25-39
at 0 degree C : 7.2 k
AMPLIFIER
0.59MPa(86psi)
ON 0.20MPa(29psi)
OFF
3.14MPa(455psi)
0.20MPa(29psi)
3.14MPa(455psi)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
(LOW PRESSURE SIDE) (HIGH PRESSURE SIDE)
(8) Solar radiation sensor This solar radiation sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode. Inspection : Check for the continuity between terminals.
(8) Solar radiation sensor This solar radiation sensor, which is used to correct the solar radiation to the auto air conditioner detects the strength and solar orientation of sunbeam after transforming them into current by means of photo diode. Inspection : Check for the continuity between terminals.
25-36
Fig. 25-41
25-36
Fig. 25-41
25. AIR-CONDITIONER SYSTEM
25.8
TROUBLESHOOTING
25.8 Air temperature does not fall.
NO
. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.
A snow mark ( ) on panel is flashing.
Inspect and correct or replace parts.
NO
.
See section monitor mode.
evaporation sensor are disconnected or shorted. Controller failed.
A snow mark ( ) on panel is flashing.
A snow mark ( ) on the panel is flashing.
Inspect and correct or replace parts.
YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.
. Both inner air sensor and .
See section monitor mode.
See section monitor mode.
Inspect and correct or replace parts.
. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.
YES
NO
. Both inner air sensor and
YES
"HL.*" is shown on the set temp. display of the panel.
YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.
evaporation sensor are disconnected or shorted. Controller failed.
See section monitor mode.
Inspect and correct or replace parts.
A NO
NO
NO
NO
. Evaporation sensor connector is disconnected or in poor contact. . Evaporation sensor is disconnected or shorted.
Cool air flowing into inner air sensor
Inspect and correct or replace parts.
YES
If M/A is at stop halfway, eliminate cause, correct and measure operating force. (less than 14.7N : OK)
NO
Refer to Troubleshooting for refrigeration cycle. NO
. Inspect, correct or replace M/A lever link. . After cleaning lever link,
NO Controller is faulty or inner air sensor is faulty.
Inspect and correct or replace parts. Cool air flowing into inner air sensor
If M/A is at stop halfway, eliminate cause, correct and measure operating force. (less than 14.7N : OK)
Turn compressor clutch on and off. Inspect and correct electric circuits. Refer to Troubleshooting for refrigeration cycle.
Inspect and replace.
YES
NO M/A failed or controller is out of order.
apply grease.
Replace.
25-37
Inspect and correct or replace parts.
YES
YES Inspect duct or eliminate cause for cool air intrusion.
. Evaporation sensor connector is disconnected or in poor contact. . Evaporation sensor is disconnected or shorted.
YES
Air mix damper is in COOLMAX. NO
Turn compressor clutch on and off. Inspect and correct electric circuits.
YES
Blowout temp. falls if temp. is set at 18.0 (64.4 ) (COOLMAX) and the blowout mode is changed to vent mode.
Inspect and correct or replace parts.
YES
Air mix damper is in COOLMAX.
A
YES
Blowout temp. falls if temp. is set at 18.0 (64.4 ) (COOLMAX) and the blowout mode is changed to vent mode.
Note : M/A is motor actuator * is any of the numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel. NO
YES
NO
Air temperature does not fall.
YES
"HL.*" is shown on the set temp. display of the panel.
A snow mark ( ) on the panel is flashing.
TROUBLESHOOTING
Note : M/A is motor actuator * is any of the numbers 0 ~ 9.
If AUTO switch or A/C switch is pushed, "HL.E" is indicated on the set temp. display of the panel.
NO
25. AIR-CONDITIONER SYSTEM
. Inspect, correct or replace M/A lever link. . After cleaning lever link,
NO Controller is faulty or inner air sensor is faulty. Inspect and replace.
YES M/A failed or controller is out of order.
apply grease.
Replace.
25-37
YES Inspect duct or eliminate cause for cool air intrusion.
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Air temperature does not rise.
Air temperature does not rise.
Note : * is any of the numbers 0 ~ 9.
HL.E is shown on the set temp. display of the panel. NO
NO
HL.E is shown on the set temp. display of the panel.
YES
NO
. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel. YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.
Inspect and correct or replace parts.
. Connector for air mix M/A is disconnected or in poor contact. . Air mix M/A is failed. . Main harness shows poor continuity.
"HL.*" is shown on the set temp. display of the panel. NO
YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact. See section monitor mode.
NO YES Inspect and correct or replace parts.
NO YES Inspect and correct or replace parts.
NO YES Blowout temp. rises at blowout mode if temp. is set at HOT MAX 32.0 (64.4 )
NO
NO NO Controller or inner air sensor is out of order.
. Inspect, correct or replace M/A lever link. . Clean lever link and apply grease.
YES
Inspect and replace.
M/A failed or controller is out of order.
Warm air is flowing into inner air sensor.
YES
YES
Inspect warm water piping.
NO
YES
Air mix damper is in HOT MAX.
Warm air is flowing into inner air sensor.
YES
If M/A action is at stop, eliminate cause, correct and measure operating force. (less than 14.7N : OK)
Inspect and correct or replace parts.
NO YES Blowout temp. rises at blowout mode if temp. is set at HOT MAX 32.0 (64.4 )
YES
Air mix damper is in HOT MAX. NO
YES
See section monitor mode.
NO
Note : * is any of the numbers 0 ~ 9.
Inspect duct or eliminate causes for warm air entry.
NO If M/A action is at stop, eliminate cause, correct and measure operating force. (less than 14.7N : OK)
YES
Inspect warm water piping. Controller or inner air sensor is out of order. NO
. Inspect, correct or replace M/A lever link. . Clean lever link and apply grease.
YES
Inspect and replace.
M/A failed or controller is out of order.
Replace.
Replace.
25-38
25-38
Inspect duct or eliminate causes for warm air entry.
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Blower motor does not run.
Note 1)
Blower motor does not run.
At air flow HI, battery voltage acts across both terminals (+) and (-) of blower motor. NO
Note 1)
YES
NO
Battery voltage acts across red (+) and body of blower motor. NO
NO
NO
YES
NO
YES
NO
Battery voltage acts across white / red wire and body of blower motor relay. NO
YES
Eliminate cause and replace blower amplifier.
YES Inspect and repair harness.
Blower turns if orange wire of blower motor relay is connected with ground. NO Replace relay.
Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
25-39
Approx. 10V acts across light green wire and grounding of blower amplifier. NO
YES
Controller is out of order. Remove blower amplifier and check for continuity across light green wire Replace and black wires ; you get continuity. NO
Battery voltage acts across white / red wire and body of blower motor relay. NO
YES
Eliminate cause and replace blower amplifier.
YES Inspect and repair harness.
Blower turns if orange wire of blower motor relay is connected with ground.
YES Inspect and correct harness or replace controller.
Replace.
YES
Wire harness is faulty. Inspect and correct or replace.
Inspect and repair harness or replace.
Blower motor fails.
YES
Inspect blower motor relay. Blower motor Note 2) rotates if white / red wire and red wire of blower motor relay are direct connected. NO
Controller is out of order. Remove blower amplifier and check for continuity across light green wire Replace and black wires ; you get continuity.
Wire harness is faulty. Inspect and correct or replace.
Inspect and repair harness or replace.
Replace.
Approx. 10V acts across light green wire and grounding of blower amplifier.
YES
Battery voltage acts across red (+) and body of blower motor.
Blower motor fails.
YES
Inspect blower motor relay. Blower motor Note 2) rotates if white / red wire and red wire of blower motor relay are direct connected.
At air flow HI, battery voltage acts across both terminals (+) and (-) of blower motor.
NO Replace relay.
YES Inspect and correct harness or replace controller.
Note 1) Measure with connector set. Note 2) Always turn off air-conditioner, starter key switch and light switch before work.
25-39
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Blower motor speed does not change.
Blower motor speed does not change.
CASE (1)
CASE (1)
*
"HL. " is shown on the set temp. display of the panel. NO
Replace blower amplifier controller.
Note)
*
is any of the numbers 0 ~ 9.
*
"HL. " is shown on the set temp. display of the panel.
YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.
NO
Replace blower amplifier controller.
Note)
YES
. Inner air sensor or harness is disconnected or shorted. . Inner air sensor connector is disconnected or in poor contact.
See section monitor mode.
See section monitor mode.
Inspect and correct or replace parts.
Inspect and correct or replace parts.
CASE (2)
CASE (2) Does not blower motor speed change because the setting mode is other face mode? YES
Does not blower motor speed change because the setting mode is other face mode?
NO
YES
Is door or front window open?
YES
See CASE (1).
NO
The limiting or control operation is actuated by door switch or front window switch.
*
is any of the numbers 0 ~ 9.
Is door or front window open?
YES
See CASE (1).
25-40
NO See CASE (1).
NO
The limiting or control operation is actuated by door switch or front window switch.
See CASE (1).
25-40
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Magnet clutch does not engage.
Magnet clutch does not engage.
Snow mark ( ) lights if A/C switch is pressed. No
Yes
Snow mark ( ) flickers and E is shown on panel display. To A On page 25-37.
No
No
Yes
Replace harness.
Voltage acts upon clutch. No
Pressure switch is faulty or refrigerant gas is under charged or overcharged.
Yes
Inspect clutch fuses.
Pressure switch is faulty or refrigerant gas is under charged or overcharged. Refer to troubleshooting for refrigeration cycle.
Inspect air-conditioner harness. No fault.
Yes
No
Replace controller.
Clutch faulty.
Yes
Voltage acts across white / green wire and Ground (Black) connector connected to excavator. No
Yes
Voltage is applied to pressure switch harness. No
Inspect air-conditioner harness. No fault.
Replace harness.
Yes Replace controller.
Inner air and outer air do not change over.
Inner air and outer air do not change over.
Inner / outer air mode display on operation panel is flickering.
Inner / outer air mode display on operation panel is flickering.
No
Yes
No
Connector of inner/outer air M/A is disconnected or in poor contact. Or M/A failed or main harness failed.
M/A lever includes foreign matter or is broken. No
To A On page 25-37.
Refer to troubleshooting for refrigeration cycle.
No
M/A failed
Clutch faulty.
Yes
Voltage acts across white / green wire and Ground (Black) connector connected to excavator.
Inspect clutch fuses.
Yes
Voltage is applied to pressure switch harness.
Yes
Snow mark ( ) flickers and E is shown on panel display.
Voltage acts upon clutch.
No
No
Snow mark ( ) lights if A/C switch is pressed.
Yes Remove foreign matter and replace parts.
Replace
Yes Connector of inner/outer air M/A is disconnected or in poor contact. Or M/A failed or main harness failed.
M/A lever includes foreign matter or is broken. No M/A failed
Inspect or replace.
Yes Remove foreign matter and replace parts.
Replace
25-41
25-41
Inspect or replace.
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Modes do not change.
Modes do not change.
Mode display (Mark of person) on operating panel is flickering.
Mode display (Mark of person) on operating panel is flickering.
No
Yes Mode M/A connector is disconnected or in poor contact or M/A failed or main harness is faulty.
M/A rod does not disengage. No
No
Yes
Repair. Each damper lever does not disengage. No Repair.
Yes
Replace.
No
Yes
No
Inspect or replace.
. Cam or damper shaft includes foreign matter or is broken . Erroneous motion occurs due to dirty grease.
. Remove foreign matter or replace parts. . Clean cam and apply new grease.
25-42
Mode M/A connector is disconnected or in poor contact or M/A failed or main harness is faulty.
M/A rod does not disengage.
Repair. Each damper lever does not disengage.
When rod is removed and cam is operated by hand, it is heavy. (more than 19.6N.) No Yes
M/A or controller is out of order.
Yes
Repair.
Yes
Inspect or replace.
When rod is removed and cam is operated by hand, it is heavy. (more than 19.6N.) No Yes
M/A or controller is out of order. Replace.
. Cam or damper shaft includes foreign matter or is broken . Erroneous motion occurs due to dirty grease.
. Remove foreign matter or replace parts. . Clean cam and apply new grease.
25-42
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
Trouble with refrigeration cycle.
Trouble with refrigeration cycle.
Both high and low pressures are lower.
Both high and low pressures are lower. Low pressure is higher.
Cooling does not work if run at high speed. NO
Expansion valve is clogged or maladjusted.
Adjust or replace expansion valve.
YES
Expansion valve is frozen or intruded by water.
After making vacuum, refill refrigerant and replace receiver.
Oil comes out from piping and parts. NO
YES
Natural leak from hose.
Gas leaks from pipe joints and parts.
Charge gas.
Retighten or replace parts.
High pressure is lower.
Compressor cylinder does not get hot.
Compressor cylinder gets very hot.
Expansion valve is maladjusted. (too much open)
Compressor does not discharge well.
Expansion valve is clogged or maladjusted.
Adjust or replace expansion valve. Replace compres
Replace expansion valve.
YES
Expansion valve is frozen or intruded by water.
After making vacuum, refill refrigerant and replace receiver.
Oil comes out from piping and parts. NO
YES
Natural leak from hose.
Gas leaks from pipe joints and parts.
Charge gas.
Retighten or replace parts.
High pressure is lower.
Compressor cylinder does not get hot.
Compressor cylinder gets very hot.
Expansion valve is maladjusted. (too much open)
Compressor does not discharge well.
Replace expansion valve.
Replace compres
High pressure is lower.
High pressure is lower.
Air bubbles are seen in sight glass.
Air bubbles are seen in sight glass.
YES
NO
High pressure circuit before receiver is clogged up.
Remove clogging or replace parts.
YES
Condenser is fouled or clogged.
High pressure gets lower slowly.
NO
High pressure circuit before receiver is clogged up.
Air bubbles are hard to go out even if water is poured on condenser. Clean condenser.
YES
NO
Condenser is fouled or clogged.
High pressure gets lower slowly.
25-43
Cooling does not work if run at high speed. NO
Air bubbles are seen in sight glass.
YES
NO
YES
NO
Air bubbles are seen in sight glass.
Air bubbles are seen in sight glass.
YES
NO
YES
NO
Air bubbles are seen in sight glass.
Low pressure is higher.
Remove clogging or replace parts.
Air is mixed. Make vacuum and refill refrigerant.
25-43
YES
NO
Air bubbles are hard to go out even if water is poured on condenser. Clean condenser.
Air is mixed. Make vacuum and refill refrigerant.
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.9
25.9
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL
SELF DIAGNOSIS FUNCTION ON DISPLAY OF PANEL
The failure of motor actuator and each sensor can be identified on the display of panel.
The failure of motor actuator and each sensor can be identified on the display of panel.
25.9.1
25.9.1
POSITION OF INDICATION FOR FAILURE.
POSITION OF INDICATION FOR FAILURE.
The error is indicated on 3 digits segment.
25.9.2
EXPLANATION OF INDICATION FOR FAILURE.
(1) Failure of Motor Actuator
The error is indicated on 3 digits segment.
25.9.2
EXPLANATION OF INDICATION FOR FAILURE.
(1) Failure of Motor Actuator
1) HL.E is indicated on 3 digits segment.
1) HL.E is indicated on 3 digits segment.
Check harness or connector to motor actuator for the air mix damper for disconnection.
2) MODE
is flickering.
Check harness or connector to motor actuator for the air mix damper for disconnection.
2) MODE
is flickering.
Check harness or connector to motor actuator for the air outlet damper for disconnection.
3) R/F
is flickering.
Check harness or connector to motor actuator for the air outlet damper for disconnection.
3) R/F Check harness or connector to motor actuator for the inner and outer air damper for disconnection. Note) The above indication and flickering does not function if the harness and connector were disconnected under the condition the panel ON/OFF switch is ON. After the failure was occured, if the panel ON/OFF switch is turned ON, it functions. After correction of failure, if the main switch is not switched from OFF to ON the error indication and flickering are not released.
25-44
is flickering. Check harness or connector to motor actuator for the inner and outer air damper for disconnection. Note) The above indication and flickering does not function if the harness and connector were disconnected under the condition the panel ON/OFF switch is ON. After the failure was occured, if the panel ON/OFF switch is turned ON, it functions. After correction of failure, if the main switch is not switched from OFF to ON the error indication and flickering are not released.
25-44
25. AIR-CONDITIONER SYSTEM (2) Failures of sensors
25. AIR-CONDITIONER SYSTEM (2) Failures of sensors
1) HL.* is indicated on 3 digits segment.
1) HL.* is indicated on 3 digits segment.
Check the inner air sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
Check the inner air sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
(* is any of the numbers 0 to 9.)
2) **E and
mark are flickering.
(* is any of the numbers 0 to 9.)
2) **E and (** is displayed leaving the present set temperature value.) Check evaporator sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the panel ON/OFF switch is ON. And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is released.
(3) Communication error of control amplifier and panel 1) E is indicated on the only use segment of display.
25-45
mark are flickering. (** is displayed leaving the present set temperature value.) Check evaporator sensor or the harness for disconnection and short circuit, and also connectors for disconnection.
Note) The above displays in items 1) and 2) are indicated by 3 digits segment when error occurred under the condition the panel ON/OFF switch is ON. And, after correction of failure if the panel ON/OFF switch is switched from OFF to ON, the error indication is released.
(3) Communication error of control amplifier and panel 1) E is indicated on the only use segment of display.
25-45
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
25.9.3
25.9.3
EXPLANATION OF MONITOR MODE
EXPLANATION OF MONITOR MODE
When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit).
When error of 25.9.2 (2) sensors is displayed, the monitor mode is available to identify the sensor condition (disconnection, short circuit).
(1) Position of monitor mode indication
(1) Position of monitor mode indication
SEGMENT FOR ONLY MONITOR INDICATION
SEGMENT FOR ONLY MONITOR INDICATION
3 DIGITS SEGMENT
3 DIGITS SEGMENT
(2) Operation of monitor mode
(2) Operation of monitor mode SPEED UP AND DOWN
INNER OR OUTER
SPEED UP AND DOWN
INNER OR OUTER
SWITCH FOR BLOWER
AIR INLET SELECT SWITCH (R/F)
SWITCH FOR BLOWER
AIR INLET SELECT SWITCH (R/F)
ON/OFF SW
ON/OFF SW
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
1) Press inner and outer air flow select switch and ON/OFF switch simultaneously for 1 second.
2) Press AUTO switch. (After all segments are lit on for 1 second, the mode is switched into monitor mode.)
2) Press AUTO switch. (After all segments are lit on for 1 second, the mode is switched into monitor mode.)
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
3) Any figures of figures from 0 to 9 or any letters of alphabet from A to F are displayed on the 3rd digit and 2nd digit of segment in three digits. The 1st digit is indicated by "H".
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch, and the required sensor is selected from the list below.
4) Any digit indicated by one of figures 0 to 2 for the exclusive segment in three digits is selected by pressing UP or DOWN of blower switch, and the required sensor is selected from the list below.
SEGMENT ASSIGNMENT LIST
SEGMENT ASSIGNMENT LIST
0
INNER AIR SENSOR
0
INNER AIR SENSOR
1
EVAPORATOR SENSOR
1
EVAPORATOR SENSOR
2
SOLAR RADIATION SENSOR
2
SOLAR RADIATION SENSOR
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF switch for 1 second again, or turning off the main switch of excavator. Notes)
(Excluding above mentioned indications, for example "from 3 to 9 and from B to F" are not used at service work.)
5) The monitor display is terminated by pressing the inner and outer air flow select switch (R/F) and ON/OFF switch for 1 second again, or turning off the main switch of excavator. Notes)
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for operation and setting until the monitor mode is cancelled.
1. The air conditioner is turned off while the monitor mode is in operation, and all switches are not available for operation and setting until the monitor mode is cancelled.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized. Therefore turn on ON/OFF switch again, and the error display is disappeared.
2. Even if each sensor is corrected while the monitor mode is in operation, the error display is memorized. Therefore turn on ON/OFF switch again, and the error display is disappeared.
25-46
25-46
25. AIR-CONDITIONER SYSTEM (3) Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. 1)
Example 1
25. AIR-CONDITIONER SYSTEM (3) Contents of monitor mode display Refer to the list of segment display exclusively used for monitor and the list of segments in three digits. 1)
Example 1
THIRD SEGMENT SECOND SEGMENT
THIRD SEGMENT SECOND SEGMENT When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments. --> The inner air sensor is in normal operating condition.
2) Example 2
When the segment exclusively used for monitor indicates 0 (displays the inner air sensor condition), since the segment indicates 3F, the sensor is in normal operating condition according to the list of 3 segments. --> The inner air sensor is in normal operating condition.
2) Example 2 When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition), since the segment indicates 00, the sensor is in disconnection condition according to the list of 3 segments --> The evaporator sensor is in disconnection condition.
3) Example 3
When the segment exclusively used for monitor indicates 1 (displays the evaporator sensor condition), since the segment indicates 00, the sensor is in disconnection condition according to the list of 3 segments --> The evaporator sensor is in disconnection condition.
3) Example 3 When the segment exclusively used for monitor indicates 2 (displays the solar radiation sensor condition), since the segment indicates FF,the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar radiation sensor is in short-circuiting condition.
4) List of 3 segments
When the segment exclusively used for monitor indicates 2 (displays the solar radiation sensor condition), since the segment indicates FF,the sensor is in short-circuiting condition according to the list of 3 segments. -->The solar radiation sensor is in short-circuiting condition.
4) List of 3 segments SECOND SEGMENT
SECOND SEGMENT
EACH SENSOR IS NORMAL
SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED) INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED) EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)
25-47
INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED) EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED) SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
THIRD SEGMENT
THIRD SEGMENT
INNER AIR SENSOR DISCONNECTION (0CH0 INDICATED) EVAPORATOR SENSOR DISCONNECTION (0CH1 INDICATED) SOLAR RADIATION SHORT-CIRCUITING (0CH2 INDICATED)
EACH SENSOR IS NORMAL
SOLAR SENSOR 5V SIDE SHORT-CIRCUITING (C7H2 INDICATED) INNER AIR SENSOR SHORT-CIRCUITING (F6H0 INDICATED) EVAPORATOR SENSOR SHORT-CIRCUITING (F6H1 INDICATED)
25-47
25. AIR-CONDITIONER SYSTEM
25. AIR-CONDITIONER SYSTEM
[MEMO]
[MEMO]
25-48
25-48
31. DISASSEMBLING AND ASSEMBLING
31. DISASSEMBLING AND ASSEMBLING
TABLE OF CONTENTS
TABLE OF CONTENTS
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...........................31-3
31.1 EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY ...........................31-3
31.1.1
FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-3
31.1.1
FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY ..................................31-3
31.1.2
INDICATION OF TIGHTENING TORQUE .............................................................31-3
31.1.2
INDICATION OF TIGHTENING TORQUE .............................................................31-3
31
31
Book Code No. S5YN3118E01 31-1
Book Code No. S5YN3118E01 31-1
31. DISASSEMBLING AND ASSEMBLING
31. DISASSEMBLING AND ASSEMBLING
Issue
Date of Issue
First edition
July, 2006
SK330–8 : LC10-07001~ SK350LC–8 : YC10-03501~
n
August, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
n
October, 2006
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
Applicable Machines
Remarks S5YN3118E01 (ASIA, OCE) n (ASIA, OCE) n (ASIA, OCE) n
December, 2006 SK850LC: LY01-00101~
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
n
n
SK235SRLC-2 : YU05-02001~
n
March, 2007
n
April, 2007
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
n
n
SK215SRLC : LA05-02001~
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
n
n
SK460-8: LS10-02001~ SK480LC–8 : YS10-01501~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
n
August, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
31-2
n (NHK) n (North America) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (ASIA, OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
Issue
Date of Issue
Applicable Machines
K
First edition
July, 2006
SK330–8 : LC10-07001~ SK350LC–8 : YC10-03501~
K
n
August, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
K
n
October, 2006
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
K
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
K
n
n
SK235SRLC-2 : YU05-02001~
K
n
March, 2007
K
n
April, 2007
K
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
K
n
n
SK215SRLC : LA05-02001~
K
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
K
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
K
n
n
SK460-8: LS10-02001~ SK480LC–8 : YS10-01501~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
K
n
August, 2007
Remarks S5YN3118E01 (ASIA, OCE) n (ASIA, OCE) n (ASIA, OCE) n
December, 2006 SK850LC: LY01-00101~
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
31-2
n (NHK) n (North America) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (ASIA, OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
K K K K K K K K K K K K K K K K K K K K
31. DISASSEMBLING AND ASSEMBLING
31. DISASSEMBLING AND ASSEMBLING
31.1
EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY
31.1
EXPLAINING CHAPTER OF WHOLE DISASSEMBLY & ASSEMBLY
31.1.1
FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
31.1.1
FORM FOR CHAPTER OF DISASSEMBLY & ASSEMBLY
This chapter is consist of 3-Section as follows.
This chapter is consist of 3-Section as follows.
(1) ATTACHMENTS .................................................................Chapter 32
(1) ATTACHMENTS .................................................................Chapter 32
1) Removing and Installing
1) Removing and Installing
2) Disassembling and Assembling
2) Disassembling and Assembling
a. Cylinder
a. Cylinder
(2) UPPER STRUCTURE ........................................................Chapter 33
(2) UPPER STRUCTURE ........................................................Chapter 33
1) Removing and Installing
1) Removing and Installing
2) Disassembling and Assembling
2) Disassembling and Assembling
a. Hydraulic pump
a. Hydraulic pump
b. Control Valve
b. Control Valve
c. Pilot Valve (ATT)
c. Pilot Valve (ATT)
d. Pilot Valve (Travel)
d. Pilot Valve (Travel)
e. Slewing Motor
e. Slewing Motor
f.
f.
Swivel Joint
(3) TRAVEL SYSTEM ..............................................................Chapter 34
Swivel Joint
(3) TRAVEL SYSTEM ..............................................................Chapter 34
1) Removing and Installing
1) Removing and Installing
2) Disassembling and Assembling
2) Disassembling and Assembling
a. Travel Motor 31.1.2
a. Travel Motor
INDICATION OF TIGHTENING TORQUE
31.1.2
INDICATION OF TIGHTENING TORQUE
Tightening torque is indicated as follows, for example ; T=98N•m(72 lbf•ft) Tolerance is ±10% unless otherwise specified.
Tightening torque is indicated as follows, for example ; T=98N•m(72 lbf•ft) Tolerance is ±10% unless otherwise specified.
•
•
Refer to "Chapter 11 TOOLS" for standard tightening torque.
31-3
Refer to "Chapter 11 TOOLS" for standard tightening torque.
31-3
31. DISASSEMBLING AND ASSEMBLING
31. DISASSEMBLING AND ASSEMBLING
[MEMO]
[MEMO]
31-4
31-4
32. ATTACHMENT
32. ATTACHMENT
TABLE OF CONTENTS
TABLE OF CONTENTS
32.1 REMOVING AND INSTALLING.......................................................................................32-3
32.1 REMOVING AND INSTALLING.......................................................................................32-3
32.1.1
ATTACHMENT ASSY.............................................................................................32-3
32.1.1
ATTACHMENT ASSY.............................................................................................32-3
32.1.2
BUCKET .................................................................................................................32-3
32.1.2
BUCKET .................................................................................................................32-3
32.1.3
ARM........................................................................................................................32-6
32.1.3
ARM........................................................................................................................32-6
32.1.4
BOOM.....................................................................................................................32-9
32.1.4
BOOM.....................................................................................................................32-9
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-13 32.2.1
32.2 DISASSEMBLING AND ASSEMBLING...........................................................................32-13
CYLINDER..............................................................................................................32-13
32.2.1
CYLINDER..............................................................................................................32-13
32
32
Book Code No. S5YN3218E02 32-1
Book Code No. S5YN3218E02 32-1
32. ATTACHMENT
32. ATTACHMENT
Issue
Date of Issue
Applicable Machines
First edition
August, 2006
Revision
February, 2007
n
March, 2007
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n E215B : YN11-45001~ E215BLC : YQ11-06001~
n
Remarks
Issue
Date of Issue
Applicable Machines
S5YN3218E01 (ASIA, OCE)
K
First edition
August, 2006
S5YN3218E02 (ASIA, OCE)
K
Revision
February, 2007
K
n
March, 2007
K
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) HS Engine
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~ n E215B : YN11-45001~ E215BLC : YQ11-06001~
n
Remarks S5YN3218E01 (ASIA, OCE)
K
S5YN3218E02 (ASIA, OCE)
K
n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) HS Engine
K K K K
PREFACE
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(2) This Manual consists of 2 sections. "Removing and Installing", and "Disassembling and Assembling".
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.
(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working.
32-2
32-2
32. ATTACHMENT
32. ATTACHMENT
32.1
REMOVING AND INSTALLING
32.1
REMOVING AND INSTALLING
32.1.1
ATTACHMENT ASSY
32.1.1
ATTACHMENT ASSY
(D) ARM CYLINDER HEAD PIN
(C) BOOM CYLINDER ROD PIN 4. BOOM
(A) BOOM FOOT PIN
(D) ARM CYLINDER HEAD PIN
ARM CYLINDER (F) BOOM TOP PIN
(E) ARM CYLINDER ROD PIN
(E) ARM CYLINDER ROD PIN
2. BUCKET
(G) BUCKET CYLINDER HEAD PIN
2. BUCKET
(G) BUCKET CYLINDER HEAD PIN (J) BUCKET DRIVE PIN
3. ARM
BUCKET CYLINDER
(I) IDLER LINK PIN
BUCKET LINK
IDLER LINK
(H) BOOM CYLINDER HEAD PIN
(K) BUCKET ATTACHING PIN
(H) BUCKET CYLINDER ROD PIN
(H) BOOM CYLINDER HEAD PIN
(K) BUCKET ATTACHING PIN
(H) BUCKET CYLINDER ROD PIN
Fig. 32-1 Front attachment and position
32.1.2.1
(J) BUCKET DRIVE PIN
3. ARM (I) IDLER LINK PIN
BUCKET LINK
IDLER LINK
32.1.2
(A) BOOM FOOT PIN
ARM CYLINDER
(F) BOOM TOP PIN
BUCKET CYLINDER
(C) BOOM CYLINDER ROD PIN 4. BOOM
Fig. 32-1 Front attachment and position
BUCKET
32.1.2
REMOVING BUCKET
32.1.2.1
(1) Put the machine in position to remove bucket.
BUCKET REMOVING BUCKET
(1) Put the machine in position to remove bucket.
Fig. 32-2 Position to remove bucket (2) Removing pin (2) Expand slit of ring (1) with screwdriver, and remove it. Push out the pin (2) with flat-blade screwdriver .
BOSS SECTION 1
DRIVER 2
Fig. 32-2 Position to remove bucket (2) Removing pin (2) Expand slit of ring (1) with screwdriver, and remove it. Push out the pin (2) with flat-blade screwdriver .
BOSS SECTION 1
SECTION OF BOSS
SECTION OF BOSS
Fig. 32-3 Removing pin (2)
32-3
DRIVER 2
Fig. 32-3 Removing pin (2)
32-3
32. ATTACHMENT
32. ATTACHMENT
(3) Removing bucket attaching pin (K) Lift up bucket, position it so that bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K).
(3) Removing bucket attaching pin (K) Lift up bucket, position it so that bucket attaching pin (K) is not loaded, adjust bucket link, and pull out bucket attaching pin (K).
K
K
Fig. 32-4 Removing bucket attaching pin (4) Removing bucket drive pin (J) Put bucket on the ground, position it so that the bucket drive pin (J) is not loaded, adjust bucket link, and pull out pin (J). Store the removed pin (J) in original position again.
J
Fig. 32-4 Removing bucket attaching pin (4) Removing bucket drive pin (J) Put bucket on the ground, position it so that the bucket drive pin (J) is not loaded, adjust bucket link, and pull out pin (J). Store the removed pin (J) in original position again.
Fig. 32-5 Removing bucket drive pin 32.1.2.2
ATTACHING BUCKET
Fig. 32-5 Removing bucket drive pin 32.1.2.2
(1) Attaching bucket drive pin (J) Attach bucket drive pin (J) first, then continue in the reverse procedure of removing.
J
ATTACHING BUCKET
(1) Attaching bucket drive pin (J) Attach bucket drive pin (J) first, then continue in the reverse procedure of removing. J
J
•
When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
•
When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
•
Check the seals for damaged and replace as necessary.
•
Check the seals for damaged and replace as necessary.
•
When inserting the pin, coat the shaft with grease.
•
When inserting the pin, coat the shaft with grease.
Fig. 32-6 Attaching bucket
32-4
Fig. 32-6 Attaching bucket
32-4
32. ATTACHMENT 32.1.2.3
PROCEDURE FOR ADJUSTING CLEARANCE
Adjustment of clearance between bucket and arm
32.1.2.3 +1.0
Apply rust preventive oil
(1) Shift O-ring (3) toward the bucket boss, using a spatula. (aob)
12 : WASHER 11 : CAPSCREW
(2) When adjusting clearance (B), bring the nonadjusting side of the bucket in contact with the arm. (3) Measure clearance (B) and check that it is within 1.0mm (0.04in).
32. ATTACHMENT
+0.039"
326 -0.5 (12.84 -0.020" ) New bucket B
3 : O-RING
b a
PROCEDURE FOR ADJUSTING CLEARANCE
Adjustment of clearance between bucket and arm (1) Shift O-ring (3) toward the bucket boss, using a spatula. (aob)
12 : WASHER 11 : CAPSCREW
(2) When adjusting clearance (B), bring the nonadjusting side of the bucket in contact with the arm. (3) Measure clearance (B) and check that it is within 1.0mm (0.04in).
7 : BUSHING
9 : SHIM
(5) An average of 5 shims (9) of 1mm (0.04in) thickness are set in the plate (8) fixed by the three capscrews (11). The clearance can be decreased by 1mm (0.04in) if one shim is removed.
B
3 : O-RING
b a
8 : PLATE Install pin (10) until the top 10 : PIN of pin is even surface with bushing.
Fig. 32-7 Adjusting clearance between bucket and arm
(4) Adjust clearance (B) where it is more than 1.0mm (0.04in).
9 : SHIM
(5) An average of 5 shims (9) of 1mm (0.04in) thickness are set in the plate (8) fixed by the three capscrews (11). The clearance can be decreased by 1mm (0.04in) if one shim is removed.
: 24mm, Tightening torque : 279N•m (206 lbf•ft) (6) After adjustment, tighten the capscrews evenly. • The gap exceeding the specified dimension causes early wear.
(6) After adjustment, tighten the capscrews evenly. • The gap exceeding the specified dimension causes early wear.
(7) Operate the bucket and confirm that the total sum of both clearance is within 1.0mm (0.04in).
(7) Operate the bucket and confirm that the total sum of both clearance is within 1.0mm (0.04in).
(8) Replace O-ring (3) on its original position.
(8) Replace O-ring (3) on its original position.
•
When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
•
When shifting O-ring (3) by means of a spatula, use care so as not to damage O-ring (3).
•
Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B) so it settles within the standard value evenly all round.
•
Remove shims (9), push out bushing (7) rightwards by means of three capscrews (11) and adjust clearance (B) so it settles within the standard value evenly all round.
Install pin (10) until the top 10 : PIN of pin is even surface with bushing.
Fig. 32-7 Adjusting clearance between bucket and arm
: 24mm, Tightening torque : 279N•m (206 lbf•ft)
32-5
+0.039"
326 -0.5 (12.84 -0.020" ) New bucket
7 : BUSHING
8 : PLATE
(4) Adjust clearance (B) where it is more than 1.0mm (0.04in).
+1.0
Apply rust preventive oil
32-5
32. ATTACHMENT
32. ATTACHMENT
32.1.3
32.1.3
ARM
32.1.3.1
REMOVING ARM
ARM
32.1.3.1
(1) Put the machine in position to remove arm. Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground.
REMOVING ARM
(1) Put the machine in position to remove arm. Extend the arm cylinder, retract the bucket cylinder and bring the arm down on the ground.
Fig. 32-8 Position to remove arm
Fig. 32-8 Position to remove arm
(2) Disconnecting piping of bucket cylinder Release pressure of hydraulic tank, place oil pan to prepare for oil leaking, and disconnect pipes.
(2) Disconnecting piping of bucket cylinder Release pressure of hydraulic tank, place oil pan to prepare for oil leaking, and disconnect pipes.
Plug both end of disconnected pipes.
Plug both end of disconnected pipes.
Plug : Tools section 11.5.2-(4) Tools section 11.5.2-(5)
Plug : Tools section 11.5.2-(4) Tools section 11.5.2-(5) OIL PAN
When the removal of bucket cylinder is not required, skip to procedure (6).
OIL PAN
Fig. 32-9 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)
After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in). SHIM
Loosen nut (9), remove capscrew M16u140 (8), and push out pin (H).
8
When the removal of bucket cylinder is not required, skip to procedure (6).
Fig. 32-9 Disconnecting piping of bucket cylinder
(3) Removing bucket cylinder rod pin (H)
After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in). SHIM
Loosen nut (9), remove capscrew M16u140 (8), and push out pin (H).
: 24mm
8
: 24mm
9 H
D
G A
A
H
SECTION D-D
Install plastic shims to bucket link side.
9 H
D
D
G A
A
H
SECTION D-D
Install plastic shims to bucket link side.
D PLASTIC SHIM
PLASTIC SHIM
STEEL SHIM
Fig. 32-10 Detail of bucket cylinder rod pin (H) (4) Removing cylinder head pin (G) Loosen nut (3), remove capscrew M16u150 (2), and push out pin (G).
Install plastic shims to bucket link side. SHIM
3
After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in).
: 24mm
Apply grease to inner wall of bushing
SHIM
Fig. 32-10 Detail of bucket cylinder rod pin (H) (4) Removing cylinder head pin (G) Loosen nut (3), remove capscrew M16u150 (2), and push out pin (G).
2
Install plastic shims to bucket link side. SHIM
3
2
After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in).
: 24mm
Apply grease to inner wall of bushing
SHIM
G
G
SECTION A-A
SECTION A-A
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
STEEL SHIM
Fig. 32-11 Detail of bucket cylinder head pin (G)
32-6
32. ATTACHMENT (5) Removing bucket cylinder Sling tube of bucket cylinder with nylon sling, and remove it. Bucket cylinder weight : 140 kg (310 lbs)
32. ATTACHMENT (5) Removing bucket cylinder Sling tube of bucket cylinder with nylon sling, and remove it. Bucket cylinder weight : 140 kg (310 lbs)
Fig. 32-12 Slinging bucket cylinder (6) Removing arm cylinder rod pin (E) Put a wooden block between the arm cylinder and the boom. Loosen nut (3), remove capscrew M16u150 (4), and push out arm cylinder rod pin (E).
Fig. 32-12 Slinging bucket cylinder
Apply grease to inner wall of bushing
2
Install plastic shims to bucket link side. SHIM
E
: 24mm
(6) Removing arm cylinder rod pin (E) Put a wooden block between the arm cylinder and the boom. Loosen nut (3), remove capscrew M16u150 (4), and push out arm cylinder rod pin (E).
Apply grease to inner wall of bushing
2
Install plastic shims to bucket link side. SHIM
E
: 24mm
3
Retract arm cylinder rod, and return pin (E) to the original position (hole).
SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in). SECTION B-B
E
F
SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in). SECTION B-B
E
Fig. 32-13 Detail of arm cylinder rod pin (E)
BLOCK
3
Retract arm cylinder rod, and return pin (E) to the original position (hole).
Fig. 32-13 Detail of arm cylinder rod pin (E)
BLOCK
F
(7) Removing boom top pin (F) Loosen capscrew M14u30 (2), and pull out boom top pin (F).
(7) Removing boom top pin (F) Loosen capscrew M14u30 (2), and pull out boom top pin (F).
Tightening torque 144N.m (106 lbf.ft) Apply loctite #242 to bolt.
1
2
SHIM Install plastic shims to arm side.
: 22 mm Insert pin (F) into the original hole.
SHIM Install plastic shims to arm side.
: 22 mm Insert pin (F) into the original hole.
Apply grease to inner wall of bushing
SHIM After adjustment of shim, the total gap should be within 0.5mm (0.02in).
F
SECTION A-A
F
SECTION A-A
Fig. 32-14 Detail of boom top pin (F)
32-7
1
2
Apply grease to inner wall of bushing
SHIM After adjustment of shim, the total gap should be within 0.5mm (0.02in).
Tightening torque 144N.m (106 lbf.ft) Apply loctite #242 to bolt.
Fig. 32-14 Detail of boom top pin (F)
32-7
32. ATTACHMENT
32. ATTACHMENT
(8) Slinging arm assy Sling arm with nylon sling and remove it.
(8) Slinging arm assy Sling arm with nylon sling and remove it.
Arm weight : 660 kg (1,455 lbs)
Arm weight : 660 kg (1,455 lbs)
Fig. 32-15 Slinging arm assy 32.1.3.2
ATTACHING ARM
Fig. 32-15 Slinging arm assy 32.1.3.2
Instal the arm in the reverse order of removing, paying attention to the following :
ATTACHING ARM
Instal the arm in the reverse order of removing, paying attention to the following :
2) Check the seals for damage and replace as necessary.
2) Check the seals for damage and replace as necessary.
3) When inserting the pin, coat the shaft with grease.
3) When inserting the pin, coat the shaft with grease.
4) Pin lock nut handling procedure
4) Pin lock nut handling procedure (0.02")
1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
(0.02")
1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
CLEARANCE
CLEARANCE
: 24 mm
: 24 mm
5) When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the thickness of shims by referring to the Maintenance Standard.
5) When installing the arm and the cylinder, inspect the clearance in the thrust direction of the pins and decide the thickness of shims by referring to the Maintenance Standard.
6) Tightening torque
6) Tightening torque
Classfication Metric threads PF,PT threads
Size
Tightening torque N.m lbf.ft
M14
144
106
M16
147
108
1/8"
16.7
12.3
Classfication Metric threads PF,PT threads
32-8
Size
Tightening torque N.m lbf.ft
M14
144
106
M16
147
108
1/8"
16.7
12.3
32-8
32. ATTACHMENT 32.1.4 32.1.4.1
BOOM
32. ATTACHMENT 32.1.4
PREPARATION FOR REMOVING AND ATTACHING BOOM
32.1.4.1
BOOM PREPARATION FOR REMOVING AND ATTACHING BOOM
When removing and attaching boom in the position shown in Fig. 32-16, to remove and attach boom foot pin (A), removing and attaching of cab and guard are required.
When removing and attaching boom in the position shown in Fig. 32-16, to remove and attach boom foot pin (A), removing and attaching of cab and guard are required.
32.1.4.2
32.1.4.2
REMOVING BOOM
(1) Put the machine in position to remove boom. Place top end of boom down on block, etc. giving attention for arm cylinder rod not to be extended.
REMOVING BOOM
(1) Put the machine in position to remove boom. Place top end of boom down on block, etc. giving attention for arm cylinder rod not to be extended.
BLOCK
BLOCK
Fig. 32-16 Position to remove boom (2) Lifting up boom cylinder temporarily Remove the right and left boom cylinders one side by one side according to the following procedure: Lift up boom cylinder temporarily to prevent it from dropping.
Fig. 32-16 Position to remove boom (2) Lifting up boom cylinder temporarily Remove the right and left boom cylinders one side by one side according to the following procedure: Lift up boom cylinder temporarily to prevent it from dropping.
A A
A A
C
C
STAND
STAND
Fig. 32-17 Lifting up boom cylinder temporarily (3) Press the boom cylinder rod pin (C) At the one side of pin (C), loosen nut (5), remove capscrew (3) (M16X150), and remove boss (4). And push pin (C) to the end of boom boss.
Install plastic shim to cylinder side. SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in).
Fig. 32-17 Lifting up boom cylinder temporarily (3) Press the boom cylinder rod pin (C) At the one side of pin (C), loosen nut (5), remove capscrew (3) (M16X150), and remove boss (4). And push pin (C) to the end of boom boss.
Install plastic shim to cylinder side. SHIM After adjustment of shim, the total gap should be within 0.6~2.0mm (0.02~0.08in).
SHIM
: 24 mm
: 24 mm
3
4 (4) Preparing for disconnecting cylinder pipes Retract the above mentioned cylinder rod, and place one side of cylinder on stand. (See Fig. 3217)
SHIM
C
4 5
32-9
3
4 (4) Preparing for disconnecting cylinder pipes Retract the above mentioned cylinder rod, and place one side of cylinder on stand. (See Fig. 3217)
C
4 5
SECTION A-A
SECTION A-A
Fig. 32-18 Detail of boom cylinder rod pin (C)
Fig. 32-18 Detail of boom cylinder rod pin (C)
32-9
32. ATTACHMENT
32. ATTACHMENT
(5) Disconnecting the arm cylinder and bucket cylinder pipings Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect pipe at (A1), (A2), (A3), (A4) and hose (B1), (B2), (B3), (B10).
(5) Disconnecting the arm cylinder and bucket cylinder pipings Release pressure from arm and bucket circuit and bleed air in hydraulic tank, and then disconnect pipe at (A1), (A2), (A3), (A4) and hose (B1), (B2), (B3), (B10).
A1 A4 A3 A2
: 36, 41 mm
A1 A4 A3 A2
: 36, 41 mm
After disconnection of pipe, plug every pipe. ORS Plug : See Tools 11.5.2-(4). O-RING B2
After disconnection of pipe, plug every pipe. ORS Plug : See Tools 11.5.2-(4).
O-RING B1 B3
O-RING B2
BUCKET (H) BUCKET (R)
B10 ARM (R)
ARM (H)
O-RING B1 B3 BUCKET (H) BUCKET (R)
B10 ARM (R)
Fig. 32-19 Boom piping disconnection
ARM (H)
Fig. 32-19 Boom piping disconnection
(6) Lifting up boom assy temporarily Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.
(6) Lifting up boom assy temporarily Lift up boom cylinder with nylon sling so that boom foot pin (A) is not loaded.
Weight of single boom : 1,310 kg (2,890 lbs)
Weight of single boom : 1,310 kg (2,890 lbs)
A
A
A
A
A
Boom assy temporary lift up procedure
(7) Removing boom foot pin (A)
Boom assy temporary lift up procedure
After adjustment of shim, the total gap should be SHIM within 0.5mm (0.02in).
1) Loosen nut (3) and remove capscrew (2) M20u175.
A
(7) Removing boom foot pin (A)
After adjustment of shim, the total gap should be SHIM within 0.5mm (0.02in).
1) Loosen nut (3) and remove capscrew (2) M20u175.
2
2
A : 30 mm
A : 30 mm
Apply molybdenum addition grease to inner wall of bushing.
2) Draw out pin (A).
3
Apply molybdenum addition grease to inner wall of bushing.
2) Draw out pin (A).
SHIM Install plastic shim to boom side.
SHIM Install plastic shim to boom side.
SECTION A-A
SECTION A-A
Fig. 32-20 Details of boom foot pin (A) section
32-10
3
Fig. 32-20 Details of boom foot pin (A) section
32-10
32. ATTACHMENT
(8) Hoisting boom assy Hoist and remove boom assy.
32. ATTACHMENT
(8) Hoisting boom assy Hoist and remove boom assy.
Weight of single boom : 1,310 kg (2,890 lbs)
D
Weight of single boom : 1,310 kg (2,890 lbs)
D
D
Boom assy hoisting procedure
Boom assy hoisting procedure
(9) Completion of removal of front attachments When the removing and attaching of cylinder are not required, the work is finished.
(9) Completion of removal of front attachments When the removing and attaching of cylinder are not required, the work is finished.
2
(10)Removing and installing arm cylinder
2
(10)Removing and installing arm cylinder
F2
1) Lift up arm cylinder (2) with nylon sling so that the head of cylinder is not loaded.
F2
1) Lift up arm cylinder (2) with nylon sling so that the head of cylinder is not loaded.
2) Disconnect hose (F1) and (F2) at position A. After disconnection of hose, plug both ends of hose. Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting 11.5.2-(5) Plugs for half clamp
D
After adjustment of shim, the total gap should be within F1 0.6~1.0mm (0.02~0.04in).
Install plastic shim to cylinder side. SHIM
3
A
2
SHIM Apply grease to inner wall of bushing
:36 mm :12 mm
2) Disconnect hose (F1) and (F2) at position A. After disconnection of hose, plug both ends of hose. Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting 11.5.2-(5) Plugs for half clamp
After adjustment of shim, the total gap should be within F1 0.6~1.0mm (0.02~0.04in).
Install plastic shim to cylinder side. SHIM
3
A
2
SHIM Apply grease to inner wall of bushing
:36 mm :12 mm
SECTION D-D
3) Removing arm cylinder head pin (D) Loosen nut (3), remove capscrew M16u150 (2) and pull out pin (D).
D
Fig. 32-21 Removing arm cylinder
: 24mm
SECTION D-D
3) Removing arm cylinder head pin (D) Loosen nut (3), remove capscrew M16u150 (2) and pull out pin (D).
Fig. 32-21 Removing arm cylinder
: 24mm
4) Removing arm cylinder (2) Weight of arm cylinder : 255 kg (560 lbs)
4) Removing arm cylinder (2) Weight of arm cylinder : 255 kg (560 lbs)
32-11
D
32-11
32. ATTACHMENT
32. ATTACHMENT
(11)Removing and installing boom cylinder
(11)Removing and installing boom cylinder
1) Release pressure from boom circuit and bleed air in hydraulic tank.
1) Release pressure from boom circuit and bleed air in hydraulic tank.
2) Sling boom cylinder (2) using nylon sling temporally not to act the weight of cylinder upon the cylinder head.
2) Sling boom cylinder (2) using nylon sling temporally not to act the weight of cylinder upon the cylinder head.
2
3) Disconnect each two hoses (C2) and (C3). And plug their both ends.
3) Disconnect each two hoses (C2) and (C3). And plug their both ends.
2 B
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting
C3
B C3
: 27,32,36,41mm
C2
C3
Fig. 32-22 Removing and installing boom cylinder After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in).
SHIM
B
After adjustment of shim, the total gap should be within 0.6~1.0mm (0.02~0.04in).
SHIM
Apply grease to inner wall of bushing
3
B
B
: 24mm
B
: 24mm
5) Remove boom cylinder (2). Weight of boom cylinder : 170 kg (375 lbs)
Apply grease to inner wall of bushing
6) Remove another boom cylinder the same way.
5) Remove boom cylinder (2). Weight of boom cylinder : 170 kg (375 lbs)
5
SECTION B-B
SHIM Install plastic shim to cylinder side.
Apply grease to inner wall of bushing
6) Remove another boom cylinder the same way.
ATTACHING BOOM
A
1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
ATTACHING BOOM
(1) Attaching boom foot pin (A) First of all, insert boom foot pin (A) and install the boom assy. Attach it in the reverse procedure of removing, paying attention to the following points.
2) Check that the dust seals is not damaged and replace as necessary.
3) When inserting the pin, coat the shaft with grease.
3) When inserting the pin, coat the shaft with grease.
B
5) When installing boom and cylinder, check the clearance of mounting section in thrust direction, and decide the thickness of shim according to the maintenance standard. Install plastic shim first, and insert iron shim into remaining gap. Regarding the position of shim, refer to Fig. 3220.
32-12
Fig. 32-24 Boom foot pin (A)
A
1) When aligning the pin holes, do not put your finger in the pin holes, but align them visually.
2) Check that the dust seals is not damaged and replace as necessary.
4) Refer to paragraph 32.1.3.2 (page 32-8) about installing of jam nut.
SHIM Install plastic shim to cylinder side.
Fig. 32-23 Removing and installing boom cylinder head pin (B) 32.1.4.3
(1) Attaching boom foot pin (A) First of all, insert boom foot pin (A) and install the boom assy. Attach it in the reverse procedure of removing, paying attention to the following points.
5
SECTION B-B
Fig. 32-23 Removing and installing boom cylinder head pin (B) 32.1.4.3
C2
Fig. 32-22 Removing and installing boom cylinder 4) Removing boom cylinder foot pin (B) (See Fig. 32-23,Fig. 32-24) Loosen nut (5), remove capscrews M16u150 (3) and pull out pin (B).
Apply grease to inner wall of bushing
3
2
Plug : TOOLS 11.5.2-(4) Plugs for ORS fitting
C3
: 27,32,36,41mm
4) Removing boom cylinder foot pin (B) (See Fig. 32-23,Fig. 32-24) Loosen nut (5), remove capscrews M16u150 (3) and pull out pin (B).
2
4) Refer to paragraph 32.1.3.2 (page 32-8) about installing of jam nut.
B
5) When installing boom and cylinder, check the clearance of mounting section in thrust direction, and decide the thickness of shim according to the maintenance standard. Install plastic shim first, and insert iron shim into remaining gap. Regarding the position of shim, refer to Fig. 3220.
32-12
Fig. 32-24 Boom foot pin (A)
32. ATTACHMENT
32. ATTACHMENT
32.2
DISASSEMBLING AND ASSEMBLING
32.2
DISASSEMBLING AND ASSEMBLING
32.2.1
CYLINDER
32.2.1
CYLINDER
32.2.1.1
PREPARATION BEFORE DISASSEMBLY
32.2.1.1
PREPARATION BEFORE DISASSEMBLY
Before assembly, secure a dustfree workshop and necessary equipment and facilities.
Before assembly, secure a dustfree workshop and necessary equipment and facilities.
32.2.1.1.1
32.2.1.1.1
WORK AREA
WORK AREA
The following working area is required for disassembly:
The following working area is required for disassembly:
(1) Ample space
(1) Ample space
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work. In terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work can be performed. (2) Suitable working environment
(2) Suitable working environment
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding operation should not be performed in the neighborhood of the working area to keep it clean. 32.2.1.1.2
For the disassembly of the hydraulic cylinder, the cylinder tube and the piston rod must be drawn out. For this reason, the first condition is that the working area is long enough for the work. In terms of width, it is also necessary to keep sufficient space to disassembly, cleaning and measuring equipment are placed and the work can be performed.
APPARATUS
The hydraulic cylinder is a precision-machined product that uses seals and packings made of rubber and plastic materials. For this reason full care should be exercised so the hydraulic cylinder is free from dust, dirt, and in particular, such hard particles as sand, metal chips, and weld slag (spatter). If the hydraulic cylinder is assembled with hard particles adhered on such components as the cylinder tube and the piston rod, the tube inner surface and the rod surface are scratched as the cylinder operates, consequently disabling it in worst cases. Damage to the piston seals and the rod seals will result in oil leaks. For this reason, grinding and welding operation should not be performed in the neighborhood of the working area to keep it clean. 32.2.1.1.2
APPARATUS
The following equipment are required for disassembly:
The following equipment are required for disassembly:
(1) Hoist or crane
(1) Hoist or crane
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making level and liner movement under load for retracting and extending the piston rod and the tube. (2) Work bench
The hoist or crane must be capable of carrying the cylinder in an assembled condition. It must also be capable of making level and liner movement under load for retracting and extending the piston rod and the tube. (2) Work bench
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large. (3) Support stand
The work bench must have strength and rigi-dity capable of accommodating the total length of the cylinder in its most retracted condition and of withstanding the repulsive force of the tightening torques of the cylinder head and the piston nut. Since a vise is attached to the bench, the width of the work bench must be sufficiently large. (3) Support stand
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent damage of seals. (4) Hydraulic source
If the piston rod is fully extended in a free condition, the bushing and the seals may be damaged as the rod bushing and the piston are twisted due to the weight of the rod. A stand is required to support the rod to prevent damage of seals. (4) Hydraulic source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak tests after completion of assembly. (5) Jet air source
A Hydraulic source is required for disassembly and assembly of the cylinder head and piston nut and for oil leak tests after completion of assembly. (5) Jet air source
It is used for drying after oil draining and cleaning of the cylinder.
It is used for drying after oil draining and cleaning of the cylinder.
(6) Cleaning bath, cleaning oil and detergent
(6) Cleaning bath, cleaning oil and detergent
(7) Oil pan and oil reservoir
(7) Oil pan and oil reservoir
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work. An oil reservoir is required to collect oil spilt on the floor and waste oil. (8) Others
An oil pan is necessary to contain oil drained from the cylinder and oil spilt during work. An oil reservoir is required to collect oil spilt on the floor and waste oil. (8) Others
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
Oil extracting hoses, wooden blocks, clean cloths and sawdust in which oil soaked are also necessary.
32-13
32. ATTACHMENT
32. ATTACHMENT
32.2.1.1.3
32.2.1.1.3
NECESSARY TOOLS
Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
NECESSARY TOOLS
Tools and jigs vary with types of cylinder, but it is necessary to prepare the tools in Table32-1 as a guideline.
Table32-1 List of Tools and Jigs Tool / Jig Hammer
Remarks
Tool / Jig
1. Steel hammer 2. Wooden or plastic mallet
Screwdriver A few types of large and small sizes Chisel
Vise
Wrench
Table32-1 List of Tools and Jigs
Flat chisel
Remarks
Tool / Jig
Spatula
Metallic one with smooth corners.
Gimlet
A sharp-point tool may be used in place of a gimlet.
Hammer
Chisel
1. Steel hammer 2. Wooden or plastic mallet
Flat chisel
Spatula
Metallic one with smooth corners.
Gimlet
A sharp-point tool may be used in place of a gimlet.
Special jig 1. For removing and press-fitting bushing. (A), (D), (C) 2. For press-fitting wiper ring. (D)
3. For inserting and reforming seal ring. (E),(F),(G),(H) See para 32.2.1.9 for detail)
3. For inserting and reforming seal ring. (E),(F),(G),(H) See para 32.2.1.9 for detail) Vise
Measuring 1. Slide caliper instruments 2. Micrometer
Wrench
3. Cylinder gauge ( Fig. 32-25)
Rust remover
One having an operation wide enough to hold cylinder head O.D. and tube mounting pins (clevis)
Measuring 1. Slide caliper instruments 2. Micrometer
1. Eye wrench 2. Allen wrench 3. Extension pipe for wrenches
3. Cylinder gauge ( Fig. 32-25)
4. V-block •
•
EXTERNAL CLEANING
Fig. 32-25 Cylinder gauge
The following describes the construction of boom cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts Manual.
32.2.1.1.5
For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4
The cylinder taken off the excavator has dust and foreign matter, and grease is usually adhered to the clevis part. For this reason, remove external soil and contamination from the cylinder with water and steam before bringing it into the workshop. •
4. V-block
For the details of special tools and jigs, refer to the back pages of this manual.
32.2.1.1.4
DISCHARGING OIL
PORT B V BLOCK PORT A
Fig. 32-25 Cylinder gauge
The following describes the construction of boom cylinder. When disassembling and servicing the cylinder, confirm the construction of cylinder referring to Parts Manual.
32.2.1.1.5 WOODEN BLOCK
EXTERNAL CLEANING
The cylinder taken off the excavator has dust and foreign matter, and grease is usually adhered to the clevis part. For this reason, remove external soil and contamination from the cylinder with water and steam before bringing it into the workshop. •
Place a wooden-block on the work bench and place the cylinder on it to prevent it from rotating. Charge air into ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port so that the hydraulic oil may not gush out.
Remarks
2. For press-fitting wiper ring. (D)
Rust remover
1. Eye wrench 2. Allen wrench 3. Extension pipe for wrenches
Tool / Jig
Screwdriver A few types of large and small sizes
Special jig 1. For removing and press-fitting bushing. (A), (D), (C)
One having an operation wide enough to hold cylinder head O.D. and tube mounting pins (clevis)
Remarks
DISCHARGING OIL
Place a wooden-block on the work bench and place the cylinder on it to prevent it from rotating. Charge air into ports A and B alternately to actuate the piston rod till the hydraulic oil in the cylinder is drained out. At this time, connect a suitable hose to each port so that the hydraulic oil may not gush out.
AIR
WOODEN BLOCK PORT B V BLOCK PORT A
AIR
OIL PAN
OIL PAN
Fig. 32-26 Preparation
32-14
Fig. 32-26 Preparation
32-14
32. ATTACHMENT 32.2.1.2
CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
25
24
32. ATTACHMENT 32.2.1.2
12
24
25
CONSTRUCTION OF CYLINDER (GENERAL EXAMPLE OF CYLINDER)
25
24
12
24
25
B
PS1/8
PT1/4
DETAIL 6
8
7
6
DETAIL B
4
PS1/8
PT1/4
15
SLIT
9
B
5
3
11 10
ONE HOLE
DETAIL 6
DETAIL C
2
1
15
SLIT
DETAIL B
13 14
15
17 16 18 19 *20 *21 22 23
9
8
7
6
4
SLIT
5
Q’ty
No.
Parts name
Q’ty
3
11 10
2
1
Piston with piston nut type
13 14
15
17 16 18 19 *20 *21 22 23
SLIT
C
Fig. 32-27 Construction of general cylinder Parts name
DETAIL C
Piston with piston nut type
C
No.
ONE HOLE
Fig. 32-27 Construction of general cylinder
No.
Parts name
Q’ty
No.
Parts name
Q’ty
No.
Parts name
Q’ty
No.
Parts name
Q’ty
1
Cylinder tube
1
10 O-ring
1
19 Slide ring
2
1
Cylinder tube
1
10 O-ring
1
19 Slide ring
2
2
Piston rod
1
11 Back-up ring
1
20 Shim
*1
2
Piston rod
1
11 Back-up ring
1
20 Shim
*1
3
Rod cover
1
12 Socket bolt
12
21 Piston nut
*1
3
Rod cover
1
12 Socket bolt
12
21 Piston nut
*1
4
Bushing
1
13 Cushion bearing
1
22 Setscrew ; M12
1
4
Bushing
1
13 Cushion bearing
1
22 Setscrew ; M12
1
5
Snap ring
1
14 Cushion seal
1
23 Steel ball
1
5
Snap ring
1
14 Cushion seal
1
23 Steel ball
1
6
Buffer ring
1
15 Piston
1
24 Pin bushing
2
6
Buffer ring
1
15 Piston
1
24 Pin bushing
2
7
U-ring
1
16 Seal ring
1
25 Wiper ring
4
7
U-ring
1
16 Seal ring
1
25 Wiper ring
4
8
Back-up ring
1
17 Back-up ring
2
8
Back-up ring
1
17 Back-up ring
2
9
Wiper ring
1
18 Slide ring
2
9
Wiper ring
1
18 Slide ring
2
Note : In case of piston with piston nut type, the parts with * are not used.
32-15
Note : In case of piston with piston nut type, the parts with * are not used.
32-15
32. ATTACHMENT
32. ATTACHMENT
32.2.1.3
32.2.1.3
DISASSEMBLY
DISASSEMBLY
• When disassembling and servicing the cylinder, check the construction and the availability of service parts as well as necessary tools and jigs on separate Parts Manual.
• When disassembling and servicing the cylinder, check the construction and the availability of service parts as well as necessary tools and jigs on separate Parts Manual.
• The figures in parentheses after part names correspond to those in Fig. 32-27.
• The figures in parentheses after part names correspond to those in Fig. 32-27.
• The following explanation and quantities are for a general use cylinder which has separated piston and piston nut. In case that piston and piston nut are combined, the construction differs from separated type, refer to the sentence in parenthesis.
• The following explanation and quantities are for a general use cylinder which has separated piston and piston nut. In case that piston and piston nut are combined, the construction differs from separated type, refer to the sentence in parenthesis.
32.2.1.3.1
REMOVING ROD COVER AND PISTON ROD
32.2.1.3.1
REMOVING ROD COVER AND PISTON ROD
(1) Hold the clevis section of the tube in a vise.
(1) Hold the clevis section of the tube in a vise.
Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
Use mouth pieces so as not to damage the machined surface of the cylinder tube. Do not make use of the outside piping as a locking means.
(2) Pull out piston rod (2) about 200mm (8in). Because the piston rod is heavy, finish extending it with air pressure after the above-mentioned oil draining operation.
(2) Pull out piston rod (2) about 200mm (8in). Because the piston rod is heavy, finish extending it with air pressure after the above-mentioned oil draining operation.
200mm (8")
(3) Loosen and remove socket bolts (12) of the rod cover in sequence.
200mm (8")
(3) Loosen and remove socket bolts (12) of the rod cover in sequence.
2 Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation.
2
Fig. 32-28 ALLEN WRENCH
Cover the extended piston rod (2) with cloths to prevent it from being accidentally damaged during operation.
12
(4) Strike the corner of the rod cover flange by means of a plastic mallet till rod cover (3) comes off.
Fig. 32-28 ALLEN WRENCH
12
(4) Strike the corner of the rod cover flange by means of a plastic mallet till rod cover (3) comes off. Turn counterclockwise
Turn counterclockwise
3 2
3
Cover here with cloths
2
Fig. 32-29
32-16
Cover here with cloths
Fig. 32-29
32-16
32. ATTACHMENT • At this time, the weight of piston rod (2) is loaded on rod cover (3). Therefore, lift the top end of the piston rod with a hoist to the extent that only the rod weight may be held.
KNOCK THIS EDGE WITH A PLASTIC MALLET.
LIFT HERE.
32. ATTACHMENT • At this time, the weight of piston rod (2) is loaded on rod cover (3). Therefore, lift the top end of the piston rod with a hoist to the extent that only the rod weight may be held.
KNOCK THIS EDGE WITH A PLASTIC MALLET.
LIFT HERE.
1
1
3
2
Fig. 32-30 Drawing out piston rod assy (2). (5) Draw out the piston rod assy from cylinder tube (1).
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out. However, when piston rod (2) has been drawing out to approximately two thirds of its length, lift it in its center to draw it completely. However, since the plated surface of piston rod (2) is lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope.
1
LIFT HERE. PULL STRAIGHT SIDEWAYS HORIZONTALLY
OIL PAN
Fig. 32-31 Method of drawing out the piston rod assy
(6) Place the removed piston rod on a horaizontal wooden V-block.
3
2
PISTON ROD ASSY
• Cover a V-block with cloths.
Fig. 32-30 Drawing out piston rod assy (2). (5) Draw out the piston rod assy from cylinder tube (1).
Since the piston rod assy is heavy in this case, lift the tip of the piston rod (2) with a hoist and draw it out. However, when piston rod (2) has been drawing out to approximately two thirds of its length, lift it in its center to draw it completely. However, since the plated surface of piston rod (2) is lifted, do not use a wire rope which may score the surface, but use a strong cloth belt or a rope.
1
LIFT HERE. PULL STRAIGHT SIDEWAYS HORIZONTALLY
OIL PAN
Fig. 32-31 Method of drawing out the piston rod assy
(6) Place the removed piston rod on a horaizontal wooden V-block.
PISTON ROD ASSY
• Cover a V-block with cloths. WOODEN V-BLOCK
WOODEN V-BLOCK
(PLACE CLOTHS)
(PLACE CLOTHS)
Fig. 32-32 Method of placing the piston rod (7) Remove slide ring (18) and (19) from piston (15).
Fig. 32-32 Method of placing the piston rod (7) Remove slide ring (18) and (19) from piston (15).
15
15
Remove slide ring by widening the slit toward the arrow
Remove slide ring by widening the slit toward the arrow
19
19
18
18
Fig. 32-33 Remove slide ring (18) and (19)
32-17
Fig. 32-33 Remove slide ring (18) and (19)
32-17
32. ATTACHMENT
32. ATTACHMENT
32.2.1.3.2
32.2.1.3.2
REMOVING PISTON ASSY
(1) Fix piston rod (2) by holding its clevis section in a vise. Fix the piston rod (2) securely as piston nut (21) is tightened to a high torque.
2
15
3
WOODEN BLOCK
REMOVING PISTON ASSY
(1) Fix piston rod (2) by holding its clevis section in a vise. Fix the piston rod (2) securely as piston nut (21) is tightened to a high torque.
15
21
3
WOODEN BLOCK
21
•
Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston (15), though the rod diameter remains the same.
•
Note that the tightening torque differs with the type, the working pressure and the mounting method of the piston (15), though the rod diameter remains the same.
•
It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths or something over the rod to prevent it from damage.
•
It is also necessary to place a suitable supporting block near the piston (15). In case a V-block is used, put cloths or something over the rod to prevent it from damage.
WOODEN V-BLOCK (PLACE CLOTHS)
WOODEN V-BLOCK (PLACE CLOTHS)
Fig. 32-34 How to loosen piston nut (21) (2) Scrape off the caulked part of setscrew (22) of piston nut (21) by means of a hand drill and loosen setscrew (22) and remove ball (23).
2
22
Fig. 32-34 How to loosen piston nut (21) (2) Scrape off the caulked part of setscrew (22) of piston nut (21) by means of a hand drill and loosen setscrew (22) and remove ball (23).
DRILL
22
DRILL
21
21
23
23
Fig. 32-35 Removing setscrew (22) and ball (23) (3) Loosen and remove piston nut (21) or [piston (15)].
•
•
Since piston nut (21) is tightened to a high torque, use a eye wrench suitable for the outside diameter of piston nut (21). In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the piston directly.
Fig. 32-35 Removing setscrew (22) and ball (23) (3) Loosen and remove piston nut (21) or [piston (15)].
TURN COUNTER CLOCKWISE.
•
15
EYE WRENCH
21
Fig. 32-36 How to loosen piston nut (21)
•
Since piston nut (21) is tightened to a high torque, use a eye wrench suitable for the outside diameter of piston nut (21). In case that piston and piston nut are combined, apply the eye wrench to hexagonal part of piston and loosen the piston directly.
(4) Remove piston (15) by tapping with plastic mallet, supporting weight of piston (15) with hoist.
(4) Remove piston (15) by tapping with plastic mallet, supporting weight of piston (15) with hoist.
In case that piston and piston nut are combined, the shim (20) is not used.
In case that piston and piston nut are combined, the shim (20) is not used.
4
15
15
EYE WRENCH
21
Fig. 32-36 How to loosen piston nut (21)
4
Fig. 32-37 Removing piston (15)
32-18
TURN COUNTER CLOCKWISE.
15
Fig. 32-37 Removing piston (15)
32-18
32. ATTACHMENT (5) After removing cushion bearing (13) and cushion seal (14), separate rod cover (3) from piston rod (2). If it is too hard to slide it, knock the flanged part of rod cover (3) with a plastic mallet. But when drawing it out, lift rod cover (3) by hoist and pull it straight horizontally.
LIFT WITH A HOIST. PULL STRAIGHT.
NOTE: DO NOT DAMAGE PISTON ROD SURFACE.
Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston rod (2). 32.2.1.3.3
STRIKE WITH A PLASTIC MALLET.
3
4
6 8,7 9
32. ATTACHMENT (5) After removing cushion bearing (13) and cushion seal (14), separate rod cover (3) from piston rod (2). If it is too hard to slide it, knock the flanged part of rod cover (3) with a plastic mallet. But when drawing it out, lift rod cover (3) by hoist and pull it straight horizontally.
LIFT WITH A HOIST. PULL STRAIGHT.
NOTE: DO NOT DAMAGE PISTON ROD SURFACE.
Take care so rod bushing (4) and the lip of packings (6,7,8,9) may not be damaged by thread of the piston rod (2).
2
Fig. 32-38 Removing rod cover (3)
DISASSEMBLING PISTON ASSY
32.2.1.3.3
(1) Remove seal ring (16) and back-up ring (17).
STRIKE WITH A PLASTIC MALLET.
3
4
6 8,7 9
2
Fig. 32-38 Removing rod cover (3)
DISASSEMBLING PISTON ASSY
(1) Remove seal ring (16) and back-up ring (17). HAMMER
HAMMER
SCREWDRIVER (OR CHISEL)
Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the groove may be damaged.
BACK-UP RING
SEAL RING
17
15
USE CARE NOT TO DAMAGE THE GROOVE.
BACK-UP RING
SEAL RING
17
16
15
O-RING
Fig. 32-39 Removing seal ring (16) and back-up ring (17)
32-19
SCREWDRIVER (OR CHISEL)
Cut the seal ring (16) by tapping it with a screwdriver or a chisel. Take care not to strike it too hard, otherwise the groove may be damaged.
USE CARE NOT TO DAMAGE THE GROOVE.
16
O-RING
Fig. 32-39 Removing seal ring (16) and back-up ring (17)
32-19
32. ATTACHMENT
32. ATTACHMENT
32.2.1.3.4
32.2.1.3.4
DISASSEMBLING ROD COVER ASSY
(1) Remove O-ring (10) and back-up ring (11). Remove back-up ring (11) and O-ring (10) in that order. Remove back-up ring (11) and O-ring (10) by pulling and stretching them with an spatula like earpick.
SPATULA
10 11
DISASSEMBLING ROD COVER ASSY
(1) Remove O-ring (10) and back-up ring (11). Remove back-up ring (11) and O-ring (10) in that order. Remove back-up ring (11) and O-ring (10) by pulling and stretching them with an spatula like earpick.
SPATULA
10 11
3
3
Fig. 32-40 Removing the outer circumferential seal of rod cover (3) (2) Remove buffer ring (6), U-ring (7) and back-up ring (8). Each seal is fixed in the groove on the bore and removing in flawless is impossible. Stab each seal with a gimlet and pull it out of the groove.
(2) Remove buffer ring (6), U-ring (7) and back-up ring (8). Each seal is fixed in the groove on the bore and removing in flawless is impossible. Stab each seal with a gimlet and pull it out of the groove.
GIMLET
8 7
3
Fig. 32-40 Removing the outer circumferential seal of rod cover (3) GIMLET
8 7
3
6
6
Take care in this operation not to damage the grooves.
Take care in this operation not to damage the grooves.
Fig. 32-41 Removing the inner circumferential seal of rod cover (3) (3) Remove wiper ring (9). When taking out wiper ring (9), fix rod cover (3) in a vise.
HAMMER SCREWDRIVER
Fig. 32-41 Removing the inner circumferential seal of rod cover (3) (3) Remove wiper ring (9). When taking out wiper ring (9), fix rod cover (3) in a vise.
3
HAMMER SCREWDRIVER
3
9 WOOD PIECE VISE
9 WOOD PIECE
WOOD PIECE
VISE
Fig. 32-42 Removing wiper ring (9) (4) Remove snap ring (5) and bushing (4). Remove snap ring (5) first, and remove bushing (4). But the bushing (4) is press fitted in rod cover (3), so push it out by press with jig as shown in the figure. See para 32.2.1.9.3 (1) for removing.
CHUCK ASSY TOOL A
PRESS HERE
BUSHING 4
Fig. 32-42 Removing wiper ring (9) (4) Remove snap ring (5) and bushing (4). Remove snap ring (5) first, and remove bushing (4). But the bushing (4) is press fitted in rod cover (3), so push it out by press with jig as shown in the figure. See para 32.2.1.9.3 (1) for removing.
BLOCK TOOL C
CHUCK ASSY TOOL A
PRESS HERE
BUSHING 4
BLOCK TOOL C
Fig. 32-43 Removing rod bushing (4)
32-20
WOOD PIECE
Fig. 32-43 Removing rod bushing (4)
32-20
32. ATTACHMENT 32.2.1.3.5
REMOVING PIN BUSHING
32. ATTACHMENT 32.2.1.3.5
REMOVING PIN BUSHING
(1) Apply driver to wiper ring (25) of cylinder tube (1) and piston rod (2), and strike it by hammer lightly.
(1) Apply driver to wiper ring (25) of cylinder tube (1) and piston rod (2), and strike it by hammer lightly.
(2) Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
(2) Push out pin bushing (24) press fitted in cylinder tube (1) and piston rod (2) with press.
Fig. 32-44 Drawing out pin bushing (24) 32.2.1.4
CLEANING
Fig. 32-44 Drawing out pin bushing (24) 32.2.1.4
CLEANING
(1) After disassembly the cylinder, wash all parts with commercial detergent.
(1) After disassembly the cylinder, wash all parts with commercial detergent.
Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc.
Never use benzene(gasoline, thinner, etc.) because it may be damage the rubber, etc.
(2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection.
(2) Do not use the used oil seal, O-ring, back-up ring, etc. even if they are not damaged after inspection.
(3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care not to damage them.
(3) After cleaning, dry all parts by compressed air, and put them on the working bench taking care not to damage them.
32.2.1.5
32.2.1.5
ASSEMBLING PIN BUSHING
Start assembling the following sub assy
Start assembling the following sub assy
• Cylinder tube assy
• Cylinder tube assy
• Piston assy
• Piston assy
• Rod cover assy
• Rod cover assy
32.2.1.5.1
ASSEMBLING PIN BUSHING
32.2.1.5.1
(1) Press fit pin bushing (24) in cylinder tube (1) and piston rod (2) respectively with press.
PUSH WITH A PRESS
(2) Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with press.
• •
ASSEMBLING PIN BUSHING
Before press fitting, apply grease on wiper ring and boss hole.
(1) Press fit pin bushing (24) in cylinder tube (1) and piston rod (2) respectively with press.
2
24
32-21
PUSH WITH A PRESS
(2) Press fit wiper ring (25) in the upper and lower sides of cylinder tube (1) and piston rod (2) respectively with press.
• OIL HOLE LOCATION
Fig. 32-45 Press fitting of pin bushing (24)
Before press fitting the pin bushing, align the position of oil hole.
ASSEMBLING PIN BUSHING
•
Before press fitting, apply grease on wiper ring and boss hole.
2
24
OIL HOLE LOCATION
Fig. 32-45 Press fitting of pin bushing (24)
Before press fitting the pin bushing, align the position of oil hole.
32-21
32. ATTACHMENT
32. ATTACHMENT
32.2.1.5.2
32.2.1.5.2
ASSEMBLING OF PISTON ASSY
(1) The fitting of seal ring (16) requires special tool as shown in Fig. 32-46. Seal ring (16) is pushed in by press, etc. with pushing in tool as shown in the figure. (The O-ring of seal ring (16) and back-up ring (17) on one side should be installed beforehand.)
PRESS HERE METAL (G) PRESS JIG (E) SLIDE JIG (F)
ASSEMBLING OF PISTON ASSY
(1) The fitting of seal ring (16) requires special tool as shown in Fig. 32-46. Seal ring (16) is pushed in by press, etc. with pushing in tool as shown in the figure. (The O-ring of seal ring (16) and back-up ring (17) on one side should be installed beforehand.)
PRESS HERE METAL (G) PRESS JIG (E) SLIDE JIG (F)
15 16
Heat them, and they may be soften. But never heat them over 100°C (212.0°F) or more.
17
(2) Fit back-up ring (17) on the other side. After fitting, correct it immediately to prevent from expansion of seal ring (16) with correcting jig (H) as shown in Fig. 32-47.
•
For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
•
•
O-RING
Fig. 32-46 How to fit seal ring (16)
16
17
PRESS HERE
CORRECTIONAL JIG (H)
15 16
Heat them, and they may be soften. But never heat them over 100°C (212.0°F) or more.
17
(2) Fit back-up ring (17) on the other side. After fitting, correct it immediately to prevent from expansion of seal ring (16) with correcting jig (H) as shown in Fig. 32-47.
For piston, stop it once tentatively (for 3 to 5 seconds), and then push it in fully.
After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted in cylinder tube (1).
•
After fitting, wind tape around seal ring (16) 2 or 3 times, and remove it immediately before piston (15) is inserted in cylinder tube (1).
Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).
•
Fit slide rings (18) (19) at the same time when piston (15) is inserted in cylinder tube (1).
Fig. 32-47 Installing seal ring (16) ASSEMBLING ROD COVER ASSY
(1) Press fit bushing (4) in rod cover (3) with bushing press-fitting jig (A). Then, fit snap ring (5) in the groove. Apply hydraulic oil on internal surface of rod cover (3).
The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.
The snap ring (5) can not be fitted when the bushing (4) is not press-fitted fully to the stop end.
RETAINER TOOL (D)
(2) Apply grease to wiper ring (9), and fit wiper ring (9), directing the lip side toward the groove of retainer tool (D). And set retainer tool (D) on rod cover (3) and press fit wiper ring (9) with press.
PRESS HERE
PRESS HERE. (STRAIGHT DOWN) RETAINER TOOL (D)
9
9
U-RING GROOVE
U-RING GROOVE
Fig. 32-48 Press fitting of bushing (4)
32-22
17
ASSEMBLING ROD COVER ASSY
(1) Press fit bushing (4) in rod cover (3) with bushing press-fitting jig (A). Then, fit snap ring (5) in the groove. Apply hydraulic oil on internal surface of rod cover (3).
PRESS HERE. (STRAIGHT DOWN)
16
Fig. 32-47 Installing seal ring (16) 32.2.1.5.3
(2) Apply grease to wiper ring (9), and fit wiper ring (9), directing the lip side toward the groove of retainer tool (D). And set retainer tool (D) on rod cover (3) and press fit wiper ring (9) with press.
Fig. 32-46 How to fit seal ring (16)
CORRECTIONAL JIG (H)
•
32.2.1.5.3
O-RING
Fig. 32-48 Press fitting of bushing (4)
32-22
32. ATTACHMENT (3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in their grooves in that order. Before setting packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the packings may be scored. When attaching seals, deform them in a heart shape as illustrated.
•
•
U-ring (7) is harder than other packing and it would be difficult to deform them in a heart shape. In such a case, put a U-ring in the groove obliquely by hand as deep as possible and push in the last part with a push bar till it is set with a click.
INSERT U-RING INTO GROOVE FROM THIS SIDE.
32. ATTACHMENT (3) Fit buffer ring (6), back-up ring (8) and U-ring (7) in their grooves in that order. Before setting packings, coat them with hydraulic oil (or vaseline if not available). If you forget the coating, the packings may be scored. When attaching seals, deform them in a heart shape as illustrated.
• Fig. 32-49 Inserting a seal into the inner circumference of rod cover.
Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and Uring.
PUSH BAR (WOOD OR PLASTIC)
10
•
11
Tube side
3
U-ring (7) is harder than other packing and it would be difficult to deform them in a heart shape. In such a case, put a U-ring in the groove obliquely by hand as deep as possible and push in the last part with a push bar till it is set with a click.
INSERT U-RING INTO GROOVE FROM THIS SIDE.
Fig. 32-49 Inserting a seal into the inner circumference of rod cover.
Buffer ring (6) should be fitted taking care of the fitting direction. The reverse fitting may cause deformation, damage, etc. of the piston due to high pressure generated between the buffer ring and Uring.
•
If U-ring (7) is set upside down, the lip may be damaged. Check that it is positioned correctly.
•
If U-ring (7) is set upside down, the lip may be damaged. Check that it is positioned correctly.
•
Attach back-up ring (11) on the open air side of Oring (10). (See Fig. 32-50).
•
Attach back-up ring (11) on the open air side of Oring (10). (See Fig. 32-50).
PUSH BAR (WOOD OR PLASTIC)
10 11
Tube side
3
6
6
7
7
8
8
9
9
Fig. 32-50 How to fit U-ring (7) 32.2.1.5.4
Fig. 32-50 How to fit U-ring (7)
INSERTING ROD COVER ASSY TO PISTON ROD
Inserting rod cover (3) to piston rod assy by the following procedure.
32.2.1.5.4 INSERT GUIDE JIG (I)
Inserting rod cover (3) to piston rod assy by the following procedure.
3
PUSH
(1) Fix piston rod assy on working bench. (2) Install rod cover (3) on piston rod (2) with inserting guide jig (I) as shown in Fig. 32-51 paying attention for the lip section of U-ring not to be caught on the stepped section.
INSERTING ROD COVER ASSY TO PISTON ROD INSERT GUIDE JIG (I) PUSH
(1) Fix piston rod assy on working bench.
2
(2) Install rod cover (3) on piston rod (2) with inserting guide jig (I) as shown in Fig. 32-51 paying attention for the lip section of U-ring not to be caught on the stepped section.
Fig. 32-51 Inserting rod cover (3)
2
Fig. 32-51 Inserting rod cover (3)
•
For the rod the outer diameter of piston installing section is small, insert spacer on the faucet section of rod first, and attach inserting guide jig.
•
For the rod the outer diameter of piston installing section is small, insert spacer on the faucet section of rod first, and attach inserting guide jig.
•
Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the insertion smooth.
•
Apply hydraulic oil on the inserting guide jig and outer surface of piston rod lightly to make the insertion smooth.
32-23
3
32-23
32. ATTACHMENT
32. ATTACHMENT
32.2.1.5.5
32.2.1.5.5
ASSEMBLING PISTON ASSY ONTO PISTON ROD
(1) Install cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following procedure.
14
PISTON
13
ASSEMBLING PISTON ASSY ONTO PISTON ROD
(1) Install cushion on the extraction side, cushion bearing (13) and cushion seal (14) by the following procedure.
1) Put cushion seal (14) on it, directing the slit machined side toward the piston side.
1) Put cushion seal (14) on it, directing the slit machined side toward the piston side.
2) Fit cushion bearing (13) on it directing the flattening side as shown in Fig. 32-52.
2) Fit cushion bearing (13) on it directing the flattening side as shown in Fig. 32-52.
14
FLAT SECTION
FLAT SECTION
Direct slit toward piston side
Direct slit toward piston side
Fig. 32-52 Cushion mechanism on extension side (2) When cushion is installed on the retraction side, fit cushion bearing (13) and cushion seal (14) by the following procedure.
Direct slit toward thread side THREADED PART
1) Fit cushion bearing before fitting piston nut. The nut attached obstructs the fitting of cushion bearing. 2) Put cushion seal on it, directing the slit machined side toward the piston side. 3) Fit cushion bearing on it directing the flattening side as shown in Fig. 32-53.
(2) When cushion is installed on the retraction side, fit cushion bearing (13) and cushion seal (14) by the following procedure.
Direct slit toward thread side THREADED PART
PISTON ROD
2) Put cushion seal on it, directing the slit machined side toward the piston side. SNAP RING
4) Put stopper in the groove. Push cushion bearing to stopper fully, and drive snap ring. Use plastic mallet in order not to damage the rod, cushion bearing.
Fig. 32-52 Cushion mechanism on extension side
1) Fit cushion bearing before fitting piston nut. The nut attached obstructs the fitting of cushion bearing.
PISTON ROD
PISTON
13
CUSHION SEAL (Slit 1 place)
STOPPER CUSHION BEARING (Divide into 2 portions)
Fig. 32-53 Cushion mechanism on retraction side
Cushion seal and cushion bearing should be fitted taking care of the fitting direction. If they are fitted in reverse directions, the cushion does not effective. After installing cushion, be sure that the cushion bearing moves up and down, and right and left.
3) Fit cushion bearing on it directing the flattening side as shown in Fig. 32-53.
SNAP RING
4) Put stopper in the groove. Push cushion bearing to stopper fully, and drive snap ring. Use plastic mallet in order not to damage the rod, cushion bearing.
STOPPER CUSHION BEARING (Divide into 2 portions)
Fig. 32-53 Cushion mechanism on retraction side
Cushion seal and cushion bearing should be fitted taking care of the fitting direction. If they are fitted in reverse directions, the cushion does not effective. After installing cushion, be sure that the cushion bearing moves up and down, and right and left.
32-24
CUSHION SEAL (Slit 1 place)
32-24
32. ATTACHMENT (3) Insert shim (20), and tighten piston nut (21) or [piston (15)] till it gets tight. Always tighten the piston nut (21) or [piston (15)] of each piston to specified torque (Refer to 32.2.1.7.3).
•
In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal part of piston and loosen the piston directly.
•
Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
•
Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes a bulge of cushion bearing and a deformation of piston contacted surface.
•
Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly.
21
EYE WRENCH
Fig. 32-54 Tightening piston nut (21) ANTI-LOOSENING
22 CAULKING
20
(3) Insert shim (20), and tighten piston nut (21) or [piston (15)] till it gets tight. Always tighten the piston nut (21) or [piston (15)] of each piston to specified torque (Refer to 32.2.1.7.3).
•
2
23
Fig. 32-55 Attaching setscrew (22)
18
19
Always correct the threads in piston nut (21) or [piston (15)] before fixing piston nut, using a tapping.
•
Insufficient tightening torque causes an inner leak and a damage of thread. And over tightening torque causes a bulge of cushion bearing and a deformation of piston contacted surface.
•
2
(4) Put steel ball (23) into hole and tighten setscrew (22).
In case that piston and piston nut are combined, the shim (20) is not used. Apply the eye wrench to hexagonal part of piston and loosen the piston directly.
•
V-BLOCK
21
22
32. ATTACHMENT
Clean and decrease (with solvent) the parts of piston assembly, and dry it, then tighten this piston assembly.
21
EYE WRENCH
Fig. 32-54 Tightening piston nut (21) ANTI-LOOSENING
22 CAULKING
20
2
23
V-BLOCK
21
Fig. 32-55 Attaching setscrew (22)
22
18
19
2
(4) Put steel ball (23) into hole and tighten setscrew (22).
: 6mm After tightening the setscrew to a specified torque, caulk the two places of the thread of the piston nut side to secure the setscrew. See para 32.2.1.7.3 for torque. (5) Attach two slide rings (18) and (19). Take off vinyl tape wound around the perimeter of piston (15), apply high-quality grease (or vaseline) to slide ring (18), (19) and attach the slide rings in a manner that they may be coiled around the groove. Set the slide rings about 180 degrees apart with each other so that the slits may not point to the same direction.
32-25
21
V-BLOCK
Fig. 32-56 Attaching slide ring (18), (19)
: 6mm After tightening the setscrew to a specified torque, caulk the two places of the thread of the piston nut side to secure the setscrew. See para 32.2.1.7.3 for torque. (5) Attach two slide rings (18) and (19). Take off vinyl tape wound around the perimeter of piston (15), apply high-quality grease (or vaseline) to slide ring (18), (19) and attach the slide rings in a manner that they may be coiled around the groove. Set the slide rings about 180 degrees apart with each other so that the slits may not point to the same direction.
32-25
21
V-BLOCK
Fig. 32-56 Attaching slide ring (18), (19)
32. ATTACHMENT
32. ATTACHMENT
32.2.1.5.6
32.2.1.5.6
OVERALL ASSEMBLY
(1) Place a V-block on a work bench (A wooden Vblock is preferable.). Place the cylinder tube assy (1) on it and fix the assy by passing a wooden bar through the clevis pin hole to lock the assy. (2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube mouth and the circumference of the piston. Align the center of the piston rod assy with the center of the cylinder tube assy and put it in straight forward. When inserting, make sure that slide rings (18), (19) on the perimeter of the piston is not out of the groove.
(1) Place a V-block on a work bench (A wooden Vblock is preferable.). Place the cylinder tube assy (1) on it and fix the assy by passing a wooden bar through the clevis pin hole to lock the assy.
1 LIFT
STRAIGHT
(3) Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in the cylinder assy, and screw in socket bolts (12) one by one. Tighten the bolts to a specified torque, taking care so the bolts may not be tightened unevenly. See para. 32.2.1.7.3 for torque. : 14 mm
OVERALL ASSEMBLY
PREVENT TURNING WITH WOODEN BAR.
Fig. 32-57 Inserting piston rod assy
12 PLACE CLOTH
ALLEN WRENCH
(2) Insert the piston rod assy into the cylinder tube assy, while lifting and moving the piston rod assy with a hoist. In this operation, apply hydraulic oil (or vaseline) to the inner surface of the tube mouth and the circumference of the piston. Align the center of the piston rod assy with the center of the cylinder tube assy and put it in straight forward. When inserting, make sure that slide rings (18), (19) on the perimeter of the piston is not out of the groove.
1 LIFT
STRAIGHT
(3) Tighten socket bolt (12). Match the bolt holes of the rod cover flange to the threaded holes in the cylinder assy, and screw in socket bolts (12) one by one. Tighten the bolts to a specified torque, taking care so the bolts may not be tightened unevenly. See para. 32.2.1.7.3 for torque. : 14 mm
12 PLACE CLOTH
TURN CLOCKWISE
Fig. 32-58 Tightening socket bolts (12)
Fig. 32-58 Tightening socket bolts (12) Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod surface with cloth is recommended to prevent damage to it.
32-26
Fig. 32-57 Inserting piston rod assy
ALLEN WRENCH
TURN CLOCKWISE
Take care so as not to damage the rod surface by accidentally slip a wrench. Covering the rod surface with cloth is recommended to prevent damage to it.
PREVENT TURNING WITH WOODEN BAR.
32-26
32. ATTACHMENT 32.2.1.6
INSPECTION AFTER ASSEMBLY
32. ATTACHMENT 32.2.1.6
(1) No-load functional test Place the cylinder level at no load, operate the piston rod 5 to 6 strokes by the directional valve and make sure that it operates without failure.
DIRECTIONAL VALVE
H
•
Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder of the machine.
•
Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in such a case.
(2) Leak test 1) Apply a test pressure to the retracting and extending sides of the cylinder for three minutes independently, and check that the rod section and the welds have external leaks and permanent deformation. For an internal leak test, connect the cylinder with a test unit as shown in Fig. 32-60.
PUMP
R
HYDRAULIC CYLINDER
Fig. 32-59 External leak test MEASURE THE INTERNAL LEAK.
FROM DIRECTIONAL VALVE
Fig. 32-60 Internal leak test
INSPECTION AFTER ASSEMBLY
(1) No-load functional test Place the cylinder level at no load, operate the piston rod 5 to 6 strokes by the directional valve and make sure that it operates without failure.
Do not raise the hydraulic pressure above the maximum pressure of 37.8MPa (5480psi) for the cylinder of the machine.
•
Grease coated on the O-rings and the seals of the rod cover may come out. Wipe it off and retest the cylinder in such a case.
(2) Leak test 1) Apply a test pressure to the retracting and extending sides of the cylinder for three minutes independently, and check that the rod section and the welds have external leaks and permanent deformation. For an internal leak test, connect the cylinder with a test unit as shown in Fig. 32-60. 2) After completing the test, apply a plug to each port and store the cylinder. (Fig. 32-61)
• For storage, place the cylinder on wooden Vblocks and bring the cylinder to the most retracted condition.
• For storage, place the cylinder on wooden Vblocks and bring the cylinder to the most retracted condition.
Fig. 32-61 How to store the cylinder
32-27
H
•
2) After completing the test, apply a plug to each port and store the cylinder. (Fig. 32-61)
DIRECTIONAL VALVE
PUMP
R
HYDRAULIC CYLINDER
Fig. 32-59 External leak test MEASURE THE INTERNAL LEAK.
FROM DIRECTIONAL VALVE
Fig. 32-60 Internal leak test
Fig. 32-61 How to store the cylinder
32-27
32. ATTACHMENT
32. ATTACHMENT
32.2.1.7
32.2.1.7
MAINTENANCE STANDARDS
32.2.1.7.1
INSPECTION AFTER DISASSEMBLY
MAINTENANCE STANDARDS
32.2.1.7.1
INSPECTION AFTER DISASSEMBLY
Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to use are not present.
Visually inspect all parts after cleaning to see that excessive wear, crack and other damage that are detrimental to use are not present.
(1) Inspection Item
(1) Inspection Item Table32-2
Part Name
Piston rod
Inspecting Section
Table32-2
Inspection Item
Remedy
Part Name
Inspecting Section
Remedy
Presence of crack
Replace.
1. Neck of rod pin
Presence of crack
Replace.
2. Weld on rod hub
Presence of crack
Replace.
2. Weld on rod hub
Presence of crack
Replace.
3. Stepped part to which piston is attached
Presence of crack
Replace.
3. Stepped part to which piston is attached
Presence of crack
Replace.
4. Threads
Presence of seizure
Recondition or replace
4. Threads
Presence of seizure
Recondition or replace
5. Bend
Measure degree of bend (See Fig. 32-62)
Refer to (Table32-3)
5. Bend
Measure degree of bend (See Fig. 32-62)
Refer to (Table32-3)
Check that: 1) Plating is not worn off to base metal
1) Replace or replate
6. Plated surface
Check that: 1) Plating is not worn off to base metal
Piston rod
6. Plated surface
1) Replace or replate
2) Rust is not present on plating. 2) Replace or replate
Cylindertube
Inspection Item
1. Neck of rod pin
3) Scratches are not present.
3) Recondition, replate or replace.
7. Rod
Wear of O. D.
Recondition, replate or replace.
2) Rust is not present on plating. 2) Replace or replate 3) Scratches are not present.
3) Recondition, replate or replace.
7. Rod
Wear of O. D.
Recondition, replate or replace.
8. Bushing at mounting part
Wear of I. D.
Replace.
8. Bushing at mounting part
Wear of I. D.
Replace.
1. Weld on bottom
Presence of crack
Replace.
1. Weld on bottom
Presence of crack
Replace.
2. Weld on head
Presence of crack
Replace.
2. Weld on head
Presence of crack
Replace.
3. Weld on hub
Presence of crack
Replace.
3. Weld on hub
Presence of crack
Replace.
4. Tube interior
Presence of damage
Replace if oil leak is seen.
4. Tube interior
Presence of damage
Replace if oil leak is seen.
5. Bushing at mounting part
Wear on inner surface
Replace.
5. Bushing at mounting part
Wear on inner surface
Replace.
1. Bushing
1) Wear on inner surface
1) See para. 32.2.1.7.2
1. Bushing
1) Wear on inner surface
1) See para. 32.2.1.7.2
2) Flaw on inner surface
2) Replace if score is deeper than coating.
2) Flaw on inner surface
2) Replace if score is deeper than coating.
Rod cover
(2) Repair method
Cylindertube
Rod cover
(2) Repair method
Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on the piston rod, observe the following procedure:
Check all seals and parts to see that they do not show excessive damage and wear. For correction of scores on the piston rod, observe the following procedure:
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as may be caught by your nail.
1) Correct very fine longitudinal scratches with an oilstone. Replace the piston rod if the scratch is so deep as may be caught by your nail.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone. If the score or the indention is excessive, replace or replate the damaged part.
2) In case of a smooth indention, recondition by removing the sharp area around the indention with an oilstone. If the score or the indention is excessive, replace or replate the damaged part.
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• Always regrind after replating. The thickness of the plating must be maximum 0.1mm (0.004in).
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the surface.
• In case plating is removed to the base metal during reconditioning with an oilstone, do not fail to replate the surface.
32-28
32-28
32. ATTACHMENT 32.2.1.7.2
LIMIT OF SERVICEABILITY
32. ATTACHMENT 32.2.1.7.2
LIMIT OF SERVICEABILITY
Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod that have no such damage as may degrade the sealing effect.
Serviceability limits represent the limits of wear on the sliding surfaces of the cylinder tube and the rod that have no such damage as may degrade the sealing effect.
(1) Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm (0.01in).
(1) Clearance between piston rod and rod bushing Replace the bushing if the clearance between the piston rod and the rod bushing exceeds 0.25mm (0.01in).
(2) Bend of piston rod The allowable bend of the rod is maximum 1mm / 1m (0.04"/3’3"). For measurement, support both ends of the parallel section of the piston rod with Vblocks, set a dial indicator in the center between the two V-block turn the piston rod, and read the difference between the maximum and minimum deflection on the dial indicator.
(2) Bend of piston rod The allowable bend of the rod is maximum 1mm / 1m (0.04"/3’3"). For measurement, support both ends of the parallel section of the piston rod with Vblocks, set a dial indicator in the center between the two V-block turn the piston rod, and read the difference between the maximum and minimum deflection on the dial indicator.
Fig. 32-62 Measuring Method
Table32-3 shows an example of measurement.
Table32-3 shows an example of measurement.
Table32-3 Example of Measurement
Table32-3 Example of Measurement
Distance between Deflection of the dial indicator in the middle of the rod. Remedy V-blocks mm (in) m (ft-in)
Distance between Deflection of the dial indicator in the middle of the rod. Remedy V-blocks mm (in) m (ft-in)
1 (3’3")
1 (0.04")
Replace
1 (3’3")
1 (0.04")
Replace
Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.
Even if the bend is within the above limit, the cylinder may not operate smoothly because of localized bend. Beware of it during function test after assembly. Replace the rod if the cylinder makes a squeaking noise or dose not operate smoothly.
32.2.1.7.3
32.2.1.7.3
TIGHTENING TORQUE
B
32.2.1.7.4
Unit : N.m (lbf.ft)
A C Cylinder
A Piston nut or [Piston]
B
C
Socket bolt
Setscrew
Boom
5460 (4030)
267 (200)
Arm
7890 (5820)
Bucket
6200 (4570)
TIGHTENING TORQUE
B
Unit : N.m (lbf.ft)
A C Cylinder
A Piston nut or [Piston]
B
C
Socket bolt
Setscrew
56.9 (42)
Boom
5460 (4030)
267 (200)
56.9 (42)
367 (270)
56.9 (42)
Arm
7890 (5820)
367 (270)
56.9 (42)
267 (200)
56.9 (42)
Bucket
6200 (4570)
267 (200)
56.9 (42)
VOLUME OF OIL LEAK
32.2.1.7.4
The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER ASSEMBLY32.2.1.6 (2).
VOLUME OF OIL LEAK
The oil leak rates as mentioned in 1.6 (2) of Inspection after Assembly are as shown in INSPECTION AFTER ASSEMBLY32.2.1.6 (2).
Cylinder
Volume of Internal Oil Leak
Cylinder
Volume of Internal Oil Leak
Boom
1.0cc (0.06 cu•in) or below / 3min
Boom
1.0cc (0.06 cu•in) or below / 3min
Arm
1.0cc (0.06 cu•in) or below / 3min
Arm
1.0cc (0.06 cu•in) or below / 3min
Bucket
1.0cc (0.06 cu•in) or below / 3min
Bucket
1.0cc (0.06 cu•in) or below / 3min
32-29
Fig. 32-62 Measuring Method
32-29
32. ATTACHMENT
32. ATTACHMENT
32.2.1.8
32.2.1.8
TROUBLESHOOTING
TROUBLESHOOTING
Table32-4 Trouble
Failed Parts
1. Oil leak through sliding 1. Back-up ring surface of piston rod. Oil ring is formed on piston rod, and the ring grows up to oil drops, and they drip.
2. U-ring OIL LEAKS FROM HERE
Table32-4
Cause
Remedy
1. Foreign matter is trapped in the bore of back-up ring
1. Remove foreign matter.
2. Lips on outer and inner diameter surfaces of back-up ring are scored.
2. Replace back-up ring.
3. Other back-up ring are failed.
3. Replace back-up ring
1. Foreign matter is trapped in the bore of ring.
1.Remove foreign matter.
Trouble
Failed Parts
1. Oil leak through sliding 1. Back-up ring surface of piston rod. Oil ring is formed on piston rod, and the ring grows up to oil drops, and they drip.
2. U-ring OIL LEAKS FROM HERE
2. Score is present on the bore of ring. 2. Replace U-ring.
3. Buffer ring
3. Other rings are failed.
3. Replace U-ring.
1. Foreign matter is trapped in the bore of ring.
1.Remove foreign matter.
4. Wiper ring
5. Piston rod
3. Replace buffer ring.
1. Foreign matter is trapped in the bore of wiper ring.
1.Remove foreign matter.
2. Lip on the bore of wiper ring is scored.
3. Buffer ring
2. Lips on outer and inner diameter surfaces of back-up ring are scored.
2. Replace back-up ring.
3. Other back-up ring are failed.
3. Replace back-up ring
1. Foreign matter is trapped in the bore of ring.
1.Remove foreign matter.
3. Other rings are failed.
3. Replace U-ring.
1. Foreign matter is trapped in the bore of ring.
1.Remove foreign matter.
3. Replace buffer ring.
1. Foreign matter is trapped in the bore of wiper ring.
1.Remove foreign matter.
2. Replace wiper ring.
2. Lip on the bore of wiper ring is scored.
2. Replace wiper ring.
3. Another wiper ring is failed.
3. Replace wiper ring.
3. Another wiper ring is failed.
3. Replace wiper ring.
1. Score is present on the sliding surface of piston rod.
1.Smooth out the sliding surface with an oilstone. If leakage occurs even if the sliding surface is finished below 1.6S, rod packings may be scored. Disassemble and inspect it and replace rod packings as required. If leak will not stop by that treatment, replace piston rod.
1. Score is present on the sliding surface of piston rod.
1.Smooth out the sliding surface with an oilstone. If leakage occurs even if the sliding surface is finished below 1.6S, rod packings may be scored. Disassemble and inspect it and replace rod packings as required. If leak will not stop by that treatment, replace piston rod.
1. O-ring is damaged.
1. Replace O-ring.
1. Back-up ring is damaged.
1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube.
1. Replace cylinder tube.
4. Wiper ring
5. Piston rod
2. Hard chromium plating has peeled 2. Replate. off 2. Oil leaks from the 1. O-ring circumference of rod cover. 2. Backup ring
1. O-ring is damaged.
1. Replace O-ring.
1. Back-up ring is damaged.
1. Replace back-up ring.
3. Cylinder tube 1. Swelling of cylinder tube.
1. Replace cylinder tube.
1. Cylinder tube 1. Welds of cylinder are broken.
1. Replace cylinder tube.
1. Piston seal
1. Remove foreign matter
OIL LEAKS FROM HERE
1. Cylinder tube 1. Welds of cylinder are broken.
1. Replace cylinder tube.
WELDS 4. Cylinder falls by it-self.
1. Remove foreign matter.
3. Other rings are failed.
OIL LEAKS FROM HERE 3. Oil leaks from welds.
1. Foreign matter is trapped in the bore of back-up ring
2. Score is present on the bore of ring. 2. Replace buffer ring.
2. Hard chromium plating has peeled 2. Replate. off 2. Oil leaks from the 1. O-ring circumference of rod cover. 2. Backup ring
Remedy
2. Score is present on the bore of ring. 2. Replace U-ring.
2. Score is present on the bore of ring. 2. Replace buffer ring. 3. Other rings are failed.
Cause
3. Oil leaks from welds.
WELDS
1. Piston seal
[When the rod is loaded with a static load equal to the maximum working pressure multiplied by the area of the 2. Slide ring cylinder bore, the maximum movement of the piston is 3. Piston rod more than 0.5mm (0.02") in ten minutes.]
1. Foreign matter is trapped in the sliding surface of seal ring.
1. Remove foreign matter
2. Score is present on the sliding surface of seal ring.
2. Replace seal ring..
1. Sliding surface of slide rings is scored.
1. Replace slide ring.
1. Elongation.Piston rod and piston are elongated. (Loose nut)
32-30
1. Replace piston rod.
4. Cylinder falls by it-self.
[When the rod is loaded with a static load equal to the maximum working pressure multiplied by the area of the 2. Slide ring cylinder bore, the maximum movement of the piston is 3. Piston rod more than 0.5mm (0.02") in ten minutes.]
1. Foreign matter is trapped in the sliding surface of seal ring. 2. Score is present on the sliding surface of seal ring.
2. Replace seal ring..
1. Sliding surface of slide rings is scored.
1. Replace slide ring.
1. Elongation.Piston rod and piston are elongated. (Loose nut)
32-30
1. Replace piston rod.
32. ATTACHMENT 32.2.1.9 32.2.1.9.1
JIGS LIST
32. ATTACHMENT 32.2.1.9
SPECIAL JIG LIST (POSSIBLE TO SUPPLY)
32.2.1.9.1
When assembling, the following jigs are required.
JIGS LIST SPECIAL JIG LIST (POSSIBLE TO SUPPLY)
When assembling, the following jigs are required. Table32-5
Application
Described paragraph
Shape
A For removing and press fitting bushing
Table32-5
A
C
32.2.1.3.4, 32.2.1.5.2
For removing and press fitting bushing
32.2.1.5.2
For press fitting wiper ring
D
E
D
D 32.2.1.5.2
H
F
F
For correcting seal ring
32.2.1.5.2
For correcting seal ring
32.2.1.5.2
G INSERTING JIG
32.2.1.3.4, 32.2.1.5.2
C
EDGE OF CHUCK
E
H
Described paragraph
Shape
D
EDGE OF CHUCK
For press fitting wiper ring
Application
G CORRECTING JIG
INSERTING JIG
I
CORRECTING JIG
I
For inserting rod cover
32.2.1.5.4
For above jigs, contact our dealer. (The Jig No. List provided by cylinder maker is shown in the following page.)
32-31
For inserting rod cover
32.2.1.5.4
For above jigs, contact our dealer. (The Jig No. List provided by cylinder maker is shown in the following page.)
32-31
32. ATTACHMENT
32. ATTACHMENT
Special Jig No. List
Special Jig No. List
(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(1) For jigs for rod cover, select jig corresponding to respective rod diameter.
(2) For jigs for piston, select jig corresponding to the cylinder bore.
(2) For jigs for piston, select jig corresponding to the cylinder bore.
Table32-6
Jig for rod cover removing & installing
Jig for seal ring inserting & correcting
Table32-6
Application rod diameter (mm)
Kit No. of maker
Application rod diameter (mm)
Kit No. of maker
65
3006J-56001
65
3006J-56001
70
3007J-06001
70
3007J-06001
75
3007J-56001
75
3007J-56001
80
3008J-06001
80
3008J-06001
85
3008J-56001
85
3008J-56001
90
3009J-06001
90
3009J-06001
95
3009J-56001
95
3009J-56001
100
3010J-06001
100
3010J-06001
105
3010J-56001
105
3010J-56001
110
3011J-06001
110
3011J-06001
115
3011J-56001
115
3011J-56001
Jig for rod cover removing & installing
120
3012J-06001
120
3012J-06001
Application cylinder bore (mm)
Kit No. of maker
Application cylinder bore (mm)
Kit No. of maker
95
3009J-51001
95
3009J-51001
100
3010J-01001
100
3010J-01001
105
3010J-51001
105
3010J-51001
110
3011J-01001
110
3011J-01001
115
3011J-51001
115
3011J-51001
120
3012J-01001
120
3012J-01001
125
3012J-51001
125
3012J-51001
130
3013J-01001
130
3013J-01001
135
3013J-51001
135
3013J-51001
140
3014J-01001
140
3014J-01001
145
3014J-51001
145
3014J-51001
150
3015J-01001
150
3015J-01001
160
3016J-01001
160
3016J-01001
170
3017J-01001
170
3017J-01001
32-32
Jig for seal ring inserting & correcting
32-32
32. ATTACHMENT OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)
32.2.1.9.2
(1) Bushing removing jig (Symbol J)
80
R2
R0.2
10 25-S
12-S
50 C2
15
15 12-S
5
D 94 94 99
d 80 85 85
Unit : mm (inch) Cylinder Used Bucket Arm Boom
MATERIAL : Mild steel
R2
R0.2
5 10 25-S
oD -3-4
15
oD -0.2 -0.4
15
oD -3-4
oD -0.5 -1
C2
80
MATERIAL : Mild steel 12-S
50
OTHER SPECIAL JIGS (PREPARED BY SERVICE SHOP)
Fig. 32-63 Bushing removing jig
12-S oD -0.2 -0.4
(1) Bushing removing jig (Symbol J)
oD -0.5 -1
32.2.1.9.2
32. ATTACHMENT
D 94 94 99
d 80 85 85
Unit : mm (inch) Cylinder Used Bucket Arm Boom
Fig. 32-63 Bushing removing jig
(2) Wrench for piston nut or [piston]
(2) Wrench for piston nut or [piston]
Unit : mm (inch) B 110 95 95 B
Unit : mm (inch)
Cylinder Used Arm Boom Bucket
B 110 95 95 B
Fig. 32-64 Wrench for piston nut or [piston]
Fig. 32-64 Wrench for piston nut or [piston]
32-33
32-33
Cylinder Used Arm Boom Bucket
32. ATTACHMENT
32. ATTACHMENT
32.2.1.9.3
32.2.1.9.3
SPECIAL JIG HANDLING PROCEDURE
(1) How to remove bushing from rod cover.
SPECIAL JIG HANDLING PROCEDURE
(1) How to remove bushing from rod cover.
1) Attaching chuck assy tool Insert tool in rod cover slowly until the edge top end of chuck assy reaches to the end of bushing (4).
1) Attaching chuck assy tool Insert tool in rod cover slowly until the edge top end of chuck assy reaches to the end of bushing (4).
• Special attention must be paid so that the inner surface of rod cover is not damaged by the edge of tool.
• Special attention must be paid so that the inner surface of rod cover is not damaged by the edge of tool.
• Attach top on the position 5mm (0.2 in) from the bushing end face so that the edge does not protrude from the end face.
• Attach top on the position 5mm (0.2 in) from the bushing end face so that the edge does not protrude from the end face.
4
4
5 (0.197")
(CHUCK)
5 (0.197")
(CHUCK)
2) Tightening chuck assy tool temporarily
2) Tightening chuck assy tool temporarily
a. Fit allen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round hole on the rear end of tool.
a. Fit allen wrench to the head of adjuster bolt on the top end of tool, and insert lever in the round hole on the rear end of tool.
b. Fix it with allen wrench and lever to the position where the tool does not drop even if the rod cover is raised, inclining it forward and rearward.
b. Fix it with allen wrench and lever to the position where the tool does not drop even if the rod cover is raised, inclining it forward and rearward.
• Move rod cover onto the working bench holding tool attached.
• Move rod cover onto the working bench holding tool attached.
• Be careful not to drop it on foots, etc.
• Be careful not to drop it on foots, etc.
A
32-34
A
32-34
32. ATTACHMENT
32. ATTACHMENT
3) Attaching tools for retainer Put retainer on the press bench directing the wiper ring fitting section of rod cover upward, then put retainer tool (D) on the rod cover.
3) Attaching tools for retainer Put retainer on the press bench directing the wiper ring fitting section of rod cover upward, then put retainer tool (D) on the rod cover.
• Fit retainer tool as shown in the right figure directing large diameter section (flange section) upward.
• Fit retainer tool as shown in the right figure directing large diameter section (flange section) upward.
• Clean the surface of press bench, and take care for the tool bottom face not to be damaged by foreign matter like dust, chip, etc.
• Clean the surface of press bench, and take care for the tool bottom face not to be damaged by foreign matter like dust, chip, etc.
4) Cutting into of the edge of chuck Press the upper section of retainer tool gradually so that the edge of chuck tool (A) cuts into the bushing surface. Set the pressing force to 2~3 tons (4410~6615 lbs).
4) Cutting into of the edge of chuck Press the upper section of retainer tool gradually so that the edge of chuck tool (A) cuts into the bushing surface. Set the pressing force to 2~3 tons (4410~6615 lbs).
PRESS HERE
After completion of pressing, tighten adjuster bolt again by hand.
After completion of pressing, tighten adjuster bolt again by hand.
• Press it with retainer tool (D).
• Press it with retainer tool (D).
CHUCKING JIG A
32-35
PRESS HERE
CHUCKING JIG A
32-35
32. ATTACHMENT
32. ATTACHMENT
15 (0.59") 15 (0.59")
oD od
5) Setting of tools for block Prepare block (C), and put rod cover (3) on it aligning them. Select corresponding block (C) in shape, dimensions, etc. from the table shown below. oD od
15 (0.59") 15 (0.59")
5) Setting of tools for block Prepare block (C), and put rod cover (3) on it aligning them. Select corresponding block (C) in shape, dimensions, etc. from the table shown below.
10
h
10
h
10 Unit : mm (inch) Class (Nominal size) o55 (2.17) o60 (2.36) o65 (2.56) o70 (2.76) o75 (2.95) o80 (3.15) o85 (3.35) o90 (3.54) o95 (3.74) o100 (3.94) o105 (4.13) o110 (4.33) o115 (4.53) o130 (5.12)
d
D
h
62 (2.44) 67 (2.64) 72 (2.83) 77 (3.03) 82 (3.23) 87 (3.43) 92 (3.62) 97 (3.82) 102 (4.02) 107 (4.21) 112 (4.41) 117 (4.61) 122 (4.80) 137 (5.39)
88 (3.46) 96 (3.78) 96 (3.78) 100 (3.94) 110 (4.33) 112 (4.41) 124 (4.88) 135 (5.31) 145 (5.71) 145 (5.71) 150 (5.91) 165 (6.50) 170 (6.69) 190 (7.48)
80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54)
10 Unit : mm (inch) Class (Nominal size) o55 (2.17) o60 (2.36) o65 (2.56) o70 (2.76) o75 (2.95) o80 (3.15) o85 (3.35) o90 (3.54) o95 (3.74) o100 (3.94) o105 (4.13) o110 (4.33) o115 (4.53) o130 (5.12)
C
6) Removing of bushing
d
D
h
62 (2.44) 67 (2.64) 72 (2.83) 77 (3.03) 82 (3.23) 87 (3.43) 92 (3.62) 97 (3.82) 102 (4.02) 107 (4.21) 112 (4.41) 117 (4.61) 122 (4.80) 137 (5.39)
88 (3.46) 96 (3.78) 96 (3.78) 100 (3.94) 110 (4.33) 112 (4.41) 124 (4.88) 135 (5.31) 145 (5.71) 145 (5.71) 150 (5.91) 165 (6.50) 170 (6.69) 190 (7.48)
80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 80 (3.15) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54) 90 (3.54)
C
6) Removing of bushing
a. Move block (C) and rod cover (3) with tool under the press.
a. Move block (C) and rod cover (3) with tool under the press.
b. Press the upper part of retainer tool (D) slowly until bushing (4) is take out from rod cover (3) (until there is a sound that the chuck tool (A) drops on the work bench)
b. Press the upper part of retainer tool (D) slowly until bushing (4) is take out from rod cover (3) (until there is a sound that the chuck tool (A) drops on the work bench)
D
• The force of 3 tons (6615 lbs or less) is necessary to press it out. The stroke of press ram is about 32~52mm (1.26in~2.04in). (But it varies according to the difference of dimension of cylinder head.)
• The force of 3 tons (6615 lbs or less) is necessary to press it out. The stroke of press ram is about 32~52mm (1.26in~2.04in). (But it varies according to the difference of dimension of cylinder head.)
• Press it with retainer tool (D).
• Press it with retainer tool (D).
When the block and rod cover assy are not aligned, interrupt the work and align the block and rod cover assy.
When the block and rod cover assy are not aligned, interrupt the work and align the block and rod cover assy.
32-36
32-36
D
32. ATTACHMENT 7) Removing of rod cover
32. ATTACHMENT 7) Removing of rod cover
a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and then move rod cover (3) to other place.
a. Remove block (C) with rod cover (3) near side, remove retainer tool (D) from rod cover (3), and then move rod cover (3) to other place.
b. Take out the chuck tool (A) with bushing from block (C).
b. Take out the chuck tool (A) with bushing from block (C).
D
D
4
Do not work under the press because it is very dangerous.
4
Do not work under the press because it is very dangerous.
A
A
C
8) Removing of bushing
C
8) Removing of bushing
a. Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and lever.
a. Place chuck tool (A) with bushing (4) sideways, and loosen adjuster bolt with allen wrench and lever.
b. Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about 5mm (0.2 in).
b. Place the chuck tool (A) vertically and turn the adjuster by hand until the wedge is raised about 5mm (0.2 in).
c. Remove the wedge from the edge of chuck.
c. Remove the wedge from the edge of chuck.
â&#x20AC;˘ Clean the surface of work bench, and be careful for the tool not to be damaged by foreign matters like dust, chips, etc.
â&#x20AC;˘ Clean the surface of work bench, and be careful for the tool not to be damaged by foreign matters like dust, chips, etc.
4
4
A
32-37
A
32-37
32. ATTACHMENT
32. ATTACHMENT
9) Tightening of adjuster bolt Tighten the chuck tool (A) the bushing (4) is removed to the extent that there is no gap between the chuck and the wedge upper face, turning the adjuster bolt by hand.
9) Tightening of adjuster bolt Tighten the chuck tool (A) the bushing (4) is removed to the extent that there is no gap between the chuck and the wedge upper face, turning the adjuster bolt by hand.
• This special tool differs according to the corresponding piston rod diameter.
• This special tool differs according to the corresponding piston rod diameter.
• The chuck edge is an important portion. Take care of handling and storage.
• The chuck edge is an important portion. Take care of handling and storage.
32-38
32-38
32. ATTACHMENT (2) Rod cover bushing press-fitting procedure
(2) Rod cover bushing press-fitting procedure
4
1) Temporary setting of head bushing Put rod cover (3) on the press-working bench directing the tube connection upward.
32. ATTACHMENT
4
1) Temporary setting of head bushing Put rod cover (3) on the press-working bench directing the tube connection upward.
Set bushing (4) on the inner surface of rod cover (3) temporarily.
Set bushing (4) on the inner surface of rod cover (3) temporarily.
• Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.
• Make sure that the inner and outer surfaces of bushing (4) are free from foreign matter.
3
2) Setting chuck assy tool (A) Insert the chuck assy tool (A) in temporary-set bushing (4) directing the flange downward, and set it on rod cover (3).
3
2) Setting chuck assy tool (A) Insert the chuck assy tool (A) in temporary-set bushing (4) directing the flange downward, and set it on rod cover (3).
A
• Be sure that the adjuster bolt is tightened to the extent that there is no gap between adjuster of chuck assy (A) and wedge.
A
• Be sure that the adjuster bolt is tightened to the extent that there is no gap between adjuster of chuck assy (A) and wedge.
3
32-39
3
32-39
32. ATTACHMENT
32. ATTACHMENT
3) Attaching retainer tool Put retainer tool (D) on the wedge stepped section of chuck assy tool (A) slowly directing the flange upward.
3) Attaching retainer tool Put retainer tool (D) on the wedge stepped section of chuck assy tool (A) slowly directing the flange upward.
• Align chuck assy (A) and the wedge.
• Align chuck assy (A) and the wedge.
4) Preparation for press-fitting Move the rod cover on which chuck tool (A) and retainer tools are attached under the press. • Adjust it so that the press ram is centered to the tool.
PRESS RAM
RETAINER(D)
4) Preparation for press-fitting Move the rod cover on which chuck tool (A) and retainer tools are attached under the press. • Adjust it so that the press ram is centered to the tool.
RETAINER(D)
CHUCK(A)
32-40
PRESS RAM
CHUCK(A)
BUSHING(4)
BUSHING(4)
BUSHING PRESSFITTING PART
BUSHING PRESSFITTING PART
32-40
32. ATTACHMENT 5) Press-fitting of bushing Push the head of retainer (D) with press, and press fit bushing (4) to the specified position of rod cover (3) slowly.
32. ATTACHMENT 5) Press-fitting of bushing Push the head of retainer (D) with press, and press fit bushing (4) to the specified position of rod cover (3) slowly.
STEP OF WEDGE
• The pressing force should be held 5 tons (11025 lbs) or less, keeping the required force for the press-fitting.
STEP OF WEDGE
• The pressing force should be held 5 tons (11025 lbs) or less, keeping the required force for the press-fitting.
• Raise the pressure gradually adjusting the force by means of pressure adjusting valve of press unit.
• Raise the pressure gradually adjusting the force by means of pressure adjusting valve of press unit.
• Be sure that the end face of bushing is located on the interior of the groove for snap ring. When it is located on near place, press fit and adjust the location again.
• Be sure that the end face of bushing is located on the interior of the groove for snap ring. When it is located on near place, press fit and adjust the location again.
LIFTING THREAD
LIFTING THREAD RETAINER JIG (D)
RETAINER JIG (D)
ADJUSTER BOLT
ADJUSTER BOLT
WEDGE
WEDGE CHUCK TOOL ASSY (A)
CHUCK TOOL ASSY (A)
CHUCK
BLOCK TOOL (C)
CHUCK
BLOCK TOOL (C)
Bushing removing and press fitting jig (For reference only)
32-41
Bushing removing and press fitting jig (For reference only)
32-41
32. ATTACHMENT
32. ATTACHMENT
[MEMO]
[MEMO]
32-42
32-42
33. UPPER STRUCTURE
33. UPPER STRUCTURE
TABLE OF CONTENTS
TABLE OF CONTENTS
33.1 REMOVING AND INSTALLING.......................................................................................33-3
33.1 REMOVING AND INSTALLING.......................................................................................33-3
33.1.1
OPERATOR SEAT .................................................................................................33-3
33.1.1
OPERATOR SEAT .................................................................................................33-3
33.1.2
CAB ........................................................................................................................33-4
33.1.2
CAB ........................................................................................................................33-4
33.1.3
BATTERY ...............................................................................................................33-6
33.1.3
BATTERY ...............................................................................................................33-6
33.1.4
GUARD...................................................................................................................33-7
33.1.4
GUARD...................................................................................................................33-7
33.1.5
UNDER COVER .....................................................................................................33-13
33.1.5
UNDER COVER .....................................................................................................33-13
33.1.6
FUEL TANK ............................................................................................................33-14
33.1.6
FUEL TANK ............................................................................................................33-14
33.1.7
HYDRAULIC TANK ................................................................................................33-16
33.1.7
HYDRAULIC TANK ................................................................................................33-16
33.1.8
HYDRAULIC PUMP................................................................................................33-20
33.1.8
HYDRAULIC PUMP................................................................................................33-20
33.1.9
AIR CLEANER........................................................................................................33-25
33.1.9
AIR CLEANER........................................................................................................33-25
33.1.10 MUFFLER...............................................................................................................33-26
33.1.10 MUFFLER...............................................................................................................33-26
33.1.11 COUNTERWEIGHT................................................................................................33-28
33.1.11 COUNTERWEIGHT................................................................................................33-28
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-29
33.1.12 RADIATOR & OIL COOLER ...................................................................................33-29
33.1.13 ENGINE ..................................................................................................................33-35
33.1.13 ENGINE ..................................................................................................................33-35
33.1.14 CONSOLE COVER ................................................................................................33-38 33.1.15 CONTROL VALVE..................................................................................................33-40
33
33.1.14 CONSOLE COVER ................................................................................................33-38 33.1.15 CONTROL VALVE..................................................................................................33-40
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................33-43
33.1.16 PILOT VALVE (FOR ATT) ......................................................................................33-43
33.1.17 PILOT VALVE (FOR TRAVEL) ...............................................................................33-44
33.1.17 PILOT VALVE (FOR TRAVEL) ...............................................................................33-44
33.1.18 SWING MOTOR UNIT ............................................................................................33-46
33.1.18 SWING MOTOR UNIT ............................................................................................33-46
33.1.19 SWIVEL JOINT.......................................................................................................33-48
33.1.19 SWIVEL JOINT.......................................................................................................33-48
33.1.20 UPPER FRAME......................................................................................................33-51
33.1.20 UPPER FRAME......................................................................................................33-51
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-54
33.2 DISASSEMBLING AND ASSEMBLING...........................................................................33-54
33.2.1
HYDRAULIC PUMP • REGULATOR ......................................................................33-54
33.2.1
HYDRAULIC PUMP • REGULATOR ......................................................................33-54
33.2.2
CONTROL VALVE..................................................................................................33-80
33.2.2
CONTROL VALVE..................................................................................................33-80
33.2.3
PILOT VALVE (ATT)...............................................................................................33-111
33.2.3
PILOT VALVE (ATT)...............................................................................................33-111
33.2.4
PILOT VALVE (FOR TRAVEL) ...............................................................................33-121
33.2.4
PILOT VALVE (FOR TRAVEL) ...............................................................................33-121
33.2.5
SWING MOTOR UNIT ............................................................................................33-130
33.2.5
SWING MOTOR UNIT ............................................................................................33-130
33.2.6
SWIVEL JOINT.......................................................................................................33-157
33.2.6
SWIVEL JOINT.......................................................................................................33-157
Book Code No. S5YN3325E01 33-1
Book Code No. S5YN3325E01 33-1
33
33. UPPER STRUCTURE Issue
Date of Issue
First edition
July, 2007
33. UPPER STRUCTURE Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~
Remarks S5YN3325E01 (NHK Russia) HS Engine
K
Issue
Date of Issue
First edition
July, 2007
Applicable Machines E215B : YN11-45001~ E215BLC : YQ11-06001~
Remarks S5YN3325E01 (NHK Russia) HS Engine
K
PREFACE
PREFACE
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(1) This Manual describes all the procedures from removing to installing, arranging them by item.
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(2) This Manual consists [Removing and installing], and [Disassembling and assembling].
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(3) The removing and installing can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.
(4) The removing and installing procedure does not completely cover all possible situations because of differences of field condition and defective section.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize the work procedure, before starting work.
(5) Recognize well that the service man must decide a work procedure before proceeding to repair. When deciding the work procedure, choose an item that is needed, familiarize yourself with the contents of the work and itemize the work procedure, before starting work.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component and wiring are performed.
(6) Disconnect the negative terminal of battery first, when the removing and the installing of the electric component and wiring are performed.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in specification.
(7) The explanatory note and figure of this manual may differ from the actual machine by the difference in specification.
33-2
33-2
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1
REMOVING AND INSTALLING
33.1
REMOVING AND INSTALLING
33.1.1
OPERATOR SEAT
33.1.1
OPERATOR SEAT
33.1.1.1
REMOVAL
33.1.1.1
(1) Preparation for removal
REMOVAL
(1) Preparation for removal
1) Remove the head rest (A1-1) of the operator’s seat (A1) to ease handling.
A1-1
2) Move the whole control stand to its foremost position.
A1
3) Move the operator’s seat to its forward end.
1) Remove the head rest (A1-1) of the operator’s seat (A1) to ease handling.
A1-1
2) Move the whole control stand to its foremost position.
A1
3) Move the operator’s seat to its forward end. B2
4) Incline the reclining seat as forward as possible. C1
(2) Remove operator’s seat. (Include upper rail.) 1) With the above-mentioned condition, remove two cap screws (B2) M8u20 from the upper rail. Then move the control stand to its rearmost end and remove two capscrews (B2) M8u20.
C1
C1
(2) Remove operator’s seat. (Include upper rail.) C2
C2
1) With the above-mentioned condition, remove two cap screws (B2) M8u20 from the upper rail. Then move the control stand to its rearmost end and remove two capscrews (B2) M8u20.
: 6 mm
C1
7
2) Remove the operator’s seat. [about 28kg (62 lbs).] Carry out the following operations as required.
1
3) Remove seat belt (C1).
13
10
7
5) Remove bracket assy (1), rail (7).
5) Remove bracket assy (1), rail (7).
Fig. 33-1 Disassembling and Assembling seat
Fig. 33-1 Disassembling and Assembling seat INSTALLATION
33.1.1.2
Install it in reverse procedure of removing according to the tightening torque table.
A5
6 17 13 13
A6
23.5 (17.3) 46.1 (34) 23 (17) 23 (17)
A3
Tightening position A1 A2
A5
Reference : Movement on rail Upper rail …… Fixed on lower surface of seat [Forward 80mm (0.26in), backward 80mm (0.26in)] Lower rail …… Fixed on seat stand. [Forward 60mm (0.19in), backward 60mm (0.19in)] Amount of adjustment of seat height [Up; 23mm (0.07in), down; 37mm (0.16in)] Suspension stroke [Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
Fig. 33-2 Disassembling and Assembling armrest
33-3
INSTALLATION
Install it in reverse procedure of removing according to the tightening torque table.
A4
Allen wrench Tightening torque N·m (lbf·ft) HEX (mm)
13
10
4) Remove armrest (A3)(A4).
Capscrew (B2) Sems bolt (C2) Capscrew (A5) Sems bolt (A6)
C2
1
3) Remove seat belt (C1).
4) Remove armrest (A3)(A4).
Tightening position
C2
: 6 mm
2) Remove the operator’s seat. [about 28kg (62 lbs).] Carry out the following operations as required.
33.1.1.2
B2
4) Incline the reclining seat as forward as possible.
Capscrew (B2) Sems bolt (C2) Capscrew (A5) Sems bolt (A6)
A4 A5
Allen wrench Tightening torque N·m (lbf·ft) HEX (mm)
6 17 13 13
A6
23.5 (17.3) 46.1 (34) 23 (17) 23 (17)
A3
A1 A2
A5
Reference : Movement on rail Upper rail …… Fixed on lower surface of seat [Forward 80mm (0.26in), backward 80mm (0.26in)] Lower rail …… Fixed on seat stand. [Forward 60mm (0.19in), backward 60mm (0.19in)] Amount of adjustment of seat height [Up; 23mm (0.07in), down; 37mm (0.16in)] Suspension stroke [Up; 37.5mm (1.48in), down; 37.5mm (1.48in)]
Fig. 33-2 Disassembling and Assembling armrest
33-3
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.2
33.1.2
33.1.2.1
CAB REMOVAL
33.1.2.1
(1) Remove floor mat.
A7
(2) Remove cover (A7) Lift cover (A7) upwards and remove it. (Fixed with 2 clips) (3) Remove cover assy (A1)
CAB REMOVAL
(1) Remove floor mat.
A7
(2) Remove cover (A7) Lift cover (A7) upwards and remove it. (Fixed with 2 clips) (3) Remove cover assy (A1)
1) Loosen 4 sems bolts (A22) M6u16 and lift cover assy (A1) up.
1) Loosen 4 sems bolts (A22) M6u16 and lift cover assy (A1) up.
2) Disconnect each connector for both speakers. Then remove cover assy (A1).
2) Disconnect each connector for both speakers. Then remove cover assy (A1).
A22
(4) Remove the harness connector (See Chapter 23)
(4) Remove the harness connector (See Chapter 23)
A1
1) Disconnect connectors of cab harness (CN515), (CN-518), (CN-71) (CN-72) and (CN-500) at rear right of cab.
1) Disconnect connectors of cab harness (CN515), (CN-518), (CN-71) (CN-72) and (CN-500) at rear right of cab.
2) Disconnect antenna cable coming from backside of tuner at rear left of cab.
2) Disconnect antenna cable coming from backside of tuner at rear left of cab.
Fig. 33-3 Disassembly and assembly of cover (A7) and cover assy (A1)
(5) Remove the plastic tube for the window washer from the rear left of cab.
A22
(6) Remove the right panel of cab
A1
Fig. 33-3 Disassembly and assembly of cover (A7) and cover assy (A1)
(5) Remove the plastic tube for the window washer from the rear left of cab. (6) Remove the right panel of cab
1) Remove 2 caps (A29) loosen 2 sems bolts (A40) M6u25 and 1 sems bolt (A39) M6u16. And right panels (A4) and (A4-2) are freed.
A3
1) Remove 2 caps (A29) loosen 2 sems bolts (A40) M6u25 and 1 sems bolt (A39) M6u16. And right panels (A4) and (A4-2) are freed.
A14
: TORX driver T30
A3
A14
: TORX driver T30
2) Lift cover (A3) upwards and remove it. (Fixed with 3 clows and 2 clips)
A22
3) Unfix 3 harness clips (A4-8) of inside on right panel (A4-2). And free the harnesses connected to key switch.
A40
B2
A4-8 A4
A29
A4-8 A40
4) With harnesses are connected condition, install key switch cover (A3) to bracket (A1) of rear cab temporally. (See Fig. 33-5)
A39 A4-8
A29
5) Disconnect harness connectors of work light switch on right panel (A4), air conditioner panel and cigarette lighter, and remove right panel (A4) and (A4-2). (See Chapter 23)
A4-2
A22
6) Loosen sems bolts (A22) M6u16 and (A23) M6u40 one each, and remove front panel (A5-2) with air conditioner duct.
2) Lift cover (A3) upwards and remove it. (Fixed with 3 clows and 2 clips)
A22
3) Unfix 3 harness clips (A4-8) of inside on right panel (A4-2). And free the harnesses connected to key switch.
A40
B2
A4-8 A4
A29
A4-8 A40
4) With harnesses are connected condition, install key switch cover (A3) to bracket (A1) of rear cab temporally. (See Fig. 33-5)
A39 A4-8
A29
5) Disconnect harness connectors of work light switch on right panel (A4), air conditioner panel and cigarette lighter, and remove right panel (A4) and (A4-2). (See Chapter 23)
A4-2
A22
6) Loosen sems bolts (A22) M6u16 and (A23) M6u40 one each, and remove front panel (A5-2) with air conditioner duct.
: Plus driver
: Plus driver
A5-2
A5-2
A23
Fig. 33-4 Disassembly and assembly of right panels (A4-2), (A3) and (A5-2)
33-4
A23
Fig. 33-4 Disassembly and assembly of right panels (A4-2), (A3) and (A5-2)
33-4
33. UPPER STRUCTURE
33. UPPER STRUCTURE
RELAY BOX ASSY
RELAY BOX ASSY
Fig. 33-5 Move switch cover assy (7) Remove cab attaching bolt
(7) Remove cab attaching bolt
1) 5 capscrews (A1) M12u65 and 1 capscrew (A3) M12u30. (Mark
1) 5 capscrews (A1) M12u65 and 1 capscrew (A3)
B4
)
2) 2 nuts (B4) M16 (Mark
M12u30. (Mark
)
A3 A1
2) Then lift up slowly avoiding interference with surroundings. Wire with hook ; Length 1.5m (4ft 11in)uDia. 8mm (0.315in)u3pcs. Weight of cab ; Approx. 250kg (550 lbs)
Fig. 33-6 Removing and installing cab mounting bolts.
INSTALLATION
Sems bolt M6 (A39)(A40)
1) Remove two plastic plugs at the front of the ceiling of the cab. Then place a wire sling with eye rings and a hook around the cab, as shown in Fig. 33-7.
Allen wrench HEX
Tightening torque N路m (lbf路ft)
24 19
191 (140) 79.4 (60
Torx driver
(T30)
Sems bolt M6 (A22)(A23) Plus driver
A3 A1
2) Then lift up slowly avoiding interference with surroundings. Wire with hook ; Length 1.5m (4ft 11in)uDia. 8mm (0.315in)u3pcs. Weight of cab ; Approx. 250kg (550 lbs) 33.1.2.2
Install it in reverse order of removing according to the Tightening Torque Table.
Nut M16 (B4) Capscrew (A1)(A3)
)
(8) Slinging cab
1) Remove two plastic plugs at the front of the ceiling of the cab. Then place a wire sling with eye rings and a hook around the cab, as shown in Fig. 33-7.
Tightening position
B4
)
2) 2 nuts (B4) M16 (Mark
(8) Slinging cab
33.1.2.2
Fig. 33-5 Move switch cover assy
Fig. 33-6 Removing and installing cab mounting bolts.
INSTALLATION
Install it in reverse order of removing according to the Tightening Torque Table. EYE BOLT M10
Tightening position Nut M16 (B4) Capscrew (A1)(A3)
Allen wrench HEX
Tightening torque N路m (lbf路ft)
24 19
191 (140) 79.4 (60
Torx driver
8.5 (6.3)
Sems bolt M6 (A39)(A40)
5.0 (3.7)
Sems bolt M6 (A22)(A23) Plus driver
(T30)
EYE BOLT M10
8.5 (6.3) 5.0 (3.7)
Fig. 33-7 Slinging cab
33-5
Fig. 33-7 Slinging cab
33-5
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.3
33.1.3
33.1.3.1
BATTERY REMOVING
33.1.3.1
BATTERY REMOVING
(1) Open left panel assy (21).
(1) Open left panel assy (21).
1) Open it with starter key.
1) Open it with starter key.
2) Open left panel assy (21).
2) Open left panel assy (21).
3) Fix it with stay.
3) Fix it with stay.
(2) Remove battery cover (1) Loosen nut (6) M10 and remove battery cover (1).
(2) Remove battery cover (1) Loosen nut (6) M10 and remove battery cover (1).
: 17 mm
: 17 mm
(3) Remove battery cable
(3) Remove battery cable
1) Remove cable (A4) [between the earth and battery (–)]. (Always remove (-) terminal first and install it at last.)
1) Remove cable (A4) [between the earth and battery (–)]. (Always remove (-) terminal first and install it at last.)
21
Fig. 33-8
2) Cable (A3) [between battery (+) and (-)]
Fig. 33-8
2) Cable (A3) [between battery (+) and (-)]
6
3) Cable (A2) [between battery (+) and battery relay]
21
6
3) Cable (A2) [between battery (+) and battery relay]
Tightening torque 15.7 N.m (11.6 lbf.ft)
: 13 mm
Tightening torque 15.7 N.m (11.6 lbf.ft)
: 13 mm 1
1
Follow the battery removal order. Start removing battery from grounding side, and finish attaching to grounding side. If this order is missed, short-circuits may occur.
Follow the battery removal order. Start removing battery from grounding side, and finish attaching to grounding side. If this order is missed, short-circuits may occur.
(4) Remove battery (B1)
(4) Remove battery (B1)
1) Loosen 2 capscrews (3) M10u235.
1) Loosen 2 capscrews (3) M10u235. A2
: 17 mm 2) Remove plate (2).
A3 2
3) Remove battery (B1). B1
A2
: 17 mm
A4
A4
2) Remove plate (2).
A3 2
3) Remove battery (B1).
3
B1
Fig. 33-9 Removing and installing battery 33.1.3.2
INSTALL
Fig. 33-9 Removing and installing battery 33.1.3.2
(1) Install the battery in the reverse order of removing. Hold down plate (2) against battery (B1), and tighten capscrew (3).
INSTALL
(1) Install the battery in the reverse order of removing. Hold down plate (2) against battery (B1), and tighten capscrew (3).
: 17 mm, Tightening torque : 10.8N•m (8.0 lbf•ft)
: 17 mm, Tightening torque : 10.8N•m (8.0 lbf•ft)
(2) Installing grounding cable Install grounding cable (A4) last. Especially care must be taken that the grounding face is free from painting, rust, etc.
(2) Installing grounding cable Install grounding cable (A4) last. Especially care must be taken that the grounding face is free from painting, rust, etc.
: 13 mm
: 13 mm
33-6
3
33-6
33. UPPER STRUCTURE 33.1.4
GUARD
33.1.4.1
33. UPPER STRUCTURE 33.1.4
PREPARATION FOR REMOVAL
GUARD
33.1.4.1
(1) Remove guard in the following procedure. Remove the guards in the order of (11)o(5)o(6)o(7)o(2)o(21)o(23)o(3)o(4)o (22) and (1).
1
7
2
6
22 5
(2) All the locked cover, open them using starter key.
PREPARATION FOR REMOVAL
(1) Remove guard in the following procedure. Remove the guards in the order of (11)o(5)o(6)o(7)o(2)o(21)o(23)o(3)o(4)o (22) and (1).
1
7
2
6
22 5
(2) All the locked cover, open them using starter key.
11
11
3
3 23
23 4
4 21
21
Fig. 33-10 Arrangement of guard assy 33.1.4.2
REMOVE GUARD
Fig. 33-10 Arrangement of guard assy 33.1.4.2
(1) Remove bonnet assy (11)
2 11
1) Unlock catches (2) and unlatch catches (2), (3), and open bonnet (11).
REMOVE GUARD
(1) Remove bonnet assy (11)
3
2 11
1) Unlock catches (2) and unlatch catches (2), (3), and open bonnet (11).
2) Remove four nuts (7) M12.
2) Remove four nuts (7) M12.
3) Remove bonnet (11).
3) Remove bonnet (11).
: 19 mm Weight : 37kg (82 lbs)
3
: 19 mm Weight : 37kg (82 lbs) 7
7 7
7
Fig. 33-11 Removing bonnet assy (11) (2) Remove guard (5)
41b
1) Remove 4 sems bolts (41a) M12u25 on upper side.
5
3) Remove guard (5)
41b 41a
C
3) Remove guard (5)
41a
: 19 mm Weight :10kg (22 lbs)
C
Fig. 33-12 Removing guard (5)
33-7
5
2) Remove 3 sems bolts (41b) M12u25 on the side. 41a
: 19 mm Weight :10kg (22 lbs)
(2) Remove guard (5) 1) Remove 4 sems bolts (41a) M12u25 on upper side.
41a
2) Remove 3 sems bolts (41b) M12u25 on the side.
Fig. 33-11 Removing bonnet assy (11)
Fig. 33-12 Removing guard (5)
33-7
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(3) Remove guard (6) and guard assy (3).
(3) Remove guard (6) and guard assy (3).
41a
1) Remove 4 sems bolts (35) M12u25.
35
2) Remove a sems bolt (41a) M12u25. 3) Remove guard (6). 4) Remove a sems bolt(41b) M12u25.
4) Remove a sems bolt(41b) M12u25.
41b
5) Remove guard assy (3). D
: 19 mm
6
35
3) Remove guard (6).
41b
5) Remove guard assy (3).
35
2) Remove a sems bolt (41a) M12u25.
6
35
41a
1) Remove 4 sems bolts (35) M12u25.
D
: 19 mm
3
3
Fig. 33-13 Removing guard (6)
Fig. 33-13 Removing guard (6)
(4) Remove stay (7)
(4) Remove stay (7)
1) Remove 2 sems bolts (41) M12u25.
1) Remove 2 sems bolts (41) M12u25. 7
2) Remove 2 sems bolts (43) M12u40.
7
2) Remove 2 sems bolts (43) M12u40. 41
3) Remove stay (7).
41
3) Remove stay (7).
: 19 mm
: 19 mm 43
43
A
A
Fig. 33-14 Removeing stay (7) (5) Remove guard (2)
Fig. 33-14 Removeing stay (7) (5) Remove guard (2)
41
1) Remove 2 sems bolts (41) M12u25.
41
1) Remove 2 sems bolts (41) M12u25.
2) Remove connector for right side deck light.
2) Remove connector for right side deck light.
2
3) Remove guard (2).
Deck light
: 19 mm
2
3) Remove guard (2).
Deck light
: 19 mm
Fig. 33-15 Removing guard (2) (6) Remove panel assy (21)
Fig. 33-15 Removing guard (2) (6) Remove panel assy (21)
21
1) Unlock panel assy (21).
1) Unlock panel assy (21).
2) Remove 4 nuts (4) M10.
2) Remove 4 nuts (4) M10.
3) Remove panel assy (21).
3) Remove panel assy (21).
: 17 mm Weight : 15kg (33 lbs)
4
21
: 17 mm Weight : 15kg (33 lbs)
4
Fig. 33-16 Removing panel assy (21)
33-8
Fig. 33-16 Removing panel assy (21)
33-8
33. UPPER STRUCTURE (7) Remove panel assy (23)
33. UPPER STRUCTURE (7) Remove panel assy (23)
23
1) Remove 4 nuts (4) M10.
23
1) Remove 4 nuts (4) M10. 4
2) Remove panel assy (23).
4
2) Remove panel assy (23).
: 17 mm Weight : 10kg (22 lbs)
: 17 mm Weight : 10kg (22 lbs)
Fig. 33-17 Removing panel assy (23) (8) Remove panel assy (22)
Fig. 33-17 Removing panel assy (23) (8) Remove panel assy (22)
22
1) Unlock and open panel assembly (22).
1) Unlock and open panel assembly (22).
2) Remove 4 nuts (4) M10.
2) Remove 4 nuts (4) M10.
3) Remove panel assy (22).
3) Remove panel assy (22).
: 17 mm Weight : 15kg (33 lbs)
: 17 mm Weight : 15kg (33 lbs)
22
4
4
Fig. 33-18 Removing panel assy (22) (9) Remove guard assy (16) and guard (14), (15), (17). 1) Remove 9 sems bolts (41) M12u25 and a sems bolt (6A) M12u30 and guard assy (17), (15), (16), (14) in order.
41 14
(9) Remove guard assy (16) and guard (14), (15), (17).
41 41
41
41
16
6A
: 19 mm
17
Fig. 33-18 Removing panel assy (22)
41
41
1) Remove 9 sems bolts (41) M12u25 and a sems bolt (6A) M12u30 and guard assy (17), (15), (16), (14) in order.
41 14
41 41
41
41
16
6A
: 19 mm
17
41
41
41
41
41
41
15
Fig. 33-19 Removing guard assy (16) and guard (14), (15), (17). (10)Remove pillar (11) 1) Remove 4 sems bolts (42) M12u30 and remove pillar.
11 42
: 19 mm
Fig. 33-19 Removing guard assy (16) and guard (14), (15), (17). (10)Remove pillar (11)
C
C
1) Remove 4 sems bolts (42) M12u30 and remove pillar.
11 42
: 19 mm
B
B
B
B
Fig. 33-20 Removing pillar (11)
33-9
15
Fig. 33-20 Removing pillar (11)
33-9
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(11)Remove beam (4)
(11)Remove beam (4)
41
1) Loosen 6 sems bolts (41) M12u25.
1) Loosen 6 sems bolts (41) M12u25.
2) Remove beam (4).
2) Remove beam (4).
: 19 mm Weight : 13kg (29 lbs)
41
: 19 mm Weight : 13kg (29 lbs)
4
4
10
10
12
12
Fig. 33-21 Removing and installing of beam (4) (12)Remove pillar (10), (12) Remove battery relay box in advance and remove pillar (10). (See Chapter 23)
Fig. 33-21 Removing and installing of beam (4) (12)Remove pillar (10), (12) Remove battery relay box in advance and remove pillar (10). (See Chapter 23)
10
1) Loosen 2 sems bolts (42) M12u30.
10
1) Loosen 2 sems bolts (42) M12u30.
2) Loosen 2 sems bolts (43) M12u40.
2) Loosen 2 sems bolts (43) M12u40.
12
3) Loosen a sems bolt (51) M12u35.
12
3) Loosen a sems bolt (51) M12u35. 42
: 19 mm 4) Remove pillar (10), (12). Weight : Pillar (10) : 12kg (26 lbs)
51
42
: 19 mm
43
4) Remove pillar (10), (12). Weight : Pillar (10) : 12kg (26 lbs)
Fig. 33-22 Removing and installing of pillar (10),(12) (13)Remove guard assy (18) and (13) 1) Loosen 4 capscrews (33) M12u20, and remove guard assy (18).
18
2) Loosen 2 sems bolts (42) M12u20, and remove guard assy (13). 33
: 19 mm Weight : 12kg (26 lbs)
E
13
33
(14)Remove guard (19) Loosen 6 sems bolts (41) M12u25, and remove guard (19).
41
1) Loosen 4 capscrews (33) M12u20, and remove guard assy (18).
19
E 42
19 18
2) Loosen 2 sems bolts (42) M12u20, and remove guard assy (13). 33
: 19 mm Weight : 12kg (26 lbs)
E
13
33
(14)Remove guard (19) Loosen 6 sems bolts (41) M12u25, and remove guard (19).
E 42
Fig. 33-23 Removing and installing of guard assy and guard
33-10
43
Fig. 33-22 Removing and installing of pillar (10),(12) (13)Remove guard assy (18) and (13)
41
51
Fig. 33-23 Removing and installing of guard assy and guard
33-10
33. UPPER STRUCTURE (15)Remove cover (2)
33. UPPER STRUCTURE (15)Remove cover (2)
1) While air cleaner is removed, loosen hose clamp of engine intake and disconnect the hose.
1) While air cleaner is removed, loosen hose clamp of engine intake and disconnect the hose.
3
2) Loosen 6 sems bolts (6) M12u25, and remove cover (2).
3
2) Loosen 6 sems bolts (6) M12u25, and remove cover (2).
: 19 mm
: 19 mm
6
(16)Remove guard assy (1) Loosen 4 sems bolts (6) M12u25, and remove guard assy (1).
6
(16)Remove guard assy (1) Loosen 4 sems bolts (6) M12u25, and remove guard assy (1). 6
: 19 mm Weight : 20kg (44 lbs)
2
1
(17)Remove guard assy (3) Loosen 4 sems bolts (6) M12u25, and remove guard assy (3).
6
6
6 6
Fig. 33-24 Removing and installing of cover and guard assy (18)Remove plate (20) Loosen 3 sems bolts (41) M12u25, and remove plate (20).
6
6
: 19 mm Weight : 15kg
6
2
1
(17)Remove guard assy (3) Loosen 4 sems bolts (6) M12u25, and remove guard assy (3).
6
: 19 mm Weight : 15kg
6
: 19 mm Weight : 20kg (44 lbs)
Fig. 33-24 Removing and installing of cover and guard assy (18)Remove plate (20) Loosen 3 sems bolts (41) M12u25, and remove plate (20).
: 19 mm Weight : 15kg (33 lbs)
B
: 19 mm Weight : 15kg (33 lbs)
B
41
41
41
41
20
20 41
41
Fig. 33-25 Removing and installing of plate (20)
33-11
Fig. 33-25 Removing and installing of plate (20)
33-11
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(19)Remove cover assy (1)
(19)Remove cover assy (1)
1) Disconnect the hose (14) which is connected to fuel feed pump and fuel tank. And disconnect the connector of harness for fuel pump. (See Fig. 33-28) 2) Unlock the locks and open cover (1-2).
1) Disconnect the hose (14) which is connected to fuel feed pump and fuel tank. And disconnect the connector of harness for fuel pump. (See Fig. 33-28) 1-2
3) Remove 4 sems bolts (41) M12u25. 4) Remove cover assy (1).
41
2) Unlock the locks and open cover (1-2).
1-2
3) Remove 4 sems bolts (41) M12u25. 4) Remove cover assy (1).
: 19 mm Weight : 30kg
: 19 mm Weight : 30kg
(20)Remove other brackets, as required.
(20)Remove other brackets, as required.
1
1
Fig. 33-26 Remove cover assy (1) 33.1.4.3
INSTALLATION
Fig. 33-26 Remove cover assy (1) 33.1.4.3
INSTALLATION
(1) Installing is done in the reverse order of removing.
(1) Installing is done in the reverse order of removing.
(2) Tightening torque
(2) Tightening torque
Unit : N.m (lbf.ft)
Unit : N.m (lbf.ft)
Size
Capscrew
Sems bolt
Size
Capscrew
Sems bolt
M8 M10 M12
121 (90)
23 (17) 46.5 (34.3) 80 (59)
M8 M10 M12
121 (90)
23 (17) 46.5 (34.3) 80 (59)
33-12
33-12
41
33. UPPER STRUCTURE 33.1.5 33.1.5.1
UNDER COVER
33. UPPER STRUCTURE 33.1.5
REMOVAL
33.1.5.1
(1) Remove under cover (1,2,3,4,5,6,7,8)
UNDER COVER REMOVAL
(1) Remove under cover (1,2,3,4,5,6,7,8)
1) Remove attaching sems bolts (9) M12u30 and (10) M12u25.
1) Remove attaching sems bolts (9) M12u30 and (10) M12u25.
2) Remove covers.
2) Remove covers.
: 19 mm
: 19 mm
8
1
4 10
8
1
4
10 10
2 9
3
10
2
10 10
5
9
10
9
3
10
7
10 10
5
9
6
6
9
9
Fig. 33-27 Under cover assy 33.1.5.2
INSTALLATION
Fig. 33-27 Under cover assy 33.1.5.2
(1) Install under cover (1,2,3,4,5,6,7,8)
INSTALLATION
(1) Install under cover (1,2,3,4,5,6,7,8)
: 19 mm Tightening torque : 79.4 N•m (60 lbf•ft)
: 19 mm Tightening torque : 79.4 N•m (60 lbf•ft)
33-13
33-13
7
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.6
33.1.6
33.1.6.1
FUEL TANK PREPARATION FOR REMOVAL
33.1.6.1
(1) Draining fuel. (See Fig. 33-30)
FUEL TANK PREPARATION FOR REMOVAL
(1) Draining fuel. (See Fig. 33-30)
1) Unlock cap (B2) with a starter key and open it.
1) Unlock cap (B2) with a starter key and open it.
2) Loosen valve (A8) under the tank.
2) Loosen valve (A8) under the tank.
3) Draining fuel Capacity of tank : 367L (97gal)
3) Draining fuel Capacity of tank : 367L (97gal)
(2) Remove stay (7) and guard (2). (See 33.1.4 GUARD)
(2) Remove stay (7) and guard (2). (See 33.1.4 GUARD)
(3) Remove the connector for level sensor (A4). (See Fig. 33-30)
(3) Remove the connector for level sensor (A4). (See Fig. 33-30)
(4) Disconnect the connector of automatic fuel stop switch (12).
12 CONNECTOR
(5) Removal of fuel feed hose 1) Loosen 2 sems bolts (6) M12u25.
8
(4) Disconnect the connector of automatic fuel stop switch (12).
14 6
(5) Removal of fuel feed hose
6
: 19 mm
12 CONNECTOR
8 14 6
1) Loosen 2 sems bolts (6) M12u25.
6
: 19 mm
2) Loosen clip (8) and disconnect hose (14).
2) Loosen clip (8) and disconnect hose (14).
3) Install the plug which fits to hose bore.
3) Install the plug which fits to hose bore.
(6) Remove the connector of fuel feed pump (1) from the tank.
(6) Remove the connector of fuel feed pump (1) from the tank.
1
1
Fig. 33-28 Removing fuel feed hose (14) (7) Remove fuel hose
Fig. 33-28 Removing fuel feed hose (14) (7) Remove fuel hose
1) Loosen clip (16),(23) and draw out hoses (24) and (7).
1) Loosen clip (16),(23) and draw out hoses (24) and (7).
2) Put in plugs that match the hose bore.
2) Put in plugs that match the hose bore.
14 21
14 21
27 7
27 7
Fig. 33-29 Removing fuel hose (7), (24)
33-14
Fig. 33-29 Removing fuel hose (7), (24)
33-14
33. UPPER STRUCTURE 33.1.6.2
REMOVAL
33. UPPER STRUCTURE 33.1.6.2
(1) Remove 4 capscrews (A1) M16u40.
REMOVAL
(1) Remove 4 capscrews (A1) M16u40.
B2
: 24 mm
B2
: 24 mm
(2) Hook the wire to the lifting eye on the fuel tank assy (C1) and remove the fuel tank. Weight : 102kg (225 lbs)
A4 C1
A6
(2) Hook the wire to the lifting eye on the fuel tank assy (C1) and remove the fuel tank. Weight : 102kg (225 lbs)
(3) Remove shim (A3).
(3) Remove shim (A3).
Record the shim locations.
Record the shim locations.
A3
A1
A1 A8
Fig. 33-30 Removing fuel tank INSTALLATION
Fig. 33-30 Removing fuel tank 33.1.6.3
(1) Installing is done in the reverse order of removing. Tank attaching bolt (A1) M16u40
INSTALLATION
(1) Installing is done in the reverse order of removing. Tank attaching bolt (A1) M16u40
: 24 mm, Apply Loctite #262 Tightening torque : 191 N•m (140 lbf•ft)
: 24 mm, Apply Loctite #262 Tightening torque : 191 N•m (140 lbf•ft)
If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.
If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.
(2) Tightening torque
(2) Tightening torque
No.
Name
Q'ty
Tightening torque N.m (lbf.ft)
No.
Name
Q'ty
Tightening torque N.m (lbf.ft)
A1
Capscrew
4
191 (140)
A1
Capscrew
4
191 (140)
A6
Machine screw
5
1.96 (1.4)
A6
Machine screw
5
1.96 (1.4)
A8
Cock
1
34 (25)
A8
Cock
1
34 (25)
6
Sems bolt
2
80 (59)
6
Sems bolt
2
80 (59)
33-15
C1
A6
A3
A8
33.1.6.3
A4
33-15
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.7
33.1.7
33.1.7.1
HYDRAULIC TANK PREPARATION FOR REMOVAL
33.1.7.1
(1) Remove panel assy (2), guard (6) and other guards necessary to remove the hydraulic oil tank. (See 33.1.4 GUARD.)
HYDRAULIC TANK PREPARATION FOR REMOVAL
(1) Remove panel assy (2), guard (6) and other guards necessary to remove the hydraulic oil tank. (See 33.1.4 GUARD.)
Fig. 33-31 Remove guard
Fig. 33-31 Remove guard
(2) Release internal pressure of tank Remove cap on air breather and push valve (head of bolt) by your finger.
Keep pressing until the hissing stops.
(2) Release internal pressure of tank Remove cap on air breather and push valve (head of bolt) by your finger.
Fig. 33-32 Bleeding internal pressure of tank
(3) Remove cover (C2).
C5 C3
: 17 mm
Fig. 33-32 Bleeding internal pressure of tank
(3) Remove cover (C2).
C5
1) Remove 6 sems bolts (C5) M10u25.
Keep pressing until the hissing stops.
C5
1) Remove 6 sems bolts (C5) M10u25.
C5 C3
: 17 mm
2) Remove cover (C2).
C2
3) Remove suction strainer (B2).
2) Remove cover (C2).
C2
3) Remove suction strainer (B2).
(4) Remove cover (C3).
(4) Remove cover (C3).
1) Remove 6 capscrews (C5) M10u25.
1) Remove 6 capscrews (C5) M10u25.
: 17 mm
: 17 mm
B
2) Remove cover (C3).
B2
C
3) Remove filter element (B6). B6
(5) Turn the handle of element assy (B), and disassemble the removed filter element (B6). Disassemble parts : (B), (C), (D)u2, (E), (F)
2) Remove cover (C3).
Air breather
E F
Hyd.tank
B6
(5) Turn the handle of element assy (B), and disassemble the removed filter element (B6). Disassemble parts : (B), (C), (D)u2, (E), (F)
D D
Air breather
E
(6) Draining hydraulic oil Place pump in tank and draw up hydraulic oil. Capacity of tank : 146 L (39gal)
F
Fig. 33-33 Remove cover (C2), (C3)
33-16
B2
C
3) Remove filter element (B6).
D D
(6) Draining hydraulic oil Place pump in tank and draw up hydraulic oil. Capacity of tank : 146 L (39gal)
B
Hyd.tank
Fig. 33-33 Remove cover (C2), (C3)
33-16
33. UPPER STRUCTURE 33.1.7.2
REMOVAL
33. UPPER STRUCTURE 33.1.7.2
REMOVAL
(1) Draw out the suction hose (A3) Remove 2 clips (A19) of the tank side and pull out hose (A3).
(1) Draw out the suction hose (A3) Remove 2 clips (A19) of the tank side and pull out hose (A3).
2 : Flat-blade screwdriver
2 : Flat-blade screwdriver
A19 At installing suction hose, A3 apply PERMATEX to the A12 inner end of both hoses.
A19 At installing suction hose, A3 apply PERMATEX to the A12 inner end of both hoses.
Fig. 33-34 Removing and installing the suction hose (2) Disconnecting the main pipe return hose Remove sems bolt (15) M8u35 and remove return hose (3).
Fig. 33-34 Removing and installing the suction hose (2) Disconnecting the main pipe return hose Remove sems bolt (15) M8u35 and remove return hose (3).
9
9
: 17 mm
6 S/M
(3) Remove drain hose (6) of pump
15
T2
H/P
3
(4) Remove drain hose (9) of swing motor
Dr
Fig. 33-35 Removing main piping return hose
1) Remove pilot hose (A1).
DR
T
3) Remove pilot hose (A13).
DR
T
A10
Fig. 33-36 Remove pilot return hose
(6) Remove drain hose (2) of pilot pump
A13 PT T
3) Remove pilot hose (A13).
S/V
: 22 mm
C/V
: 22 mm
PT
Dr
A1
2) Remove pilot hose (A10). A13
H/P
Fig. 33-35 Removing main piping return hose
: 22 mm
A1 C/V
15 3
: 27 mm
1) Remove pilot hose (A1). : 22 mm
C/V
(4) Remove drain hose (9) of swing motor
(5) Disconnecting pilot return hose
: 22 mm
Dr
T2
(5) Disconnecting pilot return hose
2) Remove pilot hose (A10).
S/M
: 36 mm
C/V
: 27 mm
6
(3) Remove drain hose (6) of pump
Dr
: 36 mm
: 17 mm
S/V T
: 22 mm
A10
Fig. 33-36 Remove pilot return hose
(6) Remove drain hose (2) of pilot pump
: 22 mm
: 22 mm 2
2
Fig. 33-37 Removing pump drain hose
33-17
Fig. 33-37 Removing pump drain hose
33-17
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(7) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M16u40.
(7) Remove hydraulic tank attaching bolt Remove 4 capscrews (A1) M16u40.
: 24 mm
: 24 mm
(8) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank. Tank weight : Approx : 140kg (310 lbs)
(8) Slinging hydraulic oil tank Place a wire sling, using the lifting plate on top of the tank. Tank weight : Approx : 140kg (310 lbs)
(9) Remove shim (A3).
A3
(9) Remove shim (A3).
A3
A1
A1
Fig. 33-38 Removing hydraulic tank
Fig. 33-38 Removing hydraulic tank
Record the shim locations.
Record the shim locations.
33.1.7.3
33.1.7.3
INSTALLATION
INSTALLATION
(1) Cleaning hydraulic oil tank
(1) Cleaning hydraulic oil tank
(2) Cleaning suction hose
(2) Cleaning suction hose
(3) Cleaning mount of tank. Installing is done in the reverse order of removing.
(3) Cleaning mount of tank. Installing is done in the reverse order of removing.
(4) Install 4 mounting capscrews (A1) M16u40 with Loctite #262. (See Fig. 33-38.)
(4) Install 4 mounting capscrews (A1) M16u40 with Loctite #262. (See Fig. 33-38.)
: 24 mm, Apply Loctite # 262 Tightening torque : 191 N•m (40 lbf•ft)
: 24 mm, Apply Loctite # 262 Tightening torque : 191 N•m (40 lbf•ft)
If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.
33-18
If the gap (looseness) between tank mount and frame exceeds 1mm (0.04inch), adjust the gap with shim (A3) and tighten capscrew (A1) to install the tank.
33-18
33. UPPER STRUCTURE (5) Connection of suction hose (A3)(See Fig. 33-34)
33. UPPER STRUCTURE (5) Connection of suction hose (A3)(See Fig. 33-34)
O-RING
1) Apply PERMATEX on pipe side of hose connection and insert it.
1) Apply PERMATEX on pipe side of hose connection and insert it.
2) Put the hose with clip (A19). Tightening torque : 5.39 N•m (4.0 lbf•ft)
2) Put the hose with clip (A19). Tightening torque : 5.39 N•m (4.0 lbf•ft)
C
(6) Assembling return element Assemble filter element by the use of element kit (B-100). (See Fig. 33-33,Fig. 33-39)
O-RING
C
(6) Assembling return element Assemble filter element by the use of element kit (B-100). (See Fig. 33-33,Fig. 33-39)
D
D
B2 SUCTION
1. Two elements (D) are used as one set. 2. Replace O-ring (C) and packing (F) with new ones respectively.
B2 SUCTION
STRAINER YW50V00004F7
1. Two elements (D) are used as one set.
F ELEMENT KIT YN52V01008R800
(7) Install return element. (See Fig. 33-33)
2. Replace O-ring (C) and packing (F) with new ones respectively.
(8) Installing suction strainer (B2)
(9) Tighten sems bolts (C5) M10u25 that attach tank covers (C2), (C3). M10 Tightening torque : 46.1 N•m (34 lbf•ft)
(9) Tighten sems bolts (C5) M10u25 that attach tank covers (C2), (C3). M10 Tightening torque : 46.1 N•m (34 lbf•ft)
Replace O-ring fitted on the back side of tank cover with new one.
33-19
F ELEMENT KIT YN52V01008R800
(7) Install return element. (See Fig. 33-33)
(8) Installing suction strainer (B2) Fig. 33-39 Element & suction strainer
STRAINER YW50V00004F7
Fig. 33-39 Element & suction strainer
Replace O-ring fitted on the back side of tank cover with new one.
33-19
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.8
33.1.8
33.1.8.1
HYDRAULIC PUMP PREPARATION FOR REMOVAL
33.1.8.1
(1) Release pressure in hydraulic oil tank. (See 33.1.7HYDRAULIC TANK)
C5
(2) Remove six capscrews (C5) M10u25.
C2
(3) Remove cover (C2) Suction stopper
: 17 mm
HYDRAULIC PUMP PREPARATION FOR REMOVAL
(1) Release pressure in hydraulic oil tank. (See 33.1.7HYDRAULIC TANK)
C5
(2) Remove six capscrews (C5) M10u25.
C2
(3) Remove cover (C2) Suction stopper
: 17 mm
(4) Take out suction strainer.
(4) Take out suction strainer.
(5) Install suction stopper. For suction stopper, see chapter 11. Tools.
Suction strainer
(5) Install suction stopper. For suction stopper, see chapter 11. Tools.
Suction strainer
Hyd.tank
Hyd.tank
Fig. 33-40 Suction stopper installing (6) Remove guards
Fig. 33-40 Suction stopper installing (6) Remove guards
1) Remove bonnet assy (1).
1) Remove bonnet assy (1).
2) Remove guard (5), (14), (15), (17) and guard assy (16).
2) Remove guard (5), (14), (15), (17) and guard assy (16).
1
3) Remove those parts that are required to remove the hydraulic pump such as the fuel filter assy. 4) Remove drain hose at the bottom of the muffler.
5
14 17
4) Remove drain hose at the bottom of the muffler.
16
5
14 17
16
15
Fig. 33-41 Removing guards
33-20
1
3) Remove those parts that are required to remove the hydraulic pump such as the fuel filter assy.
15
Fig. 33-41 Removing guards
33-20
33. UPPER STRUCTURE 33.1.8.2
REMOVAL
33. UPPER STRUCTURE 33.1.8.2
(1) Loosen sems bolts (13) M12u40 and remove half clamp (A10). And disconnect 2 hoses (A1), (A2) from the delivery side.
A2
A13
: 17 mm A2
A4
A10
A2
A13 A10 C/V
(2) Remove pilot pump suction hose (1) (See Fig. 33-43)
6
P2
A13
A10
: 36 mm
A2
A1
A13
Dr a1
C/V
: 10 mm
(3) Remove suction hose (A3) and drain hose (6)
a2
A10
1) Remove 4 capscrews (B2) M12u30.
PH2 PH1
A1
a2 a1
C/V P1
A3
PH2
2) Remove elbow (B1) of suction hose (A3) from pump.
PH1
3) Remove drain hose (6) (Dr). B1
: 36 mm
B1
: 36 mm
B2
B2
Fig. 33-42 Removing hoses (4) Removing other hoses
2
1) Disconnect hoses of the following ports.
3
22
Fig. 33-42 Removing hoses (4) Removing other hoses
A3
Drain
*Psv1
4
19
Pilot primary pressure P1 side
*Psv2
2
19
Pilot primary pressure P2 side
Psv1
A11
22
Pilot pump delivery
B3
3 Psv2 Psv1
B1
2
1) Disconnect hoses of the following ports.
Dr3
Remarks
Tool
Dr
A10
: 10 mm
3) Remove drain hose (6) (Dr).
Dr3
A4
A10
A13
1) Remove 4 capscrews (B2) M12u30.
P1
A3
2) Remove elbow (B1) of suction hose (A3) from pump.
Hose No.
6
P2
A13
A10
: 36 mm
(3) Remove suction hose (A3) and drain hose (6)
Port
A13
A1
: 17 mm
A10 C/V
(2) Remove pilot pump suction hose (1) (See Fig. 33-43)
(1) Loosen sems bolts (13) M12u40 and remove half clamp (A10). And disconnect 2 hoses (A1), (A2) from the delivery side.
A13
A1
REMOVAL
1 SOL/V
A11
P1
Port
Hose No.
Dr3
3
Remarks
Tool 22
Drain
*Psv1
4
19
Pilot primary pressure P1 side
*Psv2
2
19
Pilot primary pressure P2 side
Psv1
A11
22
Pilot pump delivery
B3
B1
Psv2
1 SOL/V
A11
P1
Fig. 33-43 Removing other hoses
Remove the parts marked * only if necessary.
2) Attach tags to hoses to identify.
2) Attach tags to hoses to identify.
3) Put a plug in the hoses and the pump.
3) Put a plug in the hoses and the pump.
33-21
3 Psv1
Fig. 33-43 Removing other hoses
Remove the parts marked * only if necessary.
A3 Dr3
33-21
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(5) Remove connector Remove 4 connectors of all pressure sensors and proportional valves.
Tightening torque 25.5N.m SEMS BOLT (19 lbf.ft)
PSV-P1:
P1 pump proportional valve
(5) Remove connector Remove 4 connectors of all pressure sensors and proportional valves.
PSV-P2:
P2 pump proportional valve
Engine side
P1 pump proportional valve
CLIP
Using Zip-tie, clamp the corrugated part of harness to the pressure sensor.
P2 pump proportional valve
SE-23:
CLIP
Pressure sensor : P2 pump
Using Zip-tie, clamp the corrugated part of harness to the pressure sensor.
SE-23:
Pressure sensor : P2 pump
Fig. 33-44 Removing connector (6) Remove main pump
0
3
Using Zip-tie, clamp the corrugated part of harness to the solenoid.
Pressure sensor : P1 pump
Fig. 33-44 Removing connector (6) Remove main pump
CLIP
SE-22:
Using Zip-tie, clamp the corrugated part of harness to the solenoid.
Pressure sensor : P1 pump
PSV-P2:
Engine side
CLIP
SE-22:
Tightening torque 25.5N.m SEMS BOLT (19 lbf.ft)
PSV-P1:
1) Put a wire sling on the hydraulic pump and tension the wire sling a little. Loosen 8 capscrews (4) M10u30.
0
3
1) Put a wire sling on the hydraulic pump and tension the wire sling a little. Loosen 8 capscrews (4) M10u30.
: 17 mm
: 17 mm
2) Draw out the power take-off assy from the flywheel housing slowly, adjusting the tension of the wire rope. On that occasion, the assembly is drawn out with the insert NA (2-3) remaining on the flywheel side.
2) Draw out the power take-off assy from the flywheel housing slowly, adjusting the tension of the wire rope. On that occasion, the assembly is drawn out with the insert NA (2-3) remaining on the flywheel side.
4
2-4
2-5
3) Remove element (2-1) from the tip of the spline shaft.
2-2
1
: 14 mm
2-5
5) Remove hub (2-2) If you loosen 2 set screws (2-6) M16u22, hub comes off from the spline shaft of the pump.
2-7
2-1
2-3
Fig. 33-45 Removing pump
: 8 mm
: 14 mm
2-2 2-5
5) Remove hub (2-2) If you loosen 2 set screws (2-6) M16u22, hub comes off from the spline shaft of the pump.
2-7
2-1
2-3
Fig. 33-45 Removing pump
6) Remove 4 capscrews (2-5) M16u45 that fasten the insert NA (2-3) with the engine side flywheel, as necessary. Then remove and spring pin (2-7) from insert NA (2-3).
7) Removing bracket (1) Loosen 4 capscrews (3) M20u55, and remove bracket (1) from pump (0).
33-22
1
: 14 mm
: 14 mm
7) Removing bracket (1) Loosen 4 capscrews (3) M20u55, and remove bracket (1) from pump (0).
2-5
2-6
4) Remove 4 capscrews (2-5) M16u50 that fasten insert R (2-4) and remove insert R (2-4).
: 8 mm
6) Remove 4 capscrews (2-5) M16u45 that fasten the insert NA (2-3) with the engine side flywheel, as necessary. Then remove and spring pin (2-7) from insert NA (2-3).
2-4
3) Remove element (2-1) from the tip of the spline shaft. 2-6
4) Remove 4 capscrews (2-5) M16u50 that fasten insert R (2-4) and remove insert R (2-4).
4
33-22
33. UPPER STRUCTURE 33.1.8.3
INSTALLATION
33. UPPER STRUCTURE 33.1.8.3
INSTALLATION
Installing is done in the reverse order of removing.
Installing is done in the reverse order of removing.
(1) Installing bracket (1) Tighten bracket (1) with capscrew (3) and install bracket temporarily.
(1) Installing bracket (1) Tighten bracket (1) with capscrew (3) and install bracket temporarily.
: 17 mm Tightening torque : 431 N•m (318lbf•ft) Apply Loctite #262
: 17 mm Tightening torque : 431 N•m (318lbf•ft) Apply Loctite #262
(2) Installing hub (2-2) Put hub (2-2) into the pump spline till it enters 3mm (0.12in) from the end face of the spline (See Fig. 33-46 Detail aa). Then install two set screws (2-6) and fix them together. : 8 mm Tightening torque : 110 N•m (81 lbf•ft)
(2) Installing hub (2-2) Put hub (2-2) into the pump spline till it enters 3mm (0.12in) from the end face of the spline (See Fig. 33-46 Detail aa). Then install two set screws (2-6) and fix them together. : 8 mm Tightening torque : 110 N•m (81 lbf•ft)
(3) Installing insert R (2-4) Install insert R (2-4) into hub (2-2) by means of capscrews (2-5).
(3) Installing insert R (2-4) Install insert R (2-4) into hub (2-2) by means of capscrews (2-5).
: 14 mm Tightening torque : 210~230 N•m (155~170 lbf•ft)
: 14 mm Tightening torque : 210~230 N•m (155~170 lbf•ft)
(4) Installing element (2-1) Put element (2-1) into hub (2-2) and insert R (2-4).
(4) Installing element (2-1) Put element (2-1) into hub (2-2) and insert R (2-4).
(5) Installing insert NA (2-3) Put spring pin (2-7) into insert NA (2-3) and install it to the engine flywheel by means of capscrews (25).
(5) Installing insert NA (2-3) Put spring pin (2-7) into insert NA (2-3) and install it to the engine flywheel by means of capscrews (25).
: 14 mm Tightening torque : 210~230 N•m (155~170 lbf•ft)
: 14 mm Tightening torque : 210~230 N•m (155~170 lbf•ft)
(See Fig. 33-45 about above mentioned (1) ~ (5).)
(See Fig. 33-45 about above mentioned (1) ~ (5).)
33-23
33-23
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(6) Installing the pump (See Fig. 33-45,Fig. 33-46) Lift the pump with bracket (1). Place coupling (2) in the groove of element (2-1) so as to receive insert NA (2-3).
(6) Installing the pump (See Fig. 33-45,Fig. 33-46) Lift the pump with bracket (1). Place coupling (2) in the groove of element (2-1) so as to receive insert NA (2-3).
(7) Coat 8 capscrews (4) M10u35 with Loctite #262 and put them in place.
(7) Coat 8 capscrews (4) M10u35 with Loctite #262 and put them in place.
: 17 mm Tightening torque : 64.7N•m (48 lbf•ft)
: 17 mm Tightening torque : 64.7N•m (48 lbf•ft)
(8) Fasten hoses (A1), (A2) on the delivery side with half clamp (A10) and sems bolt (A13) M12u40. (See Fig. 33-42)
(8) Fasten hoses (A1), (A2) on the delivery side with half clamp (A10) and sems bolt (A13) M12u40. (See Fig. 33-42)
: 17 mm Tightening torque : 62.2N•m (46 lbf•ft)
: 17 mm Tightening torque : 62.2N•m (46 lbf•ft)
(9) Install suction hose (A3) with 4 capscrews (B2) M12u30. (SeeFig. 33-42)
(9) Install suction hose (A3) with 4 capscrews (B2) M12u30. (SeeFig. 33-42)
: 10 mm Tightening torque : 66.7 N•m (49 lbf•ft)
: 10 mm Tightening torque : 66.7 N•m (49 lbf•ft)
(10)Install the hydraulic piping by referring to "HYDRAULIC SYSTEM".
(10)Install the hydraulic piping by referring to "HYDRAULIC SYSTEM".
(11)Installing the hose (See Fig. 33-43)
(11)Installing the hose (See Fig. 33-43)
Fig. 33-46 Installing hydraulic pump
Fig. 33-46 Installing hydraulic pump
(12)Installing pressure sensor connector and proportional valve connector.
(12)Installing pressure sensor connector and proportional valve connector.
(13)Remove suction stopper
(13)Remove suction stopper
(14)Install suction strainer
(14)Install suction strainer
When the pump is replaced, replenish more than 1L (0.26gal) of hydraulic oil from the drain port (Dr).
When the pump is replaced, replenish more than 1L (0.26gal) of hydraulic oil from the drain port (Dr).
(15)Bleed air in pump Bleed air by loosening the drain port (Dr).
Dr
(15)Bleed air in pump Bleed air by loosening the drain port (Dr).
(16)Check hydraulic oil level.
(16)Check hydraulic oil level.
(17)Start engine and check it for oil leak and noise.
(17)Start engine and check it for oil leak and noise.
(18)Attach drain down pipe under engine muffler.
(18)Attach drain down pipe under engine muffler.
(19)Install guards (See Fig. 33-41,Fig. 33-19)
(19)Install guards (See Fig. 33-41,Fig. 33-19)
Dr
Fig. 33-47 Bleed air port (Dr) in pump
33-24
Fig. 33-47 Bleed air port (Dr) in pump
33-24
33. UPPER STRUCTURE 33.1.9
AIR CLEANER
33.1.9.1
33. UPPER STRUCTURE 33.1.9
PREPARATION FOR REMOVAL
AIR CLEANER
33.1.9.1
PREPARATION FOR REMOVAL
(1) Opening bonnet assy (21) and (23). (See 33.1.4 GUARD)
(1) Opening bonnet assy (21) and (23). (See 33.1.4 GUARD)
(2) Open bonnet assy (11). (See 33.1.4 GUARD)
(2) Open bonnet assy (11). (See 33.1.4 GUARD)
(3) Remove Panel assy (3). (See 33.1.4 GUARD)
(3) Remove Panel assy (3). (See 33.1.4 GUARD)
(4) Unplug terminals on indicator (1-8) wiring. (See Fig. 33-49)
31 3
23
(4) Unplug terminals on indicator (1-8) wiring. (See Fig. 33-49)
31 3
21
Fig. 33-48 Preparation for removal 33.1.9.2
REMOVAL
REMOVAL
(1) Pulling out hose (3).
1) Loosen clips (5), (6) on both sides of hose (3).
1) Loosen clips (5), (6) on both sides of hose (3).
2) Pulling out hose (3)
2) Pulling out hose (3)
: Flat-blade screw driver
: Flat-blade screw driver
(2) Remove air cleaner assy (1)
(2) Remove air cleaner assy (1)
1) Remove 4 sems bolts (8) M10u25
1) Remove 4 sems bolts (8) M10u25
: 17 mm
: 17 mm
2) Remove air cleaner assy (1) from plate (4).
2) Remove air cleaner assy (1) from plate (4).
Fig. 33-49 Removing air cleaner 33.1.9.3
INSTALLATION
8
Indicator Sems bolt
5,6,7 Clip
Replacing parts
1) Put in air hoses (2), (3) to the end as shown in Fig. 33-49.
2) Tightening torque :
1-8
INSTALLATION
(1) Installing is the reverse order of removing with attention paid to the following items:
Replacing parts
1) Put in air hoses (2), (3) to the end as shown in Fig. 33-49.
Name
Fig. 33-49 Removing air cleaner 33.1.9.3
(1) Installing is the reverse order of removing with attention paid to the following items:
No.
21
Fig. 33-48 Preparation for removal 33.1.9.2
(1) Pulling out hose (3).
23
O RING (1-6) (YN11P00029S006)
Tightening torque N.m (lbf.ft)
FILTER ELEMENT (1-3) (YN11P00029S003)
3.9 (2.9) 39.2 (29) (Apply Loctite #262)
FILTER ELEMENT (1-2) (YN11P00029S002)
5.9 (4.4)
33-25
2) Tightening torque :
No. 1-8 8
Name Indicator Sems bolt
5,6,7 Clip
O RING (1-6) (YN11P00029S006)
Tightening torque N.m (lbf.ft)
FILTER ELEMENT (1-3) (YN11P00029S003)
3.9 (2.9) 39.2 (29) (Apply Loctite #262)
FILTER ELEMENT (1-2) (YN11P00029S002)
5.9 (4.4)
33-25
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.10
33.1.10
33.1.10.1
MUFFLER PREPARATION FOR REMOVAL
33.1.10.1
(1) Remove bonnet assy (11) and guard (5).
MUFFLER PREPARATION FOR REMOVAL
(1) Remove bonnet assy (11) and guard (5).
11
5
(2) Remove panel assy (22).
11
(3) Remove guard (14), (15), (17) and guard assy (16). (See Fig. 33-19)
(3) Remove guard (14), (15), (17) and guard assy (16). (See Fig. 33-19)
22
22
Fig. 33-50 Preparation for removal 33.1.10.2
Fig. 33-50 Preparation for removal
REMOVAL
33.1.10.2
(1) Remove U bolt (4).
1
1) Remove 4 nuts (10) M8.
5
(2) Remove panel assy (22).
REMOVAL
(1) Remove U bolt (4).
4
1
1) Remove 4 nuts (10) M8.
: 13 mm
4
: 13 mm
2) Remove 2 U bolts (4).
2) Remove 2 U bolts (4). 9
(2) Remove clamp assy (5)
5
1) Remove 2 capscrews (9) M10u35 : 17 mm
5
1) Remove 2 capscrews (9) M10u35
11
2) Separate clamp assy (5) from muffler (1).
9
(2) Remove clamp assy (5)
10 10
(3) Removing other parts Remove brackets (2) as necessary.
A 2
8
11
2) Separate clamp assy (5) from muffler (1).
10 10
(3) Removing other parts Remove brackets (2) as necessary. A
: 19 mm
: 17 mm
Attach washer (12) to nut (11) side. Tightening torque: 68.6~98 N.m (51~72lbf.ft) Tighten nut (11) till the no gap is here between plates of clamp.
Attach washer (12) to nut (11) side. Tightening torque: 68.6~98 N.m (51~72lbf.ft) Tighten nut (11) till the no gap is here between plates of clamp.
10mm (0.4 in) from the tip of muffler slit
10mm (0.4 in) from the tip of muffler slit
12,11,9
5
5
B
B C Procedure of fastening U bolt
A Installing clamp side (5)
Fig. 33-51 Removing and installing the muffler
33-26
8
A
: 19 mm
12,11,9
A
A 2
C Procedure of fastening U bolt
Installing clamp side (5)
Fig. 33-51 Removing and installing the muffler
33-26
33. UPPER STRUCTURE 33.1.10.3
INSTALLATION
33. UPPER STRUCTURE 33.1.10.3
INSTALLATION
Installing is the reverse order of removing with attention paid to the following items:
Installing is the reverse order of removing with attention paid to the following items:
(1) Procedure of fastening U bolt (4) (See Fig. 33-51)
(1) Procedure of fastening U bolt (4) (See Fig. 33-51)
1) Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around.
1) Tighten 4 nuts (A) till there is no space and make sure that the dimension C is even all around.
2) Tighten nuts (A) to specified torque and confirm the C dimensions on the right and left once again.
2) Tighten nuts (A) to specified torque and confirm the C dimensions on the right and left once again.
3) Tighten nuts (B) to specified torque and make sure that U bolts are not inclined.
3) Tighten nuts (B) to specified torque and make sure that U bolts are not inclined.
4) Tightening torque Nut A : 8.8 N•m (6.5 lbf•ft) Nut B : 10.8 N•m (8.0 lbf•ft)
4) Tightening torque Nut A : 8.8 N•m (6.5 lbf•ft) Nut B : 10.8 N•m (8.0 lbf•ft)
(2) Installing clamp assy (5)
(2) Installing clamp assy (5)
1) Place the end of clamp (5) 10mm (0.40in) away from the tip of the muffler slit so the joint of clamp does not extend over the slit in the muffler. (See Fig. 33-51)
1) Place the end of clamp (5) 10mm (0.40in) away from the tip of the muffler slit so the joint of clamp does not extend over the slit in the muffler. (See Fig. 33-51)
2) Install the clamp assy (5) in the illustrated direction.
2) Install the clamp assy (5) in the illustrated direction.
(3) Tightening torque :
(3) Tightening torque :
(4) Replacing parts
(4) Replacing parts
33-27
33-27
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.11
33.1.11
33.1.11.1
COUNTERWEIGHT REMOVAL
33.1.11.1
COUNTERWEIGHT REMOVAL
(1) Lifting up counterweight temporarily Hook wire rope to slinging plate, and lift it and stretch wire rope to the degree where it is providing no slack temporarily. Weight of counterweight ; Approx. 4,640kg (10,230 lb) Wire more than ø16 (0.63 inch) ; 1.5m (5ft)u2 pcs.
(1) Lifting up counterweight temporarily Hook wire rope to slinging plate, and lift it and stretch wire rope to the degree where it is providing no slack temporarily. Weight of counterweight ; Approx. 4,640kg (10,230 lb) Wire more than ø16 (0.63 inch) ; 1.5m (5ft)u2 pcs.
(2) Removing counterweight
(2) Removing counterweight
1) Remove 4 capscrews (A1) M27u355.
1) Remove 4 capscrews (A1) M27u355. Fig. 33-52 Lifting up counterweight
: 41 mm
Fig. 33-52 Lifting up counterweight
: 41 mm
2) Remove shim (A3), (A4), (A5). (Select)
2) Remove shim (A3), (A4), (A5). (Select)
3) Remove counterweight (C1).
3) Remove counterweight (C1).
C1
C1
A5 A4 A3
A5 A4 A3
A2
A2
A1
A1
Fig. 33-53 Removing counterweight 33.1.11.2
INSTALLATION
Fig. 33-53 Removing counterweight 33.1.11.2
INSTALLATION
(1) Install counterweight in the reverse order of removing.
(1) Install counterweight in the reverse order of removing.
(2) Install shim (A3), (A4), (A5) as it was. (select)
(2) Install shim (A3), (A4), (A5) as it was. (select)
(3) Slinging counterweight Check that the attaching bolts can be screwed in by hand.
(3) Slinging counterweight Check that the attaching bolts can be screwed in by hand.
A3,A4,A5
(4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2).
A3,A4,A5
(4) Apply Loctite #262 on capscrews (A1), and tighten them with washers (A2).
: 41 mm Tightening torque : 1270 N•m (940 lbf•ft)
: 41 mm Tightening torque : 1270 N•m (940 lbf•ft)
(5) Remove slinging tools.
(5) Remove slinging tools.
A1,A2
A1,A2 Fig. 33-54 Fastening the counterweight attaching capscrew
Fig. 33-54 Fastening the counterweight attaching capscrew
33-28
33-28
33. UPPER STRUCTURE
33. UPPER STRUCTURE 33.1.12 33.1.12.1
33.1.12
RADIATOR & OIL COOLER PREPARATION FOR REMOVAL
33.1.12.1
RADIATOR & OIL COOLER PREPARATION FOR REMOVAL
(1) Bleed air from the hydraulic tank and install the suction stopper.(See 33.1.7 and 33.1.8)
(1) Bleed air from the hydraulic tank and install the suction stopper.(See 33.1.7 and 33.1.8)
(2) Remove bonnet assy (11) (See 33.1.4 GUARD)
(2) Remove bonnet assy (11) (See 33.1.4 GUARD)
(3) Remove battery (See 33.1.3 BATTERY)
(3) Remove battery (See 33.1.3 BATTERY)
4
(4) Remove beam (4). (See 33.1.4 GUARD) (5) Open panel assy (21). (See 33.1.4 GUARD)
(5) Open panel assy (21). (See 33.1.4 GUARD)
(6) Removing under cover installed on lower side of radiator.
(6) Removing under cover installed on lower side of radiator.
10
1) Remove 2 sems bolts (10) M12u25.
Fig. 33-55 Removing under cover (4)
2) Remove cover (4). Clip
: 19 mm
19 13 19
(7) Drain down of radiator Put container 18L (4.8gal) under drain valve hose for draining water. [Water capacity of radiator : 5.5L (1.5gal)]
12
8 1
(8) Remove hose from radiator sub tank (1) Remove clip of radiator cap side and disconnect hose (8).
4
(4) Remove beam (4). (See 33.1.4 GUARD)
10
1) Remove 2 sems bolts (10) M12u25.
Fig. 33-55 Removing under cover (4)
2) Remove cover (4). Clip
: 19 mm
12
8 1 A
A
A
Fig. 33-56 Removing hose of sub tank (1) Do not loosen the joints of the hoses related to the airconditioner. Otherwise the refrigerant leaks.
Fig. 33-56 Removing hose of sub tank (1) Do not loosen the joints of the hoses related to the airconditioner. Otherwise the refrigerant leaks.
A
(9) Move air-conditioner condenser and receiver tank
13 19
(7) Drain down of radiator Put container 18L (4.8gal) under drain valve hose for draining water. [Water capacity of radiator : 5.5L (1.5gal)] (8) Remove hose from radiator sub tank (1) Remove clip of radiator cap side and disconnect hose (8).
A
19
A
(9) Move air-conditioner condenser and receiver tank
1) Loosen 2 sems bolts (23) M8u25 and 2 sems bolts (6) M10u25.
1) Loosen 2 sems bolts (23) M8u25 and 2 sems bolts (6) M10u25.
: 13 mm, 17 mm
: 13 mm, 17 mm
2) Move a set of air-conditioner condenser and receiver tank. (10)Disconnect connector of coolant level switch (B5). (See Fig. 33-58)
23
34
2) Move a set of air-conditioner condenser and receiver tank. (10)Disconnect connector of coolant level switch (B5). (See Fig. 33-58)
Tightening torque 46.1N.m (34 lbf.ft)
Tightening torque 46.1N.m (34 lbf.ft)
6
6
35
35
Fig. 33-57 Moving condensers and receiver tank
33-29
23
34
Fig. 33-57 Moving condensers and receiver tank
33-29
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.12.2
33.1.12.2
REMOVAL
(1) Remove radiator stay (A1).
REMOVAL
(1) Remove radiator stay (A1).
B10
1) Remove a sems bolt (A2) M12u35 and 3 sems bolts (A3) M12u30.
B10
1) Remove a sems bolt (A2) M12u35 and 3 sems bolts (A3) M12u30.
: 19 mm
: 19 mm
2) Remove 2 stays (A1).
B5
A3
(2) Remove water hose (2),(3)
B9
A1
1) Loosen the hose bands (30) for water hose (2).
2) Remove 2 stays (A1). (2) Remove water hose (2),(3)
B1
: Flat-blade screwdriver
B9
A1
1) Loosen the hose bands (30) for water hose (2).
A
B5
A3
B1
A
: Flat-blade screwdriver
2) Remove hose (2).
A2
A3
3) Loosen hose band (30) on water hose (3) and remove capscrew (22) M10u25. : Flat-blade screwdriver
A3
2) Remove hose (2).
A1
3) Loosen hose band (30) on water hose (3) and remove capscrew (22) M10u25.
A2
A3
A3 A1
: Flat-blade screwdriver
A2
A2
B
: 17 mm
B
: 17 mm
4) Remove hose (3).
4) Remove hose (3). A
A B
B
Fig. 33-58 Removing radiator assy (3) Remove hoses (4)(5) for inter-cooler
11 17 6
1) Remove two fixing U-bolts (17) from tube (11). 23
: 13 mm 2) Loosen sems bolt (21) M10u20.
C
30
19 21
30
23
(3) Remove hoses (4)(5) for inter-cooler
C
D
2) Loosen sems bolt (21) M10u20. E
4
: Flat-blade screwdriver 30
30
D
E
B
29
31 5
5) Loosen hose bands (31) and remove hose (5).
33 E
4 31 2
4) Loosen hose bands (30) and remove hose (6).
30
: Flat-blade screwdriver
30
D
E
B
29
31 3 5
5) Loosen hose bands (31) and remove hose (5). 22
22
30
22
30
31
31
Fig. 33-59 Removing hose for radiator/inter-cooler
Fig. 33-59 Removing hose for radiator/inter-cooler (4) Remove guard (12), (13) (See Fig. 33-56)
1) Remove 4 sems bolts M8u20.
1) Remove 4 sems bolts M8u20.
2) Remove guard (12), (13).
2) Remove guard (12), (13).
: 13 mm
: 13 mm
33-30
D
: Flat-blade screwdriver
22
(4) Remove guard (12), (13) (See Fig. 33-56)
C
19 19 21
30
23
: Flat-blade screwdriver 3
: Flat-blade screwdriver
15
17
B
3) Loosen hose bands (30), (31) and remove hose (4).
2
: Flat-blade screwdriver
C
30
: 17 mm
31
4) Loosen hose bands (30) and remove hose (6).
23
: 13 mm
33
B
11 17 6
1) Remove two fixing U-bolts (17) from tube (11).
19
17
: 17 mm 3) Loosen hose bands (30), (31) and remove hose (4).
15
Fig. 33-58 Removing radiator assy
33-30
33. UPPER STRUCTURE (5) Disconnecting hydraulic oil hose (1), (2)
33. UPPER STRUCTURE (5) Disconnecting hydraulic oil hose (1), (2)
15
1) Loosen 2 capscrews (16) M12u55 for attaching clamp (13).
1
2) Place an oil pan under the hose joint. Loosen 4 sems bolts (15) M12u35, and remove hoses (1) and (2).
16
16
: 19 mm
2) When lifting the engine fan, shift the radiator so it does not interfere with the engine fan.
2) Place an oil pan under the hose joint. Loosen 4 sems bolts (15) M12u35, and remove hoses (1) and (2).
T1
A2
T2
16
13
IN
Fig. 33-60 Removing hydraulic oil hose (1), (2)
: 19 mm
C/V T1
2
16
1) Remove 4 sems bolts (A2) M12u35.
13
A2 15
: 19 mm 2) When lifting the engine fan, shift the radiator so it does not interfere with the engine fan.
3) Plug up pipe ends with clean cloth, etc.
3) Plug up pipe ends with clean cloth, etc.
4) Removing radiator Place a wire sling in the lifting eyes of the radiator assy and remove the assy by crane. Weight : 92kg (203 lbs)
4) Removing radiator Place a wire sling in the lifting eyes of the radiator assy and remove the assy by crane. Weight : 92kg (203 lbs)
33-31
OUT C/V
1
(6) Remove radiator assy. (See Fig. 33-58)
13 15
: 19 mm
C/V
2
(6) Remove radiator assy. (See Fig. 33-58) 1) Remove 4 sems bolts (A2) M12u35.
1) Loosen 2 capscrews (16) M12u55 for attaching clamp (13).
T2
13
15
OUT C/V
33-31
IN
Fig. 33-60 Removing hydraulic oil hose (1), (2)
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.12.3
33.1.12.3
INSTALLATION
(1) Installing is done in the reverse order of removing. And removed clips of hose should be clamped at original position.
(1) Installing is done in the reverse order of removing. And removed clips of hose should be clamped at original position.
(2) Install radiator assy Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. And install hydraulic hose, radiator hose and hose of inter-cooler. Regarding Inserting width of hose. (See Fig. 33-61)
(2) Install radiator assy Place a wire sling in the lifting eyes of the radiator and move it to original position temporally. And install hydraulic hose, radiator hose and hose of inter-cooler. Regarding Inserting width of hose. (See Fig. 33-61)
(
1.3 35 8in)
CLIP
Torque 5.9N.m (4.4 lbf.ft)
40 (1.57in)
Insert width of hose
CLIP
Torque 5.9N.m (4.4 lbf.ft)
Fig. 33-61 Inserting width of hose
(4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below : Circumferential direction: 20±5mm (0.8in±0.2in) 39±5mm (1.5in±0.2in)
40 (1.57in)
Insert width of hose
CLIP
Torque 5.9N.m (4.4 lbf.ft)
Fig. 33-61 Inserting width of hose
(5) Clean the plastering area of the insulation thoroughly before plastering it.
(5) Clean the plastering area of the insulation thoroughly before plastering it.
(6) Making up hydraulic oil and LLC (Long Life Coolant) After completion of other installation, make up hydraulic oil and water. Coolant volume of engine body : 9 L (2.4gal) Coolant capacity of radiator : 5.5 L (1.5gal) Hydraulic oil capacity of oil cooler : 2.4 L (0.63gal)
(6) Making up hydraulic oil and LLC (Long Life Coolant) After completion of other installation, make up hydraulic oil and water. Coolant volume of engine body : 9 L (2.4gal) Coolant capacity of radiator : 5.5 L (1.5gal) Hydraulic oil capacity of oil cooler : 2.4 L (0.63gal) Fig. 33-62 Back-and-forth adjusting position of radiator
33-32
Torque 5.9N.m (4.4 lbf.ft)
40
40
(4) Adjust the clearance between the fan and the radiator shroud all around the circumference, as below : Circumferential direction: 20±5mm (0.8in±0.2in) 39±5mm (1.5in±0.2in)
CLIP
) (1.57in
(3) Radiator attaching bolt Apply Loctite #262 on 4 semsbolts (A2) M12u35. : 19 mm Tightening torque : 121 N•m (89 lbf•ft)
45
40
(1.57in)
: 19 mm Tightening torque : 121 N•m (89 lbf•ft)
(1.77in)
40
(
1.3 35 8in)
(1.57in)
) (1.57in
(3) Radiator attaching bolt Apply Loctite #262 on 4 semsbolts (A2) M12u35.
Insert width of hose
Insert width of hose
(1.77in)
Insert width of hose
Insert width of hose
45
INSTALLATION
Fig. 33-62 Back-and-forth adjusting position of radiator
33-32
33. UPPER STRUCTURE 33.1.12.4
PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE
(1) Preparation for disassembly and assembly
33. UPPER STRUCTURE 33.1.12.4
PROCEDURE OF DISASSEMBLING AND ASSEMBLING THE RADIATOR/INTER COOLER CORE
(1) Preparation for disassembly and assembly
1) Remove one under cover at the bottom of the radiator.
1) Remove one under cover at the bottom of the radiator.
2) Wait till the engine coolant cools down so you do not get burned. Then remove the cap of the radiator, discharge the coolant by opening the drain valve located at the back bottom and receive it in a container. * In case of removing inter cooler only, the above mentioned work is not necessary.
2) Wait till the engine coolant cools down so you do not get burned. Then remove the cap of the radiator, discharge the coolant by opening the drain valve located at the back bottom and receive it in a container. * In case of removing inter cooler only, the above mentioned work is not necessary.
(2) Disassembly
(2) Disassembly
1) Loosen each 2 bolts (30), (31) at head and bottom of shroud, remove upper plate (27) and lower plate (28).
1) Loosen each 2 bolts (30), (31) at head and bottom of shroud, remove upper plate (27) and lower plate (28).
2) Disconnect wiring connector of radiator coolant level switch.
2) Disconnect wiring connector of radiator coolant level switch.
3) Loosen 4 sems bolts (9) M8u20 attaching plate assy (10), remove plate assy (10).
3) Loosen 4 sems bolts (9) M8u20 attaching plate assy (10), remove plate assy (10).
4) Loosen 2 capscrews (15) M10u30 attaching radiator core.
4) Loosen 2 capscrews (15) M10u30 attaching radiator core.
5) After confirming that the coolant has been drained out completely, loosen and remove only the radiator side of hose bands (30) at the top and bottom of the radiator. (See Fig. 33-59)
5) After confirming that the coolant has been drained out completely, loosen and remove only the radiator side of hose bands (30) at the top and bottom of the radiator. (See Fig. 33-59)
6) Lift and remove radiator core using lifting eyes and hoist on the radiator core. Weight : 10kg (22lbs) Confirm the missing of rubber bushing (14) under the radiator core.
6) Lift and remove radiator core using lifting eyes and hoist on the radiator core. Weight : 10kg (22lbs) Confirm the missing of rubber bushing (14) under the radiator core.
7) Loosen 2 capscrews (15) M10u30 attaching the top of the inter-cooler core.
7) Loosen 2 capscrews (15) M10u30 attaching the top of the inter-cooler core.
8) Loosen and remove only the inter-cooler side of hose bands (31) at the top and bottom of the inter-cooler. (See Fig. 33-59)
8) Loosen and remove only the inter-cooler side of hose bands (31) at the top and bottom of the inter-cooler. (See Fig. 33-59)
9) Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler. Confirm the missing of rubber bushing (14) under the inter-cooler.
9) Lift and remove inter-cooler using lifting eyes and hoist on the inter-cooler. Confirm the missing of rubber bushing (14) under the inter-cooler.
Fig. 33-63 Removing radiator and inter-cooler
33-33
Fig. 33-63 Removing radiator and inter-cooler
33-33
33. UPPER STRUCTURE
33. UPPER STRUCTURE
10) Disconnection of oil cooler hose Disconnect hose (1), (2) from upper and lower of cooler, and drain hydraulic oil. (See Fig. 33-60)
10) Disconnection of oil cooler hose Disconnect hose (1), (2) from upper and lower of cooler, and drain hydraulic oil. (See Fig. 33-60)
11) Lift cooler temporally using cooler head flange for slinging.
11) Lift cooler temporally using cooler head flange for slinging.
12) Loosen 4 bolts (16) M8u25 attaching oil cooler.
12) Loosen 4 bolts (16) M8u25 attaching oil cooler.
13) Lift the oil cooler.
13) Lift the oil cooler.
There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler. Removing these components can be done as necessary.
There is no predetermined sequential order in removing radiator core, inter-cooler core and oil cooler. Removing these components can be done as necessary.
(3) Installing Installing is done in the reverse order of removing.
(3) Installing Installing is done in the reverse order of removing.
33-34
33-34
33. UPPER STRUCTURE 33.1.13
ENGINE
33.1.13.1
33. UPPER STRUCTURE 33.1.13
PREPARATION FOR REMOVING
ENGINE
33.1.13.1
PREPARATION FOR REMOVING
(1) Remove battery ground (See 33.1.3 BATTERY)
(1) Remove battery ground (See 33.1.3 BATTERY)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(2) Remove bonnet and guard (See 33.1.4 GUARD ) Remove under cover (See 33.1.5 UNDER COVER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(3) Remove air cleaner hose (See 33.1.9 AIR CLEANER)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(5) Remove radiator hose and inter-cooler hose (See 33.1.12 RADIATOR & OIL COOLER)
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(6) Remove fuel hose and heater hose, and if necessary disconnect air-con hose.
(7) If necessary, remove pump, muffler and radiator.
(7) If necessary, remove pump, muffler and radiator.
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
(8) Remove harness connector (Refer to ELECTRIC SYSTEM)
1) Remove E/G ground cable
1) Remove E/G ground cable
2)
2)
Starter cable-Starter B terminal
Starter cable-Starter B terminal
3) Remove the connector that connects the upper harness with the engine and ECU harness.
3) Remove the connector that connects the upper harness with the engine and ECU harness.
4) Upper harness
4) Upper harness
CN-206-E/G sub harness P5-Alternator B terminal CN-136-E/G speed sensor CN-141, CN142-Pump proportional valve CN-139, CN-140-P1,P2 pump pressure sensor CN-212-Glow P3-Starter motor C terminal
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer to Tools)
CN-206-E/G sub harness P5-Alternator B terminal CN-136-E/G speed sensor CN-141, CN142-Pump proportional valve CN-139, CN-140-P1,P2 pump pressure sensor CN-212-Glow P3-Starter motor C terminal
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer to Tools)
Fig. 33-64 Outside view of engine
Fig. 33-64 Outside view of engine
33-35
33-35
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.13.2
33.1.13.2
REMOVAL 27
27
2
16
C
27
10
*
20
27 14 11 11 12
26
*
10 12
20
23
16
23
10 12
14
27
28
A
A
10 12
22 30
20
27 14 11 11 12
D
1
20
23
25
16
*
17
2
12
20
20
A
28
A
22 30
D
16
2
D
*
5 B
23
10
A
2
*
26
B
36 26
5
11 12
3
20
A
C
11
25
3
25
20 10
3 25
*
12
B
36 26
5
2
Pin
10
17
11
25
14
14
11
10
3
25 14
Pin
27
27
14
14 17
REMOVAL
1
Fig. 33-65 Dismantling and mounting engine
D
5 B
C
17
2
C
Fig. 33-65 Dismantling and mounting engine
(1) Remove hose of engine oil filter
(1) Remove hose of engine oil filter
Place oil pan under the connection of filter (1), and disconnect hoses (2), (16), (17) at connector of filter side and hose.
positions. (2) Plug
: 17 mm, 41 mm
Place oil pan under the connection of filter (1), and disconnect hoses (2), (16), (17) at connector of filter side and hose.
positions. (2) Plug
: 17 mm, 41 mm
(2) Plug connector of filter side and hose.
(2) Plug connector of filter side and hose.
(3) Loosen engine mounting bolt of frame
(3) Loosen engine mounting bolt of frame
1) Loosen 4 nuts (20) M18.
1) Loosen 4 nuts (20) M18.
: 27 mm
: 27 mm
2) Loosen 4 capscrews (27) M18u150.
2) Loosen 4 capscrews (27) M18u150.
3) Remove 4 plates (14).
3) Remove 4 plates (14).
4) Remove upper rubber mounts (10) and (11) 2 each.
4) Remove upper rubber mounts (10) and (11) 2 each.
(4) Slinging engine body
(4) Slinging engine body
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer to "Tool".)
Prepare a stand, which withstands the weight of the engine assy and can place the removed engine firmly. (Refer to "Tool".)
1) Sling engine hooking wire to lifting lugs on the front and rear sides. Weight: Approx. 580 kg (1,280 lbs) Wire: ø6 (0.236")u1m (3ft 3in) - 2pcs.
1) Sling engine hooking wire to lifting lugs on the front and rear sides. Weight: Approx. 580 kg (1,280 lbs) Wire: ø6 (0.236")u1m (3ft 3in) - 2pcs.
(5) Position engine on the stand stably.
(5) Position engine on the stand stably.
33-36
33-36
33. UPPER STRUCTURE 33.1.13.3
INSTALLATION
33. UPPER STRUCTURE 33.1.13.3
INSTALLATION
Installing is done in the reverse order of removing.
Installing is done in the reverse order of removing.
(1) Tightening torque
(1) Tightening torque
33-37
33-37
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.14
33.1.14
33.1.14.1
CONSOLE COVER REMOVAL
33.1.14.1
(1) Removing right-hand console cover
REMOVAL
(1) Removing right-hand console cover
1) During pushing 4 locked claws of boot retaining plate (4) with flat-blade screw driver, lift the plate (4) and remove it.
1) During pushing 4 locked claws of boot retaining plate (4) with flat-blade screw driver, lift the plate (4) and remove it.
: Flat-blade screwdriver
: Flat-blade screwdriver
2) Loosen 3 sems bolts (16) M6u15.
2) Loosen 3 sems bolts (16) M6u15.
: Plus screw driver
: Plus screw driver
3) During lifting right upper console cover (3A) up; disconnect connector of tuner and antenna. Move boot (3) upwards and remove console cover (3A). â&#x20AC;˘
CONSOLE COVER
3) During lifting right upper console cover (3A) up; disconnect connector of tuner and antenna. Move boot (3) upwards and remove console cover (3A). Fig. 33-66 Removing plate (4)
Removing of boot and lever is unnecessary.
4) Loosen 3 sems bolts (16A) M6u15 and remove lower console (4).
â&#x20AC;˘
4) Loosen 3 sems bolts (16A) M6u15 and remove lower console (4).
16 3A 16
: Plus screw driver (2) Removing left-hand console cover
16B
1) Remove the boot retaining plate (4) in the same way as right-hand console cover. (See Fig. 3366) : Flat-blade screwdriver 2) Loosen 2 sems bolts (A6) M8u20 and remove left armrest assy.
16B
5
16 3A 16
: Plus screw driver (2) Removing left-hand console cover
16A 4 16B
16A
16B
1) Remove the boot retaining plate (4) in the same way as right-hand console cover. (See Fig. 3366) : Flat-blade screwdriver
16C
2) Loosen 2 sems bolts (A6) M8u20 and remove left armrest assy. 6
16B
16A
16C
3) Loosen 4 sems bolts (16B) M6u15.
: Plus screw driver
: Plus screw driver
4) Remove the left upper console cover (5) in the same way as right-hand console cover.
4) Remove the left upper console cover (5) in the same way as right-hand console cover.
5) Loosen 2 sems bolts (16C) M6u15 while lifting left under console cover (6) up, and remove left lower console cover.
Fig. 33-67 Removing console covers
INSTALLATION
5) Loosen 2 sems bolts (16C) M6u15 while lifting left under console cover (6) up, and remove left lower console cover. 33.1.14.2
Install it in reverse order of removing according to the tightening torque table.
Bolts
4
16B
5
: 13 mm
3) Loosen 4 sems bolts (16B) M6u15.
Item
16A
6
: 13 mm
33.1.14.2
Fig. 33-66 Removing plate (4)
Removing of boot and lever is unnecessary.
Fig. 33-67 Removing console covers
INSTALLATION
Install it in reverse order of removing according to the tightening torque table. A6
Tightening torque N.m (lbf.ft)
Item
Bolts
A6
Tightening torque N.m (lbf.ft)
16~16C
Sems bolt M6
8.5 (6.3)
16~16C
Sems bolt M6
8.5 (6.3)
A6
Sems bolt M6
23.5 (17.3)
A6
Sems bolt M6
23.5 (17.3)
Fig. 33-68 Removing left armrest
33-38
Fig. 33-68 Removing left armrest
33-38
33. UPPER STRUCTURE
33. UPPER STRUCTURE
This page is blank for editing convenience.
This page is blank for editing convenience.
33-39
33-39
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.15
33.1.15
CONTROL VALVE
33.1.15.1
PREPARATION FOR REMOVING
CONTROL VALVE
33.1.15.1
PREPARATION FOR REMOVING
(1) Remove guard (6) (See 33.1.4 GUARD)
(1) Remove guard (6) (See 33.1.4 GUARD)
(2) Remove under cover (5). (See 33.1.5 UNDER COVER)
(2) Remove under cover (5). (See 33.1.5 UNDER COVER)
(3) Install the suction stopper to the hydraulic oil tank.
(3) Install the suction stopper to the hydraulic oil tank.
1
(4) Remove the hoses in Fig. 33-70 and Fig. 33-71.
1
(4) Remove the hoses in Fig. 33-70 and Fig. 33-71.
Tightening torque 284N.m(209 lbf.ft)
Mark each hose with a port name before removing it.
Tightening torque 284N.m(209 lbf.ft)
Mark each hose with a port name before removing it.
4 4
4 4
Tightening torque 235N.m (173 lbf.ft)
Fig. 33-69 Removing the standard main control valve 33.1.15.2
REMOVAL
REMOVAL
(1) Remove 3 capscrews (4) M16u45, and remove control valve (1) by hoist.
: 24 mm Weight :Approx. 232kg (512 lbs) 33.1.15.3
Fig. 33-69 Removing the standard main control valve 33.1.15.2
(1) Remove 3 capscrews (4) M16u45, and remove control valve (1) by hoist.
Tightening torque 235N.m (173 lbf.ft)
: 24 mm Weight :Approx. 232kg (512 lbs)
INSTALLATION
33.1.15.3
(1) Installing is done in the reverse order of remove.
INSTALLATION
(1) Installing is done in the reverse order of remove.
1) Install control valve by tightening 3 capscrews (4) M16u45.
1) Install control valve by tightening 3 capscrews (4) M16u45.
: 24 mm Tightening torque : 235 N•m (173 lbf•ft)
: 24 mm Tightening torque : 235 N•m (173 lbf•ft)
2)
2) Tread size
PF1/4
PF3/8 PF3/4 M10 M12
Connector / Bolt Ports Pss,PLc2,PBp1,PBp2,PL, PB1,PTb,PCa,PCb,PCc PAa1,PBa1,Pab,PBb,Pac, PBc,PAL,PBL,Par,PBr,Pas, PBs,PAa2,PBa2,Pao,Pbo,DR MU Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc Ab,Bb P1,P2 T1,T2
Name
Hose nut
Opposing Tightening Opposing Tightening torque torque flats flats N.m (lbf.ft) N.m (lbf.ft)
ORS Joint
Sems bolt
(2) Check for oil leak and operation.
Remarks
Tread size
19
36 (27)
19
29 (21)
PF1/4
22 36 14 14 17 17
74 (55) 162 (119) 42.4 (31) 57 (42) 62.2 (45) 96 (70)
22 36
49 (36) 118 (87)
PF3/8 PF3/4 M10 M12
Connector / Bolt Ports Pss,PLc2,PBp1,PBp2,PL, PB1,PTb,PCa,PCb,PCc PAa1,PBa1,Pab,PBb,Pac, PBc,PAL,PBL,Par,PBr,Pas, PBs,PAa2,PBa2,Pao,Pbo,DR MU Ar,Br,AL,BL,As,Bs,Aa,Ba,Ac,Bc Ab,Bb P1,P2 T1,T2
Name
ORS Joint
Sems bolt
(2) Check for oil leak and operation.
33-40
Hose nut
Opposing Tightening Opposing Tightening torque torque flats flats N.m (lbf.ft) N.m (lbf.ft)
33-40
19
36 (27)
19
29 (21)
22 36 14 14 17 17
74 (55) 162 (119) 42.4 (31) 57 (42) 62.2 (45) 96 (70)
22 36
49 (36) 118 (87)
Remarks
33. UPPER STRUCTURE
Functions
Ports
Ports on upper sides LEFT
Ports
Arm (R) relief valve
Ports
PBa2 Arm 2 in
PAo
Mu
-
Ports on upper sides LEFT
PBp1 P1 bypass cut
-
Arm 1 out PBa1
PBb
Swing (LH)
PBs
Boom conflux
PB1
PAr
Travel left forward
PAL
-
T2
PCb
Tank return
Functions
RIGHT
P2 bypass cut PBp2 Option
Functions
33. UPPER STRUCTURE
-
Make-up line Bucket (R)relief valve Boom down Boom (H) relief valve Travel right forward Main relief valve P1 unload
Option Arm (R) relief valve
PBp1 P1 bypass cut PBa2 Arm 2 in
PAo
Mu
-
-
Arm 1 out PBa1
PBb
Make-up line Bucket (R)relief valve Boom down
Swing (LH)
PBs
Boom conflux
PB1
PAr
Travel left forward
PAL
-
T2
PCb
P1 unload
Tank return
-
Boom (H) relief valve Travel right forward Main relief valve
Ports on rear sides (on machine)
RIGHT
LEFT
RIGHT
P1
P1 pump
P1
P1 pump
P2
P2 pump
P2
P2 pump
Ports on right sides (on machine) UPPER SIDE
Functions
RIGHT
P2 bypass cut PBp2
Ports on rear sides (on machine) LEFT
Ports
Ports on right sides (on machine)
LOWER SIDE
UPPER SIDE
LOWER SIDE
Bucket dump
BC
Bucket dump
BC
Bucket dump
PBc
Bucket dump
PBc
Bucket (H) stroke limit
PCc
AC
Bucket digging
Bucket (H) stroke limit
PCc
AC
Bucket digging
Boom up
Ab
Bb
Boom down
Boom up
Ab
Bb
Boom down
Drain
Dr
BR
Travel right reverse
Drain
Dr
BR
Travel right reverse
Travel right forward
AR
Travel right forward
AR
ATT power boost
PL
ATT power boost
PL
Fig. 33-70 Control valve ports (1/2)
Fig. 33-70 Control valve ports (1/2)
33-41
33-41
33. UPPER STRUCTURE
33. UPPER STRUCTURE
Fig. 33-71 Control valve ports (2/2)
Fig. 33-71 Control valve ports (2/2)
33-42
33-42
33. UPPER STRUCTURE 33.1.16 33.1.16.1
PILOT VALVE (FOR ATT)
33. UPPER STRUCTURE 33.1.16
PREPARATION FOR REMOVING
33.1.16.1
PILOT VALVE (FOR ATT) PREPARATION FOR REMOVING
The removing procedure for right and left is the same, so the preparation for left side is described here.
The removing procedure for right and left is the same, so the preparation for left side is described here.
(1) Put attachment on ground, stop engine and release pressure in tank.
(1) Put attachment on ground, stop engine and release pressure in tank.
(2) Remove left console cover (5), (6) assy referring to Section 33.1.14CONSOLE COVER.
(2) Remove left console cover (5), (6) assy referring to Section 33.1.14CONSOLE COVER.
3 2-1
(3) Disconnect harness connector for horn at position.
3 2-1
(3) Disconnect harness connector for horn at position.
5
(4) Attach a tag to the hose to make assembly work easier.
5
(4) Attach a tag to the hose to make assembly work easier.
*
*
Fig. 33-72 Installing and removing boot and lever part 33.1.16.2
REMOVAL
Fig. 33-72 Installing and removing boot and lever part 33.1.16.2
(1) Remove hoses from your side to far side in order.
REMOVAL
(1) Remove hoses from your side to far side in order.
: 19 mm, 22 mm
: 19 mm, 22 mm
(2) Move the boot (3) up and loosen nut (5). (See Fig. 33-72)
(2) Move the boot (3) up and loosen nut (5). (See Fig. 33-72)
: 22 mm
: 22 mm
(3) Turn and loosen lever (2-1) tightened in pilot valve, and remove lever assy in a set. (See Fig. 33-72)
(3) Turn and loosen lever (2-1) tightened in pilot valve, and remove lever assy in a set. (See Fig. 33-72)
(4) Remove 4 capscrews (A14) M6u25. (See Fig. 3373)
(4) Remove 4 capscrews (A14) M6u25. (See Fig. 3373)
: 5 mm
: 5 mm
(5) Remove pilot valve.
(5) Remove pilot valve.
(6) Plug hose ends. Plug PF1/4, PF3/8
(6) Plug hose ends. Plug PF1/4, PF3/8 Fig. 33-73 Pilot valve connector
33.1.16.3
Fig. 33-73 Pilot valve connector
INSTALLATION
33.1.16.3
Install it in the reverse order of removal and tighten it.
Install it in the reverse order of removal and tighten it.
Front of machine T
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew
Arm (R) (Green)
(A14)
T
INSTALLATION
Boom (R) (Gray)
Swing (R) (Red)
: 5 mm T = 11.8 N•m (11 lbf•ft) capscrew
Bucket (R) (Blue)
T
Boom (R) (Gray)
Swing (R) (Red)
Bucket (R) (Blue)
Swing (L) (Gray)
Arm (H) (Blue)
LEFT SIDE
Bucket (H) (Red) P Boom (H) (Green) RIGHT SIDE
P
Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.
Arm (H) (Blue)
LEFT SIDE
Fig. 33-74 Pilot valve port position (from upper side)
33-43
Arm (R) (Green)
(A14)
Swing (L) (Gray)
Make sure the tightening torque for capscrews, because pilot valve is made of aluminum.
Front of machine T
Bucket (H) (Red) P Boom (H) (Green) RIGHT SIDE
P
Fig. 33-74 Pilot valve port position (from upper side)
33-43
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.17
33.1.17
33.1.17.1
PILOT VALVE (FOR TRAVEL) PREPARATION FOR REMOVING
33.1.17.1
PILOT VALVE (FOR TRAVEL) PREPARATION FOR REMOVING
(1) Release pressure in hydraulic oil tank (See 33.1.7 HYDRAULIC TANK)
(1) Release pressure in hydraulic oil tank (See 33.1.7 HYDRAULIC TANK)
(2) Remove under cover (1) (See 33.1.5 UNDER COVER)
(2) Remove under cover (1) (See 33.1.5 UNDER COVER)
A1
(3) Remove floor mat (B1).
A7
A2 A7
A8
A1
(3) Remove floor mat (B1).
A6
A7
A5
A8 A6
A5 B1
B1
A8
A8
Fig. 33-75 Removing floor mat, pedal and and lever 33.1.17.2
A7
A2
REMOVAL
Fig. 33-75 Removing floor mat, pedal and and lever 33.1.17.2
(1) Separate the two pressure sensors SE-9 (A9) and SE-10 (A9) at the connector.
REMOVAL
(1) Separate the two pressure sensors SE-9 (A9) and SE-10 (A9) at the connector.
: 24 mm
: 24 mm
(2) Attach tag, and discount connectors and hoses (A2), (A3), (A4), (A5)
(2) Attach tag, and discount connectors and hoses (A2), (A3), (A4), (A5)
: 19 mm (P port)
: 19 mm (P port)
: 22 mm (T port, 1~4 port)
: 22 mm (T port, 1~4 port)
(3) Plug hose ends Plug PF1/4, PF3/8
(3) Plug hose ends Plug PF1/4, PF3/8
(4) Remove 4 sems bolts (A8) M8u20, and remove right and left pedals (A5), (A6).
(4) Remove 4 sems bolts (A8) M8u20, and remove right and left pedals (A5), (A6).
: 13 mm
: 13 mm
(5) Remove 4 sems bolts (A7) M10u20 and remove right and left lever (A1), (A2).
(5) Remove 4 sems bolts (A7) M10u20 and remove right and left lever (A1), (A2).
: 17 mm
: 17 mm
(6) Remove 4 sems bolts (A11) M10u30.
(6) Remove 4 sems bolts (A11) M10u30.
: 17 mm
: 17 mm
(7) Remove pilot valve lifting it upward.
(7) Remove pilot valve lifting it upward.
(8) Stop up holes with plugs PF1/4.
(8) Stop up holes with plugs PF1/4.
Fig. 33-76 Installing and Removing pilot valve
33-44
Fig. 33-76 Installing and Removing pilot valve
33-44
33. UPPER STRUCTURE 33.1.17.3
INSTALLATION
33. UPPER STRUCTURE 33.1.17.3
INSTALLATION
Install it in the reverse order of removal and tighten it. Sems bolt (A11)
Install it in the reverse order of removal and tighten it. Sems bolt (A11)
: 17 mm T = 37 N•m (27.3 lbf•ft)
: 17 mm T = 37 N•m (27.3 lbf•ft)
Sems bolt (A7)
Sems bolt (A7)
: 17 mm T = 46.1 N•m (34.0 lbf•ft)
: 17 mm T = 46.1 N•m (34.0 lbf•ft)
Sems bolt (A8)
Sems bolt (A8)
: 13 mm T = 23.5 N•m (17.3 lbf•ft)
: 13 mm T = 23.5 N•m (17.3 lbf•ft)
Pressure sensor
Pressure sensor
: 24 mm T = 16.7 N•m (12.3 lbf•ft)
: 24 mm T = 16.7 N•m (12.3 lbf•ft)
33-45
33-45
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.18
33.1.18
33.1.18.1
SWING MOTOR UNIT PREPARATION FOR REMOVING
33.1.18.1
SWING MOTOR UNIT PREPARATION FOR REMOVING
(1) Park machine on firm level ground and place attachment on ground.
(1) Park machine on firm level ground and place attachment on ground.
(2) Remove the guard (6). (See 33.1.4 GUARD)
(2) Remove the guard (6). (See 33.1.4 GUARD)
(3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in circuit by operating control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE DRAINING(RELEASING) CIRCUIT)
(3) Operate the switch on gauge cluster and select the pressure release mode, and then release the inner pressure in circuit by operating control lever. (See 22.11 HYDRAULIC SYSTEM PRESSURE DRAINING(RELEASING) CIRCUIT)
(4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information.
(4) Bleed air from the hydraulic oil tank and attach to each hose a tag showing port name and other information.
33.1.18.2
33.1.18.2
REMOVAL
(1) Remove hose. 1) Remove hose (7) from the connector in the makeup port M.
(1) Remove hose.
8
S/J
REMOVAL
9
E
C/V
8
S/J
1) Remove hose (7) from the connector in the makeup port M.
9
E
C/V
MU
: 36 mm
H/D TANK
Dr
2) Remove 2 hoses (8), (9) from the Tee in the drain port Dr.
MU
: 36 mm
7
H/D TANK
Dr
2) Remove 2 hoses (8), (9) from the Tee in the drain port Dr.
M
: 27 mm
7
M
: 27 mm
3) Remove hose (3) from the elbow of the PG port (For swing parking brake) (See Fig. 33-78)
3) Remove hose (3) from the elbow of the PG port (For swing parking brake) (See Fig. 33-78) B
B
A
: 19 mm
A
: 19 mm
4) Remove 2 hoses (A4), (A7) from the connectors of the A, B port.
4) Remove 2 hoses (A4), (A7) from the connectors of the A, B port.
A7
: 36 mm Put in plugs PF3/4, PF1/2, and PF1/4 into the removed ports.
C/V
A4
Bs
C/V As
A7
: 36 mm Put in plugs PF3/4, PF1/2, and PF1/4 into the removed ports.
A4
Fig. 33-77 Removing swing unit piping
Bs
C/V As
Fig. 33-77 Removing swing unit piping
2
2
C/V
2
2 1
1
PG
PG
A17 A3
A17 A3
Fig. 33-78 Removing swing unit
33-46
Fig. 33-78 Removing swing unit
33-46
33. UPPER STRUCTURE (2) Removing the swing unit Remove 13 capscrews (1) M20u55.
33. UPPER STRUCTURE (2) Removing the swing unit Remove 13 capscrews (1) M20u55.
: 30 mm
: 30 mm
1) Remove two plastic caps (2) M10 at the top of the swing motor and install eye bolts.
1) Remove two plastic caps (2) M10 at the top of the swing motor and install eye bolts.
: Flat-blade screwdriver
: Flat-blade screwdriver
2) Put a wire sling in the eye bolts and remove the swing motor unit. Weight of swing motor unit ; Approx. 192kg (423 lbs) (Include reduction assy)
2) Put a wire sling in the eye bolts and remove the swing motor unit. Weight of swing motor unit ; Approx. 192kg (423 lbs) (Include reduction assy)
33.1.18.3
PREPARATION FOR INSTALL
33.1.18.3
PREPARATION FOR INSTALL
(1) Clean mating surfaces of swing motor unit and upper frame. Tools : spatula, wash oil
(1) Clean mating surfaces of swing motor unit and upper frame. Tools : spatula, wash oil
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
(2) Apply Loctite #515 on entire mounting surface of swing motor unit.
33.1.18.4
33.1.18.4
INSTALLATION
Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the swing motor unit.
INSTALLATION
Install the swing motor unit in the reverse order of disassembly, confirming the orientation of the swing motor unit.
Coat all the mounting surface of 1 the swing motor with Loctite #515 equivalent.
(1) Tighten 13 capscrews (1) M20u55.
Coat all the mounting surface of 1 the swing motor with Loctite #515 equivalent.
(1) Tighten 13 capscrews (1) M20u55. Detail of swing motor unit assy mount
: 30 mm Tightening torque : 539N•m (400 lbf•ft) Apply Loctite #262
Put sealing tape on the both sides of thread portion of filling tube. Tightening torque 108 N.m (80 lbf.ft)
FILLING PORT
(2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain
Apply Loctite #262
1 equivalent. Tightening torque
539N.m (400 lbf.ft)
Detail of swing motor unit assy mount
: 30 mm Tightening torque : 539N•m (400 lbf•ft) Apply Loctite #262
Put sealing tape on the both sides of thread portion of filling tube. Tightening torque 108 N.m (80 lbf.ft)
FILLING PORT
(2) Fill inside from motor drain port to casing with hydraulic oil before piping for drain
539N.m (400 lbf.ft)
LEVEL GAUGE
LEVEL GAUGE
Put sealing tape on the thread portion of tube for level gauge. Tightening torque 69.1 N.m (51 lbf.ft)
Put sealing tape on the thread portion of tube for level gauge. Tightening torque 69.1 N.m (51 lbf.ft)
Fig. 33-79 Installing swing motor unit 33.1.18.5
PREPARATION FOR DRIVE
Apply Loctite #262
1 equivalent. Tightening torque
Fig. 33-79 Installing swing motor unit 33.1.18.5
PREPARATION FOR DRIVE
(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient. Amount of oil : 3L (0.8gal)
(1) Before starting operation, check that gear oil #90 (API grade GL-4) level of swing reduction is sufficient. Amount of oil : 3L (0.8gal)
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise.
(2) When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leak and noise.
33-47
33-47
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.19
33.1.19
33.1.19.1
SWIVEL JOINT PREPARATION FOR REMOVING
33.1.19.1
SWIVEL JOINT PREPARATION FOR REMOVING
Remove boom piping hose
Remove boom piping hose
33.1.19.2
33.1.19.2
REMOVAL
(1) Remove travel motor hose and tube
(1) Remove travel motor hose and tube
1) Remove 2 hoses (A16). (E port : PF1/2)
1) Remove 2 hoses (A16). (E port : PF1/2)
: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)
: 27 mm, Tightening torque : 78.5 N•m (58 lbf•ft)
2) Remove tubes (A1), (A2). (C, D port : PF1)
2) Remove tubes (A1), (A2). (C, D port : PF1)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)
3) Remove tubes (A3), (A4). (A, B port : PF1)
3) Remove tubes (A3), (A4). (A, B port : PF1)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)
: 41 mm, Tightening torque : 275 N•m (203 lbf•ft)
4) Remove 2 hoses (A7). (F port : PF1/4)
4) Remove 2 hoses (A7). (F port : PF1/4)
: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
(TRAVEL MOTOR) VB (LOWER) (LH) REVERSE VA (UPPER) FORWARD
REMOVAL
: 19 mm, Tightening torque : 29.4 N•m (22 lbf•ft)
(TRAVEL MOTOR) VB (LOWER) (LH) REVERSE VA (UPPER) FORWARD
(TRAVEL MOTOR) VA (LOWER) REVERSE (RH) VB (UPPER) FORWARD
A2
(TRAVEL MOTOR) VA (LOWER) REVERSE (RH) VB (UPPER) FORWARD
T : Tightening torque of connector N.m (lbf.ft)
A2
T : Tightening torque of connector N.m (lbf.ft)
A4 SWIVEL JOINT
A3 A1 T=108 (80)
SWIVEL JOINT
T=255 (188)
A7 B2 T=36.3 (26.8) A7
T=255 (188)
A4
A16 T=108 (80)
A16
T=255 (188)
A7 B2 T=36.3 (26.8) A7
T=255 (188) A3 A1 T=108 (80)
A16 T=108 (80)
A16
Fig. 33-80 Removing piping (lower side)
Fig. 33-80 Removing piping (lower side)
33-48
33-48
33. UPPER STRUCTURE (2) Disconnecting the hoses on the top part of swivel joint
33. UPPER STRUCTURE (2) Disconnecting the hoses on the top part of swivel joint
1) Remove drain hose (8). (E port : PF1/2)
1) Remove drain hose (8). (E port : PF1/2)
: 27 mm Tightening torque : 78 N•m (58 lbf•ft)
: 27 mm Tightening torque : 78 N•m (58 lbf•ft)
2) Remove hoses (A8), (A5). (A, C port : 1-3/16-12UN)
2) Remove hoses (A8), (A5). (A, C port : 1-3/16-12UN)
: 36 mm Tightening torque : 177 N•m (130 lbf•ft)
: 36 mm Tightening torque : 177 N•m (130 lbf•ft)
3) Remove hoses (A9), (A6). (B, D port : 1-3/16-12UN)
3) Remove hoses (A9), (A6). (B, D port : 1-3/16-12UN)
: 36 mm Tightening torque : 177 N•m (130 lbf•ft)
: 36 mm Tightening torque : 177 N•m (130 lbf•ft)
4) Remove hose (A7). (Travel 2-speed change over port : PF1/4)
4) Remove hose (A7). (Travel 2-speed change over port : PF1/4)
: 19 mm Tightening torque : 29 N•m (21 lbf•ft)
: 19 mm Tightening torque : 29 N•m (21 lbf•ft)
Fig. 33-81 Disconnecting the hoses on the top part of swivel joint (3) Remove whirl-stop of swivel joint.
Fig. 33-81 Disconnecting the hoses on the top part of swivel joint (3) Remove whirl-stop of swivel joint.
1) Loosen the nut (36) M24.
1) Loosen the nut (36) M24.
2) Remove a capscrew (35)M124u130.
2) Remove a capscrew (35)M124u130.
: 36 mm
: 36 mm
Fig. 33-82 Removing whirl-stop nut & the capscrew (4) Remove joint for piping (See Fig. 33-80,Fig. 33-81) 1) Remove 2 connectors (B2). (F port) 2) Remove connector (1) (F port) for travel 2-speed change over. (PF1/4) : 19 mm (5) Remove seal (B4)
Tightening torque 6.8N.m (5 lbf.ft) B9
(4) Remove joint for piping (See Fig. 33-80,Fig. 33-81)
Tightening torque B8 14.7N.m (11 lbf.ft) To prevent from entering water, apply Loctite 572 or 577 around this plate (B5).
2) Remove connector (1) (F port) for travel 2-speed change over. (PF1/4)
B5
1) Remove 6 capscrews (B8) M10u25.
Fig. 33-82 Removing whirl-stop nut & the capscrew
: 17 mm
1) Remove 2 connectors (B2). (F port)
: 19 mm (5) Remove seal (B4)
Tightening torque 6.8N.m (5 lbf.ft) B9 Tightening torque B8 14.7N.m (11 lbf.ft) To prevent from entering water, apply Loctite 572 or 577 around this plate (B5).
B5
1) Remove 6 capscrews (B8) M10u25. : 17 mm
2) Remove clip (B9).
B4
: Flat-blade screwdriver
2) Remove clip (B9).
B4
: Flat-blade screwdriver Fig. 33-83 Removing seal (B4)
3) Remove seal (B4).
33-49
Fig. 33-83 Removing seal (B4)
3) Remove seal (B4).
33-49
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(6) Remove capscrew for installation Attach eye bolt, lift it up temporarily, and remove 3 capscrews (C2) M12u25.
(6) Remove capscrew for installation Attach eye bolt, lift it up temporarily, and remove 3 capscrews (C2) M12u25.
: 19 mm (See 11.7 SPECIAL TOOLS No.9 Plug)
: 19 mm (See 11.7 SPECIAL TOOLS No.9 Plug)
Fig. 33-84 Removing capscrew for installation
Fig. 33-84 Removing capscrew for installation
(7) Slinging the swivel joint Weight : Approx. 28kg (62 lbs)
(7) Slinging the swivel joint Weight : Approx. 28kg (62 lbs)
33.1.19.3
33.1.19.3
INSTALLATION
(1) Installing is done in the reverse order of removing. Piping tightening torque
Tightening torque N.m (lbf.ft) O-ring type Hydraulic hose Connector 29 (22) 36 (27)
Size PF
Tool. HEX
1/4
19
3/8
22
74 (54)
1/2
27
3/4
INSTALLATION
(1) Installing is done in the reverse order of removing. Piping tightening torque
Tightening torque N.m (lbf.ft) O-ring type Hydraulic hose Connector 29 (22) 36 (27)
Size PF
Tool. HEX
1/4
19
49 (36)
3/8
22
74 (54)
49 (36)
108 (80)
78 (58)
1/2
27
108 (80)
78 (58)
36
162 (120)
118 (87)
3/4
36
162 (120)
118 (87)
1
41
255 (180)
137 (100)
1
41
255 (180)
137 (100)
1-3/16-12UN
36
-
177 (130)
1-3/16-12UN
36
-
177 (130)
(2) Check for oil leak and the hydraulic oil level.
(2) Check for oil leak and the hydraulic oil level.
(3) Check for operating.
(3) Check for operating.
33-50
33-50
33. UPPER STRUCTURE 33.1.20 33.1.20.1
UPPER FRAME
33. UPPER STRUCTURE 33.1.20
PREPARATION FOR REMOVING
33.1.20.1
UPPER FRAME PREPARATION FOR REMOVING
(1) Remove attachment (See chapter 32)
(1) Remove attachment (See chapter 32)
(2) Remove cab (See 33.1.2 CAB)
(2) Remove cab (See 33.1.2 CAB)
(3) Remove guard (See 33.1.4 GUARD)
(3) Remove guard (See 33.1.4 GUARD)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(4) Remove counterweight (See 33.1.11 COUNTERWEIGHT)
(5) Remove swivel joint (See 33.1.19 SWIVEL JOINT)
(5) Remove swivel joint (See 33.1.19 SWIVEL JOINT)
Fig. 33-85 Temporarily lift upper frame 33.1.20.2
REMOVAL
Fig. 33-85 Temporarily lift upper frame 33.1.20.2
(1) Lifting up upper frame temporarily Insert two upper swing body lifting jigs and 2 counterweight fastening cap screws (A1) M27u335 into the counterweight mounting holes from above. Attach 2 chain blocks to the boom foot side and lift the upper frame at four points. Wire rope ; ø16 (0.630")u2.5m(8ft-2in), 2pcs. ø16 (0.630")u1.5m(4ft-11in), 2pcs Chain block ; For 2,000kg (4,410 lbs) 2pcs. (2) Marking match marks on swing bearing Put match marks on upper frame and swing bearing.
Fig. 33-86 Matching mark on swing bearing and upper frame
(3) Removing upper frame attaching bolts Remove 32 capscrews M20u100 and a reamer bolt (11) used to install swing bearing and upper frame.
REMOVAL
(1) Lifting up upper frame temporarily Insert two upper swing body lifting jigs and 2 counterweight fastening cap screws (A1) M27u335 into the counterweight mounting holes from above. Attach 2 chain blocks to the boom foot side and lift the upper frame at four points. Wire rope ; ø16 (0.630")u2.5m(8ft-2in), 2pcs. ø16 (0.630")u1.5m(4ft-11in), 2pcs Chain block ; For 2,000kg (4,410 lbs) 2pcs. (2) Marking match marks on swing bearing Put match marks on upper frame and swing bearing.
Fig. 33-86 Matching mark on swing bearing and upper frame
(3) Removing upper frame attaching bolts Remove 32 capscrews M20u100 and a reamer bolt (11) used to install swing bearing and upper frame.
: 30 mm
: 30 mm
(4) Slinging upper frame Sling according to Fig. 33-85, and remove upper frame and put it on a stand. Weight : Approx. 5ton (11,000lbs)
(4) Slinging upper frame Sling according to Fig. 33-85, and remove upper frame and put it on a stand. Weight : Approx. 5ton (11,000lbs)
Fig. 33-87 Removing upper frame attaching bolts
33-51
Fig. 33-87 Removing upper frame attaching bolts
33-51
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.1.20.3
33.1.20.3
INSTALLATION
(1) Installing is done in the reverse order of removing.
Apply Loctite #515 to the race surface over the whole circumference (shaded area) on the inside of capscrew.
(2) Cleaning mating surfaces of upper frame and swing bearing.
INSTALLATION
(1) Installing is done in the reverse order of removing.
(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.
(3) Apply Loctite #515 to the inside of the capscrews on the contact surface.
(4) Slinging upper frame Match marks and install it with a reamer bolt (11) and a washer (12) temporarily.
(4) Slinging upper frame Match marks and install it with a reamer bolt (11) and a washer (12) temporarily. Apply Loctite #262 equivalent. T=392N.m (290 lbf.ft) 11,12
Confirm the reamer bolt positions referring to Fig. 3389.
Fig. 33-88 Bearing mount
: 30 mm Apply Loctite #262 Tightening torque : 392 N•m (290 lbf•ft) Apply Loctite #262
Apply Loctite #515 to the race surface over the whole circumference (shaded area) on the inside of capscrew.
(2) Cleaning mating surfaces of upper frame and swing bearing.
Apply Loctite #262 equivalent. T=392N.m (290 lbf.ft) 11,12
Confirm the reamer bolt positions referring to Fig. 3389.
Fig. 33-88 Bearing mount
: 30 mm Apply Loctite #262 Tightening torque : 392 N•m (290 lbf•ft) Apply Loctite #262
(5) Install swing bearing Install 32 capscrews (10) M20u100.
(5) Install swing bearing Install 32 capscrews (10) M20u100.
: 30 mm Apply Loctite #262 Tightening torque : 392 N•m (290lbf•ft) Install a reamer bolt (11).
: 30 mm Apply Loctite #262 Tightening torque : 392 N•m (290lbf•ft) Install a reamer bolt (11).
: 30 mm Tightening torque : 392 N•m (290lbf•ft)
: 30 mm Tightening torque : 392 N•m (290lbf•ft) Fig. 33-89 Reamer bolt position (*) Apply Loctite to shaded area
33-52
Fig. 33-89 Reamer bolt position (*) Apply Loctite to shaded area
33-52
33. UPPER STRUCTURE
33. UPPER STRUCTURE
This page is blank for editing convenience.
This page is blank for editing convenience.
33-53
33-53
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2
DISASSEMBLING AND ASSEMBLING
33.2
DISASSEMBLING AND ASSEMBLING
33.2.1
HYDRAULIC PUMP • REGULATOR
33.2.1
HYDRAULIC PUMP • REGULATOR
33.2.1.1
HYDRAULIC PUMP
33.2.1.1.1
33.2.1.1
Structural exploded view
HYDRAULIC PUMP
33.2.1.1.1
(1) Main pump
Structural exploded view
(1) Main pump 983
953 806
981
789 535 886
531 . 548 B
732
X Z
W Y
A
953 806 728 468
113 123 127 824
983
534 792 702 532
123 127 824
271 717 490
808 954 546901
325
251 401
725
407
789 535 886
531 . 548 B
732
534 792 702 532
X Z
W Y
A
728 468
113
127
04
981
127 271 717 490
04
808 954 546901
325
251
312 490
401
725
407
312 490
C 124 314
156
B 212
151 . 152
157
717
141
E
211 261 710
406
314
D
885 886
214
124
886
727 546
153
C
156
727 467 725 466
B
D
212
151 . 152
E
885 886
211 261 710
F
A
D
546
153
214
E
774
157
717
141
886
727
406
D E
774
F
A 116 717
124
724
116 710
313 F
326
111
C
727 467 725 466
414
717 124
05
710
313 F
326
111
C
885
724
885
Fig. 33-90 Structural exploded view of main pump
Fig. 33-90 Structural exploded view of main pump
33-54
33-54
414
05
33. UPPER STRUCTURE
Marks No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313
in Fig. 33-109 show the position where regulator is installed.
Name Shaft(F) Shaft(R) 1st gear Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Retainer Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support Seal cover (F) Pump casing Valve block Valve plate (R)
Q'ty 1 1 1 2 2 3 2 18 18 2 2 18 2 2 2 2 1 2 1 1
No. 314 325 326 401 406 407 414 466 467 468 490 531 532 534 535 546 548 702 710 717
Name Valve plate (L) Sensor block Cover Socket bolt ; M20X210 Socket bolt ; M8X20 Socket bolt ; M6X55 Socket bolt ; M10X20 VP plug ; PF1/4 VP plug ; PF3/8 VP plug ; PF3/4 Plug ; NPTF1/16 Tilt pin ; M24X2 Servo piston ; M24X2 Stopper (L) Stopper (S) Spacer Feed back pin O-ring ; 1B G35 O-ring ; 1B G95 O-ring ; 1B G145
Q'ty 1 1 1 8 4 3 4 2 2 4 32 2 2 2 2 2 2 2 2 4
No. 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954 04 05
33. UPPER STRUCTURE
Marks Name O-ring ; 1B P8 O-ring ; 1B P11 O-ring ; 1B P14 O-ring ; 1B P24 O-ring ; 1B P18 Oil seal Backup ring P18 Backup ring G35 Nut ; M16 Nut ; M20 Stop ring Valve plate pin Spring pin Eye bolt ; M10 Socket screw ; M16X30 Set screw ; M20 Gear pump PTO gear case
No. 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1
No. 111 113 116 123 124 127 141 151 152 153 156 157 211 212 214 251 261 271 312 313
Name Shaft(F) Shaft(R) 1st gear Roller bearing Needle bearing Bearing spacer Cylinder block Piston Shoe Retainer Spherical bushing Cylinder spring Shoe plate Swash plate Tilting bushing Swash plate support Seal cover (F) Pump casing Valve block Valve plate (R)
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug, nut and servo piston No.
Thread size
401 406 407 414 466 467 468 490 531,532 806 808
M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20
in Fig. 33-109 show the position where regulator is installed. Q'ty 1 1 1 2 2 3 2 18 18 2 2 18 2 2 2 2 1 2 1 1
No. 314 325 326 401 406 407 414 466 467 468 490 531 532 534 535 546 548 702 710 717
Name Valve plate (L) Sensor block Cover Socket bolt ; M20X210 Socket bolt ; M8X20 Socket bolt ; M6X55 Socket bolt ; M10X20 VP plug ; PF1/4 VP plug ; PF3/8 VP plug ; PF3/4 Plug ; NPTF1/16 Tilt pin ; M24X2 Servo piston ; M24X2 Stopper (L) Stopper (S) Spacer Feed back pin O-ring ; 1B G35 O-ring ; 1B G95 O-ring ; 1B G145
33-55
No. 724 725 727 728 732 774 789 792 806 808 824 885 886 901 953 954 04 05
Name O-ring ; 1B P8 O-ring ; 1B P11 O-ring ; 1B P14 O-ring ; 1B P24 O-ring ; 1B P18 Oil seal Backup ring P18 Backup ring G35 Nut ; M16 Nut ; M20 Stop ring Valve plate pin Spring pin Eye bolt ; M10 Socket screw ; M16X30 Set screw ; M20 Gear pump PTO gear case
No. 16 9 3 4 2 1 2 2 2 2 2 2 4 2 2 2 1 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug, nut and servo piston
Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 8.8 (6.5) 240 (177) 130 (95) 240 (177)
Q'ty 1 1 1 8 4 3 4 2 2 4 32 2 2 2 2 2 2 2 2 4
No.
Thread size
401 406 407 414 466 467 468 490 531,532 806 808
M20 M8 M6 M10 PF 1/4 PF 3/8 PF 3/4 NPTF1/16 M24X2 M16 M20
Tightening torque N.m (lbf.ft) 430 (317) 29 (21) 12 (8.9) 57 (42) 36 (27) 74 (55) 170 (125) 8.8 (6.5) 240 (177) 130 (95) 240 (177)
33-55
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(2) Gear pump (For pilot)
(2) Gear pump (For pilot)
700
354
351
Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)
700
433
354
351
434
Suction port : PF3/4 Tightening torque : 73.5N.m (54.2 lbf.ft)
433
434 Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft)
Delivery port : PF1/2 Tightening torque : 53N.m (39.1 lbf.ft)
311
311
312
312 732 307
710
435
361
353
732 307
850
310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)
308 309
434
466 725
355 710
435
361
353
Fig. 33-91 No.
Parts
Q’ty
No.
850
310 Drain port : PF3/8 Tightening torque : 34.3N.m (25.3 lbf.ft)
308 309
434
466 725
355
Fig. 33-91 Parts
Q’ty
No.
Parts
Q’ty
No.
Parts
Q’ty
307 Poppet
1
361 Front case
1
307 Poppet
1
361 Front case
1
308 Seat
1
433 Flange socket; M8u40
2
308 Seat
1
433 Flange socket; M8u40
2
309 Ring
1
434 Flange socket; M8u55
2
309 Ring
1
434 Flange socket; M8u55
2
310 Spring
1
435 Flange socket; M8u20
4
310 Spring
1
435 Flange socket; M8u20
4
311 Adjust screw
1
466 VP plug ; PF1/4
1
311 Adjust screw
1
466 VP plug ; PF1/4
1
312 Lock nut ; M14u1.5
1
700 Ring
1
312 Lock nut ; M14u1.5
1
700 Ring
1
351 Gear case
1
710 O-ring ; 1B G95
1
351 Gear case
1
710 O-ring ; 1B G95
1
353 Drive gear
1
725 O-ring ; 1B P11
1
353 Drive gear
1
725 O-ring ; 1B P11
1
354 Driven gear
1
732 O-ring ; 1B P16
1
354 Driven gear
1
732 O-ring ; 1B P16
1
355 Filter
1
850 Locking ring
1
355 Filter
1
850 Locking ring
1
33-56
33-56
33. UPPER STRUCTURE 33.2.1.1.2
Disassembly and assembly of main pump
33. UPPER STRUCTURE 33.2.1.1.2
Disassembly and assembly of main pump
(1) Tools The right list shows the tools required for remove and install.
(1) Tools The right list shows the tools required for remove and install.
(2) Disassembling procedure
(2) Disassembling procedure
1) Selecting a place for disassembly.
1) Selecting a place for disassembly.
•
Choose a clean place.
•
Choose a clean place.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
2) Cleaning Remove dust and rust, etc. on pump surface with wash oil.
3) Drain oil Drain out the oil in the pump casing by removing drain port plug (466), (468).
2) Cleaning Remove dust and rust, etc. on pump surface with wash oil.
REGULATOR
3) Drain oil Drain out the oil in the pump casing by removing drain port plug (466), (468).
: 19 mm, 36 mm •
: 19 mm, 36 mm
Drain out oil from the plug of the front pump and the rear pump.
•
4) Removing regulator and PTO gear casing Remove the socket bolts [412, 413, 414 (See Fig. 33-90, Fig. 33-109)]. Then remove the regulator and the PTO cover (326).
Drain out oil from the plug of the front pump and the rear pump.
4) Removing regulator and PTO gear casing Remove the socket bolts [412, 413, 414 (See Fig. 33-90, Fig. 33-109)]. Then remove the regulator and the PTO cover (326).
: 6 mm, 8 mm •
REGULATOR
: 6 mm, 8 mm
Regarding the disassembly of the regulator, refer to article of Regulator.
•
5) Remove gear pump Remove the socket bolts (435). Then remove the gear pump (04).
Regarding the disassembly of the regulator, refer to article of Regulator.
5) Remove gear pump Remove the socket bolts (435). Then remove the gear pump (04).
: 6 mm
: 6 mm
6) Remove socket bolt (401) Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312).
6) Remove socket bolt (401) Loosen socket bolts (401) that fasten swash plate support (251), pump casing (271) and valve block (312).
: 17 mm
: 17 mm Fig. 33-92 Remove socket bolt (401)
33-57
Fig. 33-92 Remove socket bolt (401)
33-57
33. UPPER STRUCTURE
33. UPPER STRUCTURE
6) Disassembling the pump casing and the valve block Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312).
312
•
When facing the mounting surface of the regulator down, place a rubber sheet on a work bench so as not to score the mounting surface.
•
When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time.
271
Fig. 33-93 Disassembling the pump casing (271) and the valve block (312)
7) Drawing out the cylinder assy Draw out cylinder (141) out of pump casing (271) in parallel to shaft (111). At the same time draw out piston (151), plate (153), spherical bushing (156) and cylinder spring (157). •
6) Disassembling the pump casing and the valve block Place the pump level on a work bench with its mounting surface of the regulator facing down. Then separate pump casing (271) and valve block (312).
312
•
When facing the mounting surface of the regulator down, place a rubber sheet on a work bench so as not to score the mounting surface.
•
When the pump casing has been separated from the valve block, draw out the 1st gear (116) at the same time.
Fig. 33-93 Disassembling the pump casing (271) and the valve block (312)
7) Drawing out the cylinder assy Draw out cylinder (141) out of pump casing (271) in parallel to shaft (111). At the same time draw out piston (151), plate (153), spherical bushing (156) and cylinder spring (157).
Use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.
•
Use care so as not to score the sliding surface of the cylinder, spherical bushing, shoe and the swash plate.
Fig. 33-94 Drawing out the cylinder assy 8) Remove seal cover (F) Remove socket bolt (406) M8 and seal cover F (261).
271
406 261
Fig. 33-94 Drawing out the cylinder assy 8) Remove seal cover (F) Remove socket bolt (406) M8 and seal cover F (261).
: 6 mm
406 261
: 6 mm
•
The seal cover (F) may be drawn out with ease if it is taken out by tightening bolts in the tapped holes (M6 tap) of the seal cover (F).
•
The seal cover (F) may be drawn out with ease if it is taken out by tightening bolts in the tapped holes (M6 tap) of the seal cover (F).
•
An oil seal is fitted to seal cover (F). Therefore, use care so as not to score the oil seal.
•
An oil seal is fitted to seal cover (F). Therefore, use care so as not to score the oil seal.
Fig. 33-95 Removing seal cover F (261)
33-58
Fig. 33-95 Removing seal cover F (261)
33-58
33. UPPER STRUCTURE 9) Separating the swash plate support and the pump casing Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing.
33. UPPER STRUCTURE 9) Separating the swash plate support and the pump casing Knock lightly on the mounting flange of swash plate support (251) from the pump casing (271) side and separate the swash plate support from the pump casing.
Fig. 33-96 Separating the swash plate (251) support and the pump casing (271) 10) Remove shoe plate and swash plate Draw out shoe plate (211) and swash plate (212) from pump casing (271).
Fig. 33-96 Separating the swash plate (251) support and the pump casing (271) 10) Remove shoe plate and swash plate Draw out shoe plate (211) and swash plate (212) from pump casing (271).
Fig. 33-97 Removing shoe (211) and swash plate (212) 11) Drawing out the shaft Tap lightly the shaft end (111, 113) by means of a plastic hammer and draw out the shaft from the swash plate support.
Fig. 33-97 Removing shoe (211) and swash plate (212) 11) Drawing out the shaft Tap lightly the shaft end (111, 113) by means of a plastic hammer and draw out the shaft from the swash plate support.
Fig. 33-98 Drawing out the shaft (111), (113)
33-59
Fig. 33-98 Drawing out the shaft (111), (113)
33-59
33. UPPER STRUCTURE
33. UPPER STRUCTURE
12) Remove valve plate Remove valve plate (313, 314) from valve block (312).
12) Remove valve plate Remove valve plate (313, 314) from valve block (312). 312
•
The valve plate may come off during the operation under 6).
312
• 314 (313 :
The valve plate may come off during the operation under 6).
314 (313 :
Opposite Side)
Opposite Side)
Fig. 33-99 Removing valve plates (313), (314) 13) Remove other parts If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), and remove needle bearing (124) from valve block (312). •
When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig.
•
It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying undue force.
13) Remove other parts If necessary, remove stopper (L) (534), stopper (S) (535), servo piston (532) and tilting pin (531) from pump casing (271), and remove needle bearing (124) from valve block (312).
531
806
534
535
Fig. 33-99 Removing valve plates (313), (314)
532
•
When removing the tilting pin, use care so as not to score the head of the tilting pin, using a jig.
•
It is hard to separate the tilting pin from the servo piston in some cases as Loctite is coated on the mating part between them. Use care so as not to score the servo piston by applying undue force.
808
271
312
124
251
•
Do not draw out needle bearings except when their service life has ended.
•
Do not draw out needle bearings except when their service life has ended.
•
Do not loosen hex nuts (806),(808) of valve block (312) and swash plate support (251). A set flow rate changes.
•
Do not loosen hex nuts (806),(808) of valve block (312) and swash plate support (251). A set flow rate changes.
33-60
Fig. 33-100 Removing other parts
33-60
531
806
534
535
532
808
271
312
251
Fig. 33-100 Removing other parts
124
33. UPPER STRUCTURE (3) Installing procedure
33. UPPER STRUCTURE (3) Installing procedure
1) Precautions to be exercised in installation Assembly is a reverse order of disassembly, but notice the following.
1) Precautions to be exercised in installation Assembly is a reverse order of disassembly, but notice the following.
1. Repair scored parts at disassembly. Get replacements ready beforehand.
1. Repair scored parts at disassembly. Get replacements ready beforehand.
2. Wash parts sufficiently in cleaning oil and dry them with jet air.
2. Wash parts sufficiently in cleaning oil and dry them with jet air.
3. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
3. Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
4. In principle, replace sealing parts such as Orings and oil seals.
4. In principle, replace sealing parts such as Orings and oil seals.
5. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.
5. Tighten socket bolts and plugs to specified torques in this manual, using a torque wrench.
6. Do not mix up front pump parts with rear pump parts.
6. Do not mix up front pump parts with rear pump parts.
2) Installing swash plate support Attach swash plate support (251) to pump casing (271) by tapping the swash plate support lightly with a plastic hammer.
2) Installing swash plate support Attach swash plate support (251) to pump casing (271) by tapping the swash plate support lightly with a plastic hammer.
•
When the servo piston, the tilting pin, the stopper (L) and the stopper (S) have been removed, install them to the pump casing beforehand.
•
When the servo piston, the tilting pin, the stopper (L) and the stopper (S) have been removed, install them to the pump casing beforehand.
•
When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with Loctite #262.
•
When tightening servo piston and tilting pin, use a jig so as not to damage the head of the tilting pin and feedback pin. Coat the screwed part with Loctite #262.
Fig. 33-101 Installing swash plate support (251) 3) Installing swash plate Place the pump casing with its mounting surface of the regulator facing down, insert the tilting bushing of the swash plate into tilting pin (531), and fit swash plate (212) to swash plate support (251) properly.
Fig. 33-101 Installing swash plate support (251) 3) Installing swash plate Place the pump casing with its mounting surface of the regulator facing down, insert the tilting bushing of the swash plate into tilting pin (531), and fit swash plate (212) to swash plate support (251) properly.
•
Confirm by the fingers of your both hands that swash plate moves smoothly.
•
Confirm by the fingers of your both hands that swash plate moves smoothly.
•
The shaft be installed easily if grease is applied to the sliding parts of swash plate and swash plate support.
•
The shaft be installed easily if grease is applied to the sliding parts of swash plate and swash plate support.
•
Do not damage the sliding surface of shoe plate.
•
Do not damage the sliding surface of shoe plate.
Fig. 33-102 Installing swash plate (212)
33-61
Fig. 33-102 Installing swash plate (212)
33-61
33. UPPER STRUCTURE
33. UPPER STRUCTURE
4) Installing shaft Install shaft (111) fitted with bearing (123), bearing spacer (127) and snap ring (824), to swash plate support (251).
4) Installing shaft Install shaft (111) fitted with bearing (123), bearing spacer (127) and snap ring (824), to swash plate support (251).
•
Do not knock on the shaft with a hammer or something.
•
Do not knock on the shaft with a hammer or something.
•
Fix the bearing by lightly tapping the outer race of it by means of a plastic hammer and set it exactly to the end by using a steel rod and others.
•
Fix the bearing by lightly tapping the outer race of it by means of a plastic hammer and set it exactly to the end by using a steel rod and others.
Fig. 33-103 Installing shaft (111) 5) Installing seal cover Assemble seal cover (F) (261) to pump casing (271) and fix it with socket bolts (406).
Fig. 33-103 Installing shaft (111) 5) Installing seal cover Assemble seal cover (F) (261) to pump casing (271) and fix it with socket bolts (406).
: 6 mm Tightening torque : 29 N•m (22 lbf•ft)
: 6 mm Tightening torque : 29 N•m (22 lbf•ft)
•
Coat the oil seal in seal cover (F) with a thin film of grease.
•
Coat the oil seal in seal cover (F) with a thin film of grease.
•
Handle the oil seal with sufficient care so it is not scored.
•
Handle the oil seal with sufficient care so it is not scored.
Fig. 33-104 Installing seal cover F (261) 6) Inserting piston cylinder sub Assemble the piston cylinder sub [cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156) and cylinder spring (157)]. Align the spherical bushing with the cylinder spline and insert them into the pump casing.
Fig. 33-104 Installing seal cover F (261) 6) Inserting piston cylinder sub Assemble the piston cylinder sub [cylinder block (141), piston (151), shoe (152), plate (153), spherical bushing (156) and cylinder spring (157)]. Align the spherical bushing with the cylinder spline and insert them into the pump casing.
Fig. 33-105 Inserting piston cylinder sub 7) Installing valve plate Install valve plate (313), (314) to valve block (312) by aligning pin.
Fig. 33-105 Inserting piston cylinder sub 7) Installing valve plate Install valve plate (313), (314) to valve block (312) by aligning pin.
312 •
Do not mistake the suction and delivery sides of the valve plate.
312 •
314 (313 : Opposite Side)
Do not mistake the suction and delivery sides of the valve plate.
Fig. 33-106 Installing valve plates (313), (314)
33-62
314 (313 : Opposite Side)
Fig. 33-106 Installing valve plates (313), (314)
33-62
33. UPPER STRUCTURE 8) Installing valve block Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401).
312
271
401
33. UPPER STRUCTURE 8) Installing valve block Install valve block (312) to pump casing (271) and fasten them together with socket bolts (401).
: 17 mm Tightening torque ; 430 N•m (320 lbf•ft)
: 17 mm Tightening torque ; 430 N•m (320 lbf•ft)
•
Work will be promoted if assembly is started from the rear pump.
•
Work will be promoted if assembly is started from the rear pump.
•
Exercise care so as not to mistake the direction of the valve block (312). (Install it so the regulator comes up as seen from the front side and the suction flange comes on the right.)
•
Exercise care so as not to mistake the direction of the valve block (312). (Install it so the regulator comes up as seen from the front side and the suction flange comes on the right.)
•
Fig. 33-107 Installing valve block (312)
Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft.
•
9) Installing gear pump Install gear pump (04) and fasten them together with socket bolts (435).
312
271
401
Fig. 33-107 Installing valve block (312)
Insert the 1st gear into the valve block beforehand and connect it with the spline of the shaft.
9) Installing gear pump Install gear pump (04) and fasten them together with socket bolts (435).
: 6 mm, Tightening torque ; 17 N•m (12.5 lbf•ft)
: 6 mm, Tightening torque ; 17 N•m (12.5 lbf•ft)
10) Installing regulator and PTO cover Pinch feedback pin of tilting pin in feedback lever of the regulator and PTO cover (326), install the regulator and fasten socket bolt. (412)(413) (See Fig. 33-109] Socket bolt (412)(413) …… For regulator
Fig. 33-108 Installing regulator and PTO cover
10) Installing regulator and PTO cover Pinch feedback pin of tilting pin in feedback lever of the regulator and PTO cover (326), install the regulator and fasten socket bolt. (412)(413) (See Fig. 33-109] Socket bolt (412)(413) …… For regulator
: 6 mm, Tightening torque ; 29 N•m (21 lbf•ft) Socket bolt (414) …… PTO Cover (326)
: 6 mm, Tightening torque ; 29 N•m (21 lbf•ft) Socket bolt (414) …… PTO Cover (326)
: 8 mm, Tightening torque ; 57 N•m (42 lbf•ft)
: 8 mm, Tightening torque ; 57 N•m (42 lbf•ft)
•
•
Do not mistake the front regulator for the rear regulator.
11) Installing drain port plug The work is complete when drain port VP plugs (466), (468) have been set. : 19 mm, 36 mm Tightening torque ; 36 N•m (27 lbf•ft) Tightening torque ; 170 N•m (125 lbf•ft)
Do not mistake the front regulator for the rear regulator.
11) Installing drain port plug The work is complete when drain port VP plugs (466), (468) have been set. : 19 mm, 36 mm Tightening torque ; 36 N•m (27 lbf•ft) Tightening torque ; 170 N•m (125 lbf•ft)
33-63
33-63
Fig. 33-108 Installing regulator and PTO cover
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.1.1.3
33.2.1.1.3
Maintenance standards
(1) Replacement standards for abrasive parts Replace or readjust parts that exceed the following standards of wear. However, always replace such parts that show excessive damage on appearance.
(1) Replacement standards for abrasive parts Replace or readjust parts that exceed the following standards of wear. However, always replace such parts that show excessive damage on appearance.
Standard dimension
Recommended value forreplacement
0.039 (0.0015 )
0.067 (0.0026 )
0 ~ 0.1 (0.004 )
0.3 (0.012 )
Replace piston shoe assy.
Thickness of shoe
4.9 (t) (0.193 )
4.7 (0.185 )
Replace piston shoe assy.
Free height of cylinder spring
41.1 (L) (1.618 )
40.3 (1.587 )
Replace cylinder spring.
23.0 (0.906 )
22.0 (0.866 )
Replace a set of spherical bushing or retainer plate.
Part name and inspection item Clearance between piston and cylinder bore (D-d) Gap between piston and caulked part of shoe ( )
Combined height of retainer plate and spherical bushing (H-h)
Remedy
Replace piston or cylinder.
Recommended value forreplacement
0.039 (0.0015 )
0.067 (0.0026 )
Replace piston or cylinder.
0 ~ 0.1 (0.004 )
0.3 (0.012 )
Replace piston shoe assy.
Thickness of shoe
4.9 (t) (0.193 )
4.7 (0.185 )
Replace piston shoe assy.
Free height of cylinder spring
41.1 (L) (1.618 )
40.3 (1.587 )
Replace cylinder spring.
23.0 (0.906 )
22.0 (0.866 )
Replace a set of spherical bushing or retainer plate.
Clearance between piston and cylinder bore (D-d) Gap between piston and caulked part of shoe ( )
Combined height of retainer plate and spherical bushing (H-h)
Remedy
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face)
Surface roughness requiring correction
3-Z
Standard surface roughness (correction value)
Less than 0.4Z (lapping)
33-64
Standard dimension
Part name and inspection item
(2) Repair standards for cylinder, valve plate and swash plate (shoe plate face) Valve plate (sliding section) Swash plate (shoe plate face) Cylinder (sliding section) Roughness of each surface
Maintenance standards
Valve plate (sliding section) Swash plate (shoe plate face) Cylinder (sliding section) Roughness of each surface
Surface roughness requiring correction
3-Z
Standard surface roughness (correction value)
Less than 0.4Z (lapping)
33-64
33. UPPER STRUCTURE 33.2.1.1.4
Troubleshooting
33. UPPER STRUCTURE 33.2.1.1.4
(1) Locating causes of troubles The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location extremely difficult. However, faults would be found out easily if the following check items were attended to.
Troubleshooting
(1) Locating causes of troubles The pump is usually fitted with a regulator, auxiliary valves and auxiliary pumps, and this makes fault location extremely difficult. However, faults would be found out easily if the following check items were attended to.
1) Inspecting the filter and drain oil Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements may be damaged. In that case check the drain oil in the pump casing as well.
1) Inspecting the filter and drain oil Inspect the filter element to check for abnormal contaminations. Some metallic particles will be deposited on it as the shoe and the cylinder wear off. In case metallic particles are found in large quantity, the elements may be damaged. In that case check the drain oil in the pump casing as well.
2) Checking for abnormal vibration and sound Check that the pump does not vibrate and make an abnormal sound. Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
2) Checking for abnormal vibration and sound Check that the pump does not vibrate and make an abnormal sound. Check that the hunting of the regulator and the attached valveÅfs relief valve are of regular frequency. In case vibration and sound are abnormal, the pump may be making a cavitation or internally broken.
3) When two pumps are used In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This will make clear that the pumps are faulty or the circuit after the pumps is faulty.
3) When two pumps are used In case two single pumps or motors are used or when a double pump is used. change pump pipelines. This will make clear that the pumps are faulty or the circuit after the pumps is faulty.
4) Pressure measurements If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by measuring pressures.
4) Pressure measurements If the problem is related to control functions, avoid disassembling the pumps carelessly, but look for causes by measuring pressures.
(2) Troubleshooting
(2) Troubleshooting
1) Overloading to engine Cause
1) Overloading to engine Remedy
Remarks
1. Revolution and pressure are higher 1) Set pressure to specified value. than set values.
Cause
Remedy
Remarks
1. Revolution and pressure are higher 1) Set pressure to specified value. than set values.
2. Regulator torque is set higher than 2) Readjust regulator. normal.
2)Refer to Regulator Manual.
2. Regulator torque is set higher than 2) Readjust regulator. normal.
2)Refer to Regulator Manual.
3. PumpÅfs internal parts are seized or 3) Replace damaged parts. broken.
3) Check filter and drain oil to see if abnormal wear particles are present.
3. PumpÅfs internal parts are seized or 3) Replace damaged parts. broken.
3) Check filter and drain oil to see if abnormal wear particles are present.
4. Regulator is piped incorrectly.
4) Pipe regulator correctly.
4. Regulator is piped incorrectly.
2) Pump’s oil flow rate is extremely low and delivery pressure is not available. Cause 1. Regulator is out of order
Remedy 1) Repair regulator.
4) Pipe regulator correctly.
2) Pump’s oil flow rate is extremely low and delivery pressure is not available. Remarks
Cause
Remedy
1. Regulator is out of order
2. Pump’s internal parts are seized or 2)Replace damaged parts. broken.
2)Check filter and drain oil.
2. Pump’s internal parts are seized or 2)Replace damaged parts. broken.
2)Check filter and drain oil.
3. Attached pump is out of order
3) Replace damaged parts.
3) Remove attached pump and check shaft joint.
3. Attached pump is out of order
3) Replace damaged parts.
3) Remove attached pump and check shaft joint.
4. Attached valve is out of order.
4) Check attached valve. Particularly poppet, seat and spring.
4) Refer to Manual for Attached Valve.
4. Attached valve is out of order.
4) Check attached valve. Particularly poppet, seat and spring.
4) Refer to Manual for Attached Valve.
5. Regulator is piped incorrectly.
5) Pipe correctly.
5. Regulator is piped incorrectly.
5) Pipe correctly.
33-65
1) Repair regulator.
Remarks
1) Refer to Regulator Manual.
33-65
1) Refer to Regulator Manual.
33. UPPER STRUCTURE
33. UPPER STRUCTURE
3) Abnormal Sound and Vibration Cause
3) Abnormal Sound and Vibration Remedy
1. Cavitation
1) Prevent cavitation. Check that hydraulic oil is not clouded.
2. Caulked part of shoe is broken.
Remarks
Cause
Remedy
Remarks
1. Cavitation
1) Prevent cavitation. Check that hydraulic oil is not clouded.
2)Replace piston shoe and shoe plate.
2. Caulked part of shoe is broken.
2)Replace piston shoe and shoe plate.
3. Cylinder is cracked
3) Replace cylinder.
3. Cylinder is cracked
3) Replace cylinder.
4. Pump is installed improperly.
4) Correct installation.
4. Pump is installed improperly.
4) Correct installation.
5. Regulator is hunting.
5) Repair regulator,
5) See Regulator Manual.
5. Regulator is hunting.
5) Repair regulator,
5) See Regulator Manual.
6. Relief valve in attached valve is hunting.
6) Repair attached valve.
6) See the Manual for Attached Valve.
6. Relief valve in attached valve is hunting.
6) Repair attached valve.
6) See the Manual for Attached Valve.
33-66
1-1) The boost pressure is low. 1-2) The attached pump is in trouble. 1-3) The suction pipe is inhaling air. 1-4) The suction resistance is high.
33-66
1-1) The boost pressure is low. 1-2) The attached pump is in trouble. 1-3) The suction pipe is inhaling air. 1-4) The suction resistance is high.
33. UPPER STRUCTURE
33. UPPER STRUCTURE
This page is blank for editing convenience.
This page is blank for editing convenience.
33-67
33-67
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.1.2
33.2.1.2
33.2.1.2.1
REGULATOR Structural exploded view
33.2.1.2.1
REGULATOR Structural exploded view
626
626
625
625
624
624
753
753
627
627
623
623
621
732 631 898
B
D
F
622 733
874 613
875 612
652
646
651
732 631 898
644 875 643
A G
836 654 653 814
645
611
621
728
D 874 613
875 612
652
875 643 G
836
438
654 653 814
630
646 644
A
651
E
C
897
655
438
629 802 756
763
802
628
756
757
418
Z
079 041 755
466
X
734 887
418
E 601
722
496
755
876 615
439
A
B
642 755
C
8-724 041 755
466
755
755 858
734 887
876 615
662
439
A
B
F
642 755
C
876 614
724 730 725
8-724 041 755
466
755
466
641
Fig. 33-109 Structural exploded view of regulator
Fig. 33-109 Structural exploded view of regulator
33-68
33-68
755 858
G
708
466
641
E 601
722
496
755
D
X
F 876 614
724 730 725
755 858 466
W
Z
079 041 755
G
708 662
757 Y
D
801
412 413
438 W
628
924 656
Y
763
801
412 413
438
630
629
924 656
728
645
611
F
622 733
E
C
897
655
B
755 858
33. UPPER STRUCTURE
Marks
No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627
in Fig. 33-90 show the position where regulator is installed.
Name Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjust plug Compensating rod Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)
Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730
Name Adjust screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjust stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22
Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1
33. UPPER STRUCTURE
Marks
No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079
Name O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 4X19L Pin ; 7.5X11L Socket screw ; M8X20 Check valve sub Solenoid proportional reducing valve
No. 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1
No. 412 413 418 438 439 466 496 541 543 545 601 611 612 613 614 615 621 622 623 624 625 626 627
in Fig. 33-90 show the position where regulator is installed.
Name Socket bolt ; M8X50 Socket bolt ; M8X70 Socket bolt ; M5X12 Socket bolt ; M6X20 Socket bolt ; M6X25 VP plug ; PF1/4 Plug ; NPTF1/16 Seat Stopper 1 Ball Casing Feed back lever Lever (1) Lever (2) Fulcrum plug Adjust plug Compensating rod Piston case Compensating rod Spring seat (C) Outer spring Inner spring Adjusting stem (C)
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug and nut No.
Thread size
412,413 438,439 418 466 496 630 801 802
M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10
Q'ty 2 2 2 8 5 3 17 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1
No. 628 629 630 631 641 642 643 644 645 646 651 652 653 654 655 656 662 708 722 724 725 728 730
Name Adjust screw (C) Cover (C) Lock nut ; M30X1.5 Sleeve (For PF) Pilot cover Spool Pilot piston Spring seat (Q) Adjust stem (Q) Pilot spring Sleeve Spool Spring seat Return spring Set spring Block cover Spring O-ring ; 1B G75 O-ring ; 1B P6 O-ring ; 1B P8 O-ring ; 1B P10 O-ring ; 1B P18 O-ring ; 1B P22
N.m (lbf.ft) 29 (21) 12 (8.9) 6.9 (5) 36 (26) 8.8 (6.5) 160 (118) 16 (12) 19 (14)
33-69
No. 732 733 734 753 755 756 757 763 801 802 814 836 858 874 875 876 887 897 898 924 041 079
Name O-ring ; 1B P16 O-ring O-ring ; 1B G25 O-ring ; 1B P9 O-ring ; 1B P11 O-ring ; 1B P26 O-ring ; 1B P12.5 O-ring ; 1B G35 Nut ; M8 Nut ; M10 Snap ring Snap ring Snap ring Pin ; 4X11.7L Pin ; 4X8L Pin ; 5X8L Pin Pin ; 4X19L Pin ; 7.5X11L Socket screw ; M8X20 Check valve sub Solenoid proportional reducing valve
No. 1 1 1 1 7 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 2 1
The numbers in a rectangle represent adjust screws. Do not tamper with the adjust screws as much as possible. Tightening torque of bolt, plug and nut
Tightening torque
Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 8 1 1 1
No.
Thread size
412,413 438,439 418 466 496 630 801 802
M8 M6 M5 PF 1/4 NPTF1/16 M30X1.5 M8 M10
Tightening torque
N.m (lbf.ft) 29 (21) 12 (8.9) 6.9 (5) 36 (26) 8.8 (6.5) 160 (118) 16 (12) 19 (14)
33-69
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.1.2.2
33.2.1.2.2
Disassembly and assembly
Disassembly and assembly
(1) Tools The right list shows the tools required for remove and install.
(1) Tools The right list shows the tools required for remove and install.
(2) Disassembling procedure
(2) Disassembling procedure
1) Selecting a place for disassembly.
1) Selecting a place for disassembly.
•
Choose a clean place.
•
Choose a clean place.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
2) Cleaning Remove dust and rust, etc. on regulator surface with wash oil.
3) Remove regulator (SeeFig. 33-109) Remove socket bolts (412, 413) and separate the regulator from the pump body.
2) Cleaning Remove dust and rust, etc. on regulator surface with wash oil.
438 656
413
3) Remove regulator (SeeFig. 33-109) Remove socket bolts (412, 413) and separate the regulator from the pump body.
412 629
: 6 mm 4) Remove port plate (See Fig. 33-109) Remove socket bolt (438) and separate the port plate (656).
438
4) Remove port plate (See Fig. 33-109) Remove socket bolt (438) and separate the port plate (656).
438 601
: 5 mm
Fig. 33-110 Removing regulator 5) Remove cover (See Fig. 33-109) Remove socket bolts (438) and remove cover (C) (629).
: 5 mm •
412 629
Fig. 33-110 Removing regulator 5) Remove cover (See Fig. 33-109) Remove socket bolts (438) and remove cover (C) (629).
413
: 6 mm
601
: 5 mm
438 656
: 5 mm
624,625,626
The cover is equipped with adjust screws (628), adjust stem (627), lock nut (630), hex nut (801) and set screw (924). Do not loosen those screws and nuts. If they are loosened, preadjusted set pressure and flow values change.
627 801 629( 628 )
•
630 924
627 801 629( 628 )
630 924
Fig. 33-111 Removing cover (C) (629)
33-70
624,625,626
The cover is equipped with adjust screws (628), adjust stem (627), lock nut (630), hex nut (801) and set screw (924). Do not loosen those screws and nuts. If they are loosened, preadjusted set pressure and flow values change.
Fig. 33-111 Removing cover (C) (629)
33-70
33. UPPER STRUCTURE 6) Remove compensating parts (See Fig. 33-109 (D) section, See Fig. 33-111, Fig. 33-112) After removing the cover (C) (629) sub assy, take out outer spring (625), inner spring (626) and spring seat (624) from the compensating part. Then take out adjust stem (645), pilot spring (646) and spring seat (644) from the pilot part. •
33. UPPER STRUCTURE 6) Remove compensating parts (See Fig. 33-109 (D) section, See Fig. 33-111, Fig. 33-112) After removing the cover (C) (629) sub assy, take out outer spring (625), inner spring (626) and spring seat (624) from the compensating part. Then take out adjust stem (645), pilot spring (646) and spring seat (644) from the pilot part.
Adjust stem (645) comes out easily if an M4 bolt is used.
•
Adjust stem (645) comes out easily if an M4 bolt is used.
Fig. 33-112 Removing compensating parts 7) Remove pilot cover and the set spring Remove socket bolt (439) and pilot cover (641). Once the pilot cover comes off, separate set spring (655) from the pilot section. (Fig. 33-109 (A) and (B) section)
Fig. 33-112 Removing compensating parts 7) Remove pilot cover and the set spring Remove socket bolt (439) and pilot cover (641). Once the pilot cover comes off, separate set spring (655) from the pilot section. (Fig. 33-109 (A) and (B) section)
: 5 mm
: 5 mm
439
439 641
641
Fig. 33-113 Removing pilot cover (641) and set spring (655) 8)Remove spring seat, return spring and sleeve (Fig. 33-109 (A) section) Remove snap ring (814). Then remove spring seat (653), return spring (654) and sleeve (651).
Fig. 33-113 Removing pilot cover (641) and set spring (655) 8)Remove spring seat, return spring and sleeve (Fig. 33-109 (A) section) Remove snap ring (814). Then remove spring seat (653), return spring (654) and sleeve (651).
•
Sleeve (651) is equipped with snap ring (836).
•
Sleeve (651) is equipped with snap ring (836).
•
When removing snap ring (814), return spring (654) comes out : Use care so as not to lose it.
•
When removing snap ring (814), return spring (654) comes out : Use care so as not to lose it.
Fig. 33-114 Removing spring seat (653), return spring (654) and sleeve (651) 9) Remove adjust plug (Fig. 33-109 (F),(G) section) emove snap ring (858) and take out fulcrum plug (614) and adjust plug (615). •
Fig. 33-114 Removing spring seat (653), return spring (654) and sleeve (651) 9) Remove adjust plug (Fig. 33-109 (F),(G) section) emove snap ring (858) and take out fulcrum plug (614) and adjust plug (615).
Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.
•
Fulcrum plug (614) and adjust plug (615) come off easily if a M6 bolt is used.
Fig. 33-115 Removing adjust plug (615)
33-71
Fig. 33-115 Removing adjust plug (615)
33-71
33. UPPER STRUCTURE
33. UPPER STRUCTURE
Fig. 33-116 Removing fulcrum plug (614) 10) Remove lever (Fig. 33-109 (G) section) Remove lever 2 (613). Do not draw out pin (875). •
Fig. 33-116 Removing fulcrum plug (614) 10) Remove lever (Fig. 33-109 (G) section) Remove lever 2 (613). Do not draw out pin (875).
The work is eased if tweezers is used.
•
The work is eased if tweezers is used.
Fig. 33-117 Removing lever 2 (613) 11) Remove feedback lever Draw out pin (874) and remove feedback lever (611). •
Fig. 33-117 Removing lever 2 (613) 11) Remove feedback lever Draw out pin (874) and remove feedback lever (611).
Push out pin (874) [pin dia : ø4mm (0.157in)] from above with a slender steel rod so as not to interfere with lever 1 (612).
33-72
•
Push out pin (874) [pin dia : ø4mm (0.157in)] from above with a slender steel rod so as not to interfere with lever 1 (612).
Fig. 33-118 Removing feedback lever (611) [1]
Fig. 33-118 Removing feedback lever (611) [1]
Fig. 33-119 Removing feedback lever (611) [2]
Fig. 33-119 Removing feedback lever (611) [2]
33-72
33. UPPER STRUCTURE
33. UPPER STRUCTURE
12)Remove lever (Fig. 33-109 (F) section) Remove lever 1 (612). Do not draw out pin (875).
12)Remove lever (Fig. 33-109 (F) section) Remove lever 1 (612). Do not draw out pin (875).
13) Remove pilot piston and spool (Fig. 33-109 (C),(A) section) Draw out pilot piston (643) and spool (652).
13) Remove pilot piston and spool (Fig. 33-109 (C),(A) section) Draw out pilot piston (643) and spool (652).
14) Remove piston casing, compensating piston and compensating rod (Fig. 33-109 (B) section) Draw out piston casing (622), compensating piston (621) and compensating rod (623).
14) Remove piston casing, compensating piston and compensating rod (Fig. 33-109 (B) section) Draw out piston casing (622), compensating piston (621) and compensating rod (623).
â&#x20AC;˘
Piston casing (622) comes out from the opposite side of the piston casing if compensating rod (623) is pushed out.
â&#x20AC;˘
Piston casing (622) comes out from the opposite side of the piston casing if compensating rod (623) is pushed out.
Fig. 33-120 Part of exploded view of regulator 15) Remove spool (642) and spring (662) Remove VP plug (466) from pilot cover (641), and draw out spool (642) and spring (662).
Fig. 33-120 Part of exploded view of regulator 15) Remove spool (642) and spring (662) Remove VP plug (466) from pilot cover (641), and draw out spool (642) and spring (662).
This completes disassembly.
This completes disassembly.
Fig. 33-121 Part of exploded view of regulator
33-73
Fig. 33-121 Part of exploded view of regulator
33-73
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(3) Installing procedure : Assembly is the reverse order of disassembly. Do the work paying attention to the following :
(3) Installing procedure : Assembly is the reverse order of disassembly. Do the work paying attention to the following :
• Repair those parts that were damaged during disassembly and prepare replacement parts beforehand.
• Repair those parts that were damaged during disassembly and prepare replacement parts beforehand.
• If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them with jet air and assemble parts in a clean place.
• If foreign matter enters, it causes malfunction; clean parts thoroughly in cleaning oil, blow them with jet air and assemble parts in a clean place.
• Always tighten bolts and plugs to the specified torque. The tolerance of torque should be within 10%.
• Always tighten bolts and plugs to the specified torque. The tolerance of torque should be within 10%.
• Do not fail to coat the moving parts with clean hydraulic oil, before assembly.
• Do not fail to coat the moving parts with clean hydraulic oil, before assembly.
• In principle, replace seals such as O-ring.
• In principle, replace seals such as O-ring.
1) Installing compensating rod (Fig. 33-109 (B) section) Assemble compensating rod (623) into the compensating hole of casing (601).
1) Installing compensating rod (Fig. 33-109 (B) section) Assemble compensating rod (623) into the compensating hole of casing (601).
2) Assembling lever Put the pin pressed in lever 1 (612) into the groove of the compensating rod (623). Then assemble the lever to the pin (875) that is pressed in the casing.
2) Assembling lever Put the pin pressed in lever 1 (612) into the groove of the compensating rod (623). Then assemble the lever to the pin (875) that is pressed in the casing. Fig. 33-122 Part of exploded view of regulator
3) Assembling spool and sleeve (See Fig. 33-109 (A) section) Assemble spool (652) and sleeve (651) into the spool hole of the casing. •
Make sure that the spool and the sleeve move smoothly in the casing.
•
Beware of the direction of the spool.
Fig. 33-122 Part of exploded view of regulator 3) Assembling spool and sleeve (See Fig. 33-109 (A) section) Assemble spool (652) and sleeve (651) into the spool hole of the casing.
Fig. 33-123 Direction of the spool (652)
4) Assembling feedback lever Assemble feedback lever (611). Then put pin (874) into the pin hole of the feedback lever.
•
Make sure that the spool and the sleeve move smoothly in the casing.
•
Beware of the direction of the spool.
Fig. 33-123 Direction of the spool (652)
4) Assembling feedback lever Assemble feedback lever (611). Then put pin (874) into the pin hole of the feedback lever.
•
The work is eased if the pin is put in the feedback lever a little, beforehand.
•
The work is eased if the pin is put in the feedback lever a little, beforehand.
•
Take care so as not to mistake the direction of the feedback lever.
•
Take care so as not to mistake the direction of the feedback lever.
Fig. 33-124 Assembling feedback lever (611)
33-74
Fig. 33-124 Assembling feedback lever (611)
33-74
33. UPPER STRUCTURE 5) Assembling pilot piston (See Fig. 33-109 (C) section) Assemble pilot piston (643) into the positive control hole of the casing. •
33. UPPER STRUCTURE 5) Assembling pilot piston (See Fig. 33-109 (C) section) Assemble pilot piston (643) into the positive control hole of the casing.
Make sure that the pilot piston moves smoothly.
•
6) Assembling lever (See Fig. 33-109 (G) section) Place pin (875) pressed in lever 2 (613) into the groove of the pilot piston and assemble lever 2 (613).
Fig. 33-125 Assembling lever 2 (613)
7) Installing fulcrum plug (See Fig. 33-109 (F) section) Assemble fulcrum plug (614) so pin (875) pressed in the fulcrum comes in the pin hole of lever 2 (613). Then fit snap ring (858).
Make sure that the pilot piston moves smoothly.
6) Assembling lever (See Fig. 33-109 (G) section) Place pin (875) pressed in lever 2 (613) into the groove of the pilot piston and assemble lever 2 (613).
Fig. 33-125 Assembling lever 2 (613)
7) Installing fulcrum plug (See Fig. 33-109 (F) section) Assemble fulcrum plug (614) so pin (875) pressed in the fulcrum comes in the pin hole of lever 2 (613). Then fit snap ring (858).
Fig. 33-126 Installing fulcrum plug (614) 8) Installing adjust plug (See Fig. 33-109 (G) section) Insert adjust plug (615) and fit a snap ring (858).
Fig. 33-126 Installing fulcrum plug (614) 8) Installing adjust plug (See Fig. 33-109 (G) section) Insert adjust plug (615) and fit a snap ring (858).
•
Use care so as not to mistake the holes into which the fulcrum and adjust plug are inserted.
•
Use care so as not to mistake the holes into which the fulcrum and adjust plug are inserted.
•
At this point, operate the feedback lever and make sure that the gap is not large and that the lever moves smoothly.
•
At this point, operate the feedback lever and make sure that the gap is not large and that the lever moves smoothly.
Fig. 33-127 Installing adjust plug (615)
9) Installing return spring and the spring seat (See Fig. 33-109 (A) section) Assemble return spring (654) and spring seat (653) into the spool hole and fit snap ring (814).
Fig. 33-128 Installing return spring (654) and spring seat (653)
33-75
Fig. 33-127 Installing adjust plug (615)
9) Installing return spring and the spring seat (See Fig. 33-109 (A) section) Assemble return spring (654) and spring seat (653) into the spool hole and fit snap ring (814).
Fig. 33-128 Installing return spring (654) and spring seat (653)
33-75
33. UPPER STRUCTURE
33. UPPER STRUCTURE
10) Assembling compensating parts (See Fig. 33109 (A),(B) section) Assemble set spring (655) into the spool hole. Place compensating piston (621) and piston casing (622) into the compensating hole and attach pilot cover (641). Then fasten them together with socket bolts (438), (439).
10) Assembling compensating parts (See Fig. 33109 (A),(B) section) Assemble set spring (655) into the spool hole. Place compensating piston (621) and piston casing (622) into the compensating hole and attach pilot cover (641). Then fasten them together with socket bolts (438), (439).
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft)
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft) Fig. 33-129 Assembling compensating parts
11) Installing spool and spring Assemble spool (642) and spring (662) into pilot cover (641), and tighten VP plugs (466).
Fig. 33-129 Assembling compensating parts 11) Installing spool and spring Assemble spool (642) and spring (662) into pilot cover (641), and tighten VP plugs (466).
Fig. 33-130 Assembling spool (642) 12) Assembling into the pilot hole and the compensating hole (See Fig. 33-109 (E),(D) section) Put spring seat (644), pilot spring (646) and adjust stem (645) into the pilot hole. Then assemble spring seat (624), inner spring (626) and outer spring (625) into the compensating hole. •
Fig. 33-130 Assembling spool (642) 12) Assembling into the pilot hole and the compensating hole (See Fig. 33-109 (E),(D) section) Put spring seat (644), pilot spring (646) and adjust stem (645) into the pilot hole. Then assemble spring seat (624), inner spring (626) and outer spring (625) into the compensating hole.
Do not mistake the direction of the spring seat.
Fig. 33-131 Assembling into the pilot hole and compensating hole
13) Installing cover Attach cover (C) (629) fitted with adjust screws (628), (925), adjust stem (627), lock nut (630), nut (801) and socket bolt (924). Then fasten them with socket bolts (438).
•
Do not mistake the direction of the spring seat.
Fig. 33-131 Assembling into the pilot hole and compensating hole
13) Installing cover Attach cover (C) (629) fitted with adjust screws (628), (925), adjust stem (627), lock nut (630), nut (801) and socket bolt (924). Then fasten them with socket bolts (438).
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft)
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft)
14) Installing block cover (See Fig. 33-110) Attach block cover (656).
14) Installing block cover (See Fig. 33-110) Attach block cover (656).
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft)
: 5 mm Tightening torque ; 12 N•m (8.7 lbf•ft)
Fig. 33-132 Installing cover (C) (629)
This completes assembly.
Fig. 33-132 Installing cover (C) (629)
This completes assembly.
33-76
33-76
33. UPPER STRUCTURE 33.2.1.3
PTO GEAR CASING (For OCEANIA)
33.2.1.3.1
33. UPPER STRUCTURE 33.2.1.3
Structural exploded view
PTO GEAR CASING (For OCEANIA)
33.2.1.3.1
Structural exploded view
414 117
128
128
117 435
216
826
414
886
711
326
128
128 435
216
826
886
711
326
414 115
115
886
886
262 728
125
885
414
118
728
125
885
468
262 468
118
125
125
825
825 435
710
435
710
435
414
435
414
262
414
Tightening torque N•m (lbf•ft)
33 (25)
262
414
Q’ty
Tightening torque N•m (lbf•ft)
Q’ty
Tightening torque N•m (lbf•ft)
115 Idle shaft
1
33 (25)
435 Flange socket ; M10u20
4
115 Idle shaft
1
33 (25)
435 Flange socket ; M10u20
4
117 2nd gear
1
74 (54)
468 VP plug ; PF3/4
1
117 2nd gear
1
74 (54)
468 VP plug ; PF3/4
1
118 3re gear
1
710 O-ring ; 1B G80
1
118 3re gear
1
710 O-ring ; 1B G80
1
125 Ball bearing
2
711 O-ring ; 1B G85
1
125 Ball bearing
2
711 O-ring ; 1B G85
1
126 Roller bearing
1
728 O-ring ; 1B P24
1
126 Roller bearing
1
728 O-ring ; 1B P24
1
128 Bearing spacer
2
825 Snap ring
1
128 Bearing spacer
2
825 Snap ring
1
262 Cover
2
826 Snap ring
1
262 Cover
2
826 Snap ring
1
326 Gear casing
1
885 Spring pin
1
326 Gear casing
1
885 Spring pin
1
414 Socket bolt ; M10u20
4
886 Pin
2
414 Socket bolt ; M10u20
4
886 Pin
2
No.
Parts name
33-77
No.
Parts name
Q’ty
Tightening torque N•m (lbf•ft)
33 (25)
No.
Parts name
33-77
No.
Parts name
Q’ty
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.1.3.2
33.2.1.3.2
Disassembly and assembly
(1) Tools The right list shows the tools required for remove and install.
Tool name
(2) Disassembling procedure
(1) Tools The right list shows the tools required for remove and install.
Dimension
Allen wrench
Opposing flats 8,10mm
Plier
For snap ring RR-20 For snap ring RR-72
Disassembly and assembly Tool name
(2) Disassembling procedure
1) Selecting a place for disassembly.
Allen wrench
Opposing flats 8,10mm
Plier
For snap ring RR-20 For snap ring RR-72
1) Selecting a place for disassembly.
•
Choose a clean place.
•
Choose a clean place.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
•
Spread rubber sheet or cloth on work bench to protect parts from damaging.
2) Cleaning Remove dust and rust, etc. on pump surface with wash oil.
2) Cleaning Remove dust and rust, etc. on pump surface with wash oil.
3) Drain oil Drain out the oil in the pump casing by removing drain port plug (468).
3) Drain oil Drain out the oil in the pump casing by removing drain port plug (468).
: 27 mm •
Dimension
: 27 mm
Drain out the oil from the plugs of the front pump and the rear pump.
•
4) Remove cover Remove the socket bolts (414). Then remove the cover (262).
Drain out the oil from the plugs of the front pump and the rear pump.
4) Remove cover Remove the socket bolts (414). Then remove the cover (262).
FLANGE SOCKET (M10) Tightening torque : 33N.m (25 lbf.ft)}
: 8 mm
FLANGE SOCKET (M10) Tightening torque : 33N.m (25 lbf.ft)}
: 8 mm
5) Remove PTO gear casing Remove flange socket (435) and PTO gear casing.
414
: 8 mm
5) Remove PTO gear casing Remove flange socket (435) and PTO gear casing.
414
: 8 mm
262 COVER
262 COVER
PTO GEAR CASING
PTO GEAR CASING
414
414 262 COVER
262 COVER
Fig. 33-133 Removing gear pump
Fig. 33-133 Removing gear pump
HOLE FOR FLANGE SOCKET (435)
HOLE FOR FLANGE SOCKET (435)
PTO GEAR CASING
PTO GEAR CASING
Fig. 33-134 Removing PTO gear casing
33-78
Fig. 33-134 Removing PTO gear casing
33-78
33. UPPER STRUCTURE 6) Removing the 2nd gear, the roller bearing and the bearing spacer Draw out the spring pin (885) and remove idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128). •
HOLE FOR IDLE SHAFT (115)
117 (126,128)
Roller bearing (126) can not be separated from 2nd gear (117).
33. UPPER STRUCTURE 6) Removing the 2nd gear, the roller bearing and the bearing spacer Draw out the spring pin (885) and remove idle shaft (115). Then draw out 2nd gear (117), roller bearing (126) and bearing spacer (128). •
•
Fig. 33-135 Removing 2nd gear (117) 7) Removing the 3rd gear and the ball bearing Remove snap ring (825) and draw out 3rd gear (118) and ball bearing (125).
Ball bearing (125) can not be separated from 3rd gear (118).
125
•
Ball bearing (125) can not be separated from 3rd gear (118).
118
(3) Installing procedure Assembly is a reverse order of disassembly, but notice the following.
125
118
Fig. 33-136 Removing 3rd gear (118) and ball bearing (125)
Fig. 33-136 Removing 3rd gear (118) and ball bearing (125) (3) Installing procedure Assembly is a reverse order of disassembly, but notice the following.
1) Repair scored parts at disassembly. Get replacements ready beforehand.
1) Repair scored parts at disassembly. Get replacements ready beforehand.
2) Wash parts sufficiently in cleaning oil and dry them with jet air.
2) Wash parts sufficiently in cleaning oil and dry them with jet air.
3) Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
3) Do not forget to coat the sliding areas and bearings with clean hydraulic oil.
4) In principle. replace sealing parts such as O rings and oil seals.
4) In principle. replace sealing parts such as O rings and oil seals.
5) Tighten socket bolts and plugs to specified torques in Service Standard, using a torque wrench.
5) Tighten socket bolts and plugs to specified torques in Service Standard, using a torque wrench.
6) Do not mix up front pump parts with rear pump parts.
6) Do not mix up front pump parts with rear pump parts.
33.2.1.3.3
117 (126,128)
Roller bearing (126) can not be separated from 2nd gear (117).
Fig. 33-135 Removing 2nd gear (117) 7) Removing the 3rd gear and the ball bearing Remove snap ring (825) and draw out 3rd gear (118) and ball bearing (125).
HOLE FOR IDLE SHAFT (115)
Maintenance standards
33.2.1.3.3
Maintenance standards
In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage.
In case a pitching (1 pit is more than 1mm (0.039in), while the area ratio is more than 5%.) is seen on the gear tooth surface of 2nd gear (117) and 3rd gear (118), replace the gears. Replace the gears also in case they show excessive damage.
33-79
33-79
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2
33.2.2
SECTIONAL VIEW
33.2.2.1
CONTROL VALVE SECTIONAL VIEW
J
J 164
154
T2
T2
T1
PBL
PCa
YS1
PAs
PCa
YBG1
PB1
PBs
P2-20
PBs
PBL
J
P2-20
YBG1
PB1
PAL
T1
YT1
J
101
P2
PAs
YS1
YT1
PAL
164
154
101
P2
Pss
Pss
PAa1
PAo
163
PBo
PAo
(P4)
163
162 163 169 155 162 SECTION A-A 154
164
PAa1
YA1
PBa1
PBo
YP1
YA1
PBa1
YP1
33.2.2.1
CONTROL VALVE
(P4)
162 163 169 155 162 SECTION A-A 154
P1
164
102
973
PCb
973 PCb
PTb P1-20
P1-20
973
973
973
973
PAr
PBr
YT1
YT1
PBr
102
973
973
PTb
P1
PAr
973
973 PBb
PAb
973
973
PBc PCc
973 PBa2
974
973
PAa2
YAG 1
YAG 1
PAa2
PBc PCc YK1
974
974
974
162
(P3)
162 169 155 163
162
PBb
973
973 PAc
YK1
PAc
YB1
YB1
PAb
162
(P3)
162 169 155 163
SECTION B-B
SECTION B-B
Fig. 33-137 Section (1/6)
Fig. 33-137 Section (1/6)
33-80
33-80
162
PBa2
33. UPPER STRUCTURE
33. UPPER STRUCTURE A
A
B
B
H
T2
273x10 P1 unload
Travel right D
H
PB1
C
Boom conflux (P2 unload)
978x2
977
D
PB1
978x2
D
Boom
Swing PBb
E
Pss
PBa1
Bucket F
Option
G
F Arm 2
G
(P3)
Arm 1
PBp1
G
G K
B
(P3)
A
PBp1
Option
MU
K PBp2
PBp1
A
PBp1
274x4
275x4 (P4)
212
PAo
PBa2
PBp2
(P3)
K PBp2
B
PAo
PBa2
PAo PA
PBa2
MU
PBp2
274x4
275x4
213
(P4)
(P3)
212
PAa2
273x10
PBo
273x10
E
Pss
PBa1
F
PA PAo
K
PBb
PCc
Bucket F
Arm 2
Swing
E
Arm 1 PBa2
Boom conflux (P2 unload)
PBs
Boom PCc
H
C PAr
PBs
E
273x10 Travel left
(Travel straight)
Travel right D
PAL
PCb
P1 unload C
PAr
T2
273x10
USE FOR YN30V00101F1
977
H
Travel left
(Travel straight) USE FOR YN30V00101F1
C
PAL
PCb
273x10
PAa2
273x10
PBo
273x10
Fig. 33-138 Section (2/6)
Fig. 33-138 Section (2/6)
33-81
33-81
213
33. UPPER STRUCTURE
33. UPPER STRUCTURE
Fig. 33-139 Section (3/6)
Fig. 33-139 Section (3/6)
33-82
33-82
33. UPPER STRUCTURE
33. UPPER STRUCTURE Swing 203 333 331 336 322 321 603 331 211 261 266 160 160 514 524 556 164 511 521 551 164
204
PBs
Boom
333
Pss
331 336 AbR
322 321
266
As
CRb Ab
LCs
LCb
Bb
Bs
331 261 303 161 162 163 511 523 556 164
Swing 203 333 331 336 322 321 603 331 211 261 266 160 160 514 524 556 164 511 521 551 164
204
PBs
Boom
333
Pss
331 336 AbR
322 321
266
As
CRb Ab
LCs
LCb
Bb
162
Bs
266 264 206
PAb
205
160
BbR
164 551 209 216 333 331 336 322 321 602
PAs
Arm 1
PBa1
PBc
BaR
BcR
304 CRar
Bc
551 164
Ba LCc
LCa
160 514 524
205
160
BbR
209 216 333 331 336 322 321 602
PAs
SECTION E-E Bucket
PCc
201 333 331 336 322 321 603 331 261 211
Arm 1
PBa1
PBc
BaR
BcR
331 261 304
556 164 511 521
511 521
551 164
551 164
CRar
Bc
Ac
Ba LCc
LCa
160 514 524 556 164 511 521 551 164
Ac
162
162
Aa
161
Aa
161
264 603 205
162
264 206
PAb
Bucket 201 333 331 336 322 321 603 331 261 211
556 164
266
164 551
331 261
511 521
301 264 602
SECTION E-E
PCc
163 511 523
161
161 301 264 602
331 261 303 161 162
PAc AcR
PAa1
SECTION F-F
AaR
302 264
264 603
205 605
205
PAc AcR
302 264
PAa1
SECTION F-F
Fig. 33-140 Section (4/6)
Fig. 33-140 Section (4/6)
33-83
33-83
AaR
205 605
33. UPPER STRUCTURE
33. UPPER STRUCTURE 201 333 331 340 328 321
Arm 2
Option
PBa2
201 333
PAo
331 336
331 261
324 AoR
323 604 331
MU
308
261 311
162 162 162 511 521 551 164 515 521
Ao
511 521
LCAT2 LCo LCAP2
551
551 164
164
201 333 331 340 328 321
Arm 2
Option
PBa2
201 333
PAo
331 336
331 261
324 AoR
323 604 331
MU
308
261 311
162 162 162 511 521 551 164 515 521
Ao
511 521
LCAT2 LCo LCAP2
551 164 Bo
Bo
162
162
161
161
604 264
BoR
264
PBo
PAa2
205
205
SECTION G-G
604 264
BoR
264
PBo
PAa2
205
205
SECTION G-G
T2
T2
161 P1
511 521
551 164
P1
T1
163
CT1
551 164
161
163 162
511 521
T1
163
CT1
551 164
163 162
511 521
P2
511 521
P2 CT2
CT2
551
551
164
164
SECTION H-H
SECTION H-H
Fig. 33-141 Section (5/6)
Fig. 33-141 Section (5/6)
33-84
33-84
33. UPPER STRUCTURE
PBp1
207
PBp1
PBp2
606
160
33. UPPER STRUCTURE
606
207
606
160
278x5
266
278x5
266
264
264
264
264
527
528 T2
517
163
527
528 T2
T1
517
518
SECTION J-J
PBp2
606
163
T1
518
SECTION J-J SECTION K-K
SECTION K-K
Fig. 33-142 Section (6/6)
Fig. 33-142 Section (6/6)
33-85
33-85
33. UPPER STRUCTURE Tightening torque No. N•m (lbf•ft)
33. UPPER STRUCTURE
Parts name
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts name
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts name
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts name
Q’ty
101 Casing A
1
321 Spring
5
101 Casing A
1
321 Spring
5
102 Casing B
1
322 Spring
4
102 Casing B
1
322 Spring
4
220~250(162~184) 154 Plug PF3/4
3
323 Spring
3
220~250(162~184) 154 Plug PF3/4
3
323 Spring
3
110~130(81~96)
155 Plug PF1/2
2
324 Spring
3
110~130(81~96)
155 Plug PF1/2
2
324 Spring
3
20~24(15~18)
159 Plug PT1/4 (Capsule coating)
1
325 Spring
1
20~24(15~18)
159 Plug PT1/4 (Capsule coating)
1
325 Spring
1
7.8~9.8(5.8~7.2)
160 Plug PT1/16 (Capsule coating)
5
326 Spring
1
7.8~9.8(5.8~7.2)
160 Plug PT1/16 (Capsule coating)
5
326 Spring
1
161 O-ring
7
327 Spring
3
161 O-ring
7
327 Spring
3
162 O-ring
15
328 Spring
1
162 O-ring
15
328 Spring
1
163 O-ring
11
329 Spring
3
163 O-ring
11
329 Spring
3
164 O-ring
19
331 Spring seat
24
164 O-ring
19
331 Spring seat
24
333 Spacer bolt
12
169 O-ring
2
201 Cover
16~18(11~13)
16~18(11~13)
333 Spacer bolt
12
169 O-ring
2
5
336 Stopper
10
201 Cover
5
336 Stopper
10
202 Cover
4
339 Stopper
1
202 Cover
4
339 Stopper
1
203 Cover
1
340 Stopper
1
203 Cover
1
340 Stopper
1
204 Cover sub
1
511 Poppet
11
204 Cover sub
1
511 Poppet
11
205 Cover
7
512 Poppet
2
205 Cover
7
512 Poppet
2
206 Cover
1
514 Poppet
2
206 Cover
1
514 Poppet
2
1
515 Poppet
1
207
1
515 Poppet
1
209 Cover
1
517 Poppet
1
209 Cover
1
517 Poppet
1
211 Lock valve selector sub
2
518 Poppet
1
211 Lock valve selector sub
2
518 Poppet
1
212 Plate
1
521 Spring
11
212 Plate
1
521 Spring
11
213 Plate
1
522 Spring
2
213 Plate
1
522 Spring
2
216 Piston
1
523 Spring
1
216 Piston
1
523 Spring
1
261 O-ring
12
524 Spring
2
261 O-ring
12
524 Spring
2
264 O-ring
10
527 Spring
1
264 O-ring
10
527 Spring
1
266 O-ring
4
528 Spring
1
266 O-ring
4
528 Spring
1
25~34(18~25)
273 Socket bolt
40
98~120(72~89)
274 Socket bolt
4
98~120(72~89)
275 Socket bolt
4
25~34(18~25)
278 Socket bolt
5
301 Bom spool sub
1
302 Arm 1 spool
207
9.8~14(7.2~13)
Back pressure check valve cover
Loctite #262
9.8~14(7.2~13)
Back pressure check valve cover
13
25~34(18~25)
273 Socket bolt
40
552 Plug
2
98~120(72~89)
274 Socket bolt
4
230~260(170~192) 556 Plug
3
98~120(72~89)
275 Socket bolt
4
562 O-ring
2
25~34(18~25)
278 Socket bolt
5
69~78(51~58)
601 Main relief valve
1
301 Bom spool sub
1
1
69~78(51~58)
602 Over load relief valve
2
302 Arm 1 spool
303 Swing spool
1
69~78(51~58)
603 Over load relief valve
3
304 Bucket spool
1
69~78(51~58)
604 Plug assy for relief valve hole
305 Boom conflux spool
1
69~78(51~58)
306 Travel spool
2
98~120(72~89)
307 Travel straight spool
1
308 Arm 2 spool sub
230~260(170~192) 551 Plug 130~150(96~111)
Loctite #262
230~260(170~192) 551 Plug
13
552 Plug
2
230~260(170~192) 556 Plug
3
130~150(96~111)
562 O-ring
2
69~78(51~58)
601 Main relief valve
1
1
69~78(51~58)
602 Over load relief valve
2
303 Swing spool
1
69~78(51~58)
603 Over load relief valve
3
2
304 Bucket spool
1
69~78(51~58)
604 Plug assy for relief valve hole
2
605 Over load relief valve
1
305 Boom conflux spool
1
69~78(51~58)
605 Over load relief valve
1
606 By-pass cut valve
2
306 Travel spool
2
98~120(72~89)
606 By-pass cut valve
2
140~180(103~133) 973 Socket bolt
8
307 Travel straight spool
1
140~180(103~133) 973 Socket bolt
8
1
140~180(103~133) 974 Socket bolt
2
308 Arm 2 spool sub
1
140~180(103~133) 974 Socket bolt
2
309 P1 unload spool
1
977 Name plate
1
309 P1 unload spool
1
977 Name plate
1
310 P2 unload spool
1
978 Pakerrizing rivet
2
310 P2 unload spool
1
978 Pakerrizing rivet
2
311 Option spool
1
311 Option spool
1
33-86
33-86
33. UPPER STRUCTURE 33.2.2.2
PREPARATION FOR DISASSEMBLY
33. UPPER STRUCTURE 33.2.2.2
(1) General precautions
PREPARATION FOR DISASSEMBLY
(1) General precautions
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and reassembly in an especially clean location.
1) As all the hydraulic components are precisely machined, it is essential to carry out disassembly and reassembly in an especially clean location.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or sand.
2) When handling the control valve, take special care to prevent the entry of foreign matter, such as dust or sand.
3) Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm that each cap is in place and then clean the exterior of the assembly. Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
3) Cap each port of the control valve before removing the valve from the machine. Before disassembly, confirm that each cap is in place and then clean the exterior of the assembly. Use a workbench. Lay a clean sheet of paper or rubber mat over the workbench.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed spool, or the end cover. Handle the valve with care.
4) When carrying or moving the control valve, hold the body, and never put pressure on a lever, an exposed spool, or the end cover. Handle the valve with care.
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after disassembly and reassembly require hydraulic testing apparatus. For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or adjust. Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
5) Tests(for relief characteristics, leaks, overload valve setting, flow resistance, etc.) that are desired after disassembly and reassembly require hydraulic testing apparatus. For this reason, do not disassemble hydraulic units that you are capable of disassembling but cannot test or adjust. Prepare beforehand washing fluid, hydraulic oil, grease, etc. .
(2) Tools Prepare the following tools before disassembling the control valve. No.
Tools
Qâ&#x20AC;&#x2122;ty
a
Vise
b
Box end wrench
c
Allen wrench
d
Spanner
1
e
Loctite #262
1
Remarks
1
(2) Tools Prepare the following tools before disassembling the control valve. No.
Tools
Qâ&#x20AC;&#x2122;ty
a
Vise
1 of each 24mm, 27mm, 32mm size
b
Box end wrench
1 of each 24mm, 27mm, 32mm size
1 of each 5mm, 6mm, 10mm, 12mm, 14mm, 22mm size
c
Allen wrench
1 of each 5mm, 6mm, 10mm, 12mm, 14mm, 22mm size
d
Spanner
1
e
Loctite #262
1
32 mm
1
f
Spatula
1
f
Spatula
1
g
Pincers
1
g
Pincers
1
h
Adjustable wrench
1
h
Adjustable wrench
1
33.2.2.3
Remarks
DISASSEMBLY
33.2.2.3
32 mm
DISASSEMBLY
The figures in parentheses after part names in this manual represent those item numbers in the structural sectional drawing under Fig. 33-137 to Fig. 33-142.
The figures in parentheses after part names in this manual represent those item numbers in the structural sectional drawing under Fig. 33-137 to Fig. 33-142.
(1) Place the control valve on a work bench so as to locate back pressure check valve upwards.
(1) Place the control valve on a work bench so as to locate back pressure check valve upwards.
Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces.
Disassemble the valve in a clean place, and be careful not to damage flange surfaces or plate mounting surfaces. Fig. 33-143 Preparation for disassembly
33-87
Fig. 33-143 Preparation for disassembly
33-87
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.1
33.2.2.3.1
Disassembling P1 unload spool
(1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool.
Disassembling P1 unload spool
(1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for P1 unload spool.
Fig. 33-144 Removing spring cover (202) for P1 unload spring cover
Fig. 33-144 Removing spring cover (202) for P1 unload spring cover
(2) Draw out, from casing B (102), as a assy of P1 unload spool (309), spring seat (331), springs (327), (329), stopper (336) and bolt (333).
(2) Draw out, from casing B (102), as a assy of P1 unload spool (309), spring seat (331), springs (327), (329), stopper (336) and bolt (333).
When drawing out the spool assy, use care so as not to score casing B (102).
When drawing out the spool assy, use care so as not to score casing B (102).
Fig. 33-145 Drawing out P1 unload spool assy (309) (3) Fix the P1 unload spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (327), (329) and stopper (336) from P1 unload spool (309).
Fig. 33-145 Drawing out P1 unload spool assy (309) (3) Fix the P1 unload spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (327), (329) and stopper (336) from P1 unload spool (309).
Fig. 33-146 Disassembling P1 unload spool assy (309)
33-88
Fig. 33-146 Disassembling P1 unload spool assy (309)
33-88
33. UPPER STRUCTURE 33.2.2.3.2
Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.
33. UPPER STRUCTURE 33.2.2.3.2
Disassembling the travel spool (left travel and right travel)
(1) Loosen the socket bolts (273) and remove the spring cover (201) and the O-ring (261) for travel.
Fig. 33-147 Removing spring cover (201)
Fig. 33-147 Removing spring cover (201)
(2) Draw out the assy of travel spool (306), spring seat (331), springs (323), (324), stopper (336) and bolt (333) from casing A (101) or casing B (102).
(2) Draw out the assy of travel spool (306), spring seat (331), springs (323), (324), stopper (336) and bolt (333) from casing A (101) or casing B (102).
When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B (102).
When drawing out the spool assy, take care so as not to score the casing A (101) or the casing B (102).
Fig. 33-148 Drawing out travel spool (306) assy (3) Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (323), (324) and stopper (336) from travel spool (306).
Fig. 33-148 Drawing out travel spool (306) assy (3) Fix the travel spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (323), (324) and stopper (336) from travel spool (306).
Fig. 33-149 Removing right travel spring cover (201)
Fig. 33-149 Removing right travel spring cover (201)
Fig. 33-150 Disassembling travel spool (306) assy
Fig. 33-150 Disassembling travel spool (306) assy
33-89
33-89
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.3
33.2.2.3.3
Disassembling the boom conflux spool
Disassembling the boom conflux spool
(1) Loosen socket bolts (273) and remove spring cover (201) for boom conflux and O-ring (261).
(1) Loosen socket bolts (273) and remove spring cover (201) for boom conflux and O-ring (261).
(2) Draw out the assy of boom conflux spool (305), spring seat (331), springs (325), (326), stopper (339) and bolt (333) from casing A (101).
(2) Draw out the assy of boom conflux spool (305), spring seat (331), springs (325), (326), stopper (339) and bolt (333) from casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
Fig. 33-151 Removing spring cover (202)
(3) Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (326) and stopper (339) from boom conflux spool (305).
(3) Fix the boom conflux spool with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (325), (326) and stopper (339) from boom conflux spool (305).
Fig. 33-152 Drawing out boom conflux spool (305) assy 33.2.2.3.4
Fig. 33-151 Removing spring cover (202)
Disassembling the boom spool
Fig. 33-152 Drawing out boom conflux spool (305) assy 33.2.2.3.4
Disassembling the boom spool
(1) Loosen socket bolts (273) and remove spring cover (203) for boom spool and O-ring (261), (266).
(1) Loosen socket bolts (273) and remove spring cover (203) for boom spool and O-ring (261), (266).
(2) Draw out the assy of boom spool (301), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
(2) Draw out the assy of boom spool (301), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
When drawing out the spool assy, take care so as not to score casing B (102).
When drawing out the spool assy, take care so as not to score casing B (102).
Fig. 33-153 Removing spring cover (203)
33-90
Fig. 33-153 Removing spring cover (203)
33-90
33. UPPER STRUCTURE (3) Fix the boom spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.
33. UPPER STRUCTURE (3) Fix the boom spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from boom spool (301). Do not disassemble boom spool (301) further unless there is special reason.
Fig. 33-154 Drawing out boom spool (301) assy 33.2.2.3.5
Disassembling the swing spool
Fig. 33-154 Drawing out boom spool (301) assy 33.2.2.3.5
Disassembling the swing spool
(1) Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-ring (261), (266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason.
(1) Loosen the socket bolts (273) and remove the spring cover sub (204) and the O-ring (261), (266) for swing. Do not disassemble spring cover sub (204) further unless there is special reason.
(2) Draw out the assy of swing spool (303), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).
(2) Draw out the assy of swing spool (303), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
Fig. 33-155 Removing spring cover sub (204)
(3) Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).
When drawing out the spool assy, use care so as not to score casing A (101).
(3) Fix the swing spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from swing spool (303).
Fig. 33-156 Drawing out swing spool (303) assy
33-91
Fig. 33-155 Removing spring cover sub (204)
Fig. 33-156 Drawing out swing spool (303) assy
33-91
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.6
33.2.2.3.6
Disassembling bucket spool
(1) Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261).
Disassembling bucket spool
(1) Loosen socket bolts (273) and remove bucket spring cover (209) and O-ring (261).
Fig. 33-157 Removing spring cover (209)
Fig. 33-157 Removing spring cover (209)
(2) Draw out the assy of bucket spool (304), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
(2) Draw out the assy of bucket spool (304), spring seat (331), springs (321), (322), stopper (336) and bolt (333) from casing B (102).
When drawing out the spool assy, use care so as not to score casing B (102).
When drawing out the spool assy, use care so as not to score casing B (102).
Fig. 33-158 Drawing out bucket spool (304) assy
Fig. 33-158 Drawing out bucket spool (304) assy
(3) Fix the bucket spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from bucket spool (304).
(3) Fix the bucket spool assy with vise via a protective plate (aluminum plate, etc.) and remove bolt (333). Then separate spring seat (331), springs (321), (322) and stopper (336) from bucket spool (304).
(4) When needed to disassemble the spring cover of bucket spool, loosen plug (551) with casing B (102) installed. After removed cover (209) from casing B (102), remove plug (551) and then take out piston (216).
(4) When needed to disassemble the spring cover of bucket spool, loosen plug (551) with casing B (102) installed. After removed cover (209) from casing B (102), remove plug (551) and then take out piston (216). Fig. 33-159 Disassembling bucket spring cover (209)
33-92
Fig. 33-159 Disassembling bucket spring cover (209)
33-92
33. UPPER STRUCTURE 33.2.2.3.7
Disassembling arm 1 spool
33. UPPER STRUCTURE 33.2.2.3.7
Disassembling arm 1 spool
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool.
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 1 spool.
(2) Draw out the assembly which is consist of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).
(2) Draw out the assembly which is consist of arm 1 spool (302), spring seat (331), spring (321, 322), stopper (336) and bolt (333) from casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
Fig. 33-160 Removing arm 1 spring cover (201)
(3) Fix the arm 1 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 322) and stopper (336) from arm 1 spool (302).
(3) Fix the arm 1 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 322) and stopper (336) from arm 1 spool (302).
Fig. 33-161 Disassembling arm 1 spool (302) assy 33.2.2.3.8
Fig. 33-160 Removing arm 1 spring cover (201)
Disassembling arm 2 spool
Fig. 33-161 Disassembling arm 1 spool (302) assy 33.2.2.3.8
Disassembling arm 2 spool
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool.
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of arm 2 spool.
(2) Draw out the assembly which is consist of arm 2 spool (308), spring seat (331), spring (321, 328), stopper (340) and bolt (333) from casing B (102).
(2) Draw out the assembly which is consist of arm 2 spool (308), spring seat (331), spring (321, 328), stopper (340) and bolt (333) from casing B (102).
When drawing out the spool assy, use care so as not to score casing B (102).
Fig. 33-162 Removing arm 2 spring cover (201)
(3) Fix the arm 2 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 328) and stopper (340) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason.
When drawing out the spool assy, use care so as not to score casing B (102).
Fig. 33-162 Removing arm 2 spring cover (201)
(3) Fix the arm 2 spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (321, 328) and stopper (340) from arm 2 spool (308). Do not disassemble arm 2 spool (308) further unless there is special reason.
Fig. 33-163 Disassembling arm 2 spool (308) assy
33-93
Fig. 33-163 Disassembling arm 2 spool (308) assy
33-93
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.9
33.2.2.3.9
Disassembling option spool
Disassembling option spool
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool.
(1) Loosen socket bolts (273), and remove spring cover (201) and O-ring (261) of option spool.
(2) Draw out the assembly which is consist of option spool (311), spring seat (331), spring (323, 324), stopper (336) and bolt (333) from casing A (101).
(2) Draw out the assembly which is consist of option spool (311), spring seat (331), spring (323, 324), stopper (336) and bolt (333) from casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
Fig. 33-164 Removing option spring cover (201)
(3) Fix the option spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (323, 324) and stopper (336) from option spool (311).
Fig. 33-164 Removing option spring cover (201)
(3) Fix the option spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (323, 324) and stopper (336) from option spool (311).
Fig. 33-165 Drawing out option spool assy (311) 33.2.2.3.10
Disassembling travel straight spool
Fig. 33-165 Drawing out option spool assy (311) 33.2.2.3.10
Disassembling travel straight spool
(1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight.
(1) Loosen the socket bolts (273) and remove the spring cover (202) and the O-ring (261) for travel straight.
(2) Draw out the assy of travel straight spool (307), spring seat (331), springs (327), (329), stopper (336) and bolt (333) from casing B (102).
(2) Draw out the assy of travel straight spool (307), spring seat (331), springs (327), (329), stopper (336) and bolt (333) from casing B (102).
When drawing out the spool assy, take care so as not to score the casing B (102).
Fig. 33-166 Drawing out travel straight spool (307) assy
(3) Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (327, 329) and stopper (336) from travel straight spool (307).
When drawing out the spool assy, take care so as not to score the casing B (102).
Fig. 33-166 Drawing out travel straight spool (307) assy
(3) Fix the travel straight spool assy with vise via a protective plate (aluminum plate, etc.). Remove bolt (333) and separate spring seat (331), springs (327, 329) and stopper (336) from travel straight spool (307).
33-94
33-94
33. UPPER STRUCTURE 33.2.2.3.11
Disassembling P2 unload spool
33. UPPER STRUCTURE 33.2.2.3.11
Disassembling P2 unload spool
(1) Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261).
(1) Loosen socket bolts (273), and remove spring cover (202) of P2 unload spool and O-ring (261).
(2) Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (327, 329), stopper (336) and bolt (333) from casing A (101).
(2) Draw out the assembly which is consist of P2 unload spool (310), spring seat (331), spring (327, 329), stopper (336) and bolt (333) from casing A (101).
When drawing out the spool assy, use care so as not to score casing A (101).
Fig. 33-167 Removing P2 unload spring cover (202)
(3) Fix the P2 unload spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (327, 329) and stopper (336) from P2 unload spool (310).
When drawing out the spool assy, use care so as not to score casing A (101).
(3) Fix the P2 unload spool assy with vise via a protective plate (aluminum plate etc.) and remove bolt (333). Then remove spring seat (331), spring (327, 329) and stopper (336) from P2 unload spool (310).
Fig. 33-168 Drawing out P2 unload spool assy (310) 33.2.2.3.12
Fig. 33-167 Removing P2 unload spring cover (202)
Removing spool covers
Fig. 33-168 Drawing out P2 unload spool assy (310) 33.2.2.3.12
Removing spool covers
(1) Travel, boom, bucket, arm 1, arm 2 and option Loosen socket bolts (273) and remove spool cover (205) and O-ring (264).
(1) Travel, boom, bucket, arm 1, arm 2 and option Loosen socket bolts (273) and remove spool cover (205) and O-ring (264).
(2) Swing Loosen socket bolts (273) and remove spool cover (206) and O-ring (264), (266). Do not disassemble spool cover (206) further unless there is special reason.
(2) Swing Loosen socket bolts (273) and remove spool cover (206) and O-ring (264), (266). Do not disassemble spool cover (206) further unless there is special reason.
Fig. 33-169 Removing spool cover (205),(206)
33-95
Fig. 33-169 Removing spool cover (205),(206)
33-95
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.13
33.2.2.3.13
Removing relief valve and plug assy for relief valve hole
Removing relief valve and plug assy for relief valve hole
(1) Remove the main relief valve (601) and overload relief valve (602), (603) and (605) from the casing.
(1) Remove the main relief valve (601) and overload relief valve (602), (603) and (605) from the casing.
•
Distinguish overload relief valve between (602), (603) and (605) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting.
•
Distinguish overload relief valve between (602), (603) and (605) with a tag to prevent them from being confused during reassembly, as they are the same in appearance and shape but differ in pressure setting.
•
Regarding the disassembly of the relief valves themselves, do not disassemble it.
•
Regarding the disassembly of the relief valves themselves, do not disassemble it.
Fig. 33-170 Removing main relief valve (601)
Fig. 33-170 Removing main relief valve (601)
Fig. 33-171 Removing overload relief valve (602), (603) and (605)
Fig. 33-171 Removing overload relief valve (602), (603) and (605)
Fig. 33-172 Removing plug assy (604) for relief valve hole
Fig. 33-172 Removing plug assy (604) for relief valve hole
33-96
33-96
33. UPPER STRUCTURE 33.2.2.3.14
Removing by-pass cut valve
33. UPPER STRUCTURE 33.2.2.3.14
Removing by-pass cut valve
(1) Remove by-pass cut valve (606) from the casing.
(1) Remove by-pass cut valve (606) from the casing.
Remove the by-pass cut valve, giving particular attention to the poppet (606-201) and spring (606-202) which may be remained on the inside of casing.
Remove the by-pass cut valve, giving particular attention to the poppet (606-201) and spring (606-202) which may be remained on the inside of casing.
Fig. 33-173 Removing by-pass cut valve (606) 33.2.2.3.15
Removing lock valve selector valve sub
Fig. 33-173 Removing by-pass cut valve (606) 33.2.2.3.15
(1) Loosen socket bolt (211-171) and remove lock valve selector valve sub (211) from the casing. Further disassembly of the lock valve selector sub is not allowed.
Removing lock valve selector valve sub
(1) Loosen socket bolt (211-171) and remove lock valve selector valve sub (211) from the casing. Further disassembly of the lock valve selector sub is not allowed.
Fig. 33-174 Removing lock valve selector sub (211) 33.2.2.3.16
Removing back pressure check valve
Fig. 33-174 Removing lock valve selector sub (211) 33.2.2.3.16
(1) Loosen socket bolt (278) and remove back pressure check valve (207) from the casing.
Removing back pressure check valve
(1) Loosen socket bolt (278) and remove back pressure check valve (207) from the casing.
Fig. 33-175 Removing back pressure check valve cover (207)
33-97
Fig. 33-175 Removing back pressure check valve cover (207)
33-97
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(2) Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed.
(2) Remove springs (527), (528), boost check valve poppet sub (517) and by-pass check valve poppet (518) from the casing. The further disassembly of boost check valve poppet sub (517) is not allowed.
Replace control valve so that the spool cover face directs downward.
Replace control valve so that the spool cover face directs downward.
When replacing, take care so as not to score the spool cover.
When replacing, take care so as not to score the spool cover.
33.2.2.3.17
Fig. 33-176 Removing boost check valve sub (517) and by-pass check valve poppet (518)
Removing plate
33.2.2.3.17
Fig. 33-176 Removing boost check valve sub (517) and by-pass check valve poppet (518)
Removing plate
(1) Loosen socket bolts (274), (275) and remove plates (212), (213).
(1) Loosen socket bolts (274), (275) and remove plates (212), (213).
(2) After removing plates, remove all O-rings (162), (163) remained on the casing side.
(2) After removing plates, remove all O-rings (162), (163) remained on the casing side.
Fig. 33-177 Removing plate (212),(213)
33-98
Fig. 33-177 Removing plate (212),(213)
33-98
33. UPPER STRUCTURE 33.2.2.3.18
Removing check valve
33. UPPER STRUCTURE 33.2.2.3.18
Removing check valve
(1) Remove plugs of load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521).
(1) Remove plugs of load check valve, conflux check valve, etc. and then remove poppet (511) and spring (521).
(2) Load check valve on the swing section Remove plug (556) and then remove poppet (511) and spring (523).
(2) Load check valve on the swing section Remove plug (556) and then remove poppet (511) and spring (523).
The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts again.
The plug and spring in use differ from the above (1). Do not mix the parts when assembling parts again. Fig. 33-178 Removing plug (551),(556),(552)
(3) Load check valve on arm 2 section Remove plug (551) and then remove poppet (515) and spring (521).
The poppet in use differs from the above (1). Do not mix the parts when assembling parts again.
The poppet in use differs from the above (1). Do not mix the parts when assembling parts again.
(4) Lock valve Remove plug (556) and then remove poppet (514) and spring (524).
(4) Lock valve Remove plug (556) and then remove poppet (514) and spring (524). Fig. 33-179 Removing poppet (511),(512),(514),(515)
Fig. 33-179 Removing poppet (511),(512),(514),(515)
The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling parts again.
The plug, poppet and spring in use differ from the above (4). Do not mix the parts when assembling parts again.
(5) Main relief valve Remove plug (552) and then remove poppet (512) and spring (522).
(5) Main relief valve Remove plug (552) and then remove poppet (512) and spring (522).
The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling parts again.
The plug, poppet and spring in use differ from the above (5). Do not mix the parts when assembling parts again.
The plugs in which the procedure for disassembly is not included in the above procedure are usually used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.
The plugs in which the procedure for disassembly is not included in the above procedure are usually used to block auxiliary holes and holes caused by casting. Do not disassemble further if unnecessary.
33.2.2.3.19
33.2.2.3.19
Disassembling casing
Further disassembly of the casing is not allowed.
Fig. 33-178 Removing plug (551),(556),(552)
(3) Load check valve on arm 2 section Remove plug (551) and then remove poppet (515) and spring (521).
Disassembling casing
Further disassembly of the casing is not allowed.
33-99
33-99
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.3.20
33.2.2.3.20
Inspection after disassembly
Inspection after disassembly
Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet of paper or cloth for inspection.
Thoroughly clean all disassembled parts with wash oil, and dry them with jet air. Place each part on a clean sheet of paper or cloth for inspection.
(1) Control valve
(1) Control valve
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
1) Inspect the entire surface of each part for burrs, scratches, cuts, and other defects.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
2) Confirm that the O-ring groove surface of the casing or the block is free from foreign matter, dents or rust.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
3) If the check valve seat of the casing or the block has dents or damage on its surface, smooth it by lapping.
Take care not leave lapping compound behind in the casing or block.
Take care not leave lapping compound behind in the casing or block.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound.
4) Confirm that O-ring or the outer circumference of the sliding part of a manual spool is free from scratches, dents, and the like. Remove any small defects with an oil stone or lapping compound.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are free from foreign matter.
5) Manually confirm that all sliding and fitted parts move smoothly. Confirm that all grooves and passages are free from foreign matter.
6) Replace any broken or deformed spring with new one.
6) Replace any broken or deformed spring with new one.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
7) Of a relief valve malfunctions, repair it by following the relief valve disassembly and reassembly procedures.
8) Replace all O-ring with new ones.
8) Replace all O-ring with new ones.
(2) Relief valve
(2) Relief valve
1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact surface is even all over.
1) Make sure that the poppet and the seat surface at the tip of the seat are without fault and that the contact surface is even all over.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
2) Manually confirm that the main poppet slides smoothly onto and off the seat.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from defects such as scratches.
3) Confirm that the outer circumference of the main poppet and the inner circumference of its seat are free from defects such as scratches.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
4) Confirm that each spring is free from breakage, deformation, and excessive wear.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
5) Confirm that the orifices of the main poppet and its seat are not clogged.
6) Replace all O-rings with new ones. (Between casing and seal)
6) Replace all O-rings with new ones. (Between casing and seal)
33.2.2.4
REASSEMBLY
33.2.2.4
REASSEMBLY
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(1) Here, only the reassembly procedures are described. Regarding drawings, refer to the disassembly procedures.
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural sectional drawing. (Fig. 33-137 to Fig. 33-142)
(2) Figures in parentheses after part names in this instruction represent those item numbers in the structural sectional drawing. (Fig. 33-137 to Fig. 33-142)
(3) Precautions on reassembling O-ring
(3) Precautions on reassembling O-ring
1) Confirm that O-rings are free from defects caused by poor handling.
1) Confirm that O-rings are free from defects caused by poor handling.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
2) Apply thin coat of grease or hydraulic oil to O-rings and their mating parts.
3) Do not stretch O-rings to the extent that they become permanently set.
3) Do not stretch O-rings to the extent that they become permanently set.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks.
4) When installing O-rings, do not roll them into place. Twisted O-rings do not easily untwist by themselves after installation, and can cause oil leaks.
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards."
5) Use a torque wrench to tighten each attaching bolt. Tighten to the specified torque in "Maintenance Standards."
33-100
33-100
33. UPPER STRUCTURE 33.2.2.4.1
Installing check valve
33. UPPER STRUCTURE 33.2.2.4.1
Installing check valve
(1) Load check valve, conflux check valve, and so on Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (9 places)
(1) Load check valve, conflux check valve, and so on Attach poppet (511) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (9 places)
(2) Load check valve of swing section Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (1 place)
(2) Load check valve of swing section Attach poppet (511) and spring (523) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (1 place)
(3) Load check valve of arm 2 section Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (1 place)
(3) Load check valve of arm 2 section Attach poppet (515) and spring (521) in place, place O-ring (164) in plug (551) and tighten them to the specified torque. (1 place)
(4) Lock valve section Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (2 places)
(4) Lock valve section Attach poppet (514) and spring (524) in place, place O-ring (164) in plug (556) and tighten them to the specified torque. (2 places)
(5) Main relief valve section Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified torque. (2 places)
(5) Main relief valve section Attach poppet (512) and spring (522) in place, place O-ring (562) in plug (552) and tighten them to the specified torque. (2 places)
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar in shape.
Take care to prevent misassembling of parts and assembling position error because the parts in (1) to (5) are similar in shape.
33.2.2.4.2
33.2.2.4.2
Assembling plate
Assembling plate
(1) Place O-rings (162), (163) in casing.
(1) Place O-rings (162), (163) in casing.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
(2) Attach plates (212), (213) and tighten socket bolts (274), (275) to the specified torque.
Replace control valve so that this plate face directs downward.
Replace control valve so that this plate face directs downward.
33.2.2.4.3
33.2.2.4.3
Assembling back pressure check valve
Assembling back pressure check valve
(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(1) Attach boost check valve poppet sub (517), by-pass check valve poppet (518) and springs (527), (528).
(2) Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque.
(2) Attach O-rings (264), (266) in back pressure check valve cover, attach it to casing A (101) and tighten socket bolt (278) to the specified torque.
33.2.2.4.4
33.2.2.4.4
Assembling lock valve selector sub
Assembling lock valve selector sub
(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.
(1) Attach lock valve selector sub (211) to the casing and tighten socket bolt (211-171) to the specified torque.
33.2.2.4.5
33.2.2.4.5
Assembling by-pass cut valve
Assembling by-pass cut valve
(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.
(1) Attach by-pass cut valve (606) to casing and tighten it to the specified torque.
Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
Take care to prevent drop of poppet (606-201) and spring (606-202) when attaching by-pass cut valve.
33-101
33-101
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.4.6
33.2.2.4.6
Assembling relief valve and relief valve hole plug assembly
Assembling relief valve and relief valve hole plug assembly
(1) Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly (604) in respective place to the specified torque.
(1) Tighten main relief valve (601), port relief valves (602), (603), (605) and relief valve hole plug assembly (604) in respective place to the specified torque.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief valves (602), (603), (605) are similar in shape.
Assemble it giving attention to the label attached when disassembling to prevent mistake because the port relief valves (602), (603), (605) are similar in shape.
33.2.2.4.7
33.2.2.4.7
Assembling p2 unload spool
Assembling p2 unload spool
(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of P2 unload spool (310) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform P2 unload spool (310) because of careless over clamping.
•
Take care not to deform P2 unload spool (310) because of careless over clamping.
(2) Place P2 unload spool assembly in item (1) in casing A (101).
(2) Place P2 unload spool assembly in item (1) in casing A (101).
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place P2 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P2 unload spool assembly and tighten socket bolt (273) to the specified torque.
33.2.2.4.8
33.2.2.4.8
Assembling travel straight spool
Assembling travel straight spool
(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of travel straight spool (307) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform travel straight spool (307) because of careless over clamping.
•
Take care not to deform travel straight spool (307) because of careless over clamping.
(2) Place travel straight spool assembly in item (1) in casing B (102).
(2) Place travel straight spool assembly in item (1) in casing B (102).
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
Place travel straight spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of travel straight spool assembly, and tighten socket bolt (273) to the specified torque.
33-102
33-102
33. UPPER STRUCTURE 33.2.2.4.9
Assembling spool in option
33. UPPER STRUCTURE 33.2.2.4.9
Assembling spool in option
(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of spool in option (311) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform option spool (311) because of careless over clamping.
•
Take care not to deform option spool (311) because of careless over clamping.
(2) Place spool assembly in option in item (1) in casing A (101).
(2) Place spool assembly in option in item (1) in casing A (101).
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place option spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of spool assembly in option and tighten socket bolt (273) to the specified torque.
33.2.2.4.10
33.2.2.4.10
Assembling arm 2 spool
Assembling arm 2 spool
(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of arm 2 spool (308) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (328) and stopper (340) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform arm 2 spool (308) because of careless over clamping.
•
Take care not to deform arm 2 spool (308) because of careless over clamping.
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
(2) Place arm 2 spool assembly in option in item (1) in casing B (102).
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
Place arm 2 spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 2 spool assembly and tighten socket bolt (273) to the specified torque.
33.2.2.4.11
33.2.2.4.11
Assembling arm 1 spool
Assembling arm 1 spool
(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of arm 1 spool (302) with vise provided with protection plate (aluminum plate, etc.) and fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform arm 1 spool (302) because of careless over clamping.
•
Take care not to deform arm 1 spool (302) because of careless over clamping.
(2) Place arm 1 spool assembly in item (1) in casing A (101).
(2) Place arm 1 spool assembly in item (1) in casing A (101).
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place arm 1 spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of arm 1 spool assembly, and tighten socket bolt (273) to the specified torque.
33-103
33-103
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.4.12
33.2.2.4.12
Assembling bucket spool
Assembling bucket spool
(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of bucket spool (304) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform bucket spool (304) because of careless over clamping.
•
Take care not to deform bucket spool (304) because of careless over clamping.
(2) Place bucket spool assembly in item (1) in casing B (102).
(2) Place bucket spool assembly in item (1) in casing B (102).
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
Place bucket spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (209) with O-ring (261) attached to the spring side of bucket spool assembly and tighten socket bolt (273) to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
(4) Attach piston (216) to spring cover (209), place O-ring (164) in plug (551) and tighten to the specified torque.
33.2.2.4.13
33.2.2.4.13
Assembling swing spool
Assembling swing spool
(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of swing spool (303) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform swing spool (303) because of careless over clamping.
•
Take care not to deform swing spool (303) because of careless over clamping.
(2) Place swing spool assembly in item (1) in casing A (101).
(2) Place swing spool assembly in item (1) in casing A (101).
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place swing spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover sub (204) with O-rings (261), (266) attached to the spring side of swing spool assembly and tighten socket bolt (273) to the specified torque.
33-104
33-104
33. UPPER STRUCTURE 33.2.2.4.14
Assembling boom spool
33. UPPER STRUCTURE 33.2.2.4.14
Assembling boom spool
(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of boom spool (301) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (321), (322) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform boom spool (301) because of careless over clamping.
•
Take care not to deform boom spool (301) because of careless over clamping.
(2) Place boom spool assembly in item (1) in casing B (102).
(2) Place boom spool assembly in item (1) in casing B (102).
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
Place boom spool assembly in casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (203) with O-rings (261), (266) attached to the spring side of boom spool assembly and tighten socket bolt (273) to the specified torque.
33.2.2.4.15
33.2.2.4.15
Assembling boom conflux spool
Assembling boom conflux spool
(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325)(326) and stopper (339) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of boom conflux spool (305) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (325)(326) and stopper (339) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform boom conflux spool (305) because of careless over clamping.
•
Take care not to deform boom conflux spool (305) because of careless over clamping.
(2) Place boom conflux spool assembly in item (1) in casing A (101).
(2) Place boom conflux spool assembly in item (1) in casing A (101).
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place boom conflux spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of boom conflux spool assembly and tighten socket bolt (273) to the specified torque.
33.2.2.4.16
33.2.2.4.16
Assembling travel spool (travel right and left)
Assembling travel spool (travel right and left)
(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of travel spool (306) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (323), (324) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform travel spool (306) because of careless over clamping.
•
Take care not to deform travel spool (306) because of careless over clamping.
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
(2) Place travel spool assembly in item (1) in casing A (101) or casing B (102).
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
Place travel spool assembly in casing A (101) or casing B (102) carefully. Do not squeeze it into place.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (201) with O-ring (261) attached to the spring side of travel spool assembly and tighten socket bolt (273) to the specified torque.
33-105
33-105
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.4.17
33.2.2.4.17
Assembling P1 unload spool
Assembling P1 unload spool
(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
(1) Hold the mid section of P1 unload spool (309) with vise provided with protection plate (aluminum plate, etc.), fit spring seat (331), springs (327), (329) and stopper (336) and tighten bolt (333) to the specified torque.
•
Apply Loctite #262 when tightening bolt (333).
•
Apply Loctite #262 when tightening bolt (333).
•
Take care not to deform P1 unload spool (309) because of careless over clamping.
•
Take care not to deform P1 unload spool (309) because of careless over clamping.
(2) Place P1 unload spool assembly in item (1) in casing A (101).
(2) Place P1 unload spool assembly in item (1) in casing A (101).
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
Place P1 unload spool assembly in casing A (101) carefully. Do not squeeze it into place.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten socket bolt (273) to the specified torque.
(3) Attach spring cover (202) with O-ring (261) attached to the spring side of P1 unload spool assembly and tighten socket bolt (273) to the specified torque.
33.2.2.4.18
33.2.2.4.18
Assembling spool cover, and so on
Assembling spool cover, and so on
(1) Travel, boom, bucket, arm 1, arm 2, option Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(1) Travel, boom, bucket, arm 1, arm 2, option Place O-ring (264) in spool cover (205) and tighten socket bolt (273) to the specified torque.
(2) Swing Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
(2) Swing Place O-rings (264), (266) in spool cover (206) and tighten socket bolt (273) to the specified torque.
33-106
33-106
33. UPPER STRUCTURE 33.2.2.5 33.2.2.5.1
MAINTENANCE STANDARDS
33.2.2.5
Inspection of components
Part name Casing
Spool
33.2.2.5.1
Inspection item
Criterion and remedy
1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged, replace the casing.
Criterion and remedy
1) Look for scratches, rusting and corrosion. 1) If any of the following parts are damaged, replace the casing.
• Sealing and seating part of main or overload relief valve.
• Sealing and seating part of main or overload relief valve.
• Area of seating part or sliding part of poppet.
• Area of seating part or sliding part of poppet.
• Sealing part of plug.
• Sealing part of plug.
• Defects of other parts that seem to prevent normal function.
• Defects of other parts that seem to prevent normal function.
If spring is damaged, replace it.
Spool
2) Inspect the contact face of the valve seat. 2) If damaged, replace. 3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with new ones. (Between casing and seal)
1) If a detectable defect with your fingernail is found on the sliding part of the outer circumference, replace the spool.
2) Insert the spool in the casing bore, and move it while turning it.
2) If the spool damages the O-ring or does not move smoothly, repair or replace the spool. If spring is damaged, replace it.
1) Look for damage on the poppet and the spring.
2) If the poppet moves lightly without catching, it is normal.
1) Replace.
1) Look for scratches, galling, rusting and corrosion.
Poppet
1) If the seat of poppet or spring are damaged, correct or replace it.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace. breakage of the spring, spring seat, stopper, spacer bolt and cover.
33-107
Casing
Inspection item
• Area of sealing part that is in contact with O-ring.
2) If the spool damages the O-ring or does not move smoothly, repair or replace the spool.
1) Look for rust and damage on outer surface.
Part name
• Area of sealing part that is in contact with O-ring.
2) Insert the spool in the casing bore, and move it while turning it.
2) Insert the poppet in the casing, and move it.
Inspection of components
• Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied.
1) If a detectable defect with your fingernail is found on the sliding part of the outer circumference, replace the spool.
1) Look for damage on the poppet and the spring.
MAINTENANCE STANDARDS
• Sliding part of casing hole and spool, particularly the land, to which holding pressure is applied.
1) Look for scratches, galling, rusting and corrosion.
Poppet
Main relief valve Port relief valve By-pass cut valve
33. UPPER STRUCTURE
2) Insert the poppet in the casing, and move it.
1) If the seat of poppet or spring are damaged, correct or replace it. 2) If the poppet moves lightly without catching, it is normal.
Spring and related parts 1) Look for rust, corrosion, deformation, and 1) If damaged heavily, replace. breakage of the spring, spring seat, stopper, spacer bolt and cover. Main relief valve Port relief valve By-pass cut valve
1) Look for rust and damage on outer surface.
1) Replace.
2) Inspect the contact face of the valve seat. 2) If damaged, replace. 3) Inspect the O-ring, backup ring, and seal. 3) As a general rule, replace all parts with new ones. (Between casing and seal)
33-107
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.2.6
33.2.2.6
TROUBLESHOOTING
TROUBLESHOOTING
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and reassembly procedures in this manual.
(1) If an abnormal condition is noticed, check to see if the problem is with the control valve itself, one of the main pumps, the gear pump, or a circuit. To this end, you will need to measure pilot pressure, pump delivery pressure, load pressure, etc. If any part of the system is to be disassembled for inspection, follow the disassembly and reassembly procedures in this manual.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system is to be disassembled, take dust protection measures beforehand.
(2) Dust is the enemy of hydraulic components. Pay strict attention to protection from dust. If any part of the system is to be disassembled, take dust protection measures beforehand.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(3) Moving parts must be handled with care. If they are damaged, smooth the damage using an oil stone or the like.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
(4) Take care not to damage the contact face of O-rings. A damaged contact face will certainly cause oil leaks.
33.2.2.6.1
33.2.2.6.1
Control valve
Trouble 1. Travel does not occur. Slow to start up (or poor power). Slow response.
Cause
Remedy
1) Malfunctioning main relief valve. • Foreign matter between main poppet and seat.
1) Check travel relief valve pressure • Disassemble and clean. If damaged heavily, replace the assy as a unit. • Same as above.
• Foreign matter between poppet and seat. • Sticking main poppet.
• Correct sticking part with oil stone. • Replace spring. • Remove foreign matter.
• Broken or deformed spring. • Clogged main poppet throttle.
• Readjust, and tighten lock nut to specified torque.
• Loosened adjusting screw. 1) Malfunctioning travel straight valve. 2. Machine does not move straight during • Sticking spool. simultaneous operation of travel • Broken or deformed spring. and attachment. • Clogged small hole in spool. 2) Malfunctioning main relief valve.
33-108
Control valve
Trouble 1. Travel does not occur. Slow to start up (or poor power). Slow response.
Cause
Remedy
1) Malfunctioning main relief valve. • Foreign matter between main poppet and seat.
1) Check travel relief valve pressure • Disassemble and clean. If damaged heavily, replace the assy as a unit. • Same as above.
• Foreign matter between poppet and seat. • Sticking main poppet.
• Correct sticking part with oil stone. • Replace spring. • Remove foreign matter.
• Broken or deformed spring. • Clogged main poppet throttle.
• Readjust, and tighten lock nut to specified torque.
• Loosened adjusting screw. 1) Check pilot pressure. • Correct sticking part with oil stone. • Replace spring. • Remove foreign matter. 2) Remove main relief valve.
1) Malfunctioning travel straight valve. 2. Machine does not move straight during • Sticking spool. simultaneous operation of travel • Broken or deformed spring. and attachment. • Clogged small hole in spool. 2) Malfunctioning main relief valve.
33-108
1) Check pilot pressure. • Correct sticking part with oil stone. • Replace spring. • Remove foreign matter. 2) Remove main relief valve.
33. UPPER STRUCTURE Trouble
Cause
Remedy
1) Excessive clearance between casing and 1) Replace spool. 3. Excessive natural spool. falls of attachment under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure. when spool is in • Foreign matter between casing and • Disassemble, clean and smooth neutral. spool, or sticking spool. sticking part with oil stone.
33. UPPER STRUCTURE Trouble
Cause
Remedy
1) Excessive clearance between casing and 1) Replace spool. 3. Excessive natural spool. falls of attachment under its own weight 2) Spool is not completely in neutral position. 2) Check secondary pilot pressure. when spool is in • Foreign matter between casing and • Disassemble, clean and smooth neutral. spool, or sticking spool. sticking part with oil stone.
• Broken or deformed spring.
• Replace spring.
• Broken or deformed spring.
• Replace spring.
• Clogged pilot circuit.
• Remove foreign matter.
• Clogged pilot circuit.
• Remove foreign matter.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure. to item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2)) • Clean and check damage on seat surface. • Foreign matter between valve seat and casing.
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure. to item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2)) • Clean and check damage on seat surface. • Foreign matter between valve seat and casing.
4) Lock valve function is faulty. (Arm, boom)
4) Lock valve function is faulty. (Arm, boom)
4) Replace
• Foreign matter between poppet seat and casing.
• Disassemble, clean. • Correct stuck part with oil stone or replace.
• Poppet is stuck.
4) Replace
• Foreign matter between poppet seat and casing.
• Disassemble, clean. • Correct stuck part with oil stone or replace.
• Poppet is stuck.
• Replace spring. • Broken or deformed spring.
• Replace lock valve selector assy.
• Selector spool is stuck. 1) Malfunctioning load check valve. 4. When raising attachment, at first it • Foreign matter between poppet and drops. casing.
• Replace spring. • Broken or deformed spring. • Selector spool is stuck.
1) • Disassemble and clean. If heavily damaged, replace control valve.
1) Malfunctioning load check valve. 4. When raising attachment, at first it • Foreign matter between poppet and drops. casing.
• Correct sticking part with oil stone. • Replace spring.
• Broken or deformed spring.
• Broken or deformed spring. • Replace spool. • Disassemble and clean. • Correct stuck part with oil stone. • Replace spring. • Remove foreign matter.
• Disassemble and clean. If heavily damaged, replace control valve. • Replace spring.
• Sticking poppet.
1) Check secondary pilot pressure.
1)
• Correct sticking part with oil stone.
• Sticking poppet.
5. Bucket, boom, arm or 1) Malfunctioning main spool. swing does not • Excessive clearance between casing operate. and spool. Slow to start up (or • Foreign matter between casing and poor power).Slow spool. response. • Sticking spool.
• Replace lock valve selector assy.
5. Bucket, boom, arm or 1) Malfunctioning main spool. swing does not • Excessive clearance between casing operate. and spool. Slow to start up (or • Foreign matter between casing and poor power).Slow spool. response. • Sticking spool.
• Broken or deformed return spring.
• Broken or deformed return spring.
• Clogged pilot circuit.
• Clogged pilot circuit.
1) Check secondary pilot pressure. • Replace spool. • Disassemble and clean. • Correct stuck part with oil stone. • Replace spring. • Remove foreign matter.
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to item 1. 1) above. item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
2) Malfunctioning main relief valve. Refer to 2) Check main relief valve pressure. Refer to item 1. 1) above. item 1. 1) above. (See 33.2.2.3.20 (2)) (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure. (See 33.2.2.3.20 (2)) to item 1. 1) above. (See 33.2.2.3.20 (2))
3) Malfunctioning overload relief valve. Refer 3) Check overload relief valve pressure. (See 33.2.2.3.20 (2)) to item 1. 1) above. (See 33.2.2.3.20 (2))
33-109
33-109
33. UPPER STRUCTURE
33. UPPER STRUCTURE
Trouble 6. Boom conflux does not operate.
Cause
Remedy
1) Malfunctioning conflux valve. • Excessive clearance between casing and spool.
• Replace spool.
• Foreign matter between casing and spool.
• Correct stuck part with oil stone.
• Sticking spool.
33.2.2.6.2
1) Measure pilot pressure.
6. Boom conflux does not operate.
• Disassemble and clean. • Replace spring.
Cause
Remedy
1) Malfunctioning conflux valve.
• Replace spool.
• Foreign matter between casing and spool.
• Correct stuck part with oil stone.
• Broken or deformed return spring.
• Clogged pilot circuit.
• Clogged pilot circuit.
Cause
Remedy
• Disassemble and clean. • Replace spring. • Remove foreign matter.
• Broken or deformed return spring.
33.2.2.6.2
1) Measure pilot pressure.
• Excessive clearance between casing and spool.
• Sticking spool.
• Remove foreign matter.
Relief valve
Trouble
Trouble
Relief valve
Trouble
Cause
Remedy
1.No pressure rise.
Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet. and valve is open, or there is foreign matter Confirm that each component slides smoothly. on valve seat. If failure is found, replace it in an assembly.
1.No pressure rise.
Main or pilot poppet of relief valve is sticking Check for foreign matter on each poppet. and valve is open, or there is foreign matter Confirm that each component slides smoothly. on valve seat. If failure is found, replace it in an assembly.
2. Unstable relief pressure.
Main or pilot poppet of relief valve seat is damaged.
If failure is found, replace it an assembly.
2. Unstable relief pressure.
Main or pilot poppet of relief valve seat is damaged.
If failure is found, replace it an assembly.
3. Incorrect relief pressure setting.
1) Wear due to foreign matter.
1) Replace damaged assembly
1) Wear due to foreign matter.
1) Replace damaged assembly
2) Loosened locknut or adjusting screw.
2) Adjust pressure.
3. Incorrect relief pressure setting.
2) Loosened locknut or adjusting screw.
2) Adjust pressure.
4. Oil leak.
Confirm that each component operates smoothly. Replace damaged or worn component.
1) Damaged seat. Damaged O-ring.
1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches, scores, or foreign matter present before reassembling. If failure is found, replace it an assembly.
33-110
4. Oil leak.
Confirm that each component operates smoothly. Replace damaged or worn component.
1) Damaged seat. Damaged O-ring.
1) If failure is found, replace it an assembly.
2) Sticking component due to foreign matter. 2) Confirm that there are no scratches, scores, or foreign matter present before reassembling. If failure is found, replace it an assembly.
33-110
33. UPPER STRUCTURE 33.2.3
PILOT VALVE (ATT)
33.2.3.1
33.2.3
CROSS-SECTIONAL VIEW
PILOT VALVE (ATT)
33.2.3.1
212
CROSS-SECTIONAL VIEW
312
312
302
302
Apply grease on rotating and 301 sliding sections. Be careful the assembling direction
501 Apply grease on top section
212
* 246
* 218-2 211
214
213
151
* 246
* 218-2
Apply grease on rotating and 301 sliding sections. Be careful the assembling direction
501 Apply grease on top section
213
151
211
214
216-2
* 218-1 216-1
216-2
* 218-1 216-1
241-2
241-1
241-2
241-1
201-2 Secondary pressure adjusting shim Designed value t=0.4 (0.061 in), 1 pc
33. UPPER STRUCTURE
201-2
201-1
217 101
Secondary pressure adjusting shim Designed value t=0.4 (0.061 in), 1 pc
221
PORT
201-1
217 101
221
PORT
2,4
PORT
1,3
PORT
2,4
Fig. 33-180 Pilot valve (For ATT)
1,3
Fig. 33-180 Pilot valve (For ATT) Apply loctite #277 to areas marked
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Apply loctite #277 to areas marked Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
101 Casing
1
*218-1 Seat
2
101 Casing
1
*218-1 Seat
2
151 Plate
1
*218-2 Seat
2
151 Plate
1
*218-2 Seat
2
201-1 Spool
2
221 Spring
4
201-1 Spool
2
221 Spring
4
201-2 Spool
2
241-1 Spring
2
201-2 Spool
2
241-1 Spring
2
211 Plug
4
241-2 Spring
2
211 Plug
4
241-2 Spring
2
212 Push rod
4
*246 Spring
4
212 Push rod
4
*246 Spring
4
213 Seal
4
301 Joint : M14
1
213 Seal
4
301 Joint : M14
1
214 O-ring ; 1B P20
4
302 Circular plate
1
214 O-ring ; 1B P20
4
302 Circular plate
1
312 Adjust nut : M14
1
216-1 Spring seat
2
312 Adjust nut : M14
1
501 Boots
1
216-2 Spring seat
2
501 Boots
1
216-1 Spring seat
2
216-2 Spring seat
2
217 Washer 2 (Shim)
47.1 (35)
68.6 (51)
4
Note) The parts marked * might not be equipped depending on valve type.
33-111
217 Washer 2 (Shim)
47.1 (35)
68.6 (51)
4
Note) The parts marked * might not be equipped depending on valve type.
33-111
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.3.2
33.2.3.2
DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with kerosine. P port : PF1/4 1~4 and T port : PF3/8
DISASSEMBLY
(1) Plug each port of pilot valve, and clean it with kerosine. P port : PF1/4 1~4 and T port : PF3/8
501
(2) Fix pilot valve with vise via a protective plate (Alminum plate etc.), and remove boots (501).
501
(2) Fix pilot valve with vise via a protective plate (Alminum plate etc.), and remove boots (501).
Fig. 33-181 Removing boot (501) (3) Remove adjusting nut (312) applying spanners to adjusting nut (312) and circular plate (302).
Fig. 33-181 Removing boot (501) (3) Remove adjusting nut (312) applying spanners to adjusting nut (312) and circular plate (302).
312
: 22mm, 32mm
312
: 22mm, 32mm
302
302
Fig. 33-182 Removing adjusting nut (312) (4) Remove circular plate (302)
302
: 32mm
33-112
Fig. 33-182 Removing adjusting nut (312) (4) Remove circular plate (302)
302
: 32mm
Fig. 33-183 Removing circular plate (302)
Fig. 33-183 Removing circular plate (302)
Fig. 33-184 Circular plate is removed
Fig. 33-184 Circular plate is removed
33-112
33. UPPER STRUCTURE
33. UPPER STRUCTURE
Fig. 33-185 Installing Jig A (5) Turn joint (301) in counterclockwise with Jig A to remove. Jig A : See page 1-120.
Fig. 33-185 Installing Jig A (5) Turn joint (301) in counterclockwise with Jig A to remove. Jig A : See page 1-120.
: 24mm
: 24mm
301 When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out of plate (151), plug (211) and push rod (212). Remove joint (301) pressing plate (151) downward with two fingers.
301
Fig. 33-186 Removing joint (301)
(6) Remove plate (151)
When the force of return springs (221) is strong, never loosen joint (301). If loosened, it might result in jumping out of plate (151), plug (211) and push rod (212). Remove joint (301) pressing plate (151) downward with two fingers.
Fig. 33-186 Removing joint (301)
(6) Remove plate (151)
151
• When the force of return springs (221) are strong, press plate to let it come up slowly.
151
• When the force of return springs (221) are strong, press plate to let it come up slowly.
Fig. 33-187 Removing plate (151) • When the force of return springs (221) are weak, plug is left in casing (101) due to sliding resistance of O-ring (214).
Fig. 33-187 Removing plate (151) • When the force of return springs (221) are weak, plug is left in casing (101) due to sliding resistance of O-ring (214).
Pull plug (211) out with a driver.
Pull plug (211) out with a driver.
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is completely released.
211
To prevent personal injury, plug (211) must be removed slowly and evenly until the return spring (221) force is completely released.
Fig. 33-188 Removing plug (211)
33-113
211 Fig. 33-188 Removing plug (211)
33-113
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(7) Remove push rod (212), plug (211), pressure reducing valve assy (spool), return springs (221) from casing (101).
(7) Remove push rod (212), plug (211), pressure reducing valve assy (spool), return springs (221) from casing (101).
212
212
211
211 221
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
221
Record combination of port holes on casing and the pulled out parts. The stroke differs according to direction.
101
101
Fig. 33-189 Removing push rod, plug, pressure reducing valve and spring (8) Push springs (241-1), (241-2) in the range of 7mm (0.276in) that the movement of spring seats (2161), (216-2) and shift the seats (216) in a side direction, and remove spools (201-1), (201-2) through the larger hole of seat.
(8) Push springs (241-1), (241-2) in the range of 7mm (0.276in) that the movement of spring seats (2161), (216-2) and shift the seats (216) in a side direction, and remove spools (201-1), (201-2) through the larger hole of seat.
216-1 216-2
Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4)
201-1 201-2 Fig. 33-190 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (2161), (216-2), spring (241-1), (241-2) and washer (217).
241-1 241-2
Fig. 33-189 Removing push rod, plug, pressure reducing valve and spring
216-1 216-2
216-1 216-2
Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4)
201-1 201-2 Fig. 33-190 Removing spool (201)
(9) Remove spool (201-1), (201-2), spring seats (2161), (216-2), spring (241-1), (241-2) and washer (217).
241-1 241-2
217
217
201-1 201-2
201-1 201-2
Fig. 33-191 Disassembling pressure reducing valve (10)Remove spring (*246), spring seat (*218-1), (*2182) from push rod (212).
*218-1 *218-2
216-1 216-2
*246
Fig. 33-191 Disassembling pressure reducing valve (10)Remove spring (*246), spring seat (*218-1), (*2182) from push rod (212).
214
The parts marked * might not be equipped depending on valve type.
*218-1 *218-2
*246
214
The parts marked * might not be equipped depending on valve type.
212
212
211
211
Fig. 33-192 Disassembling push rod
33-114
Fig. 33-192 Disassembling push rod
33-114
33. UPPER STRUCTURE
33. UPPER STRUCTURE (11)Pull out push rod (212) from plug (211).
(11)Pull out push rod (212) from plug (211).
(12)Remove O-ring (214) from plug (211).
(12)Remove O-ring (214) from plug (211).
212
212
Fig. 33-193 Removing push rod (212)
Fig. 33-193 Removing push rod (212) (13)Remove inside seal (213) from plug (211) with small driver.
(13)Remove inside seal (213) from plug (211) with small driver.
213
213
Fig. 33-194 Removing seal (213)
Fig. 33-194 Removing seal (213) 33.2.3.3
33.2.3.3
CLEANING PARTS
CLEANING PARTS
(1) Clean parts with wash oil roughly.
(1) Clean parts with wash oil roughly.
(2) Clean parts with wash oil completely.
(2) Clean parts with wash oil completely.
(3) Dry parts by swabbing clean rag.
(3) Dry parts by swabbing clean rag.
(4) Apply rust preventives on parts.
(4) Apply rust preventives on parts.
33.2.3.4
33.2.3.4
ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring seats (216-1), (216-2) to spool (201-1), (201-2).
201-1
241-1
201-2
241-2
216-1 216-2
ASSEMBLING
(1) Fit washer 2 (217), springs (241-1), (241-2), spring seats (216-1), (216-2) to spool (201-1), (201-2).
33-115
241-1
201-2
241-2
216-1 216-2
217
217 Fig. 33-195 Assembling pressure reducing valve
201-1
Fig. 33-195 Assembling pressure reducing valve
33-115
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(2) Push spring (241-1), (241-2) in the range of that the movement of spring seats (216-1), (216-2) in a side direction, and install spools (201-1) through the larger hole of spring seat. (See Fig. 33-190)
(2) Push spring (241-1), (241-2) in the range of that the movement of spring seats (216-1), (216-2) in a side direction, and install spools (201-1) through the larger hole of spring seat. (See Fig. 33-190)
216-1 216-2
Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4)
216-1 216-2
Never push down spring seat (216-1) in 7mm (0.276in) or more. (For port 1,3) Never push down spring seat (216-2) in 9.4mm (0.370in) or more. (For port 2,4)
201-1 201-2
201-1 201-2
Fig. 33-196 Installing spools (201-1), (201-2) (3) Place spring (221) into ports 1,3 of casing (101), and then install pressure reducing valve assy in it. Place springs (221) into ports 2,4 and install it.
PRESSURE REDUCING VALVE ASSY
Fig. 33-196 Installing spools (201-1), (201-2) (3) Place spring (221) into ports 1,3 of casing (101), and then install pressure reducing valve assy in it. Place springs (221) into ports 2,4 and install it.
PRESSURE REDUCING VALVE ASSY
221 Install the removed respective assy into respective holes.
221
101
Install the removed respective assy into respective holes.
101
Fig. 33-197 Installing pressure reducing valve assy (4) Fit O-ring (214) and seal (213) into plug (211).
(4) Fit O-ring (214) and seal (213) into plug (211).
211
â&#x20AC;˘ Apply hydraulic oil on surface of push rod.
SEAL (213)
Fig. 33-197 Installing pressure reducing valve assy
213
214
PLUG (211)
SEAL (213)
213
214
PLUG (211)
-RING (214) PUSH ROD (212)
211
â&#x20AC;˘ Apply hydraulic oil on surface of push rod.
-RING (214) PUSH ROD (212)
Apply hydraulic oil
For the assembling direction of seal (213).
Fig. 33-198 Installing O-ring (214) and seal (213)
Apply hydraulic oil
For the assembling direction of seal (213).
Fig. 33-198 Installing O-ring (214) and seal (213)
(5) Insert push rod (212) in plug (211) and install spring (*246) and spring seat (*218-1) to push rod (212) on port 1,3 side. And install spring seat (*218-2) to push rod on port 2,4 side.
(5) Insert push rod (212) in plug (211) and install spring (*246) and spring seat (*218-1) to push rod (212) on port 1,3 side. And install spring seat (*218-2) to push rod on port 2,4 side.
The parts marked * might not be equipped depending on valve type.
The parts marked * might not be equipped depending on valve type.
212
211
246
218-1
Fig. 33-199 Assembling push rod, spring (246) and seat (218)
33-116
212
211
246
218-1
Fig. 33-199 Assembling push rod, spring (246) and seat (218)
33-116
33. UPPER STRUCTURE (6) Fit plug (211) assy to casing (101).
33. UPPER STRUCTURE (6) Fit plug (211) assy to casing (101).
1) When the force of spring (211) is weak, it stops at the position where it is pushed in by the sliding resistance of O-ring (214).
1) When the force of spring (211) is weak, it stops at the position where it is pushed in by the sliding resistance of O-ring (214).
101
211
101
Fig. 33-200 Installing plug assy 2) When the force of spring (221) is strong, attach plate (151) and press 4 push rods by hand at the same time, and tighten joint (301) temporarily.
211
Fig. 33-200 Installing plug assy 2) When the force of spring (221) is strong, attach plate (151) and press 4 push rods by hand at the same time, and tighten joint (301) temporarily.
301
• Install spool (201) straight and evenly into the hole of casing (101).
• Install spool (201) straight and evenly into the hole of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
• Take care so that plug (211) and plate (151) do not jump out of casing (101).
301
151
151
Fig. 33-201 Installing plug assy and plate (151) (7) Install joint (301) on casing (101) with jig A securely. Jig A : See page 1-120. Tightening torque : 47.1 N•m (35±2.2 lbf•ft)
Fig. 33-201 Installing plug assy and plate (151) (7) Install joint (301) on casing (101) with jig A securely. Jig A : See page 1-120. Tightening torque : 47.1 N•m (35±2.2 lbf•ft)
101
101
A
Fig. 33-202 Installing joint (301)
33-117
Fig. 33-202 Installing joint (301)
33-117
A
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(8) Install circular plate (302) to joint (301)
(8) Install circular plate (302) to joint (301)
•
Screw it in until it comes in contact with 4 push rods (212) equally.
•
The exceeding of screw in may cause malfunction of machine.
(9) Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular plate returning. : 32mm
312
302
Fig. 33-203 Installing circular plate (302)
: 22mm
•
Screw it in until it comes in contact with 4 push rods (212) equally.
•
The exceeding of screw in may cause malfunction of machine.
(9) Screw adjusting nut (312) in until it touches circular plate (302), and tighten it applying spanner to stop circular plate returning. : 32mm
312
302
Fig. 33-203 Installing circular plate (302)
: 22mm
• Apply Loctite #277 to threads of joint. Tightening torque : 68.6 N•m (51 lbf•ft)
• Apply Loctite #277 to threads of joint. Tightening torque : 68.6 N•m (51 lbf•ft)
(10)Apply heat-resisting grease to joint (301) rotating section and the top of push rod (212).
(10)Apply heat-resisting grease to joint (301) rotating section and the top of push rod (212). GREASE
(11)Cover it with boots.
GREASE
(11)Cover it with boots.
(12)Spray rust preventives through each port and attach plug respectively.
(12)Spray rust preventives through each port and attach plug respectively.
212
301
212
Fig. 33-204 Applying grease to joint section and push rod
33-118
301
Fig. 33-204 Applying grease to joint section and push rod
33-118
33. UPPER STRUCTURE 33.2.3.5
MAINTENANCE STANDARDS
Check item
33. UPPER STRUCTURE 33.2.3.5
Standard
Remarks
MAINTENANCE STANDARDS
Check item
Standard
Remarks
Leakage
When leakage quantity reaches to 1000cc/ min. or more where handle is set in neutral position, Conditions or to 2000cc/min. or more in operation, replace Primary pressure 2.94 MPa (426 psi) spool with new one. Hydraulic oil viscosity 23 cSt If leaked, even if the spool is replaced, replace pilot valve assy with new one.
Leakage
When leakage quantity reaches to 1000cc/ min. or more where handle is set in neutral position, Conditions or to 2000cc/min. or more in operation, replace Primary pressure 2.94 MPa (426 psi) spool with new one. Hydraulic oil viscosity 23 cSt If leaked, even if the spool is replaced, replace pilot valve assy with new one.
Spool
When the wear of sliding section is 10 more This condition may be the same as the than the that of non sliding section, replace it above. with new one.
Spool
When the wear of sliding section is 10 more This condition may be the same as the than the that of non sliding section, replace it above. with new one.
Push rod
When the wear of top is 1mm (0.04in) or more, replace it with new one.
Push rod
When the wear of top is 1mm (0.04in) or more, replace it with new one.
When looseness of 2mm (0.08in) or more on In case of the looseness due to the Looseness of control circular plate (302) on control section and joint loosening on tightening section, adjust section (301) due to wear is pro- duced, replace section it. them with new ones.
When looseness of 2mm (0.08in) or more on In case of the looseness due to the Looseness of control circular plate (302) on control section and joint loosening on tightening section, adjust section (301) due to wear is pro- duced, replace section it. them with new ones.
When trouble such as noise, hunting, drop of primary pressure, etc. has occurred in operation, and it does not restore after taking Stability of operation corrective action according to below 33.2.3.6 ( TROUBLESHOOTING), replace pilot valve assy with new one.
When trouble such as noise, hunting, drop of primary pressure, etc. has occurred in operation, and it does not restore after taking Stability of operation corrective action according to below 33.2.3.6 ( TROUBLESHOOTING), replace pilot valve assy with new one.
•
O-ring, etc. should be replaced with new one at every disassembling.
•
O-ring, etc. should be replaced with new one at every disassembling.
•
If socket bolt (125) was loosened, seal washer (121) should be replaced.
•
If socket bolt (125) was loosened, seal washer (121) should be replaced.
33.2.3.6
TROUBLESHOOTING
33.2.3.6
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer to the estimated causes and corrective actions. The following table explains general phenomenon, estimated causes and corrective actions. However, most machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore corrective action other than those described in this table is often required. The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and causes. Trouble
Cause
Remarks
1) Primary pressure is insufficient.
Secondary pressure does not rise .
Secondary pressure is unstable. Secondary pressure is high
It is very difficult to find defective section. The following table explains the several estimated causes. For repair, refer to the estimated causes and corrective actions. The following table explains general phenomenon, estimated causes and corrective actions. However, most machine problems are not caused by the failure of only one part, but involve relations with other parts. Therefore corrective action other than those described in this table is often required. The following table does not cover causes and corrective actions for all the troubles. So it may be necessary to perform further investigation of troubles and causes. Trouble
1) Secure primary pressure.
2) Secondary pressure springs (241) are 2) Replace with new ones. broken or fatigued. 3) Clearance between spool (201) and cas-ing (101 ) is abnormally large.
3) Replace spool (201).
4) Handle has a looseness.
4) Disassembly and reassembly or replace handle section.
1) Sliding parts are caught.
1) Repair the unsmoothed section.
2) Tank line pressure varies.
2) Bring pressure directly to oil tank.
3) Air has mixed into pipeline.
3) Bleed air by operating it several times.
1) Tank line pressure is high.
1) Bring pressure directly to oil tank.
2) Sliding parts are caught.
2) Correct.
33-119
TROUBLESHOOTING
Cause
Remarks
1) Primary pressure is insufficient.
Secondary pressure does not rise .
Secondary pressure is unstable. Secondary pressure is high
1) Secure primary pressure.
2) Secondary pressure springs (241) are 2) Replace with new ones. broken or fatigued. 3) Clearance between spool (201) and cas-ing (101 ) is abnormally large.
3) Replace spool (201).
4) Handle has a looseness.
4) Disassembly and reassembly or replace handle section.
1) Sliding parts are caught.
1) Repair the unsmoothed section.
2) Tank line pressure varies.
2) Bring pressure directly to oil tank.
3) Air has mixed into pipeline.
3) Bleed air by operating it several times.
1) Tank line pressure is high.
1) Bring pressure directly to oil tank.
2) Sliding parts are caught.
2) Correct.
33-119
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.3.7
33.2.3.7
JIG
(1) Jig for removing and installing joint (301)
JIG
(1) Jig for removing and installing joint (301)
(1)
Material ; SCM415 (N) Carburizing and Quenching
(2)
(1)
Material ; SCM415 (N) Carburizing and Quenching
BUSHING
(2)
Material ; S45C
BUSHING
Material ; S45C
SECTION AA
A
SECTION AA
A
A
Installing condition on joint
* (1) and (2) are tight fitted
A
Installing condition on joint
* (1) and (2) are tight fitted
Sectional drawing of jig
Sectional drawing of jig
Material ; SCM415 (N) Carburizing and Quenching Q'ty ; 2
Material ; SCM415 (N) Carburizing and Quenching Q'ty ; 2
Detail of bushing
33-120
Detail of bushing
33-120
33. UPPER STRUCTURE 33.2.4
PILOT VALVE (FOR TRAVEL)
33.2.4.1
33. UPPER STRUCTURE 33.2.4
CONSTRUCTION
PILOT VALVE (FOR TRAVEL)
33.2.4.1 T=Tightening torgue N.m (lbf.ft)
CONSTRUCTION T=Tightening torgue N.m (lbf.ft)
12-o
12-o
12-o
5
12-o
7-h
12-o 12-y
12-y 12-x
12-x
5
7-h
12-o 12-y
12-y 12-x
12-x
13 6
8
f d Loctite 262 g T=3 g
13 6
8
f d Loctite 262 g T=3 g
10
q
T=5 (3.7)
14 r
11
15
7-k T=1.2 (0.9) 7-h
15
7-j
u 17
t
r
Loctite 262 r
z
w'
7-k T=1.2 (0.9) 7-h
u t T=4 (3) 14
Parts
5
Rubber boots
6
Foot pedal (Switch plate)
Q’ty 2 (2)
7-j
No.
17
No.
12-x Seal ø14u20u3
6
5
Rubber boots
12-y Wiper ring
6
6
Foot pedal (Switch plate)
Damper spring
4
6-f Regulation screw M8u28
4
14
Check valve kit
(2)
4 (1)
14-q Plug M8
2
14-r Ball M6, 35
2
7-h Plate
1
7-i
Capscrew M10u20
2
15-u Plug M6
7-j
Shaft
2
15-t Orifice M6, ø0.6
7-k Set screw M4u10
2
15
17
Orifice
21 21 T=3~5 (2.2~3.7)
4 4
Q’ty 2 (2)
No.
Parts
12-x Seal ø14u20u3
6 6
6-d Switch plate
2
13
Damper spring
4
6-f Regulation screw M8u28
4
14
Check valve kit
(2)
6-g Set screw M5u8 7
Retaining plate kit
4 (1)
14-q Plug M8
2
14-r Ball M6, 35
2
7-h Plate
1
7-i
Capscrew M10u20
2
15-u Plug M6
7-j
Shaft
2
15-t Orifice M6, ø0.6
8
Flange kit
4
2
10
Control spool
4
17-r Ball M6, 35
2
11
Return spring
4
17-z Orifice M5, ø0.8
4
12
Damper flange kit
Control spool
4
17-r Ball M6, 35
11
Return spring
4
17-z Orifice M5, ø0.8
12
Damper flange kit
21
4
33-121
Plug
12-o Damper plunger ø14
2
(4)
17
Orifice
2
10
7-k Set screw M4u10
15
17-w’ Shuttle valve & orifice
4
Q’ty
12-y Wiper ring
(2)
Flange kit
12-o Damper plunger ø14
z
Shuttle valve kit
8
(4)
(4)
Parts
(4) 4 4
Shuttle valve kit
(2)
17-w’ Shuttle valve & orifice
2
21
4
33-121
Plug
q 21
Fig. 33-205 Exploded view of pilot valve Q’ty
u t T=4 (3) 14 T=5 (3.7)
r
13
Retaining plate kit
r
21
Loctite 262
T=3~5 (2.2~3.7)
Parts
11
15
t
w'
2
7
u
21
6-d Switch plate 6-g Set screw M5u8
15
q
Fig. 33-205 Exploded view of pilot valve No.
r
7-i T=30 (22)
21
21
14
u t T=4 (3) 15
T=5 (3.7)
21
q
T=5 (3.7)
u t T=4 (3) 15
7-i T=30 (22)
10
2 2 4
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.4.2
33.2.4.2
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
(1) Boot replacement
(1) Boot replacement
The pilot control unit does not need to be removed from the machine to perform this operation.
The pilot control unit does not need to be removed from the machine to perform this operation.
1) Remove both faulty boots. (using a flat screw driver if necessary)
1) Remove both faulty boots. (using a flat screw driver if necessary)
2) Replace both boots with a new one.
2) Replace both boots with a new one.
* Reassembly :
* Reassembly :
•
First fit the lower part of the rubber boot on the retaining plate between the 2 switch plates
•
First fit the lower part of the rubber boot on the retaining plate between the 2 switch plates
•
Then put the lower part in the external groove of the retaining plate
•
Then put the lower part in the external groove of the retaining plate
•
Finish by fitting the upper part of the rubber boot on the switch plate.
•
Finish by fitting the upper part of the rubber boot on the switch plate.
Fig. 33-206 (2) Switch plate removal
Fig. 33-206 (2) Switch plate removal
1) Remove :
1) Remove :
•
The pilot control unit from the machine.
•
The pilot control unit from the machine.
•
Both rubber boots (See 33.2.4.2 (1))
•
Both rubber boots (See 33.2.4.2 (1))
2) Remove the screw locking the axis using a 2mm socket wrench. (See Fig. 33-207 No.1)
2) Remove the screw locking the axis using a 2mm socket wrench. (See Fig. 33-207 No.1)
* Reassembly :
* Reassembly :
•
Apply a droplet of Loctite #262 on the locking screw thread.
•
Apply a droplet of Loctite #262 on the locking screw thread.
•
Torque :1.2 N•m (0.89 lbf•ft)
•
Torque :1.2 N•m (0.89 lbf•ft)
3) Fit a M3 screw on the switch plate axis in order to remove it (Using pliers if necessary). (See Fig. 33-207 No.2)
3) Fit a M3 screw on the switch plate axis in order to remove it (Using pliers if necessary). (See Fig. 33-207 No.2)
* Reassembly : •
* Reassembly :
Position the axis so that the hole is aligned with the locking screw as shown on the picture (See Fig. 33-207 No.3)
4) Mark out the position of the switch plate before removing it. 5) Repeat the operation for the second switch plate. 6) Reassemble parts in reverse order.
•
Fig. 33-207
Position the axis so that the hole is aligned with the locking screw as shown on the picture (See Fig. 33-207 No.3)
4) Mark out the position of the switch plate before removing it. 5) Repeat the operation for the second switch plate. 6) Reassemble parts in reverse order.
33-122
33-122
Fig. 33-207
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(3) Switch plate adjustment
(3) Switch plate adjustment
If the switch plate is replaced, it is necessary to adjust the regulation screws.
If the switch plate is replaced, it is necessary to adjust the regulation screws.
1) Unscrew the 2 locking screws using a 2,5mm socket wrench (See Fig. 33-208)
1) Unscrew the 2 locking screws using a 2,5mm socket wrench (See Fig. 33-208)
* Reassembly :
* Reassembly :
•
Apply a droplet of Loctite #262 on the locking screw thread.
•
Apply a droplet of Loctite #262 on the locking screw thread.
•
Torque :3 N•m 2.2 (lbf•ft)
•
Torque :3 N•m 2.2 (lbf•ft)
2) Set the switch plate horizontally.
2) Set the switch plate horizontally.
3) Screw on simultaneously both regulation screws using a flat screw driver (5,5u150) until feeling some resistance.
3) Screw on simultaneously both regulation screws using a flat screw driver (5,5u150) until feeling some resistance.
Do not misadjust the two damping screws. (See Fig. 33-209) 4) Tighten the locking screws to hold the regulation screws in position.
Fig. 33-208
Regulation screws to adjust
Damping screws already adjusted and glued
5) Repeat the operation for the second switch plate making sure both switch plates are parallel. (See Fig. 33-208)
SWITCH PLATE
Do not misadjust the two damping screws. (See Fig. 33-209) 4) Tighten the locking screws to hold the regulation screws in position.
Fig. 33-208
Regulation screws to adjust
Damping screws already adjusted and glued
5) Repeat the operation for the second switch plate making sure both switch plates are parallel. (See Fig. 33-208)
SWITCH PLATE
The figure is shown from the backside.
(4) Retaining plate removal
Fig. 33-209
1) Remove
The figure is shown from the backside.
(4) Retaining plate removal
•
The pilot control unit from the machine.
•
The pilot control unit from the machine.
•
Both rubber boots (See 33.2.4.2 (1))
•
Both rubber boots (See 33.2.4.2 (1))
•
Both switch plates (See 33.2.4.2 (2))
•
Both switch plates (See 33.2.4.2 (2))
2) Unscrew simultaneously both screws holding the retaining plate using a 8mm socket wrench. (See Fig. 33-210)
Fig. 33-209
1) Remove
2) Unscrew simultaneously both screws holding the retaining plate using a 8mm socket wrench. (See Fig. 33-210)
* Reassembly :
* Reassembly :
•
Apply a droplet of Loctite #262 on the screw thread.
•
Apply a droplet of Loctite #262 on the screw thread.
•
Torque :30 N•m (22 lbf•ft)
•
Torque :30 N•m (22 lbf•ft)
Fig. 33-210
33-123
Fig. 33-210
33-123
33. UPPER STRUCTURE
33. UPPER STRUCTURE
3) Lift the retaining plate to remove it. (See Fig. 33-211)
3) Lift the retaining plate to remove it. (See Fig. 33-211)
* Reassembly : •
* Reassembly :
Use the retaining plate to insert the 4 guides into the body simultaneously and perpendicularly. (See Fig. 33-211 left side)
•
Use the retaining plate to insert the 4 guides into the body simultaneously and perpendicularly. (See Fig. 33-211 left side)
4) Reassemble parts in reverse order.
4) Reassemble parts in reverse order.
5) Drain the pilot control unit (See 33.2.4.3).
5) Drain the pilot control unit (See 33.2.4.3). Fig. 33-211
Fig. 33-211
(5) Damping plunger seals replacement
(5) Damping plunger seals replacement
1) Remove
1) Remove
•
The pilot control unit from the machine.
•
The pilot control unit from the machine.
•
Both rubber boots. (See 33.2.4.2 (1))
•
Both rubber boots. (See 33.2.4.2 (1))
•
Both switch plates (See 33.2.4.2 (2))
•
Both switch plates (See 33.2.4.2 (2))
•
The retaining plate (See 33.2.4.2 (4))
•
The retaining plate (See 33.2.4.2 (4))
2) Remove the wiper ring of the damping plunger (1). (See Fig. 33-212 No.1)
1
WIPER RING
2
Fig. 33-212
* Reassembly : •
DAMPER PLUNGER
2) Remove the wiper ring of the damping plunger (1). (See Fig. 33-212 No.1)
1
2
Fig. 33-212
* Reassembly :
Replace with a new wiper ring.
•
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned.
Replace with a new wiper ring.
Always place the damping plunger prior to the wiper ring, and make sure the wiper ring is correctly positionned.
3) Remove the damping plunger (2). (Fig. 33-212 No.2)
3) Remove the damping plunger (2). (Fig. 33-212 No.2)
Fig. 33-213 4) Using a needle, remove the seal placed inside the body (See Fig. 33-214 No.3, 4)
Fig. 33-213 4) Using a needle, remove the seal placed inside the body (See Fig. 33-214 No.3, 4)
* Reassembly : •
WIPER RING
* Reassembly :
Replace with a new seal and grease it.
•
3
Replace with a new seal and grease it.
3
4 Fig. 33-214
33-124
4 Fig. 33-214
33-124
DAMPER PLUNGER
33. UPPER STRUCTURE
33. UPPER STRUCTURE
•
Squeeze the seal between your fingers to obtain a 8-shape. (See Fig. 33-215 No.5)
•
Squeeze the seal between your fingers to obtain a 8-shape. (See Fig. 33-215 No.5)
•
Insert the seal within the groove with your fingers (lip in bottom position). (See Fig. 33-215 No.6, 7)
•
Insert the seal within the groove with your fingers (lip in bottom position). (See Fig. 33-215 No.6, 7)
•
Push the seal against the side using the round head of a small socket wrench. (Fig. 33-215 No.8)
•
Push the seal against the side using the round head of a small socket wrench. (Fig. 33-215 No.8)
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it. 5) Repeat the operation for the other 3 assemblies.
5
7
6
8 Fig. 33-215
During the reassembly, make sure the seal is correctly positionned, and pay attention not to damage nor twist it. 5) Repeat the operation for the other 3 assemblies.
6) Extract the damping springs from the body (using flat nose pliers).
6) Extract the damping springs from the body (using flat nose pliers).
7) Inspect the damping springs. If defects are detected, replace the 4 springs.
7) Inspect the damping springs. If defects are detected, replace the 4 springs.
8) Reassemble parts in reverse order.
8) Reassemble parts in reverse order.
(6) Guide/plunger and regulation unit replacement
6
7
8 Fig. 33-215
(6) Guide/plunger and regulation unit replacement
1) Remove
1) Remove
•
The pilot control unit from the machine.
•
The pilot control unit from the machine.
•
Both rubber boots (See 33.2.4.2 (1))
•
Both rubber boots (See 33.2.4.2 (1))
•
Both switch plates (See 33.2.4.2 (2))
•
Both switch plates (See 33.2.4.2 (2))
•
The retaining plate (See 33.2.4.2 (4))
•
The retaining plate (See 33.2.4.2 (4))
2) Guide/plunger replacement : •
5
2) Guide/plunger replacement :
Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the body.
•
Insert the end of a thin screwdriver between the guide and the body, carefully lift the guide to remove it from the body.
Hold the guides with the other hand during the extraction operation to limit the effect of the return spring.
Hold the guides with the other hand during the extraction operation to limit the effect of the return spring.
3) Remove the guide / plunger assembly.
3) Remove the guide / plunger assembly.
4) Repeat the operation for the other 3 subassemblies.
4) Repeat the operation for the other 3 subassemblies.
5) Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies.
5) Visually check that the guides / plungers are in good condition. If defects are present, replace the 4 sub-assemblies.
Fig. 33-216
33-125
Fig. 33-216
33-125
33. UPPER STRUCTURE
33. UPPER STRUCTURE
6) Guide/plunger and relulation unit replacement
6) Guide/plunger and relulation unit replacement
•
Extract the regulation units from the body (using flat nose pliers).
•
Extract the regulation units from the body (using flat nose pliers).
•
Inspect the regulation units. If defects are detected on the parts, replace the 4 units.
•
Inspect the regulation units. If defects are detected on the parts, replace the 4 units.
7) Return spring replacement : •
7) Return spring replacement :
Extract the return springs from the body (using flat nose pliers).
•
Extract the return springs from the body (using flat nose pliers).
Fig. 33-217 •
Fig. 33-217
Inspect the return springs. If defects are detected, replace the 4 springs.
•
8) Reassemble parts in reverse order.
Inspect the return springs. If defects are detected, replace the 4 springs.
8) Reassemble parts in reverse order.
Fig. 33-218 (7) Throttle kit replacement
Fig. 33-218 (7) Throttle kit replacement
1) Remove
1) Remove
•
The pilot control unit from the machine
•
The pilot control unit from the machine
•
Both rubber boots (See 33.2.4.2 (1))
•
Both rubber boots (See 33.2.4.2 (1))
•
Both switch plates (See 33.2.4.2 (2))
•
Both switch plates (See 33.2.4.2 (2))
•
The retaining plate (See 33.2.4.2 (4))
•
The retaining plate (See 33.2.4.2 (4))
•
The damping plungers and springs (See 33.2.4.2 (5))
•
The damping plungers and springs (See 33.2.4.2 (5))
Fig. 33-219
33-126
Fig. 33-219
33-126
33. UPPER STRUCTURE 2) Unscrew the screw using a 3mm socket wrench. (See Fig. 33-219)
33. UPPER STRUCTURE 2) Unscrew the screw using a 3mm socket wrench. (See Fig. 33-219)
* Reassembly :
* Reassembly :
•
Apply a droplet of Loctite #262 on the screw thread
•
Apply a droplet of Loctite #262 on the screw thread
•
Screw on until it sets just above the body. (See Fig. 33-220)
•
Screw on until it sets just above the body. (See Fig. 33-220)
3) Unscrew the throttle using a 3mm socket wrench.
3) Unscrew the throttle using a 3mm socket wrench.
* Reassembly : •
* Reassembly :
Torque :4 N•m (3 lbf•ft)
•
Torque :4 N•m (3 lbf•ft)
4) Repeat the operation for the other 3 assemblies.
4) Repeat the operation for the other 3 assemblies.
5) Replace with new screws and new throttles.
5) Replace with new screws and new throttles.
6) Reassemble parts in reverse order.
6) Reassemble parts in reverse order.
Fig. 33-220 (8) Shuttle valve kit removal
Fig. 33-220 (8) Shuttle valve kit removal
1. Remove the pilot control unit from the machine
1. Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled to perform this operation.
The pilot control unit does not need to be disassembled to perform this operation.
2) Unscrew the shuttle valve using a 4mm socket wrench. (See Fig. 33-221 and Fig. 33-222)
2) Unscrew the shuttle valve using a 4mm socket wrench. (See Fig. 33-221 and Fig. 33-222)
* Reassembly :
* Reassembly :
•
Thoroughly clean the body to remove any trace of loctite.
•
Thoroughly clean the body to remove any trace of loctite.
•
Apply a droplet of Loctite #242 on the shuttle valve thread.
•
Apply a droplet of Loctite #242 on the shuttle valve thread.
•
Torque :4 N•m (3 lbf•ft)
•
Torque :4 N•m (3 lbf•ft)
Fig. 33-221
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
Fig. 33-221
Wait for 8 hours before using the machine to let the Loctite #242 dry completely.
Fig. 33-222
33-127
Fig. 33-222
33-127
33. UPPER STRUCTURE
33. UPPER STRUCTURE
3) Put the body up-side-down to remove the shuttle valve and the ball. (See Fig. 33-224)
3) Put the body up-side-down to remove the shuttle valve and the ball. (See Fig. 33-224)
4) Unscrew the throttle using a 2,5mm socket wrench.
4) Unscrew the throttle using a 2,5mm socket wrench.
* Reassembly: •
* Reassembly:
Hand tighten.
•
Hand tighten.
5) Repeat the operation for the other subassemblies.
5) Repeat the operation for the other subassemblies.
6) Inspect the shuttle valves, balls and throttles. If defects are detected, replace all the assemblies.
6) Inspect the shuttle valves, balls and throttles. If defects are detected, replace all the assemblies.
7) Reassemble parts in reverse order.
Fig. 33-223
7) Reassemble parts in reverse order.
Fig. 33-223
Fig. 33-224 (9) Check valve kit removal
Fig. 33-224 (9) Check valve kit removal
1) Remove the pilot control unit from the machine
1) Remove the pilot control unit from the machine
The pilot control unit does not need to be disassembled to perform this operation.
The pilot control unit does not need to be disassembled to perform this operation.
2) Unscrew the check valve plug using a 4mm socket wrench. (See Fig. 33-225)
2) Unscrew the check valve plug using a 4mm socket wrench. (See Fig. 33-225)
* Reassembly : •
Drain the pilot control unit (See 33.2.4.3)
•
Torque :5 N•m (3.7lbf•ft)
* Reassembly : Fig. 33-225
•
Drain the pilot control unit (See 33.2.4.3)
•
Torque :5 N•m (3.7lbf•ft)
Fig. 33-225
3) Put the body up-side-down to remove the ball.
3) Put the body up-side-down to remove the ball.
4) Repeat the operation for the second check valve kit.
4) Repeat the operation for the second check valve kit.
5) Inspect the check valve plugs, O-rings and balls. If defects are detected, replace all the assemblies. (See Fig. 33-226)
5) Inspect the check valve plugs, O-rings and balls. If defects are detected, replace all the assemblies. (See Fig. 33-226)
6) Reassemble parts in reverse order.
6) Reassemble parts in reverse order.
Fig. 33-226
33-128
Fig. 33-226
33-128
33. UPPER STRUCTURE 33.2.4.3
DRAIN OF HYDRAULIC PILOT CONTROL UNIT
33. UPPER STRUCTURE 33.2.4.3
DRAIN OF HYDRAULIC PILOT CONTROL UNIT
(1) When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit.
(1) When removing the retaining plate, the throttle kit or the shuttle valve kit, it is necessary to drain the pilot unit.
(2) Reassemble the pilot unit control completely.
(2) Reassemble the pilot unit control completely.
(3) Install the pilot unit control in the machine.
(3) Install the pilot unit control in the machine.
(4) Slightly unscrew the check valve plug using a 4mm socket wrench. (See Fig. 33-227)
(4) Slightly unscrew the check valve plug using a 4mm socket wrench. (See Fig. 33-227)
(5) Switch on the machine.
(5) Switch on the machine.
(6) Operate gently the pedal until the bubbles disappear.
(6) Operate gently the pedal until the bubbles disappear.
(7) Tighten the check valve plug.
(7) Tighten the check valve plug.
• Torque : 5 N•m (3.7 lbf•ft)
• Torque : 5 N•m (3.7 lbf•ft)
(8) Repeat the operation for the other check valve plug.
(8) Repeat the operation for the other check valve plug.
Fig. 33-227
33-129
Fig. 33-227
33-129
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5
33.2.5
33.2.5.1
SWING MOTOR UNIT CONSTRUCTION
33.2.5.1
(1) Swing motor
SWING MOTOR UNIT CONSTRUCTION
(1) Swing motor
Fig. 33-228 Swing motor
Fig. 33-228 Swing motor
33-130
33-130
33. UPPER STRUCTURE Tightening torque No. N•m (lbf•ft) 177 (130)
Parts
051 Relief valve ; M33-P1.5 051-1 O-ring ; 1B G30
36 (27)
29 (22)
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
2
69 (51)
400
Anti-reaction valve ; M22-P1.5
2
2
400-1 O-ring ; 1B P20
2
052 Anti-reaction valve sub
1
400-2 Backup ring
2
100 Casing for anti-reaction valve
1
401
Socket bolt ; M20u45
101 Drive shaft
1
443
Roller bearing
111 Cylinder
1
444
Roller bearing
1
114 Spring plate
1
121 Piston
9
122 Shoe 123 Set plate
431 (320)
33. UPPER STRUCTURE Tightening torque No. N•m (lbf•ft) 177 (130)
Parts
051 Relief valve ; M33-P1.5 051-1 O-ring ; 1B G30
Q’ty
Tightening torque N•m (lbf•ft)
No.
Parts
Q’ty
2
69 (51)
400
Anti-reaction valve ; M22-P1.5
2
2
400-1 O-ring ; 1B P20
2
052 Anti-reaction valve sub
1
400-2 Backup ring
2
4
100 Casing for anti-reaction valve
1
401
Socket bolt ; M20u45
4
1
101 Drive shaft
1
443
Roller bearing
1
111 Cylinder
1
444
Roller bearing
1
451
Pin
2
114 Spring plate
1
469
ROMH plug ; M30-P1.5
2
121 Piston
9
9
472
O-ring
1
122 Shoe
1
488
O-ring ; 1B P28
2
123 Set plate
334 (250)
431 (320)
451
Pin
2
469
ROMH plug ; M30-P1.5
2
9
472
O-ring
1
1
488
O-ring ; 1B P28
2
334 (250)
124 Shoe plate
1
491
Oil seal
1
124 Shoe plate
1
491
Oil seal
1
131 Valve plate
1
702
Brake piston
1
131 Valve plate
1
702
Brake piston
1
151 Plug ; PF1/4
2
706
O-ring
1
151 Plug ; PF1/4
2
706
O-ring
1
161 O-ring ; 1B P11
2
707
O-ring
1
161 O-ring ; 1B P11
2
707
O-ring
1
162 O-ring ; 1B P12
2
712
Brake spring
16
162 O-ring ; 1B P12
2
712
Brake spring
16
163 O-ring ; 1B P6
2
742
Friction plate
3
163 O-ring ; 1B P6
2
742
Friction plate
3
171 Socket bolt ; M8u55
4
743
Separator plate
4
171 Socket bolt ; M8u55
4
743
Separator plate
4
301 Casing
1
0.9 (0.65)
980
Plug ; PF1/4
1
301 Casing
1
0.9 (0.65)
980
Plug ; PF1/4
1
303 Valve casing
1
1.7 (1.2)
984
Plug ; PF3/8
1
303 Valve casing
1
1.7 (1.2)
984
Plug ; PF3/8
1
351 Plunger
2
4.4 (3.3)
985
Plug ; PF3/4
3
351 Plunger
2
4.4 (3.3)
985
Plug ; PF3/4
3
355 Spring
2
65 (48)
993
Plug ; PT1/2
1
355 Spring
2
65 (48)
993
Plug ; PT1/2
1
390 Name plate
1
98 (72)
994
Plug ; PT3/4
1
390 Name plate
1
98 (72)
994
Plug ; PT3/4
1
391 Rivet
2
391 Rivet
2
33-131
36 (27)
29 (22)
33-131
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(2) Swing reduction unit
(2) Swing reduction unit Be careful about installation direction of retaining ring.
Apply Three Bond #1360 or equivalent.
OIL FILLING PORT PT3/4
Caulk these 2 places with punch.
Be careful about installation direction of retaining ring.
Apply Three Bond #1360 or equivalent.
OIL FILLING PORT PT3/4
LEVEL PORT PT1/2
Apply Loctite #515.
Caulk these 2 places with punch. LEVEL PORT PT1/2
Apply Loctite #515.
SURFACE OF LUBE OIL
SURFACE OF LUBE OIL
Be careful about installation direction of spring pin.
Be careful about installation direction of spring pin.
VIEW (II) (4 places) Apply Loctite #515.
VIEW (II) (4 places) Apply Loctite #515.
Be careful about installation direction of retaining ring.
Be careful about installation direction of retaining ring.
Drive this spring pin into 1mm lower than the surface of spider.
Apply Loctite #515.
Drive this spring pin into 1mm lower than the surface of spider.
Apply Loctite #515.
Install the filling port of this fitting toward motor side.
Install the filling port of this fitting toward motor side.
Tightening torque 69.1+4.4 N.m (51.0+3.2 lbf.ft) Apply seal tape or Loctite #577.
Tightening torque 69.1+4.4 N.m (51.0+3.2 lbf.ft) Apply seal tape or Loctite #577.
Fill up this space with grease.
Fill up this space with grease.
Fig. 33-229 Sectional view of swing reduction unit Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
Fig. 33-229 Sectional view of swing reduction unit
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
Tightening torque No. N•m (lbf•ft)
Parts
Q’ty
1
Pinion shaft
1
17
Needle bearing
4
1
Pinion shaft
1
17
Needle bearing
4
2
#1 sun gear
1
18
Thrust washer
8
2
#1 sun gear
1
18
Thrust washer
8
3
#1 pinion
3
19
Snap ring
1
3
#1 pinion
3
19
Snap ring
1
4
#2 sun gear
1
20
Snap ring
1
4
#2 sun gear
1
20
Snap ring
1
5
#2 pinion
4
21
Sleeve
1
5
#2 pinion
4
21
Sleeve
1
6
Ring gear
1
22
Spring pin
4
6
Ring gear
1
22
Spring pin
4
7
Spider assy
1
23
Socket bolt ; M14u135
11
7
Spider assy
1
23
Socket bolt ; M14u135
11
8
Spider
1
24
Cap
2
8
Spider
1
24
Cap
2
9
Shaft
4
25
Tube ; L=112
1
9
Shaft
4
25
Tube ; L=112
1
10
Spherical bearing
1
26
Elbow
1
10
Spherical bearing
1
26
Elbow
1
11
Spherical bearing
1
27
Plug
1
11
Spherical bearing
1
27
Plug
1
12
Oil seal
1
28
Snap ring
3
12
Oil seal
1
28
Snap ring
3
13
Housing
1
30
Oil seal
1
13
Housing
1
30
Oil seal
1
15
Thrust washer
6
31
Grease fitting
1
15
Thrust washer
6
31
Grease fitting
1
16
Needle bearing
3
32
Relief fitting
1
16
Needle bearing
3
32
Relief fitting
1
33-132
181 (134)
69.1 (51.0)
33-132
181 (134)
69.1 (51.0)
33. UPPER STRUCTURE 33.2.5.2
Tools
33.2.5.2.1 Tools
Socket wrench
Relief valve
Tools
Remarks M33uP1.5
M8, M20 Allen wrench
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
Tools
41mm
Socket wrench
6,10,12,17mm
ROMH PLUG
M30uP1.5
14mm
ROH PLUG
PF1/4
6mm
Screwdriver
Relief valve
Remarks M33uP1.5
M8, M20 Allen wrench
Flat-bladed type, medium size 2 pcs.
41mm 6,10,12,17mm
ROMH PLUG
M30uP1.5
14mm
ROH PLUG
PF1/4
6mm
Screwdriver
Flat-bladed type, medium size 2 pcs.
Steel bar
10u8u200(0.39"u0.31"u7.87") (key material) 1 pc.
Steel bar
10u8u200(0.39"u0.31"u7.87") (key material) 1 pc.
Hammer
Plastic hammer 1 pc.
Hammer
Plastic hammer 1 pc.
Torque wrench N•m (lbf•ft)
10~45 (7.2~33) 40~180 (29~130) 120~480 (87~350)
Torque wrench N•m (lbf•ft)
Slide hammer bearing puller
10~45 (7.2~33) 40~180 (29~130) 120~480 (87~350)
Slide hammer bearing puller 14 (0.551")
14 (0.551")
85 (3.35")
85 (3.35")
30 (1.18")
30 (1.18")
15 (0.591")
15 (0.591")
5 2. 2") R1 .49 0 (
Brake piston drawing tool
100 (3.94")
M16 Through
M16 Through
M18
4 (0.158")
4 (0.158")
44 (1.73") 8 (0.315")
Brake piston drawing tool
75 (2.95")
35 (1.38")
35 (1.38")
75 (2.95")
BRAKE PISTON DRAWING TOOL
o 8 (0.315")
BRAKE PISTON CASING
33-133
5 2. 2") R1 .49 0 (
100 (3.94")
33.2.5.2.1
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
44 (1.73") 8 (0.315")
33.2.5.2
33. UPPER STRUCTURE
M18
BRAKE PISTON DRAWING TOOL
o 8 (0.315")
BRAKE PISTON CASING
33-133
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.2.2
33.2.5.2.2
Disassembly
(1) General cautions
Disassembly
(1) General cautions
1) Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care.
1) Hydraulic components are precision products and have small clearance. Therefore, assemble and disassemble in a less dusty clean place. Use clean tools and cleaning oil and handle components with full care.
2) If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water do not enter. When fitting them back to the body, do not remove the plugs till piping is completed.
2) If a component is removed from the main body, clean the area around the ports thoroughly and plug them up so no dust and water do not enter. When fitting them back to the body, do not remove the plugs till piping is completed.
3) Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-rings once removed can not be used again. Some parts can not be supplied as single parts and available only in sub assy. Prepare such parts according to the parts manual.
3) Study the structural drawing before the work begins and prepare necessary parts according to your purpose and the scope of work. Seals and O-rings once removed can not be used again. Some parts can not be supplied as single parts and available only in sub assy. Prepare such parts according to the parts manual.
4) The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block.
4) The piston and the cylinder block are shop fitted when new. If you intend to reuse them, put a matching mark on the piston and the cylinder block.
(2) Disassembly procedure The figures in parentheses after part names in this manual represent those item numbers in Fig. 33228
(2) Disassembly procedure The figures in parentheses after part names in this manual represent those item numbers in Fig. 33228
1) Draining oil Remove the drain plug and drain hydraulic oil from casing (301).
1) Draining oil Remove the drain plug and drain hydraulic oil from casing (301).
2) Preparation for removing the valve casing Fix the motor on a work bench so the drive shaft (101) end comes down. On that occasion, put a matching mark on the mating parts of casing (301) and valve casing (303).
2) Preparation for removing the valve casing Fix the motor on a work bench so the drive shaft (101) end comes down. On that occasion, put a matching mark on the mating parts of casing (301) and valve casing (303).
â&#x20AC;˘
Choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not have dents.
â&#x20AC;˘
Choose a clean place, and lay with a rubber sheet or a cloth on a work bench. Handle the valve casing with care so parts do not have dents.
Fig. 33-230 Removing valve casing (303)
33-134
Fig. 33-230 Removing valve casing (303)
33-134
33. UPPER STRUCTURE 3) Loosen relief valve (051) and separate it from valve casing (303).
33. UPPER STRUCTURE 3) Loosen relief valve (051) and separate it from valve casing (303).
: 41 mm
: 41 mm
4) Loosen anti-reaction valve sub assy (052) and remove from valve casing (303). (See Fig. 33230)
4) Loosen anti-reaction valve sub assy (052) and remove from valve casing (303). (See Fig. 33230)
: 6 mm
: 6 mm
5) Separate ROMH plug (469) from valve casing (303) and draw out spring (355) and plunger (351).
5) Separate ROMH plug (469) from valve casing (303) and draw out spring (355) and plunger (351). Fig. 33-231 Removing relief valve (651), anti-reactionvalve (052), anti-cavitation plunger (351) and valve casing (303)
: 14 mm 6) Loosen socket bolt (401) and separate valve casing (303) from casing (301). If the socket bolt (401) are loosened, the valve casing floats off casing (301) by the force of brake spring (712). Then separate valve plate (131) from valve casing (303). : 17 mm
Fig. 33-231 Removing relief valve (651), anti-reactionvalve (052), anti-cavitation plunger (351) and valve casing (303)
: 14 mm 6) Loosen socket bolt (401) and separate valve casing (303) from casing (301). If the socket bolt (401) are loosened, the valve casing floats off casing (301) by the force of brake spring (712). Then separate valve plate (131) from valve casing (303). : 17 mm
7) Draw out brake spring (712) from brake piston (702).
7) Draw out brake spring (712) from brake piston (702).
8) Put the claw of the brake piston removing jig in the concaved part of brake piston (702). Tighten 2 bolts of jig simultaneously, and draw out the brake piston (702) with the jig, from the casing.
8) Put the claw of the brake piston removing jig in the concaved part of brake piston (702). Tighten 2 bolts of jig simultaneously, and draw out the brake piston (702) with the jig, from the casing.
Fig. 33-232 Removing brake piston (702)
9) Lay the motor on its side again and draw out cylinder block (111) from drive shaft (101). Then draw out piston (121), set plate (123), spring (114) and shoe plate (124).
9) Lay the motor on its side again and draw out cylinder block (111) from drive shaft (101). Then draw out piston (121), set plate (123), spring (114) and shoe plate (124).
Handle the parts with care so as not to score the sliding surfaces of cylinder block (111) and shoe (122).
Handle the parts with care so as not to score the sliding surfaces of cylinder block (111) and shoe (122).
Fig. 33-233 Drawing cylider block (111), piston sub assy, friction plate (742) and separator plate
33-135
Fig. 33-232 Removing brake piston (702)
Fig. 33-233 Drawing cylider block (111), piston sub assy, friction plate (742) and separator plate
33-135
33. UPPER STRUCTURE
33. UPPER STRUCTURE
10) Draw out friction plate (742) and separator plate (743) from casing (301).
10) Draw out friction plate (742) and separator plate (743) from casing (301).
11) Draw out drive shaft (101) from casing (301), while lightly tapping the side face of valve casing (303) in drive shaft (101), using a plastic mallet.
11) Draw out drive shaft (101) from casing (301), while lightly tapping the side face of valve casing (303) in drive shaft (101), using a plastic mallet.
•
Do the following work as required.
•
a. Drawing the inner race of roller bearing (443) from drive shaft (101), using a press. •
Do the following work as required.
a. Drawing the inner race of roller bearing (443) from drive shaft (101), using a press.
Do not reuse the removed bearing.
Fig. 33-234 Removing drive shaft (101)
b. Drawing out the outer race of roller bearing (443) from casing (301), by lightly tapping the steel rod from the oil seal (491) housing side. (Do not reuse the bearing.) c. Separate the outer race of roller bearing (444) from valve casing (303), using a slide hammer bearing puller.
PRESS 101
443
•
Do not reuse the removed bearing.
Fig. 33-234 Removing drive shaft (101)
b. Drawing out the outer race of roller bearing (443) from casing (301), by lightly tapping the steel rod from the oil seal (491) housing side. (Do not reuse the bearing.) c. Separate the outer race of roller bearing (444) from valve casing (303), using a slide hammer bearing puller.
101
443
Put the inner race on the press bench.
Put the inner race on the press bench.
Fig. 33-235 Removing inner race of roller bearing (443)
33-136
PRESS
Fig. 33-235 Removing inner race of roller bearing (443)
33-136
33. UPPER STRUCTURE 33.2.5.2.3
Assembly
33. UPPER STRUCTURE 33.2.5.2.3
(1) General precautions
Assembly
(1) General precautions
1) Repair those parts damaged after disassembly and prepare replacement parts beforehands.
1) Repair those parts damaged after disassembly and prepare replacement parts beforehands.
2) Clean all parts thoroughly in cleaning oil and dry them with jet air.
2) Clean all parts thoroughly in cleaning oil and dry them with jet air.
3) Always coat the moving parts with clean hydraulic oil, before assembly.
3) Always coat the moving parts with clean hydraulic oil, before assembly.
4) Replace such seals as O-ring and oil seal in principle.
4) Replace such seals as O-ring and oil seal in principle.
5) Tighten socket bolts and plugs to specified torques, using a torque wrench.
5) Tighten socket bolts and plugs to specified torques, using a torque wrench.
(2) Assembly procedure The figures in parentheses after part names in this manual represent those item numbers in the Fig. 33-228.
OUTPUT SHAFT SIDE
1) Preparation for assembly Place casing (301) on a proper bench so its valve casing (303) faces upward.
443
•
101
This operation is necessary only when the roller bearing is removed.
OUTPUT SHAFT SIDE
1) Preparation for assembly Place casing (301) on a proper bench so its valve casing (303) faces upward.
443
•
2) Shrinkage fit the inner race of roller bearing (443) into drive shaft (101). 3) Shrinkage fit the inner race of roller bearing (444) to drive shaft (101). •
(2) Assembly procedure The figures in parentheses after part names in this manual represent those item numbers in the Fig. 33-228.
101
This operation is necessary only when the roller bearing is removed.
2) Shrinkage fit the inner race of roller bearing (443) into drive shaft (101). 444
Fig. 33-236 Assembling the inner race of bearings (443), (444)
This operation is necessary only when the oil seal is removed. Fit oil seal (491) to casing (301). On that occasion, coat the lip of the oil seal with grease and check the direction of it, before fixing it.
3) Shrinkage fit the inner race of roller bearing (444) to drive shaft (101). •
444
Fig. 33-236 Assembling the inner race of bearings (443), (444)
This operation is necessary only when the oil seal is removed. Fit oil seal (491) to casing (301). On that occasion, coat the lip of the oil seal with grease and check the direction of it, before fixing it.
4) Assemble the outer race of roller bearing (443) into casing (301), by lightly tapping the steel rod.
4) Assemble the outer race of roller bearing (443) into casing (301), by lightly tapping the steel rod.
5) Attach drive shaft (101) to casing (301).
5) Attach drive shaft (101) to casing (301).
Fig. 33-237 Fitting oil seal (491), outer race of roller bearing (443), and drive shaft (101)
33-137
Fig. 33-237 Fitting oil seal (491), outer race of roller bearing (443), and drive shaft (101)
33-137
33. UPPER STRUCTURE
33. UPPER STRUCTURE
6) Place casing (301) as shown in Fig. 33-238 and insert shoe plate (124). On that occasion, the shoe plate does not come off if it is coated with grease.
6) Place casing (301) as shown in Fig. 33-238 and insert shoe plate (124). On that occasion, the shoe plate does not come off if it is coated with grease. The larger chamfer side
The larger chamfer side 124
124
301
443 101
101
Fig. 33-238 Inserting shoe plate (124)
Fig. 33-238 Inserting shoe plate (124)
7) Set the set plate (123) and spring (114), then set piston sub (121, 122) assy.
7) Set the set plate (123) and spring (114), then set piston sub (121, 122) assy.
8) Assemble piston sub assy (121, 122) fixed in retainer plate (123) into cylinder (111). Match it to the spline of drive shaft (101) and insert it in place.
8) Assemble piston sub assy (121, 122) fixed in retainer plate (123) into cylinder (111). Match it to the spline of drive shaft (101) and insert it in place.
Fig. 33-239 Inserting cylinder assy
Fig. 33-239 Inserting cylinder assy
9) Replace casing (301) with oil seal (491) facing downward and assemble separator plate (743) and friction plate (742) into casing (301), in that order. Assemble four separator plates and three friction plates.
9) Replace casing (301) with oil seal (491) facing downward and assemble separator plate (743) and friction plate (742) into casing (301), in that order. Assemble four separator plates and three friction plates.
Assemble the same phases of four slits in the gears of friction plate (742). Assemble four slits in the four claws of separator plate (743) in the position of Fig. 33-240.
Assemble the same phases of four slits in the gears of friction plate (742). Assemble four slits in the four claws of separator plate (743) in the position of Fig. 33-240.
Fig. 33-240 Installing of separator plate (743), friction plate (742).
33-138
301
443
Fig. 33-240 Installing of separator plate (743), friction plate (742).
33-138
33. UPPER STRUCTURE 10) Fit O-rings (706), (707) to casing (301). In that case, if the O-rings are coated with grease, they are hard to tear off when brake piston (702) is inserted.
702
33. UPPER STRUCTURE 10) Fit O-rings (706), (707) to casing (301). In that case, if the O-rings are coated with grease, they are hard to tear off when brake piston (702) is inserted.
11) Assemble brake piston (702) into casing (301).
11) Assemble brake piston (702) into casing (301).
12) Assemble brake spring (712) into brake piston (702). In that case, make sure that a spring is placed securely in the spot faced part of the brake piston.
12) Assemble brake spring (712) into brake piston (702). In that case, make sure that a spring is placed securely in the spot faced part of the brake piston.
SLIT (OPPOSITE SIDE) PG PORT
•
This operation is necessary only where roller bearing (444) is removed.
Fig. 33-241 Assembling brake piston
•
This operation is necessary only where roller bearing (444) is removed.
13) Insert the outer race of roller bearing (444) into valve casing (303), while lightly tapping the steel rod placed on the outer race, using a hammer.
14) Assemble valve plate (131) into valve casing (303) and fit O-ring (472) in it.
14) Assemble valve plate (131) into valve casing (303) and fit O-ring (472) in it.
15) Install valve casing (303) to casing (301) and fasten them with socket bolts (401).
15) Install valve casing (303) to casing (301) and fasten them with socket bolts (401). : 17 mm, Tightening torque : 431 N•m (320 lbf•ft)
16) Fit plunger (351) and spring (355) to valve casing (303). Then tighten ROMH plug (469) fitted with O-ring (488) against valve casing (303).
16) Fit plunger (351) and spring (355) to valve casing (303). Then tighten ROMH plug (469) fitted with O-ring (488) against valve casing (303).
: 14 mm, Tightening torque : 334 N•m (250 lbf•ft)
: 14 mm, Tightening torque : 334 N•m (250 lbf•ft)
17) Fit relief valve (051) to valve casing (303).
17) Fit relief valve (051) to valve casing (303).
: 41 mm, Tightening torque : 177 N•m (130 lbf•ft)
: 41 mm, Tightening torque : 177 N•m (130 lbf•ft)
18) Fit anti-reaction sub assy (052) to valve casing (303). : 6 mm, Tightening torque : 29 N•m (22 lbf•ft)
18) Fit anti-reaction sub assy (052) to valve casing (303). : 6 mm, Tightening torque : 29 N•m (22 lbf•ft)
33-139
SLIT (OPPOSITE SIDE) PG PORT
13) Insert the outer race of roller bearing (444) into valve casing (303), while lightly tapping the steel rod placed on the outer race, using a hammer.
: 17 mm, Tightening torque : 431 N•m (320 lbf•ft)
702
33-139
Fig. 33-241 Assembling brake piston
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.3
33.2.5.3
Remarks
Spherical bearing (10) removing jig (I)
a
22
Material : Mild steel
13-o 16
b
(Position space equally)
P.C.D 146
Spherical bearing (10) removing jig (I)
Spherical bearing (11) removing jig (II)
c
Spherical bearing (11) removing jig (II)
d
Spherical bearing (10) removing jig (I)
d
Spherical bearing (10) removing jig (I)
Oil seal (30) installing jig
f
150
Material : Mild steel
e
Oil seal (30) installing jig
Spherical bearing (11) press-fit jig
f
Spherical bearing (11) press-fit jig
g
Oil seal (12) installing jig
g
Oil seal (12) installing jig
h
Spherical bearing (10) press-fit jig
h
Spherical bearing (10) press-fit jig
125
33-140
9
e
13-o 16 (Position space equally)
VIEW X
X
c
Material : Mild steel
o 162
P.C.D 146
VIEW X
X
412 270
Stand
o 162
190
b
Remarks Material : Mild steel
230
Stand
Material : Mild steel
Tool name
412 270
Material : Mild steel
a
Code
230
Tool name
Tools
22
Code
33.2.5.3.1
150 125
33-140
9
Tools
DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
190
33.2.5.3.1
DISASSEMBLY AND ASSEMBLY OF SWING REDUCTION UNIT
33. UPPER STRUCTURE Code
Tool name
Remarks
i
Snap ring plier
For shaft 200 N•m (148 lbf•ft) class
j
Torque wrench
k
Plastic hammer (Wooden mallet)
m
Press
n
Flat-bladed screw driver
p
General tools
Allen wrench, Steel bar
Thread sealant
Three Bond #1360K
Sealant
Loctite #515
q 33.2.5.3.2
33. UPPER STRUCTURE Code
30 ton (66150 lb) class
Remarks
i
Snap ring plier
For shaft 200 N•m (148 lbf•ft) class
j
Torque wrench
k
Plastic hammer (Wooden mallet)
m
Press
n
Flat-bladed screw driver
p
General tools
Allen wrench, Steel bar
Thread sealant
Three Bond #1360K
Sealant
Loctite #515
q
Disassembly
Tool name
33.2.5.3.2
30 ton (66150 lb) class
Disassembly
The numbers in parentheses correspond to the ones in construction drawings Fig. 33-228.
The numbers in parentheses correspond to the ones in construction drawings Fig. 33-228.
(1) Preparation
(1) Preparation
1) Before disassembly, clean the outside of the reduction unit thoroughly and check for no damage and scoring.
1) Before disassembly, clean the outside of the reduction unit thoroughly and check for no damage and scoring.
2) Drain gear oil from the reduction unit.
2) Drain gear oil from the reduction unit.
3) Disconnect the drain tube.
3) Disconnect the drain tube.
4) Matching Mark To facilitate the reassembly of the unit, put matching mark on the joining parts of the housing before disassembly.
4) Matching Mark To facilitate the reassembly of the unit, put matching mark on the joining parts of the housing before disassembly.
(2) Disassembling swing motor from reduction unit
(2) Disassembling swing motor from reduction unit
1) Preparation for disassembly Place the reduction unit assy on a stable work bench as shown in Fig. 33-242, remove plug (27), drain out oil and put a matching mark on the matching surface of the figure on the right. 2) Removing swing motor assy Loosen all socket bolt (23) (M14). Attach eye bolts (M10) in the lifting bolt holes in the top surface of the swing motor and lift the assy by crane. If it is hard to remove the swing motor assy from the reduction unit, float it by inserting a flat-blade screwdriver in the groove of the flange. : 12 mm (3) Disassembling reduction unit
1) Preparation for disassembly Place the reduction unit assy on a stable work bench as shown in Fig. 33-242, remove plug (27), drain out oil and put a matching mark on the matching surface of the figure on the right.
SWING MOTOR 23
MATCHING MARK
n
27
Fig. 33-242 Removing swing motor assy 7
2
2) Removing swing motor assy Loosen all socket bolt (23) (M14). Attach eye bolts (M10) in the lifting bolt holes in the top surface of the swing motor and lift the assy by crane. If it is hard to remove the swing motor assy from the reduction unit, float it by inserting a flat-blade screwdriver in the groove of the flange. : 12 mm (3) Disassembling reduction unit
6
1) Remove #1 sun gear (2).
2) Removing #1 spider assy (7). The spider assy (7) [consisting of thrust washer (15), #1 pinion (3), needle bearing (16) and snap ring (28)] can be removed from the spline easily if it is lifted up in that condition.
2) Removing #1 spider assy (7). The spider assy (7) [consisting of thrust washer (15), #1 pinion (3), needle bearing (16) and snap ring (28)] can be removed from the spline easily if it is lifted up in that condition.
33-141
Fig. 33-243 Removing #1 sun gear and #1 spider assy
23
MATCHING MARK
n
27
Fig. 33-242 Removing swing motor assy 7
2
6
1) Remove #1 sun gear (2).
13
SWING MOTOR
33-141
13
Fig. 33-243 Removing #1 sun gear and #1 spider assy
33. UPPER STRUCTURE
33. UPPER STRUCTURE
3) Removing ring gear (6) Attach eye bolts (M10) to the top surface of ring gear (6) and lift the ring gear lightly by a wire sling. Put a flat-blade screwdriver (n) into the matching surface of ring gear (6) and housing (13) and remove ring gear (6) by lightly tapping the outer circumference of the ring gear with a plastic mallet (k).
3) Removing ring gear (6) Attach eye bolts (M10) to the top surface of ring gear (6) and lift the ring gear lightly by a wire sling. Put a flat-blade screwdriver (n) into the matching surface of ring gear (6) and housing (13) and remove ring gear (6) by lightly tapping the outer circumference of the ring gear with a plastic mallet (k).
Fig. 33-244 Removing ring gear (6) 4) Remove #2 sun gear and #2 spider assy. Draw out #2 sun gear (4) and remove the #2 spider assy. Regarding the disassembly of the #2 assy, refer to par. (4) which will come up later.
Fig. 33-244 Removing ring gear (6) 4) Remove #2 sun gear and #2 spider assy. Draw out #2 sun gear (4) and remove the #2 spider assy. Regarding the disassembly of the #2 assy, refer to par. (4) which will come up later.
Fig. 33-245 Removing #2 spider assy
Fig. 33-245 Removing #2 spider assy
•
Particularly if no failure is found, the further disassembly (under condition shown in Fig. 33-246) is not allowed. Check on parts for possible failure according to the inspection procedure shown in item 33.2.5.4.2 separately in this condition. And we recommend that the pinion shaft and housing assy are replaced together as one set. But if it is unavoidably necessary to replace a part of them, follow the procedure shown below.
•
Particularly if no failure is found, the further disassembly (under condition shown in Fig. 33-246) is not allowed. Check on parts for possible failure according to the inspection procedure shown in item 33.2.5.4.2 separately in this condition. And we recommend that the pinion shaft and housing assy are replaced together as one set. But if it is unavoidably necessary to replace a part of them, follow the procedure shown below.
•
If no failure is found in this step, the disassembly later is not required.
•
If no failure is found in this step, the disassembly later is not required.
Fig. 33-246 5) Remove retaining ring (20) from pinion shaft (1).
33-142
Fig. 33-246 5) Remove retaining ring (20) from pinion shaft (1).
33-142
33. UPPER STRUCTURE 6) Pulling out pinion shaft Pull pinion shaft (1), sleeve (21), oil seal (30) and spherical bearing (lower) (11) out by means of press while supporting housing (13) as shown in the figure. •
6) Pulling out pinion shaft Pull pinion shaft (1), sleeve (21), oil seal (30) and spherical bearing (lower) (11) out by means of press while supporting housing (13) as shown in the figure.
PRESS 10 12 1
Spherical bearing (upper) (10) and oil seal (12) are left in the housing.
33. UPPER STRUCTURE
• 13
PRESS 10 12 1
Spherical bearing (upper) (10) and oil seal (12) are left in the housing.
13
JIG (a)
JIG (a)
Fig. 33-247 Pulling out pinion shaft (1) 7) Removing spherical bearing (lower) (11) Pull oil seal (30), sleeve (21) and spherical bearing (lower) (11) out by means of jigs (b) (c) while supporting pinion shaft assy as shown in the figure. Press force : 30t •
PRESS
JIG (b)
Do not use the removed oil seal and bearing.
Fig. 33-247 Pulling out pinion shaft (1) 7) Removing spherical bearing (lower) (11) Pull oil seal (30), sleeve (21) and spherical bearing (lower) (11) out by means of jigs (b) (c) while supporting pinion shaft assy as shown in the figure. Press force : 30t •
JIG (b)
Do not use the removed oil seal and bearing.
JIG (c)
JIG (c)
21 30
21 30
11
11
Fig. 33-248 Removing spherical bearing (lower) (11)
33-143
PRESS
Fig. 33-248 Removing spherical bearing (lower) (11)
33-143
33. UPPER STRUCTURE
33. UPPER STRUCTURE
8) Removing spherical bearing (upper) Set housing (13) as shown in the figure, insert jig (d) between bearing (10) and oil seal (12) and remove bearing (10) by striking from the upper side.
8) Removing spherical bearing (upper) Set housing (13) as shown in the figure, insert jig (d) between bearing (10) and oil seal (12) and remove bearing (10) by striking from the upper side.
9) Remove oil seal (12) from housing (13).
9) Remove oil seal (12) from housing (13).
•
Do not use the removed oil seal and bearing.
•
Do not use the removed oil seal and bearing.
Fig. 33-249 Removing spherical bearing (upper) (10) and oil seal (12) (4) Disassembling spider assy
7
1) Disassembling #1 spider assy
3
28
16
Fig. 33-249 Removing spherical bearing (upper) (10) and oil seal (12) (4) Disassembling spider assy
15
7
1) Disassembling #1 spider assy
1. Remove retaining ring (28) with a plier (i).
1. Remove retaining ring (28) with a plier (i).
2. Remove thrust washers (28) (15), pinion (3) needle bearing (16).
2. Remove thrust washers (28) (15), pinion (3) needle bearing (16).
15
16
15
Fig. 33-250 Disassembling #1 spider assy
•
The shaft attached to spider assy (7) is caulked. When replacing parts, replace the spider assy as a set.
•
The shaft attached to spider assy (7) is caulked. When replacing parts, replace the spider assy as a set.
•
Pinions (3) can not be replaced singly. Replace them it in a set of three.
•
Pinions (3) can not be replaced singly. Replace them it in a set of three.
9
28
15
Fig. 33-250 Disassembling #1 spider assy
2) Disassembling #2 spider assy
3
18
1. Draw out spring pin (22).
2) Disassembling #2 spider assy
9
18
1. Draw out spring pin (22).
2. Draw out shaft (9) from spider (8) and remove thrust washer (18), pinion (5) and needle bearing (17).
17 5
2. Draw out shaft (9) from spider (8) and remove thrust washer (18), pinion (5) and needle bearing (17).
17 5
18 8
Pinions (5) can not be replaced singly. Replace them it in a set of four.
33-144
18 8
22
Fig. 33-251 Disassembling #2 spider assy
Pinions (5) can not be replaced singly. Replace them it in a set of four.
33-144
22
Fig. 33-251 Disassembling #2 spider assy
33. UPPER STRUCTURE 33.2.5.3.3
Assembly
33. UPPER STRUCTURE 33.2.5.3.3
(1) Preparation
Assembly
(1) Preparation
1) Sufficiently clean every part with wash oil and dry it with compressed air.
1) Sufficiently clean every part with wash oil and dry it with compressed air.
2) Check on every part for failure.
2) Check on every part for failure.
(2) Assembling pinion shaft assy
(2) Assembling pinion shaft assy
1) Attaching oil seal Attach oil seal (30) to sleeve (21) by means of jig (e).
JIG (e)
1) Attaching oil seal Attach oil seal (30) to sleeve (21) by means of jig (e).
JIG (e)
30 Apply Loctite #515
30
21
Apply Loctite #515
Fig. 33-252 Attaching oil seal (30)
Fig. 33-252 Attaching oil seal (30)
2) Inserting sleeve Insert sleeve (21) and oils seal (30) assy in pinion shaft (1).
2) Inserting sleeve Insert sleeve (21) and oils seal (30) assy in pinion shaft (1).
3) Applying gear oil Apply gear oil to the perimeter of axis of pinion shaft (1) lightly to prevent seizure.
3) Applying gear oil Apply gear oil to the perimeter of axis of pinion shaft (1) lightly to prevent seizure.
Fig. 33-253 Inserting sleeve in pinion shaft 4) Fitting spherical bearing (lower) Seal sufficient grease in spherical bearing (lower)(11) and force it in pinion shaft (1) by means of jig (f). Press force : 4~5t â&#x20AC;˘
21
Fig. 33-253 Inserting sleeve in pinion shaft 4) Fitting spherical bearing (lower) Seal sufficient grease in spherical bearing (lower)(11) and force it in pinion shaft (1) by means of jig (f). Press force : 4~5t
Since the bearing is formed with a partition at the center section, seal grease in it from both sides.
â&#x20AC;˘
Since the bearing is formed with a partition at the center section, seal grease in it from both sides.
Fig. 33-254 Fitting spherical bearing (lower)
33-145
Fig. 33-254 Fitting spherical bearing (lower)
33-145
33. UPPER STRUCTURE
33. UPPER STRUCTURE
5) Apply sufficient grease to the pinion shaft assy. Grease : Lithium extreme-pressure grease (SHELL Albania EP2 or equivalent)
5) Apply sufficient grease to the pinion shaft assy. Grease : Lithium extreme-pressure grease (SHELL Albania EP2 or equivalent)
(3) Placing pinion shaft assy in
(3) Placing pinion shaft assy in
1) Place housing (13) on level bench.
1) Place housing (13) on level bench.
2) Attach eye bolt to screw (M10) at the axis end of pinion shaft assy, and perpendicularly hang up pinion shaft assy and place it in the housing.
2) Attach eye bolt to screw (M10) at the axis end of pinion shaft assy, and perpendicularly hang up pinion shaft assy and place it in the housing.
•
Horizontally orient the outer race of spherical bearing and insert it in by striking lightly. If the outer race is tilted, it is hard to insert even if striking. Then do not force to insert it in, but take it away once and horizontally orient the outer race twice and insert it in again.
• Fig. 33-255 Apply grease
Horizontally orient the outer race of spherical bearing and insert it in by striking lightly. If the outer race is tilted, it is hard to insert even if striking. Then do not force to insert it in, but take it away once and horizontally orient the outer race twice and insert it in again.
Fig. 33-256 Placing pinion shaft assy in 3) Set housing assy so that the pinion directs downward.
•
Apply Loctite #515 to the perimeter of oil seal.
•
•
Fig. 33-256 Placing pinion shaft assy in 3) Set housing assy so that the pinion directs downward.
JIG (g)
4) Fit oil seal (12) in housing (13) by means of jig (g).
12
JIG (g)
4) Fit oil seal (12) in housing (13) by means of jig (g).
12
•
Apply Loctite #515 to the perimeter of oil seal.
Fill one third (1/3) of the space of the grooveshaped section provided on the oil seal (12) lip with grease.
•
Fill one third (1/3) of the space of the grooveshaped section provided on the oil seal (12) lip with grease.
Insert it horizontally giving attention to the lip of oil seal so as not be damaged.
•
Insert it horizontally giving attention to the lip of oil seal so as not be damaged.
13
13
Fig. 33-257
33-146
Fig. 33-255 Apply grease
Fig. 33-257
33-146
33. UPPER STRUCTURE 5) Press fit spherical bearing (upper) (10) in pinion shaft (1) and housing (13) at the same time by means of jig (h).
33. UPPER STRUCTURE 5) Press fit spherical bearing (upper) (10) in pinion shaft (1) and housing (13) at the same time by means of jig (h).
Fig. 33-258 Spherical bearing (upper) Press-fitting 6) Attach retaining ring (20).
20
Fig. 33-258 Spherical bearing (upper) Press-fitting 6) Attach retaining ring (20).
20
Fig. 33-259 Attach retaining ring
33-147
Fig. 33-259 Attach retaining ring
33-147
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(4) Assembling spider assy
7
1) Assembling #1 Spider assy
3
28
16
(4) Assembling spider assy
15
a. Coat the bore surface of pinion (3) with grease. Put pinion (3) on thrust washer (15) and assemble needle bearing (16) into the bore surface
15
Fig. 33-260 Assembling #1 spider assy
b. Fit thrust washers (15) and pinion (3) as in Fig. 33-261 and fit snap ring (28) by means of pliers (i).
7
1) Assembling #1 Spider assy
3
28
16
a. Coat the bore surface of pinion (3) with grease. Put pinion (3) on thrust washer (15) and assemble needle bearing (16) into the bore surface
15
Fig. 33-260 Assembling #1 spider assy
b. Fit thrust washers (15) and pinion (3) as in Fig. 33-261 and fit snap ring (28) by means of pliers (i).
i
i
Fix the snap ring with the sharp edge on the motor side (top side in the position of Fig. 33-261).
Motor side
15
Fix the snap ring with the sharp edge on the motor side (top side in the position of Fig. 33-261). 15
SNAP RING (28)
Motor side
15
SNAP RING (28)
7
7 3
28
Fig. 33-261 Fixing snap ring 2) Assembling #2 Spider assy
GEAR SIDE Caulk two points with a punch.
a. Coat the bore surface of pinion (5) with grease. Put pinion (5) on thrust washer (18) and fit needle bearing (17) to the bore surface. b. Fit thrust washer (18) and pinion (5) as in Fig. 33-262 insert shaft (9) into spider (8) and drive spring pin (22).
Fig. 33-261 Fixing snap ring 2) Assembling #2 Spider assy
SLIT
b. Fit thrust washer (18) and pinion (5) as in Fig. 33-262 insert shaft (9) into spider (8) and drive spring pin (22).
17
17
5
5
18
18 8
22
#2 SPIDER ASSY
22
Fig. 33-262 Assembling #2 spider assy (5) Installing #2 spider assy Insert #2 spider assy in spline axis of pinion shaft (1).
Fig. 33-263 Assembling #2 spider assy
33-148
18
9
Insert shaft (6) into spider (8) so spring pin hole (22) is aligned.
Fig. 33-262 Assembling #2 spider assy (5) Installing #2 spider assy Insert #2 spider assy in spline axis of pinion shaft (1).
SLIT
6~7mm 6~7mm (0.24~0.28 in) (0.24~0.28 in) VIEW I (Direction of spring pin)
18
9
Insert shaft (6) into spider (8) so spring pin hole (22) is aligned.
8
GEAR SIDE Caulk two points with a punch.
a. Coat the bore surface of pinion (5) with grease. Put pinion (5) on thrust washer (18) and fit needle bearing (17) to the bore surface.
6~7mm 6~7mm (0.24~0.28 in) (0.24~0.28 in) VIEW I (Direction of spring pin)
3
28
#2 SPIDER ASSY
Fig. 33-263 Assembling #2 spider assy
33-148
33. UPPER STRUCTURE (6) Installing #2 sun gear (2) Install #2 sun gear (2) directing the spline upward.
2
33. UPPER STRUCTURE (6) Installing #2 sun gear (2) Install #2 sun gear (2) directing the spline upward.
Fig. 33-264 Installing #2 sun gear (2) (7) Installing ring gear (6) Apply a thin film of sealant Loctite #515 to the matching surface of housing (13) and ring gear (6) and assemble them, aligning the gear teeth and according to the matching marks given.
#2 SPIDER ASSY 6
Align maching marks.
2
Fig. 33-264 Installing #2 sun gear (2) (7) Installing ring gear (6) Apply a thin film of sealant Loctite #515 to the matching surface of housing (13) and ring gear (6) and assemble them, aligning the gear teeth and according to the matching marks given.
13
#2 SPIDER ASSY 6
Align maching marks.
13
Fig. 33-265 Installing ring gear (6) (8) Installing #1 spider assy
Fig. 33-265 Installing ring gear (6) (8) Installing #1 spider assy
1) Mesh the #1 spider assy with ring gear (6) and set them in place.
1) Mesh the #1 spider assy with ring gear (6) and set them in place.
2) Mesh #1 sun gear (2) with #1 pinion (3) and set them in place.
2) Mesh #1 sun gear (2) with #1 pinion (3) and set them in place.
(9) Fit drain tube (25) and plug (27).
(9) Fit drain tube (25) and plug (27).
: 12 mm
: 12 mm
(10)Filling Lube Oil Fill in 3.0L (0.8gal) of gear oil SAE90 (API Service Grade GL-4). (11)Installing swing motor assy Attach eye bolts (M10) in the tapped holes of the swing motor and put a wire sling in them Coat the matching surface of ring gear (6) with sealant Loctite #515, insert the spline joint of the swing motor and match the matching marks. Coat socket bolts (23) with sealant Three-Bond 1360K and fasten them.
Fig. 33-266 Installing #1 spider assy
M14X135 23
MACHING MARKS
: 12 mm, Tightening torque : 181 N•m (130 lbf•ft)
(10)Filling Lube Oil Fill in 3.0L (0.8gal) of gear oil SAE90 (API Service Grade GL-4). (11)Installing swing motor assy Attach eye bolts (M10) in the tapped holes of the swing motor and put a wire sling in them Coat the matching surface of ring gear (6) with sealant Loctite #515, insert the spline joint of the swing motor and match the matching marks. Coat socket bolts (23) with sealant Three-Bond 1360K and fasten them.
Fig. 33-266 Installing #1 spider assy
M14X135 23
MACHING MARKS
: 12 mm, Tightening torque : 181 N•m (130 lbf•ft)
Fig. 33-267 Installing swing motor assy
33-149
Fig. 33-267 Installing swing motor assy
33-149
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.4
33.2.5.4
33.2.5.4.1
MAINTENANCE STANDARDS Swing motor
33.2.5.4.1
(1) Replacement standards for parts The following are the standards to determine whether or not parts may be reused from values taken at disassembly. These are only general standards and in case the motor displays poor performance or parts shows extreme damage and discoloration before disassembly, it is most important to determine how many parts should be replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the user expects.
Item
Standard Dimension mm (in)
Recommended Value for Replacement mm (in)
Remedy
Clearance between piston and cylinder bore (D-d)
MAINTENANCE STANDARDS Swing motor
(1) Replacement standards for parts The following are the standards to determine whether or not parts may be reused from values taken at disassembly. These are only general standards and in case the motor displays poor performance or parts shows extreme damage and discoloration before disassembly, it is most important to determine how many parts should be replaced, depending upon the purpose of disassembly and the remaining service life of the motor that the user expects.
Item
Standard Dimension mm (in)
Recommended Value for Replacement mm (in)
0.027 (0.00160)
0.052 (0.00205)
0
0.3 (0.0112)
Replace piston and shoe assy.
5.5 (0.217)
5.3 (0.209)
Replace piston and shoe assy.
2.0 (0.0787)
1.8 (0.0709)
Replace.
Remedy
Clearance between piston and cylinder bore (D-d) 0.027 (0.00160)
0.052 (0.00205)
Replace piston or cylinder.
Gap between piston and caulked part of shoe ( )
Replace piston or cylinder.
Gap between piston and caulked part of shoe ( )
0
0.3 (0.0112)
Replace piston and shoe assy.
Thickness of shoe (t)
Thickness of shoe (t)
5.5 (0.217)
5.3 (0.209)
Replace piston and shoe assy.
Thickness of friction plate
Thickness of friction plate
2.0 (0.0787)
1.8 (0.0709)
33-150
Replace.
33-150
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(2) Standard for correcting sliding surfaces If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the parts.
(2) Standard for correcting sliding surfaces If the surface roughness of the sliding surface of parts exceeds the following standard, correct it or replace the parts.
Standard for correcting sliding surfaces
Standard for correcting sliding surfaces
Standard surface roughness
Surface roughness requiring correction
Shoe
0.8—Z (Ra=0.2) (lapping)
3—Z (Ra=0.8)
Shoe plate
0.4—Z (Ra=0.1) (lapping)
3—Z (Ra=0.8)
Cylinder
1.6—Z (Ra=0.4) (lapping)
Valve plate
0.8—Z (Ra=0.2) (lapping)
Name of parts
Standard surface roughness
Surface roughness requiring correction
Shoe
0.8—Z (Ra=0.2) (lapping)
3—Z (Ra=0.8)
Shoe plate
0.4—Z (Ra=0.1) (lapping)
3—Z (Ra=0.8)
12.5—Z (Ra=3.2)
Cylinder
1.6—Z (Ra=0.4) (lapping)
12.5—Z (Ra=3.2)
6.3—Z (Ra=1.6)
Valve plate
0.8—Z (Ra=0.2) (lapping)
6.3—Z (Ra=1.6)
Name of parts
•
Lap each sliding surface to a standard roughness level or finer.
•
Lap each sliding surface to a standard roughness level or finer.
•
If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.
•
If the spherical sliding surface of the spring (114) and cylinder (111) are roughened, replace parts in pairs.
33-151
33-151
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.4.2
33.2.5.4.2
Swing reduction gear
(1) Inspection at disassembly
Swing reduction gear
(1) Inspection at disassembly
1) Spacer and thrust washer
1) Spacer and thrust washer
a. Inspect that the parts are not seized or worn abnormally or unevenly.
a. Inspect that the parts are not seized or worn abnormally or unevenly.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
b. Inspect and measure the parts to see that the wear does not exceed the allowable values.
2) Gears
2) Gears
a. Inspect that the gear teeth do not show pitting and seizure.
a. Inspect that the gear teeth do not show pitting and seizure.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
b. Inspect by dye penetrant examination that the bottom of the teeth does not show cracks.
3) Bearing Turn the bearing and check that it does not develop abnormal sound, catching and other faults. Do not reuse spherical bearing
3) Bearing Turn the bearing and check that it does not develop abnormal sound, catching and other faults. Do not reuse spherical bearing
4) O-rings and oil seals Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.
4) O-rings and oil seals Do not reuse O-rings and oil seals; always replace them with new ones at reassembly.
(2) Inspection after assembly
(2) Inspection after assembly
1) Operation Check to see that #1 sun gear (2) is not faulty when turned by hand.
1) Operation Check to see that #1 sun gear (2) is not faulty when turned by hand.
2) Checking for oil leak and oil condition Check for oil leak. Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil SAE90 (API Service Grade GL-4).
2) Checking for oil leak and oil condition Check for oil leak. Check the oil level by level gauge and confirm that the oil is not dirty. If the oil is short, replenish gear oil SAE90 (API Service Grade GL-4).
33-152
33-152
33. UPPER STRUCTURE (3) Maintenance standards
33. UPPER STRUCTURE (3) Maintenance standards
G
A
G
D
H LUBE OIL LEVEL
A
D
H LUBE OIL LEVEL
E
E
C
C
E
E
B
B
F
F
Unit : mm (in) Code
Item
A
Wear in #1 planetary shaft
ø39
1.53 -0.0004
B
Wear in #2 planetary shaft
ø29
0.0787 -0.0079
C
Gears
Repairable level 0
Condition of tooth face
There should be no pitting exceeding 1.6mm (0.0630in) dia, abnormal wear or seizure.
Condition of tooth flank
There should be no cracks. 0
Thickness of thrust washer
1.6
0.063 -0.0079
E
Thickness of thrust washer
2.0
0.0787 -0.0079
F
Wear in shaft (Diameter of part coming in contact with oil seal )
G
Socket bolt tightening torque Lube oil
No flaking
0
D
H
Service Limit
Gear oil SAE90 (API Service Grade GL-4)
ø95
Unit : mm (in)
Remedy
Code
Item
Replace entire spider assy.
A
Wear in #1 planetary shaft
ø39
1.53 -0.0004
Replace four shafts as a set.
B
Wear in #2 planetary shaft
ø29
0.0787 -0.0079
Replace (Planetary pinion should be replaced in a set of four.)
C
Gears
Repairable level 0
Condition of tooth face
There should be no pitting exceeding 1.6mm (0.0630in) dia, abnormal wear or seizure.
Condition of tooth flank
There should be no cracks. 0
0.0512
Replace
D
Thickness of thrust washer
1.6
0.063 -0.0079
1.6
0.063
Replace
E
Thickness of thrust washer
2.0
0.0787 -0.0079
ø94.9
3.736
Replace
F
Wear in shaft (Diameter of part coming in contact with oil seal )
M14— 181 N•m (130 lbf•ft)
Apply Three-Bond 1360K and tighten to specified torque.
G
Socket bolt tightening torque
3.0 L (0.8 gal)
Replenish or replace.
H
0.0787
33-153
0 -0.003
Lube oil
No flaking
0
1.3
0
Service Limit
Gear oil SAE90 (API Service Grade GL-4)
ø95
Remedy Replace entire spider assy. Replace four shafts as a set. Replace (Planetary pinion should be replaced in a set of four.)
1.3
0.0512
Replace
0
1.6
0.063
Replace
0
ø94.9
3.736
Replace
0.0787 -0.003
M14— 181 N•m (130 lbf•ft)
Apply Three-Bond 1360K and tighten to specified torque.
3.0 L (0.8 gal)
Replenish or replace.
33-153
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.5
33.2.5.5
TROUBLESHOOTING
33.2.5.5.1
Swing motor
33.2.5.5.1
(1) Hydraulic motor does not rotate. Trouble Pressure does not rise.
Pressure rises
Cause
Remedy
1. Relief valve pressure in circuit is not adjusted correctly.
1. Set to correct value.
2. Malfunction of relief valve.
Pressure does not rise.
Cause
Remedy 1. Set to correct value.
2.
2. Malfunction of relief valve.
2.
2-1. Sticking plunger.]
2-1. Correct the stuck areas or replace the plunger.
2-1. Sticking plunger.]
2-1. Correct the stuck areas or replace the plunger.
2-2. Orifice on plunger is clogged.
2-2. Disassemble and clean.
2-2. Orifice on plunger is clogged.
2-2. Disassemble and clean.
3. Plunger seat is faulty.
3. Check the seat surface and replace the plunger if scored.
3. Plunger seat is faulty.
3. Check the seat surface and replace the plunger if scored.
4. Anti-reaction valve seat is faulty.
4. Replace the anti-reaction valve cartridge or block.
4. Anti-reaction valve seat is faulty.
4. Replace the anti-reaction valve cartridge or block.
1. Overload.
1. Eliminate overload.
1. Overload.
1. Eliminate overload.
2. Moving parts are seized.
2. Inspect and repair piston, shoe and cylinder valve plate.
2. Moving parts are seized.
2. Inspect and repair piston, shoe and cylinder valve plate.
3. Brake release pressure is not working on the motor
3. Check circuit and correct it.
3. Brake release pressure is not working on the motor
3. Check circuit and correct it.
4. Brake piston is stuck.
4. Disassemble and check.
4. Brake piston is stuck.
4. Disassemble and check.
5. Spool for releasing brake is stuck.
5. Disassemble and check.
5. Spool for releasing brake is stuck.
5. Disassemble and check.
6. Friction plate is seized.
6. Disassemble, check and repair.
6. Friction plate is seized.
6. Disassemble, check and repair.
Pressure rises
(2) Rotating direction is reverse. Cause
Remedy
1. Motor’s assembling direction is reversed. 1. Assemble correctly. 2. Piping inlets and outlets are reversed.
2. Pipe correctly.
(3) Revolution does not rise to set value.
Revolution does not rise to set value
Trouble
1. Relief valve pressure in circuit is not adjusted correctly.
Trouble
Trouble
Swing motor
(1) Hydraulic motor does not rotate.
(2) Rotating direction is reverse.
Rotating direction is reverse.
TROUBLESHOOTING
Trouble Rotating direction is reverse.
Cause
Remedy
1. Motor’s assembling direction is reversed. 1. Assemble correctly. 2. Piping inlets and outlets are reversed.
2. Pipe correctly.
(3) Revolution does not rise to set value. Cause
Remedy
1. Oil inflow is deficient.
1. Check pump’s delivery rate and circuits to motor.
2. Oil leaks are excessive due to high temperature. 3. Sliding surfaces are worn or damaged.
33-154
Trouble Revolution does not rise to set value
Cause
Remedy
1. Oil inflow is deficient.
1. Check pump’s delivery rate and circuits to motor.
2. Lower oil temperature.
2. Oil leaks are excessive due to high temperature.
2. Lower oil temperature.
3. Replace.
3. Sliding surfaces are worn or damaged.
3. Replace.
33-154
33. UPPER STRUCTURE (4) Brake torque is insufficient. Trouble Brake torque isinsufficient.
(4) Brake torque is insufficient. Cause
Remedy
1. Friction plate is worn.
1. Disassemble and check. Replace if wear is beyond standard value.
2. Brake piston is stuck.
2. Brake piston is stuck.
2. Disassemble and check.
3. Brake release pressure is not released.
3. Check and correct circuit.
3. Brake release pressure is not released.
3. Check and correct circuit.
4. Break release spool is stuck.
4. Disassemble and check.
4. Break release spool is stuck.
4. Disassemble and check.
5. Spline of friction plate is damaged.
5. Disassemble and check. Replace damaged part.
5. Spline of friction plate is damaged.
5. Disassemble and check. Replace damaged part.
Remedy
1.Relief valve malfunctions. Same as (1).
1. Replace. Same as (1).
2. Plunger seat is faulty.
2. Replace.
3. Seat of the anti-reaction valve is no good. 3. Replace the anti-reaction valve cartridge or block.
(6) Oil leaks
Trouble
Trouble The swing motor drifts much when it is actuated by external torques. (e.g. Machine is on a slope.)
Cause
Remedy
1.Relief valve malfunctions. Same as (1).
1. Replace. Same as (1).
2. Plunger seat is faulty.
2. Replace.
3. Seat of the anti-reaction valve is no good. 3. Replace the anti-reaction valve cartridge or block.
1) Oil leak from oil seal Cause
Remedy
1. Lip of seal catches contaminant and damaged.
1. Replace oil seal.
2. Shaft is damaged or worn.
Trouble
Cause
Remedy
1. Lip of seal catches contaminant and damaged.
1. Replace oil seal.
2. Shift the lip and shaft positions or replace oil seal.
2. Shaft is damaged or worn.
2. Shift the lip and shaft positions or replace oil seal.
3. Casing inner pressure has risen abnormally high, with the result that lip of oil seal is flipped.
3. Repair drain piping if clogged up.
3. Casing inner pressure has risen abnormally high, with the result that lip of oil seal is flipped.
3. Repair drain piping if clogged up.
4. Shaft is rusted.
4. Disassemble and correct.
4. Shaft is rusted.
4. Disassemble and correct.
2) Oil leak from matching surface
Oil leak from matching surface
(5) The swing motor drifts much. Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor is not faulty.
(6) Oil leaks
1) Oil leak from oil seal
Trouble
Remedy
2. Disassemble and check.
Cause
Brake torque isinsufficient.
Cause
1. Disassemble and check. Replace if wear is beyond standard value.
Trouble
Oil leaks from oil seal
Trouble
1. Friction plate is worn.
(5) The swing motor drifts much. Check the drain rate of the hydraulic motor. If it is less than 4 L/min (1.1 gal/min), you should think that the motor is not faulty.
The swing motor drifts much when it is actuated by external torques. (e.g. Machine is on a slope.)
33. UPPER STRUCTURE
Oil leaks from oil seal
2) Oil leak from matching surface Cause
Remedy
1. O-ring is missing.
1. Set O-ring correctly and assemble it.
2. O-ring has a scratch.
2. Replace.
3. Seal surface has a scratch. 4. Bolt is loose or damaged.
33-155
Trouble Oil leak from matching surface
Cause
Remedy
1. O-ring is missing.
1. Set O-ring correctly and assemble it.
2. O-ring has a scratch.
2. Replace.
3. Disassemble and correct.
3. Seal surface has a scratch.
3. Disassemble and correct.
4. Tighten to specified torque or replace.
4. Bolt is loose or damaged.
4. Tighten to specified torque or replace.
33-155
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.5.5.2
33.2.5.5.2
Reduction unit
33-156
Reduction unit
33-156
33. UPPER STRUCTURE 33.2.6
SWIVEL JOINT
33.2.6.1
33. UPPER STRUCTURE 33.2.6
CONSTRUCTION VIEW
SWIVEL JOINT
33.2.6.1
CONSTRUCTION VIEW
Fig. 33-268 Construction of swivel joint No.
Part name
Q’ty
No.
Fig. 33-268 Construction of swivel joint Part name
Q’ty
No.
Part name
Q’ty
No.
Part name
Q’ty
1
Body
1
7
O-ring (G95 1A)
1
1
Body
1
7
O-ring (G95 1A)
1
2
Stem
1
8
Socket bolt (M8u20)
2
2
Stem
1
8
Socket bolt (M8u20)
2
3
Thrust plate
1
9
Socket bolt (M8u30)
3
3
Thrust plate
1
9
Socket bolt (M8u30)
3
4
Cover
1
12
Plug
1
4
Cover
1
12
Plug
1
5
Seal
5
13
O-ring (P80)
2
5
Seal
5
13
O-ring (P80)
2
6
Seal assy
1
6
Seal assy
1
33-157
33-157
33. UPPER STRUCTURE
33. UPPER STRUCTURE
33.2.6.2
33.2.6.2
33.2.6.2.1 No. a b
DISASSEMBLY AND ASSEMBLY Tools
33.2.6.2.1
Tool Name
Used for
Remarks
Hammer
1. Steel hammer 2. Wooden or plastic mallet
Rubber mat Wrench
Disassembly Assembly
c
750 mm (30in) square or more
No. a b
1. Allen wrench
DISASSEMBLY AND ASSEMBLY Tools Tool Name
Remarks
Hammer
1. Steel hammer 2. Wooden or plastic mallet
Rubber mat Wrench
2. Double-ended and single-ended wrench
Used for
Disassembly Assembly
c
Torque wrench
Assembly
e
3. Extension pipe
98 N•m (72 lbf•ft)
Pin
d
Grind the tip of "a nail" to shape as a screwdriver.
Disassembly
Spatula
Approx. 120mm (4.72in)
Vinyl tape
g
Vise
h
Loctite
i
Lubricating oil
j
Cleaning oil
33.2.6.2.2
Disassembly Assembly
Torque wrench
Assembly
98 N•m (72 lbf•ft)
Pin e
Disassembly
Make from a hack-saw blade
Disassembly Assembly
f
Remove the edge completely and make corner round smooth.
Approx. 120mm (4.72in)
Vinyl tape
Vise movable over 150mm (6in)
g
# 242
h
Loctite
Hydraulic oil or vaseline
i
Lubricating oil
j
Cleaning oil
Apparatus
Grind the tip of "a nail" to shape as a screwdriver.
Spatula
Make from a hack-saw blade
Disassembly Assembly
f
1. Allen wrench 2. Double-ended and single-ended wrench
3. Extension pipe d
750 mm (30in) square or more
33.2.6.2.2
Vise
Disassembly Assembly
Vise movable over 150mm (6in) # 242 Hydraulic oil or vaseline
Apparatus
(1) Hoist or crane The lifting device should be capable of lifting the swivel joint assy.
(1) Hoist or crane The lifting device should be capable of lifting the swivel joint assy.
(2) Work bench The work bench should have an area of 1.2mu1.5m (4ftu5ft).
(2) Work bench The work bench should have an area of 1.2mu1.5m (4ftu5ft).
(3) Others Also prepare cloth, wooden block and oil pan.
(3) Others Also prepare cloth, wooden block and oil pan.
33.2.6.2.3
33.2.6.2.3
Cleaning outside
Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil. • Keep all ports plugged up while cleaning.
Cleaning outside
Clean the swivel joint to be free from dirt and dust, using steam and cleaning oil. • Keep all ports plugged up while cleaning.
33-158
Remove the edge completely and make corner round smooth.
33-158
33. UPPER STRUCTURE 33.2.6.2.4
Disassembly
33. UPPER STRUCTURE 33.2.6.2.4
Disassembly
The part numbers used in this disassembly procedure correspond to those of a construction drawing in Fig. 33-268.
The part numbers used in this disassembly procedure correspond to those of a construction drawing in Fig. 33-268.
(1) Removing cover
(1) Removing cover
1) Mark cover (4) and body (1) with matching marks for convenient reassembly.
1) Mark cover (4) and body (1) with matching marks for convenient reassembly.
2) Place a V-block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (9) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise.
2) Place a V-block on a work bench, place a swivel joint set on the side, fix it and loosen socket bolt (9) by means of a pipe and wrench. Alternately, the swivel joint may be fixed by holding stem (2) in a vise. Fig. 33-269 Removing cover (4)
: 6 mm 3) Remove cover (4) from body (1) and draw out Oring (7) from cover (4).
Fig. 33-269 Removing cover (4)
: 6 mm 3) Remove cover (4) from body (1) and draw out Oring (7) from cover (4).
Fig. 33-270 Removing O-ring (7) (2) Removing thrust plate Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the abovementioned cover.
Fig. 33-270 Removing O-ring (7) (2) Removing thrust plate Loosen socket bolt (8) fastening thrust plate (3), in the same manner as the removing of the abovementioned cover.
: 6 mm
: 6 mm
When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.
When removing thrust plate (3) by fixing body (1), support stem (2) so it may not fall down.
Fig. 33-271 Removing thrust plate (3) (3) Removing stem Place body (1) on a V-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand. Stem weight : 10.5 kg (23 lbs)
Fig. 33-271 Removing thrust plate (3) (3) Removing stem Place body (1) on a V-block. Put a wooden block against stem (2) via the body so about half of the stem is covered by the wooden block and knock it out using a mallet. By hitting out the stem over about 1/2 from the body, it can be easily pulled out by hand. Stem weight : 10.5 kg (23 lbs)
Fig. 33-272 Drawing out stem (2)
33-159
Fig. 33-272 Drawing out stem (2)
33-159
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(4) Removing sealing parts
(4) Removing sealing parts
SPATULA (f)
1) Remove rings (13) of seal assemblies (6) and (5) with spatula (f).
SPATULA (f)
1) Remove rings (13) of seal assemblies (6) and (5) with spatula (f). 13
Pay attention to the body (1) not to be damaged by the top edge of spatula (f).
13
Pay attention to the body (1) not to be damaged by the top edge of spatula (f). Fig. 33-273 Removing O-ring (13)
2) Pierce slipper ring of seal assemblies (6) and (5) with pin (e) and remove them from the seal groove. Fig. 33-274 shows only one pin, but use two pins to remove it securely.
Fig. 33-273 Removing O-ring (13) 2) Pierce slipper ring of seal assemblies (6) and (5) with pin (e) and remove them from the seal groove. Fig. 33-274 shows only one pin, but use two pins to remove it securely.
SLIPPER RING
BACKUP RING DETAIL (6)
SLIPPER RING
BACKUP RING DETAIL (6) O-RING GROOVE
SEAL (6) ASSY
PIN (e)
O-RING GROOVE
SEAL GROOVE
SEAL (6) ASSY
OIL GROOVE SEAL (5)
Assembly
SEAL GROOVE
SEAL (5)
Assembly
Prior to assembly, clean each parts (excluding the Oring and seal), and arrange in the sequence of assembly. Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13).
Prior to assembly, clean each parts (excluding the Oring and seal), and arrange in the sequence of assembly. Apply grease on the groove of seal to be installed on seal assembly (6) and O-ring (13).
(1) Assembling seals to body
(1) Assembling seals to body
33-160
SEAL GROOVE
Fig. 33-274 Removing out seal assy (5)(6) 33.2.6.2.5
1) Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove. Check the twist of O-ring
SEAL GROOVE OIL GROOVE
Fig. 33-274 Removing out seal assy (5)(6) 33.2.6.2.5
PIN (e)
1) Apply hydraulic oil to O-ring (13) thinly and insert it in O-ring groove. Check the twist of O-ring
33-160
33. UPPER STRUCTURE
33. UPPER STRUCTURE
2) Slipper ring is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in Fig. 33-275. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.
2) Slipper ring is assembled, after first inserting the backup ring, by slightly-distorting the shape as shown in Fig. 33-275. Also after inserting all of the seals, be certain that these are installed in the seal groove by use of the spatula.
3) Assemble seal (5) by the same procedure above mentioned.
3) Assemble seal (5) by the same procedure above mentioned.
Fig. 33-275 Inserting slipper ring (6)
Remove grease, hydraulic oil and vaseline from the groove of seal. And insert seal (5). Seals (5) have no back-up ring. (2) Assembling stem Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).
•
If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.
•
The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along the shaft center.
Press in by applying your weight by your hands.
2 STEM
O-RING 13 SEAL ASSY 6
1 BODY
SEAL 5
Fig. 33-275 Inserting slipper ring (6)
Remove grease, hydraulic oil and vaseline from the groove of seal. And insert seal (5). Seals (5) have no back-up ring. (2) Assembling stem Lightly coat the outer circumference of stem (2) and the inner surface of body (1) with grease or vaseline and slowly insert stem (2) into body (1).
•
If stem (2) is pressed in too fast, the seal may be damaged. Do it slowly.
•
The clearance between body (1) and stem (2) is about 0.1mm (0.004in). Push stem straight along the shaft center.
Press in by applying your weight by your hands.
2 STEM
O-RING 13 SEAL ASSY 6 SEAL 5
WORK BENCH
WORK BENCH
Fig. 33-276 Inserting stem (2) (3) Assembling thrust plate
1 BODY
Fig. 33-276 Inserting stem (2) (3) Assembling thrust plate
1) While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.
1) While holding stem (2) and body (1), match the hole of thrust plate (3) and the stem (2) hole.
2) Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite #242 and tighten to stem (2).
2) Next, after removing any oil from the thread of socket bolt (8), coat it with Loctite #242 and tighten to stem (2).
: 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft)
: 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft) Fig. 33-277 Tightening socket bolt (8)
33-161
Fig. 33-277 Tightening socket bolt (8)
33-161
33. UPPER STRUCTURE
33. UPPER STRUCTURE
(4) Assembling cover After installing O-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite #242 and tighten it which will then complete assembly.
(4) Assembling cover After installing O-ring (7) to cover (4) and aligning the matching marks of the cover (4) and body (1), coat socket bolt (9) with Loctite #242 and tighten it which will then complete assembly.
: 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft)
: 6 mm, Tightening torque : 30.4 N•m (22 lbf•ft)
Fig. 33-278 Tightening socket bolt (9)
33-162
Fig. 33-278 Tightening socket bolt (9)
33-162
33. UPPER STRUCTURE 33.2.6.3 33.2.6.3.1 Interval 2,000hr
MAINTENANCE STANDARDS
Seal for oil leakage outside
All sealing parts 4,000hr In principle, disassemble All sliding parts and check regardless of oil leakage or not. When All parts disassembled for repair
33.2.6.3.2
33.2.6.3.1
Checking Procedure
Remedy Replace O-ring or dust seal , if any oil leakage can be found.
Check oil leakage outside
Replace all sealing parts such as slipper seal with back-up ring and O-ring. Check abnormal wear, scoringor corrosion caused by foreignmatters or seizure.
Repair or replace referring to their limit of service.
Check them for seizure, foreignmatters, abnormal wear, anddefect of seals.
Repair or replace referring to their limit of service. O-rings and dust seal should be replaced.
Service limit of the parts Parts Sliding surface with sealing sections
Body, Stem
33.2.6.3
Inspection procedure and remedy Check Item
Interval 2,000hr
Maintenance Standards Plating worn or peeled due to seizure or contamination.
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm (0.004in) in depth due to seizure or contamination. body and stem other than sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). plate 3) Damage due to seizure or contamination repairable within wear limit 0.5mm (0.02in). 1) Worn more than 0.5mm (0.02in) or abnormality. Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). plate 3) Damage due to seizure or contamination
repairable within wear limit 0.5mm (0.02in).
33-163
Seal for oil leakage outside
Body, Stem
Replace
Checking Procedure
Remedy Replace O-ring or dust seal , if any oil leakage can be found.
Check oil leakage outside
Replace all sealing parts such as slipper seal with back-up ring and O-ring. Check abnormal wear, scoringor corrosion caused by foreignmatters or seizure.
Repair or replace referring to their limit of service.
Check them for seizure, foreignmatters, abnormal wear, anddefect of seals.
Repair or replace referring to their limit of service. O-rings and dust seal should be replaced.
Service limit of the parts Parts
Replace
Maintenance Standards Plating worn or peeled due to seizure or contamination.
Sliding surface between 1) Worn abnormally or damaged more than 0.1mm (0.004in) in depth due to seizure or contamination. body and stem other than sealing sections 2) Damaged less than 0.1mm (0.004in) in depth. 1) Worn more than 0.5mm (0.02in) or abnormality.
Smooth
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). plate 3) Damage due to seizure or contamination repairable within wear limit 0.5mm (0.02in).
Smooth Replace
Smooth
Check Item
Sliding surface with sealing sections
Replace
Smooth
Inspection procedure and remedy
When All parts disassembled for repair
Remedy
Smooth with oilstone.
MAINTENANCE STANDARDS
All sealing parts 4,000hr In principle, disassemble All sliding parts and check regardless of oil leakage or not.
33.2.6.3.2
1) Worn more than 0.5mm (0.02in) or abnormality.
Cover
33. UPPER STRUCTURE
1) Worn more than 0.5mm (0.02in) or abnormality. Cover
Sliding surface with thrust 2) Worn less than 0.5mm (0.02in). plate 3) Damage due to seizure or contamination
repairable within wear limit 0.5mm (0.02in).
33-163
Remedy Replace Replace Smooth with oilstone. Replace Smooth Smooth Replace Smooth Smooth
33. UPPER STRUCTURE Parts
33. UPPER STRUCTURE Maintenance Standards
Remedy
Parts
1) Protruded excessively from seal groove.
Maintenance Standards 1) Protruded excessively from seal groove.
Replace (With back-up ring)
Replace (With back-up ring)
2) Slipper ring 1.5mm (0.06in) narrower than seal groove, or narrower than back-up ring.
Slipper ring
1.5mm (0.02in) (max.)
2) Slipper ring 1.5mm (0.06in) narrower than seal groove, or narrower than back-up ring.
Replace (With back-up ring)
BACKUP RING
Slipper ring
1.5mm (0.02in) (max.)
Replace (With back-up ring)
BACKUP RING
3) Worn unevenly more than 0.5mm (0.02in)
3) Worn unevenly more than 0.5mm (0.02in)
Replace (With back-up ring)
33-164
Remedy
Replace (With back-up ring)
33-164
33. UPPER STRUCTURE 33.2.6.3.3
Inspection after assembly
33. UPPER STRUCTURE 33.2.6.3.3
Inspection after assembly
After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in Fig. 33-279.
After completion of assembly, inspection for oil leakage, pressure resistance, etc., using a device as shown in Fig. 33-279.
(1) High pressure port (A,B,C,D and F port) Install a directional valve and pressure gauge to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7), gradually increase the pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. Keep stop valve (6) on the low pressure relief valve side closed at this time. Check that it is free from looseness, deformation, breakage, etc. under three minutes pressurizing. And, the oil leakage must be checked for the first 1 minute, and if there be a pressure drop for any reason, the pressure drop should be in 10% of the trapped pressure. This checking must be carried out for every circuit.
(1) High pressure port (A,B,C,D and F port) Install a directional valve and pressure gauge to the stem side port and body side port respectively, and while watching the pressure gauge (for high pressure) installed on the body side and also by regulating high pressure relief valve (7), gradually increase the pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) and lock in the hydraulic oil in the swivel. Keep stop valve (6) on the low pressure relief valve side closed at this time. Check that it is free from looseness, deformation, breakage, etc. under three minutes pressurizing. And, the oil leakage must be checked for the first 1 minute, and if there be a pressure drop for any reason, the pressure drop should be in 10% of the trapped pressure. This checking must be carried out for every circuit. Fig. 33-279 Hydraulic circuit for inspection equipment
Fig. 33-279 Hydraulic circuit for inspection equipment
(2) Low pressure port (E port) Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49MPa (71psi).
(2) Low pressure port (E port) Similar to the high pressure port, install a directional valve and pressure gauge on each port of the stem side and body side. Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure) connected to the body side and also by regulating low pressure relief valve (5), gradually increase the pressure and check for outside leakage with a color check at a pressure of 0.49MPa (71psi).
33.2.6.3.4
33.2.6.3.4
Troubleshooting Trouble
Cause
1. External leakage of hydraulic oil
Defective O-ring & seal
2. Internal leakage of hydraulic oil 3. Swivel stem seized
Remedy
Troubleshooting Trouble
Remedy
1. External leakage of hydraulic oil
Defective O-ring & seal
1) Defective slipper seal
1) Replace all seals.
2. Internal leakage of hydraulic oil
1) Defective slipper seal
1) Replace all seals.
2) Sliding face worn excessively
2) Replace assy.
2) Sliding face worn excessively
2) Replace assy.
1) Stem and body seized
1) Grind and hone. Replace assy, if stem and body are too loose and causing oil leakage.
1) Stem and body seized
1) Grind and hone. Replace assy, if stem and body are too loose and causing oil leakage.
3. Swivel stem seized
2) Inappropriate swivel stopper bracket 2) Reinstall Secure 2~3mm (0.08~0.12in) allowance for bolt stopper. 4. Loose swivel stem and cover
Cause
Replace all seals.
Socket bolt tightened insufficiently.
33-165
Retighten.
Replace all seals.
2) Inappropriate swivel stopper bracket 2) Reinstall Secure 2~3mm (0.08~0.12in) allowance for bolt stopper. 4. Loose swivel stem and cover
Socket bolt tightened insufficiently.
33-165
Retighten.
33. UPPER STRUCTURE
33. UPPER STRUCTURE
[MEMO]
[MEMO]
33-166
33-166
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
TABLE OF CONTENTS
TABLE OF CONTENTS
34.1 REMOVING AND INSTALLING.......................................................................................34-3
34.1 REMOVING AND INSTALLING.......................................................................................34-3
34.1.1
TRAVEL SYSTEM .................................................................................................34-3
34.1.1
TRAVEL SYSTEM .................................................................................................34-3
34.1.2
CRAWLER..............................................................................................................34-3
34.1.2
CRAWLER..............................................................................................................34-3
34.1.3
UPPER ROLLER ....................................................................................................34-7
34.1.3
UPPER ROLLER ....................................................................................................34-7
34.1.4
LOWER ROLLER ...................................................................................................34-13
34.1.4
LOWER ROLLER ...................................................................................................34-13
34.1.5
FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.5
FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.6
SPROCKET ............................................................................................................34-30
34.1.6
SPROCKET ............................................................................................................34-30
34.1.7
TRAVEL MOTOR ..................................................................................................34-33
34.1.7
TRAVEL MOTOR ..................................................................................................34-33
34.1.8
SWING BEARING ..................................................................................................34-35
34.1.8
SWING BEARING ..................................................................................................34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38 34.2.1
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38
TRAVEL MOTOR ...................................................................................................34-38
34.2.1
TRAVEL MOTOR ...................................................................................................34-38
34
34
Book Code No. S5YN3421E01 34-1
Book Code No. S5YN3421E01 34-1
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
Issue
Date of Issue
Applicable Machines
First edition
March, 2007
n
July, 2007
n
n
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
Remarks S5YN3421E01 (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
Issue
Date of Issue
Applicable Machines
K
First edition
March, 2007
K
n
July, 2007
n
K
n
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
Remarks S5YN3421E01 (NHK Russia) n (NHK Middle East) n (NHK Russia) HS Engine
K K K
PREFACE
PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences of field condition and defective section.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions. When disassembly and assembly are required, select the necessary section, itemize the work contents with good understanding, then starts working.
34-2
34-2
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1
REMOVING AND INSTALLING
34.1
REMOVING AND INSTALLING
34.1.1
TRAVEL SYSTEM
34.1.1
TRAVEL SYSTEM
8. SWING BEARING
8. SWING BEARING
2. CRAWLER
2. CRAWLER
7. TRAVEL MOTOR 5. FRONT IDLER
7. TRAVEL MOTOR 5. FRONT IDLER
6. SPROCKET
GUARD
GUARD
LOWER FRAME 3. UPPER ROLLER
GREASE NIPPLE OF THE TRACK SPRING ADJUSTER
4. LOWER ROLLER
34.1.2.1
CRAWLER
34.1.2.1
REMOVING CRAWLER
(1) Position the machine to remove crawler.
(2) Pushing out master pin.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/ fixing position in Fig. 34-3.
1) Find the master pin and place it in its removing/ fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.
2) Loosen the grease nipple and slacken crawler.
: 19 mm
When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
•
Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.
4. LOWER ROLLER
CRAWLER
(1) Position the machine to remove crawler.
•
3. UPPER ROLLER
Fig. 34-1 Designation and location of undercarriage 34.1.2
REMOVING CRAWLER
LOWER FRAME
GREASE NIPPLE OF THE TRACK SPRING ADJUSTER
Fig. 34-1 Designation and location of undercarriage 34.1.2
6. SPROCKET
: 19 mm
Fig. 34-2 Crawler removing position
3) Pushing out master pin Apply jig on master pin and strike it out with a mallet. (Refer to Fig. 34-7 Press fitting of master pin)
•
When loosening the grease nipple of the adjuster, do not loosen it more than one turn.
•
Where grease does not come out well, move the machine back and forth. The over loosening of grease nipple may cause it to jump out incurring danger of injury. So be careful not to over loosen the grease nipple.
Fig. 34-2 Crawler removing position
3) Pushing out master pin Apply jig on master pin and strike it out with a mallet. (Refer to Fig. 34-7 Press fitting of master pin)
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by flying objects.
Fig. 34-3 Removing/fixing position of master pin
34-3
When using a big hammer, wear protective goggles and a long-sleeved uniform so you do not injure yourself by flying objects.
Fig. 34-3 Removing/fixing position of master pin
34-3
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(3) Removing crawler Put attachment on ground so that weight is not loaded to the lower frame, and remove track link assy rotating sprocket.
(3) Removing crawler Put attachment on ground so that weight is not loaded to the lower frame, and remove track link assy rotating sprocket.
Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury. Please keep well away from the equipment.
Crawler end section may fall on the ground just before extending it on the ground incurring danger of injury. Please keep well away from the equipment.
34.1.2.2
Fig. 34-4 Removing crawler
INSTALLING
34.1.2.2
INSTALLING
Installing is done in the reverse order of removing.
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction. Place the track links on the ground so they converge, facing the front idler, as shown in the figure on the right.
(1) Checking crawler installation direction. Place the track links on the ground so they converge, facing the front idler, as shown in the figure on the right.
(2) Installing crawler
(2) Installing crawler
1) Preparation for installation Treat paint flaking protection with care not to damage lower flame.
Fig. 34-4 Removing crawler
1) Preparation for installation Treat paint flaking protection with care not to damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler Insert a crowbar into the master pin hole, lift the lower frame 1 to 2cm above the ground level by holding it by hand so the machine body weight is not exerted on the shoe. Retract the sprocket to help push the back winding of the crawler.
Fig. 34-5 Installing direction of crawler
2) Winding crawler Insert a crowbar into the master pin hole, lift the lower frame 1 to 2cm above the ground level by holding it by hand so the machine body weight is not exerted on the shoe. Retract the sprocket to help push the back winding of the crawler.
(3) Preparation for press fitting master pin
(3) Preparation for press fitting master pin
1) Preparing for installation Put square wood under the shoe plate.
1) Preparing for installation Put square wood under the shoe plate.
2) Aligning master pin holes Aligning master pin holes through fine adjustment turning sprocket.
2) Aligning master pin holes Aligning master pin holes through fine adjustment turning sprocket.
Fig. 34-6 Winding crawler
•
When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing out the master pin.
•
When using a big hammer, exercise care so you are not injured by flying objects the same way as when pushing out the master pin.
•
Coat the master pin with molybdenum disulfide grease, before pressing it in.
•
Coat the master pin with molybdenum disulfide grease, before pressing it in.
(4) Press fitting of master pin Apply press fitting jig on master pin, and strike it with a mallet to press fit.
Fig. 34-7 Press fitting of master pin
34-4
Fig. 34-6 Winding crawler
(4) Press fitting of master pin Apply press fitting jig on master pin, and strike it with a mallet to press fit.
Fig. 34-7 Press fitting of master pin
34-4
34. TRAVEL SYSTEM (5) Adjusting crawler tension (See Fig. 34-8) After installing, adjust tension of crawler.
34. TRAVEL SYSTEM (5) Adjusting crawler tension (See Fig. 34-8) After installing, adjust tension of crawler.
: 19 mm
: 19 mm
A
A
Fig. 34-8 Adjusting crawler tension 34.1.2.3
CONSTRUCTION
34.1.2.3
1-1
1-8
1-3
1-4
1-6
1-1
1-8 2
1-2
1-5
4
RUBBER PAD SHOE 2
1-7
1-2
CONSTRUCTION
FLAT SHOE 2
TRIANGLE SHOE
1-7
Fig. 34-8 Adjusting crawler tension
1-1
1-8
3
1-6
1-8 TRIANGLE SHOE 2
1-2
1-7
Fig. 34-9 Track link assy and shoe plate
1-2
1-5
4
RUBBER PAD SHOE 2
1-7
3
3
1-3
1-4
FLAT SHOE 2
1-1
3
3
Fig. 34-9 Track link assy and shoe plate
YN60D00054F5
YN60D00055F4
YN60D00054F5
YN60D00055F4
No. NAME 1 .LINK ASSY YN62D00017F1 1-1 ..TRACK LINK R 1-2 ..TRACK LINK L 1-3 ..BUSHING 1-4 ..PIN 1-5 ..MASTER BUSHING 1-6 ..MASTER PIN 1-7 ..COLLAR 1-8 ..SEAL 2 .SHOE 600mm .SHOE 700mm .SHOE 800mm 3 .BOLT 2420Z1292 4 .NUT 2420Z1293
No. 1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 2
Q'TY 1 1 1 46 46 46 46 46 46 45 45 45 45 45 45 1 1 1 1 1 1 2 2 2 90 90 90 46 - - 46 - - 46 184 184 184 184 184 184
3 4
34-5
YN60D00055F5 NAME
.LINK ASSY YN62D00017F3 ..TRACK LINK R ..TRACK LINK L ..BUSHING ..PIN ..MASTER BUSHING ..MASTER PIN ..COLLAR ..SEAL .SHOE 600mm .SHOE 700mm .SHOE 800mm .BOLT 2420Z1292 .NUT 2420Z1293
Q'TY 1 1 1 49 49 49 49 49 49 48 48 48 48 48 48 1 1 1 1 1 1 2 2 2 96 96 96 49 - - 49 - - 49 196 196 196 196 196 196
Shoe assy
LC undercarriage YN60D00055F2
Shoe assy
STD undercarriage YN60D00054F2
Shoe assy
LC undercarriage YN60D00055F2
Shoe assy
STD undercarriage YN60D00054F2 YN60D00054F6
3
YN60D00054F6
No. NAME 1 .LINK ASSY YN62D00017F1 1-1 ..TRACK LINK R 1-2 ..TRACK LINK L 1-3 ..BUSHING 1-4 ..PIN 1-5 ..MASTER BUSHING 1-6 ..MASTER PIN 1-7 ..COLLAR 1-8 ..SEAL 2 .SHOE 600mm .SHOE 700mm .SHOE 800mm 3 .BOLT 2420Z1292 4 .NUT 2420Z1293
No. 1 1-1 1-2 1-3 1-4 1-5 1-6 1-7 1-8 2
Q'TY 1 1 1 46 46 46 46 46 46 45 45 45 45 45 45 1 1 1 1 1 1 2 2 2 90 90 90 46 - - 46 - - 46 184 184 184 184 184 184
3 4
34-5
YN60D00055F5 NAME
.LINK ASSY YN62D00017F3 ..TRACK LINK R ..TRACK LINK L ..BUSHING ..PIN ..MASTER BUSHING ..MASTER PIN ..COLLAR ..SEAL .SHOE 600mm .SHOE 700mm .SHOE 800mm .BOLT 2420Z1292 .NUT 2420Z1293
Q'TY 1 1 1 49 49 49 49 49 49 48 48 48 48 48 48 1 1 1 1 1 1 2 2 2 96 96 96 49 - - 49 - - 49 196 196 196 196 196 196
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.2.4
34.1.2.4
MAINTENANCE STANDARD E D
F D
MAINTENANCE STANDARD E D
F D
G
B
G
B
A
A
C
C
H
H
Fig. 34-10
Fig. 34-10 Unit : mm (in)
No.
ITEM
A
Link pitch
B
O.D. of bushing
C
Height of link
STANDARD VALUE
SERVICE LIMIT
198 (7.80) Replace the link ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Interference between bushing and link
Tolerance
Fit
+ 0.11 Interference Interference (+0.0043) ø 58.78 0.05 Shaft 0 - 0.05 (2.3142) (0.0020) (-0.0020) + 0.1 Interference Interference (+0.0039) ø 36.63 0.05 Shaft 0 - 0.05 (1.4421) (0.0020) (-0.0020)
F
Interference between master pin and link
- 0.03 Interference (-0.00118) Interference ø 36.50 0.05 Shaft - 0.088 0 (1.43701) (0.0020) (-0.00315)
G
Clearance between links
H
Tightening torque of shoe bolt
34.1.2.5
1.5 (0.06) (both side)
8 (0.32) 10 (0.39) (both side) (both side)
853 N•m (629 lbf•ft)
TOOLS AND JIGS
Unit : mm (in) No.
ITEM
A
Link pitch
B
O.D. of bushing
C
Height of link
D
Interference between bushing and link
Socket
Tolerance
+ 0.11 Interference Interference (+0.0043) ø 58.78 0.05 Shaft 0 - 0.05 (2.3142) (0.0020) (-0.0020)
- 0.03 Interference (-0.00118) Interference ø 36.50 0.05 Shaft - 0.088 0 (1.43701) (0.0020) (-0.00315)
F
Interference between master pin and link
Replace
G
Clearance between links
Reassembly
H
Tightening torque of shoe bolt
1.5 (0.06) (both side)
(1) Tightening tools Unit : mm (in)
30 (1.2)
Socket
(2) Jig
OPPOSING FLATS 30 (1.2)
(2) Jig NAME
SHAPE
NAME
Master pin fixing jig for iron crawler
SHAPE
Master pin fixing jig for iron crawler
34-6
8 (0.32) 10 (0.39) (both side) (both side)
853 N•m (629 lbf•ft)
TOOLS AND JIGS
NAME
REMEDY
Fit
+ 0.1 Interference Interference (+0.0039) ø 36.63 0.05 Shaft 0 - 0.05 (1.4421) (0.0020) (-0.0020)
Replace Link
OPPOSING FLATS
Fit
Interference between track pin and link
Unit : mm (in) NAME
SERVICE LIMIT
198 (7.80) Replace the link ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Replace
E
REPAIRAB LE LEVEL
190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64)
Basic dimension
34.1.2.5
(1) Tightening tools
STANDARD VALUE
Fit
Interference between track pin and link
E
REMEDY
190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64)
Basic dimension D
REPAIRAB LE LEVEL
34-6
Replace
Replace Link
Replace Reassembly
34. TRAVEL SYSTEM 34.1.3
UPPER ROLLER
34.1.3.1
34.1.3
UPPER ROLLER ASSY
NAME
UPPER ROLLER
34.1.3.1
UPPER ROLLER ASSY No. ITEM
34. TRAVEL SYSTEM
YN64D00032F1
UPPER ROLLER ASSY
UPPER ROLLER ASSY No.
Q’TY
REMARKS
ITEM
NAME
YN64D00032F1 Q’TY
REMARKS
1
ROLLER ASSY
4
YN64D01068F1
1
ROLLER ASSY
4
YN64D01068F1
2
CAPSCREW (SEMS SCREW)
4
M20uP2.5u100
2
CAPSCREW (SEMS SCREW)
4
M20uP2.5u100
3
NUT
4
3
NUT
4
4
WASHER
4
4
WASHER
4
34.1.3.2
REMOVING
34.1.3.2
(1) Preparation for removal Remove crawler (Above mentioned).
3
(1) Preparation for removal Remove crawler (Above mentioned).
4
(2) Removing upper roller (1)
3
2
1) Remove nuts on support tightening section, and also remove capscrew (2) M20u100.
1
: 30 mm
1
: 30 mm
Fig. 34-11 Removing upper roller 34.1.3.3
4
(2) Removing upper roller (1)
2
1) Remove nuts on support tightening section, and also remove capscrew (2) M20u100.
REMOVING
INSTALLING
Fig. 34-11 Removing upper roller 34.1.3.3
INSTALLING
Installing is done in the reverse order of removing.
Installing is done in the reverse order of removing.
(1) Inspection Before reassembling, check it that it rotates smooth manually and for leak.
(1) Inspection Before reassembling, check it that it rotates smooth manually and for leak.
COUNTERSINKING
(2) Installing upper roller (1)
COUNTERSINKING
(2) Installing upper roller (1)
2) Insert it until collar comes in contact with support.
2) Insert it until collar comes in contact with support.
3) Fit it directing the countersinking mark of shaft end upward.
3) Fit it directing the countersinking mark of shaft end upward.
4) Apply Loctite #262 on capscrew M20u100, and tighten it to the specified torque. : 30 mm Tightening torque : 539 N•m (400 lbf•ft) 2
1
CENTER OF MACHINE
1) To install the upper roller, turn up socket bolts (2) toward the center of machine.
CENTER OF MACHINE
1) To install the upper roller, turn up socket bolts (2) toward the center of machine.
4) Apply Loctite #262 on capscrew M20u100, and tighten it to the specified torque. : 30 mm Tightening torque : 539 N•m (400 lbf•ft)
3,4
2
Fig. 34-12 Installing upper roller
34-7
1
3,4
Fig. 34-12 Installing upper roller
34-7
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.3.4
34.1.3.4
CONSTRUCTION 11
1
8
10
4
5
6
7
3
CONSTRUCTION
2
11
9
1
Fig. 34-13 Construction of upper roller 34.1.3.5
DISASSEMBLY AND ASSEMBLY
10
4
5
6
7
3
2
9
Fig. 34-13 Construction of upper roller 34.1.3.5
(1) Disassembly
8
DISASSEMBLY AND ASSEMBLY
(1) Disassembly
1) Draining out oil Remove plug (10) and drain out oil.
1) Draining out oil Remove plug (10) and drain out oil.
: 6mm
: 6mm
2) Removing snap ring (11) Mount the end face inside upper roller (1) on stand jig (f) and separate snap ring (11), using snap ring pliers.
2) Removing snap ring (11) Mount the end face inside upper roller (1) on stand jig (f) and separate snap ring (11), using snap ring pliers.
3) Removing cover (5) Take off cover (5) upwards, utilizing the screwed hole for the plug.
3) Removing cover (5) Take off cover (5) upwards, utilizing the screwed hole for the plug.
4) Removing O-ring (8) Separate O-ring (8) from cover (5).
Fig. 34-14 Construction of upper roller
5) Removing plate (4) Loosen 2 socket bolts (9) and draw out plate (4) from roller (1).
4) Removing O-ring (8) Separate O-ring (8) from cover (5).
Fig. 34-14 Construction of upper roller
5) Removing plate (4) Loosen 2 socket bolts (9) and draw out plate (4) from roller (1).
: 10mm
: 10mm
6) Removing shaft (2) Put the extrusion jig (h) against the end face of shaft (2) and push shaft (2) with collar (3) for floating seal (7), using a press or hammer.
6) Removing shaft (2) Put the extrusion jig (h) against the end face of shaft (2) and push shaft (2) with collar (3) for floating seal (7), using a press or hammer.
Fig. 34-15 Extruding shaft
34-8
Fig. 34-15 Extruding shaft
34-8
34. TRAVEL SYSTEM 7) Removing floating seal (7). Take out floating seal (7) from roller (1).
34. TRAVEL SYSTEM 7) Removing floating seal (7). Take out floating seal (7) from roller (1).
Fig. 34-16 Taking out floating seal
Fig. 34-16 Taking out floating seal
8) Removing floating seal (7). Remove from collar (3), floating seal (7) that is located on the side from which shaft (2) was disassembled.
8) Removing floating seal (7). Remove from collar (3), floating seal (7) that is located on the side from which shaft (2) was disassembled.
Collar (3) is press fitted into shaft (2). Therefore do not disassemble it.
Collar (3) is press fitted into shaft (2). Therefore do not disassemble it.
Fig. 34-17 Removing floating seal and extruding bushing 9) Removing bushing (6) Since the bushing is thin, machine it on a lathe or scrape it off, take care so as not to damage the bore of roller (1). If the bushing is not worn much, mount upper roller (1) on jig (f), insert jig (g) into the end face of bushing (6) and push it out with a press.
Fig. 34-17 Removing floating seal and extruding bushing 9) Removing bushing (6) Since the bushing is thin, machine it on a lathe or scrape it off, take care so as not to damage the bore of roller (1). If the bushing is not worn much, mount upper roller (1) on jig (f), insert jig (g) into the end face of bushing (6) and push it out with a press.
Push with press (e) i 6 1
(2) Assembly Assembly of the upper roller is done in the reverse order of disassembly. 1) Place upper roller (1) on the top end face of jig (f), with its floating seal setting side facing down.
6 1
f
1) Place upper roller (1) on the top end face of jig (f), with its floating seal setting side facing down. Fig. 34-18 Pushing in bushing
7 7
Fig. 34-18 Pushing in bushing
2) Confirm that the outer surface of bushing (6) is not scuffed and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease.
2
3) Put jig (i) into bushing (6) and press it in, using the bore of the bushing and the bore of the roller as guides.
i
(2) Assembly Assembly of the upper roller is done in the reverse order of disassembly.
f
2) Confirm that the outer surface of bushing (6) is not scuffed and coat the outer surface of the inserting side of the bushing, with molybdenum disulfide grease.
Push with press (e)
1
2 7
3) Put jig (i) into bushing (6) and press it in, using the bore of the bushing and the bore of the roller as guides.
7
3
If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.
Fig. 34-19 Fixing floating seal
34-9
3
If you fail in this operation by pressing the bushing unevenly, the bushing is distorted and gets unserviceable. In that case, do not re-use the bushing as it may develop malfunctioning after assembly.
Fig. 34-19 Fixing floating seal
34-9
1
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
4) Installing floating seals (7) Two floating seals (7) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1).
2
7
• Prior to placing floating seal (7) in, apply engine oil lightly to seal surface.
4) Installing floating seals (7) Two floating seals (7) make a pair. Attach one floating seal to retainer fixed in shaft (2), and another to the inside of upper roller (1).
2
7
• Prior to placing floating seal (7) in, apply engine oil lightly to seal surface.
1
5) Inserting shaft (2) Coat shaft (2) with a thin film of oil and insert it into upper roller (1).
1
5) Inserting shaft (2) Coat shaft (2) with a thin film of oil and insert it into upper roller (1). Fig. 34-20 Inserting shaft
6) Installing plate (4) Mount upper roller (1) on the stand jig (f) and attach plate (4) to the end face of the shaft with bolt (9). : 10mm, Tightening torque : 115N•m (85 lbf•ft)
: 10mm, Tightening torque : 115N•m (85 lbf•ft)
7) Installing O-ring (8) Fit O-ring (8) to the groove of cover (5).
7) Installing O-ring (8) Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.
Fig. 34-20 Inserting shaft
6) Installing plate (4) Mount upper roller (1) on the stand jig (f) and attach plate (4) to the end face of the shaft with bolt (9).
• Apply grease to O-ring.
8) Installing cover (5) Attach cover (5) to upper roller (1). Use a press in this operation as a press fit is used.
8) Installing cover (5) Attach cover (5) to upper roller (1). Use a press in this operation as a press fit is used.
9) Installing snap ring (11) Fix snap ring (11) into upper roller (1), using snap ring pliers.
9) Installing snap ring (11) Fix snap ring (11) into upper roller (1), using snap ring pliers.
Fig. 34-21 Installing cover
10) Filling oil Fill in 30cc (1.83cu•in) of engine oil API grade CD #30 through the plug hole in cover (4).
10) Filling oil Fill in 30cc (1.83cu•in) of engine oil API grade CD #30 through the plug hole in cover (4).
11) Installing plug (10) Wind seal tape around plug (10) and screw it into the plug hole of cover (4).
11) Installing plug (10) Wind seal tape around plug (10) and screw it into the plug hole of cover (4).
: 6mm, Tightening torque : 23N•m (17 lbf•ft)
: 6mm, Tightening torque : 23N•m (17 lbf•ft)
• After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand.
• After assembling the upper roller, confirm that oil is not leaking from it and that it rotates smoothly by hand.
Fig. 34-22 Filling oil
34-10
Fig. 34-21 Installing cover
Fig. 34-22 Filling oil
34-10
34. TRAVEL SYSTEM
D
D
E F
C
E F
MAINTENANCE STANDARD
A
34.1.3.6
C
MAINTENANCE STANDARD
A
34.1.3.6
34. TRAVEL SYSTEM
D
D
B
B
G
G
Unit : mm (in) No.
ITEM
A
Dia.
B
Width
C
Tread dia.
D
Tread width
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
ø 140 (6.30)
—
—
150 (5.91)
—
—
ø 120 (4.72) 33 (1.30) Basic dimension
Clearance between shaft and bushing
ø 107 (4.21) ø 105 (4.13)
Tolerance
—
—
Fit
Fit
ø 45 (1.772) Shaft
- 0.025 (-0.00098) - 0.040 (-0.00157)
Clearance 0.7 (0.028)
F
Interference between ø 50 (1.969) Hole roller and bushing
+ 0.030 (+0.00118) 0
Interference Clearance 0 0.01 (0.0004)
G
Tightening torque of socket bolt
E
Oil Roller rotation
Clearance 1.0 (0.039)
REMEDY
Replace
No.
ITEM
A
Dia.
B
Width
C
Tread dia.
D
Tread width
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
ø 140 (6.30)
—
—
150 (5.91)
—
—
ø 120 (4.72)
—
—
Fit
Fit
ø 45 (1.772) Shaft
- 0.025 (-0.00098) - 0.040 (-0.00157)
Clearance 0.7 (0.028)
Clearance 1.0 (0.039)
F
Interference between ø 50 (1.969) Hole roller and bushing
+ 0.030 (+0.00118) 0
Interference Clearance 0 0.01 (0.0004)
G
Tightening torque of socket bolt
E
Clearance between shaft and bushing
Replace bushing
Engine oil API grade CD #30, 30cc (1.83cu•in)
Refill
Roller rotates smoothly by hand.
Reassembly
ø 107 (4.21) ø 105 (4.13)
33 (1.30) Basic dimension
115 N•m (85 lbf•ft)
34-11
Unit : mm (in)
Oil Roller rotation
Tolerance
REMEDY
Replace
Replace bushing
115 N•m (85 lbf•ft) Engine oil API grade CD #30, 30cc (1.83cu•in)
Refill
Roller rotates smoothly by hand.
Reassembly
34-11
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.3.7
34.1.3.7
TOOLS AND JIGS
(1) Tightening tools
TOOLS AND JIGS
(1) Tightening tools Unit : mm
NAME
Unit : mm
OPPOSING FLATS
NAME
30
Socket
30
Socket
6,8
Allen wrench
OPPOSING FLATS
6,8
Allen wrench
(2) Jigs
(2) Jigs Unit : mm (in) SHAPE
Unit : mm (in) No.
NAME
SHAPE
87(3.43)
34-12
160 (6.30)
(1.26)32 (1.46)37
50(1.97)
87(3.43)
(0.709) 1.949 +0.004 0
50(1.97)
1.949 +0.004 0
(1.46)37
(1.18)
(0.709) (1.18)
(1.26)32
+0.1 49.5 0
Bushing fixing jig
18
i
49(1.93)
+0.1 0
h
For extruding shaft
52.5(2.07)
60(2.36)
g
For extruding bushing
+0.1 49.5 0
Bushing fixing jig
18
i
Stand jig
49(1.93)
+0.1 0
h
For extruding shaft
f
52.5(2.07)
44.6
g
For extruding bushing
1.756 +0.004 0
Stand jig
60(2.36)
f
120 (4.72) 90 (3.54)
160 (6.30)
120 (4.72) 90 (3.54)
44.6
NAME
1.756 +0.004 0
No.
34-12
34. TRAVEL SYSTEM LOWER ROLLER
ROLLER ASSY
34.1.4.1
LOWER ROLLER ASSY B5 Apply Loctite #262
T=397N.m (290 lbf.ft)
LC undercarriage
YF64D00002F1 NAME Q'TY
1
2
1
B5 Apply Loctite #262
T=397N.m (290 lbf.ft)
LC undercarriage
YF64D00002F1 NAME Q'TY
LOW ROLLER : YN64D00019F1 - 14 LOW ROLLER : YF64D00001F1 16 CAPSCREW : M18X80(P=1.5) 64 56
2
Apply Loctite #262 T=397N.m (290 lbf.ft)
LOWER ROLLER ASSY
STD undercarriage YN64D00020F1
ITEM
LOW ROLLER : YN64D00019F1 - 14 LOW ROLLER : YF64D00001F1 16 CAPSCREW : M18X80(P=1.5) 64 56
2
LOWER ROLLER
34.1.4.1
STD undercarriage YN64D00020F1
ITEM
1
34.1.4
ROLLER ASSY
34.1.4
34. TRAVEL SYSTEM
2
B2
Fig. 34-23 Lower roller assy and track guide 34.1.4.2
REMOVAL
REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the lower frame by the front attachment and stop the engine in that condition.
1) Loosen the tension of the crawler, lift up the lower frame by the front attachment and stop the engine in that condition.
2) Place a safety block (wood) at the front and back of the lower frame.
2) Place a safety block (wood) at the front and back of the lower frame.
(2) Removing track guide Remove capscrews (B5) and remove track guide (B2).
Fig. 34-24 Preparation for removal
ITEM
Fig. 34-24 Preparation for removal
: 27mm, Weight of track guide : Approx. 25kg (55 lbs)
STD undercarriage YN01F00035F1
B2,B5
LC undercarriage
YN01F00036F1 NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 B5 CAPSCREW : M18X40(P=1.5) 8
(2) Removing track guide Remove capscrews (B5) and remove track guide (B2).
STD
LOW ROLLER
LOW ROLLER
: 27mm, Weight of track guide : Approx. 25kg (55 lbs)
ITEM
STD undercarriage YN01F00035F1
8
(3) Remove lower roller Remove capscrews (2) and remove lower roller (1). : 27 mm, Weight of lower roller : Approx. 33kg (73 lbs)
B2,B5 LC
Fig. 34-25 Installing track guide
B2,B5
LC undercarriage
YN01F00036F1 NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 B5 CAPSCREW : M18X40(P=1.5) 8
2
STD
2 8
(3) Remove lower roller Remove capscrews (2) and remove lower roller (1). : 27 mm, Weight of lower roller : Approx. 33kg (73 lbs)
B2,B5 LC
Fig. 34-25 Installing track guide
Fig. 34-26 Installing lower roller
34-13
B2
Fig. 34-23 Lower roller assy and track guide 34.1.4.2
(1) Preparation for removal
1
Apply Loctite #262 T=397N.m (290 lbf.ft)
Fig. 34-26 Installing lower roller
34-13
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.4.3
34.1.4.3
INSTALLATION
(1) Installation of lower roller Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque. : 27 mm, Tightening torque : 397N•m (290 lbf•ft)
INSTALLATION
(1) Installation of lower roller Coat mounting capscrews (2) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque. : 27 mm, Tightening torque : 397N•m (290 lbf•ft)
(2) Installation of track guide Capscrews (4) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque.
(2) Installation of track guide Capscrews (4) with Loctite #262 and fasten all 4 capscrews temporarily. Then tighten them to a specified torque.
: 27 mm, Tightening torque : 397N•m (290 lbf•ft)
: 27 mm, Tightening torque : 397N•m (290 lbf•ft)
(3) Adjusting tension of crawler Tighten grease nipple and fill it with grease.
(3) Adjusting tension of crawler Tighten grease nipple and fill it with grease.
: 19 mm, Tightening torque : 59N•m (43 lbf•ft)
: 19 mm, Tightening torque : 59N•m (43 lbf•ft)
34-14
34-14
34. TRAVEL SYSTEM 34.1.4.4
CONSTRUCTION
LOWER ROLLER
No. 1 2 3 4 5 6 7 8
NAME ROLLER COLLAR SHAFT BUSHING PIN FLOATING SEAL O RING PLUG
34.1.4.5
34.1.4.4
STD undercarriage YN64D00019F1 LC undercarriage
34. TRAVEL SYSTEM
4 1 6 2 7 5
8
YF64D00001F1
REMARKS Q'TY 1 2 1 2 2 2 1A G60 2 PT1/4 2
3
Fig. 34-27 Construction of lower roller
DISASSEMBLY AND ASSEMBLY
LOWER ROLLER
No. 1 2 3 4 5 6 7 8
STD undercarriage YN64D00019F1 LC undercarriage
NAME ROLLER COLLAR SHAFT BUSHING PIN FLOATING SEAL O RING PLUG
34.1.4.5
(1) Disassembly
CONSTRUCTION 4 1 6 2 7 5
8
YF64D00001F1
REMARKS Q'TY 1 2 1 2 2 2 1A G60 2 PT1/4 2
3
Fig. 34-27 Construction of lower roller
DISASSEMBLY AND ASSEMBLY
(1) Disassembly
1) Drain oil Remove plug (8) and drain out oil.
1) Drain oil Remove plug (8) and drain out oil.
: 6mm
: 6mm
2) Removing pin (5) Put both ends of lower roller assy on the Vshaped blocks (K), apply push-out bar (L) on upper end face of pin (5), and push pin (5) out striking with mallet.
2) Removing pin (5) Put both ends of lower roller assy on the Vshaped blocks (K), apply push-out bar (L) on upper end face of pin (5), and push pin (5) out striking with mallet.
3) Removing collar (2), O-ring (7) Put lower roller on jig (M) for repair stand so that the shaft (3) is perpendicularly located, apply push-out jig (P) on shaft end on upper side, and push shaft (3) until the O-ring (7) separate from collar (2) with press or mallet, and take out collar (2) and O-ring (7).
3) Removing collar (2), O-ring (7) Put lower roller on jig (M) for repair stand so that the shaft (3) is perpendicularly located, apply push-out jig (P) on shaft end on upper side, and push shaft (3) until the O-ring (7) separate from collar (2) with press or mallet, and take out collar (2) and O-ring (7).
Fig. 34-28 Pushing out collar fixing pin (5)
JIG P 7
4) Removing shaft (3) In addition, push out and remove shaft (3) together with the lower collar (2) and O-ring (7).
2 1
Fig. 34-28 Pushing out collar fixing pin (5)
JIG P 7
4) Removing shaft (3) In addition, push out and remove shaft (3) together with the lower collar (2) and O-ring (7).
1
3 JIG M
The shaft (3) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand.
Fig. 34-29 Removing shaft (3), collar (2), O-ring (7)
34-15
2
3 JIG M
The shaft (3) extrusion operation may cause the remaining lube oil to flow out. Prepare an oil container beforehand.
Fig. 34-29 Removing shaft (3), collar (2), O-ring (7)
34-15
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
5) Removing collar (2), O-ring (7) Remove O-ring (7) from shaft (3) that was drawn out in the previous paragraph.
5) Removing collar (2), O-ring (7) Remove O-ring (7) from shaft (3) that was drawn out in the previous paragraph.
6) Removing floating seal (6) Remove floating seal (6) from collar (2).
6) Removing floating seal (6) Remove floating seal (6) from collar (2).
7) Removing floating seal (6) Remove floating seal (6) from roller (1).
7) Removing floating seal (6) Remove floating seal (6) from roller (1).
8) Removing bushing (4) Since thickness of bushing (4) is thin [thickness is 2.0mm (0.079in)], remove it through lathe or strip it with care not damage inner hole of roller. When the wear of bushing is not large, place upper roller (1) on jig (M) for repair stand and apply the end of push-out jig on the end face of bushing (4) end, and push it out striking it with mallet.
Fig. 34-30 Removing floating seal (6)
Fig. 34-30 Removing floating seal (6)
Fig. 34-31 Removing floating seal (6)
Fig. 34-31 Removing floating seal (6)
N 1
4
8) Removing bushing (4) Since thickness of bushing (4) is thin [thickness is 2.0mm (0.079in)], remove it through lathe or strip it with care not damage inner hole of roller. When the wear of bushing is not large, place upper roller (1) on jig (M) for repair stand and apply the end of push-out jig on the end face of bushing (4) end, and push it out striking it with mallet.
JIG M
Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (N) uniformly over the circumference of bushing (4) and extrude it perpendicularly little by little.
34-16
Fig. 34-32 Extruding bushing (4)
N 1
4 JIG M
Hammer the inside surface of roller lightly so as not to damage the surface. Put the extrusion jig (N) uniformly over the circumference of bushing (4) and extrude it perpendicularly little by little.
34-16
Fig. 34-32 Extruding bushing (4)
34. TRAVEL SYSTEM (2) Installing
34. TRAVEL SYSTEM (2) Installing
1) Attach O-ring (7) to one side Install O-ring (7) to groove on shaft.
1) Attach O-ring (7) to one side Install O-ring (7) to groove on shaft.
• Grease O-ring.
• Grease O-ring. Fig. 34-33 Attach O-ring (7) to one side
• Replace O-ring with new one without fail at reassembling. 2) Press fitting bushing (4) Align inner hole of roller (1) and bushing (4) and press fit it vertically in capacity of press fit load, 5ton (11000 lbs), in the condition that bushing push-in jig (Q) is inserted into bushing (4).
Fig. 34-33 Attach O-ring (7) to one side
• Replace O-ring with new one without fail at reassembling. 2) Press fitting bushing (4) Align inner hole of roller (1) and bushing (4) and press fit it vertically in capacity of press fit load, 5ton (11000 lbs), in the condition that bushing push-in jig (Q) is inserted into bushing (4).
JIG Q
4
• Apply molybdenum disulfide grease on pressfit section of bushing, and press fit it in ordinary temperature.
• Apply molybdenum disulfide grease on pressfit section of bushing, and press fit it in ordinary temperature.
• Bushing which fails to press-fit because of the one-side pressing should not be fitted.
• Bushing which fails to press-fit because of the one-side pressing should not be fitted.
3) Press fitting collar (2) Fit O-ring (7) to the one side of shaft (3) mating pin hole of collar (2) on which floating seal (6) is fit with pin hole of shaft (3) in advance. Use the press of capacity 17 ton (37500 lbs) or more.
Fig. 34-34 Press fitting bushing (4) PRESS PIN HOLE 2
6
PIN HOLE 3
• Care should be taken not to damage O-ring (7) while press-fitting collar (2) to shaft (3). 4) Inserting pin (5) Press-fit pin (5) to pin hole on aligning pin holes of shaft (3) and collar (2).
Fig. 34-35 Press fitting collar (2)
6
7
3) Press fitting collar (2) Fit O-ring (7) to the one side of shaft (3) mating pin hole of collar (2) on which floating seal (6) is fit with pin hole of shaft (3) in advance. Use the press of capacity 17 ton (37500 lbs) or more.
JIG Q
4
Fig. 34-34 Press fitting bushing (4) PRESS PIN HOLE 2
6
PIN HOLE 3
• Care should be taken not to damage O-ring (7) while press-fitting collar (2) to shaft (3). 4) Inserting pin (5) Press-fit pin (5) to pin hole on aligning pin holes of shaft (3) and collar (2).
Fig. 34-35 Press fitting collar (2)
6
5
5
3
7
3
2
7
Fig. 34-36 Inserting pin (5)
34-17
2
Fig. 34-36 Inserting pin (5)
34-17
7
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
5) Attach floating seal (6) to roller side Fit floating seal (6) to inner holes on both ends of roller (1). • Check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal.
5) Attach floating seal (6) to roller side Fit floating seal (6) to inner holes on both ends of roller (1).
1
6
• Check that the seal surface is free from flaws, rusts, etc. before reusing the floating seal.
3
6) Inserting roller (1) Insert roller (1) from the side where collar (2), O-ring (7) is not press-fitted to the shaft (3).
2
3
6) Inserting roller (1) Insert roller (1) from the side where collar (2), O-ring (7) is not press-fitted to the shaft (3).
7
2
Fig. 34-37 Inserting roller (1) 7) Installing O-ring (7) Install O-ring (7) to groove on shaft.
7) Installing O-ring (7) Install O-ring (7) to groove on shaft. PIN HOLE 2
• Replace O-ring with new one without fail at reassembling.
7
Fig. 34-37 Inserting roller (1)
PRESS
• Grease O-ring.
1
6
PIN HOLE 7
8) Press fitting collar (2) Press-fit collar (2) to shaft (3).
PRESS PIN HOLE
• Grease O-ring.
2
• Replace O-ring with new one without fail at reassembling.
PIN HOLE 7
8) Press fitting collar (2) Press-fit collar (2) to shaft (3). 3
3
• Press-fit collar (2) on aligning pin (5) hole.
• Press-fit collar (2) on aligning pin (5) hole.
9) Inserting pin (5) Press-fit pin (5) in to the pin hole mating pin hole of collar (2) with pin hole on the end side of shaft (3).
9) Inserting pin (5) Press-fit pin (5) in to the pin hole mating pin hole of collar (2) with pin hole on the end side of shaft (3).
Fig. 34-38 Installing O-ring (7), collar (2) 10) Filling oil Remove plug (8) and fill in 160cc (9.8cu•in) of engine oil API grade CD #30.
Fig. 34-38 Installing O-ring (7), collar (2) 10) Filling oil Remove plug (8) and fill in 160cc (9.8cu•in) of engine oil API grade CD #30.
11) Check it for leakage Before tightening plug (8), check it for leakage in the condition of air pressure 0.2 MPa (29 psi). 12) Installing plug (8) Apply oil resistant sealant on plug (8), and tighten it in the plug hole on the collar (2) end face.
8
TIGHTENING TORQUE 23N.m (17 lbf.ft)
2
: 6 mm, Tightening torque : 21.6~24.5 N•m (15.9~18.1 lbf•ft)
Fig. 34-39 Installing filling oil plug (8)
After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.
34-18
11) Check it for leakage Before tightening plug (8), check it for leakage in the condition of air pressure 0.2 MPa (29 psi). 12) Installing plug (8) Apply oil resistant sealant on plug (8), and tighten it in the plug hole on the collar (2) end face.
8
TIGHTENING TORQUE 23N.m (17 lbf.ft)
2
: 6 mm, Tightening torque : 21.6~24.5 N•m (15.9~18.1 lbf•ft)
Fig. 34-39 Installing filling oil plug (8)
After assembling the lower roller, confirm that oil is not leaking and that the roller rotates smoothly by hand.
34-18
34. TRAVEL SYSTEM 34.1.4.6
MAINTENANCE STANDARD
34. TRAVEL SYSTEM 34.1.4.6
MAINTENANCE STANDARD
Fig. 34-40 Lower roller (Track roller)
Fig. 34-40 Lower roller (Track roller) Unit : mm (in)
Unit : mm (in)
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
O.D. of flange
ø 185 (7.28)
—
—
A
B
Tread dia.
ø 150 (5.91)
ø 134 (5.28)
C
Flange width
23.5 (0.925)
18 (0.709)
16.5 (0.65)
Fit
Fit
No. A
D
ITEM
Clearance between shaft and bushing (Wrapped bushing)
E
Interference between roller and bushing
F
Oil
H
Plug (8) Roller rotation
Basic dimension
Tolerance
Reinforcement weld, repair or replace ø 128 (5.04)
- 0.060 (-0.00236) ø 65 Shaft - 0.090 (2.55905) (-0.00354)
Clearance 0.7 (0.276)
Clearance 1.0 (0.394)
+ 0.030 (+0.00118) Hole - 0.020 (-0.00079)
Interference 0
Clearance 0.01 (0.0004)
ø 69 (2.71653)
REMEDY
Engine oil API grade CD #30, 160cc (9.8 cu•in)
34-19
REPAIRABLE LEVEL
SERVICE LIMIT
O.D. of flange
ø 185 (7.28)
—
—
B
Tread dia.
ø 150 (5.91)
ø 134 (5.28)
C
Flange width
23.5 (0.925)
18 (0.709)
16.5 (0.65)
Fit
Fit
- 0.060 (-0.00236) ø 65 Shaft - 0.090 (2.55905) (-0.00354)
Clearance 0.7 (0.276)
Clearance 1.0 (0.394)
+ 0.030 (+0.00118) Hole - 0.020 (-0.00079)
Interference 0
Clearance 0.01 (0.0004)
D Replace bushing
Refill
Execute air leak test at 0.2MPa (28psi) before tightening the plug. Rotates smoothly by hand.
STANDARD VALUE
No.
Reassembly
ITEM
Clearance between shaft and bushing (Wrapped bushing)
E
Interference between roller and bushing
F
Oil
H
Plug (8) Roller rotation
Basic dimension
ø 69 (2.71653)
Tolerance
REMEDY
Reinforcement weld, repair or replace ø 128 (5.04)
Engine oil API grade CD #30, 160cc (9.8 cu•in)
Replace bushing
Refill
Execute air leak test at 0.2MPa (28psi) before tightening the plug. Rotates smoothly by hand.
34-19
Reassembly
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.4.7
34.1.4.7
TOOLS AND JIGS
(1) Tightening tools
TOOLS AND JIGS
(1) Tightening tools Unit : mm
NAME
Unit : mm
OPPOSING FLATS
NAME
19, 27
Socket
19, 27
Socket
6
Allen wrench
OPPOSING FLATS
6
Allen wrench
(2) Jig
(2) Jig Unit : mm (in)
V-block
L
Pin (5) extrusion rod
N
Bushing extrusion rod
Stand jig
P
Shaft extrusion jig
160(6.30)
M
M
Stand jig
P
Shaft extrusion jig
30 (1.18)
Bushing fixing jig
86(3.39)
94.5(3.72)
64.5(2.54)
Q
270(10.6) 64 (2.52)
270(10.6)
86(3.39)
200(7.87)
290(11.4)
125 (4.92)
290(11.4)
16 (0.630)
16 (0.630)
200(7.87)
14 (0.551)
100(3.94) 14 (0.551)
100(3.94)
160(6.30)
N
Bushing extrusion rod
K
SHAPE
125 (4.92)
L
Pin (5) extrusion rod
NAME
64 (2.52)
V-block
Unit : mm (in) No.
Q
+0.1
30 (1.18)
K
SHAPE
Bushing fixing jig
94.5(3.72)
NAME
64.5(2.54)
No.
+0.1
64.6 0 (2.543 +0.004 ) 0
64.6 0 (2.543 +0.004 ) 0
34-20
34-20
34. TRAVEL SYSTEM 34.1.5
FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1
No. 1 2 3 4
34.1.5
FRONT IDLER ASSY
FRONT IDLER ASSY NAME IDLER ASSY IDLER ADJUSTER ASSY CAPSCREW GREASE NIPPLE
2 2 4 2
FRONT IDLER (IDLER ADJUSTER ASSY)
34.1.5.1
YN52D00034F1 Q'TY
34. TRAVEL SYSTEM
FRONT IDLER ASSY
APPLY LOCTITE #262 OR EQUIVALENT T=279N.m(210 lbf.ft) 1 3
REMARKS YN52D00009F1 YN54D00014F1 M16X45
FRONT IDLER ASSY
2
YN52D00034F1
No.
NAME
Q'TY
1 2 3 4
IDLER ASSY IDLER ADJUSTER ASSY CAPSCREW GREASE NIPPLE
2 2 4 2
APPLY LOCTITE #262 OR EQUIVALENT T=279N.m(210 lbf.ft) 1 3
REMARKS YN52D00009F1 YN54D00014F1 M16X45
4
4
Fig. 34-41 Front idler assy 34.1.5.2
REMOVING
Fig. 34-41 Front idler assy 34.1.5.2
REMOVING
(1) Preparation for removal Remove crawler. (Above mentioned)
(1) Preparation for removal Remove crawler. (Above mentioned)
(2) Removing idler assy Sling idler assy, and push it forward with bar. Weight of front idler assy : 210kg (463 lbs)
(2) Removing idler assy Sling idler assy, and push it forward with bar. Weight of front idler assy : 210kg (463 lbs)
BAR
BAR
Keep away from the front side of front idler.
Keep away from the front side of front idler.
(3) Installing Installing is done in the reverse order of removing.
(3) Installing Installing is done in the reverse order of removing.
(4) Where idling assy (1) has to be separated Loosen capscrew (3), and separate idler assy (1) from idler adjuster assy (2).
(4) Where idling assy (1) has to be separated Loosen capscrew (3), and separate idler assy (1) from idler adjuster assy (2).
Fig. 34-42 Removing and installation the front idler
Fig. 34-42 Removing and installation the front idler
: 24 mm Weight of idler assy : 107kg (236 lbs) Weight of idler adjuster assy : 103kg (227 lbs)
: 24 mm Weight of idler assy : 107kg (236 lbs) Weight of idler adjuster assy : 103kg (227 lbs)
• The separated idler assy (1) should be placed on square timbers.
• The separated idler assy (1) should be placed on square timbers.
Fig. 34-43 Separating idler assy (1) from idler adjuster
34-21
2
Fig. 34-43 Separating idler assy (1) from idler adjuster
34-21
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.5.3
34.1.5.3
IDLER ASSY
34.1.5.3.1
CONSTRUCTION
IDLER ASSY
34.1.5.3.1
CONSTRUCTION
Fig. 34-44 Idler assy 34.1.5.3.2
Fig. 34-44 Idler assy
REMOVING AND INSTALLING
34.1.5.3.2
(1) Removing
5
1) Drain oil Remove plug (8) on the side of collar (3) to drain.
R
: 5 mm
REMOVING AND INSTALLING
(1) Removing
5
1) Drain oil Remove plug (8) on the side of collar (3) to drain.
R
: 5 mm
2) Removing pin (5) Apply pin push bar (jig R) to the top of pin, and push out striking bar (jig R) lightly by hammer.
2) Removing pin (5) Apply pin push bar (jig R) to the top of pin, and push out striking bar (jig R) lightly by hammer.
Fig. 34-45 Removing pin (5) PUSH WITH PRESS
3) Removing collar (3) Put idler (1) on stand (U), apply push-out jig (S) on shaft (6), push out shaft (6) with collar (3), then remove collar (3).
6
S 3
1
Fig. 34-45 Removing pin (5)
U
3
PUSH WITH PRESS S 6
34-22
3
6
S 3
1
U
3
Fig. 34-46 Removing collar (3) 4) Removing collar (3) from shaft (6) If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in Par. 3).
PUSH WITH PRESS
3) Removing collar (3) Put idler (1) on stand (U), apply push-out jig (S) on shaft (6), push out shaft (6) with collar (3), then remove collar (3).
Fig. 34-46 Removing collar (3) 4) Removing collar (3) from shaft (6) If removal of collar (3) on the opposite side is required, turn over front idler and proceed with the procedure described in Par. 3).
PUSH WITH PRESS S 6
3
U
U
Fig. 34-47 Removing collar (3)
Fig. 34-47 Removing collar (3)
34-22
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
5) Removing bushing (2) With idler (1) mounted on the stand, tap bushing (2) lightly by hammer, while placing the bushing drawing rod (T) against the end face of bushing (2) evenly all round, till it comes out.
5) Removing bushing (2) With idler (1) mounted on the stand, tap bushing (2) lightly by hammer, while placing the bushing drawing rod (T) against the end face of bushing (2) evenly all round, till it comes out.
6) Removing floating seals (4) Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.
6) Removing floating seals (4) Take out floating seals (4) from idler (1), collar (3). If you intend to re-use floating seals (4), confirm that there is no scoring and rusting on the contact surface and store the floating seals in pairs by placing card board between the sealing faces.
Fig. 34-48 Removing bushing (2)
7) Removing O-ring (7) Separate O-ring (7) from shaft (6).
Fig. 34-48 Removing bushing (2)
7) Removing O-ring (7) Separate O-ring (7) from shaft (6).
(2) Assembly
2
1) Pressing in bushing (2) Align inner hole of idler (1) and bushing (2) and press fit it vertically with press so that jig (V) for bushing press-fitting is inserted into bushing (2).
PUSH WITH PRESS
(2) Assembly
V 1
2) Installing O-ring (7) Fit O-ring (7) to O-ring groove on shaft (6).
2
1) Pressing in bushing (2) Align inner hole of idler (1) and bushing (2) and press fit it vertically with press so that jig (V) for bushing press-fitting is inserted into bushing (2).
V 1
2) Installing O-ring (7) Fit O-ring (7) to O-ring groove on shaft (6). Fig. 34-49 Pressing in bushing (2)
â&#x20AC;˘
PUSH WITH PRESS
Apply grease to O-ring
Fig. 34-49 Pressing in bushing (2) â&#x20AC;˘
3) Installing collar (3) (See Fig. 34-50) Press fit the O-ring (7) installed side of shaft (6) into collar (3), and drive pin (5).
PRESSING 6
4) Installing floating seal (4) Fit the half of floating seal (4) on each side of collar (3) and idler (1).
3 5
5) Inserting idler (1) Insert floating seal (4) fitted side of idler (1) into shaft (6).
Fig. 34-50 Installing collar (3), shaft (6)
6) Installing floating seal (4) Fit floating seal (4) on the other side of idler (1).
Apply grease to O-ring
3) Installing collar (3) (See Fig. 34-50) Press fit the O-ring (7) installed side of shaft (6) into collar (3), and drive pin (5).
PRESSING 6
4) Installing floating seal (4) Fit the half of floating seal (4) on each side of collar (3) and idler (1).
3 5
5) Inserting idler (1) Insert floating seal (4) fitted side of idler (1) into shaft (6).
Fig. 34-50 Installing collar (3), shaft (6)
6) Installing floating seal (4) Fit floating seal (4) on the other side of idler (1).
Fig. 34-51 Inserting idler (1) and installing floating seal (4)
34-23
Fig. 34-51 Inserting idler (1) and installing floating seal (4)
34-23
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
7) Installing collar (3) Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hummer.
7) Installing collar (3) Fit the half of floating seal (4) on the other collar (3), press fit it in shaft (6), and drive pin (5) in with hummer.
8) Filling oil•Inspection Fill in 200cc (12.2cu•in) of engine oil API grade CD #30 through the plug hole of collar (3), wind seal tape and tighten plug (8).
8) Filling oil•Inspection Fill in 200cc (12.2cu•in) of engine oil API grade CD #30 through the plug hole of collar (3), wind seal tape and tighten plug (8).
: 5 mm
34.1.5.3.3
After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly.
•
MAINTENANCE STANDARD
34.1.5.3.3
Fig. 34-52 Installing collar (3) and filling oil
After installing the idler assy to the idler adjuster assy, make certain that no oil leaks from floating seal and plug (8) and that idler (1) rotates smoothly. MAINTENANCE STANDARD
160(6.30) C
160(6.30) C
Fig. 34-53 Front idler
E
B
A
D
E
F
B
A
F
D
•
: 5 mm
Fig. 34-52 Installing collar (3) and filling oil
Fig. 34-53 Front idler Unit : mm (in)
No. A
ITEM Dia. of idler projection
B
Tread dia.
C
Flange width
STANDARD VALUE ø 535 (21.1) ø 497 (19.6) 84 ± 0.5 (3.307±0.020) Basic dimension
Clearance between shaft and bushing
Tolerance
REPAIRABLE SERVICE LEVEL LIMIT —
—
ø 490 (19.3) ø 487 (19.2) 78 (3.07)
76 (2.99)
Fit
Fit
ø 75 Shaft (2.95275)
- 0.03 (-0.00118) - 0.06 (-0.00236)
Clearance 1.5 (0.059)
Clearance 2.0 (0.079)
E
Interference between idler and ø 83 Hole bushing (3.26771)
+ 0.035 (+0.00138) 0
Interference 0
Clearance 0.01 (0.0004)
F
Oil
D
Idler rotation
REMEDY
No. A
Replace
ITEM Dia. of idler projection
B
Tread dia.
C
Flange width
STANDARD VALUE ø 535 (21.1) ø 497 (19.6) 84 ± 0.5 (3.307±0.020)
Reassemble
ø 490 (19.3) ø 487 (19.2)
Fit
ø 75 Shaft (2.95275)
- 0.03 (-0.00118) - 0.06 (-0.00236)
Clearance 1.5 (0.059)
Clearance 2.0 (0.079)
E
Interference between idler and ø 83 Hole bushing (3.26771)
+ 0.035 (+0.00138) 0
Interference 0
Clearance 0.01 (0.0004)
F
Oil
Clearance between shaft and bushing
Idler rotation
Tolerance
REMEDY
—
Fit
Replace bushing
Rotates smoothly by hand
—
76 (2.99)
D
Refill
REPAIRABLE SERVICE LEVEL LIMIT
78 (3.07)
Basic dimension
Engine oil API grade CD #30, 200cc (12.2cu•in)
34-24
Unit : mm (in)
Replace
Replace bushing
Engine oil API grade CD #30, 200cc (12.2cu•in)
Refill
Rotates smoothly by hand
Reassemble
34-24
34. TRAVEL SYSTEM 34.1.5.3.4
TOOLS AND JIGS
34. TRAVEL SYSTEM 34.1.5.3.4
(1) Tightening tools
TOOLS AND JIGS
(1) Tightening tools Unit : mm
NAME
Unit : mm
OPPOSING FLATS
NAME
24
Socket
24
Socket
5
Allen wrench
OPPOSING FLATS
(2) Jigs
Allen wrench
5
No.
NAME
SHAPE
R
Pin striking jig
(2) Jigs
(0.591) 15
70(2.76)
Bushing press fitting jig
74.6
W Collar press fitting jig
Bushing drawing rod
U
Stand
74 (2.91) 105(4.13)
V
Bushing press fitting jig
+0.1 0
74.6
+0.1 0
(2.937 +0.004 ) 0
(2.937 +0.004 ) 0
103(4.06)
103(4.06)
W Collar press fitting jig
34-25
(0.630) 16
T
20 (0.787)
74 (2.91) 105(4.13)
(0.630) 16
Stand
Shaft push out jig
20 (0.787)
U
90(3.54)
Bushing drawing rod
S
300(11.8)
(1.18) 30
T
V
340 (13.4)
Shaft push out jig
300(11.8)
(0.591) 15
90(3.54)
340 (13.4)
S
30 (1.18) 105(4.13)
70(2.76)
105(4.13)
Unit : mm (in)
(1.18) 30
Pin striking jig
30 (1.18)
R
SHAPE (0.591) 15
NAME
(0.591) 15
Unit : mm (in) No.
34-25
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.5.4
34.1.5.4
34.1.5.4.1
IDLER ADJUSTER ASSY CONSTRUCTION
IDLER ADJUSTER ASSY No. 1 2 3 4 5 6 7 8 9 10 11
NAME GREASE CYLINDER BRACKET NUT SPRING PIN SPRING PISTON COLLAR O-RING U-PACKING PIN COVER
34.1.5.4.2
34.1.5.4.1
1 1 1 1 1 1 1 1 1 2 1
CONSTRUCTION
IDLER ADJUSTER ASSY
YN54D00014F1 Q'TY
IDLER ADJUSTER ASSY
No.
REMARKS
8X80
Fig. 34-54 Idler adjuster assy
1B G80
DISASSEMBLY AND ASSEMBLY
1 2 3 4 5 6 7 8 9 10 11
NAME GREASE CYLINDER BRACKET NUT SPRING PIN SPRING PISTON COLLAR O-RING U-PACKING PIN COVER
34.1.5.4.2
(1) Disassembly
M30
1) Spring set special jig Before disassembling and assembling the idler adjuster assy, prepare spring setting jig (V). Capacity of hydraulic jack : more than 20 tons (44000 lbs)
HOLDING-DOWN NUT RETAINER PLATE
V
: 46 mm
YN54D00014F1 Q'TY
1 1 1 1 1 1 1 1 1 2 1
REMARKS
8X80
Fig. 34-54 Idler adjuster assy
1B G80
DISASSEMBLY AND ASSEMBLY
(1) Disassembly
M30
1) Spring set special jig Before disassembling and assembling the idler adjuster assy, prepare spring setting jig (V). Capacity of hydraulic jack : more than 20 tons (44000 lbs)
HOLDING-DOWN NUT RETAINER PLATE
V
: 46 mm HYDRAULIC JACK
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
Large power is needed to set the spring. Prepare a special jig before disassembly and assembly.
BASE
2) Preparation for working Place a hydraulic jack between the jig base and the stand. Loosen the holding-down nuts of the jig and draw out the retainer plate upward.
HYDRAULIC JACK
Fig. 34-55 Spring set special jig (V) 2
: 46 mm
BASE
2) Preparation for working Place a hydraulic jack between the jig base and the stand. Loosen the holding-down nuts of the jig and draw out the retainer plate upward.
Fig. 34-55 Spring set special jig (V) 2
: 46 mm
3) Draw out grease cylinder (See Fig. 34-54) Draw out piston (6) from grease cylinder (1) of the idler adjuster assy.
5
4) Removing U-packing (9), O-ring (8) (See Fig. 3454) Remove U-packing (9) and O-ring (8) from grease cylinder (1). 5) Slinging work idler adjuster Set the idler adjuster assy on the stand of the jig, with its bracket side facing up.
34-26
V
Fig. 34-56 Slinging work idler adjuster
3) Draw out grease cylinder (See Fig. 34-54) Draw out piston (6) from grease cylinder (1) of the idler adjuster assy.
5
4) Removing U-packing (9), O-ring (8) (See Fig. 3454) Remove U-packing (9) and O-ring (8) from grease cylinder (1). 5) Slinging work idler adjuster Set the idler adjuster assy on the stand of the jig, with its bracket side facing up.
34-26
V
Fig. 34-56 Slinging work idler adjuster
34. TRAVEL SYSTEM 6) Fixing idler adjuster assy Fit retainer plate to bracket (2), tighten holdingdown nuts alternately, and secure idler adjuster assy.
34. TRAVEL SYSTEM 6) Fixing idler adjuster assy Fit retainer plate to bracket (2), tighten holdingdown nuts alternately, and secure idler adjuster assy.
3
: 46 mm
HOLDING-DOWN NUT
3
: 46 mm
HOLDING-DOWN NUT
RETAINER PLATE
4
Fig. 34-57 Fixing idler adjuster assy 7) Compression of spring (5) Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut (3).
RETAINER PLATE
4
Fig. 34-57 Fixing idler adjuster assy 7) Compression of spring (5) Remove spring pin (4), press spring (5) lifting it with jack so that nut (3) can be turned freely, and remove nut (3).
: Bar ø7.5u120
: Bar ø7.5u120
: 80 mm
: 80 mm
Fig. 34-58 Compression of spring (5) 8) Removing bracket (2) Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (2), cover (11). The free length of the spring : 540.1 mm (21.3 in)
RETAINER PLATE
Fig. 34-58 Compression of spring (5) 8) Removing bracket (2) Allow the hydraulic jack to retract slowly till the spring is extended to its free length. Remove the retainer plate and take off bracket (2), cover (11). The free length of the spring : 540.1 mm (21.3 in)
RETAINER PLATE
2
2
11
11
Fig. 34-59 Removing retainer plate, bracket (2) 9) Removing spring (5), grease cylinder (1) Hook lifting eye nut (W) to screw M52uP3 on grease cylinder (1) top end and hoist it. Then, remove the set of grease cylinder (1) and spring (5) using crane from the jig. Remove spring (5), collar (7), grease cylinder (1), in that order.
Fig. 34-59 Removing retainer plate, bracket (2) 9) Removing spring (5), grease cylinder (1) Hook lifting eye nut (W) to screw M52uP3 on grease cylinder (1) top end and hoist it. Then, remove the set of grease cylinder (1) and spring (5) using crane from the jig. Remove spring (5), collar (7), grease cylinder (1), in that order.
Fig. 34-60 Removing spring (5), grease cylinder (1)
34-27
Fig. 34-60 Removing spring (5), grease cylinder (1)
34-27
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(2) Assembly Assembly is done in the reverse order of disassembly.
(2) Assembly Assembly is done in the reverse order of disassembly.
W 1
1) Installing spring (5), grease cylinder (1) Insert grease cylinder (1), collar (7) into spring (5) and attach lifting eye nut (W) to screw M52uP3 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright. 2) Fixing idler adjuster assy Install bracket (2), cover (11) on top of spring (5). Center the rod of grease cylinder (1) and the holes in bracket (2). Attach the retainer plate and four holding-down nuts. Fasten the nuts evenly all round and fix the idler adjuster assy to the jig body. (See Fig. 34-65)
W 1
1) Installing spring (5), grease cylinder (1) Insert grease cylinder (1), collar (7) into spring (5) and attach lifting eye nut (W) to screw M52uP3 at the tip of the grease cylinder. Lift the grease cylinder by crane and erect it in the center of the jig stand upright.
5
Fig. 34-61 Attach spring (5) and grease cylinder (1) to the jig
: 46 mm
2) Fixing idler adjuster assy Install bracket (2), cover (11) on top of spring (5). Center the rod of grease cylinder (1) and the holes in bracket (2). Attach the retainer plate and four holding-down nuts. Fasten the nuts evenly all round and fix the idler adjuster assy to the jig body. (See Fig. 34-65)
5
Fig. 34-61 Attach spring (5) and grease cylinder (1) to the jig
: 46 mm
3) Compressing spring (5) and tightening nut (3) Extend the hydraulic jack, compress spring (5) to a set length and screw in nut (3) to the screwed part at the tip of grease cylinder (1). Set length of the spring : 429mm (16.9in)
HOLDINGDOWN NUT RETAINER PLATE
2 4 3
4) Installing spring pin (4) Tighten nut (3) till the holes for locking spring pins (4) are aligned. Then fit spring pin (4).
11
: 80 mm
7 1
3) Compressing spring (5) and tightening nut (3) Extend the hydraulic jack, compress spring (5) to a set length and screw in nut (3) to the screwed part at the tip of grease cylinder (1). Set length of the spring : 429mm (16.9in)
HOLDINGDOWN NUT RETAINER PLATE
2 4 3
4) Installing spring pin (4) Tighten nut (3) till the holes for locking spring pins (4) are aligned. Then fit spring pin (4).
11
: 80 mm
1
5
5
Fig. 34-62 Compression of spring (5), and attaching nut (3) and spring pin (4) 5) Removing idler adjuster assy Remove idler adjuster assy from jig.
7
Fig. 34-62 Compression of spring (5), and attaching nut (3) and spring pin (4) 5) Removing idler adjuster assy Remove idler adjuster assy from jig.
Fig. 34-63 Removing idler adjuster assy
34-28
Fig. 34-63 Removing idler adjuster assy
34-28
34. TRAVEL SYSTEM 6) Installing U-packing (9), O-ring (8) Fit U-packing (9) and O-ring (8) to grease cylinder (1). •
1
9
8
6
34. TRAVEL SYSTEM 6) Installing U-packing (9), O-ring (8) Fit U-packing (9) and O-ring (8) to grease cylinder (1).
Grease oil seal (9) and O-ring (8).
•
7) Filling grease cylinder(1) with grease. Fill up grease in cylinder (1), remove the grease nipple from piston (6) to discharge the inside air, and press in the piston by hand. •
GREASE NIPPLE
8) Installing grease nipple Tighten grease nipple to piston (6).
•
GREASE NIPPLE
Fig. 34-64 Grease cylinder (1)
Direct grease nipple hole downward to make air discharge easier.
8) Installing grease nipple Tighten grease nipple to piston (6). : 19 mm,
Tightening torque : 59 N•m (43 lbf•ft)
Tightening torque : 59 N•m (43 lbf•ft)
MAINTENANCE STANDARD
No.
8
Grease oil seal (9) and O-ring (8).
: 19 mm,
34.1.5.4.3
9
7) Filling grease cylinder(1) with grease. Fill up grease in cylinder (1), remove the grease nipple from piston (6) to discharge the inside air, and press in the piston by hand.
Fig. 34-64 Grease cylinder (1)
Direct grease nipple hole downward to make air discharge easier.
1
ITEM
34.1.5.4.3
MAINTENANCE STANDARD
STANDARD VALUE
No.
ITEM
STANDARD VALUE
429mm (16.9 in)
A
Installed length of spring
Approx. 540.1mm (21.3 in)
B
Free length of spring
A
Installed length of spring
B
Free length of spring
C
Stroke
51.8mm (2.04in)
C
Stroke
51.8mm (2.04in)
D
Set length
716mm (28.2in)
D
Set length
716mm (28.2in)
E
Outside view of piston
Nor scoring and rusting
E
Outside view of piston
F
Tightening torque of grease nipple
59N•m (43 lbf•ft)
F
Tightening torque of grease nipple
X
C X
Y
D
Approx. 540.1mm (21.3 in)
Nor scoring and rusting 59N•m (43 lbf•ft)
X
E
A, B
429mm (16.9 in)
C
F
X
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
E
A, B
Y
D
INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.
BRACKET
DETAIL Y
F
BRACKET
DETAIL Y SECTION XX
SECTION XX
Fig. 34-65
Fig. 34-65
34-29
34-29
6
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.6
34.1.6
34.1.6.1
SPROCKET REMOVING
34.1.6.1
(1) Preparation for removal Remove crawler referring to "34.1.2 CRAWLER", lift up crawler frame with attachment, and put it on square timbers to float and stabilize.
SPROCKET REMOVING
(1) Preparation for removal Remove crawler referring to "34.1.2 CRAWLER", lift up crawler frame with attachment, and put it on square timbers to float and stabilize.
Fig. 34-66 Preparation for removal (2) Removing sprocket Loosen 26 capscrews (2) M16u45, for the attaching of the sprocket by means of a socket and remove the sprocket (1).
Fig. 34-66 Preparation for removal (2) Removing sprocket Loosen 26 capscrews (2) M16u45, for the attaching of the sprocket by means of a socket and remove the sprocket (1).
Weight of sprocket : 48kg (106 lbs)
Weight of sprocket : 48kg (106 lbs)
: 24 mm
: 24 mm
3
3 2
2
Fig. 34-67 Removing sprocket 34.1.6.2
INSTALLING
Fig. 34-67 Removing sprocket 34.1.6.2
INSTALLING
(1) Check before installing Check the mating portion of the travel reduction unit and the sprocket, eliminate burrs and contamination thoroughly and install the sprocket.
(1) Check before installing Check the mating portion of the travel reduction unit and the sprocket, eliminate burrs and contamination thoroughly and install the sprocket.
(2) Installing sprocket temporarily Coat the sprocket attaching capscrews with Loctite #262 and fasten the sprocket temporarily.
(2) Installing sprocket temporarily Coat the sprocket attaching capscrews with Loctite #262 and fasten the sprocket temporarily.
(3) Installing sprocket completely Remove the wooden blocks under the truck frame, bring the machine down on the ground and tighten the sprocket.
(3) Installing sprocket completely Remove the wooden blocks under the truck frame, bring the machine down on the ground and tighten the sprocket.
: 27 mm
: 27 mm
Tightening torque : 279 N•m (206 lbf•ft)
Tightening torque : 279 N•m (206 lbf•ft) Fig. 34-68 Installing sprocket completely
34-30
Fig. 34-68 Installing sprocket completely
34-30
34. TRAVEL SYSTEM 34.1.6.3
MAINTENANCE STANDARD (YN51D01003P1) PITCH
96.07mm (3.78in)
ROLLER DIA.
ø58.72mm (2.31in)
SPECIFICATION
34. TRAVEL SYSTEM 34.1.6.3
NUMBER OF TEETH
21
PITCH DIA.
644.602 (25.333in)
MAINTENANCE STANDARD (YN51D01003P1) PITCH
96.07mm (3.78in)
NUMBER OF TEETH
21
ROLLER DIA.
ø58.72mm (2.31in)
PITCH DIA.
644.602 (25.333in)
SPECIFICATION
Fig. 34-69 Sprocket
C
A
B
C
A
B
Fig. 34-69 Sprocket Unit:mm (in)
No.
NAME
STANDARD VALUE
REPAIRABLE LEVEL
SERVICE LIMIT
ø 659 (25.9)
ø 651 (25.6)
ø 649 (25.6)
A
O.D. of sprocket
B
Width of sprocket teeth
66±2 (2.520±0.079)
60 (2.36)
58 (2.28)
C
O.D. of sprocket bottom
ø 586 (23.1)
ø 578 (22.8)
ø 576 (22.7)
34.1.6.4
TOOLS AND JIGS
REMEDY
Unit:mm (in) No.
NAME
REPAIRABLE LEVEL
SERVICE LIMIT
ø 659 (25.9)
ø 651 (25.6)
ø 649 (25.6)
Reinforcement weld, repair or replace.
A
O.D. of sprocket
Replace.
B
Width of sprocket teeth
66±2 (2.520±0.079)
60 (2.36)
58 (2.28)
Reinforcement weld, repair or replace.
C
O.D. of sprocket bottom
ø 586 (23.1)
ø 578 (22.8)
ø 576 (22.7)
34.1.6.4
(1) Tools
STANDARD VALUE
TOOLS AND JIGS
(1) Tools Unit : mm NAME Socket
OPPOSING FLATS
Unit : mm NAME
24
Socket
34-31
OPPOSING FLATS 24
34-31
REMEDY Reinforcement weld, repair or replace. Replace. Reinforcement weld, repair or replace.
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(2) Sprocket tooth profile gauge : W
(2) Sprocket tooth profile gauge : W
Unit : mm (in)
Unit : mm (in)
)
.7823) 96.07(3
R ( 6 0 .23 6"
.7823) 96.07(3
R ( 6 0 .23 6" )
Fig. 34-70 Tooth profile gauge (Full scale)
Fig. 34-70 Tooth profile gauge (Full scale)
34-32
34-32
34. TRAVEL SYSTEM 34.1.7 34.1.7.1
TRAVEL MOTOR
34. TRAVEL SYSTEM 34.1.7
TRAVEL MOTOR
34.1.7.1
TRAVEL MOTOR TRAVEL MOTOR
3
3
APPLY LOCTITE #262 OR EQUIVALENT TIGHTENING TORQUE: 279 N.m(206 lbf.ft)
APPLY LOCTITE #262 OR EQUIVALENT TIGHTENING TORQUE: 279 N.m(206 lbf.ft)
4
4
Fig. 34-71 Installing travel motor 34.1.7.2
REMOVING
Fig. 34-71 Installing travel motor 34.1.7.2
REMOVING
(1) Preparation for removal Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize.
(1) Preparation for removal Remove crawler, lift up crawler frame using attachment, and put it on square timbers to float and stabilize.
(2) Removing cover (1) Remove sems bolt (6) M12u25 and also remove covers (1).
(2) Removing cover (1) Remove sems bolt (6) M12u25 and also remove covers (1).
: 19 mm
: 19 mm
(3) Preparation of oil pan
(3) Preparation of oil pan
(4) Removing hydraulic pipe Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust.
(4) Removing hydraulic pipe Release pressure from travel circuit, and bleed air in hydraulic oil tank, then remove all pipes connecting to travel motor. Then plug up all pipes and joint section to protect them from entry of dust.
Fig. 34-72 Removing and installing cover (1)
: 19mm, 27mm, 41mm Refer to "Hydraulic pipe plug" 5.1 (See Chapter 11. TOOLS) "Plug for flare hose" 5.2 (3) (See Chapter 11. TOOLS)
Fig. 34-72 Removing and installing cover (1)
: 19mm, 27mm, 41mm Refer to "Hydraulic pipe plug" 5.1 (See Chapter 11. TOOLS) "Plug for flare hose" 5.2 (3) (See Chapter 11. TOOLS)
Fig. 34-73 Removing and installing hydraulic pipe
34-33
Fig. 34-73 Removing and installing hydraulic pipe
34-33
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(5) Removing sprocket Removing twenty two (one side) capscrews (2) M18u55.
(5) Removing sprocket Removing twenty two (one side) capscrews (2) M18u55.
: 24 mm
: 24 mm
Fig. 34-74 Removing and installing sprocket (6) Loosening travel motor attaching bolts (3) Apply match marks on travel motor and crawler frame, and remove seventeen (one side) capscrews (3) M20u60.
REMOVE PIPES (DISCONNECT)
Fig. 34-74 Removing and installing sprocket (6) Loosening travel motor attaching bolts (3) Apply match marks on travel motor and crawler frame, and remove seventeen (one side) capscrews (3) M20u60.
: 24 mm
REMOVE PIPES (DISCONNECT)
: 24 mm 3
3
Fig. 34-75 Removing and installing travel motor attaching bolts (7) Slinging travel motor assy Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor.
Fig. 34-75 Removing and installing travel motor attaching bolts (7) Slinging travel motor assy Sling travel motor with nylon sling applied on the side close to sprocket installing section and remove the motor.
Weight of motor : About. 260kg (573 lbs)
Weight of motor : About. 260kg (573 lbs)
Fig. 34-76 Slinging travel motor 34.1.7.3
INSTALLING
Fig. 34-76 Slinging travel motor 34.1.7.3
Installing of the travel motor piping is performed in the reverse order of removal.
INSTALLING
Installing of the travel motor piping is performed in the reverse order of removal.
1) Cleaning Check that contact surface of travel motor and crawler frame is free from burr and stain.
1) Cleaning Check that contact surface of travel motor and crawler frame is free from burr and stain.
2) Tightening torque Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque".
2) Tightening torque Tighten capscrew and hydraulic pipes to the torque specified in "Tightening Torque".
3) Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.
3) Fill inside from motor drain port to casing with hydraulic oil before piping for drain. When starting operation, operate motor in low idling and at low speed for several minutes, and check it for possible oil leakage and noise.
34-34
34-34
34. TRAVEL SYSTEM 34.1.8 34.1.8.1
SWING BEARING
34. TRAVEL SYSTEM 34.1.8
SWING BEARING ASSY
34.1.8.1
FRONT
A
SWING BEARING SWING BEARING ASSY
A
FRONT
A
INNER S ZONE POSITION OF SWING BEARING
INNER S ZONE POSITION OF SWING BEARING
1
1
2
2
SECTION AA
SECTION AA
Fig. 34-77 Swing bearing assy 34.1.8.2
REMOVING
Fig. 34-77 Swing bearing assy 34.1.8.2
(1) Matchmarks Remove upper structure, apply matchmarks on inner race of swing bearing and lower frame.
SWING BEARING OUTER RACE INNER RACE
(2) Remove 36 capscrews (2) M20u65 for installation inner race.
A
MATCHMARKS
: 30 mm
REMOVING
(1) Matchmarks Remove upper structure, apply matchmarks on inner race of swing bearing and lower frame.
SWING BEARING OUTER RACE INNER RACE
(2) Remove 36 capscrews (2) M20u65 for installation inner race.
MATCHMARKS
: 30 mm
(3) Removing grease Remove grease in grease bath.
Fig. 34-78 Matchmarks SWING BEARING
(4) Removing swing bearing Attach eyebolt on swing bearing and sling it.
EYE BOLT
Weight of swing bearing : 243kg (536 lbs)
(3) Removing grease Remove grease in grease bath.
Fig. 34-78 Matchmarks SWING BEARING
(4) Removing swing bearing Attach eyebolt on swing bearing and sling it.
EYE BOLT
Weight of swing bearing : 243kg (536 lbs)
GREASE BATH
Fig. 34-79 Removing and installing swing bearing
34-35
GREASE BATH
Fig. 34-79 Removing and installing swing bearing
34-35
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.1.8.3
34.1.8.3
INSTALLING
INSTALLING
(1) Cleaning Clean it completely so that installing surfaces of swing bearing and lower frame are free from dust and dirt.
(1) Cleaning Clean it completely so that installing surfaces of swing bearing and lower frame are free from dust and dirt.
(2) Installing Install swing bearing on lower frame meeting the matchmarks and positioning the S mark on inner race as shown in Fig. 34-80.
(2) Installing Install swing bearing on lower frame meeting the matchmarks and positioning the S mark on inner race as shown in Fig. 34-80.
(3) Temporary fastening of inner race Coat the threads of the capscrews (2) with Loctite #262 and tighten all the capscrews (2) temporarily.
(3) Temporary fastening of inner race Coat the threads of the capscrews (2) with Loctite #262 and tighten all the capscrews (2) temporarily.
: 30 mm
: 30 mm
(4) Regular tightening of inner race Tighten the capscrews (2) at 180 degrees intervals alternately to a specified torque.
Fig. 34-80 Location of S mark on swing bearing
: 30 mm, Tightening torque : 563 N•m (415 lbf•ft)
(4) Regular tightening of inner race Tighten the capscrews (2) at 180 degrees intervals alternately to a specified torque. : 30 mm, Tightening torque : 563 N•m (415 lbf•ft)
(5) Filling grease Fill grease bath with 8.6kg (19 lbs) of grease NLGI2 (containing molybdenum disulfide) or equivalent.
(5) Filling grease Fill grease bath with 8.6kg (19 lbs) of grease NLGI2 (containing molybdenum disulfide) or equivalent.
Fig. 34-81 Removing and installing capscrew (2) 34.1.8.4
CONSTRUCTION
Fig. 34-81 Removing and installing capscrew (2) 34.1.8.4
CONSTRUCTION
6
6 8
1
8
1
9
9 7
3
7
3
5 2
5 2
Fig. 34-82 Sectional view of swing bearing 34.1.8.5
Fig. 34-80 Location of S mark on swing bearing
DISASSEMBLY AND ASSEMBLY
Fig. 34-82 Sectional view of swing bearing 34.1.8.5
(1) Disassembly
DISASSEMBLY AND ASSEMBLY
(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer circumference under inner race (2) and seal (6) fitted in the groove in the inner circumference on top of outer race (1) and place them level on a square wooden block or something. 2) Remove taper pin (7), using a hammer and an extrusion rod.
EYE BOLT 7
6
2
1 SQUARE WOODEN BLOCK
2) Remove taper pin (7), using a hammer and an extrusion rod.
8
3) Remove plug (8), utilizing an pull bolt inserted in the screwed hole (M10) in the center of the plug and using a puller.
34-36
1) Remove seal (5) fitted in the groove in the outer circumference under inner race (2) and seal (6) fitted in the groove in the inner circumference on top of outer race (1) and place them level on a square wooden block or something.
5
Fig. 34-83 Disassembling swing bearing
EYE BOLT 7
6
2
1 SQUARE WOODEN BLOCK 8
3) Remove plug (8), utilizing an pull bolt inserted in the screwed hole (M10) in the center of the plug and using a puller.
34-36
5
Fig. 34-83 Disassembling swing bearing
34. TRAVEL SYSTEM 4) While rotating outer race (1) little by little, take out ball (3) and retainer (4) through plug hole, in that order.
34. TRAVEL SYSTEM 4) While rotating outer race (1) little by little, take out ball (3) and retainer (4) through plug hole, in that order.
1
3
4
2 3
Fig. 34-84 Removing balls (3) and retainers (4) (2) Installing
4
2
Fig. 34-84 Removing balls (3) and retainers (4) (2) Installing
1) Thoroughly degrease the groove for seal (6) located on the inner surface of outer race (1) and the groove for seal (5) located on the outer surface of inner race (2). Coat the grooves with adhesive Cyano Bond PX-3000 equivalent, fit seal (5) and place it on a surface plate. 2) Lower outer race (1) to the position where upper surface of inner race (2) and lower portion of seal groove is mated, put adjusting washer under outer race (1) so that outer raceway surface of ball (3) aligns with inner raceway, and support it. 3) Insert ball (3) and retainer (4), on which grease is applied, through plug (8) hole on outer race (1), alternately.
1 PUSH ROD
6 2
SQUARE WOODEN BLOCK
5
3
Fig. 34-85 Fitting balls (3) EYE BOLT
4) Fit plug (8) to outer race (1) while checking it for direction and position of taper pin hole.
1) Thoroughly degrease the groove for seal (6) located on the inner surface of outer race (1) and the groove for seal (5) located on the outer surface of inner race (2). Coat the grooves with adhesive Cyano Bond PX-3000 equivalent, fit seal (5) and place it on a surface plate. 2) Lower outer race (1) to the position where upper surface of inner race (2) and lower portion of seal groove is mated, put adjusting washer under outer race (1) so that outer raceway surface of ball (3) aligns with inner raceway, and support it. 3) Insert ball (3) and retainer (4), on which grease is applied, through plug (8) hole on outer race (1), alternately.
HOOKED ROD
To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting fingers into plug hole.
4 SQUARE WOODEN BLOCK
Fig. 34-86 Fitting retainer (4)
To insert ball (3) and retainer (4), use a push rod, etc., to protect persons from injury from inserting fingers into plug hole. 4) Fit plug (8) to outer race (1) while checking it for direction and position of taper pin hole. 5) Coat seal (6) with adhesive Cyano Bond PX3000 equivalent and fit it in the groove of outer race (1).
6) After completion of assembly, caulk the edge of taper pin (7) by punching.
6) After completion of assembly, caulk the edge of taper pin (7) by punching.
7) Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for smooth rotation and flaws on seal lip portion.
7) Check that grease nipple (9) is properly fitted, and fill it with grease. Then, check bearing for smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 160cc (9.76cu•in)
1 PUSH ROD
6 2
SQUARE WOODEN BLOCK
5
3
Fig. 34-85 Fitting balls (3) EYE BOLT
HOOKED ROD
5) Coat seal (6) with adhesive Cyano Bond PX3000 equivalent and fit it in the groove of outer race (1).
34.1.8.6
1
4 SQUARE WOODEN BLOCK
Fig. 34-86 Fitting retainer (4)
• Shell Albania EP#2 ; 160cc (9.76cu•in)
MAINTENANCE STANDARD
34.1.8.6
Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-37
MAINTENANCE STANDARD
Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.
34-37
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.2
REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
34.2
REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT
34.2.1
TRAVEL MOTOR
34.2.1
TRAVEL MOTOR
34.2.1.1
CROSS-SECTIONAL VIEW
34.2.1.1
A
CROSS-SECTIONAL VIEW
A
A
A
B
B
SECTION B-B
SECTION B-B
B
C
B
C
SECTION C-C
C
C
SECTION C-C SECTION A-A
34-38
SECTION A-A
34-38
34. TRAVEL SYSTEM No.
Parts
Q'ty
No.
Parts Piston assembly
Q'ty
1
Hub
1
1
3
Carrier [1]
1
161 • Piston
1
4
Sun gear [1]
1
163 • Seal
1
5
Planetary gear [1]
3
162 Steel ball
1
6
Carrier pin [1]
3
102 Shaft
1
7
Carrier [2]
1
8
Sun gear [2]
1
9
Planetary gear [2]
3
10 Carrier pin [2]
No.
Parts
Q'ty
Rear flange assembly
34. TRAVEL SYSTEM No.
Parts
Q'ty
No.
Parts
1
Hub
1
3
Carrier [1]
1
161 • Piston
1
4
Sun gear [1]
1
163 • Seal
1
1
5
Planetary gear [1]
3
162 Steel ball
1
323 •• Spool
1
6
Carrier pin [1]
3
102 Shaft
1
326 •• Plug
2
7
Carrier [2]
1
1
327 •• Valve
2
8
Sun gear [2]
1
103 • Swash plate
1
328 •• Spring
2
9
Planetary gear [2]
3
3
167 • Pivot
2
331 •• O-ring
2
10 Carrier pin [2]
11 Thrust washer [1]
6
107 Retainer plate
1
324 • Plug
2
12 Thrust washer [2]
6
108 Thrust ball
1
325 • Spring retainer
13 Thrust plate
1
109 Timing plate
1
14 Cover
1
112 Piston
15 Coupling
1
16 Parallel pin [1]
301 • Rear flange • Spool assembly
1
Piston assembly
Q'ty 1
No.
Parts
Q'ty
Rear flange assembly 301 • Rear flange • Spool assembly
1 1
323 •• Spool
1
326 •• Plug
2
1
327 •• Valve
2
103 • Swash plate
1
328 •• Spring
2
3
167 • Pivot
2
331 •• O-ring
2
11 Thrust washer [1]
6
107 Retainer plate
1
324 • Plug
2
2
12 Thrust washer [2]
6
108 Thrust ball
1
325 • Spring retainer
2
329 • O-ring
2
13 Thrust plate
1
109 Timing plate
1
329 • O-ring
2
1
330 • Spring
2
14 Cover
1
112 Piston
1
330 • Spring
2
113 Spring
8
363 • Spool
1
15 Coupling
1
113 Spring
8
363 • Spool
1
3
114 Spring
9
364 • Connector
1
16 Parallel pin [1]
3
114 Spring
9
364 • Connector
1
17 Parallel pin [2]
3
115 Friction plate
3
365 • Pin
1
17 Parallel pin [2]
3
115 Friction plate
3
365 • Pin
1
22 Lock washer
2
116 Separator plate
4
366 • Spring
1
22 Lock washer
2
116 Separator plate
4
366 • Spring
1
23 Shim
1
119 Shim
1~2
367 • Spring retainer
1
23 Shim
1
119 Shim
1~2
367 • Spring retainer
1
24 Angular ball bearing
2
132 Oil seal
1
368 • G (PF) 1/4 plug
2
24 Angular ball bearing
2
132 Oil seal
1
368 • G (PF) 1/4 plug
2
27 Needle-roller bearing
3
133 Snap ring (for hole)
1
369 • O-ring
2
27 Needle-roller bearing
3
133 Snap ring (for hole)
1
369 • O-ring
2
28 Needle-roller bearing
3
135 D ring
1
370 • G (PF) 3/8 plug
1
28 Needle-roller bearing
3
135 D ring
1
370 • G (PF) 3/8 plug
1
29 Floating seal
1
139 D ring
1
371 • O-ring
2
29 Floating seal
1
139 D ring
1
371 • O-ring
2
30 Plug
3
149 Taper roller bearing
1
372 • Orifice
2
30 Plug
3
149 Taper roller bearing
1
372 • Orifice
2
31 O-ring
3
150 Taper roller bearing
1
373 • Orifice spring
2
31 O-ring
3
150 Taper roller bearing
1
373 • Orifice spring
2
35 Socket bolt
18
374 • G (PF) 1/8 plug
5
35 Socket bolt
18
374 • G (PF) 1/8 plug
5
36 Snap ring (for hole)
1
375 • O-ring
6
36 Snap ring (for hole)
1
375 • O-ring
6
Swash plate kit
Relief valve assembly 201 • Valve seat
2
376 • M6 orifice
3
Swash plate kit
Relief valve assembly 201 • Valve seat
2
376 • M6 orifice
3
101 Spindle
1
202 • Valve
1
377 • Check valve
3
101 Spindle
1
202 • Valve
1
377 • Check valve
3
137 Socket plug
1
203 • Sleeve
1
378 • Check valve spring
3
137 Socket plug
1
203 • Sleeve
1
378 • Check valve spring
3
138 Expander
1
204 • Plug
1
379 • O-ring
1
138 Expander
1
204 • Plug
1
379 • O-ring
1
205 • Spring retainer
1
380 • O-ring
1
205 • Spring retainer
1
380 • O-ring
1
Piston kit
1
206 • Piston
1
341 • Parallel pin
1
Piston kit
1
206 • Piston
1
341 • Parallel pin
1
• Piston assembly
9
207 • Spring
1
343 • Socket bolt
8
• Piston assembly
9
207 • Spring
1
343 • Socket bolt
8
345 • Socket plug
15
345 • Socket plug
15
399 Name plate
1
105 •• Piston
1
208 • Piston seal
1
106 •• Shoe
1
209 • Piston seal
1
104 Cylinder block
1
210 • O-ring
1
34-39
399 Name plate
1
105 •• Piston
1
208 • Piston seal
1
106 •• Shoe
1
209 • Piston seal
1
104 Cylinder block
1
210 • O-ring
1
34-39
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.2.1.2
34.2.1.2
34.2.1.2.1
GENERAL FOR MAINTENANCE Tools
34.2.1.2.1
(1) Standard tools No.
GENERAL FOR MAINTENANCE Tools
(1) Standard tools Tools
1
Allen wrench
2
Socket wrench (Ratchet handle) (JIS B 4641)
Size
Q'ty
3 (For M6), 4 (For PT1/16) 5 (For PF1/8), 6 (For PF1/4) 8 (For M10 and PF3/8) 10 (For PF1/2), 14 (For M16)
No.
Tools
1 each
1
Allen wrench
1
2
Socket wrench (Ratchet handle) (JIS B 4641)
Size
Q'ty
3 (For M6), 4 (For PT1/16) 5 (For PF1/8), 6 (For PF1/4) 8 (For M10 and PF3/8) 10 (For PF1/2), 14 (For M16)
1 each
1
Torque wrench
Dial type Approx. 50N•m (37lbf•ft) Dial type Approx. 100N•m (74lbf•ft) Dial type Approx. 300N•m (221lbf•ft) Dial type Approx. 400N•m (295lbf•ft)
4
Adapter for torque wrench
Nominal 32 (O.D. 44mm (1.73inch) or less), 46 Socket, Nominal 3,4,5,6,8,10,14 Hex key
1 each
4
Adapter for torque wrench
Nominal 32 (O.D. 44mm (1.73inch) or less), 46 Socket, Nominal 3,4,5,6,8,10,14 Hex key
5
Torque wrench (Wrench type)
Opposing flats 21mm (0.83inch)
1
5
Torque wrench (Wrench type)
Opposing flats 21mm (0.83inch)
1
6
Extension bar
150mm (5.91inch)
1
6
Extension bar
150mm (5.91inch)
1
7
Hammer
Various size
1 each
7
Hammer
Various size
8
Plastic mallet
L= Approx. 400mm (15.7inch)
1
8
Plastic mallet
L= Approx. 400mm (15.7inch)
Flat-bladed screw driver
Approx. 50mm (2 inch) Approx. 150mm (6 inch)
1 each
9
Flat-bladed screw driver
Approx. 50mm (2 inch) Approx. 150mm (6 inch)
1 1
10
3
9
Snap ring
For shaft For hole
11
Lifting tool
Lifting capacity 9800 N (7230 lbf) Eye bolt for M16 Eye bolt for M10 Eye bolt for PF1/2 Wire with hook
12
Leather gloves
10
1 each
3
Torque wrench
Dial type Approx. 50N•m (37lbf•ft) Dial type Approx. 100N•m (74lbf•ft) Dial type Approx. 300N•m (221lbf•ft) Dial type Approx. 400N•m (295lbf•ft)
1 each
1 each
Snap ring
For shaft For hole Lifting capacity 9800 N (7230 lbf) Eye bolt for M16 Eye bolt for M10 Eye bolt for PF1/2 Wire with hook
1 set (2) (3) (2) (1)
11
Lifting tool
1 set
12
Leather gloves
(2) Apparatuses
1 each 1 1 each 1 1 1 set (2) (3) (2) (1) 1 set
(2) Apparatuses
Application item (Use or number of relevant parts)
Apparatus
Q'ty
Application item (Use or number of relevant parts)
Apparatus
Disassembly and assembly
Work bench for general-use
1 set
Disassembly and assembly
Work bench for general-use
Cleaning the parts
Cleaning bath
For rough cleaning and finish cleaning
1 set
Cleaning the parts
Cleaning bath
For rough cleaning and finish cleaning
1 set
24 (Angular ball bearing)
Work bench for press
Pressing capacity 9800 N (7230 lbf) or over
1 set
24 (Angular ball bearing)
Work bench for press
Pressing capacity 9800 N (7230 lbf) or over
1 set
Drying after cleaning
Compressed air
Pressure 0.29 to 0.49 MPa (42 to71 psi)
—
Drying after cleaning
Compressed air
Pressure 0.29 to 0.49 MPa (42 to71 psi)
—
Size
34-40
Remarks
Size
Remarks
Q'ty 1 set
34-40
34. TRAVEL SYSTEM (3) JIGS
34. TRAVEL SYSTEM (3) JIGS
Name: Work bench for travel motor
Name: Work bench for travel motor
•
•
This is used to disassemble and to assemble of travel motor safely and securely.
This is used to disassemble and to assemble of travel motor safely and securely.
Name: Fixing metal
Name: Fixing metal
•
•
This is used to assemble spindle (101) and hub (1).
This is used to assemble spindle (101) and hub (1).
Name: Jig for installing lock washer
Name: Jig for installing lock washer
•
•
Jig for installing lock washer (22) into groove of spindle (101).
Jig for installing lock washer (22) into groove of spindle (101).
Name: Jig for press-fitting angular ball bearing
Name: Jig for press-fitting angular ball bearing
•
•
Jig for press-fit angular ball bearing (24) into hub (1).
Jig for press-fit angular ball bearing (24) into hub (1).
Name: Steel bar (I)
Name: Steel bar (I)
•
•
This is used to remove angular ball bearing (24) from hub (1).
34-41
This is used to remove angular ball bearing (24) from hub (1).
34-41
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM Name: Long eye bolts
Name: Long eye bolts
•
•
These are used to lift travel motor, spindle (101) and hub (1).
These are used to lift travel motor, spindle (101) and hub (1).
Name: Spatula
Name: Spatula
•
•
This is used to remove timing plate (109) from rear flange (301).
This is used to remove timing plate (109) from rear flange (301).
Name: Jig for installing floating seal (I)
Name: Jig for installing floating seal (I)
•
•
This is used to install floating seal (29) into hub (1).
This is used to install floating seal (29) into hub (1).
Name: Jig for installing floating seal (II)
Name: Jig for installing floating seal (II)
•
•
This is used to install floating seal (29) into hub (1) and spindle (101).
This is used to install floating seal (29) into hub (1) and spindle (101).
Name: Jig for installing floating seal (III)
Name: Jig for installing floating seal (III)
•
•
This is used to install floating seal (29) into spindle (101).
34-42
This is used to install floating seal (29) into spindle (101).
34-42
34. TRAVEL SYSTEM 34.2.1.2.2
Tightening torque
34.2.1.2.2
Bolt / Nut
Number of relevant parts (In cross-sectional view)
34. TRAVEL SYSTEM
Opposing flats Q'ty mm (inch)
Tightening torque
Tightening torque N•m (lbf•ft)
Number of relevant parts (In cross-sectional view)
Name
Size
30
Plug
PF1/2
10 (0.394)
3
98.1±19.6 (72.4±14.5)
35
Socket bolt
M10 (P1.5)
8 (0.315)
18
137
Socket plug
PT1/16
4 (0.1575)
204
Plug
M27 (P1.5)
324
Plug
364
Bolt / Nut Opposing flats Q'ty mm (inch)
Tightening torque N•m (lbf•ft)
Name
Size
30
Plug
PF1/2
10 (0.394)
3
98.1±19.6 (72.4±14.5)
57.9±9.81 (42.7±7.24)
35
Socket bolt
M10 (P1.5)
8 (0.315)
18
57.9±9.81 (42.7±7.24)
1
13.7±1.37 (10.1±1.01)
137
Socket plug
PT1/16
4 (0.1575)
1
13.7±1.37 (10.1±1.01)
32 (1.2598)
2
157~177 (116~131)
204
Plug
M27 (P1.5)
32 (1.2598)
2
157~177 (116~131)
M38 (P1.5)
46 (1.811)
2
304~324 (224~239)
324
Plug
M38 (P1.5)
46 (1.811)
2
304~324 (224~239)
Connector
PF3/8
21 (0.8268)
1
49.0~58.8 (36.1~43.4)
364
Connector
PF3/8
21 (0.8268)
1
49.0~58.8 (36.1~43.4)
368
Plug
PF1/4
6 (0.2362)
2
29.4±2.94 (21.7±2.17)
368
Plug
PF1/4
6 (0.2362)
2
29.4±2.94 (21.7±2.17)
370
Plug
PF3/8
8 (0.315)
1
49.0~58.8 (36.1~43.4)
370
Plug
PF3/8
8 (0.315)
1
49.0~58.8 (36.1~43.4)
374
Plug
PF1/8
5 (0.1969)
5
14.7±1.47 (10.8±1.08)
374
Plug
PF1/8
5 (0.1969)
5
14.7±1.47 (10.8±1.08)
343
Bolt
M16
14 (0.5512)
8
230±23.0 (170±17)
343
Bolt
M16
14 (0.5512)
8
230±23.0 (170±17)
34.2.1.2.3
Weight of component
Number of relevant parts (In cross-sectional view)
34.2.1.2.3 Components
Weight kg (lb)
Travel motor assembly
Approx. 277 (610)
Weight of component
Number of relevant parts (In cross-sectional view)
Components
Weight kg (lb)
Travel motor assembly
Approx. 277 (610)
1
Hub
Approx.79 (175)
1
Hub
Approx.79 (175)
101
Spindle
Approx. 60 (130)
101
Spindle
Approx. 60 (130)
3 and others
Carrier (ÇP) Assy
Approx. 27 (60)
3 and others
Carrier (ÇP) Assy
Approx. 27 (60)
7 and others
Carrier (ÇQ) Assy
Approx. 47 (105)
7 and others
Carrier (ÇQ) Assy
Approx. 47 (105)
34-43
34-43
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.2.1.3
34.2.1.3
34.2.1.3.1
DISASSEMBLY Preparation
34.2.1.3.1
DISASSEMBLY Preparation
The following preparations must be made before disassembly.
The following preparations must be made before disassembly.
(1) Preparing working bench
(1) Preparing working bench
•
Prepare work bench for travel motor.
•
Prepare work bench for travel motor.
•
Prepare work bench which is sturdy for disassembly and assembly of the travel motor's inner parts and has enough space to put the parts, and from which the possibility of the dropping and movement of parts is eliminated.
•
Prepare work bench which is sturdy for disassembly and assembly of the travel motor's inner parts and has enough space to put the parts, and from which the possibility of the dropping and movement of parts is eliminated.
•
Cover the work bench with rubber sheet, vinyl sheet, etc.
•
Cover the work bench with rubber sheet, vinyl sheet, etc.
(2) Preparing tools and materials. Prepare the tools and materials which are specified in paragraph 34.2.1.2.1.
(2) Preparing tools and materials. Prepare the tools and materials which are specified in paragraph 34.2.1.2.1.
34.2.1.3.2
34.2.1.3.2
General cautions required to perform the work
General cautions required to perform the work
The inner parts which are under disassembly may be easily slipped because they are coated by gear oil and hydraulic oil. Special attention must be given to the handling of parts which might fall and injure, and might be damaged.
The inner parts which are under disassembly may be easily slipped because they are coated by gear oil and hydraulic oil. Special attention must be given to the handling of parts which might fall and injure, and might be damaged.
When flammable like diesel oil or kerosene, etc. is used to wash and clean the removed parts, pay attention to the handling so as not to start a fire and get burn because the flammable is tending to catch fire.
When flammable like diesel oil or kerosene, etc. is used to wash and clean the removed parts, pay attention to the handling so as not to start a fire and get burn because the flammable is tending to catch fire.
(1) Identify the items to be checked and the property of abnormalities detected rightly before disassembly, and carry out the disassembly according to the specified procedure.
(1) Identify the items to be checked and the property of abnormalities detected rightly before disassembly, and carry out the disassembly according to the specified procedure.
(2) Handle parts taking care so as not to collide each other and not to drop because the each part is precisely made.
(2) Handle parts taking care so as not to collide each other and not to drop because the each part is precisely made.
(3) Do not strike or pry parts even if made by hard material, otherwise the assembly might be difficult due to burrs and damage and may cause the deterioration of performance.
(3) Do not strike or pry parts even if made by hard material, otherwise the assembly might be difficult due to burrs and damage and may cause the deterioration of performance.
(4) If the parts removed or under disassembly are left, it may cause rusting of parts due to moisture and dusts. If it is unavoidably necessary to suspend the work, do not fail to protect the parts form rust and dust.
(4) If the parts removed or under disassembly are left, it may cause rusting of parts due to moisture and dusts. If it is unavoidably necessary to suspend the work, do not fail to protect the parts form rust and dust.
(5) Mark the mating face of each part at the time of disassembly.
(5) Mark the mating face of each part at the time of disassembly.
(6) Go ahead with the work while putting the removed parts in order so as not to damage or miss the parts during disassembly.
(6) Go ahead with the work while putting the removed parts in order so as not to damage or miss the parts during disassembly.
(7) The removed seals, etc. must be replaced with new ones even if no damage is found. Prepare the spare parts before starting disassembling.
(7) The removed seals, etc. must be replaced with new ones even if no damage is found. Prepare the spare parts before starting disassembling.
(8) The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and figure differs from those of products in use, it has not an effect on the disassembling procedure.
(8) The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and figure differs from those of products in use, it has not an effect on the disassembling procedure.
34-44
34-44
34. TRAVEL SYSTEM 34.2.1.3.3
Disassembling procedure
34. TRAVEL SYSTEM 34.2.1.3.3
(1) Cleaning travel motor
Disassembling procedure
(1) Cleaning travel motor
1) Tighten eye bolt to the tapped hole for spindle (2), hang up the travel motor with hoist and carry it to washing bath.
1) Tighten eye bolt to the tapped hole for spindle (2), hang up the travel motor with hoist and carry it to washing bath.
Tighten two eye bolts to the tapped holes for spindle in such locations that they are symmetrical each other.
Tighten two eye bolts to the tapped holes for spindle in such locations that they are symmetrical each other.
2) Clean each section of travel motor with car washing brush.
Carefully clean the space between hub (1) and spindle (101) (floating seal fitting section) because earth and sand might be entered.
(2) Installing travel motor
2) Clean each section of travel motor with car washing brush.
Carefully clean the space between hub (1) and spindle (101) (floating seal fitting section) because earth and sand might be entered.
(2) Installing travel motor
1) Put travel motor on work bench.
1) Put travel motor on work bench.
Align the thread hole of hub (1) to the threaded hole of work bench and softly insert the travel motor in attaching hole of work bench.
Align the thread hole of hub (1) to the threaded hole of work bench and softly insert the travel motor in attaching hole of work bench.
2) Attach the travel motor on the work bench in such locations that two socket bolts are symmetrical each other.
2) Attach the travel motor on the work bench in such locations that two socket bolts are symmetrical each other.
Securely tighten the socket bolt. If not, there is a possibility of injury due to the drop of travel motor when it has been turned over.
Securely tighten the socket bolt. If not, there is a possibility of injury due to the drop of travel motor when it has been turned over.
(3) Draining lube oil.
(3) Draining lube oil.
1) Lay the travel motor horizontally. (Direct the drain port downward.)
1) Lay the travel motor horizontally. (Direct the drain port downward.)
2) Loosen oil filler plug (30) and release the pressure in the reduction unit, and then lightly tighten the plug again.
2) Loosen oil filler plug (30) and release the pressure in the reduction unit, and then lightly tighten the plug again.
If the pressure is applied to the inside of reduction unit, lubricating oil may be gushed out when loosening the plug of drain port. 3) Put the oil pan under the top end of drain port and slowly loosen the plug of drain port and then drain lubricating oil.
Prepare the oil pan of which the capacity is sufficient for the lubricating oil quantity specified to the reduction unit, 5.3L.
34-45
If the pressure is applied to the inside of reduction unit, lubricating oil may be gushed out when loosening the plug of drain port. 3) Put the oil pan under the top end of drain port and slowly loosen the plug of drain port and then drain lubricating oil.
Prepare the oil pan of which the capacity is sufficient for the lubricating oil quantity specified to the reduction unit, 5.3L.
34-45
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
4) If it is hard to drain lubricating oil, slowly loosen and remove the plug of oil filler port.
4) If it is hard to drain lubricating oil, slowly loosen and remove the plug of oil filler port.
5) Remove O-ring (31) from the removed plug.
5) Remove O-ring (31) from the removed plug.
Do not use the removed O-ring (31). It may cause oil leak. (4) Removing cover
Do not use the removed O-ring (31). It may cause oil leak. (4) Removing cover
1) Turn over travel motor. (Direct reduction unit upward.)
1) Turn over travel motor. (Direct reduction unit upward.)
2) Loosen and remove bolt 18-M10.
2) Loosen and remove bolt 18-M10.
3) Since the sealant is used on the mating faces of cover (14) and hub (1), apply a protecting plate to the cover obliquely and remove the cover while striking it upward.
3) Since the sealant is used on the mating faces of cover (14) and hub (1), apply a protecting plate to the cover obliquely and remove the cover while striking it upward.
Be careful about the cover which might be sprung up when striking the cover obliquely upward. Pay attention to the cover which might be drop on foot, etc.
Be careful about the cover which might be sprung up when striking the cover obliquely upward. Pay attention to the cover which might be drop on foot, etc.
4) Attach eye bolt to the PF1/2 port and hang up and move the cover from the hub.
4) Attach eye bolt to the PF1/2 port and hang up and move the cover from the hub.
(5) Removing 1st gear
(5) Removing 1st gear
1) Attach eye bolts to 3 tapped holes M10 for carrier [1] (3) and hang up and move carrier [1] assembly by hoist.
1) Attach eye bolts to 3 tapped holes M10 for carrier [1] (3) and hang up and move carrier [1] assembly by hoist.
When lifting carrier [1] assembly, slowly lift it directing center shaft of hub and carrier [1] assembly upright to protect the internal gear of hub from being damaged by the edge of planetary gear [1] (5).
When lifting carrier [1] assembly, slowly lift it directing center shaft of hub and carrier [1] assembly upright to protect the internal gear of hub from being damaged by the edge of planetary gear [1] (5).
2) Lift and remove sun gear [1] (4) by hand.
2) Lift and remove sun gear [1] (4) by hand.
Pay attention to sun gear [1] in order not to drop because it is slippery because of lubricating oil applied.
34-46
Pay attention to sun gear [1] in order not to drop because it is slippery because of lubricating oil applied.
34-46
34. TRAVEL SYSTEM (6) Removing 2nd gear
34. TRAVEL SYSTEM (6) Removing 2nd gear
1) Attach eye bolts to 3 tapped holes M10 for carrier [2](7) and lift and move carrier [2] assembly by hoist.
1) Attach eye bolts to 3 tapped holes M10 for carrier [2](7) and lift and move carrier [2] assembly by hoist.
When lifting carrier [2] assembly, slowly lift directing center shaft of hub and carrier [2] assembly upright to protect the internal gear of hub from being damaged by the edge of planetary gear [2] (9).
When lifting carrier [2] assembly, slowly lift directing center shaft of hub and carrier [2] assembly upright to protect the internal gear of hub from being damaged by the edge of planetary gear [2] (9).
2) Lift and remove sun gear [2] (8) from carrier [2] assembly by hand.
2) Lift and remove sun gear [2] (8) from carrier [2] assembly by hand.
Pay attention to sun gear [2] in order not to drop because it is slippery because of lubricating oil applied.
Pay attention to sun gear [2] in order not to drop because it is slippery because of lubricating oil applied.
(7) Removing coupling
(7) Removing coupling
1) Remove coupling (15) from shaft (102).
1) Remove coupling (15) from shaft (102).
(8) Removing lock washer
(8) Removing lock washer
1) Direct the spindle side upward.
1) Direct the spindle side upward.
2) Secure it in shaft direction with special jig to protect the spindle from dropping out by making use of threaded hole M16 of hub (1) and spindle (101).
2) Secure it in shaft direction with special jig to protect the spindle from dropping out by making use of threaded hole M16 of hub (1) and spindle (101).
34-47
34-47
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
3) Apply flat-blade driver or equivalent to the space between two lock washers (22) and remove it while striking the driver obliquely downward.
(9) Removing spindle
3) Apply flat-blade driver or equivalent to the space between two lock washers (22) and remove it while striking the driver obliquely downward.
(9) Removing spindle
1) Direct the spindle side upward.
1) Direct the spindle side upward.
2) Remove the special jig used to secure hub and spindle.
2) Remove the special jig used to secure hub and spindle.
3) Attach eye bolt to spindle and lift the spindle by hoist.
3) Attach eye bolt to spindle and lift the spindle by hoist.
Slowly lift the spindle in parallel with the shaft of hub. If the spindle is obliquely lift, a large force which might cause the breakage of the hoisting accessory, eye bolt, etc. is applied resulting in injury by being hit by the hoisting accessory. When it is hard to pull it out, do not be forced to lift, but use press, etc. to pull it out safely.
Slowly lift the spindle in parallel with the shaft of hub. If the spindle is obliquely lift, a large force which might cause the breakage of the hoisting accessory, eye bolt, etc. is applied resulting in injury by being hit by the hoisting accessory. When it is hard to pull it out, do not be forced to lift, but use press, etc. to pull it out safely.
(10) Removing floating seal
(10) Removing floating seal
1) Touch the inner side of floating seal (29) by hand, and remove it pushing upward.
1) Touch the inner side of floating seal (29) by hand, and remove it pushing upward.
There is a case where the edge of floating seal cuts your finger. We recommend using glove when removing it. And when it is stuck due to the intrusion of mud, remove it using screw driver as a lever.
There is a case where the edge of floating seal cuts your finger. We recommend using glove when removing it. And when it is stuck due to the intrusion of mud, remove it using screw driver as a lever.
(11) Removing angular ball bearing
(11) Removing angular ball bearing
1) Apply iron bar to the inner ring of angular ball bearing (24) and remove it little by little while striking 3 or 4 points divided into equal divisions on the circumference by hammer.
1) Apply iron bar to the inner ring of angular ball bearing (24) and remove it little by little while striking 3 or 4 points divided into equal divisions on the circumference by hammer.
If the inner ring is struck, the raceway surface may be damaged, and consequently the reuse of ball bearing might be impossible. Therefore the angular ball bearing should be removed only when required to be replaced.
If the inner ring is struck, the raceway surface may be damaged, and consequently the reuse of ball bearing might be impossible. Therefore the angular ball bearing should be removed only when required to be replaced.
34-48
34-48
34. TRAVEL SYSTEM (12) Removing rear flange assembly
34. TRAVEL SYSTEM (12) Removing rear flange assembly
1) Directs rear flange (301) upward.
1) Directs rear flange (301) upward.
2) Loosen 8 socket bolts (348) and remove rear flange.
2) Loosen 8 socket bolts (348) and remove rear flange.
3) Remove rear flange from spindle (101).
3) Remove rear flange from spindle (101).
When the rear flange is removed by both hands, pay attention to timing plate (109) and spring (113) so as not to drop.
When the rear flange is removed by both hands, pay attention to timing plate (109) and spring (113) so as not to drop.
When disassembling the parts of rear flange section, loosen each plug before loosening socket bolts used to secure rear flange [operation of (12) 2] to facilitate going ahead with the disassembly which is carried out later.
When disassembling the parts of rear flange section, loosen each plug before loosening socket bolts used to secure rear flange [operation of (12) 2] to facilitate going ahead with the disassembly which is carried out later.
34-49
34-49
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(13) Removing taper roller bearing
(13) Removing taper roller bearing
1) Secure sliding surface of cylinder block (104) with fixing plate.
1) Secure sliding surface of cylinder block (104) with fixing plate.
Insert rubber-like cushioning material between cylinder block sliding surface and fixing plate giving attention to the sliding surface of cylinder block so as not to damage.
Insert rubber-like cushioning material between cylinder block sliding surface and fixing plate giving attention to the sliding surface of cylinder block so as not to damage.
2) Apply puller axis to the center hole of shaft (102) and hook claw to the inner ring of taper roller bearing (150).
2) Apply puller axis to the center hole of shaft (102) and hook claw to the inner ring of taper roller bearing (150).
3) Pull the taper roller bearing out of the shaft while slowly turning the axis of puller with spanner, etc. Put rear flange (301) on work bench while directing the mating face with spindle (101) upward.
3) Pull the taper roller bearing out of the shaft while slowly turning the axis of puller with spanner, etc. Put rear flange (301) on work bench while directing the mating face with spindle (101) upward.
When the retainer (cage) of the taper roller bearing is accidentally damaged by puller, replace the retainer (cage) with new one.
When the retainer (cage) of the taper roller bearing is accidentally damaged by puller, replace the retainer (cage) with new one.
(14) Disassembling parking brake
(14) Disassembling parking brake
1) Pull the piston out making use of the threaded hole M6 of piston (112).
1) Pull the piston out making use of the threaded hole M6 of piston (112).
2) Turn work bench sideways.
2) Turn work bench sideways.
3) Remove separator plate (116) and friction plate (115).
3) Remove separator plate (116) and friction plate (115).
34-50
34-50
34. TRAVEL SYSTEM (15) Disassembling rotary section
34. TRAVEL SYSTEM (15) Disassembling rotary section
1) Pull out cylinder block, piston (105) and retainer plate (107) together.
1) Pull out cylinder block, piston (105) and retainer plate (107) together.
2) Remove swash plate (103).
2) Remove swash plate (103).
3) Remove shaft (102).
3) Remove shaft (102).
Slowly pull the shaft out being care not to damage the lip of oil seal (132).
Slowly pull the shaft out being care not to damage the lip of oil seal (132).
(16) Removing piston
(16) Removing piston
1) Apply cloth on piston (161), blow air through the drilled hole and remove the piston of spindle (101).
34-51
1) Apply cloth on piston (161), blow air through the drilled hole and remove the piston of spindle (101).
34-51
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.2.1.4
34.2.1.4
SERVICE STANDARDS
SERVICE STANDARDS
Disassemble GM motor according to this standard. At this time do not damage the moving and sliding part.
Disassemble GM motor according to this standard. At this time do not damage the moving and sliding part.
34.2.1.4.1
34.2.1.4.1
Seals
Seals
Replace all seals (O-ring, oil seal, floating seal with new one) once used even if no damage is seen.
Replace all seals (O-ring, oil seal, floating seal with new one) once used even if no damage is seen.
34.2.1.4.2
34.2.1.4.2
Wear parts maintenance standard
Wear parts maintenance standard
(1) Replace any part that shows damage on appearance.
(1) Replace any part that shows damage on appearance.
(2) Replace such parts that show the following abnormalities, as well.
(2) Replace such parts that show the following abnormalities, as well.
Item No.
Parts
Trouble
Reference value
Allowable value
Item No.
Parts
• Severe damage to appearance. (1)
Hub
• Pitting occurs on tooth surface of ring gear.
Spindle
(3) and other
Carrier assembly
(4) (8) (5) (9)
Sun gear 1 Sun gear 2 Planetary gear 1 Planetary gear 2
(11) (12)
Thrust washer 1 Thrust washer 2
• Severe damage to appearance. • Abnormal wear such as scoring is present. • Abnormal wear such as scoring is present. • Pitting occurs on tooth surface of gear. • Flaking is seen on race of bearing. • Discoloration and abnormal wear appears on the sliding surface.
—
—
(1)
Hub
Angular ball bearing • Flaking is seen.
—
—
(101)
Spindle
—
—
(3) and other
Carrier assembly
—
—
(4) (8) (5) (9)
Sun gear 1 Sun gear 2 Planetary gear 1 Planetary gear 2
—
—
(11) (12)
Thrust washer 1 Thrust washer 2
Needle-roller bearing
—
—
(301)
Rear flange
(102)
Shaft
• Sliding part is damaged due to valve (263) motion. • Contact face between shaft and oil seal (132) was worn.
(24)
Swash plate
• Seizure is present.
—
—
(27) (28)
Needle-roller bearing
—
—
(301)
Rear flange
—
—
(102)
Shaft
(105) (106)
Cylinder block
Piston assembly piston shoe
—
—
(103)
Swash plate
Retainer plate
• Abnormal wear such as scoring is present.
—
—
• Abnormal wear such as scoring is present.
—
—
• Pitting occurs on tooth surface of gear. • Flaking is seen on race of bearing.
—
—
• Discoloration and abnormal wear appears on the sliding surface.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
Clearance on diameter 0 to 0.05mm (0.002inch)
Clearance on diameter 0 to 0.2mm (0.008inch)
—
—
• Pitting occurs on roller. • Abnormal wear is present on the end of cage. • Sliding part is damaged due to valve (263) motion. • Contact face between shaft and oil seal (132) was worn. • Seizure is present. • Spline is worn.
• Bore surface is worn badly. • The face between sliding surface and timing plate (109) was scored or worn unevenly. • Clearance is present in the axial direction between piston and shoe. • Shoe is worn abnormally and unevenly.
—
—
Clearance on diameter 0 to 0.05mm (0.002inch)
Clearance on diameter 0 to 0.2mm (0.008inch)
(104)
(105) (106)
Cylinder block
Piston assembly piston shoe
• Deformation is present. (107)
—
• Spline was worn.
• Spline is worn. (104)
• Severe damage to appearance.
Angular ball bearing • Flaking is seen.
• Spline was worn. (103)
—
• Uneven wear is present.
• Pitting occurs on roller. • Abnormal wear is present on the end of cage.
• Pitting occurs on tooth surface of ring gear.
• Dent is present.
• Uneven wear is present. (27) (28)
Allowable value
• Abnormal wear such as scoring is present.
• Dent is present. (24)
Reference value
• Severe damage to appearance.
• Abnormal wear such as scoring is present. (101)
Trouble
• The sliding surface between thrust ball (108) and plate is scored and worn unevenly.
34-52
• Bore surface is worn badly. • The face between sliding surface and timing plate (109) was scored or worn unevenly. • Clearance is present in the axial direction between piston and shoe. • Shoe is worn abnormally and unevenly. • Deformation is present.
—
—
(107)
Retainer plate
• The sliding surface between thrust ball (108) and plate is scored and worn unevenly.
34-52
34. TRAVEL SYSTEM
Item No.
Reference value
Allowable value
Parts
Trouble
Reference value
Allowable value
(108)
Thrust ball
• The sliding surface between retainer plate (107) and spherical sliding part is worn unevenly.
—
—
(109)
Timing plate
• Sliding surface is seized or worn unevenly.
—
—
(115) (116)
Friction plate Separator plate
—
(112) (135) (139)
Piston D ring D ring
—
(149) (150)
Taper roller bearing
Parts
Trouble
(108)
Thrust ball
• The sliding surface between retainer plate (107) and spherical sliding part is worn unevenly.
—
—
(109)
Timing plate
• Sliding surface is seized or worn unevenly.
—
—
(115) (116)
Friction plate Separator plate
(112) (135) (139)
Piston D ring D ring
• Both end face are worn unevenly. • Special torque can not be reached. • Seizure is seen. • Outer circumstance is scored. • Wear or nibbling are seen on D ring.
Braking torque Braking torque 470N•m 470N•m (347lbf•ft) (347lbf•ft) —
• Dent is present.
(149) (150)
Taper roller bearing
(161) (163)
Piston Seal
(323) (363)
Spool
• Flaking is seen.
—
• Uneven wear is present. • Wear or nibbling are seen on seal. • Outer circumstance is scored. • Outer circumstance is worn unevenly.
34-53
34. TRAVEL SYSTEM
Item No.
• Both end face are worn unevenly. • Special torque can not be reached. • Seizure is seen. • Outer circumstance is scored. • Wear or nibbling are seen on D ring.
Braking torque Braking torque 470N•m 470N•m (347lbf•ft) (347lbf•ft) —
—
—
—
—
—
—
—
• Dent is present. • Flaking is seen. • Uneven wear is present.
—
—
(161) (163)
Piston Seal
—
—
(323) (363)
Spool
• Wear or nibbling are seen on seal. • Outer circumstance is scored. • Outer circumstance is worn unevenly.
34-53
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
34.2.1.5
34.2.1.5
ASSEMBLY
ASSEMBLY
The assembly is carried out by the reverse procedure of disassembly.
The assembly is carried out by the reverse procedure of disassembly.
34.2.1.5.1
34.2.1.5.1
Preparation
Preparation
Prepare work bench, tools and materials similarly to the disassembly specified in paragraph 34.2.1.3.
Prepare work bench, tools and materials similarly to the disassembly specified in paragraph 34.2.1.3.
34.2.1.5.2
34.2.1.5.2
General caution necessary to perform the work
General caution necessary to perform the work
(1) Pay attention to the same general caution as the disassembly explained in paragraph 34.2.1.3.
(1) Pay attention to the same general caution as the disassembly explained in paragraph 34.2.1.3.
(2) On assembling, remove metal chips and foreign matters from all parts and make sure that parts are free from burr, dent, etc. If burr and dent are found, remove them by means of oil stone.
(2) On assembling, remove metal chips and foreign matters from all parts and make sure that parts are free from burr, dent, etc. If burr and dent are found, remove them by means of oil stone.
(3) Replace O-ring, oil seal and floating seal with new one.
(3) Replace O-ring, oil seal and floating seal with new one.
(4) Remove adhesive left on the threaded hole of hub (1) by passing tap M10uP1.5 through the hole. Then clean and degrease the threaded hole, and blow air to remove cleaning fluid. Replace socket bolt (7) with new one.
(4) Remove adhesive left on the threaded hole of hub (1) by passing tap M10uP1.5 through the hole. Then clean and degrease the threaded hole, and blow air to remove cleaning fluid. Replace socket bolt (7) with new one.
(5) Use care about O-ring, oil seal and floating seal when fitting them so as not to damage. (Apply grease in small amounts to smooth.)
(5) Use care about O-ring, oil seal and floating seal when fitting them so as not to damage. (Apply grease in small amounts to smooth.)
(6) Be sure to apply clean hydraulic oil (NAS grade 9 or more) to the moving parts and sliding parts provided on the hydraulic motor and valve before assembling.
(6) Be sure to apply clean hydraulic oil (NAS grade 9 or more) to the moving parts and sliding parts provided on the hydraulic motor and valve before assembling.
(7) Do not use cloth glove during assembling work. (To prevent malfunction due to lint of fiber)
(7) Do not use cloth glove during assembling work. (To prevent malfunction due to lint of fiber)
(8) Torque bolts and plugs to values specified in paragraph 34.2.1.2.2 "Table of Torque".
(8) Torque bolts and plugs to values specified in paragraph 34.2.1.2.2 "Table of Torque".
(9) At the time the assembly was completed, plug all ports to prevent dust entering.
(9) At the time the assembly was completed, plug all ports to prevent dust entering.
(10)The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and figure differs from those of products in use, it has not an effect on the assembling procedure.
(10)The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and figure differs from those of products in use, it has not an effect on the assembling procedure.
34.2.1.5.3
34.2.1.5.3
Assembling procedure
Assembling procedure
•
Remove adhesive adhered on female thread hole M10 of hub (1) by means of tapping.
•
Remove adhesive adhered on female thread hole M10 of hub (1) by means of tapping.
•
Remove sealant adhered on mating surface of hub (1) and cover (14) with scraper, grindstone, etc.
•
Remove sealant adhered on mating surface of hub (1) and cover (14) with scraper, grindstone, etc.
•
Sufficiently clean all parts in cleaning bath before assembling.
•
Sufficiently clean all parts in cleaning bath before assembling.
34-54
34-54
34. TRAVEL SYSTEM (1) Assembling spindle
34. TRAVEL SYSTEM (1) Assembling spindle
1) Set spindle (101) on work bench.
1) Set spindle (101) on work bench.
2) Fit outer ring of taper roller bearing (149) into the center hole of spindle.
2) Fit outer ring of taper roller bearing (149) into the center hole of spindle.
3) Place piston (161) in the cylinder hole of spindle.
3) Place piston (161) in the cylinder hole of spindle.
4) Place steel balls (162) in piston hole.
4) Place steel balls (162) in piston hole.
Apply grease to the steel ball to fix on the piston hole to be sure the steel ball does not drop out of the piston during assembly which will be carried out later.
Apply grease to the steel ball to fix on the piston hole to be sure the steel ball does not drop out of the piston during assembly which will be carried out later.
5) Attach L side of pivot (167) to the left side in the picture.
5) Attach L side of pivot (167) to the left side in the picture.
6) Insert shaft (102).
6) Insert shaft (102).
Apply grease to spline of shaft and slowly insert it taking care not to damage the lip of oil seal.
Apply grease to spline of shaft and slowly insert it taking care not to damage the lip of oil seal.
(2) Assembling rotary section
(2) Assembling rotary section
1) Apply grease to the sliding surface of swash plate (103) and pivot.
1) Apply grease to the sliding surface of swash plate (103) and pivot.
2) Tilt the swash plate and place it in spindle.
2) Tilt the swash plate and place it in spindle.
•
Make sure that the speed is changed in High and Low smoothly while blowing air through the drilled hole after assembling the swash plate in.
•
Make sure that the speed is changed in High and Low smoothly while blowing air through the drilled hole after assembling the swash plate in.
•
Apply clean hydraulic oil to the sliding surface of swash plate.
•
Apply clean hydraulic oil to the sliding surface of swash plate.
3) Turn work bench sideways.
3) Turn work bench sideways.
4) Set cylinder block (104), piston (105), spring (114), thrust ball (108) and retainer plate (107) and insert it in the shaft.
4) Set cylinder block (104), piston (105), spring (114), thrust ball (108) and retainer plate (107) and insert it in the shaft.
•
Apply clean hydraulic oil to the sliding surface of cylinder block, piston, thrust ball and shoe (106).
•
Apply clean hydraulic oil to the sliding surface of cylinder block, piston, thrust ball and shoe (106).
•
On inserting cylinder block assembly in the shaft, fix the reduction unit side of shaft first and the insertion can be performed smoothly.
•
On inserting cylinder block assembly in the shaft, fix the reduction unit side of shaft first and the insertion can be performed smoothly.
34-55
34-55
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(3) Assembling parking brake
(3) Assembling parking brake
1) Direct rear flange attaching face of piston upward while turning the work bench.
1) Direct rear flange attaching face of piston upward while turning the work bench.
2) Install separator plate (116), friction plate and separator plate in that order.
2) Install separator plate (116), friction plate and separator plate in that order.
3) Apply soft metal bar to piston (112) and insert it in spindle (101) while striking the bar with a hammer.
3) Apply soft metal bar to piston (112) and insert it in spindle (101) while striking the bar with a hammer.
Strike 3 or 4 points divided into equal divisions on the circumference of piston in order and assemble it in the condition where the piston is held in level because the sliding surface might be damaged if the piston is largely tilted.
Strike 3 or 4 points divided into equal divisions on the circumference of piston in order and assemble it in the condition where the piston is held in level because the sliding surface might be damaged if the piston is largely tilted.
(4) Assembling taper roller bearing
(4) Assembling taper roller bearing
1) Push taper roller bearing (150) on which the outer ring has been removed against shaft (102), and then apply metal bar to the inner race and insert it while striking the bar with a hammer.
34-56
1) Push taper roller bearing (150) on which the outer ring has been removed against shaft (102), and then apply metal bar to the inner race and insert it while striking the bar with a hammer.
34-56
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(5) Adjusting clearance of taper roller bearing
(5) Adjusting clearance of taper roller bearing
When spindle (101), shaft (102), rear flange (301) or taper roller bearing (149) (150) is replaced, adjust the clearance of taper roller bearing. When the clearance is improper, the life of taper roller bearing might be shortened.
When spindle (101), shaft (102), rear flange (301) or taper roller bearing (149) (150) is replaced, adjust the clearance of taper roller bearing. When the clearance is improper, the life of taper roller bearing might be shortened.
1) Direct the mating surface with the rear flange of spindle (101) upward.
1) Direct the mating surface with the rear flange of spindle (101) upward.
2) Press taper roller bearing (150) into shaft (102) while striking it with plastic hammer.
2) Press taper roller bearing (150) into shaft (102) while striking it with plastic hammer.
3) Measure dimension A.
3) Measure dimension A.
4) Measure dimension B of rear flange (301).
4) Measure dimension B of rear flange (301).
5) Subtract dimension A from dimension B, and select shim (119) which makes the clearance to 0~0.17mm (0~0.0067in).
5) Subtract dimension A from dimension B, and select shim (119) which makes the clearance to 0~0.17mm (0~0.0067in).
(6) Assembling rear flange
(6) Assembling rear flange
1) Place shim and outer race of taper roller bearing (150) in the center hole of rear flange (301) in that order.
1) Place shim and outer race of taper roller bearing (150) in the center hole of rear flange (301) in that order.
2) Install timing plate to rear flange so that parallel pin (341) which is press-fitted in the rear flange aligns with the hole on the perimeter of timing plate (109).
2) Install timing plate to rear flange so that parallel pin (341) which is press-fitted in the rear flange aligns with the hole on the perimeter of timing plate (109).
3) Install spring (113) into the hole of rear flange.
3) Install spring (113) into the hole of rear flange.
Apply grease to timing plate and spring to prevent the parts from missing when the rear flange assembly is assembled to the spindle.
Apply grease to timing plate and spring to prevent the parts from missing when the rear flange assembly is assembled to the spindle.
4) Make sure those O-rings (375), (379), (380) are fitted into O-ring grooves of rear flange.
4) Make sure those O-rings (375), (379), (380) are fitted into O-ring grooves of rear flange.
34-57
34-57
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
5) Turn work bench sideways.
5) Turn work bench sideways.
6) Install rear flange.
6) Install rear flange.
7) Tighten socket bolt (343) to the specified torque.
7) Tighten socket bolt (343) to the specified torque.
When the parts of rear flange are disassembled, tighten each plug to the specified torque.
When the parts of rear flange are disassembled, tighten each plug to the specified torque.
34-58
34-58
34. TRAVEL SYSTEM (7) Assembling hub
34. TRAVEL SYSTEM (7) Assembling hub
PRESS
1) Place hub (1) on press work bench. 2) Install angular ball bearing (24) in the hub, place ball bearing press fitting jig on the outer race of angular ball bearing, and press fit it in the hub by means of press.
PRESS
1) Place hub (1) on press work bench. 2) Install angular ball bearing (24) in the hub, place ball bearing press fitting jig on the outer race of angular ball bearing, and press fit it in the hub by means of press.
HUB JIG FOR PRESS-FITTING ANGULAR BALL BEARING
3) Turn over the hub.
3) Turn over the hub.
4) Press fit angular ball bearing in the hub by the same procedure as that described in above 2).
4) Press fit angular ball bearing in the hub by the same procedure as that described in above 2).
BALL BEARING
HUB JIG FOR PRESS-FITTING ANGULAR BALL BEARING
BALL BEARING
STAND
Pay attention to the direction of ball bearing (24) to be attached.
JIG FOR INSTALLING F/S (II)
5) Place the hub on work bench and fix it.
STAND
Pay attention to the direction of ball bearing (24) to be attached.
JIG FOR INSTALLING F/S (II)
5) Place the hub on work bench and fix it.
JIG FOR INSTALLING F/S (I)
FROATING SEAL (F/S)
JIG FOR INSTALLING F/S (I)
FROATING SEAL (F/S)
HUB
6) Apply grease to O-ring of floating seal (29), and fit floating seal into floating seal groove of hub (1).
6) Apply grease to O-ring of floating seal (29), and fit floating seal into floating seal groove of hub (1).
7) Similarly, fit floating seal into floating seal groove of spindle (101).
7) Similarly, fit floating seal into floating seal groove of spindle (101).
•
When applying grease to O-ring of floating seal, take O-ring out of floating seal and apply thin coat of grease to perimeter of O-ring.
•
When applying grease to O-ring of floating seal, take O-ring out of floating seal and apply thin coat of grease to perimeter of O-ring.
•
Remove jig F/S (I) for installing floating seal and make sure that spindle groove end face is in parallel with floating seal surface within the range of 1mm. When it is not in parallel, it might cause leaking oil and seizure. Perform the procedure from the first again.
•
Remove jig F/S (I) for installing floating seal and make sure that spindle groove end face is in parallel with floating seal surface within the range of 1mm. When it is not in parallel, it might cause leaking oil and seizure. Perform the procedure from the first again.
34-59
34-59
HUB
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(8) Adjust clearance of angular contact ball bearing
(8) Adjust clearance of angular contact ball bearing
When hub (1), angular ball bearing (24) or spindle (101) is replaced, do not fail to adjust the clearance. When the clearance is improper, the life of angular ball bearing might be shortened.
When hub (1), angular ball bearing (24) or spindle (101) is replaced, do not fail to adjust the clearance. When the clearance is improper, the life of angular ball bearing might be shortened.
1) Temporarily attach lock washer (22) to spindle, and measure dimension C.
1) Temporarily attach lock washer (22) to spindle, and measure dimension C.
2) Measure bearing width D of angular ball bearing as shown in figure.
2) Measure bearing width D of angular ball bearing as shown in figure.
Turn hub and angular ball bearing several times to make the bearing level.
Turn hub and angular ball bearing several times to make the bearing level.
3) Subtract dimension D from dimension C and select shim (23) which makes the clearance within -0.08~+0.02mm (-0.0031~+0.0008in).
3) Subtract dimension D from dimension C and select shim (23) which makes the clearance within -0.08~+0.02mm (-0.0031~+0.0008in).
(9) Assembling spindle :
(9) Assembling spindle :
1) Fit shim (23) in spindle (101) with grease.
1) Fit shim (23) in spindle (101) with grease.
2) Align the lifted spindle with the center shaft of hub (1) and insert the spindle in angular ball bearing (24) while lowering the spindle slowly.
2) Align the lifted spindle with the center shaft of hub (1) and insert the spindle in angular ball bearing (24) while lowering the spindle slowly.
3) Tighten and secure it with special jig making use of the threaded hole M16 of hub and spindle.
3) Tighten and secure it with special jig making use of the threaded hole M16 of hub and spindle.
4) Direct the reduction unit upward while turning work bench.
4) Direct the reduction unit upward while turning work bench.
5) Apply metal bar to the inner race of angular ball bearing on the reduction side and strike it lightly by means of hammer to make the inner race level.
5) Apply metal bar to the inner race of angular ball bearing on the reduction side and strike it lightly by means of hammer to make the inner race level.
34-60
34-60
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
6) Fit lock washer (22) to the groove of spindle.
6) Fit lock washer (22) to the groove of spindle.
7) Press lock washer into the groove of spindle by means of jig.
7) Press lock washer into the groove of spindle by means of jig.
Be sure to press lock washer into the groove bottom to prevent the interference with the lock washer when placing carrier [2] (7) in.
Be sure to press lock washer into the groove bottom to prevent the interference with the lock washer when placing carrier [2] (7) in.
8) Direct spindle upward while turning work bench.
8) Direct spindle upward while turning work bench.
9) Remove special jig which is used to fix hub and spindle.
9) Remove special jig which is used to fix hub and spindle.
10) Turn spindle several times.
10) Turn spindle several times.
The sliding surface of floating seal fits surface of hub and spindle by turning the spindle. This results in prevention of imitated oil leaks at test run.
The sliding surface of floating seal fits surface of hub and spindle by turning the spindle. This results in prevention of imitated oil leaks at test run.
(10)Assembling 2nd stage gear
(10)Assembling 2nd stage gear
1) Assemble coupling (15) to shaft (102).
1) Assemble coupling (15) to shaft (102).
2) Hoist carrier [2] assembly. And install it in hub (1).
2) Hoist carrier [2] assembly. And install it in hub (1).
When placing carrier [2] assembly in, align the center shaft of carrier [2] assembly with the hub and lower it in slowly giving attention to the internal tooth of hub in order not to be damaged by the edge of planetary gear [2] (9).
When placing carrier [2] assembly in, align the center shaft of carrier [2] assembly with the hub and lower it in slowly giving attention to the internal tooth of hub in order not to be damaged by the edge of planetary gear [2] (9).
34-61
34-61
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
Locate planetary gear [2] and the port of flange as shown in the figure.
Locate planetary gear [2] and the port of flange as shown in the figure.
PLANETARY GEAR (2)
(11)Assembling 2nd stage gear
PLANETARY GEAR (2)
(11)Assembling 2nd stage gear
1) Hoist carrier [1] assembly. And install it in the hub (1).
1) Hoist carrier [1] assembly. And install it in the hub (1).
When placing carrier [2] assembly in, align the center shaft of carrier [2] assembly with the hub and lower it in slowly giving attention to the internal tooth of hub in order not to be damaged by the edge of planetary gear [1] (5).
When placing carrier [2] assembly in, align the center shaft of carrier [2] assembly with the hub and lower it in slowly giving attention to the internal tooth of hub in order not to be damaged by the edge of planetary gear [1] (5).
2) Place sun gear [1](4) in while being matched to the spline of coupling.
2) Place sun gear [1](4) in while being matched to the spline of coupling.
In cases where it is hard to place sun gear [1] in because the spline of sun gear [1] interferes with the gear tooth of planetary gear, lift carrier [1] assembly once until the connection of coupling to sun gear [2](8) comes off and place sun gear [1] in again.
In cases where it is hard to place sun gear [1] in because the spline of sun gear [1] interferes with the gear tooth of planetary gear, lift carrier [1] assembly once until the connection of coupling to sun gear [2](8) comes off and place sun gear [1] in again.
3) Place thrust plate (13) in carrier [1](3).
3) Place thrust plate (13) in carrier [1](3).
34-62
34-62
34. TRAVEL SYSTEM (12)Assembling cover
34. TRAVEL SYSTEM (12)Assembling cover
1) Apply sealant "Loctite #515" to the surface of hub in contact with the cover.
1) Apply sealant "Loctite #515" to the surface of hub in contact with the cover.
Apply sealant throughout the end face of hub (1) as shown in figure.
Apply sealant throughout the end face of hub (1) as shown in figure.
2) Place cover on hub to the position of bolt hole.
2) Place cover on hub to the position of bolt hole.
3) Tighten socket bolts (35) to the specified torque.
3) Tighten socket bolts (35) to the specified torque.
34-63
34-63
34. TRAVEL SYSTEM
34. TRAVEL SYSTEM
(13)Lubricating
(13)Lubricating
1) Fill lubrication oil through filling port.
1) Fill lubrication oil through filling port.
2) Tighten plug (30) to the specified torque at respective ports.
2) Tighten plug (30) to the specified torque at respective ports.
34-64
34-64
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
TABLE OF CONTENTS
TABLE OF CONTENTS
46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3
46.1 JUDGMENT OF ACTUAL THING AT SITE .....................................................................46-3
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.2 CLASSIFICATION OF FAILURE AND TROUBLESHOOTING .......................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-4
46.3 THE BLOWN FUSE OF MECHATRO CONTROLLER ....................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
46.4 TROUBLESHOOTING BY ERROR CODE......................................................................46-4
46
46
Book Code No. S5YN4618E02 46-1
Book Code No. S5YN4618E02 46-1
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Issue
Date of Issue
Applicable Machines
First edition
July, 2006
SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~
n
August, 2006
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
Revision
February, 2007
n
March, 2007
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n E215B : YN11-45001~ E215BLC : YQ11-06001~
46-2
Remarks
Issue
Date of Issue
K
First edition
July, 2006
SK330-8 : LC10-07001~ SK350LC-8 : YC10-03501~
n
K
n
August, 2006
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
K
n
K
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
n
K
K
Revision
February, 2007
K
n
March, 2007
K
n
April, 2007
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
S5YN4618E01 (ASIA, OCE)
S5YN4618E02 (ASIA, OCE) n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine
Applicable Machines
n E215B : YN11-45001~ E215BLC : YQ11-06001~
46-2
Remarks S5YN4618E01 (ASIA, OCE)
S5YN4618E02 (ASIA, OCE) n (NHK Russia) n ASIA (HS Engine) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine
K
K K K K K K
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Preface
Preface
Troubleshooting provides process locating for the cause of trouble in the order that trouble occurred. This manual describes how to solve the specific phenomenon systematically as early as possible. For troubleshooting concerning the inside of equipment, refer to troubleshooting for each manual of equipment.
Troubleshooting provides process locating for the cause of trouble in the order that trouble occurred. This manual describes how to solve the specific phenomenon systematically as early as possible. For troubleshooting concerning the inside of equipment, refer to troubleshooting for each manual of equipment.
Fig. 46-1 Attending the field to verify actual thing.
46.1
JUDGMENT OF ACTUAL THING AT SITE
Fig. 46-1 Attending the field to verify actual thing.
46.1
JUDGMENT OF ACTUAL THING AT SITE
(1) Get to the site as quickly as possible. Verify model, serial number, situation of trouble and field, and notify person of arrival time.
(1) Get to the site as quickly as possible. Verify model, serial number, situation of trouble and field, and notify person of arrival time.
(2) Verify background of trouble occurred
(2) Verify background of trouble occurred
1) Model name and serial number
1) Model name and serial number
2) Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable.
2) Kind of attachment Check that the combination of attachment is proper or that the operating method is not unreasonable.
3) Operating time by hour-meter
3) Operating time by hour-meter
4) History of trouble occurred and additional works.
4) History of trouble occurred and additional works.
5) Recurrence of past trouble, or problems on the additional works.
Fig. 46-2 Verifying background of trouble occurred.
(3) How to diagnose trouble
5) Recurrence of past trouble, or problems on the additional works.
Fig. 46-2 Verifying background of trouble occurred.
(3) How to diagnose trouble
1) Verify defective part
1) Verify defective part
2) Make the condition of trouble again
2) Make the condition of trouble again
3) Where defective parts can not be verified, surmise causes systematically.
3) Where defective parts can not be verified, surmise causes systematically.
4) Verify reasons for surmise
4) Verify reasons for surmise
5) Report methods, procedure, and period for repairing to user.
5) Report methods, procedure, and period for repairing to user.
(4) Explanation of the cause of trouble
(4) Explanation of the cause of trouble
1) Explain the cause of trouble to clients. For example, oil leak through piston is caused by flaws on the piston rod. And the method of using the machines should be explained so that the same kind of trouble does not reoccur.
Fig. 46-3 Confirm the symptoms of the trouble.
2) Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. Protect them from entry of water, soils, etc. into port of hydraulic unit, etc. and return them. And also use care not to flaw and damage those surfaces.
Fig. 46-4 Diagnosing fail by means troubleshooting.
46-3
1) Explain the cause of trouble to clients. For example, oil leak through piston is caused by flaws on the piston rod. And the method of using the machines should be explained so that the same kind of trouble does not reoccur.
Fig. 46-3 Confirm the symptoms of the trouble.
2) Treatment of damaged parts The damaged parts to be claimed and returned are evidence so they should be handled with care. Protect them from entry of water, soils, etc. into port of hydraulic unit, etc. and return them. And also use care not to flaw and damage those surfaces.
Fig. 46-4 Diagnosing fail by means troubleshooting.
46-3
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
46.2
46.2
CLASSIFICATION OF FAILURE AND TROUBLESHOOTING
Classify failures into the following 3 types and carry out the troubleshooting. No.
Classes of failure When error code after self-diagnosis is displayed on gauge cluster
B
C
46.3
Classify failures into the following 3 types and carry out the troubleshooting. Troubleshooting
A
CLASSIFICATION OF FAILURE AND TROUBLESHOOTING
No.
Carry out troubleshooting according to the error code.
Classes of failure
Troubleshooting
A
When error code after self-diagnosis is displayed on gauge cluster
When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel after self diagnosis is remained in trouble history the data in the history and reproduce the failed situation or suppose the cause according to the troubleshooting by error code, and then repair it.
B
When no failure is detected currently but error code When it is hard to recreate the failure situation, cancel after self diagnosis is remained in trouble history the data in the history and reproduce the failed situation or suppose the cause according to the troubleshooting by error code, and then repair it.
When error code after self diagnosis is not displayed or is not remained in the history
C
When error code after self diagnosis is not displayed or is not remained in the history
• Carry out troubleshooting according to instructions in Chapter 47 "TROUBLESHOOTING BY TROUBLE". • Carry out troubleshooting according to instructions in Chapter 48 "TROUBLE DIAGNOSIS MODE".
THE BLOWN FUSE OF MECHATRO CONTROLLER
46.3
Carry out troubleshooting according to the error code.
• Carry out troubleshooting according to instructions in Chapter 47 "TROUBLESHOOTING BY TROUBLE". • Carry out troubleshooting according to instructions in Chapter 48 "TROUBLE DIAGNOSIS MODE".
THE BLOWN FUSE OF MECHATRO CONTROLLER
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
If the fuse of mechatro controller has blown, the following display appears on the gauge cluster.
(1) The blown fuse of mechatro controller
(1) The blown fuse of mechatro controller
a. Blown fuse 5A of mechatro controller : "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed.
a. Blown fuse 5A of mechatro controller : "DATA COMMUNICATION ERROR" is displayed on the gauge cluster in the condition where the controller program is not executed.
b. Blown fuse 20A of mechatro controller The controller functions normally but the power supply applied when the controller drives the solenoid, etc. stops. Many error codes are displayed on the gauge cluster. D013, D023, D033, D063, E013, E023, F021
b. Blown fuse 20A of mechatro controller The controller functions normally but the power supply applied when the controller drives the solenoid, etc. stops. Many error codes are displayed on the gauge cluster. D013, D023, D033, D063, E013, E023, F021
46.4
TROUBLESHOOTING BY ERROR CODE
46.4
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the troubleshooting referring to applicable page in the contents of error codes.
Error Code
Trouble
Described page
TROUBLESHOOTING BY ERROR CODE
When error code was displayed on the gauge cluster with the aid of self-diagnosis display function, carry out the troubleshooting referring to applicable page in the contents of error codes.
Error Code
Trouble
Described page
A015
Engine adjustment (A adjustment) is not adjusted yet or is failed.
46-7
A015
Engine adjustment (A adjustment) is not adjusted yet or is failed.
46-7
A025
Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
46-7
A025
Pump propo. valve adjustment (B adjustment) is not adjusted yet or is failed.
46-7
A035
Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
46-8
A035
Unload valve adjustment (C adjustment) is not adjusted yet or is failed.
46-8
A215
Written data of ROM adjustment data is incorrect.
46-8
A215
Written data of ROM adjustment data is incorrect.
46-8
A225
Writing of ROM adjustment data is incorrect.
46-9
A225
Writing of ROM adjustment data is incorrect.
46-9
A235
Written data of ROM hour meter data is incorrect.
46-9
A235
Written data of ROM hour meter data is incorrect.
46-9
A245
Writing of ROM hour meter data is incorrect.
46-10
A245
Writing of ROM hour meter data is incorrect.
46-10
A255
Writing of proportional valve adjustment data is incorrect.
46-10
A255
Writing of proportional valve adjustment data is incorrect.
46-10
B012
Incorrect output of boom up pressure sensor
46-11
B012
Incorrect output of boom up pressure sensor
46-11
B013
Disconnection of boom up pressure sensor
46-11
B013
Disconnection of boom up pressure sensor
46-11
B014
Short-circuit of boom up pressure sensor
46-12
B014
Short-circuit of boom up pressure sensor
46-12
B022
Incorrect output of boom down pressure sensor
46-12
B022
Incorrect output of boom down pressure sensor
46-12
B023
Disconnection of boom down pressure sensor
46-13
B023
Disconnection of boom down pressure sensor
46-13
B024
Short-circuit of boom down pressure sensor
46-13
B024
Short-circuit of boom down pressure sensor
46-13
46-4
46-4
46. TROUBLE SHOOTING (BY ERROR CODES) Error Code
Trouble
Described page
46. TROUBLE SHOOTING (BY ERROR CODES) Error Code
Trouble
Described page
B032
Incorrect output of arm out pressure sensor
46-14
B032
Incorrect output of arm out pressure sensor
46-14
B033
Disconnection of arm out pressure sensor
46-14
B033
Disconnection of arm out pressure sensor
46-14
B034
Short-circuit of arm out pressure sensor
46-15
B034
Short-circuit of arm out pressure sensor
46-15
B042
Incorrect output of arm in pressure sensor
46-15
B042
Incorrect output of arm in pressure sensor
46-15
B043
Disconnection of arm in pressure sensor
46-16
B043
Disconnection of arm in pressure sensor
46-16
B044
Short-circuit of arm in pressure sensor
46-16
B044
Short-circuit of arm in pressure sensor
46-16
B052
Incorrect output of bucket digging pressure sensor
46-17
B052
Incorrect output of bucket digging pressure sensor
46-17
B053
Disconnection of bucket digging pressure sensor
46-17
B053
Disconnection of bucket digging pressure sensor
46-17
B054
Short-circuit of bucket digging pressure sensor
46-18
B054
Short-circuit of bucket digging pressure sensor
46-18
B062
Incorrect output of bucket dump pressure sensor
46-18
B062
Incorrect output of bucket dump pressure sensor
46-18
B063
Disconnection of bucket dump pressure sensor
46-19
B063
Disconnection of bucket dump pressure sensor
46-19
B064
Short-circuit of bucket dump pressure sensor
46-19
B064
Short-circuit of bucket dump pressure sensor
46-19
B072
Incorrect output of swing pressure sensor
46-20
B072
Incorrect output of swing pressure sensor
46-20
B073
Disconnection of swing pressure sensor
46-20
B073
Disconnection of swing pressure sensor
46-20
B074
Short-circuit of swing pressure sensor
46-21
B074
Short-circuit of swing pressure sensor
46-21
B092
Incorrect output of travel right pressure sensor
46-21
B092
Incorrect output of travel right pressure sensor
46-21
B093
Disconnection of travel right pressure sensor
46-22
B093
Disconnection of travel right pressure sensor
46-22
B094
Short-circuit of travel right pressure sensor
46-22
B094
Short-circuit of travel right pressure sensor
46-22
B102
Incorrect output of travel left pressure sensor
46-23
B102
Incorrect output of travel left pressure sensor
46-23
B103
Disconnection of travel left pressure sensor
46-23
B103
Disconnection of travel left pressure sensor
46-23
B104
Short-circuit of travel left pressure sensor
46-24
B104
Short-circuit of travel left pressure sensor
46-24
B113
Disconnection of pressure sensor of optional selector positioning
46-24
B113
Disconnection of pressure sensor of optional selector positioning
46-24
B114
Short-circuit of pressure sensor of optional selector positioning
46-25
B114
Short-circuit of pressure sensor of optional selector positioning
46-25
B162
Incorrect output of P1 optional side pressure sensor
46-25
B162
Incorrect output of P1 optional side pressure sensor
46-25
B163
Disconnection of P1 side optional pressure sensor
46-26
B163
Disconnection of P1 side optional pressure sensor
46-26
B164
Short-circuit of P1 side optional pressure sensor
46-26
B164
Short-circuit of P1 side optional pressure sensor
46-26
B172
Incorrect output of P2 optional side pressure sensor
46-27
B172
Incorrect output of P2 optional side pressure sensor
46-27
B173
Disconnection of P2 side optional pressure sensor
46-27
B173
Disconnection of P2 side optional pressure sensor
46-27
B174
Short-circuit of P2 side optional pressure sensor
46-28
B174
Short-circuit of P2 side optional pressure sensor
46-28
C012
Incorrect output of P1 pump pressure sensor
46-28
C012
Incorrect output of P1 pump pressure sensor
46-28
C013
Disconnection of P1 pump pressure sensor
46-29
C013
Disconnection of P1 pump pressure sensor
46-29
C014
Short-circuit of P1 pump pressure sensor
46-29
C014
Short-circuit of P1 pump pressure sensor
46-29
C022
Incorrect output of P2 pump pressure sensor
46-30
C022
Incorrect output of P2 pump pressure sensor
46-30
C023
Disconnection of P2 pump pressure sensor
46-30
C023
Disconnection of P2 pump pressure sensor
46-30
C024
Short-circuit of P2 pump pressure sensor
46-31
C024
Short-circuit of P2 pump pressure sensor
46-31
C033
Disconnection of boom head pressure sensor
46-31
C033
Disconnection of boom head pressure sensor
46-31
C034
Short-circuit of boom head pressure sensor
46-32
C034
Short-circuit of boom head pressure sensor
46-32
C043
Disconnection of boom rod pressure sensor
46-32
C043
Disconnection of boom rod pressure sensor
46-32
C044
Short-circuit of boom rod pressure sensor
46-33
C044
Short-circuit of boom rod pressure sensor
46-33
D012
Failure of output transistor ON at P1 unload proportional valve
46-33
D012
Failure of output transistor ON at P1 unload proportional valve
46-33
D013
Disconnection of P1 unload proportional valve
46-34
D013
Disconnection of P1 unload proportional valve
46-34
D022
Failure of output transistor ON at P2 unload proportional valve
46-34
D022
Failure of output transistor ON at P2 unload proportional valve
46-34
D023
Disconnection of P2 unload proportional valve
46-35
D023
Disconnection of P2 unload proportional valve
46-35
D032
Failure of output transistor ON at travel straight proportional valve
46-35
D032
Failure of output transistor ON at travel straight proportional valve
46-35
D033
Disconnection of travel straight proportional valve
46-36
D033
Disconnection of travel straight proportional valve
46-36
D062
Failure of output transistor ON at arm in high speed proportional valve
46-36
D062
Failure of output transistor ON at arm in high speed proportional valve
46-36
D063
Disconnection of arm in high speed proportional valve
46-37
D063
Disconnection of arm in high speed proportional valve
46-37
E012
Failure of output transistor ON at P1 pump proportional valve
46-37
E012
Failure of output transistor ON at P1 pump proportional valve
46-37
46-5
46-5
46. TROUBLE SHOOTING (BY ERROR CODES) Error Code
46. TROUBLE SHOOTING (BY ERROR CODES) Trouble
Described page
Error Code
Trouble
Described page
E013
Disconnection of P1pump proportional valve
46-38
E013
Disconnection of P1pump proportional valve
46-38
E022
Failure of output transistor ON at P2 pump proportional valve
46-38
E022
Failure of output transistor ON at P2 pump proportional valve
46-38
E023
Disconnection of P2 pump proportional valve
46-39
E023
Disconnection of P2 pump proportional valve
46-39
F011
Failure of output transistor OFF and GND short of attachment boost SOL valve
46-39
F011
Failure of output transistor OFF and GND short of attachment boost SOL valve
46-39
F013
Failure of output transistor ON and disconnection of attachment boost SOL valve
46-40
F013
Failure of output transistor ON and disconnection of attachment boost SOL valve
46-40
F021
Failure of output transistor OFF and GND short of swing parking SOL valve
46-40
F021
Failure of output transistor OFF and GND short of swing parking SOL valve
46-40
F023
Failure of output transistor ON and disconnection of swing parking SOL valve
46-41
F023
Failure of output transistor ON and disconnection of swing parking SOL valve
46-41
F031
Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
46-41
F031
Failure of output transistor OFF and GND short of travel 1-2 speed SOL valve
46-41
F033
Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
46-42
F033
Failure of output transistor ON and disconnection of travel 1-2 speed SOL valve
46-42
F041
Failure of output transistor OFF and GND short of optional selector SOL valve
46-42
F041
Failure of output transistor OFF and GND short of optional selector SOL valve
46-42
F043
Failure of output transistor ON and disconnection of optional selector SOL valve
46-43
F043
Failure of output transistor ON and disconnection of optional selector SOL valve
46-43
G032
Overrun of speed sensor of direct input Mechatro-controller
46-43
G032
Overrun of speed sensor of direct input Mechatro-controller
46-43 46-44
G033
Disconnection of speed sensor of direct input Mechatro-controller
46-44
G033
Disconnection of speed sensor of direct input Mechatro-controller
G042
Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-44
G042
Overrun of speed sensor of direct input Mechatro-controller and received data from E/G controller. 46-44
G043
Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller.
46-45
G043
Disconnection of speed sensor of direct input Mechatro-controller and received data from E/G controller.
46-45
H013
Disconnection of acceleration potentio
46-46
H013
Disconnection of acceleration potentio
46-46
H014
Power short-circuit of acceleration potentio
46-46
H014
Power short-circuit of acceleration potentio
46-46
H023
Disconnection of boom angle potentio
46-47
H023
Disconnection of boom angle potentio
46-47
H024
Power short-circuit of boom angle potentio
46-47
H024
Power short-circuit of boom angle potentio
46-47
H033
Disconnection of arm angle potentio
46-48
H033
Disconnection of arm angle potentio
46-48
H034
Power short-circuit of arm angle potentio
46-48
H034
Power short-circuit of arm angle potentio
46-48
H091
Failure of GND short-circuit of fuel sensor
46-49
H091
Failure of GND short-circuit of fuel sensor
46-49
H093
Disconnection of fuel sensor
46-49
H093
Disconnection of fuel sensor
46-49
I111
Received error of CAN1 communication (passive error)
46-50
I111
Received error of CAN1 communication (passive error)
46-50
I113
Received error of CAN1 communication (time-out)
46-50
I113
Received error of CAN1 communication (time-out)
46-50
I313
Received error of cluster communication (time-out error)
46-51
I313
Received error of cluster communication (time-out error)
46-51
K014
Adhesion of battery relay terminal
46-51
K014
Adhesion of battery relay terminal
46-51
R014
Failure of arc prevention relay of wiper motor
46-52
R014
Failure of arc prevention relay of wiper motor
46-52
R024
Failure of normal rotation relay of wiper motor
46-53
R024
Failure of normal rotation relay of wiper motor
46-53
R034
Failure of reverse rotation relay of wiper motor
46-54
R034
Failure of reverse rotation relay of wiper motor
46-54
R044
Failure of washer motor relay
46-55
R044
Failure of washer motor relay
46-55
R134
Failure of swing flasher relay
46-55
R134
Failure of swing flasher relay
46-55
R144
Failure of swing flasher relay
46-56
R144
Failure of swing flasher relay
46-56
R154
Failure of travel alarm relay
46-56
R154
Failure of travel alarm relay
46-56
R164
Failure of auto idling stop relay 2
46-57
R164
Failure of auto idling stop relay 2
46-57
R174
Failure of engine forcible stop relay
46-58
R174
Failure of engine forcible stop relay
46-58
R184
Failure of lever lock relay
46-59
R184
Failure of lever lock relay
46-59
R214
Failure of safety relay
46-59
R214
Failure of safety relay
46-59
46-6
46-6
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-1
Table46-1
Error code
A015
Error code
A015
Trouble
Not yet adjusted engine or failed adjustment of engine (A adjustment)
Trouble
Not yet adjusted engine or failed adjustment of engine (A adjustment)
Judging condition
Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Judging condition
Engine adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom
Deviated from the reqired value, but no problem in normal operations.
Symptom
Deviated from the reqired value, but no problem in normal operations.
Control in the event of failure
Rotate with the default engine
Control in the event of failure
Rotate with the default engine
Returned in The engine adjustment is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
G-3 SPEED SET
Checking object
Returned in The engine adjustment is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
2
G-3 SPEED SET
Checking object
Checking contents and remedy
1
•Checking
Carry out engine adjustment (A adjustment). When "ERROR ENG" was displayed during adjustment, refer to the section "Adjustment procedure Measures to be taken with the adjustment failed"
1
•Checking
Carry out engine adjustment (A adjustment). When "ERROR ENG" was displayed during adjustment, refer to the section "Adjustment procedure Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
3 Table46-2
Table46-2
Error code
A025
Error code
A025
Trouble
Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Trouble
Not yet adjusted engine or failed adjustment of pump proportional valve (B adjustment)
Judging condition
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Judging condition
Pump proportional valve adjustment is missed. Or it is impossible to set the adjusting value within the adjusting range.
Symptom
Deviated from the rated output, but no problem in normal operation
Symptom
Deviated from the rated output, but no problem in normal operation
Control in the event of failure
Workable with the default proportional valve output.
Control in the event of failure
Workable with the default proportional valve output.
Returned in The pump proportional valve adjustment is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
9
E-1 P1 PUMP
9
E-2 P2 PUMP
Returned in The pump proportional valve adjustment is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
9
E-1 P1 PUMP
9
E-2 P2 PUMP
Checking object
Checking contents and remedy
1
•Checking
Carry out pump adjustment (B adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
1
•Checking
Carry out pump adjustment (B adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
3
46-7
46-7
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-3
Table46-3
Error code
A035
Error code
A035
Trouble
Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Trouble
Not yet adjusted unload valve or failed adjustment of unload valve (C adjustment)
Judging condition
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting range.
Judging condition
The adjustment of unload valve is missed. Or the adjusting value can not be set in the adjusting range.
Symptom
It is not normal output, but no problem in normal operation
Symptom
It is not normal output, but no problem in normal operation
Control in the event of failure
Work with the aid of output by default proportional valve.
Control in the event of failure
Work with the aid of output by default proportional valve.
Returned in The adjustment of unload valve is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
D-1 P1 UN-LOAD (BP-CUT)
8
D-2 P2 UN-LOAD (BP-CUT)
Checking object
Returned in The adjustment of unload valve is completed normally. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
8
D-1 P1 UN-LOAD (BP-CUT)
8
D-2 P2 UN-LOAD (BP-CUT)
Checking object
Checking contents and remedy
1
•Checking
Carry out adjustment of unload valve (C adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
1
•Checking
Carry out adjustment of unload valve (C adjustment). When"ERROR PUMP" was displayed during adjustment, refer to the section "Adjustment procedure - Measures to be taken with the adjustment failed"
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
3 Table46-4
Table46-4
Error code
A215
Error code
A215
Trouble
The data of ROM adjustment is written incorrectly.
Trouble
The data of ROM adjustment is written incorrectly.
Judging condition
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Judging condition
Check adjustment data, and judge the content of memory is correct or not. (Trouble history only)
Symptom
No affect.
Symptom
No affect.
Control in the event of failure
Control at side of correct memory data.
Control in the event of failure
Control at side of correct memory data.
Returned in It does not regain. Replace controller. normal condition
Returned in It does not regain. Replace controller. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
Checking object 1
2
2
3
3
46-8
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
46-8
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-5
Table46-5
Error code
A225
Error code
A225
Trouble
The data of ROM adjustment is written incorrectly.
Trouble
The data of ROM adjustment is written incorrectly.
Judging condition
Check adjustment data, and judge the data is correct or not.
Judging condition
Check adjustment data, and judge the data is correct or not.
Symptom
It is not normal output, but no problem in normal operation
Symptom
It is not normal output, but no problem in normal operation
Control in the event of failure
Control can be done by default value.
Control in the event of failure
Control can be done by default value.
Returned in It does not regain. Replace controller. normal condition
Returned in It does not regain. Replace controller. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
Checking object 1
2
2
3
3
Mechatro controller
Table46-6
Checking contents and remedy Check that the error is corrected after replacement of controller.
Table46-6
Error code
A235
Error code
A235
Trouble
The data of ROM hourmeter is written incorrectly.
Trouble
The data of ROM hourmeter is written incorrectly.
Judging condition
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Judging condition
Check hourmeter memory, and judge the data is correct or not. (Trouble history only)
Symptom
No affect.
Symptom
No affect.
Control in the event of failure
Control at side of correct memory data.
Control in the event of failure
Control at side of correct memory data.
Returned in It does not regain. Replace controller. normal condition
Returned in It does not regain. Replace controller. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
Checking object 1
2
2
3
3
46-9
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
46-9
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-7
Table46-7
Error code
A245
Error code
A245
Trouble
The data of ROM hourmeter is written incorrectly.
Trouble
The data of ROM hourmeter is written incorrectly.
Judging condition
Check hourmeter memory, and judge the data is incorrect.
Judging condition
Check hourmeter memory, and judge the data is incorrect.
Symptom
The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Symptom
The hour meter data which was judged as error is taken as 0 Hr. No problem in normal operation
Control in the event of failure
Normal control is available.
Control in the event of failure
Normal control is available.
Returned in It does not regain. Replace controller. normal condition
Returned in It does not regain. Replace controller. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
Checking object 1
2
2
3
3
Mechatro controller
Table46-8
Checking contents and remedy Check that the error is corrected after replacement of controller.
Table46-8
Error code
A255
Error code
A255
Trouble
The data of proportional valve adjustment is written incorrectly.
Trouble
The data of proportional valve adjustment is written incorrectly.
Judging condition
Check proportional valve adjustment data, and judge the data is incorrect.
Judging condition
Check proportional valve adjustment data, and judge the data is incorrect.
Symptom
It is not normal output, but no problem in normal operation
Symptom
It is not normal output, but no problem in normal operation
Control in the event of failure
Using fixed value of proportional valve correction data, usual control is done.
Control in the event of failure
Using fixed value of proportional valve correction data, usual control is done.
Returned in It does not regain. Replace controller. normal condition
Returned in It does not regain. Replace controller. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
Checking object 1
2
2
3
3
46-10
Mechatro controller
Checking contents and remedy Check that the error is corrected after replacement of controller.
46-10
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-9
Table46-9
Error code
B012
Error code
B012
Trouble
Boom up pressure sensor outputs error
Trouble
Boom up pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The boom up operability becomes poor.
Symptom
The boom up operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-1 BOOM RAISE
Checking object
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
B-1 BOOM RAISE
Checking object
Checking contents and remedy
1
• Boom up pressure sensor SE-3
When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Boom up pressure sensor SE-3
When B012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom up pressure sensor and controller CN-126F CN-101F
When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom up pressure sensor and controller CN-126F CN-101F
When B012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-10
Table46-10
Error code
B013
Error code
B013
Trouble
Boom up pressure sensor’s wiring disconnects.
Trouble
Boom up pressure sensor’s wiring disconnects.
Judging condition
The input voltage from boom up pressure sensor is less than 0.1V.
Judging condition
The input voltage from boom up pressure sensor is less than 0.1V.
Symptom
The boom up speed slows down.
Symptom
The boom up speed slows down.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object 1
• Boom up pressure sensor SE-3
2
3
B-1 BOOM RAISE
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When B013 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
5
Checking object
B-1 BOOM RAISE
Checking contents and remedy
1
• Boom up pressure sensor SE-3
When B013 is displayed after the connector is exchanged with other sensor. • Wiring between boom up pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-126F CN-101F
2
When B013 is displayed after the connector is exchanged with other sensor. • Wiring between boom up pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-126F CN-101F
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-11
When B013 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
46-11
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-11
Table46-11
Error code
B014
Error code
B014
Trouble
Boom up pressure sensor’s power source is shortcut.
Trouble
Boom up pressure sensor’s power source is shortcut.
Judging condition
The input voltage from boom up pressure sensor is 4.7V or more.
Judging condition
The input voltage from boom up pressure sensor is 4.7V or more.
Symptom
The boom up speed slows down.
Symptom
The boom up speed slows down.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-1 BOOM RAISE
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Boom up pressure sensor SE-3
2
3
When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
5
B-1 BOOM RAISE
Checking object
Checking contents and remedy
1
• Boom up pressure sensor SE-3
When B014 is displayed after the connector is exchanged with other sensor. • Wiring between boom up pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-126F CN-101F
2
When B014 is displayed after the connector is exchanged with other sensor. • Wiring between boom up pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-126F CN-101F
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
When B014 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
Table46-12
Table46-12
Error code
B022
Error code
B022
Trouble
Boom down pressure sensor outputs error
Trouble
Boom down pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The boom down operability becomes poor.
Symptom
The boom down operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-2 BOOM LOWER
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on SE-4 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
3
• Mechatro controller
5
Checking object
B-2 BOOM LOWER
Checking contents and remedy
1
• Boom down pressure sensor When B022 is cancelled and other error occurs by turning starter switch on SE-4 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-12
46-12
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-13
Table46-13
Error code
B023
Error code
B023
Trouble
Boom down pressure sensor’s wiring is disconnecting.
Trouble
Boom down pressure sensor’s wiring is disconnecting.
Judging condition
The input voltage from boom down pressure sensor is 0.1V or less.
Judging condition
The input voltage from boom down pressure sensor is 0.1V or less.
Symptom
The boom down operability becomes poor.
Symptom
The boom down operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-2 BOOM LOWER
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
B-2 BOOM LOWER
Checking object
Checking contents and remedy
1
• Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the SE-4 connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Boom down pressure sensor When B023 is cancelled and other error occurs after exchanging the SE-4 connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-127F CN-101F
2
• Wiring between boom down When B023 is displayed after the connector is exchanged with other sensor. pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-127F CN-101F
3
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Check that the error is corrected after replacement of controller.
Table46-14
Table46-14
Error code
B024
Error code
B024
Trouble
Boom down pressure sensor’s power source is shortcut.
Trouble
Boom down pressure sensor’s power source is shortcut.
Judging condition
The input voltage from boom down pressure sensor is 4.7V or more.
Judging condition
The input voltage from boom down pressure sensor is 4.7V or more.
Symptom
The boom down operability becomes poor.
Symptom
The boom down operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-2 BOOM LOWER
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on SE-4 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
3
• Mechatro controller
5
Checking object
B-2 BOOM LOWER
Checking contents and remedy
1
• Boom down pressure sensor When B024 is cancelled and other error occurs by turning starter switch on SE-4 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom down pressure sensor and controller CN-127F CN-101F
When B024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-13
46-13
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-15
Table46-15
Error code
B032
Error code
B032
Trouble
Arm-in pressure sensor outputs error
Trouble
Arm-in pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The arm-out operability becomes poor.
Symptom
The arm-out operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-3 ARM OUT
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
5
B-3 ARM OUT
Checking object
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Arm-out pressure sensor SE-8
When B032 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-16
Table46-16
Error code
B033
Error code
B033
Trouble
Arm-out pressure sensor’s wiring is disconnecting.
Trouble
Arm-out pressure sensor’s wiring is disconnecting.
Judging condition
The input voltage from arm-out pressure sensor is 0.1V or less.
Judging condition
The input voltage from arm-out pressure sensor is 0.1V or less.
Symptom
Shock at stopping of arm-out is great.
Symptom
Shock at stopping of arm-out is great.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object 1
• Arm-out pressure sensor SE-8
2
3
B-3 ARM OUT
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When B033 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
5
Checking object
B-3 ARM OUT
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B033 is displayed after the connector is exchanged with other sensor. • Wiring between arm-out pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-131F CN-101F
2
When B033 is displayed after the connector is exchanged with other sensor. • Wiring between arm-out pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-131F CN-101F
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-14
When B033 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
46-14
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-17
Table46-17
Error code
B034
Error code
B034
Trouble
Arm-out pressure sensor’s power source is shortcut.
Trouble
Arm-out pressure sensor’s power source is shortcut.
Judging condition
The input voltage from arm-out pressure sensor is 4.7V or more.
Judging condition
The input voltage from arm-out pressure sensor is 4.7V or more.
Symptom
Shock at stopping of arm-out is great.
Symptom
Shock at stopping of arm-out is great.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-3 ARM OUT
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
5
B-3 ARM OUT
Checking object
Checking contents and remedy
1
• Arm-out pressure sensor SE-8
When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Arm-out pressure sensor SE-8
When B034 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between arm-out pressure sensor and controller CN-131F CN-101F
When B034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-18
Table46-18
Error code
B042
Error code
B042
Trouble
Arm-in pressure sensor outputs error
Trouble
Arm-in pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the arm-in pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The arm-in operability becomes poor.
Symptom
The arm-in operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-4 ARM IN
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
Checking object
B-4 ARM IN
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Arm-in pressure sensor SE-7
When B042 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-in pressure sensor and controller CN-130F CN-101F
When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between arm-in pressure sensor and controller CN-130F CN-101F
When B042 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-15
46-15
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-19
Table46-19
Error code
B043
Error code
B043
Trouble
Arm-in pressure sensor’s wiring is disconnecting.
Trouble
Arm-in pressure sensor’s wiring is disconnecting.
Judging condition
The input voltage from arm-in pressure sensor is 0.1V or less.
Judging condition
The input voltage from arm-in pressure sensor is 0.1V or less.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode) Set output of arm 2 arm-in proportional valve to 200mA.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 and P2 unload proportional valve to 0mA. (Valve emergency mode) Set output of arm 2 arm-in proportional valve to 200mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-4 ARM IN
Checking object 1
• Arm-in pressure sensor SE-7
2
3
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
5
B-4 ARM IN
Checking object
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B043 is displayed after the connector is exchanged with other sensor. • Wiring between arm-in pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-130F CN-101F
2
When B043 is displayed after the connector is exchanged with other sensor. • Wiring between arm-in pressure sensor and controller Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. CN-130F CN-101F
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
When B043 is cancelled and other error occurs after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
Table46-20
Table46-20
Error code
B044
Error code
B044
Trouble
Arm-in pressure sensor’s power source is shortcut.
Trouble
Arm-in pressure sensor’s power source is shortcut.
Judging condition
The input voltage from arm-in pressure sensor is 4.7V or more.
Judging condition
The input voltage from arm-in pressure sensor is 4.7V or more.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Symptom
Cavitation occurs at independent work of arm-in. Arm horizontal arm pulling can be barely done but if attachment is pulled in the air, arm falls first. Bucket can drag under the condition that the bucket bottom put on the ground.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode) Set output of arm 2 arm-in proportional valve to 200mA.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1, P2 unload proportional valves to 0mA. (Valve emergency mode) Set output of arm 2 arm-in proportional valve to 200mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-4 ARM IN
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
Checking object
B-4 ARM IN
Checking contents and remedy
1
• Arm-in pressure sensor SE-7
When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Arm-in pressure sensor SE-7
When B044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between arm-in pressure sensor and controller CN-130F CN-101F
When B044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between arm-in pressure sensor and controller CN-130F CN-101F
When B044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-16
46-16
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-21
Table46-21
Error code
B052
Error code
B052
Trouble
Bucket digging pressure sensor outputs error
Trouble
Bucket digging pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket digging pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The bucket digging operability becomes poor.
Symptom
The bucket digging operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-5 BUCKET DIG
Checking object
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
B-5 BUCKET DIG
Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor SE-1
When B052 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Bucket digging pressure sensor SE-1
When B052 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B052 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-22
Table46-22
Error code
B053
Error code
B053
Trouble
Bucket digging pressure sensor’s wiring is disconnected.
Trouble
Bucket digging pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from bucket digging pressure sensor is 0.1V or less.
Judging condition
The input voltage from bucket digging pressure sensor is 0.1V or less.
Symptom
The bucket digging speed slows down a little.
Symptom
The bucket digging speed slows down a little.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-5 BUCKET DIG
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Bucket digging pressure sensor SE-1
When B053 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
3
• Mechatro controller
5
Checking object
B-5 BUCKET DIG
Checking contents and remedy
1
• Bucket digging pressure sensor SE-1
When B053 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B053 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-17
46-17
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-23
Table46-23
Error code
B054
Error code
B054
Trouble
Bucket digging pressure sensor’s power source is shortcut.
Trouble
Bucket digging pressure sensor’s power source is shortcut.
Judging condition
The input voltage from bucket digging pressure sensor is 4.7V or more.
Judging condition
The input voltage from bucket digging pressure sensor is 4.7V or more.
Symptom
The bucket digging speed slows down a little.
Symptom
The bucket digging speed slows down a little.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-5 BUCKET DIG
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
B-5 BUCKET DIG
Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor SE-1
When B054 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Bucket digging pressure sensor SE-1
When B054 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between bucket digging pressure sensor and controller CN-124F CN-101F
When B054 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-24
Table46-24
Error code
B062
Error code
B062
Trouble
Bucket dump pressure sensor outputs error
Trouble
Bucket dump pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the bucket dump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The bucket dump operability becomes poor.
Symptom
The bucket dump operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-6 BUCKET DUMP
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
Checking object
B-6 BUCKET DUMP
Checking contents and remedy
1
• Bucket digging pressure sensor SE-2
When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Bucket digging pressure sensor SE-2
When B062 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B062 is displayed after turning the starter switch on after the connector is exchanged with other sensor.
• Mechatro controller
Check that the error is corrected after replacement of controller.
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
46-18
3
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
46-18
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-25
Table46-25
Error code
B063
Error code
B063
Trouble
Bucket dump pressure sensor’s wiring is disconnected.
Trouble
Bucket dump pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from bucket dump pressure sensor is 0.1V or less.
Judging condition
The input voltage from bucket dump pressure sensor is 0.1V or less.
Symptom
The bucket dump speed slows down a little.
Symptom
The bucket dump speed slows down a little.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
B-6 BUCKET DUMP
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
5
B-6 BUCKET DUMP
Checking object
Checking contents and remedy
1
• Bucket digging pressure sensor SE-2
When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Bucket digging pressure sensor SE-2
When B063 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-26
Table46-26
Error code
B064
Error code
B064
Trouble
Bucket dump pressure sensor’s power source is shortcut.
Trouble
Bucket dump pressure sensor’s power source is shortcut.
Judging condition
The input voltage from bucket dump pressure sensor is 4.7V or more.
Judging condition
The input voltage from bucket dump pressure sensor is 4.7V or more.
Symptom
The bucket dump speed slows down a little.
Symptom
The bucket dump speed slows down a little.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
5
Checking object
B-6 BUCKET DUMP
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Bucket digging pressure sensor SE-2
When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
3
• Mechatro controller
5
Checking object
B-6 BUCKET DUMP
Checking contents and remedy
1
• Bucket digging pressure sensor SE-2
When B064 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between bucket digging pressure sensor and controller CN-125F CN-101F
When B064 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-19
46-19
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-27
Table46-27
Error code
B072
Error code
B072
Trouble
Swing pressure sensor outputs error
Trouble
Swing pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the swing pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The swing operability becomes poor.
Symptom
The swing operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-7 SWING
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
6
B-7 SWING
Checking object
Checking contents and remedy
1
• Swing pressure sensor SE-5
When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Swing pressure sensor SE-5
When B072 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B072 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B072 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-28
Table46-28
Error code
B073
Error code
B073
Trouble
Swing pressure sensor’s wiring is disconnected.
Trouble
Swing pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from swing pressure sensor is 0.1V or less.
Judging condition
The input voltage from swing pressure sensor is 0.1V or less.
Symptom
The swing operability becomes poor.
Symptom
The swing operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-7 SWING
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-7 SWING
Checking contents and remedy
1
• Swing pressure sensor SE-5
When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Swing pressure sensor SE-5
When B073 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B073 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B073 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-20
46-20
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-29
Table46-29
Error code
B074
Error code
B074
Trouble
Swing pressure sensor’s power source is shortcut.
Trouble
Swing pressure sensor’s power source is shortcut.
Judging condition
The input voltage from swing pressure sensor is 4.7V or more.
Judging condition
The input voltage from swing pressure sensor is 4.7V or more.
Symptom
The swing operability becomes poor.
Symptom
The swing operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-7 SWING
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
6
B-7 SWING
Checking object
Checking contents and remedy
1
• Swing pressure sensor SE-5
When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Swing pressure sensor SE-5
When B074 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B074 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between swing pressure sensor and controller CN-169F CN-103F
When B074 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-30
Table46-30
Error code
B092
Error code
B092
Trouble
Travel right pressure sensor outputs error
Trouble
Travel right pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel right pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The travel right operability becomes poor.
Symptom
The travel right operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-9 TRAVEL (R)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-9 TRAVEL (R)
Checking contents and remedy
1
• Travel right pressure sensor SE-9
When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel right pressure sensor SE-9
When B092 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B092 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-21
46-21
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-31
Table46-31
Error code
B093
Error code
B093
Trouble
Travel right pressure sensor’s wiring is disconnected.
Trouble
Travel right pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from Travel right pressure sensor is 0.1V or less.
Judging condition
The input voltage from Travel right pressure sensor is 0.1V or less.
Symptom
The Travel right operability becomes poor.
Symptom
The Travel right operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-9 TRAVEL (R)
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
B-9 TRAVEL (R)
Checking object
Checking contents and remedy
1
• Travel right pressure sensor SE-9
When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel right pressure sensor SE-9
When B093 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B093 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-32
Table46-32
Error code
B094
Error code
B094
Trouble
Travel right pressure sensor’s power source is shortcut.
Trouble
Travel right pressure sensor’s power source is shortcut.
Judging condition
The input voltage from Travel right pressure sensor is 4.7V or more.
Judging condition
The input voltage from Travel right pressure sensor is 4.7V or more.
Symptom
The Travel right operability becomes poor.
Symptom
The Travel right operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-9 TRAVEL (R)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-9 TRAVEL (R)
Checking contents and remedy
1
• Travel right pressure sensor SE-9
When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel right pressure sensor SE-9
When B094 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel right pressure sensor and controller CN-301F CN-102F
When B094 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-22
46-22
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-33
Table46-33
Error code
B102
Error code
B102
Trouble
Travel left pressure sensor outputs error
Trouble
Travel left pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the travel left pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The travel left operability becomes poor.
Symptom
The travel left operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-10 TRAVEL (L)
Checking object
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
B-10 TRAVEL (L)
Checking object
Checking contents and remedy
1
• Travel left pressure sensor SE-10
When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel left pressure sensor SE-10
When B102 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B102 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-34
Table46-34
Error code
B103
Error code
B103
Trouble
Travel left pressure sensor’s wiring is disconnected.
Trouble
Travel left pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from Travel left pressure sensor is 0.1V or less.
Judging condition
The input voltage from Travel left pressure sensor is 0.1V or less.
Symptom
The Travel left operability becomes poor.
Symptom
The Travel left operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-10 TRAVEL (L)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-10 TRAVEL (L)
Checking contents and remedy
1
• Travel left pressure sensor SE-10
When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel left pressure sensor SE-10
When B103 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B103 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-23
46-23
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-35
Table46-35
Error code
B104
Error code
B104
Trouble
Travel left pressure sensor’s power source is shortcut.
Trouble
Travel left pressure sensor’s power source is shortcut.
Judging condition
The input voltage from Travel left pressure sensor is 4.7V or more.
Judging condition
The input voltage from Travel left pressure sensor is 4.7V or more.
Symptom
The Travel left operability becomes poor.
Symptom
The Travel left operability becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) P1, Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-10 TRAVEL (L)
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
B-10 TRAVEL (L)
Checking object
Checking contents and remedy
1
• Travel left pressure sensor SE-10
When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Travel left pressure sensor SE-10
When B104 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel left pressure sensor and controller CN-302F CN-102F
When B104 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-36
Table46-36
Error code
B113
Error code
B113
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from option selector position detect pressure sensor is 0.1V or less.
Judging condition
The input voltage from option selector position detect pressure sensor is 0.1V or less.
Symptom
When B mode is selected, option selector valve error is indicated.
Symptom
When B mode is selected, option selector valve error is indicated.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
16
Checking object
B-11
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
16
Checking object
B-11
Checking contents and remedy
1
• Option selector position detect pressure sensor SE-29
When B113 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Option selector position detect pressure sensor SE-29
When B113 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B113 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-24
46-24
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-37
Table46-37
Error code
B114
Error code
B114
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Trouble
Option selector position detect pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from selector position detect pressure sensor is 4.7V or more.
Judging condition
The input voltage from selector position detect pressure sensor is 4.7V or more.
Symptom
When B mode is selected, option selector valve error is indicated.
Symptom
When B mode is selected, option selector valve error is indicated.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
16
B-11
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
16
B-11
Checking object
Checking contents and remedy
1
• Option selector position detect pressure sensor SE-29
When B114 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Option selector position detect pressure sensor SE-29
When B114 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between option selector position detect pressure sensor and controller CN-162F CN-104F
When B114 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-38
Table46-38
Error code
B162
Error code
B162
Trouble
P1 side option pressure sensor outputs error
Trouble
P1 side option pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The P1 side option operability becomes poor.
Symptom
The P1 side option operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-16 P1 OPT.
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-16 P1 OPT.
Checking contents and remedy
1
• P1 side option pressure sensor SE-20
When B162 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P1 side option pressure sensor SE-20
When B162 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F
When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 side option pressure sensor and controller CN-304F CN-102F
When B162 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-25
46-25
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-39
Table46-39
Error code
B163
Error code
B163
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P1 side option pressure sensor is 0.1V or less.
Judging condition
The input voltage from P1 side option pressure sensor is 0.1V or less.
Symptom
The P1 side option does not work.
Symptom
The P1 side option does not work.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-16 P1 OPT.
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P1 side option pressure sensor SE-20
2
3
6
B-16 P1 OPT.
Checking object
Checking contents and remedy
1
• P1 side option pressure sensor SE-20
• Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-304F and repair it if necessary. CN-102F
2
• Wiring between P1 side option When B163 is displayed after turning the starter switch on after the connector pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-304F and repair it if necessary. CN-102F
• Mechatro controller
3
• Mechatro controller
When B163 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
When B163 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
Table46-40
Table46-40
Error code
B164
Error code
B164
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Trouble
P1 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P1 side option pressure sensor is 4.7V or more.
Judging condition
The input voltage from P1 side option pressure sensor is 4.7V or more.
Symptom
The P1 side option does not work.
Symptom
The P1 side option does not work.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P1 unload proportional valve to 0mA. (Valve emergency mode) But normal control is done when the left control pedal selection is ON.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object 1
• P1 side option pressure sensor SE-20
2
3
B-16 P1 OPT.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
6
Checking object
B-16 P1 OPT.
Checking contents and remedy
1
• P1 side option pressure sensor SE-20
• Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-304F and repair it if necessary. CN-102F
2
• Wiring between P1 side option When B164 is displayed after turning the starter switch on after the connector pressure sensor and controller is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure CN-304F and repair it if necessary. CN-102F
• Mechatro controller
3
• Mechatro controller
When B164 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
46-26
When B164 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
Check that the error is corrected after replacement of controller.
46-26
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-41
Table46-41
Error code
B172
Error code
B172
Trouble
P2 side option pressure sensor outputs error
Trouble
P2 side option pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 side option pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The P2 side option operability becomes poor.
Symptom
The P2 side option operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-17 P2 OPT.
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
6
B-17 P2 OPT.
Checking object
Checking contents and remedy
1
• P2 side option pressure sensor SE-11
When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P2 side option pressure sensor SE-11
When B172 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B172 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-42
Table46-42
Error code
B173
Error code
B173
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P2 side option pressure sensor is 0.1V or less.
Judging condition
The input voltage from P2 side option pressure sensor is 0.1V or less.
Symptom
The selection of conflux does not work.
Symptom
The selection of conflux does not work.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
Checking object
B-17 P2 OPT.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P2 side option pressure sensor SE-11
When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
3
• Mechatro controller
6
Checking object
B-17 P2 OPT.
Checking contents and remedy
1
• P2 side option pressure sensor SE-11
When B173 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B173 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-27
46-27
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-43
Table46-43
Error code
B174
Error code
B174
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Trouble
P2 side option pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P2 side option pressure sensor is 4.7V or more.
Judging condition
The input voltage from P2 side option pressure sensor is 4.7V or more.
Symptom
The selection of conflux does not work.
Symptom
The selection of conflux does not work.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode) Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
6
B-17 P2 OPT.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
6
B-17 P2 OPT.
Checking object
Checking contents and remedy
1
• P2 side option pressure sensor SE-11
When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P2 side option pressure sensor SE-11
When B174 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 side option pressure sensor and controller CN-303F CN-102F
When B174 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-44
Table46-44
Error code
C012
Error code
C012
Trouble
P1 pump pressure sensor outputs error
Trouble
P1 pump pressure sensor outputs error
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P1 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The P1 pump operability becomes poor.
Symptom
The P1 pump operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
7
Checking object
C-1 PUMP P1
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
Checking object
C-1 PUMP P1
Checking contents and remedy
1
• P1 pump pressure sensor SE-22
When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P1 pump pressure sensor SE-22
When C012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-28
46-28
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-45
Table46-45
Error code
C013
Error code
C013
Trouble
P1 pump pressure sensor’s wiring is disconnected.
Trouble
P1 pump pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P1 pump pressure sensor is 0.1V or less.
Judging condition
The input voltage from P1 pump pressure sensor is 0.1V or less.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
C-1 PUMP P1
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
C-1 PUMP P1
Checking object
Checking contents and remedy
1
• P1 pump pressure sensor SE-22
When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P1 pump pressure sensor SE-22
When C013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-46
Table46-46
Error code
C014
Error code
C014
Trouble
P1 pump pressure sensor’s power source is shortcut.
Trouble
P1 pump pressure sensor’s power source is shortcut.
Judging condition
The input voltage from P1 pump pressure sensor is 4.7V or more.
Judging condition
The input voltage from P1 pump pressure sensor is 4.7V or more.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Symptom
The delicate operability of P1 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
Checking object
C-1 PUMP P1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
Checking object
C-1 PUMP P1
Checking contents and remedy
1
• P1 pump pressure sensor SE-22
When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P1 pump pressure sensor SE-22
When C014 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 pump pressure sensor and controller CN-139F CN-103F
When C014 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-29
46-29
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-47
Table46-47
Error code
C022
Error code
C022
Trouble
P2 pump pressure sensor outputs error.
Trouble
P2 pump pressure sensor outputs error.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Judging condition
After starter switch ON and engine does not start yet. And the input voltage from the P2 pump pressure sensor after starter switch ON is in the range of 1.4V or more to less than 4.7V.
Symptom
The P2 pump operability becomes poor.
Symptom
The P2 pump operability becomes poor.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
7
C-2 PUMP P2
Checking object
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
C-2 PUMP P2
Checking object
Checking contents and remedy
1
• P2 pump pressure sensor SE-23
When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P2 pump pressure sensor SE-23
When C022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-48
Table46-48
Error code
C023
Error code
C023
Trouble
P2 pump pressure sensor’s wiring is disconnected.
Trouble
P2 pump pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from P2 pump pressure sensor is 0.1V or less.
Judging condition
The input voltage from P2 pump pressure sensor is 0.1V or less.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
Checking object
C-2 PUMP P2
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
Checking object
C-2 PUMP P2
Checking contents and remedy
1
• P2 pump pressure sensor SE-23
When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P2 pump pressure sensor SE-23
When C023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-30
46-30
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-49
Table46-49
Error code
C024
Error code
C024
Trouble
P2 pump pressure sensor’s power source is shortcut.
Trouble
P2 pump pressure sensor’s power source is shortcut.
Judging condition
The input voltage from P2 pump pressure sensor is 4.7V or more.
Judging condition
The input voltage from P2 pump pressure sensor is 4.7V or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
C-2 PUMP P2
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
7
C-2 PUMP P2
Checking object
Checking contents and remedy
1
• P2 pump pressure sensor SE-23
When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• P2 pump pressure sensor SE-23
When C024 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 pump pressure sensor and controller CN-140F CN-103F
When C024 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-50
Table46-50
Error code
C033
Error code
C033
Trouble
Boom head pressure sensor’s wiring is disconnected.
Trouble
Boom head pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from boom head pressure sensor is 0.1V or less.
Judging condition
The input voltage from boom head pressure sensor is 0.1V or less.
Symptom
Indication load value of High-reach crane becomes abnormal.
Symptom
Indication load value of High-reach crane becomes abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
Checking object
C-3 BOOM-HEAD
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on SE-24 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom head pressure sensor and controller CN-706F CN-104F
3
• Mechatro controller
7
Checking object
C-3 BOOM-HEAD
Checking contents and remedy
1
• Boom head pressure sensor When C033 is cancelled and other error occurs by turning starter switch on SE-24 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom head pressure sensor and controller CN-706F CN-104F
When C033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-31
46-31
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-51
Table46-51
Error code
C034
Error code
C034
Trouble
Boom head pressure sensor’s power source is shortcut.
Trouble
Boom head pressure sensor’s power source is shortcut.
Judging condition
The input voltage from boom head pressure sensor is 4.7V or more.
Judging condition
The input voltage from boom head pressure sensor is 4.7V or more.
Symptom
Indication load value of High-reach crane becomes abnormal.
Symptom
Indication load value of High-reach crane becomes abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
C-3 BOOM-HEAD
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on SE-24 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom head pressure sensor and controller CN-706F CN-104F
3
• Mechatro controller
7
C-3 BOOM-HEAD
Checking object
Checking contents and remedy
1
• Boom head pressure sensor When C034 is cancelled and other error occurs by turning starter switch on SE-24 after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom head pressure sensor and controller CN-706F CN-104F
When C034 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-52
Table46-52
Error code
C043
Error code
C043
Trouble
Boom rod pressure sensor’s wiring is disconnected.
Trouble
Boom rod pressure sensor’s wiring is disconnected.
Judging condition
The input voltage from boom rod pressure sensor is 0.1V or less.
Judging condition
The input voltage from boom rod pressure sensor is 0.1V or less.
Symptom
Indication load value of High-reach crane becomes abnormal.
Symptom
Indication load value of High-reach crane becomes abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
Checking object
C-4 BOOM-ROD
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
Checking object
C-4 BOOM-ROD
Checking contents and remedy
1
• Boom rod pressure sensor SE-25
When C043 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Boom rod pressure sensor SE-25
When C043 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom rod pressure sensor and controller CN-705F CN-104F
When C043 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom rod pressure sensor and controller CN-705F CN-104F
When C043 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-32
46-32
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-53
Table46-53
Error code
C044
Error code
C044
Trouble
Boom rod pressure sensor’s power source is shortcut.
Trouble
Boom rod pressure sensor’s power source is shortcut.
Judging condition
The input voltage from boom rod pressure sensor is 4.7V or more.
Judging condition
The input voltage from boom rod pressure sensor is 4.7V or more.
Symptom
Indication load value of High-reach crane becomes abnormal.
Symptom
Indication load value of High-reach crane becomes abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
7
C-4 BOOM-ROD
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
7
C-4 BOOM-ROD
Checking object
Checking contents and remedy
1
• Boom rod pressure sensor SE-25
When C044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
1
• Boom rod pressure sensor SE-25
When C044 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between boom rod pressure sensor and controller CN-705F CN-104F
When C044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom rod pressure sensor and controller CN-705F CN-104F
When C044 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-54
Table46-54
Error code
D012
Error code
D012
Trouble
P1 unload proportional valve and output transistor ON are failure.
Trouble
P1 unload proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
Option conflux can not be done.
Symptom
Option conflux can not be done.
Control in the event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object
D-1 P1 UN-LOAD (BP-CUT)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on PSV-D after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 unload proportional valve and controller CN-120F CN-105F
3
• Mechatro controller
8
Checking object
D-1 P1 UN-LOAD (BP-CUT)
Checking contents and remedy
1
• P1 unload proportional valve When D012 is cancelled and other error occurs by turning starter switch on PSV-D after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 unload proportional valve and controller CN-120F CN-105F
When D012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-33
46-33
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-55
Table46-55
Error code
D013
Error code
D013
Trouble
P1 unload proportional valve’s wiring is disconnected.
Trouble
P1 unload proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
Option conflux can not be done.
Symptom
Option conflux can not be done.
Control in the event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set output of P1 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object
D-1 P1 UN-LOAD (BP-CUT)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on PSV-D after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P1 unload proportional valve and controller CN-120F CN-105F
3
• Mechatro controller
8
Checking object
D-1 P1 UN-LOAD (BP-CUT)
Checking contents and remedy
1
• P1 unload proportional valve When D013 is cancelled and other error occurs by turning starter switch on PSV-D after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P1 unload proportional valve and controller CN-120F CN-105F
When D013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-56
Table46-56
Error code
D022
Error code
D022
Trouble
P2 unload proportional valve and output transistor ON are failure.
Trouble
P2 unload proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object
D-2 P2 UN-LOAD (BP-CUT)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on PSV-B after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 unload proportional valve and controller CN-118F CN-105F
3
• Mechatro controller
8
Checking object
D-2 P2 UN-LOAD (BP-CUT)
Checking contents and remedy
1
• P2 unload proportional valve When D022 is cancelled and other error occurs by turning starter switch on PSV-B after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 unload proportional valve and controller CN-118F CN-105F
When D022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-34
46-34
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-57
Table46-57
Error code
D023
Error code
D023
Trouble
P2 unload proportional valve’s wiring is disconnected.
Trouble
P2 unload proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Symptom
Independent operations of boom up and of bucket digging/dump become slow.
Control in the event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Control in the event of failure
Set output of P2 unload proportional valve to 0mA. (Valve emergency mode)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
D-2 P2 UN-LOAD (BP-CUT)
Checking object
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on PSV-B after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between P2 unload proportional valve and controller CN-118F CN-105F
3
• Mechatro controller
8
D-2 P2 UN-LOAD (BP-CUT)
Checking object
Checking contents and remedy
1
• P2 unload proportional valve When D023 is cancelled and other error occurs by turning starter switch on PSV-B after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it.
When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between P2 unload proportional valve and controller CN-118F CN-105F
When D023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-58
Table46-58
Error code
D032
Error code
D032
Trouble
Travel straight proportional valve and output transistor ON are failure.
Trouble
Travel straight proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Control in the event of failure
Set Travel straight proportional valve output to 0mA.
Control in the event of failure
Set Travel straight proportional valve output to 0mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object
D-3 S-TRAVEL
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on PSV-C after exchanging the connector with other sensor.
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
3
• Mechatro controller
8
Checking object
D-3 S-TRAVEL
Checking contents and remedy
1
• Travel straight proportional valve When D032 is cancelled and other error occurs by turning starter switch on PSV-C after exchanging the connector with other sensor.
When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D032 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Check sensor unit for possible failure. If failure found, replace it.
46-35
Check sensor unit for possible failure. If failure found, replace it.
46-35
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-59
Table46-59
Error code
D033
Error code
D033
Trouble
Travel straight proportional valve’s wiring is disconnected.
Trouble
Travel straight proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Symptom
Travel deviation occurs by combined operation of travel and attachment.
Control in the event of failure
Set Travel straight proportional valve output to 0mA.
Control in the event of failure
Set Travel straight proportional valve output to 0mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object 1
D-3 S-TRAVEL
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on PSV-C after exchanging the connector with other sensor.
8
Checking object 1
D-3 S-TRAVEL
Checking contents and remedy
• Travel straight proportional valve When D033 is cancelled and other error occurs by turning starter switch on PSV-C after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between Travel straight proportional valve and controller CN-119F CN-105F
When D033 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-60
Table46-60
Error code
D062
Error code
D062
Trouble
Arm-in spool 2 proportional valve and output transistor ON are failure.
Trouble
Arm-in spool 2 proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
Operability of combined operation with arm-in becomes poor.
Symptom
Operability of combined operation with arm-in becomes poor.
Control in the event of failure
Set Arm-in spool 2 proportional valve output to 0mA.
Control in the event of failure
Set Arm-in spool 2 proportional valve output to 0mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
Checking object
D-4 ARM IN-2-SPEED
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on PSV-A after exchanging the connector with other sensor.
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
3
• Mechatro controller
8
Checking object
D-4 ARM IN-2-SPEED
Checking contents and remedy
1
• Arm-in spool 2 proportional valve When D062 is cancelled and other error occurs by turning starter switch on PSV-A after exchanging the connector with other sensor.
When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D062 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Check sensor unit for possible failure. If failure found, replace it.
46-36
Check sensor unit for possible failure. If failure found, replace it.
46-36
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-61
Table46-61
Error code
D063
Error code
D063
Trouble
Arm-in spool 2 proportional valve’s wiring is disconnected.
Trouble
Arm-in spool 2 proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
Operability of combined operation with arm-in becomes poor.
Symptom
Operability of combined operation with arm-in becomes poor.
Control in the event of failure
Set Arm-in spool 2 proportional valve output to 0mA.
Control in the event of failure
Set Arm-in spool 2 proportional valve output to 0mA.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
8
D-4 ARM IN-2-SPEED
Checking object 1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on PSV-A after exchanging the connector with other sensor.
8
D-4 ARM IN-2-SPEED
Checking object 1
Checking contents and remedy
• Arm-in spool 2 proportional valve When D063 is cancelled and other error occurs by turning starter switch on PSV-A after exchanging the connector with other sensor.
Check sensor unit for possible failure. If failure found, replace it.
Check sensor unit for possible failure. If failure found, replace it.
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between Arm-in spool 2 proportional valve and controller CN-121F CN-105F
When D063 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-62
Table46-62
Error code
E012
Error code
E012
Trouble
P1 pump proportional valve and output transistor ON are failure.
Trouble
P1 pump proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
9
Checking object
E-1 PUMP P1
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
9
Checking object
E-1 PUMP P1
Checking contents and remedy
1
• P1 pump proportional valve PSV-P1
When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
1
• P1 pump proportional valve PSV-P1
When E012 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E012 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-37
46-37
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-63
Table46-63
Error code
E013
Error code
E013
Trouble
P1 pump proportional valve’s wiring is disconnected.
Trouble
P1 pump proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
9
E-1 PUMP P1
Checking object
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
9
E-1 PUMP P1
Checking object
Checking contents and remedy
1
• P1 pump proportional valve PSV-P1
When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
1
• P1 pump proportional valve PSV-P1
When E013 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
2
• Wiring between P1 pump proportional valve and controller CN-141F CN-105F
When E013 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-64
Table46-64
Error code
E022
Error code
E022
Trouble
P2 pump proportional valve and output transistor ON are failure.
Trouble
P2 pump proportional valve and output transistor ON are failure.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Judging condition
The feed-back value from proportional valve is 1000mA or more.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
9
Checking object
E-2 PUMP P2
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
9
Checking object
E-2 PUMP P2
Checking contents and remedy
1
• P2 pump proportional valve PSV-P2
When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
1
• P2 pump proportional valve PSV-P2
When E022 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E022 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-38
46-38
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-65
Table46-65
Error code
E023
Error code
E023
Trouble
P2 pump proportional valve’s wiring is disconnected.
Trouble
P2 pump proportional valve’s wiring is disconnected.
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Judging condition
The feed-back value from proportional valve is 100mA or less. (If output is 100mA or less, judging is not done.)
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Symptom
The delicate operability of P2 pump related attachment becomes poor.
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Control in the event of failure
Set proportional valve output rate of P1 and P2 pumps to 0mA. (Hydraulic pump emergency mode)
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
9
E-2 PUMP P2
Returned in Not returned automatically under normal condition. Switch the power OFF once and turns on it normal condition again. Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
9
E-2 PUMP P2
Checking object
Checking contents and remedy
1
• P2 pump proportional valve PSV-P2
When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
1
• P2 pump proportional valve PSV-P2
When E023 is cancelled and other error occurs by turning starter switch on after exchanging the connector with other sensor. Check sensor unit for possible failure. If failure found, replace it. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
2
• Wiring between P2 pump proportional valve and controller CN-142F CN-105F
When E023 is displayed after turning the starter switch on after the connector is exchanged with other sensor. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. When replacing of connector is executed, turn off power source once.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-66
Table46-66
Error code
F011
Error code
F011
Trouble
ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Trouble
ATT boost solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
ATT boost is not available.
Symptom
ATT boost is not available.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
F-1 POWER BOOST
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
1
• ATT boost solenoid valve SV-2
When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
3
• Mechatro controller
3
F-1 POWER BOOST
Checking object
Checking contents and remedy
1
• ATT boost solenoid valve SV-2
When F011 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
When F011 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F011 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-39
46-39
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-67
Table46-67
Error code
F013
Error code
F013
Trouble
ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Trouble
ATT boost solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Symptom
ATT boost is not available or is leaving available.
Symptom
ATT boost is not available or is leaving available.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
F-1 POWER BOOST
Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
F-1 POWER BOOST
Checking object
Checking contents and remedy
Checking object
Checking contents and remedy
1
• ATT boost solenoid valve SV-2
When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• ATT boost solenoid valve SV-2
When F013 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F013 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between ATT boost solenoid valve and controller CN-117F CN-105F
When F013 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-68
Table46-68
Error code
F021
Error code
F021
Trouble
Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Trouble
Swing parking solenoid valve and output transistor OFF are failure, and grounding is short-circuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Swing parking is not available.
Symptom
Swing parking is not available.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
Checking object
F-2 SWING-BRAKE
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
3
Checking object
F-2 SWING-BRAKE
Checking contents and remedy
1
• Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Swing parking solenoid valve When F021 is cancelled and other error occurs by exchanging the connector SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F021 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-40
46-40
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-69
Table46-69
Error code
F023
Error code
F023
Trouble
Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Trouble
Swing parking solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Symptom
Swing parking is not available or is leaving available.
Symptom
Swing parking is not available or is leaving available.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is grounding level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
F-1 POWER BOOST
Checking object
Returned in The feed-back signal is grounding level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
3
F-1 POWER BOOST
Checking object
Checking contents and remedy
1
• Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Swing parking solenoid valve When F023 is cancelled and other error occurs by exchanging the connector SV-1 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between swing parking solenoid valve and controller CN-123F CN-105F
When F023 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-70
Table46-70
Error code
F031
Error code
F031
Trouble
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.
Trouble
Travel 1, 2 speed solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Travel 2 speed is not obtainable.
Symptom
Travel 2 speed is not obtainable.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
Checking object
F-3 1/2-TRAVEL
Returned in The feed-back signal is 24V level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
3
Checking object
F-3 1/2-TRAVEL
Checking contents and remedy
1
• Travel 1, 2speed solenoid valve SV-3
When F031 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Travel 1, 2speed solenoid valve SV-3
When F031 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F
When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F
When F031 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-41
46-41
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-71
Table46-71
Error code
F033
Error code
F033
Trouble
Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Trouble
Travel 1, 2 speed solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Symptom
Travel 2 speed is not obtainable or is keeping 1 speed.
Symptom
Travel 2 speed is not obtainable or is keeping 1 speed.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
3
F-3 1/2-TRAVEL
Checking object
Returned in The feed-back signal is grounding level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
3
F-3 1/2-TRAVEL
Checking object
Checking contents and remedy
1
• Travel 1, 2speed solenoid valve SV-3
When F033 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Travel 1, 2speed solenoid valve SV-3
When F033 is cancelled and other error occurs by exchanging the connector for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F
When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between travel 1, 2speed solenoid valve and controller CN-122F CN-105F
When F033 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-72
Table46-72
Error code
F041
Error code
F041
Trouble
Option selector solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.
Trouble
Option selector solenoid valve and output transistor OFF are failure, and grounding is shortcircuit.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Judging condition
The feed-back signal is grounding level while exciting command is output.
Symptom
Option selector valve does not change to breaker side.
Symptom
Option selector valve does not change to breaker side.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is ground level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
11
Checking object
F-4 OPT SELECT
Returned in The feed-back signal is ground level while exciting command is output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
11
Checking object
F-4 OPT SELECT
Checking contents and remedy
1
• Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector SV-13 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Option selector solenoid valve When F041 is cancelled and other error occurs by exchanging the connector SV-13 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F041 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-42
46-42
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-73
Table46-73
Error code
F043
Error code
F043
Trouble
Option selector solenoid valve and output transistor ON are failure, and disconnection.
Trouble
Option selector solenoid valve and output transistor ON are failure, and disconnection.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Judging condition
The feed-back signal is 24V level while exciting command is not output.
Symptom
Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Symptom
Option selector valve does not change to breaker side or it does not change from breaker to nibbler.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in The feed-back signal is ground level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
11
F-4 OPT SELECT
Checking object
Returned in The feed-back signal is ground level while exciting command is not output. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
11
F-4 OPT SELECT
Checking object
Checking contents and remedy
1
• Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector SV-13 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
1
• Option selector solenoid valve When F043 is cancelled and other error occurs by exchanging the connector SV-13 for other solenoid valve. Check solenoid valve unit for possible failure. If failure found, replace it.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F043 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between option selector solenoid valve and controller CN-251F CN-105F
When F043 is displayed after the connector is exchanged with other solenoid valve. Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-74
Table46-74
Error code
G032
Error code
G032
Trouble
Mechatro controller direct input speed sensor is overrun.
Trouble
Mechatro controller direct input speed sensor is overrun.
Judging condition
Engine rpm input is 3000rpm or more. (Only trouble history)
Judging condition
Engine rpm input is 3000rpm or more. (Only trouble history)
Symptom
Operate without problem.
Symptom
Operate without problem.
Control in the event of failure
Receive rpm from engine controller and control the rpm.
Control in the event of failure
Receive rpm from engine controller and control the rpm.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
• Engine speed sensor SE-13
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy Measure the resistance between terminals of speed sensor.
Checking object 1
Normal value: 1.6~2.0k
• Engine speed sensor SE-13
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller) Checking contents and remedy Measure the resistance between terminals of speed sensor. Normal value: 1.6~2.0k
2
• Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. sensor and controller Especially check wiring for false disconnection and noise included. CN-136F CN-106F
2
• Wiring between engine speed Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. sensor and controller Especially check wiring for false disconnection and noise included. CN-136F CN-106F
3
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
46-43
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
46-43
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-75
Table46-75
Error code
G033
Error code
G033
Trouble
Mechatro controller direct input speed sensor, Disconnection
Trouble
Mechatro controller direct input speed sensor, Disconnection
Judging condition
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
Judging condition
Voltage of alternator is 12V or more, and speed sensor indicates excess low engine rpm.
Symptom
Operate without problem.
Symptom
Operate without problem.
Control in the event of failure
Receive rpm from engine controller and control the rpm.
Control in the event of failure
Receive rpm from engine controller and control the rpm.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
2
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
2
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
Normal value: 1.6~2.0k
Normal value: 1.6~2.0k
Table46-76
Table46-76
Error code
G042
Error code
G042
Trouble
Mechatro controller direct input speed sensor and received data from engine controller are overrun.
Trouble
Mechatro controller direct input speed sensor and received data from engine controller are overrun.
Judging condition
Engine rpm input is 3000rpm or more. (Only trouble history)
Judging condition
Engine rpm input is 3000rpm or more. (Only trouble history)
Symptom
Operate without problem.
Symptom
Operate without problem.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
2
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Especially check wiring for false disconnection and noise included.
• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. speed sensor and controller pressure sensor and controller Especially check wiring for false disconnection and noise included.
4
• Mechatro controller
5
• Engine controller
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
Normal value: 1.6~2.0k
3
2
2
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. Especially check wiring for false disconnection and noise included.
Normal value: 1.6~2.0k
3
• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. speed sensor and controller pressure sensor and controller Especially check wiring for false disconnection and noise included.
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
4
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
Check that the error is corrected after replacement of controller.
5
• Engine controller
Check that the error is corrected after replacement of controller.
46-44
46-44
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-77
Table46-77
Error code
G043 When cranking is executed for five seconds or more, this error code might be displayed. In case that the engine does not start, check by the table of "Section 47.3 Engine related Troubleshooting". Execute the following check when the error code G043 is displayed after starting the engine.
Error code
G043 When cranking is executed for five seconds or more, this error code might be displayed. In case that the engine does not start, check by the table of "Section 47.3 Engine related Troubleshooting". Execute the following check when the error code G043 is displayed after starting the engine.
Trouble
Mechatro controller direct input speed sensor and received data from engine controller are disconnected.
Trouble
Mechatro controller direct input speed sensor and received data from engine controller are disconnected.
Judging condition
Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller indicate excess low engine rpm.
Judging condition
Voltage of alternator is 12V or more, and speed sensor and receipt data from engine controller indicate excess low engine rpm.
Symptom
Engine speed down may cause extension by abrupt loading.
Symptom
Engine speed down may cause extension by abrupt loading.
Control in the event of failure
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
Control in the event of failure
Enter 0 rpm for engine speed. Enter 0 for ESS power shift command.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
2
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. speed sensor and controller pressure sensor and controller
4
• Mechatro controller
5
• Engine controller
G-3 MEAS 1 (for mechatro controller)
2
G-3 MEAS 2 (receive from engine controller)
Checking object 1
Normal value: 1.6~2.0k
3
2
2
Checking contents and remedy
• Engine speed sensor SE-13
Measure the resistance between terminals of speed sensor.
• Wiring between engine speed sensor and controller CN-136F CN-106F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
Normal value: 1.6~2.0k
3
• Wiring between ECU engine Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. speed sensor and controller pressure sensor and controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
4
• Mechatro controller
Check that the error is corrected after replacement of controller. (Controller is broken by only applying power to grounding of signal.)
Check that the error is corrected after replacement of controller.
5
• Engine controller
Check that the error is corrected after replacement of controller.
46-45
46-45
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-78
Table46-78
Error code
H013
Error code
H013
Trouble
Accel potentiometer is disconnected.
Trouble
Accel potentiometer is disconnected.
Judging condition
The input voltage from accel potentiometer is 0.1V or less.
Judging condition
The input voltage from accel potentiometer is 0.1V or less.
Symptom
LOW idling is fixed.
Symptom
LOW idling is fixed.
Control in the event of failure
LOW idling is fixed.
Control in the event of failure
LOW idling is fixed.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
H-1 ACCEL VOLT.
Checking object 1
• Accel potentiometer SE-16
2
3
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
2
H-1 ACCEL VOLT.
Checking object
Checking contents and remedy
Measure the resistance between terminals of speed sensor. 1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
1
• Accel potentiometer SE-16
Measure the resistance between terminals of speed sensor. 1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
• Wiring between accel potentiometer and controller CN-402F CN-102F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between accel potentiometer and controller CN-402F CN-102F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-79
Table46-79
Error code
H014
Error code
H014
Trouble
Accel potentiometer’s power source is shortcut.
Trouble
Accel potentiometer’s power source is shortcut.
Judging condition
The input voltage from accel potentiometer is 4.7V or more.
Judging condition
The input voltage from accel potentiometer is 4.7V or more.
Symptom
LOW idling is fixed.
Symptom
LOW idling is fixed.
Control in the event of failure
LOW idling is fixed.
Control in the event of failure
LOW idling is fixed.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
2
Checking object 1
H-1 ACCEL VOLT.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Accel potentiometer SE-16
Measure the resistance between terminals of accel potentiometer.
2
• Wiring between accel potentiometer and controller CN-402F CN-102F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Checking object 1
H-1 ACCEL VOLT.
Checking contents and remedy
• Accel potentiometer SE-16
Measure the resistance between terminals of accel potentiometer.
2
• Wiring between accel potentiometer and controller CN-402F CN-102F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
46-46
2
1.6~2.4k Turn the potentiometer and measure resistance between signal and GND.
46-46
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-80
Table46-80
Error code
H023
Error code
H023
Trouble
Boom angle potentiometer’s wiring is disconnected.
Trouble
Boom angle potentiometer’s wiring is disconnected.
Judging condition
The input voltage from boom angle potentiometer is 0.1V or less.
Judging condition
The input voltage from boom angle potentiometer is 0.1V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
12
H-2 BOOM
Checking object 1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Boom angle potentiometer SE-17
Measure the resistance between terminals of boom angle potentiometer.
2
• Wiring between boom angle potentiometer and controller CN-702F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
12
H-2 BOOM
Checking object 1
Checking contents and remedy
• Boom angle potentiometer SE-17
Measure the resistance between terminals of boom angle potentiometer.
2
• Wiring between boom angle potentiometer and controller CN-702F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
Table46-81
Table46-81
Error code
H024
Error code
H024
Trouble
Boom angle potentiometer’s power source is shortcut.
Trouble
Boom angle potentiometer’s power source is shortcut.
Judging condition
The input voltage from boom angle potentiometer is 0.1V or less.
Judging condition
The input voltage from boom angle potentiometer is 0.1V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Normal control
Control in the event of failure
Normal control
Control in the event of failure
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
12
Checking object 1
• Boom angle potentiometer SE-17
H-2 BOOM
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer.
12
Checking object 1
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND.
• Boom angle potentiometer SE-17
Normal value: 0 to all resistance (4.0~6.0)k
H-2 BOOM
Checking contents and remedy Measure the resistance between terminals of boom angle potentiometer. 4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between boom angle potentiometer and controller CN-702F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between boom angle potentiometer and controller CN-702F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-47
46-47
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-82
Table46-82
Error code
H033
Error code
H033
Trouble
Arm angle potentiometer’s wiring is disconnected.
Trouble
Arm angle potentiometer’s wiring is disconnected.
Judging condition
The input voltage from arm angle potentiometer is 0.1V or less.
Judging condition
The input voltage from arm angle potentiometer is 0.1V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Control in the event of failure
Normal control
Control in the event of failure
Normal control
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
12
H-3 ARM
Checking object 1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Arm angle potentiometer SE-19
Measure the resistance between terminals of arm angle potentiometer.
2
• Wiring between arm angle potentiometer and controller CN-703F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
12
H-3 ARM
Checking object 1
Checking contents and remedy
• Arm angle potentiometer SE-19
Measure the resistance between terminals of arm angle potentiometer.
2
• Wiring between arm angle potentiometer and controller CN-703F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
Table46-83
Table46-83
Error code
H034
Error code
H034
Trouble
Arm angle potentiometer’s power source is shortcut.
Trouble
Arm angle potentiometer’s power source is shortcut.
Judging condition
The input voltage from arm angle potentiometer is 0.1V or less.
Judging condition
The input voltage from arm angle potentiometer is 0.1V or less.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Symptom
Indications of rating load and working radius of High-reach crane become abnormal.
Normal control
Control in the event of failure
Normal control
Control in the event of failure
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
12
Checking object 1
• Arm angle potentiometer SE-19
H-3 ARM
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer.
12
Checking object 1
4.0~6.0k Turn the potentiometer and measure resistance between signal and GND.
• Arm angle potentiometer SE-19
Normal value: 0 to all resistance (4.0~6.0)k
H-3 ARM
Checking contents and remedy Measure the resistance between terminals of arm angle potentiometer. 4.0~6.0k Turn the potentiometer and measure resistance between signal and GND. Normal value: 0 to all resistance (4.0~6.0)k
2
• Wiring between arm angle potentiometer and controller CN-703F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between arm angle potentiometer and controller CN-703F CN-103F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-48
46-48
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-84
Table46-84
Error code
H091
Error code
H091
Trouble
Fuel sensor grounding is short-circuited.
Trouble
Fuel sensor grounding is short-circuited.
Judging condition
The input voltage from fuel sensor is 0.1V or less.
Judging condition
The input voltage from fuel sensor is 0.1V or less.
Symptom
Warning for low fuel level is indicated.
Symptom
Warning for low fuel level is indicated.
Control in the event of failure
Fuel level becomes 0%.
Control in the event of failure
Fuel level becomes 0%.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
10
H-9 FUEL LEVEL
Checking object 1
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Fuel sensor potentiometer SE-15
Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95
10
H-9 FUEL LEVEL
Checking object 1
Checking contents and remedy
• Fuel sensor potentiometer SE-15
~ FULL 5
Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95
~ FULL 5
2
• Wiring between fuel sensor and controller CN-152F CN-104F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between fuel sensor and controller CN-152F CN-104F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-85
Table46-85
Error code
H093
Error code
H093
Trouble
Fuel sensor’s wiring is disconnection.
Trouble
Fuel sensor’s wiring is disconnection.
Judging condition
The input voltage from fuel sensor is 4.7V or more.
Judging condition
The input voltage from fuel sensor is 4.7V or more.
Symptom
Warning for low fuel level is indicated.
Symptom
Warning for low fuel level is indicated.
Control in the event of failure
Fuel level becomes 0%.
Control in the event of failure
Fuel level becomes 0%.
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
10
H-9 FUEL LEVEL
Checking object 1
• Fuel sensor potentiometer SE-15
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95
10
H-9 FUEL LEVEL
Checking object 1
• Fuel sensor potentiometer SE-15
~ FULL 5
Checking contents and remedy Move fuel sensor and measure the resistance between terminals of fuel sensor. EMPTY 95
~ FULL 5
2
• Wiring between fuel sensor and controller CN-152F CN-104F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Wiring between fuel sensor and controller CN-152F CN-104F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-49
46-49
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-86
Table46-86
Error code
I111
Error code
I111
Trouble
Reception of CAN1 communication is abnormal. (Passive error)
Trouble
Reception of CAN1 communication is abnormal. (Passive error)
Judging condition
Reception from engine controller can not receive correctly.
Judging condition
Reception from engine controller can not receive correctly.
Symptom
It has been affected little.
Symptom
It has been affected little.
Control in the event of failure
Keep the last receiving condition.
Control in the event of failure
Keep the last receiving condition.
Returned in It returns automatically in normal condition. normal condition
Returned in It returns automatically in normal condition. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
Checking object
Checking contents and remedy
1
• Wiring between ECU and controller CN-3F CN-101F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection.)
1
• Wiring between ECU and controller CN-3F CN-101F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. (There is a possibility of false disconnection.)
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-87
Table46-87
Error code
I113
Error code
I113
Trouble
Reception of cluster communication is abnormal. (Time-out error)
Trouble
Reception of cluster communication is abnormal. (Time-out error)
Judging condition
Reception from gauge cluster can not receive correctly. It has been affected little.
Judging condition
Reception from gauge cluster can not receive correctly. It has been affected little.
Symptom
It has been affected little.
Symptom
It has been affected little.
It can be operated in condition that coolant temperature is 20°C.
Control in the event of failure
It can be operated in condition that coolant temperature is 20°C.
Control in the event of failure
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
2
G-5 WATER TEMP
Returned in It returns automatically in normal condition. normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
Checking object
2
G-5 WATER TEMP
Checking contents and remedy
1
• Wiring between ECU and controller CN-3F CN-101F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
1
• Wiring between ECU and controller CN-3F CN-101F
Check wiring for possible failure according to the wiring checking procedure and repair it if necessary.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-50
46-50
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-88
Table46-88
Error code
I313
Error code
I313
Trouble
Reception of cluster communication is abnormal. (Time-out error)
Trouble
Reception of cluster communication is abnormal. (Time-out error)
Judging condition
Reception from gauge cluster can not receive correctly.
Judging condition
Reception from gauge cluster can not receive correctly.
Symptom
Switch operation of gauge cluster can not be done.
Symptom
Switch operation of gauge cluster can not be done.
Control in the event of failure
Keep the condition after immediately key-on is operated.
Control in the event of failure
Keep the condition after immediately key-on is operated.
Returned in It returns automatically in normal condition. normal condition
Returned in It returns automatically in normal condition. normal condition
Screen No. Service Screen No. diagnosis checking screen Screen No.
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object
Checking contents and remedy
Checking object
Checking contents and remedy
1
• Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. and controller CN-600F CN-101F
1
• Wiring between gauge cluster Check wiring for possible failure according to the wiring checking procedure and repair it if necessary. and controller CN-600F CN-101F
2
• Mechatro controller
2
• Mechatro controller
Check that the error is corrected after replacement of controller.
Check that the error is corrected after replacement of controller.
Table46-89 Error code
Table46-89
K014
Error code
Trouble
Battery relay contact welded
Trouble
Battery relay contact welded
Judging condition
The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF
Judging condition
The power 24V is continuously supplied to controller for 40 seconds or more while the key switch ON signal turned OFF
Symptom
The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Symptom
The power on the battery relay secondary side does not turn OFF even if the key switch is turned OFF.
Control in the event of failure
Normal control with key switch OFF
Control in the event of failure
Normal control with key switch OFF
Returned in Turn key switch ON. normal condition Or when the power supply 24V to mechatro controller is stopped Screen No. Service Screen No. diagnosis checking screen Screen No.
4
K-1 AIS RELAY 2
4
K-3 KEY SWITCH OFF
Checking object 1
2
Returned in Turn key switch ON. normal condition Or when the power supply 24V to mechatro controller is stopped Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Battery relay R-1 CN-256F
Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.
• Auto idle stop relay 2 R-24 • Alternator relay R-28
Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.
K014
4
K-1 AIS RELAY 2
4
K-3 KEY SWITCH OFF
Checking object 1
2
Checking contents and remedy
• Battery relay R-1 CN-256F
Turn key switch off and disconnect the connector (CN-256F) on the battery relay coil. If 24V power lives on battery relay secondary side, check on battery relay for failure and replace it if failed.
• Auto idle stop relay 2 R-24 • Alternator relay R-28
Turn off the key switch, and remove the connector (CN-256F) on the battery relay coil side. If power of battery relay on secondary side falls, remove either auto idling stop relay 2 or alternator relay. The failure may be occurred in case where the power falls after the relay was removed, and therefore check on the relay unit and replace it with new one if failed.
3
• Wiring between auto idle stop relay/alternator relay and controller CN-109F, CN2-1 • Fuse& relay box E-1
When K014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and K014 is left displayed Replace fuse/relay box.
3
• Wiring between auto idle stop relay/alternator relay and controller CN-109F, CN2-1 • Fuse& relay box E-1
When K014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and K014 is left displayed Replace fuse/relay box.
4
• Mechatro controller
Check that the error is corrected after replacement of controller.
4
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-51
46-51
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-90
Table46-90
Error code
R014
Error code
R014
Trouble
Wiper motor arc prevention relay error
Trouble
Wiper motor arc prevention relay error
Judging condition
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to wiper motor arc prevention relay is short-circuited with the power source.
Symptom
Wiper does not move.
Symptom
Wiper does not move.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
25
Checking object 1
Returned in When the power is OFF normal condition
PREVENT ARC
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, R-31 check relay unit for failure, replace it with new one if failed.
25
Checking object 1
PREVENT ARC
Checking contents and remedy
• Wiper motor arc prevention relay When error is cancelled after removing wiper motor arc prevention relay, R-31 check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse & relay box E-1
When R014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R014 is left displayed Replace fuse/relay box.
2
• Wiring between wiper motor arc prevention relay and controller CN-109F, CN2-1 • Fuse & relay box E-1
When R014 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R014 is left displayed Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-52
46-52
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-91
Table46-91
Error code
R024
Error code
R024
Trouble
Wiper motor forward rotation relay error
Trouble
Wiper motor forward rotation relay error
Judging condition
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to wiper motor forward rotation relay is short-circuited with the power source.
Symptom
Wiper does not move.
Symptom
Wiper does not move.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
25
Checking object
Returned in When the power is OFF normal condition
CW MOTOR RLY
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, relay check relay unit for failure, replace it with new one if failed. R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1
3
• Mechatro controller
25
Checking object
CW MOTOR RLY
Checking contents and remedy
1
• Wiper motor forward rotation When error is cancelled after removing wiper motor forward rotation relay, relay check relay unit for failure, replace it with new one if failed. R-29 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
When R024 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R024 is left displayed Replace fuse/relay box.
2
• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1
When R024 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R024 is left displayed Replace fuse/relay box.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-53
46-53
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-92
Table46-92
Error code
R034
Error code
R034
Trouble
Wiper motor reverse rotation relay error
Trouble
Wiper motor reverse rotation relay error
Judging condition
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to wiper motor reverse rotation relay is short-circuited with the power source.
Symptom
Wiper does not move after forward rotation.
Symptom
Wiper does not move after forward rotation.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
25
Checking object
Returned in When the power is OFF normal condition
CCW MOTOR RLY
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
1
• Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, relay check relay unit for failure, replace it with new one if failed. R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1
3
• Mechatro controller
25
Checking object
CCW MOTOR RLY
Checking contents and remedy
1
• Wiper motor reverse rotation When error is cancelled after removing wiper motor reverse rotation relay, relay check relay unit for failure, replace it with new one if failed. R-30 When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
When R034 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R034 is left displayed Replace fuse/relay box.
2
• Wiring between wiper motor forward rotation relay and controller CN-109F, CN2-1 •Fuse & relay box E-1
When R034 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R034 is left displayed Replace fuse/relay box.
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-54
46-54
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-93
Table46-93
Error code
R044
Error code
R044
Trouble
Washer motor relay error
Trouble
Washer motor relay error
Judging condition
The mechatro controller output line to washer motor relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to washer motor relay is short-circuited with the power source.
Symptom
Washer motor does not move.
Symptom
Washer motor does not move.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
25
Returned in When the power is OFF normal condition
MOTOR RELAY
Checking object 1
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Washer motor relay R-32
When error is cancelled after removing washer motor relay, check relay unit for failure, replace it with new one if failed.
25
MOTOR RELAY
Checking object 1
Checking contents and remedy
• Washer motor relay R-32
When error is cancelled after removing washer motor relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between washer motor relay and controller CN-112F, CN2-1 •Fuse & relay box E-1
When R044 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R044 is left displayed Replace fuse/relay box.
2
• Wiring between washer motor relay and controller CN-112F, CN2-1 •Fuse & relay box E-1
When R044 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R044 is left displayed Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-94
Table46-94
Error code
R134
Error code
R134
Trouble
Swing flasher relay error
Trouble
Swing flasher relay error
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom
Right swing flasher does not light.
Symptom
Right swing flasher does not light.
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking object 1
• Swing flasher relay R-19
22
Returned in When the power is OFF normal condition
D13
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0
Checking object 1
• Swing flasher relay R-19
, it is in abnormal condition.
22
D13
Checking contents and remedy When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0
, it is in abnormal condition.
2
• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.
2
• Wiring between swing flasher When R134 is left displayed with the relay removed relay and controller Check that no power 24V is produced on relay (-) line (as shown right upper CN-74F, CN-109F figure C) according to the wiring checking procedure and replace it if necessary.
3
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-55
Check that the error is corrected after replacement of controller.
46-55
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-95
Table46-95
Error code
R144
Error code
R144
Trouble
Swing flasher relay error
Trouble
Swing flasher relay error
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to swing flasher relay is short-circuited with the power source.
Symptom
Left swing flasher does not light.
Symptom
Left swing flasher does not light.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
22
D14
Checking object 1
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Swing flasher relay R-19
When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (HB) and (HC) is 0
22
D14
Checking object 1
Checking contents and remedy
• Swing flasher relay R-19
When error is cancelled after removing connector (CN-74F) of swing flasher relay, check relay unit for failure, replace it with new one if failed.
, it is in abnormal condition.
When resistance between relays (HB) and (HC) is 0
, it is in abnormal condition.
2
• Wiring between swing flasher When R144 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line (as shown right upper relay and controller figure B) according to the wiring checking procedure and replace it if CN-74F, CN-109F necessary.
2
• Wiring between swing flasher When R144 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line (as shown right upper relay and controller figure B) according to the wiring checking procedure and replace it if CN-74F, CN-109F necessary.
3
• Mechatro controller
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Check that the error is corrected after replacement of controller.
Table46-96
Table46-96
Error code
R154
Error code
R154
Trouble
Travel alarm relay error
Trouble
Travel alarm relay error
Judging condition
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to travel alarm relay is short-circuited with the power source.
Symptom
Travel alarm does not actuate.
Symptom
Travel alarm does not actuate.
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
23
Checking object 1
• Travel alarm relay R-8
Returned in When the power is OFF normal condition
D15
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When error is cancelled after removing of travel alarm relay, check relay unit for failure, replace it with new one if failed.
23
Checking object 1
• Travel alarm relay R-8
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
D15
Checking contents and remedy When error is cancelled after removing of travel alarm relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between travel alarm relay and controller CN-109F, CN2-2 •Fuse & relay box E-1
When R154 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R154 is left displayed. Replace fuse/relay box.
2
• Wiring between travel alarm relay and controller CN-109F, CN2-2 •Fuse & relay box E-1
When R154 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R154 is left displayed. Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-56
46-56
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-97
Table46-97
Error code
R164
Error code
R164
Trouble
Auto idle stop relay 2 relay error
Trouble
Auto idle stop relay 2 relay error
Judging condition
The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Judging condition
The mechatro controller output line to auto idle stop relay 2 is short-circuited with the power source.
Symptom
Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate.
Symptom
Power source for mechatro controller often turns off. Auto idle stop relay 2 does not actuate.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
4
Checking object 1
• Auto idle stop relay 2 relay R-24
Returned in When the power is OFF normal condition
K-1 AIS RELAY 2
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When error is cancelled after removing of auto idle stop relay 2, check relay unit for failure, replace it with new one if failed.
4
Checking object 1
• Auto idle stop relay 2 relay R-24
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
K-1 AIS RELAY 2
Checking contents and remedy When error is cancelled after removing of auto idle stop relay 2, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between auto idle stop relay 2 and controller CN-109F, CN2-2 •Fuse & relay box E-1
When R164 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R164 is left displayed. Replace fuse/relay box.
2
• Wiring between auto idle stop relay 2 and controller CN-109F, CN2-2 •Fuse & relay box E-1
When R164 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R164 is left displayed. Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-57
46-57
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES) Table46-98
Table46-98
Error code
R174
Error code
R174
Trouble
Engine forcibly stop relay error
Trouble
Engine forcibly stop relay error
Judging condition
The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
Judging condition
The mechatro controller output line to engine forcibly stop is short-circuited with the power source.
Symptom
When key switch is turned off but engine does not stop. Engine auto idle stop function does not actuate.
Symptom
When key switch is turned off but engine does not stop. Engine auto idle stop function does not actuate.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
4
Checking object 1
• Engine forcibly stop relay R-25
Returned in When the power is OFF normal condition
K-3 ENG STOP
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When error is cancelled after removing of engine forcibly stop relay, check relay unit for failure, replace it with new one if failed.
4
Checking object 1
• Engine forcibly stop relay R-25
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
K-3 ENG STOP
Checking contents and remedy When error is cancelled after removing of engine forcibly stop relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between engine forcibly stop relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R174 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R174 is left displayed. Replace fuse/relay box.
2
• Wiring between engine forcibly stop relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R174 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R174 is left displayed. Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-58
46-58
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
Table46-99
Table46-99
Error code
R184
Error code
R184
Trouble
Safety lock lever relay error
Trouble
Safety lock lever relay error
Judging condition
The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to safety lock lever relay is short-circuited with the power source.
Symptom
Safety lock lever timer does not actuate.
Symptom
Safety lock lever timer does not actuate.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
4
Returned in When the power is OFF normal condition
K-4 LOCK LEVER
Checking object 1
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy
• Safety lock lever relay R-26
When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed.
4
K-4 LOCK LEVER
Checking object 1
Checking contents and remedy
• Safety lock lever relay R-26
When error R184 is cancelled after removing of safety lock lever relay, check relay unit for failure, replace it with new one if failed.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R184 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box.
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R184 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R184 is left displayed. Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
Table46-100
Table46-100
Error code
R214
Error code
R214
Trouble
Safety relay error
Trouble
Safety relay error
Judging condition
The mechatro controller output line to safety relay is short-circuited with the power source.
Judging condition
The mechatro controller output line to safety relay is short-circuited with the power source.
Symptom
Safety relay does not actuate.
Symptom
Safety relay does not actuate.
Relay output is stopped.
Control in the event of failure
Relay output is stopped.
Control in the event of failure
Returned in When the power is OFF normal condition Screen No. Service Screen No. diagnosis checking screen Screen No.
4
Checking object 1
• Safety lock lever relay R-26
Returned in When the power is OFF normal condition
K-2 SAFETY RLY
Screen No. Service Screen No. diagnosis checking screen Screen No.
Checking contents and remedy When error R214 is cancelled after removing of safety relay, check relay unit for failure, replace it with new one if failed.
4
Checking object 1
• Safety lock lever relay R-26
When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
K-2 SAFETY RLY
Checking contents and remedy When error R214 is cancelled after removing of safety relay, check relay unit for failure, replace it with new one if failed. When resistance between relays (1) and (2) is 0 , it is in abnormal condition.
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R214 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R214 is left displayed. Replace fuse/relay box.
2
• Wiring between safety lock lever relay and controller CN-109F, CN2-2 • Fuse & relay box E-1
When R214 is left displayed with the relay removed Check that no power 24V is produced on relay (-) line according to the wiring checking procedure and replace it if necessary. When no failure found after checking on wiring and R214 is left displayed. Replace fuse/relay box.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
3
• Mechatro controller
Check that the error is corrected after replacement of controller.
46-59
46-59
46. TROUBLE SHOOTING (BY ERROR CODES)
46. TROUBLE SHOOTING (BY ERROR CODES)
[MEMO]
[MEMO]
46-60
46-60
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
TABLE OF CONTENTS
TABLE OF CONTENTS
47.1 HYDRAULIC SYSTEM ....................................................................................................47-3
47.1 HYDRAULIC SYSTEM ....................................................................................................47-3
47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2 ELECTRIC SYSTEMS .....................................................................................................47-27
47.2.1
WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.1
WIRING CHECKING PROCEDURE ......................................................................47-27
47.2.2
TROUBLE...............................................................................................................47-30
47.2.2
TROUBLE...............................................................................................................47-30
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33
47.3 ENGINE RELATED TROUBLESHOOTING ....................................................................47-33
47
47
Book Code No. S5YN4718E01 47-1
Book Code No. S5YN4718E01 47-1
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
Issue
Date of Issue
Applicable Machines
First edition
Augst, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
n
March, 2007
n
April, 2007
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
n
n
SK215SRLC : LA05-02001~
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
47-2
Remarks S5YN4718E01 n n (NHK) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine
Issue
Date of Issue
Applicable Machines
K
First edition
Augst, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
K
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
K
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
K
n
March, 2007
K
n
April, 2007
K
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
K
n
n
SK215SRLC : LA05-02001~
K
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
K
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
47-2
Remarks S5YN4718E01 n n (NHK) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine
K K K K K K K K K K K K K K
47. TROUBLESHOOTING (BY TROUBLE)
47.1
HYDRAULIC SYSTEM
47. TROUBLESHOOTING (BY TROUBLE)
47.1
Preface: The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
HYDRAULIC SYSTEM
Preface: The troubleshooting for the failures shown below is explained here. Identify the failure and trouble and carry forward the troubleshooting in order of the failure item number.
(1) All controls do not function/slow
(1) All controls do not function/slow
(2) Engine down/stalled
(2) Engine down/stalled
(3) Move at lever neutral position
(3) Move at lever neutral position
(4) Poor fine operability
(4) Poor fine operability
(5) Slow boom up, insufficient power
(5) Slow boom up, insufficient power
(6) Slow boom down, insufficient power for lifting up body
(6) Slow boom down, insufficient power for lifting up body
(7) Slow arm in, insufficient power
(7) Slow arm in, insufficient power
(8) Slow independent arm out (in the air)
(8) Slow independent arm out (in the air)
(9) Slow bucket digging
(9) Slow bucket digging
(10)Slow bucket dumping
(10)Slow bucket dumping
(11)Swing operation not functioned/slow
(11)Swing operation not functioned/slow
(12)Noise during swing operation
(12)Noise during swing operation
(13)Swing on a slope drifts when control lever is in neutral position
(13)Swing on a slope drifts when control lever is in neutral position
(14)Swing drifts when swing operation is stopped
(14)Swing drifts when swing operation is stopped
(15)Slow travel speed/weak
(15)Slow travel speed/weak
(16)Travel deviation
(16)Travel deviation
(17)Travel 1st/2nd speed not changed
(17)Travel 1st/2nd speed not changed
(18)Travel parking on a slope is not held
(18)Travel parking on a slope is not held
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(19)Travel does not run straightly when both crawlers and attachment operated simultaneously.
(20)Slow breaker (crusher) operation, weak power
(20)Slow breaker (crusher) operation, weak power
(21)Option selector valve malfunction: not switched to breaker circuit
(21)Option selector valve malfunction: not switched to breaker circuit
(22)Option selector valve malfunction: not switched to nibbler (crusher) circuit
(22)Option selector valve malfunction: not switched to nibbler (crusher) circuit
47-3
47-3
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
(1) All controls do not function/slow
(1) All controls do not function/slow
No.
Sections
Contents/normal value
Corrective action, others
1 Fuse
Check fuse No.4 (10A)
If the fuse is blown out, check on the short-circuited section.
2 Safety lever lock switch
Carry out service diagnosis
3 Safety lever lock switching
Check that the solenoid is switched correctly
No.
Sections
Contents/normal value
Corrective action, others
1 Fuse
Check fuse No.4 (10A)
If the fuse is blown out, check on the short-circuited section.
No.4 K-4 switch: Check action of switch by tester, Push down the lever and it turns on, push or check that the power voltage up and it turns off. is lowered by pushing the lever down.
2 Safety lever lock switch
Carry out service diagnosis
No.4 K-4 switch: Check action of switch by tester, Push down the lever and it turns on, push or check that the power voltage up and it turns off. is lowered by pushing the lever down.
Measure both terminals of solenoid Check solenoid unit for possible connector. 24V by pushing the lever down, failure. 0V by pushing it up Check harness for possible failure.
3 Safety lever lock switching
Check that the solenoid is switched correctly
Measure both terminals of solenoid Check solenoid unit for possible connector. 24V by pushing the lever down, failure. 0V by pushing it up Check harness for possible failure.
4 Safety lever lock relay Carry out service diagnosis
No.4 K-4 lock lever: Check action of relay by tester Push down the lever and it turns off, push up and it turns on.
4 Safety lever lock relay Carry out service diagnosis
No.4 K-4 lock lever: Check action of relay by tester Push down the lever and it turns off, push up and it turns on.
5 Pilot pressure sensor
•Stop engine stop and key is on position. Check 5V power for controller All pilot low pressure sensors are 0MPa to 0.1MPa.
5 Pilot pressure sensor
•Stop engine stop and key is on position. Check 5V power for controller All pilot low pressure sensors are 0MPa to 0.1MPa.
6 Solenoid valve for safety lock lever
Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve solenoid A1 port 4MPa or more by push it down.
6 Solenoid valve for safety lock lever
Measure pressure of About 0MPa by pushing the lever up, and Replace solenoid valve solenoid A1 port 4MPa or more by push it down.
7 Pilot line filter
Disassemble and check it visually
7 Pilot line filter
Disassemble and check it visually
8 Pilot gear pump
Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief pressure at gear valve for possible failure pump
8 Pilot gear pump
Measure pilot primary Check that it is 4MPa or more in high idling Check gear pump and the relief pressure at gear valve for possible failure pump
9 Multi control valve (in case that travel is operable)
Change position
Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position.
9 Multi control valve (in case that travel is operable)
Change position
10 Actual measuring Carry out service current value of P1/P2 diagnosis unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve)
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.3 Boom up full lever & relief proportional valve and controller for possible failure.
10 Actual measuring Carry out service current value of P1/P2 diagnosis unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) D-1 P2 unload valve (cut valve)
11 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2MPa in boom up full lever and high idling operation
Replace proportional valve
11 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary pressures are within the range of 0.5 to 1.2MPa in boom up full lever and high idling operation
Replace proportional valve
12 Actual measuring Carry out service current value of P1/P2 diagnosis. pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
12 Actual measuring Carry out service current value of P1/P2 diagnosis. pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
13 Secondary pressure of Measure the pump pump proportional proportional valve valve secondary pressure directly in idling operation. (Ports a3, a4)
Check that pump proportional valve Replace proportional valve secondary pressure is 2.7MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve
13 Secondary pressure of Measure the pump pump proportional proportional valve valve secondary pressure directly in idling operation. (Ports a3, a4)
Check that pump proportional valve Replace proportional valve secondary pressure is 2.7MPa or more in right (left) travel full lever and high idling operation Right travel: P1 pump proportional valve Left travel: P2 pump proportional valve
Check filter for clogging
•See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
47-4
Clean filter
Check filter for clogging
Clean filter
Since all are blocked due to poor switching performance, check that the lever select pattern is set to the proper position. In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.3 Boom up full lever & relief proportional valve and controller for possible failure.
•See Service Diagnosis Data List Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
47-4
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
14 Main relief pressure
Carry out service diagnosis
•See Service Diagnosis Data List Measure the relief pressure Operation No.3 Boom up full lever & relief actually
14 Main relief pressure
Carry out service diagnosis
•See Service Diagnosis Data List Measure the relief pressure Operation No.3 Boom up full lever & relief actually
15
Check set pressure
Check that P1 and P2 pump pressures are Reset or replace 32MPa in boom up full lever, high idling and H mode operation.
15
Check set pressure
Check that P1 and P2 pump pressures are Reset or replace 32MPa in boom up full lever, high idling and H mode operation.
16 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
16 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
17 Pump
Visual check
When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
Replace
17 Pump
Visual check
When removing, inside parts (cylinder block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
Replace
(2) Engine down/stalled No.
(2) Engine down/stalled
Sections
Contents/normal value
1 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
2 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Corrective action, others
Sections
Contents/normal value
Corrective action, others
1 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 0.5 to 1.0MPa in control lever neutral and high idling operation.
2 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 0.5 to 1.0MPa in control lever neutral and high idling operation.
3 Pressure sensor of P1, Check pressure P2 pump
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.3 Boom up full lever & relief
Check pressure sensor and replace it if necessary
3 Pressure sensor of P1, Check pressure P2 pump
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.3 Boom up full lever & relief
Check pressure sensor and replace it if necessary
4 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
4 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
5 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
5 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
•See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
No.
(3) Move at lever neutral position No.
Sections
(3) Move at lever neutral position Contents/normal value
1 Pilot pressure sensor
Carry out service diagnosis
2 Remote control valve
•See Service Diagnosis Data List Operation No. 1 Operation is nil
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that targeted pilot pressure of sensor is 0MPa in high idling
Corrective action, others
No.
Sections
Contents/normal value Carry out service diagnosis
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
2 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
3 Main spool
Check targeted spool visually
Check that spool is free from abnormal Replace damage and spring is free from breakage
3 Main spool
Check targeted spool visually
Check that spool is free from abnormal Replace damage and spring is free from breakage
4 Over load relief valve
Check targeted spool visually
Free from dust entered in port relief valve. Seat is free from abnormality
4 Over load relief valve
Check targeted spool visually
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
Check that targeted pilot pressure of sensor is 0MPa in high idling
Corrective action, others
1 Pilot pressure sensor
47-5
Check remote control valve
47-5
Check remote control valve
Replace
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
5 Lock valve poppet (in case of boom and arm)
Check targeted poppet Seat is free from abnormality visually
Replace
5 Lock valve poppet (in case of boom and arm)
Check targeted poppet Seat is free from abnormality visually
Replace
6 Lock valve selector (in case of boom and arm)
Exchange lock valve selector of boom/arm and boom/arm
Replace
6 Lock valve selector (in case of boom and arm)
Exchange lock valve selector of boom/arm and boom/arm
Replace
Check that the trouble is reversed
Check that the trouble is reversed
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace boom sliding of spool in sleeve sliding Do not pull spool out of sleeve (in case of boom) forcibly.
7 Holding valve spool for Check that smooth Free from abnormal resistance against Replace boom sliding of spool in sleeve sliding Do not pull spool out of sleeve (in case of boom) forcibly.
8 Holding valve relief valve for boom (in case of boom)
Check targeted spool visually
Replace
8 Holding valve relief valve for boom (in case of boom)
Check targeted spool visually
9 Cylinder
Check targeted cylinder Make sure of no problem of seals by visually disassembling and investigation
Replace cylinder or seals
9 Cylinder
Check targeted cylinder Make sure of no problem of seals by visually disassembling and investigation
Filter free from abnormal contamination
(4) Poor fine operability No.
Contents/normal value Carry out service diagnosis
•See Service Diagnosis Data List Operation No. 1 Operation is nil
Corrective action, others Replace pressure sensor
No.
Sections
1 Pressure sensor
Contents/normal value Carry out service diagnosis
•All low pressure sensors are 0MPa to 0.1MPa 2 Actual measuring current value of P1/P2 unload proportional valve
Replace
Replace cylinder or seals
(4) Poor fine operability
Sections
1 Pressure sensor
Filter free from abnormal contamination
•See Service Diagnosis Data List Operation No. 1 Operation is nil
Corrective action, others Replace pressure sensor
•All low pressure sensors are 0MPa to 0.1MPa
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No. 1 Operation is nil for possible failure.
2 Actual measuring current value of P1/P2 unload proportional valve
3 Secondary pressure of Measure the unload proportional proportional valve valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block
Check that P1/P2 unloads secondary Replace proportional valve pressures is within the range of 2.7MPa or more in control lever neutral and high idling operation
3 Secondary pressure of Measure the unload proportional proportional valve valve secondary pressure directly at the ports A7 and A8 of 8 sections solenoid block
Check that P1/P2 unloads secondary Replace proportional valve pressures is within the range of 2.7MPa or more in control lever neutral and high idling operation
4 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
4 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
5 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of Check regulator 0.5 to 1.0MPa in control lever neutral and high idling operation
5 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of Check regulator 0.5 to 1.0MPa in control lever neutral and high idling operation
6 Slow return check valve Visual check of pilot line (in case of boom up or arm out)
Check that slow return check valve Clean and replace installed on pilot line is free from dust entered
6 Slow return check valve Visual check of pilot line (in case of boom up or arm out)
Check that slow return check valve Clean and replace installed on pilot line is free from dust entered
Carry out service diagnosis
•See Service Diagnosis Data List Operation No. 1 Operation is nil
47-6
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Carry out service diagnosis
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No. 1 Operation is nil for possible failure.
•See Service Diagnosis Data List Operation No. 1 Operation is nil
47-6
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
47. TROUBLESHOOTING (BY TROUBLE) (5) Slow boom up, insufficient power No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) (5) Slow boom up, insufficient power
Contents/normal value
Corrective action, others
1 Boom up pressure sensor
Carry out service diagnosis
•See Service Diagnosis Data List Check and replace pressure Operation No.3 boom up full lever and sensor relief Check remote control valve
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in boom up full lever and high idling When equipped with multi boom up operation control valve, check it while changing lever pattern
No.
Sections
Contents/normal value
Corrective action, others
1 Boom up pressure sensor
Carry out service diagnosis
•See Service Diagnosis Data List Check and replace pressure Operation No.3 boom up full lever and sensor relief Check remote control valve
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in boom up full lever and high idling When equipped with multi boom up operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List When there is difference Operation No.4 boom up full lever and between P1 and P2 pump in operation pressures, check high pressure sensor.
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List When there is difference Operation No.4 boom up full lever and between P1 and P2 pump in operation pressures, check high pressure sensor.
4 Actual measuring current value of P1/P2 unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.3 Boom up full lever & proportional valve and controller for possible failure. relief
4 Actual measuring current value of P1/P2 unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.3 Boom up full lever & proportional valve and controller for possible failure. relief
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5~1.2MPa in boom up full lever and high idling operation
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5~1.2MPa in boom up full lever and high idling operation
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.4 boom up full lever & in proportional valve and controller for possible failure. operation
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.8 to 3.0MPa in boom up full lever and high idling operation
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.8 to 3.0MPa in boom up full lever and high idling operation
8 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
8 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
Carry out service diagnosis
9 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
10 Lock valve poppet <Trouble> Both P1 and P2 pressures are low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
11 Conflux check valve <Trouble> Only P2 pressure is high.
Visual check
12 Holding valve for boom Visual check (poppet) <Trouble> Both P1 and P2 pressures are high.
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.4 boom up full lever & in proportional valve and controller for possible failure. operation
9 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
Replace (Check on the casing side for damage)
10 Lock valve poppet <Trouble> Both P1 and P2 pressures are low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
11 Conflux check valve <Trouble> Only P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
12 Holding valve for boom Visual check (poppet) <Trouble> Both P1 and P2 pressures are high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
47-7
47-7
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
13 Boom spool <Trouble> Only P1 pressure is high.
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Corrective action, others Replace (Check on the casing side for damage)
No.
Sections
13 Boom spool <Trouble> Only P1 pressure is high.
Contents/normal value Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Corrective action, others Replace (Check on the casing side for damage)
14 Check boom spool and Disassembly and recirculation investigation <Trouble> Only P1 pressure is low.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
14 Check boom spool and Disassembly and recirculation investigation <Trouble> Only P1 pressure is low.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
15 Conflux spool <Trouble> Only P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage. Free from abnormal damage, etc on outside surface
15 Conflux spool <Trouble> Only P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage. Free from abnormal damage, etc on outside surface
16 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
16 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
17 Over load relief valve <Trouble> Relief pressure is low.
Visual check (Head side)
Pressure is 32MPa or more in boom up When only relief pressure of full lever and high idling. Free from boom up is low, replace valve dust entered in over load relief valve. Seat is free from abnormality
17 Over load relief valve <Trouble> Relief pressure is low.
Visual check (Head side)
Pressure is 32MPa or more in boom up When only relief pressure of full lever and high idling. Free from boom up is low, replace valve dust entered in over load relief valve. Seat is free from abnormality
Replace (Check on the casing side for damage)
(6) Slow boom down/insufficient power for lifting up body No.
Sections
Contents/normal value
1 Boom down pressure sensor
Carry out service diagnosis
2 Remote control valve
3 Actual measuring current value of P1 unload proportional valve
Replace (Check on the casing side for damage)
(6) Slow boom down/insufficient power for lifting up body Corrective action, others
•See Service Diagnosis Data List Check and replace pressure Operation No.5 boom down full lever sensor. & in operation Check remote control valve.
No.
Sections
Contents/normal value
Corrective action, others
1 Boom down pressure sensor
Carry out service diagnosis
Measure remote control Check that pressure is 3.0MPa or more Check remote control valve pressure of boom down in boom down full lever and high idling When equipped with multi directly operation control valve, check it while changing lever pattern.
2 Remote control valve
Measure remote control Check that pressure is 3.0MPa or more Check remote control valve pressure of boom down in boom down full lever and high idling When equipped with multi directly operation control valve, check it while changing lever pattern.
Carry out service diagnosis
P1 unload valve (cut valve)
In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.5 boom down full lever & measured value, check proportional valve and controller in operation for possible failure.
3 Actual measuring current value of P1 unload proportional valve
Carry out service diagnosis
4 Secondary pressure of Measure the P1 unload proportional proportional valve valve secondary pressure directly at the ports A7 of 8 sections solenoid block.
Check that P1 unload secondary Replace proportional valve pressures are within the range of 0.8 to 1.2MPa in boom down full lever and high idling operation
4 Secondary pressure of Measure the P1 unload proportional proportional valve valve secondary pressure directly at the ports A7 of 8 sections solenoid block.
Check that P1 unload secondary Replace proportional valve pressures are within the range of 0.8 to 1.2MPa in boom down full lever and high idling operation
5 Actual measuring Carry out service diagnosis current value of P1 pump proportional valve
•No.9 E-1 P1 pump
In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.5 boom down full lever measured value, check proportional valve and controller & in operation for possible failure.
5 Actual measuring Carry out service diagnosis current value of P1 pump proportional valve
•No.9 E-1 P1 pump
6 Secondary pressure of Measure the pump P1 pump proportional proportional valve valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.0 to 2.5MPa in boom down full lever and high idling operation
6 Secondary pressure of Measure the pump P1 pump proportional proportional valve valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures are within the range of 2.0 to 2.5MPa in boom down full lever and high idling operation
47-8
•See Service Diagnosis Data List Check and replace pressure Operation No.5 boom down full lever sensor. & in operation Check remote control valve.
P1 unload valve (cut valve)
In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.5 boom down full lever & measured value, check proportional valve and controller in operation for possible failure.
In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.5 boom down full lever measured value, check proportional valve and controller & in operation for possible failure.
47-8
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
7 Actual measuring current value of travel straight proportional valve
Carry out service diagnosis
8 Travel straight proportional valve secondary pressure
Measure directly the travel straight proportional valve secondary pressure.
9 Remote control valve
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
7 Actual measuring current value of travel straight proportional valve
Carry out service diagnosis
8 Travel straight proportional valve secondary pressure
Measure directly the travel straight proportional valve secondary pressure.
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
9 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
10 Lock valve poppet <Trouble> Boom down is low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
10 Lock valve poppet <Trouble> Boom down is low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
11 Holding valve (poppet) <Trouble> Boom down is slow.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
11 Holding valve (poppet) <Trouble> Boom down is slow.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
12 Boom spool <Trouble> Boom down is slow.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
12 Boom spool <Trouble> Boom down is slow.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
High idling pressure is 0.8MPa or less Replace proportional valve regardless neutral/operation
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
High idling pressure is 0.8MPa or less Replace proportional valve regardless neutral/operation
13 Check boom spool and Disassembly and recirculation investigation <Trouble> Machine can not be lifted by supporting with boom.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
13 Check boom spool and Disassembly and recirculation investigation <Trouble> Machine can not be lifted by supporting with boom.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
14 Main relief valve <Trouble> Relief pressure is low.
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
14 Main relief valve <Trouble> Relief pressure is low.
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
Free from dust entered in port relief valve. Seat is free from abnormality
15 Over load relief valve Visual check <Trouble> Machine can not be lifted by supporting with boom.
Check set pressure
15 Over load relief valve Visual check <Trouble> Machine can not be lifted by supporting with boom.
Replace
(7) Slow arm in, insufficient power No.
Sections
2 Remote control valve pressure
Free from dust entered in port relief valve. Seat is free from abnormality
Replace
(7) Slow arm in, insufficient power Contents/normal value
1 Arm in pressure sensor Carry out service diagnosis
Check set pressure
•See Service Diagnosis Data List Operation No.6 arm in full lever and relief
Corrective action, others Check and replace pressure sensor Check remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of arm in arm in full lever and high idling When equipped with multi in operation control valve, check it while changing lever pattern
47-9
No.
Sections
Contents/normal value
1 Arm in pressure sensor Carry out service diagnosis 2 Remote control valve pressure
•See Service Diagnosis Data List Operation No.6 arm in full lever and relief
Corrective action, others Check and replace pressure sensor Check remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of arm in arm in full lever and high idling When equipped with multi in operation control valve, check it while changing lever pattern
47-9
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List When there is difference Operation No.7 arm in full lever and in between P1 and P2 pump operation pressures, check high pressure sensor
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List When there is difference Operation No.7 arm in full lever and in between P1 and P2 pump operation pressures, check high pressure sensor
4 Actual measuring current value of P1/P2 unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.6 Arm in full lever & for possible failure. relief
4 Actual measuring current value of P1/P2 unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.6 Arm in full lever & for possible failure. relief
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in arm in full lever and high idling operation.
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block.
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in arm in full lever and high idling operation.
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are 2.0MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly. (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are 2.0MPa or more in arm in full lever and high idling operation. (Secondary pressure is affected by oil temperature and attachment weight)
8 Actual measuring current value of arm in spool 2 proportional valve
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.6 Arm in full lever & relief Operation No.7 Arm in full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
8 Actual measuring current value of arm in spool 2 proportional valve
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.6 Arm in full lever & relief Operation No.7 Arm in full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check that secondary pressure of proportional valve secondary pressures are within the range of following Lever neutral: 0MPa Motion in the air: 1.7 to 2.2MPa Arm in relief: 2.5MPa or more
Replace proportional valve
9 Secondary pressure of Measure directly the arm in spool 2 proportional valve proportional valve secondary pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block.
Check that secondary pressure of proportional valve secondary pressures are within the range of following Lever neutral: 0MPa Motion in the air: 1.7 to 2.2MPa Arm in relief: 2.5MPa or more
Replace proportional valve
Check that the value is not change regardless of operation
•Check pressure sensor of travel
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
10 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Carry out service diagnosis
Carry out service diagnosis
9 Secondary pressure of Measure directly the arm in spool 2 proportional valve proportional valve secondary pressure at the ports A8 (arm 2 spool) of 8 sections solenoid block. 10 Actual measuring current value of travel straight proportional valve
Carry out service diagnosis
11 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
•See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
47-10
Carry out service diagnosis
Carry out service diagnosis
Carry out service diagnosis
11 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
•See Service Diagnosis Data List Operation No.7 Arm in full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
47-10
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
12 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
12 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
13 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
13 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
Pressure is 32MPa or more in arm in and relief. Free from dust entered in over load relief valve. Seat is free from abnormality
14 Over load relief valve Visual check (Head <Trouble> side) P1, P2 pressure is low.
14 Over load relief valve Visual check (Head <Trouble> side) P1, P2 pressure is low.
When only relief pressure of arm in is low, replace valve
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief Pressure is 32MPa or more in arm in and relief. Free from dust entered in over load relief valve. Seat is free from abnormality
When only relief pressure of arm in is low, replace valve
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm <Trouble> and relief. out is low, replace valve P1, P2 pressure is low. Free from dust entered in over load relief valve. Seat is free from abnormality.
15 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm <Trouble> and relief. out is low, replace valve P1, P2 pressure is low. Free from dust entered in over load relief valve. Seat is free from abnormality.
16 Arm 1 spool Visual check <Trouble> P1, P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
16 Arm 1 spool Visual check <Trouble> P1, P2 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17 Arm 2 spool Visual check <Trouble> P1, P2 pressure is high or low.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17 Arm 2 spool Visual check <Trouble> P1, P2 pressure is high or low.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18 Check arm 2 spool and Disassembly and recirculation investigation <Trouble> Arm in power is poor.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
18 Check arm 2 spool and Disassembly and recirculation investigation <Trouble> Arm in power is poor.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
19 Check lock valve poppet Visual check <Trouble> Both P1, P2 pressures are high.
Free from abnormal resistance against Replace sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface
19 Check lock valve poppet Visual check <Trouble> Both P1, P2 pressures are high.
Free from abnormal resistance against Replace sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface
(8) Slow independent arm out (in the air) No.
Sections
(8) Slow independent arm out (in the air) Contents/normal value
Corrective action, others
1 Arm out pressure sensor
Carry out service diagnosis
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of arm in arm out full lever and high idling When equipped with multi out operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation. 4 Actual measuring current value of P1/P2 unload proportional valve
Carry out service diagnosis
•See Service Diagnosis Data List Check and replace pressure Operation No.8 arm out full lever and sensor relief Check remote control valve
No.
Sections
Contents/normal value Carry out service diagnosis
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of arm in arm out full lever and high idling When equipped with multi out operation control valve, check it while changing lever pattern
When there is difference •See Service Diagnosis Data List Operation No.9 arm out full lever and between P1 and P2 pump in operation pressures, check high pressure sensor
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.8 Arm out full lever & for possible failure. relief
4 Actual measuring current value of P1/P2 unload proportional valve
47-11
Corrective action, others
1 Arm out pressure sensor
Carry out service diagnosis
•See Service Diagnosis Data List Check and replace pressure Operation No.8 arm out full lever and sensor relief Check remote control valve
When there is difference •See Service Diagnosis Data List Operation No.9 arm out full lever and between P1 and P2 pump in operation pressures, check high pressure sensor •No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.8 Arm out full lever & for possible failure. relief
47-11
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in arm out full lever and high idling operation
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in arm out full lever and high idling operation
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.9 Arm out full lever & in proportional valve and controller for possible failure. operation
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.5 to 2.7MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 pump proportional Replace proportional valve valve pressures are within the range of 1.5 to 2.7MPa in arm out full lever and high idling operation (Secondary pressure is affected by oil temperature and attachment weight)
8 Actual measuring current value of travel straight proportional valve
Check that the value is not change regardless of operation
•Check pressure sensor of travel
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
8 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Carry out service diagnosis
9 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
Carry out service diagnosis
9 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.9 Arm out full lever & in proportional valve and controller for possible failure. operation
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
10 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
10 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
11 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
11 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm <Trouble> and relief. out is low, replace valve P1, P2 pressure is low. Free from dust entered in over load relief valve. Seat is free from abnormality
•See Service Diagnosis Data List Reset or replace Operation No.3 boom up full lever and relief
12 Over load relief valve Visual check (Rod side) Pressure is 32MPa or more in arm out When only relief pressure of arm <Trouble> and relief. out is low, replace valve P1, P2 pressure is low. Free from dust entered in over load relief valve. Seat is free from abnormality
13 Arm 1 spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
13 Arm 1 spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
14 Arm 2 spool <Trouble> P1 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
14 Arm 2 spool <Trouble> P1 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
47-12
47-12
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
15 Check arm 2 spool and Disassembly and recirculation investigation (spring <Trouble> side) Both P1, P2 pressures are low.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
15 Check arm 2 spool and Disassembly and recirculation investigation (spring <Trouble> side) Both P1, P2 pressures are low.
Free from abnormal resistance against Replace spool assembly sliding Spring is free from breakage.
16 Check lock valve poppet Visual check <Trouble> Both P1, P2 pressures are high.
Free from abnormal resistance against Replace sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface
16 Check lock valve poppet Visual check <Trouble> Both P1, P2 pressures are high.
Free from abnormal resistance against Replace sliding (Check on the casing side for Free from abnormal damage, etc on damage) outside surface
(9) Bucket digging is slow No.
(9) Bucket digging is slow
Sections
Contents/normal value
1 Bucket digging pressure Carry out service sensor diagnosis 2 Remote control valve
•See Service Diagnosis Data List Operation No.12 bucket digging full lever and relief
Corrective action, others Check and replace pressure sensor Check remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in bucket digging full lever and high When equipped with multi bucket digging idling operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List Operation No.13 Bucket digging full lever and in operation
4 Actual measuring current value of P1/P2 unload proportional valve
No.
Sections
Contents/normal value
1 Bucket digging pressure Carry out service sensor diagnosis 2 Remote control valve
•See Service Diagnosis Data List Operation No.12 bucket digging full lever and relief
Corrective action, others Check and replace pressure sensor Check remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in bucket digging full lever and high When equipped with multi bucket digging idling operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List Operation No.13 Bucket digging full lever and in operation
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.12 Bucket digging full proportional valve and controller for possible failure. lever & relief
4 Actual measuring current value of P1/P2 unload proportional valve
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.12 Bucket digging full proportional valve and controller for possible failure. lever & relief
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in bucket digging full lever and high idling operation
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in bucket digging full lever and high idling operation
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7MPa or more and P2 pump proportional valve pressure is 1.6 to 2.2MPa in bucket digging full lever and high idling operation.
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7MPa or more and P2 pump proportional valve pressure is 1.6 to 2.2MPa in bucket digging full lever and high idling operation.
8 Attachment boost solenoid command
Carry out service diagnosis
No.3 POWER BOOST Bucket digging COMP OFF, MEAS OFF
Check harness Replace solenoid valve
8 Attachment boost solenoid command
Carry out service diagnosis
No.3 POWER BOOST Bucket digging COMP OFF, MEAS OFF
9 Attachment boost solenoid secondary pressure
Measure switching valve secondary pressure
Check that pressure is 0MPa in bucket Replace solenoid valve digging full lever and high idling operation
9 Attachment boost solenoid secondary pressure
Measure switching valve secondary pressure
Check that pressure is 0MPa in bucket Replace solenoid valve digging full lever and high idling operation
Carry out service diagnosis
•See Service Diagnosis Data List Operation No.13 Bucket digging full lever & in operation
47-13
When there is difference between P1 and P2 pump pressures, check high pressure sensor
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Carry out service diagnosis
•See Service Diagnosis Data List Operation No.13 Bucket digging full lever & in operation
47-13
When there is difference between P1 and P2 pump pressures, check high pressure sensor
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Check harness Replace solenoid valve
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
10 Actual measuring current value of travel straight proportional valve
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Carry out service diagnosis
•See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief
Corrective action, others In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
No.
Sections
10 Actual measuring current value of travel straight proportional valve
Contents/normal value Carry out service diagnosis
•See Service Diagnosis Data List Operation No.12 Bucket digging full lever & relief
Corrective action, others In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
11 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in bucket digging full lever and high idling operation
11 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in bucket digging full lever and high idling operation
12 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
12 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
13 Check stroke limiter <Trouble> Both P1, P2 pressures are high.
Visual check
When piston is removed from cover, it Replace is free from abnormal resistance (Check on the casing side for against sliding damage.) Free from abnormal damage, etc on outside surface
13 Check stroke limiter <Trouble> Both P1, P2 pressures are high.
Visual check
When piston is removed from cover, it Replace is free from abnormal resistance (Check on the casing side for against sliding damage.) Free from abnormal damage, etc on outside surface
14 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
14 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
15 Main relief valve
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 Boom up full lever and relief
15 Main relief valve
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 Boom up full lever and relief
16 Travel straight spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
16 Travel straight spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17 Bucket spool <Trouble> Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
17 Bucket spool <Trouble> Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
18 Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief valve. Seat is free from abnormality.
Replace
18 Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief valve. Seat is free from abnormality.
Replace
(10)Bucket dump is slow No.
(10)Bucket dump is slow
Sections
Contents/normal value
1 Bucket dump pressure sensor
Carry out service diagnosis
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in bucket dump full lever and high When equipped with multi bucket dump idling operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List Operation No.14 Bucket dump full lever and relief
Corrective action, others
•See Service Diagnosis Data List Operation No.15 Bucket dump full lever and in operation
47-14
Check and replace pressure sensor Check remote control valve
When there is difference between P1 and P2 pump pressures, check high pressure sensor
No.
Sections
Contents/normal value
1 Bucket dump pressure sensor
Carry out service diagnosis
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in bucket dump full lever and high When equipped with multi bucket dump idling operation control valve, check it while changing lever pattern
3 Pump pressure sensor Carry out service diagnosis for P1, P2 pump pressures in operation.
•See Service Diagnosis Data List Operation No.14 Bucket dump full lever and relief
Corrective action, others
•See Service Diagnosis Data List Operation No.15 Bucket dump full lever and in operation
47-14
Check and replace pressure sensor Check remote control valve
When there is difference between P1 and P2 pump pressures, check high pressure sensor
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
4 Actual measuring current value of P1/P2 unload proportional valve
Contents/normal value
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.14 Bucket dump full for possible failure. lever & relief
4 Actual measuring current value of P1/P2 unload proportional valve
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5~1.2MPa in bucket dump full lever and high idling operation. Replace proportional valve
5 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5~1.2MPa in bucket dump full lever and high idling operation. Replace proportional valve
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve Carry out service diagnosis.
•No.9 E-1 P1 pump E-2 P2 pump
6 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve Carry out service diagnosis.
•No.9 E-1 P1 pump E-2 P2 pump
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7MPa or more and P2 pump proportional valve pressure is 0.9 to 1.4MPa in bucket dump full lever and high idling operation.
7 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1 pump proportional valve Replace proportional valve pressures is 2.7MPa or more and P2 pump proportional valve pressure is 0.9 to 1.4MPa in bucket dump full lever and high idling operation.
8 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief
8 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No.14 Bucket dump full lever & relief
Carry out service diagnosis
Carry out service diagnosis
•See Service Diagnosis Data List Operation No.15 Bucket dump full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
Carry out service diagnosis
Carry out service diagnosis
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List proportional valve and controller Operation No.14 Bucket dump full for possible failure. lever & relief
•See Service Diagnosis Data List Operation No.15 Bucket dump full lever & in operation
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
9 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in bucket dump full lever and high idling operation
9 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in bucket dump full lever and high idling operation
10 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBP2 port.)
10 P2 by-pass cut valve Visual check <Trouble> Only P2 pressure is low.
No problem for sliding ability of main Clean and replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBP2 port.)
11 Check stroke limiter <Trouble> Pilot pressure is low.
Visual check
Free from abnormal damage and wear Replace on outside of piston inside cover (Check on the casing side for damage.)
11 Check stroke limiter <Trouble> Pilot pressure is low.
Visual check
Free from abnormal damage and wear Replace on outside of piston inside cover (Check on the casing side for damage.)
12 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace damage and spring is free from control valve breakage
12 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace damage and spring is free from control valve breakage
13 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 Boom up full lever and relief
13 Main relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.3 Boom up full lever and relief
14 Travel straight spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
14 Travel straight spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface
Replace (Check on the casing side for damage)
15 Bucket spool <Trouble> Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15 Bucket spool <Trouble> Both P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
47-15
47-15
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
16 Over load relief valve
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Check targeted spool visually
Free from dust entered in over load relief valve. Seat is free from abnormality.
Corrective action, others Replace
(11)Swing does not move/slow No.
Sections
No.
Sections
16 Over load relief valve
Contents/normal value Check targeted spool visually
Free from dust entered in over load relief valve. Seat is free from abnormality.
Corrective action, others Replace
(11)Swing does not move/slow Contents/normal value
1 Swing pressure sensor Carry out service diagnosis
Corrective action, others
•See Service Diagnosis Data List Check and replace pressure Operation No.11 Swing full lever and sensor in operation Check remote control valve
No.
Sections
Contents/normal value
1 Swing pressure sensor Carry out service diagnosis
Corrective action, others
•See Service Diagnosis Data List Check and replace pressure Operation No.11 Swing full lever and sensor in operation Check remote control valve
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in boom up full lever and high idling When equipped with multi swing operation control valve, check it while changing lever pattern
2 Remote control valve
Measure directly remote Check that pressure is 3.0MPa or more Check remote control valve control pressure of in boom up full lever and high idling When equipped with multi swing operation control valve, check it while changing lever pattern
3 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
3 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
Visual check
No contamination on spool cover Clean or replace (short side) and orifice No damage on spool cover (long side) and shuttle
5 Shuttle valve <Trouble> Pilot pressure is low.
Visual check
No contamination on spool cover Clean or replace (short side) and orifice No damage on spool cover (long side) and shuttle
6 Pump pressure sensor Carry out service diagnosis for P2 pump pressures in operation
•See Service Diagnosis Data List Check high pressure sensor Operation No.11 Swing full lever and in operation
6 Pump pressure sensor Carry out service diagnosis for P2 pump pressures in operation
•See Service Diagnosis Data List Check high pressure sensor Operation No.11 Swing full lever and in operation
7 Actual measuring current value of P2 unload proportional valve
•No.8 D-2 P2 unload valve (cut valve) In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.11 Swing full lever & in measured value, check proportional valve and controller operation for possible failure.
7 Actual measuring current value of P2 unload proportional valve
•No.8 D-2 P2 unload valve (cut valve) In case where the reading is largely differed from the actually •See Service Diagnosis Data List Operation No.11 Swing full lever & in measured value, check proportional valve and controller operation for possible failure.
8 Secondary pressure of Measure the P2 unload proportional proportional valve valve secondary pressure directly at the ports A5 of 8 sections solenoid block
Check that P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in swing full lever and high idling operation
8 Secondary pressure of Measure the P2 unload proportional proportional valve valve secondary pressure directly at the ports A5 of 8 sections solenoid block
Check that P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa in swing full lever and high idling operation
9 Actual measuring Carry out service current value of P2 diagnosis pump proportional valve
•No.9 E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.11 Swing full lever & in proportional valve and controller for possible failure. operation
9 Actual measuring Carry out service current value of P2 diagnosis pump proportional valve
•No.9 E-2 P2 pump
10 Secondary pressure of Measure the pump P2 pump proportional proportional valve secondary pressure valve directly (Ports a3, a4)
Check that P2 pump proportional valve Replace proportional valve pressure is 2.7MPa or more in swing full lever and high idling operation
10 Secondary pressure of Measure the pump P2 pump proportional proportional valve secondary pressure valve directly (Ports a3, a4)
Check that P2 pump proportional valve Replace proportional valve pressure is 2.7MPa or more in swing full lever and high idling operation
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
11 Actual measuring current value of travel straight proportional valve (Check this trouble by only swing operation)
4
Swing parking brake solenoid
5 Shuttle valve <Trouble> Pilot pressure is low.
11 Actual measuring current value of travel straight proportional valve (Check this trouble by only swing operation)
Carry out service diagnosis
Carry out service diagnosis
47-16
4
Swing parking brake solenoid
Carry out service diagnosis
Carry out service diagnosis
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.11 Swing full lever & in proportional valve and controller for possible failure. operation
Check that the value is not change regardless of operation
•Check pressure sensor of travel
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
47-16
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
12 Secondary pressure of travel straight proportional valve (Check this trouble by only swing operation)
Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
13 Remote control valve
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
12 Secondary pressure of travel straight proportional valve (Check this trouble by only swing operation)
Measure directly the proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
13 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
14 Travel straight spool <Trouble> P2 pressure is low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
14 Travel straight spool <Trouble> P2 pressure is low.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15 Swing spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
15 Swing spool <Trouble> P2 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
16 Swing relief valve <Trouble> Relief pressure is low.
Check set pressure
â&#x20AC;˘See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief
16 Swing relief valve <Trouble> Relief pressure is low.
Check set pressure
â&#x20AC;˘See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief
17 Swing motor
Visual check
Inner parts (cylinder block, piston, valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
17 Swing motor
Visual check
Inner parts (cylinder block, piston, valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
18 Swing reduction gear oil Take sample oil from swing reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
18 Swing reduction gear oil Take sample oil from swing reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
19 Swing reduction
Tooth surface is not worn abnormally and is not chipped.
Replace
19 Swing reduction
Tooth surface is not worn abnormally and is not chipped.
Replace
Visual check
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
(12)Noise occurred at swing operation No.
Sections
Visual check
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
(12)Noise occurred at swing operation Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
1 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
1 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness
2
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
2
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
3 Boost check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
3 Boost check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
4 By-pass check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
4 By-pass check valve (Sound of cavitation at stopping)
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
5 Swing motor (Brake valve/friction plate)
Visual check
Disassemble and inspect abnormal wear and scuffing
Replace
5 Swing motor (Brake valve/friction plate)
Visual check
Disassemble and inspect abnormal wear and scuffing
Replace
6 Swing motor piston
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
6 Swing motor piston
Visual check
When removing, free from abnormal resistance against sliding Spring is free from breakage.
Replace
47-17
47-17
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
7 Swing reduction gear oil Take sample oil from swing reduction gear drain.
Sampling oil does not include a lot of metal powder.
8 Swing reduction
Tooth surface has no abnormally worn Replace and chipped.
Visual check
Disassemble and inspect reduction gear
(13)Swing drifts on a slope while swing control lever is in neutral position No.
Sections
Contents/normal value
1 Swing pressure sensor Carry out service diagnosis
•Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1MPa.
No.
Sections
Contents/normal value
Corrective action, others
7 Swing reduction gear oil Take sample oil from swing reduction gear drain.
Sampling oil does not include a lot of metal powder.
8 Swing reduction
Tooth surface has no abnormally worn Replace and chipped.
Visual check
Disassemble and inspect reduction gear
(13)Swing drifts on a slope while swing control lever is in neutral position Corrective action, others Check and replace pressure sensor
No.
Sections
Contents/normal value
1 Swing pressure sensor Carry out service diagnosis
•Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1MPa.
Corrective action, others Check and replace pressure sensor
2 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
2 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
3 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness Check parking brake release switch
3 Swing parking brake solenoid
Carry out service diagnosis
No.3 F-2 SWING-BRAKE Lever neutral: COMP ON, MEAS ON Swing: COMP OFF, MEAS OFF
Check swing pressure sensor Check harness Check parking brake release switch
4
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
4
Measurement of solenoid valve A2 port
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
5 Swing motor (Brake valve/friction plate)
Visual check
Disassemble and inspect abnormal wear and scuffing
Replace
5 Swing motor (Brake valve/friction plate)
Visual check
Disassemble and inspect abnormal wear and scuffing
Replace
6 Parking brake
Visual check
Piston and friction plate do not have abnormal resistance against sliding Free from spring damage
Replace
6 Parking brake
Visual check
Piston and friction plate do not have abnormal resistance against sliding Free from spring damage
Replace
(14)Swing drifts at stopping No.
(14)Swing drifts at stopping
Sections
1 Shuttle valve <Trouble> Pilot pressure is low
Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
No contamination on spool cover Clean or replace (short side) and orifice. No damage on spool cover (long side) and shuttle.
1 Shuttle valve <Trouble> Pilot pressure is low
2 Swing pressure sensor Carry out service diagnosis
•Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1MPa.
2 Swing pressure sensor Carry out service diagnosis
•Engine stop & starter key ON All pilot low pressure sensors are within range of 0 to 0.1MPa.
3 Swing relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief
3 Swing relief valve <Trouble> Relief pressure is low.
Check set pressure
•See Service Diagnosis Data List Reset or replace Operation No.10 Swing full lever and relief
4 Anti-reaction valve
Visual check
Free from dirt entering Clean or replace Sliding part should be free from foreign matter entering, abnormal damage and wear.
4 Anti-reaction valve
Visual check
Free from dirt entering Clean or replace Sliding part should be free from foreign matter entering, abnormal damage and wear.
5 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
5 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
6 Swing motor
Visual check
6 Swing motor
Visual check
Visual check
Inner parts (cylinder block, piston, valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
47-18
Replace pressure sensor
Replace
Visual check
No contamination on spool cover Clean or replace (short side) and orifice. No damage on spool cover (long side) and shuttle.
Inner parts (cylinder block, piston, valve brake etc) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
47-18
Replace pressure sensor
Replace
47. TROUBLESHOOTING (BY TROUBLE) (15)Travel speed is slow/poor No.
Sections
(15)Travel speed is slow/poor Contents/normal value
1 Travel right and left pressure sensor
Carry out service diagnosis
2 Remote control valve
3 Actual measuring current value of P1/P2 unload proportional valve
47. TROUBLESHOOTING (BY TROUBLE)
Corrective action, others
•See Service Diagnosis Data List Check and replace pressure Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
No.
Sections
Contents/normal value
Corrective action, others
1 Travel right and left pressure sensor
Carry out service diagnosis
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve control pressure of in travel right (left), forward (reverse) travel right and left full lever and high idling operation
2 Remote control valve
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve control pressure of in travel right (left), forward (reverse) travel right and left full lever and high idling operation
Carry out service diagnosis
3 Actual measuring current value of P1/P2 unload proportional valve
Carry out service diagnosis
•No.9 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
•See Service Diagnosis Data List Check and replace pressure Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
•No.9 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
4 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0MPa Travel left (P2 unload): 0.5 to 1.0MPa
4 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0MPa Travel left (P2 unload): 0.5 to 1.0MPa
5 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
5 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
6 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7MPa or more Travel left (P2 pump): 2.7MPa or more
6 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7MPa or more Travel left (P2 pump): 2.7MPa or more
7 Actual measuring current value of travel straight proportional valve
Check that the value is not change regardless of operation
7 Actual measuring current value of travel straight proportional valve
Check that the value is not change regardless of operation
Carry out service diagnosis
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
8 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure 9 Remote control valve
•Check voltage of low pressure sensor other than sensor for travel •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
Check targeted remote Check that spool is free from abnormal Replace damage and spring is free from control valve breakage Check sealing ability of shuttle valve and entry of dust in orifice
47-19
Carry out service diagnosis
•See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
8 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure 9 Remote control valve
•Check voltage of low pressure sensor other than sensor for travel •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
Check targeted remote Check that spool is free from abnormal Replace damage and spring is free from control valve breakage Check sealing ability of shuttle valve and entry of dust in orifice
47-19
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
10 Travel straight spool <Trouble> P1 pressure is high.
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Visual check
Corrective action, others
No.
Sections
Contents/normal value
Replace (Check on the casing side for damage)
10 Travel straight spool <Trouble> P1 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
11 Travel spool Visual check of targeted When removing, free from abnormal <Trouble> spool resistance against sliding Pump pressure is high. Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
11 Travel spool Visual check of targeted When removing, free from abnormal <Trouble> spool resistance against sliding Pump pressure is high. Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
12 Travel motor relief valve Check set pressure
Check P1 and P2 pump pressures are 32MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed.
12 Travel motor relief valve Check set pressure
Check P1 and P2 pump pressures are 32MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed.
13 Travel motor
Visual check
Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
13 Travel motor
Visual check
Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
14 Parking brake in travel motor
Visual check
When removing, free from abnormal resistance against sliding No sticking on friction plate and separator plate
Replace
14 Parking brake in travel motor
Visual check
When removing, free from abnormal resistance against sliding No sticking on friction plate and separator plate
Replace
15 Travel reduction gear oil Take sample oil from travel reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
15 Travel reduction gear oil Take sample oil from travel reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
16 Travel reduction
Tooth surface is not worn abnormally and is not chipped.
Replace
16 Travel reduction
Tooth surface is not worn abnormally and is not chipped.
Replace
Visual check
(16)Travel deviation No.
Visual check
Corrective action, others
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Visual check
(16)Travel deviation
Sections
Contents/normal value
1 Travel right and left pressure sensor
Carry out service diagnosis
2 Remote control valve
3 Actual measuring current value of travel straight proportional valve
Corrective action, others
Sections
Contents/normal value
Corrective action, others
1 Travel right and left pressure sensor
Carry out service diagnosis
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve control pressure of in travel right (left), forward (reverse) travel right and left full lever and high idling operation
2 Remote control valve
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve control pressure of in travel right (left), forward (reverse) travel right and left full lever and high idling operation
Carry out service diagnosis
3 Actual measuring current value of travel straight proportional valve
Carry out service diagnosis
4 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure
•See Service Diagnosis Data List Check and replace pressure Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
No.
Check that the value is not change regardless of operation •See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•Check voltage of low pressure sensor other than sensor for travel •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
47-20
4 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure
•See Service Diagnosis Data List Check and replace pressure Operation No.18 Travel right full lever sensor and idling Check remote control valve Operation No.19 Travel left full lever and idling
Check that the value is not change regardless of operation •See Service Diagnosis Data List Operation No. 1 Operation is nil Operation No.18 Travel right full lever & idling Operation No.19 Travel left full lever & idling
•Check voltage of low pressure sensor other than sensor for travel •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
0.8MPa or less in high idling operation Replace proportional valve regardless of neutral/operation
47-20
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
5 Actual measuring current value of P1/P2 unload proportional valve
Contents/normal value Carry out service diagnosis
Corrective action, others
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
5 Actual measuring current value of P1/P2 unload proportional valve
Contents/normal value Carry out service diagnosis
Operation No.19 Travel left full lever & idling
Corrective action, others
•No.8 D-1 P1 unload valve (cut valve) In case where the reading is D-1 P2 unload valve (cut valve) largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
6 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0MPa Travel left (P2 unload): 0.5 to 1.0MPa
6 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 unload): 0.5 to 1.0MPa Travel left (P2 unload): 0.5 to 1.0MPa
7 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
7 Actual measuring Carry out service current value of P1/P2 diagnosis pump proportional valve
•No.9 E-1 P1 pump E-2 P2 pump
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling Operation No.19 Travel left full lever & idling
8 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Operation No.19 Travel left full lever & idling
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7MPa or more Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2
Exchange delivery pipe Check the direction of deviation of P1 for P2
10 Remote control valve
11 Travel straight spool <Trouble> P1 pressure is high.
In case where the reading is largely differed from the actually measured value, check •See Service Diagnosis Data List Operation No.18 Travel right full lever proportional valve and controller for possible failure. & idling
If the direction is changed, inspect a pump. If the direction is not changed, inspect a valve and travel unit.
8 Secondary pressure of Measure the pump P1, P2 pump proportional valve proportional valve secondary pressure directly (Ports a3, a4)
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of followings in travel right (left), forward (reverse) full lever and high idling operation Travel right (P1 pump): 2.7MPa or more Travel left (P2 pump): 2.7MPa or more
9 Exchange P1 for P2
Exchange delivery pipe Check the direction of deviation of P1 for P2
If the direction is changed, inspect a pump. If the direction is not changed, inspect a valve and travel unit.
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
10 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage Check sealing ability of shuttle valve and entry of dust in orifice
Visual check
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
11 Travel straight spool <Trouble> P1 pressure is high.
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
12 Travel spool Visual check of targeted When removing, free from abnormal <Trouble> spool resistance against sliding Pump pressure is high. Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
12 Travel spool Visual check of targeted When removing, free from abnormal <Trouble> spool resistance against sliding Pump pressure is high. Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
13 Travel motor relief valve Check set pressure
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed. Replace as necessary
13 Travel motor relief valve Check set pressure
If P1 is low, right travel motorÅfs relief valve is failed. If P2 is low, left travel motorÅfs relief valve is failed. Replace as necessary
Check P1 and P2 pump pressures are 32MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
47-21
Check P1 and P2 pump pressures are 32MPa or more in right and left travel levers full lever (relief operation at locked crawler belt) and high idling
47-21
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
14 Travel motor
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Visual check
Corrective action, others
No.
Sections
Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
14 Travel motor
15 Travel reduction gear oil Take sample oil from travel reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
16 Travel reduction
Visual check
Tooth surface is not worn abnormally and is not chipped.
17 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
18 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
Sections
Contents/normal value
Corrective action, others
Inner parts (piston, cylinder block, valve plate, brake valve spool) are to be free from abnormal resistance against sliding. Free from abnormal damage, etc on outside surface (brake plate etc)
Replace
15 Travel reduction gear oil Take sample oil from travel reduction gear drain
Sampling oil does not include a lot of metal powder.
Disassemble and inspect reduction gear
Replace
16 Travel reduction
Visual check
Tooth surface is not worn abnormally and is not chipped.
Replace
Replace
17 Pump regulator
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring free from breakage, damage, etc.
Replace
18 Pump
Visual check
When removing, inside parts (cylinder Replace block, piston, valve plate, shaft, etc.) are free from abnormal resistance against sliding, abnormal damage, etc.
(17)Travel 1/2 speed cannot be switched (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change.) No.
Contents/normal value
Corrective action, others
Visual check
(17)Travel 1/2 speed cannot be switched (In case of the traveling under heavy loading (for example traveling on a slope or traveling on a soft ground), the speed may sometimes does not change from 1st to 2nd because this machine equips the function of automatic speed change.) No.
Sections
Contents/normal value
Corrective action, others
1 Travel 1/2 speed switching solenoid
Carry out service diagnosis
Switch travel 1/2 speed to 2nd speed No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON
Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster
1 Travel 1/2 speed switching solenoid
Carry out service diagnosis
Switch travel 1/2 speed to 2nd speed No.3 F-3 1/2-TRAVEL Lever neutral COMP OFF, MEAS OFF Travel operation COMP ON, MEAS ON
Check pressure sensor Check harness Check travel 1/2 speed switch on gauge cluster
2 Travel 1/2 speed switching solenoid
Measure A3 port pressure on solenoid valve
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
2 Travel 1/2 speed switching solenoid
Measure A3 port pressure on solenoid valve
Lever neutral: 0MPa In operation: 4MPa or more
Replace solenoid valve
3 1/2 speed switching spool in travel motor
Visual check
Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for breakage damage)
3 1/2 speed switching spool in travel motor
Visual check
Check that spool is free from abnormal Replace damage and spring is free from (Check on the casing side for breakage damage)
4 1/2 speed switching orifice in travel motor
Visual check
Free from entry of dust
Remove dust or replace
4 1/2 speed switching orifice in travel motor
Visual check
Free from entry of dust
Remove dust or replace
5 Tilting piston in travel motor
Visual check
Free from abnormal wear on piston and seal
Replace (Check on the casing side for damage)
5 Tilting piston in travel motor
Visual check
Free from abnormal wear on piston and seal
Replace (Check on the casing side for damage)
(18)Machine does not stay on a slope in traveling No.
Sections
(18)Machine does not stay on a slope in traveling
Contents/normal value
Corrective action, others
1 Pilot pressure sensor
Carry out service diagnosis
â&#x20AC;˘Engine stop & starter key switch is ON Check pressure sensor and Targeted pilot low pressure sensor is replace as necessary in range of 0 to 0.1MPa Check remote control valve
2 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
47-22
No.
Sections
Contents/normal value
Corrective action, others
1 Pilot pressure sensor
Carry out service diagnosis
â&#x20AC;˘Engine stop & starter key switch is ON Check pressure sensor and Targeted pilot low pressure sensor is replace as necessary in range of 0 to 0.1MPa Check remote control valve
2 Remote control valve
Check targeted remote Check that spool is free from abnormal Replace control valve damage and spring is free from breakage
47-22
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
Contents/normal value
Corrective action, others
3 Parking brake in travel motor
Visual check
When removing, free from abnormal resistance against sliding Spring free from breakage, damage, etc.
Replace
3 Parking brake in travel motor
Visual check
When removing, free from abnormal resistance against sliding Spring free from breakage, damage, etc.
Replace
4 Orifice of passage for parking brake in travel motor
Visual check
Free from entry of dust
Remove dust or replace
4 Orifice of passage for parking brake in travel motor
Visual check
Free from entry of dust
Remove dust or replace
(19)Machine does not travel straight in simultaneous operation of traveling and attachment No.
Sections
1 Actual measuring current value of travel straight proportional valve
Contents/normal value Carry out service diagnosis
Corrective action, others
No.8 D-3 S-TRAVEL is should be COMP 590mA and MEAS 560 to 620mA in both travel full lever and in boom up full lever at high idling
•Check voltage of low pressure sensor other than travel sensor
2 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure
Check secondary pressure is within range of 1.8 to 2.2MPa in both travel full lever and in boom up full lever at high idling
Replace proportional valve
3 Travel straight spool
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Visual check
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight) No.
Sections
Contents/normal value
1 Pressure sensor for optional attachment
Carry out service diagnosis
2 Remote control valve
3 Actual measuring current value of P1/P2 unload proportional valve
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief
Corrective action, others
No.
Sections
1 Actual measuring current value of travel straight proportional valve
Contents/normal value Carry out service diagnosis
Corrective action, others
No.8 D-3 S-TRAVEL is should be COMP 590mA and MEAS 560 to 620mA in both travel full lever and in boom up full lever at high idling
•Check voltage of low pressure sensor other than travel sensor
2 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure
Check secondary pressure is within range of 1.8 to 2.2MPa in both travel full lever and in boom up full lever at high idling
Replace proportional valve
3 Travel straight spool
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
Visual check
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
(20)Breaker works slowly and power is poor (In case of conflux, check p1 unload/pump and travel straight) No.
Sections
Contents/normal value Carry out service diagnosis
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0 control pressure of in optional attachment full lever and travel right and left high idling operation
2 Remote control valve
Measure directly remote Check that pressure is 2.1MPa or more Check remote control valve0 control pressure of in optional attachment full lever and travel right and left high idling operation
Carry out service diagnosis
3 Actual measuring current value of P1/P2 unload proportional valve
Carry out service diagnosis
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief
Corrective action, others
1 Pressure sensor for optional attachment
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief
Check and replace pressure senso Check remote control valve
(19)Machine does not travel straight in simultaneous operation of traveling and attachment
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief
Check and replace pressure senso Check remote control valve
•In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
4 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa
4 Secondary pressure of Measure the P1, P2 unload proportional valve proportional valve secondary pressure directly at the ports A7 and A5 of 8 sections solenoid block
Check that P1/P2 unload secondary Replace proportional valve pressures are within the range of 0.5 to 1.2MPa
5 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever & relief
5 Actual measuring current value of travel straight proportional valve
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever & relief
Carry out service diagnosis
•Check voltage of low pressure sensor other than sensor for optional attachment •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
47-23
Carry out service diagnosis
•Check voltage of low pressure sensor other than sensor for optional attachment •In case where the reading is largely differed from the actually measured value, check proportional valve and controller for possible failure.
47-23
47. TROUBLESHOOTING (BY TROUBLE) No.
Sections
47. TROUBLESHOOTING (BY TROUBLE) Contents/normal value
Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
6 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in optional attachment full lever and high idling operation
6 Secondary pressure of Measure directly the travel straight proportional valve proportional valve secondary pressure at the ports A6 (travel straight) of 8 sections solenoid block
Check that travel straight secondary Replace proportional valve pressure is 2.7MPa or more in optional attachment full lever and high idling operation
7 P1 by-pass cut valve Visual check <Trouble> Only P1 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
7 P1 by-pass cut valve Visual check <Trouble> Only P1 pressure is low.
No problem for sliding ability of main Clean or replace poppet and no contamination on orifice No problem for sliding ability of internal piston (Check it through PBp2 port.)
8 Relief pressure
Check set pressure
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief (Set value of factory shipment is 24.5MPa.)
Reset or replace
8 Relief pressure
Check set pressure
•See Service Diagnosis Data List Operation No.16 P2 side OPT full lever and relief (Set value of factory shipment is 24.5MPa.)
9 Remote control valve
Check targeted remote Check sealing ability of shuttle valve control valve and entry of dust in orifice.
Replace
9 Remote control valve
Check targeted remote Check sealing ability of shuttle valve control valve and entry of dust in orifice.
Replace
10 Travel straight spool <Trouble> P1 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
10 Travel straight spool <Trouble> P1 pressure is high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
11 Spool for optional attachment <Trouble> P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
11 Spool for optional attachment <Trouble> P1, P2 pressures are high.
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
Replace (Check on the casing side for damage)
12 Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief valve Seat is free from abnormality.
Replace
12 Over load relief valve
Check targeted spool visually
Free from dust entered in over load relief valve Seat is free from abnormality.
Replace
(21)Selector valve for option malfunctions: Breaker circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
Contents/normal value
Corrective action, others
Reset or replace
(21)Selector valve for option malfunctions: Breaker circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
Contents/normal value
Corrective action, others
1 N&B selector spool
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
1 N&B selector spool
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage
Replace (Check on the casing side for damage)
2 N&B selector solenoid
Screw for emergency
Check that the error indication is disappeared by turning emergency screw
Replace solenoid valve
2 N&B selector solenoid
Screw for emergency
Check that the error indication is disappeared by turning emergency screw
Replace solenoid valve
3 N&B selector solenoid
Carry out service diagnosis
•No.11 F-4 Option selector is B mode Check solenoid valve COMP ON, MEAS ON Check harness Spool position BRK Selector switch BRK
3 N&B selector solenoid
Carry out service diagnosis
•No.11 F-4 Option selector is B mode Check solenoid valve COMP ON, MEAS ON Check harness Spool position BRK Selector switch BRK
4 N&B selector pressure sensor
Carry out service diagnosis
•No.16 B-11 Data List 3.0MPa at B mode and 0.0MPa at A mode
4 N&B selector pressure sensor
Carry out service diagnosis
•No.16 B-11 Data List 3.0MPa at B mode and 0.0MPa at A mode
47-24
Check pressure sensor Check harness
47-24
Check pressure sensor Check harness
47. TROUBLESHOOTING (BY TROUBLE) (22)Selector valve for option malfunctions: Nibbler circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
Contents/normal value
Corrective action, others
1 N&B selector spool
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
2 N&B selector solenoid
Carry out service diagnosis
â&#x20AC;˘No.11 F-4 Option selector is A mode Check solenoid valve COMP OFF, MEAS OFF Check harness Spool position NIB Selector switch NIB
47-25
Replace (Check on the casing side for damage)
47. TROUBLESHOOTING (BY TROUBLE) (22)Selector valve for option malfunctions: Nibbler circuit is not obtained. (Indication of failure is displayed. For reference, see "Table47-1 Action of optional selector solenoid valve") No.
Sections
Contents/normal value
Corrective action, others
1 N&B selector spool
Visual check
When removing, free from abnormal resistance against sliding Free from abnormal damage, etc on outside surface Spring is free from breakage.
2 N&B selector solenoid
Carry out service diagnosis
â&#x20AC;˘No.11 F-4 Option selector is A mode Check solenoid valve COMP OFF, MEAS OFF Check harness Spool position NIB Selector switch NIB
47-25
Replace (Check on the casing side for damage)
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
Table47-1 Action of optional selector solenoid valve
No.
1 2
Safety lock Safety lock Engine lever SW's lever relay's condition input output Running
ON
OFF
Work mode
Optional selector valve COMP. MEAS.
A
OFF
Selector valve Spool detecting position pressure sensor
Warning display
Table47-1 Action of optional selector solenoid valve
Failure diagnosis display
No.
Nibbler
Normal —
—
1
[F042] displayed simultaneously
2
Running
ON
OFF
A
ON
Breaker
"SELECTOR VALVE Normal FAILURE"
Running
ON
OFF
A
OFF
Breaker
Normal
4
Running
ON
OFF
A
ON
Nibbler
Normal —
[F042] displayed
5
Running
ON
OFF
B
ON
Breaker
Normal —
—
Running
ON
OFF
B
OFF
Nibbler
Normal
"SELECTOR VALVE FAILURE"
[F043] displayed simultaneously
6
Running
ON
OFF
B
ON
N&B
Normal
"SELECTOR VALVE FAILURE"
—
Running
ON
OFF
B
OFF
Breaker
Running
ON
OFF
—
—
—
Failure
3
6 7 8 9
10 Stopping
"SELECTOR VALVE FAILURE"
Normal —
—
[F043] displayed
"SELECTOR VALVE FAILURE"
[B113] displayed
Safety lock Safety lock Engine lever SW's lever relay's condition input output Running
ON
OFF
Work mode
Optional selector valve COMP. MEAS.
A
OFF
Selector valve Spool detecting position pressure sensor
Warning display
Failure diagnosis display
Nibbler
Normal —
— [F042] displayed simultaneously
Running
ON
OFF
A
ON
Breaker
"SELECTOR VALVE Normal FAILURE"
Running
ON
OFF
A
OFF
Breaker
Normal
4
Running
ON
OFF
A
ON
Nibbler
Normal —
[F042] displayed
5
Running
ON
OFF
B
ON
Breaker
Normal —
—
Running
ON
OFF
B
OFF
Nibbler
Normal
"SELECTOR VALVE FAILURE"
[F043] displayed simultaneously
Running
ON
OFF
B
ON
N&B
Normal
"SELECTOR VALVE FAILURE"
—
Running
ON
OFF
B
OFF
Breaker
Running
ON
OFF
—
—
—
Failure
3
7 8 9
"SELECTOR VALVE FAILURE"
Normal —
—
[F043] displayed
"SELECTOR VALVE FAILURE"
[B113] displayed
—
—
—
—
—
—
—
—
10 Stopping
—
—
—
—
—
—
—
—
11
—
OFF
—
—
—
—
—
—
—
11
—
OFF
—
—
—
—
—
—
—
12
—
—
ON
—
—
—
—
—
—
12
—
—
ON
—
—
—
—
—
—
47-26
47-26
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
47.2
ELECTRIC SYSTEMS
47.2
ELECTRIC SYSTEMS
47.2.1
WIRING CHECKING PROCEDURE
47.2.1
WIRING CHECKING PROCEDURE
Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding.
Check for continuity between connector terminals, presence or absences of short-circuit with other wires, and presence or absences of short-circuit with machine body grounding.
CONNECTOR
WIRE
(1) Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors,) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.
JUMPER WIRE TESTER FRAME BODY GROUNDING
The resistance is 1M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.
(When both ends measurement is difficult because of long distance between connectors,) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition.
JUMPER WIRE TESTER FRAME BODY GROUNDING
(2) Checking for presence or absence of short-circuit with machine body Measure the resistance using tester. Pull out opposite connector first.
or more, it is in normal TESTER
(3) Checking for presence or absence of short-circuit between wirings. Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1M condition.
TESTER
The resistance is 1M or more when the terminal on one side is not connected to frame body grounding with jumper wire, it is in normal condition.
(2) Checking for presence or absence of short-circuit with machine body Measure the resistance using tester. Pull out opposite connector first. When the resistance is 1M condition.
WIRE
(1) Checking for disconnection between connectors. (When both ends measurement is easy because of short distance between connectors,) Measure the resistance using tester. Pull out opposite connector first. When the resistance is zero (0), it is in normal condition.
TESTER
(When both ends measurement is difficult because of long distance between connectors,) Measure the resistance using tester. Pull out opposite connector first. Where the resistance is zero (0), if the terminal on one side is connected to frame body grounding with jumper wire, it is in normal condition.
CONNECTOR
When the resistance is 1M condition.
or more, it is in normal TESTER
FRAME BODY GROUNDING
(3) Checking for presence or absence of short-circuit between wirings. Measure the resistance using tester. Pull out opposite connector first.
or more, it is in normal TESTER
47-27
When the resistance is 1M condition.
or more, it is in normal TESTER
47-27
FRAME BODY GROUNDING
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
(4) Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.
INSERT
MALE TERMINAL
FEMALE TERMINAL
(4) Checking connector terminal for contact Insert male terminal into female terminal unit, and then check that the inserting force is equivalent to other female terminals. If looseness is there, replace the female terminal with new one. Clean the dirt terminal.
INSERT
MALE TERMINAL
Do not insert the male terminal the thickness differs. It may cause loose connection.
Do not insert the male terminal the thickness differs. It may cause loose connection.
(5) Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.
(5) Caution which should be paid in measuring voltage When measuring the power supply to electric equipment at connector position with the grounding terminal contained inside of connector, measure the voltage between grounding inside of connector and power terminal. When measuring the voltage between frame body grounding and power source, the disconnection of wiring to grounding inside of connector cannot be identified. Since the voltage may vary between with connector connected and with connector not connected. Measure the voltage with each connector connected whenever possible.
(6) Checking the general view of connector
CRIMPED PART
a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.
47-28
RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG
FEMALE TERMINAL
(6) Checking the general view of connector
CRIMPED PART
a. Check the terminal crimped condition. Pull one electric cable with the about 3kg force, and make sure that the cable does not come out of the terminal. When came out, replace the terminal and crimp it again. b. Check connector for imperfect insertion Check that all top ends form a line on the same position as seen from the connector engaged side. When moved along, push it in further through wire inserting hole. c. Check connector for intruding of water. Pull out the connector and check that the inside is free from intruding of water. When water intruding is found, check rubber plug for damage and also that the sealing is fitted properly.
47-28
RUBBER PLUG RECEPTACLE. CONTACT PLUG SEALING (is housed in plug) DOUBLE LOCK PLATE FOR PLUG DOUBLE LOCK PLATE FOR CAP CAP TAB.CONTACT RUBBER PLUG
47. TROUBLESHOOTING (BY TROUBLE) (7) When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations.
47. TROUBLESHOOTING (BY TROUBLE) (7) When abnormality occurs at intervals When the abnormality situation can not be reoccurred during checking operation, try the following operations.
a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine.
a. Check that variable of display exists or not on the service diagnosis screen while shaking the harness or giving shock by operating the machine.
b. Check that variables of resistance and voltage exist or not using tester while shaking the harness.
b. Check that variables of resistance and voltage exist or not using tester while shaking the harness.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.
c. Turn starter switch on and apply electricity continuously, and check it again after the temperature of wiring and equipment was raised.
(8) Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion.
(8) Checking on body grounding Check attaching bolts of grounding terminal for loosening. And also check that there is no loose connection due to corrosion.
There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light.
47-29
Block of grounding is located under floor plate of cab.
There are multiple groundings like centralized grounding box shown in the figure and battery grounding, engine grounding, horn grounding fixed together with horn, body grounding placed on attaching section of boom working light.
47-29
Block of grounding is located under floor plate of cab.
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
47.2.2
47.2.2
TROUBLE
TROUBLE
(1) Engine does not stop.
(1) Engine does not stop.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(3) Auto accel does not actuate. (The engine speed does not automatically slow down.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.)
(5) Wiper does not function.
(5) Wiper does not function.
47-30
47-30
47. TROUBLESHOOTING (BY TROUBLE) (1) Engine does not stop. No.
(1) Engine does not stop.
Sections
Contents/normal value
1 Starter key switch
Check signal of starter key switch ON by carrying out service diagnosis.
2 Engine forcible stop relay
3 Wiring
Corrective action, others
Sections
Contents/normal value
Corrective action, others
Check signal of starter key switch ON by carrying out service diagnosis.
When ON is displayed No.4 K-3 Key switch Check on engine forcible stop with the starter switch OFF at starter key switch OFF position relay OFF, then pull out R-25 ON at starter key switch ON position engine forcible stop relay and carry out the service diagnosis.
2 Engine forcible stop relay
When ON is displayed No.4 K-3 Key switch Check on engine forcible stop with the starter switch OFF at starter key switch OFF position relay OFF, then pull out R-25 ON at starter key switch ON position engine forcible stop relay and carry out the service diagnosis.
Voltage between line 0V when starter switch is OFF No.62 among starter switch, engine forcible stop relay, mechatro controller and the body grounding
3 Wiring
Voltage between line 0V when starter switch is OFF No.62 among starter switch, engine forcible stop relay, mechatro controller and the body grounding
Check harness Check diode D-9 between starter switch and auto idling stop relay 1
Sections
Contents/normal value
Corrective action, others
No.1 fuse (5A)
Not blown fuse
2 Mechatro controller
Accel control
Engine speed varies according to Check mechatro controller and accel potentiometer operation. replace as necessary (Use remote control because the auto accel function is working.)
3 Wiring
Transmission circuit line See "WIRING CHECKING No.770 from mechatro PROCEDURE" controller to gauge cluster
4 Gauge cluster
Gauge cluster
Check harness Replace fuse
Check harness Check diode D-9 between starter switch and auto idling stop relay 1
No.
Sections
Contents/normal value
Corrective action, others
1 Fuse
No.1 fuse (5A)
Not blown fuse
2 Mechatro controller
Accel control
Engine speed varies according to Check mechatro controller and accel potentiometer operation. replace as necessary (Use remote control because the auto accel function is working.)
Repair wiring
3 Wiring
Transmission circuit line See "WIRING CHECKING No.770 from mechatro PROCEDURE" controller to gauge cluster
Repair wiring
Replace gauge cluster
4 Gauge cluster
Gauge cluster
Replace gauge cluster
(3) Auto accel does not actuate. (The engine speed does not automatically slow down). Sections
No.4 K-3 Key switch Check continuity between OFF at starter key switch OFF position terminals of starter switch using ON at starter key switch ON position tester
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display.
1 Fuse
No.
No.
1 Starter key switch
No.4 K-3 Key switch Check continuity between OFF at starter key switch OFF position terminals of starter switch using ON at starter key switch ON position tester
(2) "CPU DATA COMMUNICATION ERROR" is displayed on multi display. No.
47. TROUBLESHOOTING (BY TROUBLE)
Contents/normal value
Check harness Replace fuse
(3) Auto accel does not actuate. (The engine speed does not automatically slow down). Corrective action, others
No.
Sections
Contents/normal value
Corrective action, others
1 Engine coolant temperature
Check engine coolant No.2 G-5 WATER TEMP temperature by carrying Auto accel does not work in the out service diagnosis. temperature -15°C or less. Warm up and raise the coolant temperature to – 15°C or more
Replace engine coolant sensor
1 Engine coolant temperature
Check engine coolant No.2 G-5 WATER TEMP temperature by carrying Auto accel does not work in the out service diagnosis. temperature -15°C or less. Warm up and raise the coolant temperature to – 15°C or more
Replace engine coolant sensor
2 Gauge cluster
Indication of auto accel Mark "Display/not display" for auto accel switches by auto accel switch operation on gauge cluster.
Replace gauge cluster
2 Gauge cluster
Indication of auto accel Mark "Display/not display" for auto accel switches by auto accel switch operation on gauge cluster.
Replace gauge cluster
3 Low pressure sensor
Service diagnosis
Check low pressure sensor
3 Low pressure sensor
Service diagnosis
Check low pressure sensor
Each control pressure of No.5 and No.6 is in the range of 0~0.1MPa at control lever neutral position.
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.) No.
Sections
1 Low pressure sensor
Contents/normal value Service diagnosis
Each control pressure of No.5 and No.6 is raised with control lever operated.
47-31
Each control pressure of No.5 and No.6 is in the range of 0~0.1MPa at control lever neutral position.
(4) Auto accel does not actuate. (The engine speed does not automatically speed up.) Corrective action, others
Check low pressure sensor
No.
Sections
1 Low pressure sensor
Contents/normal value Service diagnosis
Each control pressure of No.5 and No.6 is raised with control lever operated.
47-31
Corrective action, others Check low pressure sensor
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
(5) Wiper does not function
(5) Wiper does not function
Wiping range of forward and reverse movements
Wiping range of forward and reverse movements
Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range
Rise up (storing) position Upper reversing position Lower reversing position No.
Sections
Contents/normal value
Corrective action, others
1 Fuse
Check fuse No.20
Replace fuse
2 SW-19: Wiper interlock switch
Service diagnosis No.19 D125 Check wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary
3 Rise up limit switch built- Service diagnosis No.25 Wiper system in wiper motor Reverse limit switch Switch action in operation
Check according to "WIRING CHECKING PROCEDURE"
No.
Sections
Contents/normal value
Corrective action, others
1 Fuse
Check fuse No.20
2 SW-19: Wiper interlock switch
Service diagnosis No.19 D125 Check wiper interlock switch Wiper switch display (D125) is OFF with front window closed. and repair it if necessary Check according to "WIRING CHECKING PROCEDURE" and repair it if necessary
Replace fuse
3 Rise up limit switch built- Service diagnosis No.25 Wiper system in wiper motor Reverse limit switch Switch action in operation
Normal condition
4 R-31: Arc prevention relay R-29: Forward rotation relay R-30: Reverse rotation relay
Wiper motor Rise up limit switch's ON range Reverse limit switch's ON range
Rise up (storing) position Upper reversing position Lower reversing position
Check according to "WIRING CHECKING PROCEDURE"
Normal condition
Rise up limit switch
ON
OFF
OFF
Rise up limit switch
ON
OFF
OFF
Reverse limit switch
ON
ON
OFF
Reverse limit switch
ON
ON
OFF
Service diagnosis No.25 Wiper system When started by forward rotation:
STOP
START
Arc prevention relay
OFF
ON
ON
ON
ON
OFF
(STOP)
ON
ON
ON
OFF
ON
Forward rotation relay
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
Reverse rotation relay
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
Check that the relay is worked as shown in the table. * When the limit switch does not change in OFF after 4 seconds from the wiper startup, turn OFF all relay's outputs.
47-32
(STOP)
(REVERSE)
Check that the relay is excited. Check relay & fuse box and replace it if necessary.
(FORWARD)
4 R-31: Arc prevention relay R-29: Forward rotation relay R-30: Reverse rotation relay
Service diagnosis No.25 Wiper system When started by forward rotation:
STOP
START
Arc prevention relay
OFF
ON
ON
ON
ON
OFF
(STOP)
ON
ON
ON
OFF
Forward rotation relay
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
ON
Reverse rotation relay
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
OFF
OFF
Check that the relay is worked as shown in the table. * When the limit switch does not change in OFF after 4 seconds from the wiper startup, turn OFF all relay's outputs.
47-32
(STOP)
(REVERSE)
Check that the relay is excited. Check relay & fuse box and replace it if necessary.
(FORWARD)
ON
47. TROUBLESHOOTING (BY TROUBLE)
Faulty starting
Faulty engine starting/engine does not rotate.
Engine poor run-up (Low follow-up ability)
Poor output Insufficient rotation
Engine poor run-up (Low follow-up ability)
Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Exhaust smoke is white
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Early contamination of oil
Other failures
Exhaust smoke is black
Intruding of oil in coolant, back flow, reduction of coolant quantity
Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (Monitor lights up)
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Oil quantity increased. (Intruding of water and fuel)
Vibration
Vibration
47-33
47-33
Muffler clogged
Air leak between turbocharger and intake manifold
Poor or deteriorated battery
Contamination of water and fuel with oil
Oil level of oil pan
Coolant level
Improper fuel in use
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Oil filter clogged
Air cleaner clogged
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection)
Exhaust smoke is black
Larger fuel consumption
Shortage of fuel level
Muffler clogged
Air leak between turbocharger and intake manifold
Poor or deteriorated battery
Contamination of water and fuel with oil
Oil level of oil pan
Coolant level
Improper fuel in use
Breather hose crushed or clogged
Fan belt slipped, fan pulley worn
Oil filter clogged
Fuel filter clogged
Faulty engine starting/engine does not rotate.
Other failures
Poor start ability (Take a long time)
Faulty starting
Trouble
Poor start ability (Take a long time) Faulty engine starting/engine rotates but no exhaust gas (No fuel injection)
Leak, clogging
Factors
Poor output Insufficient rotation
Trouble
Air cleaner clogged
Shortage of fuel level
Factors
Checking Liquid
Filters
Leak, clogging
Engine oil leak
Filters
Fuel filter clogged
Checking Liquid
ENGINE RELATED TROUBLESHOOTING
Engine oil leak
47.3
Leak, clogging of fuel system and intruding of air
ENGINE RELATED TROUBLESHOOTING
Leak, clogging of fuel system and intruding of air
47.3
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
Faulty engine starting/engine does not rotate.
Faulty starting
Faulty engine starting/engine does not rotate.
Engine poor run-up (Low follow-up ability)
Poor output Insufficient rotation
Engine poor run-up (Low follow-up ability)
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating Exhaust smoke is black
Exhaust smoke is white
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Early contamination of oil
Other failures
Exhaust smoke is black
Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity
Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (Monitor lights up)
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Oil quantity increased. (Intruding of water and fuel)
Vibration
Vibration
47-34
47-34
Hydraulic switch
Safety relay
Starter motor
Glow relay
Glow plug
Engine side
Alternator
Battery relay
Shovel side
Starter switch key
Failure of hydraulic system
Peeling of space insulation around radiator
Radiator core clogged/fin clogged and crushed
Failure of radiator pressure cap
Hydraulic switch
Safety relay
Starter motor
Glow relay
Glow plug
Alternator
Battery relay
Loose connection of battery cable terminal
Starter switch key
Startup circuit wiring
Failure of hydraulic system
Peeling of space insulation around radiator
Radiator core clogged/fin clogged and crushed
Poor start ability (Take a long time)
Other failures
Poor start ability (Take a long time) Faulty starting
Trouble
Poor output Insufficient rotation
Trouble
Electric equipment
Shovel side Factors
Failure of radiator pressure cap
Loose mounting bolts, damage of mounting rubber
Factors
Checking
Engine side
Startup circuit wiring
Electric equipment Shovel side
Loose mounting bolts, damage of mounting rubber
Checking Shovel side
Loose connection of battery cable terminal
47. TROUBLESHOOTING (BY TROUBLE)
47. TROUBLESHOOTING (BY TROUBLE)
Intake and
Fuel system exhaust system
47. TROUBLESHOOTING (BY TROUBLE)
Lubrication Cooling system system
Intake and
Fuel system exhaust system
Faulty engine starting/engine does not rotate.
Faulty starting
Faulty engine starting/engine does not rotate.
Engine poor run-up (Low follow-up ability)
Poor output Insufficient rotation
Engine poor run-up (Low follow-up ability)
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection) Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Exhaust smoke is white
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Early contamination of oil
Other failures
Exhaust smoke is black
Intruding of oil in coolant, back flow, reduction of coolant quantity
Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (Monitor lights up)
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Oil quantity increased. (Intruding of water and fuel)
Vibration
Vibration
47-35
47-35
Failure of thermostat (Not open)
Damage of water pump
Leak and crush of hydraulic piping
Failure of regulator valve
Failure of relief valve
Failure of oil pump
Damage of EGR cooler
Seizing and interference of turbocharger
Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Fuel leak into the head cover
Improper fuel injection time
Failure of supply pump
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection)
Exhaust smoke is black
Larger fuel consumption
Failure of injector
Failure of thermostat (Not open)
Damage of water pump
Leak and crush of hydraulic piping
Failure of regulator valve
Failure of relief valve
Failure of oil pump
Damage of EGR cooler
Seizing and interference of turbocharger
Seal of turbocharger worn, damaged
Turbocharger oil drain tube clogged
Fuel leak into the head cover
Improper fuel injection time
Poor start ability (Take a long time)
Other failures
Poor start ability (Take a long time) Faulty starting
Trouble
Poor output Insufficient rotation
Trouble
Failure of supply pump
Factors
Failure of injector
Factors
Lubrication Cooling system system
47. TROUBLESHOOTING (BY TROUBLE)
Faulty starting
Faulty engine starting/engine does not rotate.
Engine poor run-up (Low follow-up ability)
Poor output Insufficient rotation
Engine poor run-up (Low follow-up ability)
Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Faulty engine starting/exhaust gas is emitted but engine does not start (With fuel injection) Rotation in bad condition (hunting) Engine stalled during operation. Output is lowered. Overheating
Exhaust smoke is white
Exhaust smoke is white
Larger oil consumption (or blue exhaust gas)
Larger oil consumption (or blue exhaust gas)
Early contamination of oil
Early contamination of oil
Other failures
Exhaust smoke is black
Intruding of oil in coolant, back flow, reduction of coolant quantity
Larger fuel consumption Intruding of oil in coolant, back flow, reduction of coolant quantity
Hydraulic pressure down (Monitor lights up)
Hydraulic pressure down (Monitor lights up)
Oil quantity increased. (Intruding of water and fuel)
Oil quantity increased. (Intruding of water and fuel)
Vibration
Vibration
47-36
47-36
Damage of flywheel gear
Damage of dumper
Wear and damage of rear oil seal and seal surface
Hole due to cavitation
Wear of piston ring and liner, ring stick
Damage and seizing of piston and connecting rod
Wear and failure of valve and valve guide
Damage of cylinder head and head gasket
Strainer clogged, damage of oil pipe
Faulty engine starting/engine rotates but no exhaust gas (No fuel injection)
Exhaust smoke is black
Larger fuel consumption
Damage of engine oil cooler core and O-ring
Damage of flywheel gear
Damage of dumper
Wear and damage of rear oil seal and seal surface
Hole due to cavitation
Wear of piston ring and liner, ring stick
Damage and seizing of piston and connecting rod
Wear and failure of valve and valve guide
Damage of cylinder head and head gasket
Strainer clogged, damage of oil pipe
Damage of engine oil cooler core and O-ring
Faulty engine starting/engine does not rotate.
Other failures
Poor start ability (Take a long time)
Faulty starting
Trouble
Poor start ability (Take a long time) Faulty engine starting/engine rotates but no exhaust gas (No fuel injection)
Engine body
Factors
Poor output Insufficient rotation
Trouble
Failure of injection holder sleeve
Engine body
Factors
Failure of injection holder sleeve
47. TROUBLESHOOTING (BY TROUBLE)
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
TABLE OF CONTENTS
TABLE OF CONTENTS
48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-3
48.1 TROUBLE DIAGNOSIS MODE .......................................................................................48-3
48
48
Book Code No. S5YN4818E01 48-1
Book Code No. S5YN4818E01 48-1
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE) Issue
Date of Issue
First edition
July, 2006
SK330–8 : LC10-07001~ SK350LC–8 : YC10-03501~
n
August, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
n
March, 2007
n
April, 2007
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
n
n
SK215SRLC : LA05-02001~
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
n
n
n
August, 2007
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Applicable Machines
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
48-2
Remarks
Issue
Date of Issue
K
First edition
July, 2006
SK330–8 : LC10-07001~ SK350LC–8 : YC10-03501~
n
K
n
August, 2006
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
n
K
n
K
n
October, 2006
SK250-8 : LQ12-06001~ SK260LC-8 : LL12-05001~
n
K
K
n
February, 2007
E235BSR : YF05-02001~ E235BSR(N)LC : YU05-02001~
K
n
March, 2007
K
n
April, 2007
K
n
n
SK200-8 : YN11-45001~ SK210LC-8 : YQ11-06001~
K
n
May, 2007
SK250-8: LQ12-06001~ SK260LC–8 : LL12-05001~
K
n
June, 2007
E225BSR : YB05-03001~ E225BSRLC : LA05-02001~
K
n
n
SK215SRLC : LA05-02001~
K
n
July, 2007
E135BSR : YY05-12001~ E135BSRLC : YH05-07001~
K
n
n
SK225SR : YB05-03001~ SK225SRLC : LA05-02001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
E265B : LQ12-06001~ E265BLC : LL12-05001~
K
n
n
E215B : YN11-45001~ E215BLC : YQ11-06001~
K
n
n
K
n
August, 2007
S5YN4818E01 (ASIA, OCE)
n (NHK) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
Applicable Machines
E215B : YN11-45001~ E215BLC : YQ11-06001~ SK235SR-2 : YF05-02001~ SK235SRLC-2 : YU05-02001~
n E385B : LC10-07001~ E385BLC : YC10-03501~
48-2
Remarks S5YN4818E01 (ASIA, OCE)
n (NHK) n (NHK Russia) n (OCE) n ASIA (HS Engine) n ASIA (HS Engine) n (NHK) n (North America) n (NHK) n (OCE) n (NHK Middle East) n (NHK Russia) n (NHK Russia) HS Engine n (NHK Middle East) HS Engine
n (NHK Middle East)
K
K K K K K K K K K K K K K K
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48.1
TROUBLE DIAGNOSIS MODE
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48.1
TROUBLE DIAGNOSIS MODE
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
The trouble diagnosis mode is used to automatically specify the failed sections for the troubles which can not be detected by auto diagnosis function (the trouble can be specified by error code) like disconnection, abnormal output.
(1) Function There are two types of trouble diagnosis mode.
(1) Function There are two types of trouble diagnosis mode.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system.
1) Trouble diagnosis mode 1: Used to diagnose unload system, pump system, travel straight system and engine system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not operated, both selector valve and proportional valve are automatically actuated, the sensor detects the machine condition and the mechatro controller identifies the normal condition or failed condition of the system.
2) Trouble diagnosis mode 2: Used to diagnose pilot system. In any mode, with the attachment not operated, both selector valve and proportional valve are automatically actuated, the sensor detects the machine condition and the mechatro controller identifies the normal condition or failed condition of the system.
(2) How to use and flow chart The operation is performed through gauge cluster.
(2) How to use and flow chart The operation is performed through gauge cluster.
No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.)
No.1 Select service adjustment select screen. (Switch starter key on while pressing buzzer stop switch and press select switch three times while pressing buzzer stop switch on the service diagnosis screen No.1.)
No.2 Select Trouble diagnosis mode
No.2 Select Trouble diagnosis mode
(Move the cursor to the desired position with screen change switch "
", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2" ", and press the select switch.)
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge. No.1
No.2
ADJUSTING MODE 1 PRESET BY FACTORY
No.1 SELECT SWITCH
DIAG MODE 1 DIAG MODE 2
BUZZER STOP SWITCH
FEED
CHECK
", and press the select switch.)
No.3
8 FAULT DIAG MODE
ADJUSTING MODE 1 PRESET BY FACTORY
SCREEN CHANGE SWITCH
SELECT SWITCH
DIAG MODE 1 DIAG MODE 2
BUZZER STOP SWITCH
FEED
SCREEN CHANGE SWITCH
CASE OF DIAG MODE 1
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M
LOWER BOOM
DIAG MODE 1
RELEASE LOCK LEVER
TO GROUND
RESULT OF DIAGNOSIS
When not failed,
DIAG MODE 1 ENGINE STOP
RESULT OF DETAIL
DIAG MODE 1
1 P1 UNLOAD
OK
O K DATA END
Engine stops automatically.
FEED
DIAG MODE 1 RESULT 1 P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG
DATA END
BACK TO No.3
Notes:
FEED
For the diagnosing items, see Table 48-1. When required to stop in diagnosis operation, press the buzzer stop switch and the operation is forcedly stopped.
1 P1 UNLOAD
NG DATA END
FEED
C-2 00.0M
LOWER BOOM
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
BACK TO No.3
RESULT OF DIAGNOSIS
When not failed,
DIAG MODE 1
END
C-2 00.0M
ENGINE STOP
RESULT OF DETAIL
DIAG MODE 1
1 P1 UNLOAD
OK
O K DATA END
E-2 005mA D-2 300mA
Engine stops automatically.
DIAG MODE 1 RESULT 1
DATA END
E-2 005mA D-2 300mA
The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed " " button. For diagnosis results and corrective actions to be taken, see Table 48-2.
FEED
About 15 minutes
BACK TO No.3
Notes:
FEED
For the diagnosing items, see Table 48-1. When required to stop in diagnosis operation, press the buzzer stop switch and the operation is forcedly stopped. The data at the time of judgment can be confirmed with the select switch.
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M E-2 005mA D-2 300mA
The other judgments can be confirmed with the feed button.
RESULT OF DIAGNOSIS
P1 UN-LOAD PSV NG P1 UN-LOAD SPOOL NG
C-2 00.0M
In diagnosis operation
START
E-2 005mA D-2 300mA
When failed, ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
DIAG MODE 1
RELEASE LOCK LEVER
TO GROUND
The data at the time of judgment can be confirmed with the select switch.
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. 2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. 3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis obtained. In this case, contact our dealer/distributor. 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
48-3
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
Turn engine on manually.
The other judgments can be confirmed with the feed button.
RESULT OF DIAGNOSIS
When failed,
CHECK
About 15 minutes
E-2 005mA D-2 300mA
BACK TO No.3
SENSOR CHECK In diagnosis operation
START
Turn engine on manually.
END
No.2
LANGUAGE/LOGO
CASE OF DIAG MODE 1 SENSOR CHECK
(Move the cursor to the desired position with screen change switch "
No.4 Go ahead the operation according to the instructions on the screen of cluster gauge.
No.3
8 FAULT DIAG MODE
", and press the select switch.)
No.3 Select either "DIAG MODE 1" or "DIAG MODE 2"
(Move the cursor to the desired position with screen change switch "
LANGUAGE/LOGO
(Move the cursor to the desired position with screen change switch "
1 P1 UNLOAD
NG DATA END
FEED
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M E-2 005mA D-2 300mA
The suspected trouble sections are displayed in order of possibility. The suspected three sections in maximum are displayed. When desired to see other suspected trouble sections, press feed " " button. For diagnosis results and corrective actions to be taken, see Table 48-2.
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death.Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. 2. Before executing the trouble diagnosis mode, check each pressure sensor proportional valve and select valve for possible abnormality. Check that the commands of proportional valve and select valve do not largely differ from the actually measured values through the service diagnosis. The preliminary investigation of electric system makes the time saving and high precision diagnosis possible. 3. For the diagnosis results and the corrective actions to be taken, usually occurred troubles are taken as an example. When multiple troubles are occurred at the same time, there is a case no accordance of diagnosis obtained. In this case, contact our dealer/distributor. 4. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
48-3
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
No.4 CASE OF DIAG MODE 2 SENSOR CHECK
CHECK
No.4 CASE OF DIAG MODE 2
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
C-2 00.0M
LOWER BOOM TO GROUND
DIAG MODE 2
SENSOR CHECK
START
CHECK
E-2 005mA D-2 300mA
Turn engine on manually.
AT CONTROL LEVER IS NEUTRAL
WHEN FINISHING OF DIAGNOSIS IS REQUIRED.
BOOM UP
OK SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P1 side option
MPa
PRESSURE 1.5
MPa
PRESSURE 3.0
AT CONTROL LEVER IS NEUTRAL
Example: Case of boom up WHEN FINISHING OF DIAGNOSIS IS REQUIRED.
BOOM UP
OK
BACK TO No.3
SEARCHABLE OPERATION Boom up Boom down Bucket digging Bucket dump Arm in Arm out Swing Travel right Travel left P1 side option P1 side option
In the normal condition, OK is displayed when the control lever is moved to stroke end.
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers. 2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication. 3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
PRESSURE 0.0
MPa
PRESSURE 1.5
MPa
PRESSURE 3.0
BACK TO No.3 MPa
In the normal condition, OK is displayed when the control lever is moved to stroke end.
Notes:
1. When the trouble diagnosis mode is operating, lower the attachment and put the bucket on the ground. If the machine failed; the unexpected touch to the lever may move the attachment and it causes injury or death. Because the bucket-grounded/bucket-not-grounded can not be automatically identified, do not fail to start operating the trouble diagnosis mode after making sure of the bucket-grounded condition. Place the bucket on the ground between both crawlers. 2. In the case of "DIAG MODE2", pump pressure is unloaded with unload valve in order not to actuate attachment. When trouble diagnosis is performed, if the pump pressure is generated, the engine stops and "UN-LOAD PSV NG" is displayed. Check the troubled section according to indication. 3. When the trouble diagnosis mode is executing, the error display with self-diagnosis and warning does not appear. If necessary, examine the presence or absence of trouble referring to the trouble history.
Table48-1 Failure diagnosis Mode-1/Diagnosis item Display
START
TO GROUND
BOOM UP
MPa
Notes:
No.
C-2 00.0M
DIAG MODE 2
LOWER BOOM
E-2 005mA D-2 300mA
Turn engine on manually.
Example: Case of boom up
BOOM UP
PRESSURE 0.0
START ENG
ENGINE SPEED 0000 rpm PRESSURE C-1 00.0M PROPO-VALVE E-1 005mA D-1 300mA
Table48-1 Failure diagnosis Mode-1/Diagnosis item
Contents of diagnosis
No.
Display
Contents of diagnosis
1
1 P1 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position?
1
1 P1 UNLOAD
Is normal pressure generated in the condition that the flow rate at P1 side is minimum and the unloading valve is in the emergency position?
2
2 P1 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?
2
2 P1 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P1 side?
3
3 P1 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?
3
3 P1 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P1 side flow rate is minimum?
4
1 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?
4
1 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is minimum?
5
2 P2 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?
5
2 P2 UNLOAD
Is normal pressure generated in the condition that the minimum flow rate is relieved at P2 side?
6
3 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?
6
3 P2 UNLOAD
Is normal pressure generated in the condition that the unload valve is fully opened, and P2 side flow rate is minimum?
7
1 P1 PUMP
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?
7
1 P1 PUMP
Is normal pressure generated in the condition that the flow rate at P1 side is emergency and the unloading valve is in the emergency position?
8
2 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?
8
2 P1 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P1 side flow rate is minimum?
9
3 P1 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?
9
3 P1 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P1 side flow rate is maximum?
10 1 P2 PUMP
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?
10 1 P2 PUMP
Is normal pressure generated in the condition that the flow rate at P2 side is emergency and the unloading valve is in the emergency position?
11 2 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?
11 2 P2 PUMP
Is normal pressure generated in the condition that the unload valve is emergency, and P2 side flow rate is minimum?
12 3 P2 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?
12 3 P2 PUMP
Is normal pressure generated in the condition that the unload valve is in emergency position, and P2 side flow rate is maximum?
48-4
48-4
HINO DIESEL ENGINE WORKSHOP MANUAL
HINO DIESEL ENGINE WORKSHOP MANUAL
J05E-TG
J05E-TG
(HS Engine) KSS-SMJ5-E011E 2007.4
(HS Engine) KSS-SMJ5-E011E 2007.4
GENERAL
1
GENERAL
1
STANDARD VALUE
2
STANDARD VALUE
2
PARTS TO BE PREPARED
3
PARTS TO BE PREPARED
3
ENGINE ASSEMBLY/DISASSEMBLY
4
ENGINE ASSEMBLY/DISASSEMBLY
4
FUEL SYSTEM
5
FUEL SYSTEM
5
EMISSION CONTROL
6
EMISSION CONTROL
6
ELECTRICAL
7
ELECTRICAL
7
INTAKE
8
INTAKE
8
ENGINE MECHANICAL
9
ENGINE MECHANICAL
9
EXHAUST
10
EXHAUST
10
COOLING
11
COOLING
11
LUBRICATION
12
LUBRICATION
12
STARTING AND CHARGING
13
STARTING AND CHARGING
13
TURBOCHARGER
14
TURBOCHARGER
14
AIR COMPRESSOR
15
AIR COMPRESSOR
15
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
16
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
16
ENGINE DIAGNOSIS CODE
17
ENGINE DIAGNOSIS CODE
17
For your information:
For your information:
This documentation does not contain any descriptions in regard to the hatched part
This documentation does not contain any descriptions in regard to the hatched part
"6. Emission Control". "15. Air Compressors".
"6. Emission Control". "15. Air Compressors".
GENERAL
1â&#x20AC;&#x201C;1
GENERAL
ENGINE
1 GENERAL General information
Warning................................................................... 1-2 How to read this manual ........................................ 1-3 Precautions for work ............................................... 1-7 Tightening of engine bolts and nuts ...................... 1-10 Tightening of chassis bolts and nuts..................... 1-12 Tightening of flare nuts and hoses........................ 1-14 Taper thread sealant for piping ............................. 1-15 Assembly of joints and gaskets for piping ............. 1-16 Handling of liquid gasket....................................... 1-18 Failure diagnosis table for each problem .............. 1-19 Failure diagnosis using HinoDX ............................ 1-20 Connection method of HinoDX ............................. 1-23 Chassis number and engine number ................... 1-23
1â&#x20AC;&#x201C;1
ENGINE
1
1 GENERAL General information
Warning................................................................... 1-2 How to read this manual ........................................ 1-3 Precautions for work ............................................... 1-7 Tightening of engine bolts and nuts ...................... 1-10 Tightening of chassis bolts and nuts..................... 1-12 Tightening of flare nuts and hoses........................ 1-14 Taper thread sealant for piping ............................. 1-15 Assembly of joints and gaskets for piping ............. 1-16 Handling of liquid gasket....................................... 1-18 Failure diagnosis table for each problem .............. 1-19 Failure diagnosis using HinoDX ............................ 1-20 Connection method of HinoDX ............................. 1-23 Chassis number and engine number ................... 1-23
1
1–2
1–2
GENERAL
Warning
GENERAL
Warning JP31199010102001
JP31199010102001
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
Observe the following precautions to work safely and to prevent damage to customers' vehicles.
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
This manual is prepared for qualified service engineers who are recognized as technical expert. Those who are not
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
qualified, who are not appropriately trained, who performs service without appropriate tool or equipment, or who
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
perform service with the way not specified in this manual may not only damage the vehicle, but also put service
engineers and surrounding people in danger.
engineers and surrounding people in danger.
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
• Appropriate service and repair are essential to ensure safety of service engineers and safety and reliability of
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
vehicles. Be sure to use Hino genuine parts for replacement of parts. Do not use deteriorated parts in quality.
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
• Items described in this manual are the procedures to be observed in service and repair. For service and repair
according to this procedure, be sure to use the special tools designed for each purpose. • If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles may be impaired. Never use a method or tool not recommended. • This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
according to this procedure, be sure to use the special tools designed for each purpose. • If a method or a tool not recommended is used, safety of service engineers, and safety and reliability of vehicles may be impaired. Never use a method or tool not recommended. • This manual shows “Warning” and “Caution” for items that need to be observed so that accidents may not occur
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
during service or repair, or that damage to vehicle due to improper method may not impair safety and reliability of
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
vehicles. These instructions cannot give warning for all possible hazards. Note that items with “Warning” or
“Caution” are not absolute for safety.
“Caution” are not absolute for safety.
1–3
GENERAL
How to read this manual
How to read this manual JP31199010102002
1.
Scope of repair work (1)
JP31199010102002
1.
Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
Scope of repair work (1)
Repair work is classified into three large categories of "Diagnosis", "Mounting/removal, replacement,
assembly disassembly and inspection adjustment" and "Final inspection". (2)
assembly disassembly and inspection adjustment" and "Final inspection".
This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
(2)
This manual describes "Diagnosis" in the first process and "Mounting/removal, replacement,
assembly disassembly and inspection adjustment" in the second process. Explanation of "Final inspection"
assembly disassembly and inspection adjustment" in the second process. Explanation of "Final inspection"
in the third process is omitted here. (3)
2.
3.
4.
(3)
Although the following work is not described in this manual, it should be performed in actual work.
a.
Jacking and lifting
a.
Jacking and lifting
b.
Cleaning and washing of removed parts as required
b.
Cleaning and washing of removed parts as required
c.
Visual inspection
c.
Visual inspection
2.
Standard value, limit, action and tightening torque described in the text are summarized in tables.
Items to be prepared (1)
in the third process is omitted here.
Although the following work is not described in this manual, it should be performed in actual work.
Standard value (1)
1–3
GENERAL
Standard value (1)
3.
Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
Standard value, limit, action and tightening torque described in the text are summarized in tables.
Items to be prepared (1)
Items to be prepared before work are SST, tools, gauges and lubricant, etc. These are listed in the list
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
section of items to be prepared. Items such as general tools, jack, rigid rack, etc. that are usually
equipped in general service shop are omitted.
equipped in general service shop are omitted.
How to read sections and titles
4.
How to read sections and titles
(1)
Sections are classified according to J2008, SAE standard.
(1)
Sections are classified according to J2008, SAE standard.
(2)
For areas that show system names like "Engine control system", "Inspection", "Adjustment",
(2)
For areas that show system names like "Engine control system", "Inspection", "Adjustment",
"Replacement", "Overhaul", etc. of components are described.
"Replacement", "Overhaul", etc. of components are described.
(3)
For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(3)
For areas that show part names like "Injection pump", "Mounting/removal and disassembly" is described.
(4)
Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
(4)
Illustrations of the parts catalog are shown for part layout. (Part codes in the parts catalog are described in
the illustration. Major names and tightening torque are listed in the table.) ! CAUTION
The part layouts in this manual are inserted based on illustrations and part numbers of the
the illustration. Major names and tightening torque are listed in the table.) ! CAUTION
The part layouts in this manual are inserted based on illustrations and part numbers of the
parts catalog CD-ROM issued in march, 2007. (Some areas do not show exploded view. They
parts catalog CD-ROM issued in march, 2007. (Some areas do not show exploded view. They
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
will be additionally issued when the parts catalog CD is revised.) Be sure to use the parts
catalog for confirmation of illustrations and part numbers and for ordering parts.
catalog for confirmation of illustrations and part numbers and for ordering parts.
1–4 5.
GENERAL How to read troubleshooting (1)
5.
Failure diagnosis in this manual describes Step 2 and Step 3 below :
(1) Question
1–4
"Step 1"
Hear from customers for conditions and environments of failures and check the fact.
GENERAL How to read troubleshooting (1)
Failure diagnosis in this manual describes Step 2 and Step 3 below :
(1) Question
"Step 1"
Perform diagnosis inspection, status inspection, (2) Pre-inspection (3) Reproduction method
"Step 2"
diagnosis code (5) Troubleshooting for each failure
"Step 3"
status
(2) Pre-inspection
failure status. If it is difficult to reproduce the problem
(3) Reproduction method
"Step 2"
Summarize inspection results obtained from Step 2.
(4) Troubleshooting for each
Perform inspection systematically according to
diagnosis code
troubleshooting procedures for each diagnosis code or
(5) Troubleshooting for each failure
failure status.
status
"Step 4" to reproduce a failure, perform the confirmation test
Pre-inspection
"Step 3"
inspection
Perform inspection systematically according to troubleshooting procedures for each diagnosis code or failure status. Check if failure occurs again after repair. If it is difficult
(6) Confirmation test
"Step 4" to reproduce a failure, perform the confirmation test under the conditions and environment of the failure.
(2)
Pre-inspection
• Pre-inspection is performed in the following steps :
Pre-
failure status. If it is difficult to reproduce the problem
Summarize inspection results obtained from Step 2.
under the conditions and environment of the failure. (2)
function inspection and basic inspection. Check the with status inspection, use the reproduction method.
Check if failure occurs again after repair. If it is difficult (6) Confirmation test
of failures and check the fact. Perform diagnosis inspection, status inspection,
function inspection and basic inspection. Check the with status inspection, use the reproduction method.
(4) Troubleshooting for each
Hear from customers for conditions and environments
• Pre-inspection is performed in the following steps :
Diagnosis inspectionoDiagnosis deletionoFailure status check (Use the reproduction
Diagnosis inspectionoDiagnosis deletionoFailure status check (Use the reproduction
method if not reproduced.)oDiagnosis reconfirmation
method if not reproduced.)oDiagnosis reconfirmation
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
• Estimate the failure system before the reproduction test. Attach a tester and evaluate
estimated failure together with failure status. Refer to the troubleshooting chart for
estimated failure together with failure status. Refer to the troubleshooting chart for
estimated cause of a failure. • An error code is displayed if a failure occurs instantaneously. If any specific failure is not found, perform troubleshooting using the reproduction method. • Failure status check
Preinspection
estimated cause of a failure. • An error code is displayed if a failure occurs instantaneously. If any specific failure is not found, perform troubleshooting using the reproduction method. • Failure status check
If failure is reproduced, perform Step 2 o Step 3 o Step 4.
If failure is reproduced, perform Step 2 o Step 3 o Step 4.
If failure is not reproduced, use the reproduction method (simulation of external
If failure is not reproduced, use the reproduction method (simulation of external
conditions or check of each wire harness and connector, etc.)
conditions or check of each wire harness and connector, etc.)
1–5
GENERAL 6.
How to read explanation details (1)
6.
Part layout
How to read explanation details (1)
Example
1–5
GENERAL
Part layout
Example 9–17
ENGINE MECHANICAL [J08E]
9–17
ENGINE MECHANICAL [J08E]
Timing Gear Cover and Flywheel Housing
Timing Gear Cover and Flywheel Housing
Part layout
Part layout JP04117090402003
JP04117090402003
Part name code
Part name code
Part catalog Fig. No.
Part catalog Fig. No. SAPH041170900182
11308
Flywheel housing
11390
End plate
11309
Oil seal retainer
9828A
Front oil seal*
11357
Gasket*
9828B
Rear oil seal*
11357A
Gasket*
*Parts not to be reused.
Description of part name code
SAPH041170900182
11308
Flywheel housing
11390
End plate
11309
Oil seal retainer
9828A
Front oil seal*
11357
Gasket*
9828B
Rear oil seal*
11357A
Gasket*
*Parts not to be reused.
Left: Part name code (nut)
Tightening torque
Description of part name code
Left: Part name code (nut)
Tightening torque
9069H
M14 : 171.5N m{1, 750kgf cm}
9419A
M16 : 196N m{2, 000kgf cm}
9069H
M14 : 171.5N m{1, 750kgf cm}
9419A
M16 : 196N m{2, 000kgf cm}
9069J
M12 : 97N m{990kgf cm}
9419B
M16 : 196N m{2, 000kgf cm}
9069J
M12 : 97N m{990kgf cm}
9419B
M16 : 196N m{2, 000kgf cm}
Service procedure Overhaul item
Service procedure Overhaul item
SAPH311990100001
✩:It is the ID number for parts to prepare electronic data. It is not required for repair work.
SAPH311990100001
✩:It is the ID number for parts to prepare electronic data. It is not required for repair work.
1–6 7.
1–6
GENERAL Definition of terms
7.
GENERAL Definition of terms
Terms in this manual are defined as follows :
Terms in this manual are defined as follows :
(1)
(1)
Direction a.
Individual unit
Direction a.
Front/back direction
The power input side is front and the output side is back.
The power input side is front and the output side is back.
Rotating direction
Rotating direction
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
When viewed from the rear, the clockwise direction is right rotation and the counterclockwise direction is
left rotation.
left rotation.
Vertical direction
Vertical direction
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is lower.
With a unit mounted on the vehicle (chassis), the upward direction is upper and the downward direction is lower.
Left/right direction
Left/right direction
When viewed from the rear, the left direction is left and the right direction is right.
When viewed from the rear, the left direction is left and the right direction is right.
(2)
Standard value Basic dimension excluding tolerance and clearance generated by tolerances when two
(3)
Repair limit It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
(2)
Standard value Basic dimension excluding tolerance and clearance generated by tolerances when two
(3)
Repair limit It is the value requiring repair. Symbol of + or - with the value means increase or decrease to
parts are joined
parts are joined
the standard value.
the standard value.
(4)
Service limit It is the value requiring replacement. Symbol of + or - with the value means increase or
(5)
(4)
Service limit It is the value requiring replacement. Symbol of + or - with the value means increase or
Warning It is an item that may result in risk of human life or serious injury by incorrect handling.
(5)
Warning It is an item that may result in risk of human life or serious injury by incorrect handling.
(6)
Caution It is an item that should not be performed including inhibited work or an item that require
(6)
Caution It is an item that should not be performed including inhibited work or an item that require
decrease to the standard value.
decrease to the standard value.
attention in working procedures. (7) 8.
attention in working procedures.
Reference It is supplementary explanation in work.
(7)
Unit (1)
8. SI unit is used in this manual. SI unit is the international unit to unify the conventional different international
(1)
SI unit
Conversion value*1
ional
(1[Conventional
unit
unit] = X [SI unit]) 1kgf=9.80665N
Force
N
kgf
Torque*2
N m
kgf cm
1kgf cm=0.0980665 N m
SI unit
Spring constant Volume
Convent
Conversion value*1
ional
(1[Conventional unit]
unit
= X [SI unit])
N/mm
kgf/mm
L
cc
SI unit is used in this manual. SI unit is the international unit to unify the conventional different international units into one unit per quantity and to promote smooth technical communications.
This manual shows both the SI unit and conventional units. The conventional units are shown in { }. Convent
Reference It is supplementary explanation in work.
Unit
units into one unit per quantity and to promote smooth technical communications. (2)
Individual unit
Front/back direction
1kgf/mm=980665N/ mm 1cc=1mL
(2)
This manual shows both the SI unit and conventional units. The conventional units are shown in { }.
SI unit
Convent
Conversion value*1
ional
(1[Conventional
unit
unit] = X [SI unit]) 1kgf=9.80665N
Force
N
kgf
Torque*2
N m
kgf cm
1kgf/ kgf/cm Pressure
2
speed
r/min min-1
*1
Efficiency
W
PS
1PS=0.735499kW
Calorific
Pa
value
1rpm=1min-1
kgf/cm Pressure
1mmHg=0.133322k
1rpm=1r/min rpm
W h
cal
g/W h
g/PS h
Fuel consumpt
ional
(1[Conventional unit]
unit
= X [SI unit]) 1kgf/mm=980665N/
N/mm
kgf/mm
Volume
L
cc
1cc=1mL
Efficiency
W
PS
1PS=0.735499kW
W h
cal
1kcal=1.163W h
g/W h
g/PS h
constant
mm
Rotational
kW h
speed
: X means the value when 1 [Conventional unit] is converted to the SI unit. : The conversion value of the torque may vary depending on the unit. Observe the standard values described for each unit.
r/min min-1
*1
cm2=98.0665kPa =0.0980665MPa
mmHg
1g/PS h=1.3596g/
ion rate
2
Pa
1kcal=1.163W h
It is used as the conversion factor from the conventional unit to the SI unit. *2
N m
Spring
Conversion value*1
1kgf/
=0.0980665MPa
Pa mmHg
Rotational
cm2=98.0665kPa
1kgf cm=0.0980665
SI unit
Convent
1mmHg=0.133322k
Calorific
Pa
value
1rpm=1r/min rpm
1rpm=1min-1
Fuel consumpt
1g/PS h=1.3596g/
ion rate
: X means the value when 1 [Conventional unit] is converted to the SI unit. It is used as the conversion factor from the conventional unit to the SI unit.
*2
: The conversion value of the torque may vary depending on the unit. Observe the standard values described for each unit.
kW h
1–7
GENERAL Safety information
Safety information
Precautions for work
Precautions for work JP31199010101001
1.
General precautions
JP31199010101001
1.
General precautions
To ensure safety in work and to prevent accidents, observe the following items :
To ensure safety in work and to prevent accidents, observe the following items :
(1)
(1)
Appearance
Appearance
a.
Wear safety goggles.
a.
Wear safety goggles.
b.
Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
b.
Do not wear watch, necktie, ring, bracelet, necklace, etc. to prevent accident before work.
c.
Bind long hair at the back.
c.
Bind long hair at the back.
d.
Be sure to wear a cap and safety shoes.
d.
Be sure to wear a cap and safety shoes.
(2)
Safety work
(2)
Safety work
a.
Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
a.
Do not touch radiator, muffler, exhaust pipe, tail pipe, etc. after stop of the engine to prevent burn.
b.
Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
b.
Do not put your clothes or tools near the rotating part (in particular, cooling fan or V–belt) during
operation of the engine.
operation of the engine.
c.
Remove the starter key when the engine is not started.
c.
Remove the starter key when the engine is not started.
d.
Start the engine at a well ventilated place so that carbon monoxide may not be filled.
d.
Start the engine at a well ventilated place so that carbon monoxide may not be filled.
e.
Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
e.
Since gas from the fuel or the battery is flammable, do not spark a fire or smoke a cigarette near the area.
f.
Since the battery fluid is poisonous and corrosive, be careful for handling.
f.
Since the battery fluid is poisonous and corrosive, be careful for handling.
g.
Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
g.
Do not short-circuit the cable of the battery or starter. Otherwise, the cable may be burned or burn may
occur. h.
occur.
If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine,
h.
resulting in injury. i. 2.
If a tool or rag is left in the engine compartment, it may be bounced with a rotating part of the engine, resulting in injury.
To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.
Precautions for service work
i. 2.
To tow a failure machine, refer to "Towing" in the "Operation manual" of the machine.
Precautions for service work
Pay attention to the following points before service work
Pay attention to the following points before service work
(1)
(1)
Preparation before disassembly
Preparation before disassembly
a.
Prepare general tools, special tools and gauges before work.
a.
Prepare general tools, special tools and gauges before work.
b.
To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
b.
To disassemble a complicated area, put a stamp or match mark on the location not functionally affected
c. (2)
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
to ease assembly. To repair the electric system, disconnect the cable from the minus terminal of the
battery before work.
battery before work.
Perform inspection according to the procedure in the text before disassembly. Inspection during disassembly
c. (2)
Inspection during disassembly Every time parts are removed, check the area where the parts are assembled and check for deformation,
damage, wear or scratch.
damage, wear or scratch.
Arrangement of disassembled parts
(4)
Washing of disassembled parts
(3)
Arrangement of disassembled parts
(4)
Washing of disassembled parts
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
Place removed parts neatly in order. Separate parts to be replaced from parts to be reused.
Clean and wash parts to be reused well. (5)
Inspection and measurement
Clean and wash parts to be reused well. (5)
Inspection and measurement
Inspect and measure parts to be reused as required. (6)
Assembly a.
Perform inspection according to the procedure in the text before disassembly.
Every time parts are removed, check the area where the parts are assembled and check for deformation, (3)
Inspect and measure parts to be reused as required. (6)
Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct
Assembly a.
parts in the correct order.
Keep the specified standard values (tightening torque, adjusting values, etc.) and assemble correct parts in the correct order.
b.
Be sure to use genuine parts for parts to be replaced.
b.
Be sure to use genuine parts for parts to be replaced.
c.
Use new packing, gasket, O–ring and cotter pin.
c.
Use new packing, gasket, O–ring and cotter pin.
d.
Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
d.
Use seal gaskets for some areas where gaskets are used. Apply specified oil or grease to sliding areas
where application of oil is required, and apply specified grease to the oil seal lip before assembly. (7)
1–7
GENERAL
Check of adjustment Make adjustments to the service standard values using a gauge or tester.
where application of oil is required, and apply specified grease to the oil seal lip before assembly. (7)
Check of adjustment Make adjustments to the service standard values using a gauge or tester.
1â&#x20AC;&#x201C;8
GENERAL 3.
1â&#x20AC;&#x201C;8
GENERAL
Precautions for electric system (1)
Removal of battery cable a.
b.
Loosen
3.
Precautions for electric system (1)
In an electric system, remove the cable from the
Removal of battery cable a.
battery minus (-) terminal to prevent burnout due to
battery minus (-) terminal to prevent burnout due to
short-circuit.
short-circuit.
When the battery cable is removed, the battery terminal may be damaged. Loosen the nut completely
b.
Loosen
SAPH311990100002
When the battery cable is removed, the battery terminal may be damaged. Loosen the nut completely
and never pry it for removal.
and never pry it for removal.
SAPH311990100002
(2)
Handling of electronic parts a.
(2)
Do not give impact on electronic parts such as
Handling of electronic parts a.
computer and relay. b. c.
Do not place electronic parts at a high temperature and
b.
Do not place electronic parts at a high temperature and humidity area.
Do not expose electronic parts to water in washing of a
c.
vehicle.
SAPH311990100003
Do not give impact on electronic parts such as computer and relay.
humidity area.
Do not expose electronic parts to water in washing of a vehicle.
SAPH311990100003
(3)
Handling of wire harness a.
(3)
Mark clamps and clips to prevent interference of a wire
Handling of wire harness a.
harness with body edge, sharp edge and bolts. Be sure
Mark clamps and clips to prevent interference of a wire harness with body edge, sharp edge and bolts. Be sure
to reassemble it to the original position. b.
to reassemble it to the original position.
When parts are assembled, be careful not to pinch a
b.
wire harness.
SAPH311990100004
In an electric system, remove the cable from the
When parts are assembled, be careful not to pinch a wire harness.
SAPH311990100004
GENERAL (4)
1â&#x20AC;&#x201C;9
GENERAL
Handling of connector a.
b.
(4)
When a connector is removed, hold the connector (as
Handling of connector a.
When a connector is removed, hold the connector (as
shown by the arrow in the left) and pull it out. Do not pull
shown by the arrow in the left) and pull it out. Do not pull
the wire harness.
the wire harness.
Unlock the locking connector before pulling.
b.
c.
Insert the locking connector completely until it clicks.
c.
Insert the locking connector completely until it clicks.
d.
To insert a test lead into the connector, insert it from the
d.
To insert a test lead into the connector, insert it from the
back of the connector. e.
Unlock the locking connector before pulling.
back of the connector.
If it is difficult to insert a test lead from the back of the
e.
connector, prepare a harness for inspection.
If it is difficult to insert a test lead from the back of the connector, prepare a harness for inspection.
SAPH311990100005
4.
1â&#x20AC;&#x201C;9
SAPH311990100005
Precautions for electric welding
4.
Precautions for electric welding
Inadvertent electric welding on a cab or chassis may cause reverse welding current from the grounding
Inadvertent electric welding on a cab or chassis may cause reverse welding current from the grounding
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
circuit, resulting in damage to electric and electronic parts. Observe the following items for electric
welding.
welding.
(1)
Turn "OFF" the starter switch.
(1)
Turn "OFF" the starter switch.
(2)
Make sure that switches are "OFF".
(2)
Make sure that switches are "OFF".
(3)
Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(3)
Disconnect the minus (-) terminal of the battery according to the removal procedure of the battery cable.
(4)
Disconnect connectors of each computer.
(4)
Disconnect connectors of each computer.
(5)
Remove all fuses. (For locations of fuses, refer to "Electrical System Chapter".)
(5)
Remove all fuses. (For locations of fuses, refer to "Electrical System Chapter".)
(6)
Be sure to connect grounding of the electric welding machine near the welding area.
(6)
Be sure to connect grounding of the electric welding machine near the welding area.
(7)
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Connect grounding from a bolt (plated bolt) or a frame near the welding area.
Remove paint of the frame for connection of grounding from the frame.
Remove paint of the frame for connection of grounding from the frame.
Other precautions a.
(7)
Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they
Other precautions a.
may not be exposed to spatter. b.
may not be exposed to spatter.
Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also
b.
maintain welding quality. (8)
(9)
Put a cover on rubber hoses, wire harnesses, pipes, tires, etc. around the welding area so that they Perform welding under appropriate conditions and minimize heat effect in the peripheral area. Also maintain welding quality.
After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
(8)
After welding, connect and assemble in the order of the fuse and the minus terminal of the battery
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
disassembled. When paint is removed from a frame or cab, apply rust preventive coating with the same
color.
color.
After reassembly, check the function if it operates correctly. General information
(9)
After reassembly, check the function if it operates correctly. General information
1–10
1–10
GENERAL
Tightening of engine bolts and nuts
GENERAL
Tightening of engine bolts and nuts JP31199010102003
1.
Tightening torque of general standard bolts (1)
JP31199010102003
1.
For bolts with seatings
Tightening torque of general standard bolts (1)
For bolts with seatings
Unit : N m{kgf cm}
Unit : N m{kgf cm}
Screw diameter x Pitch
7T
9T
Screw diameter x Pitch
7T
9T
M8 x 1.25 (Coarse thread)
28.5{290}
36{370}
M8 x 1.25 (Coarse thread)
28.5{290}
36{370}
M10 x 1.25 (Fine thread)
60{610}
74.5{760}
M10 x 1.25 (Fine thread)
60{610}
74.5{760}
M10 x 1.5 (Coarse thread)
55{560}
68.5{700}
M10 x 1.5 (Coarse thread)
55{560}
68.5{700}
M12 x 1.25 (Fine thread)
108{1, 100}
136{1, 390}
M12 x 1.25 (Fine thread)
108{1, 100}
136{1, 390}
M12 x 1.75 (Coarse thread)
97{990}
125{1, 280}
M12 x 1.75 (Coarse thread)
97{990}
125{1, 280}
M14 x 1.5 (Fine thread)
171.5{1, 750}
216{2, 210}
M14 x 1.5 (Fine thread)
171.5{1, 750}
216{2, 210}
M14 x 2 (Coarse thread)
154{1, 570}
199{2, 030}
M14 x 2 (Coarse thread)
154{1, 570}
199{2, 030}
Remark
Bolt with number “7” on the head
Bolt with number “9” on the head
Remark
Bolt with number “7” on the head
Bolt with number “9” on the head
! CAUTION
(2)
• 8T bolt is in accordance with 7T bolt.
! CAUTION
For bolts with washers
(2)
• 8T bolt is in accordance with 7T bolt.
For bolts with washers
Unit : N m{kgf cm}
Unit : N m{kgf cm}
Screw diameter x Pitch
4T
7T
9T
Screw diameter x Pitch
4T
7T
9T
M6 x 1 (Coarse thread)
6{60}
10{100}
13{130}
M6 x 1 (Coarse thread)
6{60}
10{100}
13{130}
M8 x 1.25 (Coarse thread)
14{140}
25{250}
31{320}
M8 x 1.25 (Coarse thread)
14{140}
25{250}
31{320}
M10 x 1.25 (Fine thread)
29{300}
51{520}
64{650}
M10 x 1.25 (Fine thread)
29{300}
51{520}
64{650}
M10 x 1.5 (Coarse thread)
26{270}
47{480}
59{600}
M10 x 1.5 (Coarse thread)
26{270}
47{480}
59{600}
M12 x 1.25 (Fine thread)
54{550}
93{950}
118{1, 200}
M12 x 1.25 (Fine thread)
54{550}
93{950}
118{1, 200}
M12 x 1.75 (Coarse thread)
49{500}
83{850}
108{1, 100}
M12 x 1.75 (Coarse thread)
49{500}
83{850}
108{1, 100}
M14 x 1.5 (Fine thread)
83{850}
147{1, 500}
186{1, 900}
M14 x 1.5 (Fine thread)
83{850}
147{1, 500}
186{1, 900}
M14 x 2 (Coarse thread)
74{750}
132{1, 350}
172{1, 750}
M14 x 2 (Coarse thread)
74{750}
132{1, 350}
172{1, 750}
Bolt with number “4”on Remark
Bolt with number “4”on
the head
Bolt with number“7”on
Projection bolt Stud
the head Stud with C
with R surface at free
surface at free end
Bolt with number “9”on the head
Remark
end
! CAUTION
the head
Bolt with number“7”on
Projection bolt Stud
the head Stud with C
with R surface at free
surface at free end
Bolt with number “9”on the head
end
• 8T bolt is in accordance with 7T bolt.
R surface (4T)
! CAUTION
C surface (7T)
• 8T bolt is in accordance with 7T bolt.
R surface (4T)
SAPH311990100006
C surface (7T)
SAPH311990100006
1–11
GENERAL 2.
Precoated bolt
2.
Precoated bolt
Precoated bolt is the bolt with an application of a seal lock
Precoated bolt is the bolt with an application of a seal lock
agent at the thread.
agent at the thread.
(1)
(1)
When re-application of lock agent is required a. b.
When precoated bolts are removed When precoated bolts are moved due to tightening
b.
(2)
tightening torque allowable value. If
movement is found, tighten the bolt
movement is found, tighten the bolt
according to the procedure below.
according to the procedure below.
Re-use method of precoated bolt lock a.
Clean bolt and screw holes. (Clean screw holes for
b. c.
(2)
Re-use method of precoated bolt lock a.
Clean bolt and screw holes. (Clean screw holes for
Dry completely by blowing air.
b.
Dry completely by blowing air.
Apply the specified seal lock agent to the thread of the
c.
Apply the specified seal lock agent to the thread of the
replacement.)
bolt.
bolt.
Plastic region tightening method (angle method) (1)
Precautions Some engines are tightened with the plastic region
Tighten it 90°
3. One turn by 90°
Plastic region tightening method (angle method) (1)
Some engines are tightened with the plastic region
Tighten it 90°
tightening method.
Since it is different from the conventional method, tighten
Since it is different from the conventional method, tighten
it according to the instruction in the text.
it according to the instruction in the text.
SAPH311990100008
(2) Tighten it 45° (Second time)
Parts tightened Cylinder head bolt, crankshaft main bearing cap bolt,
(2) One turn by 90° One turn by 45°
Tighten it 45° (Second time)
! CAUTION
• Measure the overall length of the bolt before
connecting rod bearing cap bolt, etc. Tighten it 90° (First time)
assembly and replace the bolt if the length
exceeds the service limit.
exceeds the service limit.
Apply engine oil to bolt seating and bolt
Apply engine oil to bolt seating and bolt
thread in assembly.
thread in assembly.
Tightening method after tightening to seating torque Tightening of 90 q, 135 q(90 qonce and 45 qonce) and 180 q(90 qtwice) is available.
Tighten it 90° (First time)
SAPH311990100010
• Measure the overall length of the bolt before
SAPH311990100009
(3) Tighten it 90° (Second time)
! CAUTION
assembly and replace the bolt if the length
SAPH311990100009
Two turns by 90°
Parts tightened Cylinder head bolt, crankshaft main bearing cap bolt,
connecting rod bearing cap bolt, etc. Tighten it 90° (First time)
Precautions
tightening method.
SAPH311990100008
One turn by 90° One turn by 45°
• Check torque with the lower limit of the
SAPH311990100007
replacement.)
3.
When precoated bolts are moved due to tightening
NOTICE
tightening torque allowable value. If
SAPH311990100007
When precoated bolts are removed check (for loosening or tightening)
Seal Lock Agent
• Check torque with the lower limit of the
NOTICE
When re-application of lock agent is required a.
check (for loosening or tightening)
Seal Lock Agent
One turn by 90°
1–11
GENERAL
(3) Two turns by 90°
Tighten it 90° (Second time)
Tightening method after tightening to seating torque Tightening of 90 q, 135 q(90 qonce and 45 qonce) and 180 q(90 qtwice) is available.
Tighten it 90° (First time)
SAPH311990100010
1â&#x20AC;&#x201C;12
1â&#x20AC;&#x201C;12
GENERAL
Tightening of chassis bolts and nuts
GENERAL
Tightening of chassis bolts and nuts JP31199010102004
1.
Tightening torque of general standard bolts and nuts (1)
1.
Selection method of tightening torque a.
JP31199010102004
Tightening torque of general standard bolts and nuts (1)
Find the applicable strength zone from the table below and select the bolt tightening torque from the
Selection method of tightening torque a.
table described later. b. (2)
table described later.
Select the nut tightening torque from the mating bolt as described above.
b.
Identification method of bolt strength zone a.
(2)
Identification method with product
and upset on the head with the symbol in the table.
6T
7T
8T
9T
10T
11T
12T
6
7
8
q*1
10
11
12
Strength zone Identification symbol for part
(*1) : 9 may be misread with 6. It is expressed in q. Depression
Relief
Identification method with product
Hexagonal bolt Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression
and upset on the head with the symbol in the table.
Identification symbol for part
Select the nut tightening torque from the mating bolt as described above. Identification method of bolt strength zone
a.
Hexagonal bolt Strength zone of hexagonal bolts is, in principle, indicated with recession, relief, surface depression
Strength zone
Find the applicable strength zone from the table below and select the bolt tightening torque from the
Base depression
6T
7T
8T
9T
10T
11T
12T
6
7
8
q*1
10
11
12
(*1) : 9 may be misread with 6. It is expressed in q. Upset
Depression
Relief
Base depression
SAPH311990100011
Hexagonal nut Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
SAPH311990100011
Hexagonal nut Symbol example for identification of the strength zone of the hexagonal nut is shown in the table below :
Formula
(3)
Formula
Types of general standard bolts and nuts Standard seating
Upset
Seating A with flange
(3) Seating B with flange
Types of general standard bolts and nuts Standard seating
Seating A with flange
Seating B with flange
1–13
GENERAL (4)
Standard tightening torque table of general standard bolts and nuts
1–13
GENERAL (4)
(Representative standard seating is described)
Standard tightening torque table of general standard bolts and nuts (Representative standard seating is described)
Unit : N m{kgf cm}
Unit : N m{kgf cm}
Strength
Strength
zone
zone
Bolt
4T
7T
9T
Bolt
diameter
diameter
(mm)
(mm) 4.5r1.8{50r20}
M6
M8
(Cab) 5.5r1.1{60r10}
9.0r1.8{90r20}
11.5r2.0{117r23}
M6
M12
(Cab) 5.5r1.1{60r10}
(Chassis)
(Chassis)
14.0r3.5{140r40}
14.0r3.5{140r40}
(Cab) 17.0r3.0{170r30}
27.0r5.0{276r55}
48.0r9.5{490r98}
7T
9T
9.0r1.8{90r20}
11.5r2.0{117r23}
22.0r4.0{220r40} *2
29.0r5.5{300r60} *2
43.0r8.5{440r90} *2
57.0r11.0{580r110} *2
(Cab)
(Cab)
51.5r10.0{530r100}
68.5r13.5{700r140}
4.5r1.8{50r20}
22.0r4.0{220r40} *2
29.0r5.5{300r60} *2
M8
(Chassis)
M10
4T
(Cab) 17.0r3.0{170r30} (Chassis)
43.0r8.5{440r90} *2
57.0r11.0{580r110} *2
(Cab)
(Cab)
51.5r10.0{530r100}
68.5r13.5{700r140}
(Chassis)
(Chassis)
(Chassis)
(Chassis)
76.0r15.0{776r150} *2
100.0r20.0{1, 020r200} *2
76.0r15.0{776r150} *2
100.0r20.0{1, 020r200} *2
(Cab)
(Cab)
(Cab)
(Cab)
91.0r18.0{930r180}
120.0r24.0{1, 220r240}
91.0r18.0{930r180}
120.0r24.0{1, 220r240}
(Chassis)
(Chassis)
(Chassis)
(Chassis)
M10
M12
27.0r5.0{276r55}
48.0r9.5{490r98}
M14
77.0r15.0{786r157}
120.0r24.0{1, 220r240}
160.0r32.0{1, 630r326}
M14
77.0r15.0{786r157}
120.0r24.0{1, 220r240}
160.0r32.0{1, 630r326}
M16
120.0r24.0{1, 220r244}
190.0r38.0{1, 940r390}
250.0r50.0{2, 550r510}
M16
120.0r24.0{1, 220r244}
190.0r38.0{1, 940r390}
250.0r50.0{2, 550r510}
M18
165.0r33.0{1, 680r336}
260.0r52.0{2, 650r530}
345.0r69.0{3, 520r704}
M18
165.0r33.0{1, 680r336}
260.0r52.0{2, 650r530}
345.0r69.0{3, 520r704}
M20
235.0r47.0{2, 400r480}
370.0r74.0{3, 770r750}
490.0r98.0{5, 000r1, 000}
M20
235.0r47.0{2, 400r480}
370.0r74.0{3, 770r750}
490.0r98.0{5, 000r1, 000}
M22
320.0r64.0{3, 270r654}
505.0r100.0{5, 150r1, 030}
670.0r130.0{6, 840r1, 370}
M22
320.0r64.0{3, 270r654}
505.0r100.0{5, 150r1, 030}
670.0r130.0{6, 840r1, 370}
M24
405.0r81.0{4, 130r826}
640.0r125.0{6, 530r1, 310}
845.0r165.0{8, 620r1, 720}
M24
405.0r81.0{4, 130r826}
640.0r125.0{6, 530r1, 310}
845.0r165.0{8, 620r1, 720}
! CAUTION
• Use the tightening torque value for seating A with flange except for *2 in the table larger by 10% than the tightening torque value in the table. • Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
! CAUTION
• Use the tightening torque value for seating A with flange except for *2 in the table larger by 10% than the tightening torque value in the table. • Use the tightening torque value for seating B with flange of *2 in the table larger by 20%
than the tightening torque value in the table.
than the tightening torque value in the table.
The tightening torque value of M8 for seating B with flange remaines unchanged.
The tightening torque value of M8 for seating B with flange remaines unchanged.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in pairs. Use the standard seating for the tightening torque value.
• Seating B with flange of *2 in the table is interchangeable with the standard seating in pairs. Use the standard seating for the tightening torque value.
1–14
1–14
GENERAL
Tightening of flare nuts and hoses
GENERAL
Tightening of flare nuts and hoses JP31199010102005
1.
Tightening torque of pipe flare nut
JP31199010102005
1.
Tightening torque of pipe flare nut
Unit : N m{kgf cm}
Unit : N m{kgf cm}
Pipe outer
Pipe outer
diameter
I4.76
I6.35
I8
I10
I12
Material Steel pipe 2.
diameter
I15
I4.76
I6.35
I8
I10
I12
I15
15r5{150r50}
25r5{250r50}
36r5{370r50}
52r7{530r70}
67r7{680r70}
88r8{900r80}
Material 15r5{150r50}
25r5{250r50}
36r5{370r50}
52r7{530r70}
67r7{680r70}
88r8{900r80}
Tightening torque of hoses
Steel pipe 2.
Tightening torque of hoses
Unit : N m{kgf cm} Hose outer diameter
Hose outer diameter
I13, I20, I22, fitting at
I10.5 fitting
packing
Unit : N m{kgf cm}
Hose outer diameter
Hose outer diameter
PF3/8 fitting
I10.5 fitting
21.5r1.5{215r15} Air hose
3.
I13, I20, I22, fitting at packing
—
41.5r2.5{425r25}
Only meter gauge
Air hose
Only meter gauge
41.5r2.5{425r25}
—
Packing
—
51.5r7.5{525r75}
—
Brake hose
—
—
3.
Packing 51.5r7.5{525r75}
Lock nut tightening torque of brass joint
Unit : N m{kgf cm}
size Tightening torque
PF3/8 fitting
10{100}
Lock nut tightening torque of brass joint
Screw nominal
Hose outer diameter
21.5r1.5{215r15}
10{100} Brake hose
Hose outer diameter
M12
M16
M20
M27
15r2{150r20}
66r6{670r60}
97r9{990r90}
209r19{2130r190}
Unit : N m{kgf cm} Screw nominal size Tightening torque
M12
M16
M20
M27
15r2{150r20}
66r6{670r60}
97r9{990r90}
209r19{2130r190}
1–15
GENERAL
1–15
GENERAL
Taper thread sealant for piping
Taper thread sealant for piping JP31199010102006
The taper thread of the air pipe joint has application of sealant
The taper thread of the air pipe joint has application of sealant
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
[Loctite # 575 (by Japan Loctite)]. Follow the procedures below for
connection or disconnection of pipes.
connection or disconnection of pipes.
1.
For disconnection
1.
Removal of joint (Example: Use of magnetic valve)
(1)
The sealant ( # Loctite 575) has strong sealing feature. The return torque of the taper joint is increased about 1.5
Air pipe (Flare joint) (No application of sealant)
Air hose
disconnected, use a long wrench for disconnection. (2)
When a joint at a poorly accessible area is replaced, remove accessories first and disconnect the joint. Air hose
times the initial tightening torque. When the joint is disconnected, use a long wrench for disconnection.
Since sealant is applied to this area, remove accessories with the joint attached and remove the joint.
(2)
When a joint at a poorly accessible area is replaced, remove accessories first and disconnect the joint.
SAPH311990100016
2.
For connection (1)
2.
For application of sealant ( # Loctite 575), wipe the
1/4 turn
For connection (1)
Amount of application: 0.1 g/piece
sealing area completely with a rag or thinner. Apply with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
For application of sealant ( # Loctite 575), wipe the sealing area completely with a rag or thinner. Apply
sealant directly to about three ridges for quarter round 3 threads
SAPH311990100017
The sealant ( # Loctite 575) has strong sealing feature. The return torque of the taper joint is increased about 1.5
Air pipe (Flare joint) (No application of sealant)
Frame
times the initial tightening torque. When the joint is
Since sealant is applied to this area, remove accessories with the joint attached and remove the joint.
Amount of application: 0.1 g/piece
(1)
Magnetic valve
SAPH311990100016
1/4 turn
For disconnection
Removal of joint (Example: Use of magnetic valve)
Magnetic valve Frame
JP31199010102006
sealant directly to about three ridges for quarter round 3 threads
with offset of one ridge from the end. Tighten it according
1 thread
to the tightening torque in the table below.
Remove dirt completely from the mating part (female)
Remove dirt completely from the mating part (female)
before tightening.
before tightening.
! CAUTION
• If your eye or skin comes in contact with
SAPH311990100017
! CAUTION
sealant, wash it off immediately with water. Tightening torque of taper joint
Unit : N m{kgf cm}
Screw diameter
sealant, wash it off immediately with water. Tightening torque of taper joint
1/4
3/8
1/2
diameter
1/4
3/8
1/2
Material
Steel
49r10{500r100}
Aluminum, brass
25r5{250r50}
64r15{650r150} 34r5{350r50}
44r5{450r50}
When a sealing tape is replaced with sealant, remove the
Steel
! CAUTION
• Be careful to prevent entry of dirt or foreign
49r10{500r100}
Aluminum, brass (2)
tape completely first as in (1).
If air leak is found after assembly with application of
25r5{250r50}
64r15{650r150} 34r5{350r50}
44r5{450r50}
When a sealing tape is replaced with sealant, remove the tape completely first as in (1).
! CAUTION
matter in the pipe. (3)
Unit : N m{kgf cm}
Screw
Material
(2)
• If your eye or skin comes in contact with
• Be careful to prevent entry of dirt or foreign matter in the pipe.
(3)
If air leak is found after assembly with application of
sealant, air leak cannot be stopped with additional
sealant, air leak cannot be stopped with additional
tightening. Assemble the part again according to (1) and
tightening. Assemble the part again according to (1) and
(2).
(2).
1–16
1–16
GENERAL
Assembly of joints and gaskets for piping
GENERAL
Assembly of joints and gaskets for piping JP31199010102007
1.
Tightening torque of joints
JP31199010102007
1.
Tightening torque of joints
Unit : N m{kgf cm} Metal sealing method
Sealing method Gasket sealing method Tightening screw
Unit : N m{kgf cm}
(Aluminum + Rubber or Copper) Type A
size M8
13{130}
M10
20{200}
M12
25{250}
M14
Type B
Metal sealing method
Sealing method
(Flare pipe type, nipple connector type)
Gasket sealing method Tightening screw
(Flare pipe type, nipple connector type)
(Aluminum + Rubber or Copper) Type A
size M8
13{130}
M10
20{200}
20{200}
M12
25{250}
20{200}
25{250}
31{320}
M14
25{250}
31{320}
M16
29{300}
39{400}
M16
29{300}
39{400}
M18
39{400}
59{600}
M18
39{400}
59{600}
M20
*39{400}
64{650}
M20
*39{400}
64{650}
M24
69{700}
M24
69{700}
M28
*127{1300}
M28
*127{1300}
2.
11{110}
20{200}
Joint assembly procedure and subsequent inspection (1)
Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint,
2.
Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten
11{110}
20{200}
Joint assembly procedure and subsequent inspection (1)
gasket, etc.). (2)
Type B
Before assembly, make sure that there is no dirt or burr on the seating surface (mating part, pipe joint, gasket, etc.).
(2)
pipes finally after temporary tightening to prevent leak.
Since pipes have some degrees of freedom for assembly, the seating surface tends to incline. Tighten pipes finally after temporary tightening to prevent leak.
(3)
After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(3)
After tightening, apply the specified pressure to each pipe joint to ensure that there is no leak.
(4)
Observe the values above for each tightening torque.
(4)
Observe the values above for each tightening torque.
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
*When assembled soft washer # 4840FR-N (aluminum and rubber carbon pressure bonding) is loosened
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.
or removed, be sure to replace it with a new part. This is not necessary for normal retightening.
1â&#x20AC;&#x201C;17
GENERAL 3.
Examples of joint methods in various pipes
3.
Examples of joint methods in various pipes
Metal sealing method Gasket sealing method
Metal sealing method Gasket sealing method
Type A
Type B
(Flare pipe type)
(Nipple connector type)
Flare pipe Connector Flare nut
Sealing surface: 3 places
Joint bolt Gasket
Nut
Type A
Type B
(Flare pipe type)
(Nipple connector type)
Flare pipe Connector Flare nut
Sealing surface: 3 places
Joint bolt Gasket
Connector nipple
Joint bolt
Sealing surface : 4 places Flare connector
Gasket
Gasket Gasket
Gasket
Joint bolt
Sealing surface : 5 places
Lock washer
Sealing surface: 5 places
Nut Bracket
One piece eye joint with sleeve
Flare connector
Gasket
Gasket Gasket
Gasket
Joint bolt
Sealing surface : 5 places
Lock washer
Nut
Nut Bracket
Sealing surface : 8 places
Connector nipple Sealing surface: 1 place
Connector nipple
Sealing surface: 1 place
Sealing surface: 1 place
Flare connector
Nut
Nut
3-way joint
3-way joint Sealing surface : 8 places
Joint pipe
Joint pipe
Bracket Sealing surface : 3 places
Bracket Sealing surface : 3 places
One piece eye joint without sleeve
One piece eye joint without sleeve
Joint bolt
Joint bolt
Joint pipe
Sealing surface: 6 places
Lock washer
Box nut
Sealing surface : 8 places
Sealing surface: 1 place Flare connector
Lock washer
Box nut
Joint bolt
Sealing surface: 5 places
Nut
Sealing surface : 8 places
Sealing surface: 4 places
Nut Connector nipple
Joint bolt
Sealing surface : 4 places One piece eye joint with sleeve
1â&#x20AC;&#x201C;17
GENERAL
Sealing surface: 4 places
Joint bolt
Joint pipe
Sealing surface: 6 places
1â&#x20AC;&#x201C;18
1â&#x20AC;&#x201C;18
GENERAL
Handling of liquid gasket
GENERAL
Handling of liquid gasket JP31199010102008
1.
Application of liquid gasket and part assembly procedure (1)
JP31199010102008
1.
Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
Application of liquid gasket and part assembly procedure (1)
deposit of oil, moisture, dirt, etc.
Be sure to overap parts at the beginning and at the end of application.
Be sure to overap parts at the beginning and at the end of application.
(2)
Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
(3)
Assemble parts within 20 minutes after application of the liquid gasket.
(2)
Be careful for offset with the mating part when a part applied with liquid gasket is assembled. Apply the
(3)
Assemble parts within 20 minutes after application of the liquid gasket.
liquid gasket again if offset occurs.
liquid gasket again if offset occurs.
If 20 minutes has passed, remove the liquid gasket and apply it again. (4) 2.
3.
(4) 2.
When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
Start the engine at least 15 minutes or more after assembly of parts.
Removal of parts (1)
When parts are removed, do not pry one place only. Remove parts by prying each other using collar or
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
clearance on the flange. When gasket is removed, be careful to prevent entry of gasket offal into the
engine.
engine.
Others (1)
If 20 minutes has passed, remove the liquid gasket and apply it again.
Start the engine at least 15 minutes or more after assembly of parts.
Removal of parts (1)
Remove old liquid gasket on each part and mating part completely. Clean the parts with a rag to prevent
deposit of oil, moisture, dirt, etc.
3.
When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in a cartridge, use the application gun.
Others (1)
When the liquid gasket is contained in a tube, use the accompanying winding tool. When it is contained in a cartridge, use the application gun.
Winding tool
Winding tool
Application gun
Tube: 150 g
Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
Application gun
Tube: 150 g
Cartridge type: 300 g
For a tube, desired application width may be obtained from the cut position at the nozzle end.
1 : Approx. 2 mm at the 1st section cut
1 : Approx. 2 mm at the 1st section cut
2 : Approx. 5 mm at the 2nd section cut
2 : Approx. 5 mm at the 2nd section cut
Nozzle of tube
Nozzle of tube General information Description of function
General information Description of function
1â&#x20AC;&#x201C;19
GENERAL
Failure diagnosis table for each problem
1â&#x20AC;&#x201C;19
GENERAL
Failure diagnosis table for each problem JP31199010301001
Causes and actions are described for each item.
Engine mechanical
JP31199010301001
Causes and actions are described for each item.
Engine mechanical
JP03Z01020601001
Status Engine overheat (coolant)
Cause
JP03Z01020601001
Action
Insufficient coolant
Replenish coolant
Faulty thermostat
Status Engine overheat (coolant)
Cause
Action
Insufficient coolant
Replenish coolant
Replace thermostat
Faulty thermostat
Replace thermostat
Water leak from cooling system
Correction
Water leak from cooling system
Correction
Faulty coolant pump
Repair or replace
Faulty coolant pump
Repair or replace
Faulty head gasket
Replace head gasket
Faulty head gasket
Replace head gasket
Engine overheat
Clogging of radiator
Cleaning of radiator
Engine overheat
Clogging of radiator
Cleaning of radiator
(radiator)
Corrosion of cooling system
Clean and repair cooling system
(radiator)
Corrosion of cooling system
Clean and repair cooling system
Clogging of radiator core front part
Clean radiator
Clogging of radiator core front part
Clean radiator
Faulty radiator cap
Replace radiator cap
Faulty radiator cap
Replace radiator cap
Engine overheat (compression
Non-synchronous injection timing
Adjust injection timing.
Engine overheat (compression
Non-synchronous injection timing
Adjust injection timing.
pressure)
Faulty fuel injection pressure
Adjust injection pressure
pressure)
Faulty fuel injection pressure
Adjust injection pressure
Faulty fuel
Replace with correct fuel
Faulty fuel
Replace with correct fuel
Faulty injector
Replace injector
Faulty injector
Replace injector
Engine overheat (lubrication
Deterioration of engine oil
Replace engine oil
Engine overheat (lubrication
Deterioration of engine oil
Replace engine oil
unit)
Faulty oil pump
Replace oil pump
unit)
Faulty oil pump
Replace oil pump
Insufficient engine oil
Replenish engine oil
Insufficient engine oil
Replenish engine oil
Large engine oil consumption
Wear of piston ring and cylinder
Replace piston ring and cylinder
Large engine oil consumption
Wear of piston ring and cylinder
Replace piston ring and cylinder
(piston, cylinder liner and piston
liner
liner
(piston, cylinder liner and piston
liner
liner
ring)
Damage to piston ring
Replace piston ring and cylinder
ring)
Damage to piston ring
Replace piston ring and cylinder
liner Faulty fixing of piston ring
liner
Replace piston ring and cylinder
Faulty fixing of piston ring
liner Faulty assembly of piston ring
Replace piston ring and cylinder liner
Replace piston ring and cylinder
Faulty assembly of piston ring
liner
Replace piston ring and cylinder liner
Faulty engine oil
Replace engine oil
Faulty engine oil
Faulty piston ring joint
Reassemble piston ring
Faulty piston ring joint
Reassemble piston ring
Large engine oil consumption
Wear of valve stem
Replace valve and valve guide
Large engine oil consumption
Wear of valve stem
Replace valve and valve guide
(valve and valve guide)
Wear of valve guide
Replace valve guide
(valve and valve guide)
Wear of valve guide
Replace valve guide
Faulty assembly of valve stem seal
Replace stem seal
Faulty assembly of valve stem seal
Replace stem seal
Excessive oil lubrication to rocker
Inspection of clearance between
Excessive oil lubrication to rocker
Inspection of clearance between
arm
rocker arm and rocker arm shaft
arm
rocker arm and rocker arm shaft
Large engine oil consumption
Faulty oil level gauge
Replace with correct level gauge
Large engine oil consumption
Faulty oil level gauge
Replace with correct level gauge
(others)
Excessive filling of engine oil
Fill with appropriate amount of oil.
(others)
Excessive filling of engine oil
Fill with appropriate amount of oil.
Leak of engine oil
Repair or replace the part of oil
Leak of engine oil
leak. Piston seizure (in operation)
Sudden stop of engine
Piston seizure (lubrication unit)
Insufficient engine oil
Replenish engine oil
Deterioration of engine oil
Replace engine oil
Repair or replace the part of oil leak.
Perform warm-up before stop of
Piston seizure (in operation)
Sudden stop of engine
Piston seizure (lubrication unit)
Insufficient engine oil
Replenish engine oil
Replace engine oil
Deterioration of engine oil
Replace engine oil
Incorrect engine oil
Replace with correct engine oil.
Incorrect engine oil
Replace with correct engine oil.
Low oil pressure
Inspection of lubrication unit
Low oil pressure
Inspection of lubrication unit
Faulty oil pump
Replace oil pump
engine
Perform warm-up before stop of engine
Faulty oil pump
Replace oil pump
Piston seizure
Abnormal combustion
Refer to overheat section.
Piston seizure
Abnormal combustion
Refer to overheat section.
Piston seizure
Cooling unit
Refer to overheat section.
Piston seizure
Cooling unit
Refer to overheat section.
SAPH311990100031
SAPH311990100031
1–20
1–20
GENERAL
GENERAL
Failure diagnosis using HinoDX
Failure diagnosis using HinoDX JP31199010301002
! CAUTION
JP31199010301002
• HinoDX is used for inspection and adjustment
! CAUTION
• HinoDX is used for inspection and adjustment
of the system in addition to failure diagnosis. 1.
HinoDX (1)
SAPH311990100032
1.
With HinoDX, failure of the common rail fuel injection
Part No.
(DOS/V standard)
and the special cable are required for connection to the
vehicle.
vehicle.
Special tool : 09121-1040 Hino-Bowie
SAPH311990100032
09042-1220 Cable between vehicle and CD-ROM HinoDX
CD-ROM HinoDX
• Install the software of the Hino Diagnostic
! CAUTION
(Interface box)
Cable between
• Install the software of the Hino Diagnostic
eXplorer (HinoDX) in the PC. For the
eXplorer (HinoDX) in the PC. For the
installation method, refer to the instruction
installation method, refer to the instruction
manual accompanying the CD.
manual accompanying the CD. 2.
External shape
General description and function
List of failure diagnosis tools Part name
Part No.
External shape
General description and function • Operating system (OS) : Windows95,
PC (DOS/V standard)
Windows98(IE5.0 or later),
Windows2000(SP3, IE5.0 or later),
Windows2000(SP3, IE5.0 or later),
WindowsXP(SP1a, IE6.0 or later)
WindowsXP(SP1a, IE6.0 or later)
• CPU and memory : Conditions that
—
• CPU and memory : Conditions that
assure operation of the above operating
assure operation of the above operating
system
system • Display : 800 x 600, 256 colors or
more 09121 - 1040
09042-1220 Cable between vehicle and Hino-Bowie
• Display : 800 x 600, 256 colors or Hino-Bowie
Special tool : 09121-1040 Hino-Bowie
Hino-Bowie
Windows98(IE5.0 or later),
—
With HinoDX, failure of the common rail fuel injection system can be diagnosed. The interface box (Hino-Bowie)
• Operating system (OS) : Windows95,
PC
(1)
and the special cable are required for connection to the
List of failure diagnosis tools Part name
HinoDX
system can be diagnosed. The interface box (Hino-Bowie)
! CAUTION
2.
of the system in addition to failure diagnosis.
• PC interface
more Hino-Bowie
09121 - 1040
(Interface box)
Cable between
vehicle and Hino-
vehicle and Hino-
Bowie (09042 -
Bowie (09042 -
1220)
1220)
• PC interface
Signal check
09049 - 1080
Interrupting installation between vehicle
Signal check
09049 - 1080
Interrupting installation between vehicle
harness
(for common rail fuel
harness and ECU allows inspection with a
harness
(for common rail fuel
harness and ECU allows inspection with a
injection system)
tester rod while the power is supplied.
injection system)
tester rod while the power is supplied.
1–21
GENERAL 3.
Deletion of past failures (1)
3.
To delete past failures of the engine ECU, use HinoDX on
Deletion of past failures (1)
To delete past failures of the engine ECU, use HinoDX on
the PC. (Refer to "HinoDX operation manual".)
the PC. (Refer to "HinoDX operation manual".)
SAPH311990100032
SAPH311990100032
4.
Connection of signal check harness (1)
4.
To prevent damage to the ECU connector and to improve
a.
(1)
testing rod on the signal check connector of the signal
testing rod on the signal check connector of the signal
check harness for meaurement.
check harness for meaurement.
Disconnect the connector from the ECU. • Do not break the locking tab of the connector.
a.
! CAUTION
Unit harness
Connect the signal check harness to the machine
b.
harness and the ECU. Signal check harness
• Do not break the locking tab of the connector.
Connect the signal check harness to the machine harness and the ECU. Signal check harness
Test lead
(for common rail fuel injection system)
SAPH311990100036
Disconnect the connector from the ECU.
Signal check harness
b.
Signal check connector
To prevent damage to the ECU connector and to improve accessibility, connect the signal check harness and put a
Signal check harness
Test lead
Connection of signal check harness
accessibility, connect the signal check harness and put a
! CAUTION
Unit harness
1–21
GENERAL
(for common rail fuel injection system)
Part No.
Part No.
09049-1080
09049-1080 Signal check connector
SAPH311990100036
1â&#x20AC;&#x201C;22 (2)
1â&#x20AC;&#x201C;22
GENERAL Terminal No.
(2)
For the signal check harness connector, the ECU terminal number in the text is treated as follows :
GENERAL Terminal No. For the signal check harness connector, the ECU terminal number in the text is treated as follows :
ECU unit
ECU unit
Signal check harness
Signal check harness
ECU side
Unit side
ECU side
SAPH311990100038
Unit side
SAPH311990100038
1â&#x20AC;&#x201C;23
GENERAL
1â&#x20AC;&#x201C;23
GENERAL
Connection method of HinoDX
Connection method of HinoDX JP31199010301003
1.
JP31199010301003
Connection of HinoDX (1)
1.
Remove the left side cover at the rear of the driver's seat
Connection of HinoDX (1)
and connect the failure diagnosis connector with a PC
which installed HinoDX through the interface box.
which installed HinoDX through the interface box.
Special tool : 09121-1040 Hino-Bowie (Interface box)
Special tool : 09121-1040 Hino-Bowie (Interface box)
09042-1220 Connecting cable
09042-1220 Connecting cable
CD-ROM HinoDX
Engine ECU
(2)
CD-ROM HinoDX
Engine ECU
Set the starter key to "ON" and start HinoDX.
(2)
Failure diagnosis connector
Set the starter key to "ON" and start HinoDX.
Failure diagnosis connector
SAPH311990100039
SAPH311990100039
Failure diagnosis connector
Failure diagnosis connector
Hino-Bowie
Connect to the failure diagnosis connector at the unit side.
Remove the left side cover at the rear of the driver's seat
and connect the failure diagnosis connector with a PC
Hino-Bowie
Connecting cable
Connect to the failure diagnosis connector at the unit side.
SAPH311990100040
Connecting cable SAPH311990100040
Setup layout Layout
Setup layout Layout
Chassis number and engine number
Chassis number and engine number JP31199010401001
1. (Example)
Engine type and engine number (1)
Stamp position
SAPH311990100041
JP31199010401001
Engine type and engine number are stamped at the left cylinder block when viewed from the cooling fan. For order
1. (Example)
Engine type and engine number (1)
Stamp position
Engine type and engine number are stamped at the left cylinder block when viewed from the cooling fan. For order
of parts, information of this number will facilitate
of parts, information of this number will facilitate
procedures smoothly.
procedures smoothly.
Ex. J05E TA10101
Ex. J05E TA10101
SAPH311990100041
STANDARD VALUE
2â&#x20AC;&#x201C;1
STANDARD VALUE
ENGINE
2 STANDARD VALUE Specification System drawing (performance)
2â&#x20AC;&#x201C;1
ENGINE
2
2 STANDARD VALUE Specification System drawing (performance)
Engine Body................................................................ 2-2 Standard value........................................................ 2-2 Tightening torque .................................................... 2-2
Engine Body................................................................ 2-2 Standard value........................................................ 2-2 Tightening torque .................................................... 2-2
Fuel System ................................................................ 2-2 Tightening torque .................................................... 2-2
Fuel System ................................................................ 2-2 Tightening torque .................................................... 2-2
Electrical...................................................................... 2-3 Standard value........................................................ 2-3 Tightening torque .................................................... 2-3
Electrical...................................................................... 2-3 Standard value........................................................ 2-3 Tightening torque .................................................... 2-3
Intake ........................................................................... 2-3 Tightening torque .................................................... 2-3
Intake ........................................................................... 2-3 Tightening torque .................................................... 2-3
Engine Mechanical ..................................................... 2-4 Standard value........................................................ 2-4 Tightening torque .................................................. 2-11
Engine Mechanical ..................................................... 2-4 Standard value........................................................ 2-4 Tightening torque .................................................. 2-11
Exhaust...................................................................... 2-12 Tightening torque .................................................. 2-12
Exhaust...................................................................... 2-12 Tightening torque .................................................. 2-12
Cooling ...................................................................... 2-12 Standard value...................................................... 2-12
Cooling ...................................................................... 2-12 Standard value...................................................... 2-12
Lubrication ................................................................ 2-12 Standard value...................................................... 2-12 Tightening torque .................................................. 2-14
Lubrication ................................................................ 2-12 Standard value...................................................... 2-12 Tightening torque .................................................. 2-14
Starting and Charging.............................................. 2-14 Standard value (Alternator 50A) .......................... 2-14 Tightening torque (Alternator 50A) ....................... 2-15 Standard value (starter) ........................................ 2-15 Tightening torque (starter) .................................... 2-16
Starting and Charging.............................................. 2-14 Standard value (Alternator 50A) .......................... 2-14 Tightening torque (Alternator 50A) ....................... 2-15 Standard value (starter) ........................................ 2-15 Tightening torque (starter) .................................... 2-16
Turbocharger............................................................. 2-16 Standard value...................................................... 2-16 Tightening torque .................................................. 2-16
Turbocharger............................................................. 2-16 Standard value...................................................... 2-16 Tightening torque .................................................. 2-16
2
2–2
2–2
STANDARD VALUE
STANDARD VALUE
Engine Body
Engine Body
Standard value
Standard value JP31199020205001
2
JP31199020205001
2
MPa {kgf/cm2, lbf/in.2}
MPa {kgf/cm , lbf/in. } Inspection item
Standard value
Compression pressure
3.4-3.7
(Engine revolution per cylinder: 150 r/min)
{35-38, 493-237}
Repair
Service
limit
limit
—
Action
2.7
Inspection item
Standard value
Compression pressure
{28, 392}
3.4-3.7
(Engine revolution per cylinder: 150 r/min)
Tightening torque
{35-38, 493-237}
Repair
Service
limit
limit
—
2.7 {28, 392}
Tightening torque JP31199020205002
Unit:N m{kgf cm, lbf ft}
JP31199020205002
Unit:N m{kgf cm, lbf ft}
Tightening area
Tightening torque
Remark
7.8 - 8.8
Starter B terminal
3.3 - 4.4
41 {420, 30}
Fuel System
Injector clamp
3.3 - 4.4 {33 - 45, 2.4 - 3.2} 41 {420, 30} 4.5 - 5.0 {45 - 50, 3.3 - 3.7}
Fuel System
Tightening torque Tightening area
{80 - 110, 5.8 - 6.5}
Radiator hose band
{45 - 50, 3.3 - 3.7}
Tightening torque Tightening torque 25 {250, 18}
JP31199020205003
JP31199020205003
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Remark
Tightening area Injector clamp
Tightening torque 25 {250, 18}
Supply pump - Bearing holder case
28.5 {290, 21}
Supply pump - Bearing holder case
28.5 {290, 21}
Bearing holder case - Pump drive
28.5 {290, 21}
Bearing holder case - Pump drive
28.5 {290, 21}
Supply pump coupling flange mounting nut
63.7 {650, 47}
Supply pump coupling flange mounting nut
63.7 {650, 47}
Fuel filter air bleeding bolt
Remark
7.8 - 8.8
Oil pan drain cock
4.5 - 5.0
Radiator hose band
Tightening torque
Alternator B terminal
{33 - 45, 2.4 - 3.2}
Oil pan drain cock
Tightening area Starter B terminal
{80 - 110, 5.8 - 6.5}
Alternator B terminal
Injector harness
Action
2.2 {22, 1.6} 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}
Injector harness Fuel filter air bleeding bolt
2.2 {22, 1.6} 1.7 - 2.6 {17.3 - 23, 1.2 - 1.9}
Remark
2–3
STANDARD VALUE
2–3
STANDARD VALUE
Electrical
Electrical
Standard value
Standard value JP31199020205018
Inspection item
item
item
Standard value
Remark
8 - 10mm {0.3152 - 0.394in.}
Compression
(Reference push force 98N
gauge (09444-
{10kgf, 22lbf})
1210) is used.
Deflection When installing
JP31199020205018
Inspection item
{50 - 58 kgf, 110 - 128 lbf}
adjustment Deflection
00090 Denso
Compression
adjustment
(Reference push force 98N {10kgf,
gauge (09444-
22lbf})
1210) is used.
Tension
{33 - 41 kgf, 72 - 90 lbf}
(Reference push force 98N
gauge (09444-
{10kgf, 22lbf})
1210) is used. Belt tension
{50 - 58 kgf, 110 - 128 lbf}
Deflection
(Reference push force 98N {10kgf,
gauge (09444-
22lbf})
1210) is used. Belt tension
inspection
00090 Denso
320 - 400 N
Tension
{33 - 41 kgf, 72 - 90 lbf}
part No.) is
part No.) is
Tightening torque Tightening torque
JP31199020205019
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Remark
Tightening area
Tightening torque
Starter mounting bolt
154 {1,570, 114}
Starter mounting nut
171.5 {1,750, 126}
Starter mounting nut
171.5 {1,750, 126}
16 - 22 {165 - 225, 11 - 16}
Alternator through bolt
Battery cable mounting nut
83 {850, 61}
Fixing bolt at brace
E terminal bolt
51{520, 38}
Remark
16 - 22 {165 - 225, 11 - 16}
Alternator through bolt
3.2 - 4.4{33 - 45, 2 - 3}
83 {850, 61} 3.2 - 4.4{33 - 45, 2 - 3}
Fixing bolt at brace
51{520, 38}
Outside B terminal mounting nut
3.2 - 4.4{33 - 45, 2 - 3}
Outside B terminal mounting nut
3.2 - 4.4{33 - 45, 2 - 3}
Through bolt
7.8 - 9.8{80 - 99, 6 - 7}
Through bolt
7.8 - 9.8{80 - 99, 6 - 7}
Intake
Intake
Tightening torque
Intake manifold mounting bolt
00090 Denso
JP31199020205019
154 {1,570, 114}
Tightening area
gauge (95506-
used.
Starter mounting bolt
E terminal bolt
part No.) is
Compression
At the time of
gauge (95506-
Tightening torque
Battery cable mounting nut
00090 Denso
10 - 12mm {0.394 - 0.472in.}
used.
Tightening area
gauge (95506-
490 - 570 N
used.
Belt tension 320 - 400 N
Compression
part No.) is
10 - 12mm {0.394 - 0.472in.}
inspection
8 - 10mm {0.3152 - 0.394in.}
Tension V-belt tension
At the time of
Remark
a new belt
used.
V-belt tension
Standard value
When installing
gauge (95506-
490 - 570 N
Tension
item
Deflection
Belt tension
a new belt
item
Tightening torque Tightening torque 28.5 {290, 21}
JP31199020205005
JP31199020205005
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Remark
Tightening area Intake manifold mounting bolt
Tightening torque 28.5 {290, 21}
Remark
2–4
2–4
STANDARD VALUE
STANDARD VALUE
Engine Mechanical
Engine Mechanical
Standard value
Standard value
Inspection item IN
Unit : mm {in.}
Repair limit
Service limit
0.30 {0.0118}
—
—
—
—
—
—
Cylinder liner protrusion
0.45 {0.0177} 0.01 - 0.08
Cylinder liner protrusion
JP31199020205006
Unit : mm {in.} Standard value
Valve clearance (cold) EX
JP31199020205006
{0.003 - 0.003}
Action
Inspection item
Standard value
Repair limit
Service limit
IN
0.30 {0.0118}
—
—
EX
0.45 {0.0177}
—
—
—
—
Valve clearance (cold) 0.01 - 0.08 {0.003 - 0.003}
Cylinder liner flange width
8 {0.314}
—
—
Cylinder liner flange width
8 {0.314}
—
—
Cylinder block flange width
8 {0.314}
—
—
Cylinder block flange width
8 {0.314}
—
—
—
—
—
—
—
—
—
—
—
—
C
—
—
—
—
A
—
—
—
—
—
—
—
—
—
—
—
—
—
—
A
Cylinder block inner diameter
B
C
A
Cylinder liner outer diameter
B
C Clearance between cylinder liner and cylinder block
Cylinder liner inner diameter
Piston outer diameter (Pin hole 23mm{0.9 in.} above the lower end of the skirt Square direction)
117 - 117.008 {4.6063 - 4.6066} 117.008 - 117.014 {4.6066 - 4.6068} 117.014 - 117.022 {4.6068 - 4.6072} 116.982 - 116.99 {4.6056 - 4.6059} 116.99 - 116.996 {4.6059 - 4.6061} 116.996 - 117.004 {4.6061 - 4.6064} 0.01 - 0.026 {0.0003 - 0.0010}
112 {4.4094}
111.9r0.006 {4.4089r0.0002}
—
112.15 {4.4154}
A
Cylinder block inner diameter
Cylinder liner outer diameter
B
B
C Clearance between cylinder liner and cylinder block
{4.6063 - 4.6066} 117.008 - 117.014 {4.6066 - 4.6068} 117.014 - 117.022 {4.6068 - 4.6072} 116.982 - 116.99 {4.6056 - 4.6059} 116.99 - 116.996 {4.6059 - 4.6061} 116.996 - 117.004 {4.6061 - 4.6064} 0.01 - 0.026 {0.0003 - 0.0010}
Cylinder Replace
Cylinder liner inner diameter
112 {4.4094}
—
liner Piston outer diameter
—
117 - 117.008
—
(Pin hole 23mm{0.9 in.} above the lower end of the skirt Square direction)
111.9r0.006 {4.4089r0.0002}
—
112.15 {4.4154}
0.088 - 0.112 {0.0034 - 0.0044}
—
—
Liner Replace piston
Cylinder Replace liner
—
Cylinder Piston clearance
Action
Cylinder Piston clearance
0.088 - 0.112 {0.0034 - 0.0044}
—
—
Liner Replace piston
2–5
STANDARD VALUE
Inspection item
Standard value Top
Approx. 11.5 {0.4527}
Repair limit
Service limit
—
—
Action
Inspection item
Top
of piston ring
Second
ring Oil
dimension
Piston ring groove
0.3 - 0.40 {0.0118 - 0.0157} 0.75 - 0.9 {0.0295 - 0.0354} 0.15 - 0.3 {0.0059 - 0.0118}
—
—
—
1.5 {0.0591}
—
1.2 {0.0472}
—
1.2 {0.0472}
Second
2 {0.0787}
—
Oil
4 {0.1574}
—
Top
2.5 {0.0984}
—
Second
2 {0.0787}
—
Oil
4 {0.1574}
—
Clearance between piston ring and
{0.5512}
—
Top
Piston
Approx. 14
2.5 {0.0984}
Top Ring width B
Approx. 11.5 {0.4527}
Repair limit
Service limit
—
—
—
—
—
1.5 {0.0591}
—
1.2 {0.0472}
—
1.2 {0.0472}
Action
Free joint clearance Second
Piston
Standard value Top
Free joint clearance
Gap between ends
2–5
STANDARD VALUE
Second
piston ring groove Oil
0.09 - 0.13 {0.0035 - 0.0051} 0.04 - 0.08 {0.00016 - 0.0031} 0.02 - 0.06 {0.0008 - 0.0024}
—
Second
Top Replace piston ring
Gap between ends Piston ring
Oil
–0.1 –0.1 {–0.0039}
Replace
Ring width B
piston ring
dimension
–0.1 {–0.0039} +0.2 {+0.0079} +0.2 {+0.0079}
Replace
Piston ring groove
piston
+0.1 {+0.0039} — —
or piston. —
Piston pin outer diameter
37 {1.4567}
—
Piston boss inner diameter
37 {1.4567}
—
piston ring and
–0.04 {–0.0015} +0.05 {+0.0020}
piston pin Replace piston
and piston boss
4 {0.1574}
—
Top
2.5 {0.0984}
—
Second
2 {0.0787}
—
Oil
4 {0.1574}
—
Second
—
allowance,
37 {1.4567}
0.09 - 0.13 {0.0035 - 0.0051} 0.04 - 0.08 {0.00016 - 0.0031} 0.02 - 0.06 {0.0008 - 0.0024}
—
piston ring
–0.1 {–0.0039} –0.1 {–0.0039}
Replace piston ring
–0.1 {–0.0039} +0.2 {+0.0079} +0.2 {+0.0079}
Replace piston
+0.1 {+0.0039} — Replace
—
—
piston ring or piston.
—
Piston pin outer diameter
37 {1.4567}
—
Piston boss inner diameter
37 {1.4567}
—
0.05 {0.0020}
Replace piston pin or piston
Clearance between piston pin and piston boss
L : Clearance)
Connecting rod bushing inner diameter
{0.0059 - 0.0118}
Replace
— –0.04 {–0.0015} +0.05 {+0.0020}
Replace piston pin Replace piston
–0.002T - 0.025L
{0.0000 - 0.0010} (T : Tightening
0.15 - 0.3
Oil
–0.002T - 0.025L Clearance between piston pin
{0.0295 - 0.0354}
—
Oil Replace
0.75 - 0.9
2 {0.0787}
piston ring groove
—
{0.0118 - 0.0157}
Second
Clearance between Piston
0.3 - 0.40
—
Top
piston ring
{0.5512}
2.5 {0.0984}
Top
{–0.0039}
Replace —
of piston ring
Second
Approx. 14
{0.0000 - 0.0010} (T : Tightening
—
allowance,
0.05 {0.0020}
Replace piston pin or piston
L : Clearance) —
+0.1 {0.0039}
Replace connecting rod bushing
Connecting rod bushing inner diameter
37 {1.4567}
—
+0.1 {0.0039}
Replace connecting rod bushing
2–6
2–6
STANDARD VALUE
Inspection item
Standard value
Repair limit
Service limit
Action
STANDARD VALUE
Inspection item
Standard value
Repair limit
Service limit
Replace Connecting rod bushing oil clearance
0.015 - 0.036 {0.0006 - 0.0014}
—
0.08 {0.0031}
Replace
piston pin or
Connecting rod bushing oil clearance
connecting
0.015 - 0.036 {0.0006 - 0.0014}
—
0.08 {0.0031}
rod bushing
Crank pin outer diameter
Thickness of connecting rod bearing
65 {2.5590}
2.0 {0.0787}
—
—
63.8 {2.5118}
Connecting rod oil clearance
Crank journal outer diameter
{0.0012 - 0.0032}
Replace the crankshaft.
Crank pin outer diameter
65 {2.5590}
—
(Note 1) Thickness of connecting rod
—
bearing
80{3.1496}
—
clearance of
Connecting rod oil clearance
0.3 or more
—
78.8 {3.1024}
2.0 {0.0787}
—
63.8 {2.5118}
Thickness of main bearing
2.5 {0.2342}
—
Crankshaft oil clearance
0.051 - 0.102 {0.0020 - 0.0040}
—
36 {1.4173}
—
Thickness of thrust bearing
2.5 {0.2342}
—
+1.00 {+0.039}
0.031 - 0.082 {0.0012 - 0.0032}
bearing for 0.2 {0.0079}
—
Crank
Replace
Crank journal outer diameter
shaft (Note
80{3.1496}
—
78.8 {3.1024}
bearing
Replace crankshaft.
0.50
1.219
{0.0020 - 0.0086}
{0.0020}
{0.0480}
thrust bearing or
Thickness of main bearing
2.5 {0.2342}
—
—
Crank pin width
34 {13.386}
0.15 {0.0059} —
— +0.8 {+0.0315}
Ground to under-size Replace crankshaft
shaft (Note
—
haft Crankshaft oil clearance
0.051 - 0.102 {0.0020 - 0.0040}
Replace 0.2 {0.0079}
—
bearing (Note 2)
Center journal width
36 {1.4173}
—
Thickness of thrust bearing
2.5 {0.2342}
—
+1.00 {+0.039}
Replace crankshaft.
— Replace
Crankshaft end play
0.050 - 0.219
0.50
1.219
{0.0020 - 0.0086}
{0.0020}
{0.0480}
crankshaft Crankshaft runout
Replace 1)
Cranks
—
0.050 - 0.219
clearance of 0.3 or more
Replace Crankshaft end play
(Note 1)
Crank
(Note 2)
Center journal width
crankshaft.
(Note 2)
Replace 0.2 {0.0079}
Replace the
(Note 2)
—
haft
connecting
—
1) Cranks
or
Replace
bearing for 0.2 {0.0079}
piston pin
rod bushing
Replace 0.031 - 0.082
Action
thrust bearing or crankshaft
—
Crankshaft runout
Crank pin width
34 {13.386}
0.15 {0.0059} —
— +0.8 {+0.0315}
Ground to under-size Replace crankshaft
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or
Note 1 : Correction with re-grinding for eccentric wear of 0.10 or more. Re-grinding for wear of 0.20 or
more. Replace crankshaft for wear of 1.20 or more.
more. Replace crankshaft for wear of 1.20 or more.
Note 2 : Under-size bearing values are 0.25, 0.50, 0.75 and 1.00.
Note 2 : Under-size bearing values are 0.25, 0.50, 0.75 and 1.00.
Connecting rod large end width
34 {1.3386}
—
–0.8 {–0.0315}
Replace connecting rod
Connecting rod large end width
34 {1.3386}
—
–0.8 {–0.0315}
Replace connecting rod
2–7
STANDARD VALUE
Inspection item
Standard value
Repair limit
Service limit
2–7
STANDARD VALUE
Action
Inspection item
Standard value
Repair limit
Service limit
Replace 0.20 - 0.52
Connecting rod end play
{0.0079 - 0.0205}
—
1.0 {0.0394}
connecting rod or
Replace 0.20 - 0.52
Connecting rod end play
{0.0079 - 0.0205}
—
1.0 {0.0394}
crankshaft Camshaft journal outer
40 {1.5748}
diameter Camshaft bearing inner
40 {1.5748}
diameter
Camshaft bearing oil
0.020 - 0.063
Clearance
Camsha Cam height ft
{0.0008 - 0.0025}
—
—
Replace
Camshaft journal outer
{–0.0059}
camshaft
diameter
{+0.059}
Bearing Replacemen t Replace
—
—
camshaft or bearing
IN
50.067 {1.9711}
—
–0.08
Replace
EX
52.104 {2.0513}
—
{–0.0031}
camshaft
IN
8.067 {0.3175}
—
–0.08
Replace
10.104 {0.3978}
—
{–0.0031}
camshaft
33 {1.2992}
—
—
—
—
—
0.1 {0.039}
Cam lift EX Camshaft journal width (Rear journal)
0.100 - 0.178
Camshaft end play
{0.0039 - 0.0070} 0.04
Camshaft runout
{0.0016}
Rocker shaft outer diameter
22 {0.8661}
—
Rocker arm bushing inner diameter
22 {0.8661}
—
0.030 - 0.101
Rocker arm oil clearance
{0.00012 - 0.0040} IN
7 {0.2756}
Valve stem outer diameter
— —
–0.08
camshaft Replace camshaft Replace rocker shaft
+0.08
Replace rocker arm bushing
0.15 {0.0059} —
Replace
EX
7 {0.2756}
—
—
IN
7 {0.2756}
—
—
Replace
—
—
valve guide
—
—
Replace
EX IN Oil clearance between valve guide
7 {0.2756} 0.023 - 0.058 {0.0009 - 0.0020}
valve or
and valve stem EX
IN
0.050 - 0.083 {0.0020 - 0.0033} 0.55 - 0.85 {0.0217 - 0.0335}
—
—
—
1.1 {0.0433}
Valve sink
valve guide
EX
{0.0453 - 0.0571}
—
1.7 {0.0669}
Camshaft bearing oil
0.020 - 0.063
Clearance
Camsha Cam height ft
{0.0008 - 0.0025}
valve seat
rod or
—
—
–0.15
Replace
{–0.0059}
camshaft
+0.15 {+0.059}
Bearing Replacemen t Replace
—
—
camshaft or bearing
IN
50.067 {1.9711}
—
–0.08
Replace
EX
52.104 {2.0513}
—
{–0.0031}
camshaft
IN
8.067 {0.3175}
—
–0.08
Replace
EX
10.104 {0.3978}
—
{–0.0031}
camshaft
33 {1.2992}
—
—
—
—
—
0.1 {0.039}
Cam lift
0.100 - 0.178
Camshaft end play
{0.0039 - 0.0070} 0.04
Camshaft runout
{0.0016}
Rocker shaft outer diameter
22 {0.8661}
—
Rocker arm bushing inner diameter
22 {0.8661}
—
0.030 - 0.101 {0.00012 - 0.0040}
—
–0.08
Replace camshaft Replace camshaft Replace
{–0.0031}
rocker shaft
+0.08
Replace rocker
{+0.0031}
arm bushing
0.15 {0.0059}
IN
7 {0.2756}
—
—
Replace
EX
7 {0.2756}
—
—
valve
IN
7 {0.2756}
—
—
Replace
EX
7 {0.2756}
—
—
valve guide
—
—
Replace
Valve stem outer diameter
Valve guide inner diameter
IN Oil clearance between valve guide
0.023 - 0.058 {0.0009 - 0.0020}
valve or
and valve stem EX
IN
Replace valve and
1.15 - 1.45
40 {1.5748}
diameter
Rocker arm oil clearance
valve
Valve guide inner diameter
Camshaft bearing inner
(Rear journal)
{–0.0031}
{+0.0031}
40 {1.5748}
Camshaft journal width
Replace
connecting crankshaft
–0.15
+0.15
Action
0.050 - 0.083 {0.0020 - 0.0033} 0.55 - 0.85 {0.0217 - 0.0335}
—
—
—
1.1 {0.0433}
Valve sink
valve guide
Replace valve and
EX
1.15 - 1.45 {0.0453 - 0.0571}
—
1.7 {0.0669}
valve seat
2–8
2–8
STANDARD VALUE
Inspection item
Standard value IN
30q
Repair limit
Service limit
Action
STANDARD VALUE
Inspection item
Allowable angle 30q - 30q35'
Valve seat angle
Standard value
Repair limit
Service limit
IN
30q
Allowable angle 30q - 30q35'
EX
45q
Allowable angle 45q - 30q30'
IN
30q
Allowable angle 29q30 - 45q
EX
45q
Allowable angle 44q30 - 45q
Action
Valve seat angle EX
45q
Allowable angle 45q - 30q30' Correction
IN
30q
Allowable angle 29q30 - 45q
EX
45q
Allowable angle 44q30 - 45q
Valve face angle
Correction Valve face angle
Set length
Set load
44.8 {1.764} 129N {13.1kgf, 29lbf}
—
—
Set length
—
—
Set load
Inner Free length
Squareness Valve spring Set length
Set load
64.6 {2.5433} — 46.8 {1.8252} 314N {32.0kgf, 70lbf}
— —
Free length
Squareness
{2.9803} —
{–0.3543} 2.0 {0.0787}
—
—
—
—
Outer 75.7
–3.0
— —
–3.0 {–0.3543} 2.0 {0.0787}
44.8 {1.764} 129N {13.1kgf, 29lbf}
—
—
—
—
Inner Replace
Free length
spring Replace spring
Squareness Valve spring Set length
Set load
64.6 {2.5433} — 46.8 {1.8252} 314N {32.0kgf, 70lbf}
— —
spring Replace spring
Free length
Squareness
75.7 {2.9803} —
{–0.3543} 2.0 {0.0787}
—
—
—
—
Outer Replace
–3.0
— —
–3.0 {–0.3543} 2.0 {0.0787}
Replace spring Replace spring
Replace spring Replace spring
2–9
STANDARD VALUE
Inspection item Crank - Main idle Main idle - Pump drive idle Pump drive idle Pump drive Backla sh
Main idle - Sub-idle
Sub-idle - Oil pump
Sub-idle - Cam idle
Cam idle - Cam Shaft outer diameter Bushing inner diameter Timing gear Main
Standard value 0.030 - 0.167 {0.0012 - 0.0066} 0.032 - 0.096 {0.0013 - 0.0038} 0.020 - 0.083 {0.0008 - 0.0033} 0.030 - 0.113 {0.0012 - 0.0044} 0.030 - 0.113 {0.0012 - 0.0044} 0.050 - 0.218 {0.0020 - 0.0086} 0.030 - 0.253 {0.0012 - 0.0100}
— — — — — — —
Service limit
0.10
0.30 {0.0012}
0.20 {0.0079}
44 {1.7322}
—
—
Bushing inner diameter
0.30 {0.0012}
50 {1.9685}
—
—
50 {1.9685}
—
—
Clearance between
0.025 - 0.075
shaft and bushing
{0.0010 - 0.0030}
idle
—
0.20 {0.0079}
Gear width
22 {0.8661}
—
—
Shaft length
22 {0.8661}
—
—
End play
0.040 - 0.120 {0.0016 - 0.0047}
—
sh
0.30 {0.0012}
Main idle - Sub-idle
Sub-idle - Oil pump
Sub-idle - Cam idle
Cam idle - Cam
{0.0012}
Shaft length
Shaft outer diameter
replacement
0.30
—
—
Backla
0.30
—
{0.0045 - 0.0063}
Gear
{0.0012}
44 {1.7322}
End play
Pump drive
{0.0012}
Gear width
0.114 - 0.160
Pump drive idle -
0.30
—
{0.0012 - 0.0084}
drive idle
{0.00393}
—
shaft and bushing
Main idle - Pump
0.10
57 {2.2441}
—
Crank - Main idle
{0.00393}
—
0.030 - 0.090
Inspection item
{0.0012}
—
Clearance between
Action
0.30
57 {2.2441}
idle
Sub-
Repair limit
Shaft outer diameter Bushing inner diameter Replace
Timing
shaft or
gear
bushing
Main
Standard value 0.030 - 0.167 {0.0012 - 0.0066} 0.032 - 0.096 {0.0013 - 0.0038} 0.020 - 0.083 {0.0008 - 0.0033} 0.030 - 0.113 {0.0012 - 0.0044} 0.030 - 0.113 {0.0012 - 0.0044} 0.050 - 0.218 {0.0020 - 0.0086} 0.030 - 0.253 {0.0012 - 0.0100}
— —
{0.00393} 0.30 {0.0012}
0.30 {0.0012} 0.30 {0.0012}
0.20 {0.0079}
—
—
Shaft length
44 {1.7322}
—
—
0.114 - 0.160 {0.0045 - 0.0063}
—
0.30 {0.0012}
50 {1.9685}
—
—
50 {1.9685}
—
—
Clearance between
0.025 - 0.075
shaft and bushing
{0.0010 - 0.0030}
idle
—
0.20 {0.0079}
Gear width
22 {0.8661}
—
—
Shaft length
22 {0.8661}
—
—
Replace End play
0.040 - 0.120 {0.0016 - 0.0047}
—
replacement
{0.0012}
—
—
Gear
0.30
44 {1.7322}
diameter
gear
—
0.10
Gear width
Bushing inner
shaft or
—
0.10 {0.00393}
—
{0.0012 - 0.0084}
Shaft outer diameter
Sub-
—
{0.0012}
57 {2.2441}
shaft and bushing
gear
shaft or
—
Action
0.30
—
0.030 - 0.090
End play
Replace
—
Service limit
—
Clearance between
Replace shaft or
Repair limit
57 {2.2441}
idle
bushing
2–9
STANDARD VALUE
0.30 {0.0012}
Replace shaft or bushing
Replace shaft or gear
Replace shaft or bushing
Replace shaft or gear
2–10
2–10
STANDARD VALUE
Inspection item Shaft outer diameter Bushing inner diameter
Cam
Standard value
Repair limit
Service limit
34 {1.3386}
—
—
34 {1.3386}
—
—
Clearance between
0.025 - 0.075
shaft and bushing
{0.0002 - 0.0030}
idle
—
0.20 {0.0079}
Gear width
22 {8.6614}
—
—
Shaft length
22 {8.6614}
—
—
0.040 - 0.120
End play
{0.0016 - 0.0047}
Timing gear Shaft outer diameter Bushing inner diameter
—
0.30 {0.0012}
34 {1.3386}
—
—
34 {1.3386}
—
—
Pump
Clearance between
0.025 - 0.075
drive
shaft and bushing
{0.0002 - 0.0030}
idle
—
0.10 {0.0039}
Gear width
28.5 {1.1220}
—
—
Shaft length
28.5 {1.1220}
— —
0.016 - 0.22
End play
{0.0006 - 0.0087}
Flatness above cylinder block
Shaft outer diameter Bushing inner diameter Replace shaft or bushing
—
Square direction
34 {1.3386}
—
—
34 {1.3386}
—
—
shaft and bushing
{0.0002 - 0.0030}
idle
thrust plate or gear
0.20 {0.0079}
22 {8.6614}
—
—
Shaft length
22 {8.6614}
—
—
0.040 - 0.120
End play
{0.0016 - 0.0047}
Timing gear Shaft outer diameter Bushing inner diameter
Replace
—
Gear width
Replace
—
0.30 {0.0012}
34 {1.3386}
—
—
34 {1.3386}
—
—
shaft or
Pump
Clearance between
0.025 - 0.075
bushing
drive
shaft and bushing
{0.0002 - 0.0030}
idle
—
0.10 {0.0039}
—
—
—
Shaft length
28.5 {1.1220}
—
—
—
End play
—
—
0.016 - 0.22 {0.0006 - 0.0087}
0.20 {0.0079}
backlash between cam idle –
or gear
Replace shaft or bushing
because
Longitudinal direction 0.06
Flatness under cylinder head
{0.0024}
Flatness above cylinder block
—
Square direction
0.20 {0.0079}
backlash between cam idle – sub-idle
0.03 {0.0012}
gears is changed.
31 {1.2205}
Bearing cap bolt (Crankshaft mounting)
—
—
108 {4.2520}
Connecting rod bolt
—
—
68.0 {2.6772} Replacement
long
—
—
middle
—
—
short
—
—
126.5
thrust plate
changed.
—
{4.9803}
Replace
gears is
—
{6.1614}
bushing
inhibited
Camshaft gear mounting bolt
156.5
shaft or
inhibited
—
{7.3819}
Replace
Grinding is
—
187.5
Action
Grinding is
Surface runout of flywheel
{0.0060}
Service limit
0.025 - 0.075
sub-idle
0.15
Repair limit
28.5 {1.1220}
0.03 {0.0012}
Head bolt
Cam
Standard value
Clearance between
because
direction 0.06 {0.0024}
Inspection item
Gear width
Longitudinal Flatness under cylinder head
Action
STANDARD VALUE
0.15
Surface runout of flywheel
—
Replacement
Camshaft gear mounting bolt
—
—
31 {1.2205}
Replacement
Replacement
Bearing cap bolt (Crankshaft mounting)
—
—
108 {4.2520}
Replacement
Connecting rod bolt
—
—
68.0 {2.6772} Replacement
long
—
—
middle
—
—
short
—
—
Replacement
Replacement
Replacement
Head bolt
{0.0060}
—
187.5 {7.3819} 156.5 {6.1614} 126.5 {4.9803}
Replacement
Replacement
Replacement
2–11
STANDARD VALUE Valve timing
2–11
STANDARD VALUE Valve timing
Exhaust valve open (before BDC)
54q
Exhaust valve open (before BDC)
54q
Exhaust valve close (after TDC)
13q
Exhaust valve close (after TDC)
13q
Intake valve open (before TDC)
14q
Intake valve open (before TDC)
14q
Intake valve close (after BDC)
30q
Intake valve close (after BDC)
30q
Tightening torque Tightening area
Tightening torque Tightening torque
JP31199020205007
JP31199020205007
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Remark
Tightening area
Tightening torque
Crankshaft pulley mounting bolt
118 {1,203, 87}
Crankshaft pulley mounting bolt
118 {1,203, 87}
Head cover mounting bolt
28.5 {290, 21}
Head cover mounting bolt
28.5 {290, 21}
Camshaft bearing cap mounting bolt
28.5 {290, 21}
Camshaft bearing cap mounting bolt
28.5 {290, 21}
Union bolt of leakage pipe
13.5 {135, 10}
Union bolt of leakage pipe
13.5 {135, 10}
Injector harness mounting nut
28 {290, 21}
Injector harness mounting nut
28 {290, 21}
Camshaft gear mounting bolt
59 {600, 44}+90q
Camshaft gear mounting bolt
59 {600, 44}+90q
Rocker arm and crosshead adjusting screw lock nut Rocker arm support bolt Head bolt Cam idle gear shaft mounting bolt
nut
59 {600, 44}
Rocker arm support bolt
59 {600, 44}+90q+90q
Head bolt
108 {1,100, 80}
Main bearing cap mounting bolt
69 {700, 51}+90q+45q
Connecting rod cap mounting bolt
69 {700, 51}+90q+45q
Oil check valve
Rocker arm and crosshead adjusting screw lock
25 {250, 18}
Cam idle gear shaft mounting bolt Refer to the main text.
22 {220, 16}
25 {250, 18} 59 {600, 44} 59 {600, 44}+90q+90q 108 {1,100, 80}
Main bearing cap mounting bolt
69 {700, 51}+90q+45q
Connecting rod cap mounting bolt
69 {700, 51}+90q+45q
Oil check valve
108 {1,100, 80}
Sub-idle gear shaft mounting bolt
108 {1,100, 80}
Main idle gear shaft mounting bolt
172 {1,750, 127}
Main idle gear shaft mounting bolt
172 {1,750, 127}
Flywheel mounting bolt
186 {1,900, 137}
Flywheel mounting bolt
186 {1,900, 137}
Flywheel housing mounting bolt
Flywheel housing stay - Flywheel housing Rear end plate torx bolt Supply pump bearing case mounting bolt
M16
55 {560, 41}
M10
36 {370, 27}
M8
171.5 {1, 750}
M14
55 {560, 41} 28.5 {290, 21}
Flywheel housing mounting bolt
Flywheel housing stay - Flywheel housing Rear end plate torx bolt Supply pump bearing case mounting bolt
Refer to the main text.
22 {220, 16}
Sub-idle gear shaft mounting bolt
196 {2,000, 145}
Remark
196 {2,000, 145}
M16
55 {560, 41}
M10
36 {370, 27}
M8
171.5 {1, 750}
M14
55 {560, 41} 28.5 {290, 21}
2–12
2–12
STANDARD VALUE
STANDARD VALUE
Exhaust
Exhaust
Tightening torque
Tightening torque
Tightening area
JP31199020205008
JP31199020205008
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Tightening torque
Remark
Tightening area
Tightening torque
Exhaust manifold mounting stud bolt
30 {300, 22}
Exhaust manifold mounting stud bolt
30 {300, 22}
Exhaust manifold mounting nut
53 {540, 40}
Exhaust manifold mounting nut
53 {540, 40}
Cooling
Remark
Cooling
Standard value
Standard value JP31199020205009
Inspection item
Standard
Repair
Service
value
limit
limit
Action
JP31199020205009
Inspection item
74.5 - 78.5qC Thermostat valve open temperature
—
Replacement
Thermostat valve open temperature
173.3qF} Thermostat valve lift (Set temperature 95 qC)
10mm {0.3937 in.} or
—
—
Replacement
more
limit
—
—
Replacement
—
—
Replacement
Action
{166.1 -
Thermostat valve lift (Set temperature 95 qC)
10mm {0.3937 in.} or more
Lubrication
Standard value
Standard value
Standard value
Repair
Service
limit
limit
—
—
JP31199020205010
JP31199020205010
Unit : mm {in.}
Unit : mm {in.}
Action
Inspection item
39kPa Hydraulic alarm switch operation pressure
Service
limit
173.3qF}
Lubrication
Inspection item
Repair
value 74.5 - 78.5qC
—
{166.1 -
Standard
{0.4kgf/cm2, 5.66lbf/in.2}
Standard value
Repair
Service
limit
limit
—
—
39kPa Hydraulic alarm switch operation pressure
{0.4kgf/cm2, 5.66lbf/in.2}
Action
2–13
STANDARD VALUE
Inspection item Outer diameter of drive gear Cylinder block side Oil pump chamber inner diameter Clearance between drive gear and cylinder block Drive gear width Cylinder block side Depth of oil pump chamber Drive gear end play
Oil pump
Repair
Service
limit
limit
54 {2.1260}
—
—
54 {2.1260}
—
—
Standard value
0.100 - 0.202 {0.0039 - 0.0080}
—
0.30
—
—
28.5 {1.1220}
—
—
0.049 - 0.113 {0.00193 - 0.0044}
—
Action
Inspection item Outer diameter of drive gear Cylinder block side Oil pump chamber inner diameter
Replace drive
Clearance between drive gear and
{0.0118} gear or oil pump
28.5 {1.1220}
0.15 {0.059}
2–13
STANDARD VALUE
cylinder block Drive gear width Cylinder block side Depth of oil pump chamber
Replace drive
Drive gear end play
gear or oil pump
Repair
Service
limit
limit
54 {2.1260}
—
—
54 {2.1260}
—
—
Standard value
0.100 - 0.202 {0.0039 - 0.0080}
—
0.30
—
—
28.5 {1.1220}
—
—
{0.00193 - 0.0044}
—
0.15 {0.059}
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Cylinder block hole diameter
18 {0.7087}
—
—
Cylinder block hole diameter
18 {0.7087}
—
—
—
—
Clearance between drive gear shaft outer diameter and bushing inner diameter at cylinder block side
0.040 - 0.099 {0.0016 - 0.0039}
—
—
Replace drive
Oil
gear or bushing
pump
Clearance between drive gear shaft outer diameter and bushing inner diameter at cylinder block side
0.040 - 0.099 {0.0016 - 0.0039}
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Cylinder block hole diameter
18 {0.7087}
—
—
Cylinder block hole diameter
18 {0.7087}
—
—
—
—
Clearance between driven gear shaft outer diameter and cylinder block hole diameter
0.030 - 0.075 {0.0012 - 0.0030}
—
—
Replace oil pump
Clearance between driven gear shaft outer diameter and cylinder block hole diameter
0.030 - 0.075 {0.0012 - 0.0030}
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Outer diameter of driven gear shaft
18 {0.7087}
—
—
Inner diameter of driven gear bushing
18 {0.7087}
—
—
Inner diameter of driven gear bushing
18 {0.7087}
—
—
Clearance between driven gear shaft outer diameter and gear bushing inner diameter Backlash between drive gear and driven gear
0.040 - 0.083 {0.016 - 0.0033} 0.072 - 0.277 {0.0028 - 0.0109}
—
—
0.15 {0.059} 0.30
Replace oil
Clearance between driven gear shaft
pump or
outer diameter and gear bushing inner
bushing
diameter
Replace oil
Backlash between drive gear and driven
{0.0118} pump
gear
0.040 - 0.083 {0.016 - 0.0033} 0.072 - 0.277 {0.0028 - 0.0109}
—
—
Replace drive
{0.0118} gear or oil pump
28.5 {1.1220}
0.049 - 0.113
Action
0.15 {0.059} 0.30
Replace drive gear or oil pump
Replace drive gear or bushing
Replace oil pump
Replace oil pump or bushing Replace oil
{0.0118} pump
2–14
2–14
STANDARD VALUE
Tightening torque
STANDARD VALUE
Tightening torque
Tightening area
JP31199020205011
JP31199020205011
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Tightening torque
Remark
Tightening area
Tightening torque
Oil pan mounting bolt
30 {300, 22}
Oil pan mounting bolt
30 {300, 22}
Oil strainer
31 {320, 23}
Oil strainer
31 {320, 23}
Oil pan drain cock
41 {420, 30}
Oil pan drain cock
41 {420, 30}
Oil pump mounting bolt
28.5 {290, 21}
Oil pump mounting bolt
M14
24.5r4.9 {250r50, 18r4}
M20
24.5r4.9 {250r50, 18r4}
Oil circuit spring plug
Remark
28.5 {290, 21} M14
24.5r4.9 {250r50, 18r4}
M20
24.5r4.9 {250r50, 18r4}
M22
29.4r4.9 {300r50, 22r4}
M24
34.3r4.9 {350r50, 25r4}
Oil circuit spring plug
Oil cooler
M22
29.4r4.9 {300r50, 22r4}
M24
34.3r4.9 {350r50, 25r4}
Coolant drain plug
Oil cooler
44.1r4.9 {450r50, 33r4}
Oil cooler case assembly mounting bolt
Coolant drain plug
24.5r4.9 {250r50, 18r4}
44.1r4.9 {450r50, 33r4}
Oil cooler case assembly mounting bolt
Starting and Charging
24.5r4.9 {250r50, 18r4}
Starting and Charging
Standard value (Alternator 50A)
Standard value (Alternator 50A) JP31199020205012
Inspection item Resistance between stator coil terminals (for 2 phases) Resistance between stator coil core and coil Resistance of feed coil
Front Shaft outer diameter of Rear Forward resistance value
diode and rectifier holder Reverse resistance value Forward regulator terminals F — E
0.22 - 0.26: 1M:or more
1M:or more 25mm {0.9843 in.}
Repair limit
Service limit
Action
resistance value
17mm {0.6693 in.} Approx. 10:
Approx. 10:
Replacement
—
—
Replacement
Resistance between stator coil core and coil
—
—
Replacement
Resistance of feed coil
—
—
Replacement
Resistance between feed coil core and coil
— — —
resistance value
Infinite
Shaft outer diameter of Rear Forward
— —
—
— —
Resistance between
resistance value
diode and rectifier holder Reverse resistance value Forward Resistance between regulator terminals F — E
value 0.22 - 0.26: 1M:or more
1M:or more 25mm {0.9843 in.}
Repair limit
Service limit
Action
—
—
Replacement
—
—
Replacement
—
—
Replacement
—
—
Replacement
—
24.98mm {0.9835 in.} Replacement
rotor assembly
{0.6685 in.}
Standard
5.6 - 6.8:
Front
16.98mm
—
—
2 phases)
24.98mm {0.9835 in.}
Replacement Reverse
Resistance between stator coil terminals (for
—
Replacement Infinite
Inspection item
—
Replacement
rotor assembly
Resistance between
value
5.6 - 6.8:
Resistance between feed coil core and coil
Resistance between
Standard
JP31199020205012
resistance value
17mm {0.6693 in.} Approx. 10:
— —
16.98mm {0.6685 in.} — Replacement
Infinite Approx. 10:
—
—
—
— Replacement
Reverse resistance value
Infinite
—
—
2–15
STANDARD VALUE
Tightening torque (Alternator 50A)
2–15
STANDARD VALUE
Tightening torque (Alternator 50A)
Tightening area
JP31199020205013
JP31199020205013
Unit : N m{kgf cm, lbf ft}
Unit : N m{kgf cm, lbf ft}
Tightening torque
Bearing cover mounting bolt
Remark
1.9 - 2.5 {20 - 25, 1 - 2}
Pulley mounting nut
2.9 - 3.9 {30 - 39, 2 - 3}
Heat sink mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
Regulator mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
Inside B terminal mounting nut
Tightening torque
Bearing cover mounting bolt
127 - 157 {1, 300 - 1, 600, 94 - 116}
Feed coil - Rear bracket
Tightening area
Remark
1.9 - 2.5 {20 - 25, 1 - 2}
Pulley mounting nut
127 - 157 {1, 300 - 1, 600, 94 - 116}
Feed coil - Rear bracket
2.9 - 3.9 {30 - 39, 2 - 3}
Screw lock is
Heat sink mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
Screw lock is
used
Regulator mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
used
4.9 - 5.9 {50 - 60, 4 - 4}
Inside B terminal mounting nut
4.9 - 5.9 {50 - 60, 4 - 4}
Front side - Rear side mounting bolt
7.8 - 9.8 {80 - 99, 6 - 7}
Front side - Rear side mounting bolt
7.8 - 9.8 {80 - 99, 6 - 7}
Coupler holder mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
Coupler holder mounting bolt
1.9 - 2.5 {20 - 25, 1 - 2}
Cover mounting bolt
3.3 - 4.4 {34 - 44, 2 - 3}
Cover mounting bolt
3.3 - 4.4 {34 - 44, 2 - 3}
Standard value (starter)
Inspection item Resistance between coil lead Yoke
wire and yoke
Standard value (starter) Standard value —
Service limit
1k:or less
JP31199020205014
JP31199020205014
Unit : mm {in.}
Unit : mm {in.}
Action Replace yoke assembly
assembly 18 {0.7087}
13 {0.5118} or less
1M:or more
1k:or less
Commutator outer diameter
36{1.4173}
34 {1.1458} or less
Shaft outer diameter A
12 {0.4724}
11.98 {0.4717} or less
Shaft outer diameter B
9 {0.3643}
8.98 {0.3535} or less
Resistance between commutator and core
assembly
Replace brush
Resistance between holder
18 {0.7087}
13 {0.5118} or less
1M:or more
1k:or less
Commutator outer diameter
36{1.4173}
34 {1.1458} or less
Shaft outer diameter A
12 {0.4724}
11.98 {0.4717} or less
Shaft outer diameter B
9 {0.3643}
8.98 {0.3535} or less
wire and yoke
and plate
0.5 - 0.8 {0.0197} —
0.2{0.0079} or less
1k:or less
Brush length
Replace armature Armature assembly
Correction
Action Replace yoke assembly
Replace holder assembly
Resistance between holder Holder
Replace brush
Replace armature assembly
Undercut depth
0.5 - 0.8 {0.0197}
0.2{0.0079} or less
—
1k:or less
Brush length
18 {0.7087}
13 {0.5118} or less
A
26 {1.0236}
25.90 {1.0197} or less
and plate
Correction Replace holder assembly
assembly Brush length
18 {0.7087}
13 {0.5118} or less
A
26 {1.0236}
25.90 {1.0197} or less
Replace brush Shaft
assembly
Replace shaft
assembly
outer
assembly
outer
B
12.1 {0.4764}
12.04 {4.7401} or less
diameter Clutch assembly inner sleeve outer diameter Metal bushing inner diameter of pinion case Metal bushing inner diameter of center bracket
Service limit
1k:or less
commutator and core
assembly Shaft
value —
Resistance between
assembly
Undercut depth
Holder
Resistance between coil lead Yoke
Standard
assembly Brush length
Armature
Inspection item
Replace brush
Replace shaft B
12.1 {0.4764}
12.04 {4.7401} or less
assembly
diameter 25 {0.9843}
24.90 {0.9803} or more Replacement
25 {0.9843}
25.2 {0.9921} or more
26 {1.02362}
26.2 {1.0315}
Clutch assembly inner sleeve outer diameter
Replace brush
Metal bushing inner diameter of pinion case
Replace center
Metal bushing inner diameter of center
bracket
bracket
25 {0.9843}
24.90 {0.9803} or more Replacement
25 {0.9843}
25.2 {0.9921} or more
26 {1.02362}
26.2 {1.0315}
Replace brush Replace center bracket
2–16
2–16
STANDARD VALUE
Standard
Inspection item
Service limit
value
Metal bushing inner diameter of shaft
9 {0.3543}
assembly
Action
9.2 {0.3622}
28 {1.1024}
bracket
28.1 {1.1063} or more
Metal bushing inner diameter of shaft
assembly
assembly
commutator end frame
Start
Between C terminal and M
magnet
terminal (P coil)
switch
Between C terminal and body
assembly
(H coil)
—
0.12 - 0.15:
Replace start magnet switch assembly
—
1.13 - 1.25:
Tightening torque (starter)
Standard
Inspection item
Replace shaft
Replace
Bearing housing inner diameter of rear
STANDARD VALUE
Service limit
value 9 {0.3543}
Action Replace shaft
9.2 {0.3622}
assembly Replace
Bearing housing inner diameter of rear
28 {1.1024}
bracket
28.1 {1.1063} or more
commutator end frame
Start
Between C terminal and M
magnet
terminal (P coil)
switch
Between C terminal and body
assembly
(H coil)
—
0.12 - 0.15:
Replace start magnet switch assembly
—
1.13 - 1.25:
Tightening torque (starter)
Tightening area
JP31199020205015
JP31199020205015
Unit : N m{kgf cm, lbf tt}
Unit : N m{kgf cm, lbf tt}
Tightening torque
Remark
Tightening area
Tightening torque
Remark
C lead wire mounting bolt
2 - 3 {19 - 25, 1 - 2}
C lead wire mounting bolt
2 - 3 {19 - 25, 1 - 2}
M lead wire mounting nut
12.3 - 15.2 {126 - 154, 9 - 11}
M lead wire mounting nut
12.3 - 15.2 {126 - 154, 9 - 11}
Commutator end frame mounting through bolt Brush holder set bolts of commutator end frame Start magnet switch assembly mounting bolt at pinion case Pinion case switch set bolts
15.7 - 17.6 {160 - 179, 12 - 13}
Commutator end frame mounting through bolt
3.6 - 4.9 {37 - 49, 3 - 4}
Brush holder set bolts of commutator end frame Start magnet switch assembly mounting bolt at
3.6 - 4.9 {37 - 49, 3 - 4}
pinion case
14 - 16 {140 - 160, 10 - 12}
Pinion case switch set bolts
Turbocharger
15.7 - 17.6 {160 - 179, 12 - 13} 3.6 - 4.9 {37 - 49, 3 - 4} 3.6 - 4.9 {37 - 49, 3 - 4} 14 - 16 {140 - 160, 10 - 12}
Turbocharger
Standard value
Standard value
Inspection item Axial direction
Standard value 0.1 {0.0039}
Turbine shaft play Diameter direction
1.0 {0.0397}
Repair limit
Service limit
—
—
—
—
JP31199020205016
JP31199020205016
Unit : mm {in.}
Unit : mm {in.}
Action
Turbocharger mounting nut
Standard value
Repair limit
Service limit
Axial direction
0.1 {0.0039}
—
—
Diameter direction
1.0 {0.0397}
—
—
Turbine shaft play
Tightening torque
Tightening area
Inspection item
Action
Tightening torque
Tightening torque 56 {570, 41}
JP31199020205017
JP31199020205017
Unit : N m{kgf cm, lbf tt}
Unit : N m{kgf cm, lbf tt}
Remark
Tightening area Turbocharger mounting nut
Tightening torque 56 {570, 41}
Remark
PARTS TO BE PREPARED
3–1
PARTS TO BE PREPARED
ENGINE
3–1
ENGINE
3 PARTS TO BE PREPARED
3 PARTS TO BE PREPARED
Special tool (SST)
Special tool (SST)
3
3
Engine Body................................................................ 3-2 Special tool ............................................................. 3-2
Engine Body................................................................ 3-2 Special tool ............................................................. 3-2
Fuel System ................................................................ 3-2 Lubricant, etc. ........................................................ 3-2
Fuel System ................................................................ 3-2 Lubricant, etc. ........................................................ 3-2
Electrical...................................................................... 3-2 Special tool ............................................................. 3-2
Electrical...................................................................... 3-2 Special tool ............................................................. 3-2
Engine Mechanical ..................................................... 3-3 Special tool ............................................................. 3-3 Instruments ............................................................. 3-6 Lubricant, etc. ........................................................ 3-6
Engine Mechanical ..................................................... 3-3 Special tool ............................................................. 3-3 Instruments ............................................................. 3-6 Lubricant, etc. ........................................................ 3-6
Lubrication .................................................................. 3-6 Special tool ............................................................. 3-6 Lubricant, etc. ........................................................ 3-6
Lubrication .................................................................. 3-6 Special tool ............................................................. 3-6 Lubricant, etc. ........................................................ 3-6
Starting and Charging................................................ 3-7 Jig (reference dimensional drawing for manufacture) ................................................................................ 3-7 Instruments ............................................................. 3-8 Lubricant, etc. ........................................................ 3-8
Starting and Charging................................................ 3-7 Jig (reference dimensional drawing for manufacture) ................................................................................ 3-7 Instruments ............................................................. 3-8 Lubricant, etc. ........................................................ 3-8
Turbocharger............................................................... 3-8 Special tool ............................................................. 3-8
Turbocharger............................................................... 3-8 Special tool ............................................................. 3-8
Engine Failure Diagnosis........................................... 3-9 Special tool ............................................................. 3-9
Engine Failure Diagnosis........................................... 3-9 Special tool ............................................................. 3-9
3–2
3–2
PARTS TO BE PREPARED
PARTS TO BE PREPARED
Engine Body
Engine Body
Special tool
Special tool JP31199030901001
Shape
Part No.
Description
09491–1010
Wire rope
09552–1030
Remark
JP31199030901001
Shape
Part No.
For engine lifting
Description
09491–1010
Wire rope
Compression gauge adapter
09552–1030
Compression gauge adapter
09552–1060
Compression gauge adapter
09552–1060
Compression gauge adapter
09552–1110
Compression gauge adapter
09552–1110
Compression gauge adapter
Fuel System
Remark
For engine lifting
Fuel System
Lubricant, etc.
Lubricant, etc. JP31199030901002
Name
JP31199030901002
Remark
Guide bolt (9069-08180)
Name
For supply pump positioning
Remark
Guide bolt (9069-08180)
For supply pump positioning
Electrical
Electrical
Special tool
Special tool JP31199030901003
Shape
Part No.
09444–1210
95506–00090 (Denso part No.)
Name
Compression gauge
Belt tension gauge
Remark
For V–belt tension adjustment
For V–belt tension adjustment
JP31199030901003
Shape
Part No.
09444–1210
95506–00090 (Denso part No.)
Name
Compression gauge
Belt tension gauge
Remark
For V–belt tension adjustment
For V–belt tension adjustment
3–3
PARTS TO BE PREPARED
3–3
PARTS TO BE PREPARED
Engine Mechanical
Engine Mechanical
Special tool
Special tool JP31199030901004
Shape
Part No.
Name
09420–1731
Oil seal puller
09407–1030
Oil seal press
09433–1070
Eye bolt
09470–1170
Valve spring press
09471–1520
Guide
09472–1210
Bar
9800–06100
Steel ball
09431–1020
Valve lapping tool
Remark
For crankshaft front oil seal
JP31199030901004
Shape
Part No.
Name
Remark
For crankshaft front oil seal
09420–1731
Oil seal puller
09407–1030
Oil seal press
09433–1070
Eye bolt
09470–1170
Valve spring press
For valve guide press-fit
09471–1520
Guide
For valve guide press-fit
For nozzle seat clamping
09472–1210
Bar
For nozzle seat clamping
9800–06100
Steel ball
09431–1020
Valve lapping tool
removal
For crankshaft front oil seal press-fit
For assembly/disassembly of cylinder head
For assembly/disassembly of valve spring retainer
For nozzle seat clamping (together with 09472–1210)
For valve adjustment
removal
For crankshaft front oil seal press-fit
For assembly/disassembly of cylinder head
For assembly/disassembly of valve spring retainer
For nozzle seat clamping (together with 09472–1210)
For valve adjustment
3–4
3–4
PARTS TO BE PREPARED
Shape
Part No.
Name
09472–2100
Bar
09420–2100
Cylinder liner puller
09442–1011
Piston ring expander
Remark
For valve stem seal mounting
For removal and inspection of cylinder liner
For assembly/disassembly of piston ring
PARTS TO BE PREPARED
Shape
Part No.
Name
09472–2100
Bar
09420–2100
Cylinder liner puller
09442–1011
Piston ring expander
For mounting of connecting 9191–08252
09402–1530
9233–10360
09481–1130
09402–1540
09481–1540
Bolt
Press sub-assembly
Wing nut
Guide
Spindle
Guide
rod small end bushing (together with 09402–1480
Remark
For valve stem seal mounting
For removal and inspection of cylinder liner
For assembly/disassembly of piston ring
For mounting of connecting 9191–08252
Bolt
rod small end bushing (together with 09402–1480
or 09402–1540)
or 09402–1540)
For assembly/disassembly
For assembly/disassembly
of connecting rod small end
09402–1530
Press sub-assembly
of connecting rod small end
bushing
bushing
For assembly/disassembly
For assembly/disassembly
of connecting rod small end bushing (together with
9233–10360
Wing nut
of connecting rod small end bushing (together with
09402–1530)
09402–1530)
For assembly/disassembly
For assembly/disassembly
of connecting rod small end bushing (together with
09481–1130
Guide
of connecting rod small end bushing (together with
09402–1530)
09402–1530)
For assembly/disassembly
For assembly/disassembly
of connecting rod small end
09402–1540
Spindle
of connecting rod small end
bushing
bushing
For mounting of connecting
For mounting of connecting
rod small end bushing (together with 09402–1540)
09481–1540
Guide
rod small end bushing (together with 09402–1540)
3–5
PARTS TO BE PREPARED
Shape
Part No.
Name
09441–1370
Piston ring holder
09481–1340
Guide
09420–1742
Oil seal puller
Remark
For piston mounting
For assembly/disassembly of flywheel
For crankshaft rear oil seal removal
09420–1100
3–5
PARTS TO BE PREPARED
Shape
Part No.
Name
09441–1370
Piston ring holder
09481–1340
Guide
09420–1742
Oil seal puller
Remark
For piston mounting
For assembly/disassembly of flywheel
For crankshaft rear oil seal removal
09420–1100 For main/sub idle gear Sliding hammer
09420–1442
assembly and cam idle gear shaft removal
09411–1300
Socket wrench
09407–1040
Oil seal press
09471–1490
Guide
09472–1620
Tool
9001–24262
Check bolt
For main/sub idle gear
For assembly/disassembly
Sliding hammer 09420–1442
assembly and cam idle gear shaft removal
For assembly/disassembly
09411–1300
Socket wrench
09407–1040
Oil seal press
For insertion of cylinder liner
09471–1490
Guide
For insertion of cylinder liner
For cooling jet repair
09472–1620
Tool
For cooling jet repair
9001–24262
Check bolt
of Torx bolt
For crankshaft rear oil seal press-fit
For cooling jet inspection and adjustment
of Torx bolt
For crankshaft rear oil seal press-fit
For cooling jet inspection and adjustment
3–6
3–6
PARTS TO BE PREPARED
Shape
Part No.
Name
09470–1280
Remark
PARTS TO BE PREPARED
Shape
Part No.
For cooling jet inspection
Tool assembly
09470–1280
and adjustment
Instruments
Name
Remark
For cooling jet inspection
Tool assembly
and adjustment
Instruments JP31199030901005
Name
JP31199030901005
Remark
Name
Remark
Micrometer
For measurement of part outer diameter
Micrometer
For measurement of part outer diameter
Cylinder gauge
For measurement of part inner diameter
Cylinder gauge
For measurement of part inner diameter
Thickness gauge
For measurement of each clearance
Thickness gauge
For measurement of each clearance
Dial gauge
For measurement of parts
Dial gauge
For measurement of parts
Lubricant, etc.
Lubricant, etc. JP31199030901006
Name
JP31199030901006
Remark
Liquid gasket (Threebond TB1207B or equivalent : Black) Liquid gasket (Threebond TB1207D or equivalent : Silver)
Name
Remark
Liquid gasket (Threebond TB1207B or equivalent :
For sealing of parts
Black) Liquid gasket (Threebond TB1207D or equivalent :
For sealing of parts
Silver)
For sealing of parts
For sealing of parts
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts
Red lead
Valve adjustment
Red lead
Valve adjustment
Dye penetrant
For inspection of crack
Dye penetrant
For inspection of crack
Lubrication
Lubrication
Special tool
Special tool JP31199030901007
Shape
Part No.
09503–1110
Name
JP31199030901007
Remark
Shape
Part No.
Oil filter wrench
09503–1110
Lubricant, etc.
Name
Remark
Oil filter wrench
Lubricant, etc. JP31199030901008
Name Liquid gasket (Threebond TB1207D or equivalent : Silver)
JP31199030901008
Remark For sealing of parts
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts
Name Liquid gasket (Threebond TB1207D or equivalent : Silver)
Remark For sealing of parts
Liquid gasket (Threebond TB1211 or equivalent : White) For sealing of parts
3–7
PARTS TO BE PREPARED
3–7
PARTS TO BE PREPARED
Starting and Charging
Starting and Charging
Jig (reference dimensional drawing for manufacture)
Jig (reference dimensional drawing for manufacture) JP31199030901009
This is used for assembly of bearing. Reference dimensions are shown in the figures below: Jig B (Support jig)
Jig A (Roller bearing insertion jig) φ23{20.827}
JP31199030901009
This is used for assembly of bearing. Reference dimensions are shown in the figures below: Unit : mm{in.}
φ23{20.827}
φ25{0.984}
1C{0.039}
Jig B (Support jig)
Jig A (Roller bearing insertion jig)
φ25{0.984}
1C{0.039}
35{1.378}
35{1.378}
50{1.964}
50{1.964} 70{2.756}
70{2.756}
50{1.964}
1C{0.039}
φ50{1.969}
φ30{1.181}
Jig C
Jig D
φ34{1.339}
φ60{2.362}
φ50{1.969}
10 - 20 {0.394 - 0.787}
+0.5{0.0196} φ19{0.748} 0
φ30{1.181}
φ54{2.126}
50{1.964}
1C{0.039}
10 - 20 {0.394 - 0.787}
+0.5{0.0196} φ19{0.748} 0
Unit : mm{in.}
Jig C
10{0.394}
Jig D
φ34{1.339}
φ41{1.614}
φ41{1.614}
20{0.787}
20{0.787}
20{0.787}
20{0.787}
40{1.575}
40{1.575}
40{1.575}
40{1.575}
φ64{2.520}
10{0.394}
φ54{2.126} φ60{2.362}
φ70{2.756} SAPH311990300034
10{0.394}
φ64{2.520}
10{0.394}
φ70{2.756} SAPH311990300034
3â&#x20AC;&#x201C;8
3â&#x20AC;&#x201C;8
PARTS TO BE PREPARED
Instruments
PARTS TO BE PREPARED
Instruments JP31199030901010
Alternator
JP31199030901010
Alternator Name
Remark
Name
Remark
Circuit tester
For measurement of parts
Circuit tester
For measurement of parts
Micrometer
For measurement of parts
Micrometer
For measurement of parts
Regulator checker (G&M Machinery ICD-101D or equivalent)
Regulator checker (G&M Machinery ICD-101D or
For inspection of regulator
equivalent)
Starter
For inspection of regulator
Starter Name
Remark
Name
Remark
Circuit tester
For measurement of parts
Circuit tester
For measurement of parts
Micrometer
For measurement of part outer diameter
Micrometer
For measurement of part outer diameter
Growler tester
For inspection of armature
Growler tester
For inspection of armature
Cylinder gauge
For measurement of part inner diameter
Cylinder gauge
For measurement of part inner diameter
Lubricant, etc.
Lubricant, etc. JP31199030901011
Name
JP31199030901011
Remark
Name
Remark
Kyodo Yushi Multemp AC-N
For lubrication of parts
Kyodo Yushi Multemp AC-N
For lubrication of parts
Nisseki Mitsubishi Pyroknock #2
For lubrication of parts
Nisseki Mitsubishi Pyroknock #2
For lubrication of parts
Turbocharger
Turbocharger
Special tool
Special tool JP31199030901012
Shape
Part No.
09444-1800
Name
Tool assembly
Remark
JP31199030901012
Shape
Part No.
09444-1800
Name
Tool assembly
Remark
3–9
PARTS TO BE PREPARED
3–9
PARTS TO BE PREPARED
Engine Failure Diagnosis
Engine Failure Diagnosis
Special tool
Special tool JP31199030901016
Shape
Part No.
Name
Remark
JP31199030901016
Shape
Part No.
Name
• Operating
–
• Operating
system(OS):Windows95,
system(OS):Windows95,
Windows98(IE5.0 or
Windows98(IE5.0 or
later),
later),
Windows2000(SP3,
Windows2000(SP3,
IE5.0 or later),
IE5.0 or later),
WindowsXP(SP1a, IE6.0 Personal computer (DOS-V)
or later)
–
WindowsXP(SP1a, IE6.0 Personal computer (DOS-V)
• CPU and memory: Conditions that assure
Conditions that assure
operation of the above
operation of the above
operating system
operating system • Display: 800 x 600, 256
colors or more
colors or more
Failure diagnosis software
HinoDX
(CD-ROM) Used together with the
09121–1040
Hino-Bowie (Interface box)
cable between the vehicle and Hino-Bowie (09042-
Signal check harness
Failure diagnosis software (CD-ROM) Used together with the
09121–1040
Hino-Bowie (Interface box)
cable between the vehicle and Hino-Bowie (09042-
1220)
1220)
This is installed as
This is installed as
interruption between vehicle 09049–1080
or later) • CPU and memory:
• Display: 800 x 600, 256
HinoDX
Remark
harness and the ECU.
interruption between vehicle 09049–1080
Signal check harness
harness and the ECU.
Tester inspection is allowed
Tester inspection is allowed
in energized status.
in energized status.
ENGINE ASSEMBLY/DISASSEMBLY
4–1
ENGINE ASSEMBLY/DISASSEMBLY
ENGINE
ENGINE
4 ENGINE ASSEMBLY/DISASSEMBLY
4 ENGINE ASSEMBLY/DISASSEMBLY
Service procedure Overhaul item
Inspection Before Service ......................................... 4-2 Measurement of compression pressure ................. 4-2 Engine Body................................................................ 4-4 Removal .................................................................. 4-4 Installation............................................................... 4-6 Work after installation ............................................. 4-6
4–1
Service procedure Overhaul item
4
Inspection Before Service ......................................... 4-2 Measurement of compression pressure ................. 4-2 Engine Body................................................................ 4-4 Removal .................................................................. 4-4 Installation............................................................... 4-6 Work after installation ............................................. 4-6
4
4–2
4–2
ENGINE ASSEMBLY/DISASSEMBLY
ENGINE ASSEMBLY/DISASSEMBLY
Inspection Before Service
Inspection Before Service
Measurement of compression pressure
Measurement of compression pressure
JP31199040702001
• Measure the compression pressure before
NOTICE
1.
JP31199040702001
disassembly of the engine and record the
disassembly of the engine and record the
result. Regular measurement of the
result. Regular measurement of the
compression pressure can tell the engine
compression pressure can tell the engine
status.
status.
Preparation before measurement
1.
Preparation before measurement
(1)
Charge the battery completely.
(1)
Charge the battery completely.
(2)
Check the valve clearance and adjust it when exceeding
(2)
Check the valve clearance and adjust it when exceeding
the standard value.
the standard value.
(3)
Warm the engine and set the water temperature to 80
(3)
Warm the engine and set the water temperature to 80
(4)
Remove the air cleaner.
(4)
Remove the air cleaner.
(5)
Remove the head cover.
(5)
Remove the head cover.
(6)
Remove all injectors.
(6)
Remove all injectors.
(7)
To prevent spread of engine oil, attach a jig which cuts a head
(7)
To prevent spread of engine oil, attach a jig which cuts a head
qC{176qF}.
qC{176qF}.
cover in half. (Cut it so that the camshaft may be covered. 2.
cover in half. (Cut it so that the camshaft may be covered.
Measurement (1)
Special tool
• Measure the compression pressure before
NOTICE
2.
Attach a special tool to the nozzle sheet of the cylinder
(1)
Attach a special tool to the nozzle sheet of the cylinder
where the compression pressure is measured with nozzle
where the compression pressure is measured with nozzle
clamp and clamp fixing bolts.
clamp and clamp fixing bolts.
Special tool : Compression gauge adapter Engine
Part No. 09952-1110
SAPH311990400001
09552-1030 (3/4-16 UNF) 09552-1060 (W16 ridges 18) (2)
Measurement
Parts tightened mounting area
Engine
Part No. 09952-1110
SAPH311990400001
09552-1030
Adjusting to screw size of
(3/4-16 UNF)
air gauge, the adapter
09552-1060
which it selects
• Do not operate the starter for 15 seconds or more. • Since the air cleaner is removed, prevent entry of dirt.
Special tool : Compression gauge adapter
Insert in the injector
Turn the starter and measure the compression pressure.
! CAUTION
Special tool
(W16 ridges 18) (2)
Parts tightened Insert in the injector mounting area Adjusting to screw size of air gauge, the adapter which it selects
Turn the starter and measure the compression pressure.
! CAUTION
• Do not operate the starter for 15 seconds or more. • Since the air cleaner is removed, prevent entry of dirt.
4â&#x20AC;&#x201C;3
ENGINE ASSEMBLY/DISASSEMBLY (3)
Measure the compression pressure of each cylinder
Measure the compression pressure of each cylinder continuously.
Engine revolution 150r/min {rpm}
Engine revolution 150r/min {rpm}
Service limit Difference between cylinders
(5)
(3)
continuously.
Standard value
(4)
4â&#x20AC;&#x201C;3
ENGINE ASSEMBLY/DISASSEMBLY
Compression pressure:
Compression pressure:
Unit MPa {kgf/cm2,lbf/in.2}
Unit MPa {kgf/cm2,lbf/in.2}
3.4 - 3.7 {35 - 38 ,493 - 537}
Standard value
2.7 {28, 392}
Service limit Difference between
0.3{3, 44} or less
If the compression pressure is the service limit or less or if
cylinders (4)
3.4 - 3.7 {35 - 38 ,493 - 537} 2.7 {28, 392} 0.3{3, 44} or less
If the compression pressure is the service limit or less or if
the difference between cylinders is over the standard
the difference between cylinders is over the standard
value, overhaul the engine.
value, overhaul the engine.
After measurement, reassemble the removed parts.
(5)
After measurement, reassemble the removed parts.
4–4
4–4
ENGINE ASSEMBLY/DISASSEMBLY
ENGINE ASSEMBLY/DISASSEMBLY
Engine Body
Engine Body
Removal
Removal JP31199040702002
1.
2. Right side of engine
JP31199040702002
Preliminary work before removal of engine
1.
Preliminary work before removal of engine
(1)
Place the vehicle on a level ground.
(1)
Place the vehicle on a level ground.
(2)
Block tires with scotch.
(2)
Block tires with scotch.
(3)
Remove the battery cable from the battery minus terminal.
(3)
Remove the battery cable from the battery minus terminal.
Drain of coolant and engine oil (1)
Drain coolant from the radiator drain cock and the oil
2. Right side of engine
Drain of coolant and engine oil (1)
cooler drain plug.
cooler drain plug.
• Removal of the filler cap facilitates quick
NOTICE
Drain coolant from the radiator drain cock and the oil
• Removal of the filler cap facilitates quick
NOTICE
drain.
drain.
• Connection of an appropriate hose to the oil
• Connection of an appropriate hose to the oil
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH311990400002
! CAUTION
cooler drain pipe facilitates drain of coolant
Oil cooler drain plug
without spread.
SAPH311990400002
• To prevent burn, drain coolant after the
! CAUTION
temperature is sufficiently low.
temperature is sufficiently low.
• To dispose coolant, observe the specified
(2)
• To dispose coolant, observe the specified
method (waste disposal) or the method with
method (waste disposal) or the method with
attention to environment.
attention to environment.
Drain engine oil from the oil pan drain plug as required.
! CAUTION
(2)
• To prevent burn, drain coolant after the
Drain engine oil from the oil pan drain plug as required.
! CAUTION
temperature is sufficiently low.
3.
• Dispose coolant according to the specified
• Dispose coolant according to the specified
method (waste treatment) or with a method
method (waste treatment) or with a method
considering the environment.
considering the environment.
Removal of intake hose, intercooler hose and exhaust
(1) (2)
3.
Loosen the clamp and remove the intake hose. Remove nuts and remove the exhaust pipe.
Intake manifold
• Close the opening of the intake manifold with the engine.
(1)
Loosen the clamp and remove the intake hose.
(2)
Remove nuts and remove the exhaust pipe.
! CAUTION
a packing tape to prevent entry of dirt inside
SAPH311990400003
Removal of intake hose, intercooler hose and exhaust pipe
! CAUTION Cylinder head Cover
• To prevent burn, drain coolant after the temperature is sufficiently low.
pipe Intake manifold
• To prevent burn, drain coolant after the
• Close the opening of the intake manifold with a packing tape to prevent entry of dirt inside
Cylinder head Cover
SAPH311990400003
the engine.
ENGINE ASSEMBLY/DISASSEMBLY 4.
4–5
ENGINE ASSEMBLY/DISASSEMBLY
Disconnection of fuel hose (1)
4.
Remove the fuel hoses (feed side and return side). Wrap
(1)
Remove the fuel hoses (feed side and return side). Wrap the removed hose with a plastic sheet with its end facing
upward to prevent spill of fuel.
upward to prevent spill of fuel.
• Wipe spilled fuel with a rag.
! CAUTION
SAPH311990400004
5.
Connector
Disconnection of water, engine oil pipes, etc. (1)
Disconnect the hose between the radiator and the engine.
(2)
Disconnect the car heater pipe.
(3)
Disconnect the oil filter hose.
(4)
Disconnect the fuel filter hose.
! CAUTION
• Wipe off spilled water and engine oil with
Fan shroud
5. Cooling Fan
Connector
Clip
Disconnection of water, engine oil pipes, etc. (1)
Disconnect the hose between the radiator and the engine.
(2)
Disconnect the car heater pipe.
(3)
Disconnect the oil filter hose.
(4)
Disconnect the fuel filter hose.
! CAUTION
waste. SAPH311990400005
6. Within 30
Engine lifting (Lifting the engine single unit) (1)
Shackle
Place a commercially available shackle and a special tool
6. Shackle
Within 30
Engine lifting (Lifting the engine single unit) (1)
Shackle
wire rope with the engine hanger.
(2)
Special tool : 09491–1010 Wire rope
Keep a little slack of the wire rope.
! CAUTION
Place a commercially available shackle and a special tool wire rope with the engine hanger.
Special tool : 09491–1010 Wire rope (2)
• Keep the wire inclination 30q from the vertical
Keep a little slack of the wire rope.
! CAUTION
line. SAPH311990400006
(3)
When the wire is completely tense, make sure that the wire is firmly engaged with the engine hanger. Then, lift
(3)
Image drawing
! CAUTION
When the wire is completely tense, make sure that the wire is firmly engaged with the engine hanger. Then, lift
the engine slowly.
the engine slowly.
• Work carefully so that the engine may not
! CAUTION
come in contact with the frame and others.
SAPH311990400007
• Keep the wire inclination 30q from the vertical line.
SAPH311990400006
Image drawing
• Wipe off spilled water and engine oil with waste.
SAPH311990400005
Shackle
• Wipe spilled fuel with a rag.
SAPH311990400004
Cooling Fan
Clip
Disconnection of fuel hose
the removed hose with a plastic sheet with its end facing
! CAUTION
Fan shroud
4–5
• Work carefully so that the engine may not come in contact with the frame and others.
SAPH311990400007
4–6
4–6
ENGINE ASSEMBLY/DISASSEMBLY
ENGINE ASSEMBLY/DISASSEMBLY
Installation
Installation JP31199040702003
1.
JP31199040702003
Connection of fuel hose (1)
1.
Insert a fuel hose and fix it with a hose band.
Connection of fuel hose (1)
Work after installation
Insert a fuel hose and fix it with a hose band.
Work after installation JP31199040702004
1.
JP31199040702004
Inspection of engine oil
1.
Inspection of engine oil
(1)
Make sure that the drain cock is closed.
(1)
Make sure that the drain cock is closed.
(2)
Pour engine oil.
(2)
Pour engine oil.
(3)
Check the amount of oil with an oil level gauge.
(3)
Check the amount of oil with an oil level gauge.
Engine oil amount (L{us gal})
Engine oil amount (L{us gal})
Oil pan
Oil filter and etc
Approx. 18{4.76}
Approx. 2.5{0.66}
Filler cap SAPH311990400008
! CAUTION
SAPH311990400008
• Please use Hino genuine engine oil
Approx. 2.5{0.66}
! CAUTION
• Please use Hino genuine engine oil
SAE #10W-30
Multi grade
SAE #10W-30
Single grade
SAE #30
Single grade
SAE #30
Air bleeding of fuel system
2.
Air bleeding of fuel system
Air bleeding bolt Priming pump
(1)
Prepare a rag to receive fuel at the end of the drain valve.
(1)
Prepare a rag to receive fuel at the end of the drain valve.
(2)
Loosen the air bleeding plug of the fuel filter.
(2)
Loosen the air bleeding plug of the fuel filter.
(3)
The priming pump is moved front and back.
(3)
The priming pump is moved front and back.
(4)
Move the pump until fuel without bubble comes out from
(4)
Move the pump until fuel without bubble comes out from
the drain valve. (5)
Tighten the air bleeding bolt.
the drain valve. Drain valve
(5)
Tightening torque : (6)
Move the priming pump again until it becomes heavy.
! CAUTION
• After work, wipe off spilled fuel. After start of
Tighten the air bleeding bolt. Tightening torque :
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft} SAPH311990400009
Approx. 18{4.76}
Multi grade
2.
Drain valve
Oil filter and etc
Filler cap
Air bleeding bolt Priming pump
Oil pan
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft} SAPH311990400009
(6)
Move the priming pump again until it becomes heavy.
! CAUTION
• After work, wipe off spilled fuel. After start of
the engine, make sure that there is no fuel
the engine, make sure that there is no fuel
leak.
leak.
FUEL SYSTEM
5–1
FUEL SYSTEM
ENGINE
ENGINE
5 FUEL SYSTEM
5 FUEL SYSTEM
Setup layout Layout
Fuel System ................................................................ 5-2 Fuel system diagram............................................... 5-2 Part layout .............................................................. 5-3 Fuel filter drain (on machine main unit)................... 5-5 Replacement of fuel filter element (on machine main unit) ........................................... 5-6 Replacement of supply pump ................................ 5-7 Inspection of supply pump ...................................... 5-9 Replacement of injector ........................................ 5-10 Inspection of injector ............................................. 5-11 Replacement of common rail ................................ 5-12 Inspection of common rail ..................................... 5-12
5–1
Setup layout Layout
5
Fuel System ................................................................ 5-2 Fuel system diagram............................................... 5-2 Part layout .............................................................. 5-3 Fuel filter drain (on machine main unit)................... 5-5 Replacement of fuel filter element (on machine main unit) ........................................... 5-6 Replacement of supply pump ................................ 5-7 Inspection of supply pump ...................................... 5-9 Replacement of injector ........................................ 5-10 Inspection of injector ............................................. 5-11 Replacement of common rail ................................ 5-12 Inspection of common rail ..................................... 5-12
5
5–2
5–2
FUEL SYSTEM
FUEL SYSTEM
Fuel System
Fuel System
Fuel system diagram
Fuel system diagram JP31199050402001
Feed pipe
JP31199050402001
Feed pipe
Injection pipe Flow damper
Injection pipe Flow damper
Injector
Injector
Common rail
Common rail Leakage pipe
Pressure limiter
Through feed pipe
Overflow pipe
Leakage pipe
Pressure limiter
Through feed pipe
Overflow pipe
Supply pump
Supply pump
Fuel tank
Fuel tank
Fuel filter
Fuel filter
SAPH311990500001
SAPH311990500001
5–3
FUEL SYSTEM
Part layout
5–3
FUEL SYSTEM
Part layout JP31199050402003
JP31199050402003
SAPH311990500034
SAPH311990500034
11195
Nozzle clamp holder
23670
Injector
11195
Nozzle clamp holder
23670
Injector
11334
Bearing holder case
23810
Common rail assembly
11334
Bearing holder case
23810
Common rail assembly
11491A
Common rail bracket
9645A
O–ring*
11491A
Common rail bracket
9645A
O–ring*
22100
Supply pump
9851A
O–ring*
22100
Supply pump
9851A
O–ring*
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
22825
63.7N m {650 kgf cm, 47lbf ft}
9068-08320
28.5N m {290kgf cm, 21lbf ft}
22825
63.7N m {650 kgf cm, 47lbf ft}
9068-08320
28.5N m {290kgf cm, 21lbf ft}
900124
108N m {1,100 kgf cm, 80lbf ft}
9068-08400
28.5N m {290kgf cm, 21lbf ft}
900124
108N m {1,100 kgf cm, 80lbf ft}
9068-08400
28.5N m {290kgf cm, 21lbf ft}
900124A
25N m {250 kgf cm, 18lbf ft}
9068-08850
28.5N m {290kgf cm, 21lbf ft}
900124A
25N m {250 kgf cm, 18lbf ft}
9068-08850
28.5N m {290kgf cm, 21lbf ft}
9068-08250
28.5N m {290kgf cm, 21lbf ft}
9068-08250
28.5N m {290kgf cm, 21lbf ft}
5–4
5–4
FUEL SYSTEM
FUEL SYSTEM
SAPH311990500035
SAPH311990500035
23081
Leakage pipe
23816A
Through feed pipe
23081
Leakage pipe
23816A
Through feed pipe
23711
Injection pipe
23816B
Through feed pipe
23711
Injection pipe
23816B
Through feed pipe
23712
Injection pipe
9659B
Gasket*
23712
Injection pipe
9659B
Gasket*
23713
Injection pipe
9659C
Gasket*
23713
Injection pipe
9659C
Gasket*
23714
Injection pipe
9659D
Gasket*
23714
Injection pipe
9659D
Gasket*
23783A
Fuel pipe
9659E
Gasket*
23783A
Fuel pipe
9659E
Gasket*
23816
Through feed pipe
23816
Through feed pipe
*Parts not to be reused.
*Parts not to be reused. Service procedure Replacement procedure item
Service procedure Replacement procedure item
5–5
FUEL SYSTEM
5–5
FUEL SYSTEM
Fuel filter drain (on machine main unit)
Fuel filter drain (on machine main unit)
JP31199050704001
1.
JP31199050704001
Prepare a water container under the drain pipe.
Air bleeding bolt
1.
Prepare a water container under the drain pipe.
2.
Loosen the fuel filter air bleeding bolt and the drain valve.
Air bleeding bolt
Priming pump
Priming pump
2.
Loosen the fuel filter air bleeding bolt and the drain valve. Discharge water at the bottom of the fuel filter case.
! CAUTION
Discharge water at the bottom of the fuel filter case.
• Since discharged water contains fuel,
! CAUTION
observe the local disposal procedure for Drain valve
disposal. 3.
observe the local disposal procedure for Drain valve
Close the drain valve.
SAPH311990500006
• Since discharged water contains fuel, disposal.
3.
Close the drain valve.
4.
Start the priming pump and bleed air from the system.
SAPH311990500006
4.
Start the priming pump and bleed air from the system.
! CAUTION
• Make sure that the fuel filter air bleeding bolt
! CAUTION
is loose. 5.
Tighten the fuel filter air bleeding bolt.
• Make sure that the fuel filter air bleeding bolt is loose.
5.
Tighten the fuel filter air bleeding bolt.
Tightening torque :
Tightening torque :
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft}
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft}
! CAUTION
• After work, wipe off spilled water or fuel.
! CAUTION
• After work, wipe off spilled water or fuel.
After start of the engine, make sure that there
After start of the engine, make sure that there
is no fuel leak.
is no fuel leak.
5–6
5–6
FUEL SYSTEM
FUEL SYSTEM
Replacement of fuel filter element (on
Replacement of fuel filter element (on
machine main unit)
machine main unit) JP31199050704002
1.
Removal of water cup (1)
Fuel filter head
O-ring
1.
Refer to "Drain of the fuel filter" and discharge water from the fuel filter.
Fuel filter element
(2) O-ring
JP31199050704002
(1) Fuel filter head
Removal of fuel filter element
(2)
(1)
Water cup
Remove the fuel filter element.
! CAUTION
3.
Installation of fuel filter element (1)
The soiling and the foreign material of the clamp face are
2.
• The fuel is applied to the O-ring surface of
Remove the fuel filter element.
! CAUTION
3.
Installation of fuel filter element (1)
The soiling and the foreign material of the clamp face are removed.
! CAUTION
fuel filter element. (2)
After the O-ring of the fuel filter element touches the fuel
fuel filter element. (2)
After the O-ring of the fuel filter element touches the fuel
filter head, turn by 3/4 to 1 1/2 and install the fuel filter
filter head, turn by 3/4 to 1 1/2 and install the fuel filter head.
• The fuel is applied to the O-ring surface of the
! CAUTION
water cup.
(4)
After the O-ring of the water cup touches the fuel filter
water cup. (3)
After the O-ring of the water cup touches the fuel filter element, turn by 1/2 to 3/4 and install the fuel filter
element.
element.
Tighten the fuel filter drain valve. • Element is not reused.
Start the priming pump and bleed air from the system.
! CAUTION
• Make sure that the fuel filter air bleeding bolt
(4)
Tighten the fuel filter drain valve.
! CAUTION
(5)
Tighten the fuel filter air bleeding bolt.
• Element is not reused.
Start the priming pump and bleed air from the system.
! CAUTION
is loose. (6)
• The fuel is applied to the O-ring surface of the
element, turn by 1/2 to 3/4 and install the fuel filter
! CAUTION
(5)
• The fuel is applied to the O-ring surface of
head. ! CAUTION
(3)
• Since the filter contains diesel oil, prepare a tray.
SAPH311990500007
removed. ! CAUTION
Remove the water cup of the fuel filter.
Removal of fuel filter element (1)
Water cup
• Since the filter contains diesel oil, prepare a tray.
SAPH311990500007
O-ring
Refer to "Drain of the fuel filter" and discharge water from the fuel filter.
Fuel filter element
Remove the water cup of the fuel filter. O-ring
2.
Removal of water cup
• Make sure that the fuel filter air bleeding bolt is loose.
(6)
Tighten the fuel filter air bleeding bolt.
Tightening torque :
Tightening torque :
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft}
1.7 - 2.6 N m {17.3 - 23 kgf cm, 1.2 - 1.9 lbf ft}
! CAUTION
• After work, wipe off spilled fuel. After start of
! CAUTION
• After work, wipe off spilled fuel. After start of
the engine, make sure that there is no fuel
the engine, make sure that there is no fuel
leak.
leak.
5–7
FUEL SYSTEM
5–7
FUEL SYSTEM
Replacement of supply pump
Replacement of supply pump JP31199050704003
1.
JP31199050704003
Compression upper dead center setting of No.1 cylinder (1)
1.
Turn the crankshaft counterclockwise when viewed from
Compression upper dead center setting of No.1 cylinder (1)
the flywheel. Set the timing mark in the flywheel housing
the flywheel. Set the timing mark in the flywheel housing
inspection window to "1". Flywheel
Turn the crankshaft counterclockwise when viewed from inspection window to "1".
Flywheel
(2)
Remove the inspection window plug in the bearing holder
(2)
case of the supply pump. Tighten the guide bolt (9069-
1 Flywheel housing
08180) very gently and make sure that the bolt seating
case of the supply pump. Tighten the guide bolt (9069-
1 Flywheel housing
08180) very gently and make sure that the bolt seating
comes in close contact with the bearing holder. ! CAUTION
comes in close contact with the bearing holder.
• If it is raised, there must be contact other than
! CAUTION
the stopper key for the coupling flange. Do
SAPH311990500008
Remove the inspection window plug in the bearing holder
the stopper key for the coupling flange. Do
SAPH311990500008
not tighten hard.
not tighten hard.
Close contact
Close contact
Raised
Raised
SAPH311990500009
SAPH311990500009
2.
Removal of supply pump (1)
! CAUTION Pipe A
2.
Remove the fuel pipe connected to the supply pump.
Supply pump
Remove the supply pump at the bearing holder case.
(3)
Remove the drive gear using the special tool designed for
! CAUTION Pipe A
Remove the supply pump at the bearing holder case.
(3)
Remove the drive gear using the special tool designed for that purpose.
Special tool : 09650-1101 Bearing puller
Special tool : 09650-1101 Bearing puller
3. O-ring
Fit a new O-ring to the supply pump and install the bearing holder case.
Assembly of supply pump and bearing holder case (1)
Fit a new O-ring to the supply pump and install the bearing holder case.
Supply pump
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Bearing holder case
Bearing holder case
Bolt SAPH311990500011
(2)
that purpose.
Assembly of supply pump and bearing holder case (1)
Bolt
• Do not remove pipes A.
SAPH311990500010
3.
Supply pump
Remove the fuel pipe connected to the supply pump.
Supply pump
• Do not remove pipes A.
(2)
Removal of supply pump (1)
SAPH311990500010
O-ring
• If it is raised, there must be contact other than
SAPH311990500011
5–8
5–8
FUEL SYSTEM (2)
FUEL SYSTEM
Secure the supply pump, install the injection pump drive
(2)
Secure the supply pump, install the injection pump drive
gear on the shaft, and use a vice or similar to prevent
gear on the shaft, and use a vice or similar to prevent
turning while tightening the nut.
turning while tightening the nut.
Tightening torque : 63.7 N m {650 kgf cm, 47 lbf ft}
Tightening torque : 63.7 N m {650 kgf cm, 47 lbf ft}
! CAUTION
• Do not use the guide bolt for stopper key of
! CAUTION
the shaft.
the shaft.
SAPH311990500012
SAPH311990500012
4.
Installation of supply pump (1)
4.
Match the match mark of the bearing holder case with the
Installation of supply pump (1)
missing tooth of the injection pump drive gear.
Match the match mark of the bearing holder case with the missing tooth of the injection pump drive gear.
SAPH311990500013
SAPH311990500013
(2) Supply pump
• Do not use the guide bolt for stopper key of
O-ring
Install a new O-ring and mount the air compressor and supply pump assembly on the flywheel housing.
(2) Supply pump
O-ring
supply pump assembly on the flywheel housing.
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft} ! CAUTION
Install a new O-ring and mount the air compressor and
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
• Adjust the gear so that the compression top
! CAUTION
dead center alignment of the No.1 cylinder
dead center alignment of the No.1 cylinder
may not be changed.
may not be changed.
• Be sure to remove the guide bolt in cranking
• Be sure to remove the guide bolt in cranking
the engine. • After assembly, be sure to remove the guide
SAPH311990500014
the engine. • After assembly, be sure to remove the guide
SAPH311990500014
bolt and install the inspection window plug. 5.
Update of supply pump learning value (1)
• Adjust the gear so that the compression top
When the supply pump is replaced, update the learning
bolt and install the inspection window plug. 5.
Update of supply pump learning value (1)
When the supply pump is replaced, update the learning
value memorized in the engine ECU with the failure
value memorized in the engine ECU with the failure
diagnosis tool (HinoDX) using PC. (Refer to "HinoDX
diagnosis tool (HinoDX) using PC. (Refer to "HinoDX
operation manual".)
operation manual".)
! CAUTION
• If learning value is not updated, correct
! CAUTION
• If learning value is not updated, correct
common rail pressure is not controlled,
common rail pressure is not controlled,
resulting in engine stall or high common rail
resulting in engine stall or high common rail
pressure. Therefore, when the supply pump is
pressure. Therefore, when the supply pump is
replaced, be sure to update the learning
replaced, be sure to update the learning
value.
value.
5â&#x20AC;&#x201C;9
FUEL SYSTEM
5â&#x20AC;&#x201C;9
FUEL SYSTEM
Inspection of supply pump
Inspection of supply pump JP31199050704004
1.
JP31199050704004
Inspection of suction control valve and fuel temperature
1.
sensor
sensor
(1)
(1)
Measure the resistance of the suction control valve terminals and the fuel temperature sensor terminals using a circuit tester. If it is beyond the standard, remove the
Fuel temperature sensor
supply pump assembly and request for replacement at the
Suction control valve
a circuit tester. If it is beyond the standard, remove the
Fuel temperature sensor
supply pump assembly and request for replacement at the Denso service shop.
Between suction control valve terminals Standard value
Measure the resistance of the suction control valve terminals and the fuel temperature sensor terminals using
Denso service shop.
SAPH311990500026
Inspection of suction control valve and fuel temperature
Suction control valve
Between suction control valve terminals SAPH311990500026
7.65 - 8.15:(at 20qC {68qF})
Standard value
Terminals between fuel temperature
Terminals between fuel temperature
sensors
sensors
13.5 - 16.5k:(at -20qC{68qF}) Standard value
7.65 - 8.15:(at 20qC {68qF})
2.2 - 2.7k:(at 20qC{68qF}) 0.29 - 0.35k:(at 80qC{176qF})
13.5 - 16.5k:(at -20qC{68qF}) Standard value
2.2 - 2.7k:(at 20qC{68qF}) 0.29 - 0.35k:(at 80qC{176qF})
5–10
5–10
FUEL SYSTEM
FUEL SYSTEM
Replacement of injector
Replacement of injector JP31199050704005
1.
JP31199050704005
Removal of injector (1)
1.
Remove the fixing bolt and remove the plate and the
Removal of injector (1)
injection pipe oil seal. (2) 2.
injection pipe oil seal.
Remove the nozzle clamp holder and remove the injector.
(2)
Installation of injector (1)
2.
Attach a new O-ring to the groove of the cylinder head and
Injector
! CAUTION
• Apply engine oil to the O-ring and be careful
Remove the nozzle clamp holder and remove the injector.
Installation of injector (1)
insert the injector. Fixing bolt
Remove the fixing bolt and remove the plate and the
Attach a new O-ring to the groove of the cylinder head and insert the injector.
Fixing bolt
Injector
! CAUTION
to prevent pinching of the O-ring. Injection pipe
(2)
to prevent pinching of the O-ring. Injection pipe
Install the nozzle clamp holder and tack weld the injector
(2)
temporarily. ! CAUTION
Nozzle clamp holder
• Do not fix the nozzle holder until the injection pipe is tack welded.
(3)
(4)
3.
! CAUTION
undue force to the injection nozzle. (Offset
O-ring
position between the injection pipe oil seal
and the injection nozzle may cause oil leak or
and the injection nozzle may cause oil leak or
poor assembly of the injection pipe.)
poor assembly of the injection pipe.)
Assemble the injection pipe temporarily and tighten the
(4)
SAPH311990500027
fixing bolt of the nozzle clamp holder.
Tightening torque : 25 N m {250 kgf cm, 1.8 lbf ft}
Tightening torque : 25 N m {250 kgf cm, 1.8 lbf ft}
! CAUTION
3.
Entry of injector correction value to the engine ECU (entry using HinoDX and QR code reader)
QR code
• When the injector is replaced, it is necessary
! CAUTION
to enter the injector correction value (QR
code) described on the new injector to the
code) described on the new injector to the
value may result in faulty engine. NOTICE
• When the injector is replaced, it is necessary
to enter the injector correction value (QR engine ECU. Incorrect entry of the correction
SAPH311990500028
Assemble the injection pipe temporarily and tighten the
fixing bolt of the nozzle clamp holder.
Entry of injector correction value to the engine ECU (entry
Injector
• Install the injection pipe oil seal to prevent
position between the injection pipe oil seal
using HinoDX and QR code reader)
QR code
Put a new injection pipe oil seal on the injector and install the plate.
Injection pipe oil seal
• Install the injection pipe oil seal to prevent
• Do not fix the nozzle holder until the injection pipe is tack welded.
(3)
undue force to the injection nozzle. (Offset
O-ring
SAPH311990500027
! CAUTION
Nozzle clamp holder
Put a new injection pipe oil seal on the injector and install
! CAUTION
Install the nozzle clamp holder and tack weld the injector temporarily.
the plate.
Injection pipe oil seal
• Apply engine oil to the O-ring and be careful
• Available entry methods of the injector correction value are the PC tool and the QR code reader.
engine ECU. Incorrect entry of the correction Injector
value may result in faulty engine. NOTICE
SAPH311990500028
• Available entry methods of the injector correction value are the PC tool and the QR code reader.
• The flow of work is described in the following.
• The flow of work is described in the following.
If you want details regarding any procedure,
If you want details regarding any procedure,
however, refer to the PC Tools instruction
however, refer to the PC Tools instruction
manual.
manual.
5–11
FUEL SYSTEM (1)
Read the injector QR code with the scanner of the QR
(1)
code reader and prepare the correction data file. (2)
5–11
FUEL SYSTEM
Read the injector QR code with the scanner of the QR code reader and prepare the correction data file.
Enter the injector correction value directly from the PC
(2)
tools to the engine ECU.
Enter the injector correction value directly from the PC tools to the engine ECU.
PC
PC
QR Code reader
QR Code reader
Hino-Bowie
Hino-Bowie
Engine-use code
Engine-use code
QR code
QR code
Connector
Connector
New injector
New injector ECU
ECU
SAPH311990500029
SAPH311990500029
Inspection of injector
Inspection of injector JP31199050704006
1. <Cross-section view of injector head>
JP31199050704006
Inspection of injector insulation
1.
(1)
Remove the injector plastic terminal cap (upper).
(2)
Measure the insulation resistance between the injector
<Cross-section view of injector head>
Inspection of injector insulation (1)
Remove the injector plastic terminal cap (upper).
(2)
Measure the insulation resistance between the injector
upper body and one terminal (no polarity) of two terminals
upper body and one terminal (no polarity) of two terminals
for the injector harness. Terminal (harness tightening area)
for the injector harness. Terminal (harness tightening area)
Terminal cap (upper)
Standard value (normal Terminal cap (lower)
temperature) (3)
1000M:or more
temperature) (3)
0.45:r0.1
SAPH311990500030
2.
If the resistance value in (2) and (3) exceeds the standard
Cleaning of injector (1)
Remove sludge at or around the terminal, if any.
! CAUTION
• In removing sludge, do not use a cleaning agent. Wipe it off with a rag. Use of a cleaning
Measure the resistance value between two terminals
Standard value (at 20qC) (4)
value, replace the injector assembly.
Upper body
1000M:or more
above.
Injector harness and rubber seal
Standard value (at 20qC) (4)
Standard value (normal Terminal cap (lower)
Measure the resistance value between two terminals above.
Injector harness and rubber seal
Terminal cap (upper)
0.45:r0.1
If the resistance value in (2) and (3) exceeds the standard value, replace the injector assembly.
Upper body
SAPH311990500030
2.
Cleaning of injector (1)
Remove sludge at or around the terminal, if any.
! CAUTION
• In removing sludge, do not use a cleaning agent. Wipe it off with a rag. Use of a cleaning
agent may result in electric failure due to
agent may result in electric failure due to
penetration of the agent.
penetration of the agent.
5–12
5–12
FUEL SYSTEM
FUEL SYSTEM
Replacement of common rail
Replacement of common rail JP31199050704007
1.
JP31199050704007
Removal of common rail (1)
Remove the common rail together with the flow damper,
Removal of common rail (1)
Remove the common rail together with the flow damper,
pressure sensor and pressure limiter from the intake
pressure sensor and pressure limiter from the intake
manifold.
manifold.
! CAUTION Pressure limiter
1.
• Remove dirt around parts before removing
! CAUTION Pressure limiter
the common rail
Flow damper
• Remove dirt around parts before removing the common rail
Flow damper
Pressure sensor
Pressure sensor SAPH311990500031
SAPH311990500031
2.
Installation of common rail (1)
2.
Install the common rail on the intake manifold.
Installation of common rail (1)
SAPH311990500032
Install the common rail on the intake manifold.
SAPH311990500032
Inspection of common rail
Inspection of common rail JP31199050704008
1.
Inspection of common rail pressure sensor (1)
JP31199050704008
1.
Measure the resistance value between terminals using a
Inspection of common rail pressure sensor (1)
Measure the resistance value between terminals using a
circuit tester. If it exceeds the standard value, replace the
circuit tester. If it exceeds the standard value, replace the
common rail assembly
common rail assembly
Between 1 and 2 Between 2 and 3 SAPH311990500033
SAPH311990500033
Standard value (k:) At stop of engine
Between 1 and 2 Between 2 and 3
0.5 - 3.0
6.5 - 18.5
Standard value (k:) At stop of engine
0.5 - 3.0
6.5 - 18.5
ELECTRICAL
7–1
ELECTRICAL
ENGINE
ENGINE
7 ELECTRICAL
7 ELECTRICAL
Setup layout Layout
Electrical System........................................................ 7-2 Part layout ............................................................... 7-2 Part layout ............................................................... 7-5 Layout of components............................................. 7-5 Inspection of components ....................................... 7-8 Installation of component ...................................... 7-10 Installation of starter ............................................. 7-10 Installation of alternator ........................................ 7-11
7–1
Setup layout Layout
7
Electrical System........................................................ 7-2 Part layout ............................................................... 7-2 Part layout ............................................................... 7-5 Layout of components............................................. 7-5 Inspection of components ....................................... 7-8 Installation of component ...................................... 7-10 Installation of starter ............................................. 7-10 Installation of alternator ........................................ 7-11
7
7–2
7–2
ELECTRICAL
ELECTRICAL
Electrical System
Electrical System
Part layout
Part layout JP31199070402001
JP31199070402001
SAPH311990700001
SAPH311990700001
82051
Injector harness
89390
Boost pressure sensor
82051
Injector harness
89390
Boost pressure sensor
83420
Water temperature sender gauge
89410
Engine sub revolution sensor
83420
Water temperature sender gauge
89410
Engine sub revolution sensor
83530
Oil pressure warning switch
89411
Engine main revolution sensor
83530
Oil pressure warning switch
89411
Engine main revolution sensor
Tightening torque
Tightening torque
9190-06121
9190-06121
4N m{40kgf cm, 3lbf ft}
4N m{40kgf cm, 3lbf ft}
7–3
ELECTRICAL
7–3
ELECTRICAL
SAPH311990700002
SAPH311990700002
12509
Alternator brace
9011-64410
Through bolt
12509
Alternator brace
9011-64410
Through bolt
12511
Alternator bracket
9241-10107
Fixing bolt at brace
12511
Alternator bracket
9241-10107
Fixing bolt at brace
27040
Alternator assembly
9189A
Adjusting bolt
27040
Alternator assembly
9189A
Adjusting bolt
28100
Starter assembly
28100
Starter assembly
Tightening torque
Tightening torque
9069A
154N m{1,570kgf cm, 114lbf ft}
9241-10107
51N m{520kgf cm, 38lbf ft}
9069A
154N m{1,570kgf cm, 114lbf ft}
9241-10107
51N m{520kgf cm, 38lbf ft}
9011-64401
83N m{850kgf cm, 61lbf ft}
9241-14147
154N m{1,570kgf cm, 114lbf ft}
9011-64401
83N m{850kgf cm, 61lbf ft}
9241-14147
154N m{1,570kgf cm, 114lbf ft}
9189A
5.9N m{60kgf cm, 4lbf ft}
9189A
5.9N m{60kgf cm, 4lbf ft}
7–4
7–4
ELECTRICAL
ELECTRICAL
SAPH311990700003
19110
Glow plug
SAPH311990700003
19110
Glow plug
7â&#x20AC;&#x201C;5
ELECTRICAL
Layout of components
7â&#x20AC;&#x201C;5
ELECTRICAL
Layout of components JP31199070402003
Boost pressure sensor
JP31199070402003
Boost pressure sensor Engine sub revolution sensor
Engine sub revolution sensor
Engine main revolution sensor
Engine main revolution sensor
Engine revolution sensor
Common rail pressure sensor
Fuel temperature sensor Suction control valve (SCV)
Left side view
Engine revolution sensor
Common rail pressure sensor
Fuel temperature sensor Suction control valve (SCV)
Left side view SAPH311990700004
SAPH311990700004
7â&#x20AC;&#x201C;6
7â&#x20AC;&#x201C;6
ELECTRICAL
ELECTRICAL
Oil pressure warning switch Coolamt temperature sender gauge
Oil pressure warning switch Coolamt temperature sender gauge
Engine sub revolution sensor
Engine sub revolution sensor
Engine main revolution sensor
Boost pressure sensor
Suction control valve (SCV)
Fuel temperature sensor
Upper view
Engine main revolution sensor
Boost pressure sensor
Suction control valve (SCV)
Fuel temperature sensor
Upper view SAPH311990700005
SAPH311990700005
7â&#x20AC;&#x201C;7
ELECTRICAL
7â&#x20AC;&#x201C;7
ELECTRICAL
Boost pressure sensor
Boost pressure sensor
Coolamt temperature sender gauge
Coolamt temperature sender gauge
Engine revolution sensor
Front view
Engine revolution sensor
Front view SAPH311990700006
Service procedure Overhaul item
SAPH311990700006 Service procedure Overhaul item
7â&#x20AC;&#x201C;8
7â&#x20AC;&#x201C;8
ELECTRICAL
ELECTRICAL
Inspection of components
Inspection of components JP31199070702001
1.
JP31199070702001
Inspection of oil pressure warning switch
1.
(Laid out on the oil filter)
(Laid out on the oil filter)
(1)
(1)
Apply pressure with air or oil and check continuity
between terminals using a circuit tester. If it is faulty,
replace it.
replace it.
{0.4kgf/cm2
2
With continuity
2
Without continuity
,5.6565lbf/in. }
At 39kPa
SAPH311990700007
Apply pressure with air or oil and check continuity
between terminals using a circuit tester. If it is faulty,
At no load or less than 39kPa
{0.4kgf/cm2
,5.6565lbf/in. }
Oil pressure warning switch
At no load or less than 39kPa
With continuity
{0.4kgf/cm2 ,5.6565lbf/in.2} At 39kPa
SAPH311990700007
{0.4kgf/cm2 ,5.6565lbf/in.2}
Without continuity
Oil pressure warning switch
39.2 - 58.8kPa 2 2 {0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
39.2 - 58.8kPa 2 2 {0.4 - 0.6kgf/cm ,5.7 - 8.5 lbf/in } ON
2
2
2.9kPa{0.3kgf/cm , 2 4.7lbf/in } Within
2.9kPa{0.3kgf/cm , 2 4.7lbf/in } Within
Toward pressure increase
OFF
Inspection of oil pressure warning switch
Toward pressure increase
OFF SAPH311990700008
SAPH311990700008
2. Coolant temperature sender gauge
Inspection of coolant temperature sender gauge
2. Coolant temperature sender gauge
(Installation on thermostat case)
Connector color: Dark
(1)
Heat the coolant temperature sender gauge using hot
Inspection of coolant temperature sender gauge (Installation on thermostat case)
Connector color: Dark
(1)
water. (2)
A
water.
Measure the resistance between terminals using a circuit
(2)
A
tester. If it is faulty, replace the gauge.
B
Temperat SAPH311990700009
ure (qC{qF}) Resistanc e value (:)
Temperat ure (qC,qF)
B
-20
20
80
110
{-68}
{68}
{176}
{230}
13.84 -
2.32 -
0.31 -
0.1399 -
16.33
2.59
0.326
0.1435
100
{167}
{212}
(:)
79 - 92
Temperat SAPH311990700009
ure (qC{qF}) Resistanc e value (:)
-20
20
80
110
{-68}
{68}
{176}
{230}
13.84 -
2.32 -
0.31 -
0.1399 -
16.33
2.59
0.326
0.1435
Between B and body
75
Resistanc e value
Between A and C
C
Between B and body
Measure the resistance between terminals using a circuit tester. If it is faulty, replace the gauge.
Between A and C
C
Heat the coolant temperature sender gauge using hot
35.5 42.5
Temperat ure (qC,qF)
75
100
{167}
{212}
Resistanc e value (:)
79 - 92
35.5 42.5
7â&#x20AC;&#x201C;9
ELECTRICAL 3.
Inspection of glow plug (1)
3.
Measure continuity between the body and the terminal
Inspection of glow plug (1)
using a circuit tester. If it is faulty, replace the glow plug.
Measure continuity between the body and the terminal using a circuit tester. If it is faulty, replace the glow plug.
Standard value
Standard value
Resistance value : :(Normal temperature
7â&#x20AC;&#x201C;9
ELECTRICAL
Resistance value : :(Normal temperature
2.59 - 3.29
20qC{68qF})
2.59 - 3.29
20qC{68qF})
SAPH311990700010
SAPH311990700010
4.
Inspection of suction control valve SCV and fuel
4.
Inspection of suction control valve SCV and fuel
temperature sensor
temperature sensor
(1)
(1)
For inspection and replacement of the suction control valve (SCV) and the fuel temperature sensor, refer to the
Fuel temperature sensor
chapter of "J05E FUEL SYSTEM ".
Suction control valve (SCV)
For inspection and replacement of the suction control valve (SCV) and the fuel temperature sensor, refer to the
Fuel temperature sensor
chapter of "J05E FUEL SYSTEM ".
Suction control valve (SCV) SAPH311990700011
SAPH311990700011
5.
Inspection of common rail pressure sensor (1)
5.
For inspection and replacement of the common rail
Inspection of common rail pressure sensor (1)
For inspection and replacement of the common rail
pressure sensor, refer to the chapter of "J05E FUEL
pressure sensor, refer to the chapter of "J05E FUEL
SYSTEM".
SYSTEM".
SAPH311990700012
SAPH311990700012
6.
Inspection of injector (1)
For inspection and replacement of the injector, refer to the chapter of "J05E FUEL SYSTEM".
6.
Inspection of injector (1)
For inspection and replacement of the injector, refer to the chapter of "J05E FUEL SYSTEM".
7–10
7–10
ELECTRICAL
ELECTRICAL
Installation of component
Installation of component JP31199070702002
1.
Installation of engine revolution sensor (1)
O-ring
JP31199070702002
NOTICE
1.
Confirm that there are O-rings on the sensors and then
Installation of engine revolution sensor (1)
Confirm that there are O-rings on the sensors and then
mount one sensor on top of the flywheel housing and one
mount one sensor on top of the flywheel housing and one
on the cam housing.
on the cam housing.
• Since this sensor is a flange type, gap does
O-ring
NOTICE
not have to be adjusted.
• Since this sensor is a flange type, gap does not have to be adjusted.
Engine sub-revolution sensor
Engine sub-revolution sensor
O-ring
O-ring
Engine main revolution sensor
Engine main revolution sensor
SAPH311990700013
SAPH311990700013
Installation of starter
Installation of starter JP31199070702003
1.
JP31199070702003
Install the starter with bolts and nuts.
1.
Tightening torque : 154 N m {1,570 kgf cm, 114 lbf ft}
SAPH311990700014
Install the starter with bolts and nuts. Tightening torque : 154 N m {1,570 kgf cm, 114 lbf ft}
SAPH311990700014
7–11
ELECTRICAL
7–11
ELECTRICAL
Installation of alternator
Installation of alternator JP31199070702004
1.
JP31199070702004
Installation of alternator (1)
1.
Tighten the alternator temporarily using through bolts and
Installation of alternator (1)
nuts. (2) 2. 㧭
Tighten the adjusting bolts and fixing bolts temporarily.
(2)
V–belt tension adjustment
2.
Coolant Pump Pulley
㧭
When installing a
Item
new belt
Deflection Alternator Pulley
8 - 10mm
10 - 12mm
{0.3152 - 0.394in.}
{0.394 - 0.472in.}
{50 - 58 kgf, 110 -
Crankshaft Pulley SAPH311990700015
128 lbf}
320 - 400 N {33 - 41 kgf, 72 - 90 lbf}
Special tool : 09444-1210 Compression gauge (used at
! CAUTION
NOTICE
(1)
V–belt tension adjustment
(4)
new belt
Deflection Alternator Pulley
At the time of inspection
8 - 10mm
10 - 12mm
{0.3152 - 0.394in.}
{0.394 - 0.472in.}
490 - 570 N Tension
{50 - 58 kgf, 110 -
Crankshaft Pulley SAPH311990700015
128 lbf}
320 - 400 N {33 - 41 kgf, 72 - 90 lbf}
Special tool : 09444-1210 Compression gauge (used at
the time of measuring the deflection
the time of measuring the deflection
amount) [ Reference push force 98N {10kgf,
amount) [ Reference push force 98N {10kgf,
22lbf} ]
22lbf} ]
95506-00090 (Denso part No.) Belt tension
95506-00090 (Denso part No.) Belt tension
gauge (used at the time of measuring the
gauge (used at the time of measuring the
tension force)
tension force)
• If the V-belt is replaced with a new one, it
! CAUTION
• If the V-belt is replaced with a new one, it
becomes loose due to initial fitting. Run the
becomes loose due to initial fitting. Run the
engine for three to five minutes and adjust the
engine for three to five minutes and adjust the
tension of the belt again.
tension of the belt again.
• At the time of inspection, the new V-belt has
NOTICE
• At the time of inspection, the new V-belt has
reached the value after complete initial
reached the value after complete initial
stretching. A new V-belt completes initial
stretching. A new V-belt completes initial
stretching after running the engine for
stretching after running the engine for
approximately two hours.
approximately two hours.
Tighten the through bolt of the commutator end frame.
(1)
Tighten the lock nut on the brace side.
Tighten the through bolt of the commutator end frame. Tightening torque : Through bolt
83 N m {850 kgf cm, 61 lbf ft}
(3)
When installing a
Item
Tightening torque : Through bolt (2)
Tighten the adjusting bolts and fixing bolts temporarily.
Coolant Pump Pulley
At the time of inspection
490 - 570 N Tension
Tighten the alternator temporarily using through bolts and nuts.
83 N m {850 kgf cm, 61 lbf ft} (2)
Tighten the lock nut on the brace side.
Tightening torque : Adjusting bolt
Tightening torque : Adjusting bolt
51 N m {520 kgf cm, 38 lbf ft}
51 N m {520 kgf cm, 38 lbf ft}
Tighten the adjusting bolt and make sure the bolt is
(3)
Tighten the adjusting bolt and make sure the bolt is
locked.
locked.
Tightening torque : Adjusting bolt
Tightening torque : Adjusting bolt
5.9 N m {60 kgf cm, 4 lbf ft}
5.9 N m {60 kgf cm, 4 lbf ft}
Securely connect the ground wire terminal for the
(4)
Securely connect the ground wire terminal for the
alternator.
alternator.
Tightening torque : Adjusting bolt
Tightening torque : Adjusting bolt
4 N m {40 kgf cm, 3 lbf ft}
4 N m {40 kgf cm, 3 lbf ft}
INTAKE
8–1
INTAKE
ENGINE
8–1
ENGINE
8 INTAKE
8 INTAKE
Setup layout Layout
Setup layout Layout
Intake Manifold ........................................................... 8-2 Part layout ............................................................... 8-2 Replacement........................................................... 8-4
Intake Manifold ........................................................... 8-2 Part layout ............................................................... 8-2 Replacement........................................................... 8-4
8
8
8–2
8–2
INTAKE
INTAKE
Intake Manifold
Intake Manifold
Part layout
Part layout JP31199080402001
JP31199080402001
SAPH311990800001
SAPH311990800001
17103
Intake pipe
17113
Intake pipe
17103
Intake pipe
17113
Intake pipe
17111
Intake manifold
17171
Gasket*
17111
Intake manifold
17171
Gasket*
9240-08087
28.5 N m {290 kgf cm, 21lbf ft}
*Parts not to be reused.
*Parts not to be reused.
Tightening torque 9068-08320
28.5 N m {290 kgf cm, 21lbf ft}
9068-08550
28.5 N m {290 kgf cm, 21lbf ft}
Tightening torque 9240-08087
28.5 N m {290 kgf cm, 21lbf ft}
9068-08320
28.5 N m {290 kgf cm, 21lbf ft}
9068-08550
28.5 N m {290 kgf cm, 21lbf ft}
8â&#x20AC;&#x201C;3
INTAKE
8â&#x20AC;&#x201C;3
INTAKE
SAPH311990800002
17104A
Gasket*
17148
*Parts not to be reused.
Plate
SAPH311990800002
17104A
Gasket*
17148
*Parts not to be reused. Service procedure Replacement procedure item
Service procedure Replacement procedure item
Plate
8–4
8–4
INTAKE
INTAKE
Replacement
Replacement JP31199080704001
1.
Removal of intake manifold (1)
2.
JP31199080704001
1.
Remove bolts and nuts and remove the intake manifold.
Removal of intake manifold (1)
Installation of intake manifold
2.
Remove bolts and nuts and remove the intake manifold.
Installation of intake manifold
(1)
Clean inside of the intake manifold and the cylinder head.
(1)
Clean inside of the intake manifold and the cylinder head.
(2)
Assemble a new gasket.
(2)
Assemble a new gasket.
! CAUTION
• Install the gasket so that the protrusion may
! CAUTION
• Install the gasket so that the protrusion may
come at the rear end stud bolt of the cylinder
come at the rear end stud bolt of the cylinder
head.
head.
Protrusion
Protrusion
SAPH311990800003
SAPH311990800003
(3)
Install the intake manifold and tighten it with bolts and
(3)
Install the intake manifold and tighten it with bolts and
nuts.
nuts.
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
SAPH311990800004
SAPH311990800004
3.
Installation of intake pipe (1)
After removing contamination on the contact surface,
3.
Installation of intake pipe (1)
apply liquid gasket [Threebond TB1207B(black) or
apply liquid gasket [Threebond TB1207B(black) or
equivalent] to the circumference of the contact surface.
equivalent] to the circumference of the contact surface.
! CAUTION
• Apply it continuously.
! CAUTION
• Apply the liquid gasket at the width of 1.5 to
2.5 mm {0.0591 to 0.09843 in.}
• Install the oil cooler within 20 minutes after
• Install the oil cooler within 20 minutes after
application of the liquid gasket. Install the intake pipe with bolts and nuts.
• Apply it continuously. • Apply the liquid gasket at the width of 1.5 to
2.5 mm {0.0591 to 0.09843 in.}
(2)
After removing contamination on the contact surface,
application of the liquid gasket. (2)
Install the intake pipe with bolts and nuts.
ENGINE MECHANICAL
9–1
ENGINE MECHANICAL
ENGINE
9–1
ENGINE
9 ENGINE MECHANICAL
9 ENGINE MECHANICAL
Setup layout Layout
Setup layout Layout
Cylinder Head ............................................................. 9-2 Part layout ............................................................... 9-2 Replacement of cylinder head ................................ 9-4 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) ....... 9-7 Replacement of head cover .................................... 9-7 Overhaul of cylinder head ....................................... 9-8
Cylinder Head ............................................................. 9-2 Part layout ............................................................... 9-2 Replacement of cylinder head ................................ 9-4 Liquid gasket application procedure for semicircular plug (only when semicircular plug is removed) ....... 9-7 Replacement of head cover .................................... 9-7 Overhaul of cylinder head ....................................... 9-8
Cylinder Block .......................................................... 9-11 Part layout ............................................................. 9-11 Overhaul ............................................................... 9-12
Cylinder Block .......................................................... 9-11 Part layout ............................................................. 9-11 Overhaul ............................................................... 9-12
Timing Gear Cover and Flywheel Housing............. 9-16 Part layout ............................................................. 9-16 Replacement of flywheel housing ......................... 9-17 Replacement of end plate ..................................... 9-17 Replacement of crankshaft front oil seal............... 9-18 Replacement of crankshaft rear oil seal................ 9-20
Timing Gear Cover and Flywheel Housing............. 9-16 Part layout ............................................................. 9-16 Replacement of flywheel housing ......................... 9-17 Replacement of end plate ..................................... 9-17 Replacement of crankshaft front oil seal............... 9-18 Replacement of crankshaft rear oil seal................ 9-20
9
Main Moving Parts.................................................... 9-22 Part layout ............................................................. 9-22 Replacement of piston and connecting rod .......... 9-23 Inspection of piston and connecting rod ............... 9-27 Replacement of connecting rod bushing............... 9-29 Replacement of crankshaft ................................... 9-31 Inspection of crankshaft ........................................ 9-33 Replacement of crankshaft pulley ......................... 9-36 Replacement of flywheel ...................................... 9-36
Main Moving Parts.................................................... 9-22 Part layout ............................................................. 9-22 Replacement of piston and connecting rod .......... 9-23 Inspection of piston and connecting rod ............... 9-27 Replacement of connecting rod bushing............... 9-29 Replacement of crankshaft ................................... 9-31 Inspection of crankshaft ........................................ 9-33 Replacement of crankshaft pulley ......................... 9-36 Replacement of flywheel ...................................... 9-36
Camshaft and Idle Gear ........................................... 9-39 Part layout ............................................................. 9-39 Removal of camshaft ............................................ 9-40 Disassembly of camshaft ...................................... 9-40 Inspection of camshaft and camshaft bearing ...... 9-41 Assembly of camshaft........................................... 9-42 Installation of camshaft ......................................... 9-43 Gear train layout ................................................... 9-45 Removal of timing gear ........................................ 9-45 Inspection of timing gear components .................. 9-46 Installation of timing gear ...................................... 9-47 Overhaul of sub-idle gear (bearing case side) ...... 9-49 Inspection of installation status for each gear ...... 9-51
Camshaft and Idle Gear ........................................... 9-39 Part layout ............................................................. 9-39 Removal of camshaft ............................................ 9-40 Disassembly of camshaft ...................................... 9-40 Inspection of camshaft and camshaft bearing ...... 9-41 Assembly of camshaft........................................... 9-42 Installation of camshaft ......................................... 9-43 Gear train layout ................................................... 9-45 Removal of timing gear ........................................ 9-45 Inspection of timing gear components .................. 9-46 Installation of timing gear ...................................... 9-47 Overhaul of sub-idle gear (bearing case side) ...... 9-49 Inspection of installation status for each gear ...... 9-51
Valve System............................................................. 9-55 Part layout ............................................................. 9-55 Overhaul of valve system...................................... 9-56 Adjustment of valve clearance .............................. 9-59
Valve System............................................................. 9-55 Part layout ............................................................. 9-55 Overhaul of valve system...................................... 9-56 Adjustment of valve clearance .............................. 9-59
9
9–2
9–2
ENGINE MECHANICAL
ENGINE MECHANICAL
Cylinder Head
Cylinder Head
Part layout
Part layout JP31199090402001
JP31199090402001
SAPH311990900001
SAPH311990900001
11101
Cylinder head assembly
11135
Exhaust valve seat
11101
Cylinder head assembly
11135
Exhaust valve seat
11122
Valve guide
11176
Nozzle seat
11122
Valve guide
11176
Nozzle seat
11131
Intake valve seat
900115
O-ring*
11131
Intake valve seat
900115
O-ring*
*Parts not to be reused.
*Parts not to be reused.
9–3
ENGINE MECHANICAL
9–3
ENGINE MECHANICAL
SAPH311990900002
SAPH311990900002
11115
Cylinder head gasket
12108
Oil filler cap
11115
Cylinder head gasket
12108
Oil filler cap
11188
Semicircular plug
12505
Silent block
11188
Semicircular plug
12505
Silent block
11201
Cylinder head cover
23074
Injection pipe oil seal*
11201
Cylinder head cover
23074
Injection pipe oil seal*
11213
Head cover gasket
11213
Head cover gasket
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
11185
59N m{600kgf cm, 44lbf ft}+90q+90q
9069B
59N m{600kgf cm, 44lbf ft}
11185
59N m{600kgf cm, 44lbf ft}+90q+90q
9069B
59N m{600kgf cm, 44lbf ft}
11185A
59N m{600kgf cm, 44lbf ft}+90q+135q
9349A
30N m{300kgf cm, 22lbf ft}
11185A
59N m{600kgf cm, 44lbf ft}+90q+135q
9349A
30N m{300kgf cm, 22lbf ft}
11185B
59N m{600kgf cm, 44lbf ft}+90q+180q
SZ105
59N m{600kgf cm, 44lbf ft}
11185B
59N m{600kgf cm, 44lbf ft}+90q+180q
SZ105
59N m{600kgf cm, 44lbf ft}
9068-08400
28.5N m{290kgf cm, 21lbf ft}
9068-08400
28.5N m{290kgf cm, 21lbf ft}
Service procedure Replacement procedure item
Service procedure Replacement procedure item
9–4
9–4
ENGINE MECHANICAL
ENGINE MECHANICAL
Replacement of cylinder head
Replacement of cylinder head JP31199090704001
1.
JP31199090704001
Removal of cylinder head and head gasket (1)
1.
Loosen the head bolts from outside to inside gradually (1/
Removal of cylinder head and head gasket (1)
4 turn for each) as shown in the order of the figure and 10
6
18
14
7
21
15 11
17
13
20 19
9
remove them. 6 4
12 16
4 turn for each) as shown in the order of the figure and 10
5
18
14
7
8
17
21
15 11
No.4 - No.21 : M12 Bolts
Loosen the head bolts from outside to inside gradually (1/
13
20 19
9
4
12 16
remove them. 5
8
No.4 - No.21 : M12 Bolts SAPH311990900003
SAPH311990900003
(2) Figure is an example of work.
Remove the cylinder head using a special tool and hoist. Special tool : 09433–1070 Eye bolt
NOTICE
2.
SAPH311990900005
Remove the cylinder head using a special tool and hoist. Special tool : 09433–1070 Eye bolt
NOTICE
• If it is difficult to remove the cylinder head,
insert a chisel between the cylinder head and
insert a chisel between the cylinder head and
the cylinder block, and move the chisel
the cylinder block, and move the chisel
vertically so that the contact surface may not
vertically so that the contact surface may not
be damaged. Then, separate the cylinder
be damaged. Then, separate the cylinder head.
SAPH311990900004
Inspection of head bolt length (1)
Underhead length
Figure is an example of work.
• If it is difficult to remove the cylinder head,
head.
SAPH311990900004
(2)
2.
Measure the underhead length of the head bolt (M12 only)
Inspection of head bolt length (1)
Measure the underhead length of the head bolt (M12 only)
using vernier calipers. If it is beyond the service limit,
using vernier calipers. If it is beyond the service limit,
replace it with a new one.
replace it with a new one.
Service limit (mm{in.})
126.5{4.9803 in.}
Underhead length
SAPH311990900005
Service limit (mm{in.})
126.5{4.9803 in.}
ENGINE MECHANICAL 3.
9–5
ENGINE MECHANICAL
Installation of cylinder head gasket and liquid gasket
3.
application procedure (1) Water hole seal ring
(2)
Installation of cylinder head gasket and liquid gasket application procedure
Cut the rear end plate gasket to be flush with the surface of the cylinder block upper surface using a scraper.
(1) Water hole seal ring
Cut the rear end plate gasket to be flush with the surface of the cylinder block upper surface using a scraper.
Install the cylinder head gasket on the cylinder block and
(2)
the flywheel housing. ! CAUTION
Install the cylinder head gasket on the cylinder block and the flywheel housing.
• Remove dirt, water or oil from the mounting
! CAUTION
surfaces of the cylinder head and the cylinder
block before work.
SAPH311990900006
• Never reuse the gasket. Otherwise, it may
• Never reuse the gasket. Otherwise, it may
damage the engine.
damage the engine.
• The water hole seal ring of the cylinder head
• The water hole seal ring of the cylinder head
gasket is susceptible to damage. Avoid
gasket is susceptible to damage. Avoid
contact with hand or object.
contact with hand or object.
• Before installation of the cylinder head
(3)
• Before installation of the cylinder head
gasket, make sure that there is no fall of or
gasket, make sure that there is no fall of or
damage to the seal ring.
damage to the seal ring.
Apply appropriate amount of liquid gasket [Threebond TB1211 (white) or equivalent] to the cylinder head gasket
Application area of liquid gasket
(3)
hole at the joint surface between the cylinder block and The arrow shape area is different from the actual shape.
the flywheel housing. ! CAUTION
• Apply the liquid gasket so that the surface of the liquid gasket may be raised on the
the flywheel housing. ! CAUTION
cylinder head gasket.
• Install the oil cooler within 20 minutes after application of the liquid gasket. Cylinder head
Flywheel housing
Small
Cylinder block
Rear end plate
Flywheel housing
Small
Rear end plate
Clearance
Clearance Too small
Section A - A
application of the liquid gasket.
Liquid gasket
Cylinder head
Clearance
• Install the oil cooler within 20 minutes after
Application area of liquid gasket
Liquid gasket Cylinder block
• Apply the liquid gasket so that the surface of the liquid gasket may be raised on the
cylinder head gasket. Application area of liquid gasket
Apply appropriate amount of liquid gasket [Threebond TB1211 (white) or equivalent] to the cylinder head gasket
Application area of liquid gasket
hole at the joint surface between the cylinder block and The arrow shape area is different from the actual shape.
• Remove dirt, water or oil from the mounting surfaces of the cylinder head and the cylinder
block before work.
SAPH311990900006
9–5
Too small
Clearance
Clearance Raised from upper surface
Section A - A
SAPH311990900007
Clearance Raised from upper surface SAPH311990900007
4.
Installation of cylinder head (1)
Clean the head bolt seat at the cylinder head upper
4.
Installation of cylinder head (1)
surface and the cylinder head lower surface. (2)
Apply engine oil to the head bolt seat and the bolt thread.
Clean the head bolt seat at the cylinder head upper surface and the cylinder head lower surface.
(2)
Apply engine oil to the head bolt seat and the bolt thread.
9â&#x20AC;&#x201C;6
9â&#x20AC;&#x201C;6
ENGINE MECHANICAL (3)
Align the dowel pins of the cylinder block using a special tool and hoist and mount the cylinder head.
Figure is an example of work.
ENGINE MECHANICAL
Special tool : 09433â&#x20AC;&#x201C;1070 Eye bolt ! CAUTION
(3)
Align the dowel pins of the cylinder block using a special tool and hoist and mount the cylinder head.
Figure is an example of work.
Special tool : 09433â&#x20AC;&#x201C;1070 Eye bolt
â&#x20AC;˘ Before mounting the cylinder head, make
! CAUTION
sure that there is no foreign matter in the
sure that there is no foreign matter in the
cylinder.
cylinder.
â&#x20AC;˘ When the cylinder head is mounted, be
â&#x20AC;˘ When the cylinder head is mounted, be
careful for engagement between the cam idle
SAPH311990900004
careful for engagement between the cam idle
SAPH311990900004
gear and the sub-idle gear. (Contact of gear
gear and the sub-idle gear. (Contact of gear
teeth with undue force may cause impact
teeth with undue force may cause impact
mark or chipping, resulting in abnormal noise
mark or chipping, resulting in abnormal noise
or missing tooth.)
or missing tooth.)
â&#x20AC;˘ Mounting of the cylinder head with guide bolt
NOTICE
â&#x20AC;˘ Mounting of the cylinder head with guide bolt
NOTICE
can prevent displacement of the liquid gasket. (4)
(5)
can prevent displacement of the liquid gasket.
Tighten the Nos. 21 - 4 head bolts (M12 only) in order,
(4)
starting at the center and working outward.
Tightening torque : 59 NÂ&#x2DC;m {600 kgfÂ&#x2DC;cm, 44 lbfÂ&#x2DC;ft}
Tightening torque : 59 NÂ&#x2DC;m {600 kgfÂ&#x2DC;cm, 44 lbfÂ&#x2DC;ft}
Re-tighten the Nos. 21 - 4 head bolts in order, starting at Tightening torque : 59 NÂ&#x2DC;m {600 kgfÂ&#x2DC;cm, 44 lbfÂ&#x2DC;ft}
(6)
Mark the heads of the head bolts (M12 only) using paint.
(7)
Tighten the head bolts (M12 only) 90q more, following the
(5)
Tightening torque : 59 NÂ&#x2DC;m {600 kgfÂ&#x2DC;cm, 44 lbfÂ&#x2DC;ft} (6)
Mark the heads of the head bolts (M12 only) using paint.
(7)
Tighten the head bolts (M12 only) 90q more, following the tightening sequence. (1st time)
SAPH311990900008
(8)
Using the same procedure, tighten the head bolts (M12
(8)
only) to the angles shown in the table. (2nd time)
Using the same procedure, tighten the head bolts (M12 only) to the angles shown in the table. (2nd time)
Tightening angle
Head bolts No.
Tightening angle
Head bolts No.
90q
1,2,7,8,9,10,15,16,17
90q
1,2,7,8,9,10,15,16,17
135q
4,5,12,13
135q
4,5,12,13
180q
3,6,11,14,18
180q
3,6,11,14,18
SAPH311990900009
SAPH311990900009
(9)
Make sure the head bolts that have the same tightening angle markings have the same orientation.
! CAUTION
(9)
Make sure the head bolts that have the same tightening angle markings have the same orientation.
Paint mark
â&#x20AC;˘ If a bolt is turned excessively in retightening,
! CAUTION
do not loosen it.
SAPH311990900010
Re-tighten the Nos. 21 - 4 head bolts in order, starting at the center and working outward.
tightening sequence. (1st time) SAPH311990900008
Paint mark
Tighten the Nos. 21 - 4 head bolts (M12 only) in order,
starting at the center and working outward.
the center and working outward.
â&#x20AC;˘ Before mounting the cylinder head, make
â&#x20AC;˘ If a bolt is turned excessively in retightening, do not loosen it.
SAPH311990900010
9–7
ENGINE MECHANICAL (10) Tighten remaining head bolts (M10) in the order in the
(10) Tighten remaining head bolts (M10) in the order in the
figure. This just 3 tighten
figure. This just 3 tighten
Tightening torque : 59 N m {600 kgf cm, 44 lbf ft}
3
Tightening torque : 59 N m {600 kgf cm, 44 lbf ft}
3
2
2
1
1
SAPH311990900012
SAPH311990900012
Liquid gasket application procedure for
Liquid gasket application procedure for
semicircular plug (only when semicircular
semicircular plug (only when semicircular
plug is removed)
plug is removed) JP31199090704002
1.
JP31199090704002
Remove liquid gasket from the cylinder plug and the
1.
camshaft housing.
Semicircular plug
2.
3.
Liquid gasket application region
Coat the semicircular plugs at the front and rear of the
2.
Coat the semicircular plugs at the front and rear of the
cylinder head with liquid gasket (Three Bond TB 1207B-
cylinder head with liquid gasket (Three Bond TB 1207B-
Black or equivalent), and install the semicircular plugs.
Black or equivalent), and install the semicircular plugs.
Temporarily install the cylinder head cover with the gasket
! CAUTION
3.
Liquid gasket application region
semicircular plugs.
SAPH311990900013
Remove liquid gasket from the cylinder plug and the camshaft housing.
Semicircular plug
attached, and execute a parallel adjustment of the
Temporarily install the cylinder head cover with the gasket attached, and execute a parallel adjustment of the semicircular plugs.
SAPH311990900013
• Be sure to wipe protruding liquid gasket.
! CAUTION
Replacement of head cover
• Be sure to wipe protruding liquid gasket.
Replacement of head cover JP31199090704003
1.
(2)
1.
Wipe off the liquid gasket stuck to the sides of the
semicircular plugs on the front and rear ends of the
cylinder head.
cylinder head.
Wipe dirt (including liquid gasket) and oil on the joint
head cover.
SAPH311990900014
Wipe off the liquid gasket stuck to the sides of the
semicircular plugs on the front and rear ends of the (2)
housing. Install a new head cover gasket on the cylinder head cover.
bolt
Silent Block
Wipe dirt (including liquid gasket) and oil on the joint surfaces of the cylinder head cover and the camshaft
Cylinder Head Cover
housing. Install a new head cover gasket on the cylinder
Cylinder Head Cover Gasket
Installation of head cover (1)
surfaces of the cylinder head cover and the camshaft
bolt
Silent Block
JP31199090704003
Installation of head cover (1)
Cylinder Head Cover
9–7
ENGINE MECHANICAL
Cylinder Head Cover Gasket SAPH311990900014
9–8
9–8
ENGINE MECHANICAL (3)
ENGINE MECHANICAL
Coat the semicircular plugs with liquid gasket (Three Bond
(3)
Coat the semicircular plugs with liquid gasket (Three Bond
TB 1207B-Black or equivalent) just before you install the
TB 1207B-Black or equivalent) just before you install the
cylinder head cover.
cylinder head cover.
! CAUTION
• Install the oil cooler within 20 minutes after
! CAUTION
application of the liquid gasket.
application of the liquid gasket.
SAPH311990900015
SAPH311990900015
(4) Cylinder Head cover
Bolt
Put the cylinder head cover on the cylinder head and
(4) Cylinder Head cover
tighten bolts.
Bolt
Silent block
Put the cylinder head cover on the cylinder head and tighten bolts.
Silent block
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
• Silent block the rubber is attached to the
NOTICE Cylinder Head cover gasket
• Install the oil cooler within 20 minutes after
spacer Cylinder Head cover lower surface
• Silent block the rubber is attached to the
NOTICE Cylinder Head cover gasket
Cylinder head
spacer Cylinder Head cover lower surface Cylinder head
SAPH311990900016
SAPH311990900016
Overhaul item
Overhaul item
Overhaul of cylinder head
Overhaul of cylinder head JP31199090702001
1.
JP31199090702001
Cleaning of cylinder head
1.
(1)
Remove carbon or other deposit using a scraper.
(1)
Remove carbon or other deposit using a scraper.
(2)
Clean the cylinder head.
(2)
Clean the cylinder head.
! CAUTION
• To remove carbon or other deposit, do not
! CAUTION
damage the lower surface of the cylinder
head.
head.
SAPH311990900017
2.
Replacement of valve guide
Exhaust
Lower surface of cylinder head SAPH311990900018
• To remove carbon or other deposit, do not
damage the lower surface of the cylinder
SAPH311990900017
Intake
Cleaning of cylinder head
2. Intake
Replacement of valve guide
Exhaust
(1)
Remove the valve stem seal.
(1)
Remove the valve stem seal.
(2)
Remove the valve guide using a brass bar or press.
(2)
Remove the valve guide using a brass bar or press.
(3)
When a new valve guide is assembled, do not pry the end
(3)
When a new valve guide is assembled, do not pry the end
in assembly and press fit using a special tool.
in assembly and press fit using a special tool.
Special tool : 09471–1520 Guide
Special tool : 09471–1520 Guide
! CAUTION
• In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide. • In press fit, be sure to apply engine oil to the circumference of the valve guide.
Lower surface of cylinder head SAPH311990900018
! CAUTION
• In press fit, be careful not to damage the valve stem at the upper/lower ends of the guide. • In press fit, be sure to apply engine oil to the circumference of the valve guide.
ENGINE MECHANICAL 3. Backing metal
Valve
Valve seat
9–9
ENGINE MECHANICAL
Replacement of valve seat
! CAUTION
• The valve seat replacement procedure below may damage the cylinder head depending on
Cut three areas from here.
Backing metal
Valve seat
Replacement of valve seat
! CAUTION
may damage the cylinder head depending on the case. It is recommended that a request for
replacement be made to a machining vendor.
replacement be made to a machining vendor.
If the valve seat is replaced, use an out-of-use valve. After cutting three pieces from the valve circumference,
Valve
Electric welding
(1) Cut three areas from here.
! CAUTION
(2)
• Apply grease to protect the cylinder head
weld them to the valve seat. SAPH311990900019
! CAUTION
(4)
lower surface from welding spatter before
work.
work.
Put a backup metal (e.g. brass bar) at the valve stem
(2)
Put a backup metal (e.g. brass bar) at the valve stem head and pull out the valve seat using a press.
Remove welding spatter or dirt on the valve seat surface.
(3)
Heat the cylinder head to approx. 80 to 100 qC and strike
(4)
Remove welding spatter or dirt on the valve seat surface. Heat the cylinder head to approx. 80 to 100 qC and strike
the cooled valve seat into the mounting area of the
the cooled valve seat into the mounting area of the
cylinder head.
cylinder head.
SAPH311990900020
SAPH311990900020
(5)
Apply small amount of lapping compound to the contact
(5)
surface between the valve and the valve seat. (6)
Apply small amount of lapping compound to the contact surface between the valve and the valve seat.
Strike gently while turning the valve using a special tool
(6)
Strike gently while turning the valve using a special tool
for adjustment.
for adjustment.
Special tool : 09431–1020 Valve lapping tool
Special tool : 09431–1020 Valve lapping tool
SAPH311990900021
SAPH311990900021
4.
Replacement of nozzle seat (1)
4.
Tap the nozzle seat from the cylinder head lower part.
Replacement of nozzle seat (1)
Then, put an appropriate bolt inside. (2)
Hit the bolt head using a hammer and pull out the nozzle
(2) (3)
• After pulling out the nozzle seat, be sure to
Remove the O-ring from the cylinder head.
! CAUTION
remove deposit such as remaining liquid gasket or dirt.
Hit the bolt head using a hammer and pull out the nozzle seat toward the the cylinder head upper part.
Remove the O-ring from the cylinder head.
! CAUTION
Tap the nozzle seat from the cylinder head lower part. Then, put an appropriate bolt inside.
seat toward the the cylinder head upper part. (3)
SAPH311990900022
• Apply grease to protect the cylinder head
lower surface from welding spatter before
head and pull out the valve seat using a press. (3)
If the valve seat is replaced, use an out-of-use valve. After cutting three pieces from the valve circumference,
weld them to the valve seat. SAPH311990900019
• The valve seat replacement procedure below
the case. It is recommended that a request for Electric welding
(1)
3.
9–9
• After pulling out the nozzle seat, be sure to remove deposit such as remaining liquid
SAPH311990900022
gasket or dirt.
9–10
9–10
ENGINE MECHANICAL (4)
ENGINE MECHANICAL
After attaching a new O-ring into the nozzle seat hole of
Cylinder head
(4)
the cylinder head, apply the liquid gasket [Threebond TB1211 (white) or equivalent] at the lower part of a new
O-ring
After attaching a new O-ring into the nozzle seat hole of
Cylinder head
the cylinder head, apply the liquid gasket [Threebond TB1211 (white) or equivalent] at the lower part of a new
O-ring
nozzle seat and assemble it on the cylinder head. Nozzle sheet
! CAUTION
nozzle seat and assemble it on the cylinder head.
• Be sure to replace the O-ring with a new part.
Nozzle sheet
• Be sure to replace the O-ring with a new part.
Reuse may cause water leak or gas leak,
Reuse may cause water leak or gas leak,
resulting in overheat or crack of the cylinder
resulting in overheat or crack of the cylinder
head.
head.
SAPH311990900023
SAPH311990900023
(5)
Clamp the nozzle seat using a special tool.
Nozzle seat
Bar
! CAUTION
(5)
Clamp the nozzle seat using a special tool.
Nozzle seat
Bar
Special tool : 09472–1210 Bar
Special tool : 09472–1210 Bar
9800–06100 Steel ball
9800–06100 Steel ball
Cylinder Head
Cylinder Head
Steel ball
Steel ball Stamp out and clamp
Stamp out and clamp SAPH311990900024
SAPH311990900024
5.
Inspection of cylinder head (1)
5.
Inspection of cylinder head distortion a.
Inspection of cylinder head (1)
Measure distortion of the cylinder head lower surface
Inspection of cylinder head distortion a.
and the manifold mounting surface using a ruler. Standard value (mm{in.})
and the manifold mounting surface using a ruler.
Service limit (mm{in.})
Standard value (mm{in.})
Longitudinal direction 0.06{0.0024}
0.2{0.0079}
0.06{0.0024}
b.
replace it.
(2)
• Repair of the lower surface by grinding can
! CAUTION
• Repair of the lower surface by grinding can
change backlash of the timing gear. Do not
change backlash of the timing gear. Do not
grind it.
grind it. (2)
With dye penetrant test method (red check), make sure
Inspection of cylinder head crack a.
that there is no crack or damage in the cylinder head.
With dye penetrant test method (red check), make sure that there is no crack or damage in the cylinder head.
Setup layout Layout
SAPH311990900025
If the measurement value is beyond the service limit, replace it.
Inspection of cylinder head crack a.
0.2{0.0079}
Square direction 0.03{0.0012}
If the measurement value is beyond the service limit,
! CAUTION
Service limit (mm{in.})
Longitudinal direction
Square direction 0.03{0.0012} b.
Measure distortion of the cylinder head lower surface
Setup layout Layout
SAPH311990900025
9–11
ENGINE MECHANICAL
9–11
ENGINE MECHANICAL
Cylinder Block
Cylinder Block
Part layout
Part layout JP31199090402002
JP31199090402002
SAPH311990900026
11401
Cylinder block assembly
11408
Cooling jet
11467
Cylinder liner
Tightening torque 11521
SAPH311990900026
11401
Cylinder block assembly
11408
Cooling jet
11467
Cylinder liner
15605
22N m{220kgf cm, 16lbf ft}
Tightening torque
69N m{700kgf cm, 51lbf ft}+90q+45q Service procedure Overhaul item
15605
22N m{220kgf cm, 16lbf ft}
11521
69N m{700kgf cm, 51lbf ft}+90q+45q Service procedure Overhaul item
9–12
9–12
ENGINE MECHANICAL
ENGINE MECHANICAL
Overhaul
Overhaul JP31199090702002
1.
JP31199090702002
Replacement of cylinder liner (1)
1.
Put match marks on the flange surfaces of the cylinder
Replacement of cylinder liner (1)
block and the cylinder liner using a oil based marker. ! CAUTION
block and the cylinder liner using a oil based marker.
• Store removed cylinder liners for each cylinder number.
Match mark
Put match marks on the flange surfaces of the cylinder
! CAUTION
cylinder number.
Match mark
• Never provide match marks with a punch.
SAPH311990900027
• Never provide match marks with a punch.
SAPH311990900027
(2)
Pull out the cylinder liner toward the cylinder block upper
(2)
Pull out the cylinder liner toward the cylinder block upper
part using a special tool.
part using a special tool.
Special tool : 09420-2100 Cylinder liner puller
Special tool : 09420-2100 Cylinder liner puller
! CAUTION
• Be careful for handling of the cylinder liner.
! CAUTION
• Be careful for handling of the cylinder liner.
Do not reuse the cylinder liner which has
Do not reuse the cylinder liner which has
been dropped.
been dropped.
• Do not touch the cooling jet during work. SAPH311990900028
SAPH311990900029
• Store removed cylinder liners for each
• Do not touch the cooling jet during work. SAPH311990900028
(3)
Apply engine oil to the inner bore of the cylinder block.
(3)
Apply engine oil to the inner bore of the cylinder block.
(4)
Align the match mark of the cylinder liner with that of the
(4)
Align the match mark of the cylinder liner with that of the
cylinder block. Install the cylinder liner using a special tool.
cylinder block. Install the cylinder liner using a special tool.
Special tool : 09471–1490 Guide
Special tool : 09471–1490 Guide
SAPH311990900029
9–13
ENGINE MECHANICAL
! CAUTION Liner identification mark
Engine type
• When a new cylinder liner is installed, install the cylinder liner with the same identification
! CAUTION Liner identification mark
Engine type
mark (A, B, C) stamped on the cylinder block.
Block front
Block front
Front of engine
Front of engine
SAPH311990900030
SAPH311990900030
Cylinder liner
Cylinder liner
A, B and C marking position
A, B and C marking position
SAPH311990900031
SAPH311990900031
2.
Inspection of protrusion at cylinder liner flange (1)
(2)
2.
Fix the cylinder liner using a special tool.
Inspection of protrusion at cylinder liner flange (1)
Fix the cylinder liner using a special tool.
Tightening torque : 9.8 N m {100 kgf cm, 7 lbf ft}
Tightening torque : 9.8 N m {100 kgf cm, 7 lbf ft}
Special tool : 09420–2100 Cylinder liner puller
Special tool : 09420–2100 Cylinder liner puller
Measure protrusion of the flange using a dial gauge.
Standard value (mm{in.})
(2)
0.01 - 0.08
Measure protrusion of the flange using a dial gauge.
Standard value (mm{in.})
{0.0004 - 0.0031}
SAPH311990900032
0.01 - 0.08 {0.0004 - 0.0031}
SAPH311990900032
3.
Inspection and adjustment of cooling jet (1)
3.
Remove the standard oil check valve and install the
Inspection and adjustment of cooling jet (1)
Remove the standard oil check valve and install the
cooling jet on the cylinder block using a special tool.
cooling jet on the cylinder block using a special tool.
Special tool : 9001–24262 Check bolt
Special tool : 9001–24262 Check bolt
Check bolt SAPH311990900033
• When a new cylinder liner is installed, install the cylinder liner with the same identification
mark (A, B, C) stamped on the cylinder block.
Check bolt
9–13
ENGINE MECHANICAL
SAPH311990900033
9–14
9–14
ENGINE MECHANICAL (2)
ENGINE MECHANICAL
Connect the injection test oil hose from the lower part of
(2)
the cylinder block to the special tool check bolt. ! CAUTION
Connect the injection test oil hose from the lower part of the cylinder block to the special tool check bolt.
• Use new engine oil for injection of oil.
! CAUTION
Check bolt
Check bolt
Oil hose
Oil hose
SAPH311990900034
SAPH311990900034
(3)
Set a special tool on the cylinder block.
(3)
Special tool : 09470–1280 Tool assembly Special tool Tool assembly
Set a special tool on the cylinder block. Special tool : 09470–1280 Tool assembly
Special tool Tool assembly
Cylinder liner
Cylinder liner
Cooling jet
Cooling jet
SAPH311990900035
SAPH311990900035
(4) Oil injection unit (example) Oil Hose
Inject oil from the nozzle of the cooling jet at the hydraulic pressure of
Pressure Regulator
196kPa{2kgf/cm2,
28lbf/in.2}.
• Refer to the drawing for the oil injection unit.
NOTICE Air tank (Oil tank)
(4) Oil injection unit (example) Oil Hose Compressed air
Air gauge
Air hose To cooling jet
Valve
Valve
SAPH311990900036
SAPH311990900036
(5)
When the injection center hits within the specified line of
(5)
the gauge, it is considered normal. Injection
• Refer to the drawing for the oil injection unit.
NOTICE Air tank (Oil tank)
Air hose To cooling jet
Inject oil from the nozzle of the cooling jet at the hydraulic pressure of 196kPa{2kgf/cm2, 28lbf/in.2}.
Pressure Regulator
Compressed air
Air gauge
Gauge target circle
! CAUTION
• Oil is susceptible to combustion due to
When the injection center hits within the specified line of the gauge, it is considered normal.
Injection
Gauge target circle
! CAUTION
spread. Do not use fire near around.
Faulty
Normal
Normal
(6)
Make sure that the jet position check gauge hole at the
• Work at well ventilated place. Faulty
Faulty
Normal
Normal
tool assembly end may not interfere with the cooling jet
(6)
Make sure that the jet position check gauge hole at the tool assembly end may not interfere with the cooling jet
pipe. SAPH311990900037
• Oil is susceptible to combustion due to spread. Do not use fire near around.
• Work at well ventilated place. Faulty
• Use new engine oil for injection of oil.
pipe. SAPH311990900037
9–15
ENGINE MECHANICAL (7)
If injection does not hit the target circle, correct it with a
(8)
(7)
If injection does not hit the target circle, correct it with a
special tool.
special tool.
Special tool : 09472–1620 Tool
Special tool : 09472–1620 Tool
If it cannot be corrected, install a new cooling jet for
(8)
If it cannot be corrected, install a new cooling jet for
reinspection. (9)
reinspection.
Remove the check bolt and install the cooling jet on the
(9)
Remove the check bolt and install the cooling jet on the
cylinder block using the genuine oil check valve.
cylinder block using the genuine oil check valve.
Tightening torque : 22 N m {220 kgf cm, 16 lbf ft} SAPH311990900038
(10) After assembly of the piston, make sure that the cooling
4.
Tightening torque : 22 N m {220 kgf cm, 16 lbf ft} SAPH311990900038
(10) After assembly of the piston, make sure that the cooling
jet does not interfere with the piston at the piston bottom
jet does not interfere with the piston at the piston bottom
dead center.
dead center.
Inspection of cylinder block (1)
4.
Inspection of cylinder block distortion a.
Inspection of cylinder block (1)
Measure distortion on the cylinder block using a ruler. Standard value (mm{in.})
Inspection of cylinder block distortion a.
Service limit (mm{in.})
0.06{0.0024} Square direction
Measure distortion on the cylinder block using a ruler. Standard value (mm{in.})
Longitudinal direction
0.06{0.0024}
0.2{0.0079}
Square direction
b.
replace it.
(2)
• Repair of the upper surface by grinding can
! CAUTION
• Repair of the upper surface by grinding can
change backlash of the timing gear. Do not
change backlash of the timing gear. Do not
grind it.
grind it. (2)
With dye penetrant test method (red check), make sure
Inspection of cylinder block crack a.
that there is no crack or damage in the cylinder block.
With dye penetrant test method (red check), make sure that there is no crack or damage in the cylinder block.
Setup layout Layout
SAPH311990900039
If the measurement value is beyond the service limit, replace it.
Inspection of cylinder block crack a.
0.2{0.0079}
0.03{0.0012}
If the measurement value is beyond the service limit,
! CAUTION
Service limit (mm{in.})
Longitudinal direction
0.03{0.0012} b.
9–15
ENGINE MECHANICAL
Setup layout Layout
SAPH311990900039
9–16
9–16
ENGINE MECHANICAL
ENGINE MECHANICAL
Timing Gear Cover and Flywheel Housing
Timing Gear Cover and Flywheel Housing
Part layout
Part layout JP31199090402003
JP31199090402003
SAPH311990900040
SAPH311990900040
11309
Front oil seal retainer
11390
End plate
11309
Front oil seal retainer
11390
End plate
11351
Flywheel housing
9828A
Front oil seal*
11351
Flywheel housing
9828A
Front oil seal*
11357
Gasket*
9828B
Rear oil seal*
11357
Gasket*
9828B
Rear oil seal*
11357A
Gasket*
11357A
Gasket*
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
9068-08000
36N m{370kgf cm, 27lbf ft}
90124A
196N m{2,000kgf cm, 145lbf ft}
9068-08000
36N m{370kgf cm, 27lbf ft}
90124A
196N m{2,000kgf cm, 145lbf ft}
9068-10750
55N m{560kgf cm, 41lbf ft}
9241-10107
55N m{560kgf cm, 41lbf ft}
9068-10750
55N m{560kgf cm, 41lbf ft}
9241-10107
55N m{560kgf cm, 41lbf ft}
9068-60850
55N m{560kgf cm, 41lbf ft}
9339A
55N m{560kgf cm, 41lbf ft}
9068-60850
55N m{560kgf cm, 41lbf ft}
9339A
55N m{560kgf cm, 41lbf ft}
90124
196N m{2,000kgf cm, 145lbf ft}
9419A
196N m{2,000kgf cm, 145lbf ft}
90124
196N m{2,000kgf cm, 145lbf ft}
9419A
196N m{2,000kgf cm, 145lbf ft}
Service procedure Overhaul item
Service procedure Overhaul item
9–17
ENGINE MECHANICAL
Replacement of flywheel housing
Replacement of flywheel housing JP31199090702003
1.
JP31199090702003
Removal of flywheel housing (1)
1.
Remove bolts and remove the flywheel housing.
! CAUTION
Removal of flywheel housing (1)
• Remove bolts fixing the flywheel housing
Remove bolts and remove the flywheel housing.
! CAUTION
from the cylinder block.
SAPH311990900041
2. Liquid gasket
Installation of flywheel housing
2.
(1)
Remove contamination from the joint surfaces of the
(2)
Apply the liquid gasket [Threebond TB1207D (silver) or
Liquid gasket
Installation of flywheel housing (1)
Remove contamination from the joint surfaces of the
(2)
Apply the liquid gasket [Threebond TB1207D (silver) or
flywheel housing and the end plate using a scraper.
flywheel housing and the end plate using a scraper.
equivalent] to the flywheel housing as shown in the figure. ! CAUTION
equivalent] to the flywheel housing as shown in the figure.
• Apply it continuously.
! CAUTION
• Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}. SAPH311990900042
• Install the oil cooler within 20 minutes after
• Install the oil cooler within 20 minutes after
application of the liquid gasket. (3) B
C A A
application of the liquid gasket.
Install the flywheel housing on the cylinder block with
(3) B
A
bolts.
C
Tightening torque :
A B
196 N m {2,000 kgf cm, 145 lbf ft} (Area A)
C
C
36 N m {370 kgf cm, 27 lbf ft} (Area B)
C A A
55 N m {560 kgf cm, 41 lbf ft} (Area C) ! CAUTION
• Apply it continuously. • Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}. SAPH311990900042
B
• Remove bolts fixing the flywheel housing from the cylinder block.
SAPH311990900041
A
A
• Tighten bolts fixing the flywheel housing from
A
Install the flywheel housing on the cylinder block with
A
bolts.
C
Tightening torque : 196 N m {2,000 kgf cm, 145 lbf ft} (Area A)
C
36 N m {370 kgf cm, 27 lbf ft} (Area B)
C A A
55 N m {560 kgf cm, 41 lbf ft} (Area C) ! CAUTION
the cylinder block.
• Tighten bolts fixing the flywheel housing from the cylinder block.
SAPH311990900043
SAPH311990900043
Replacement of end plate
Replacement of end plate JP31199090702004
1.
SAPH311990900044
9–17
ENGINE MECHANICAL
JP31199090702004
Removal of end plate
1.
Removal of end plate
(1)
Remove bolts.
(1)
Remove bolts.
(2)
Remove the Torx bolt and remove the end plate using a
(2)
Remove the Torx bolt and remove the end plate using a
special tool.
special tool.
Special tool : 09411–1300 Socket wrench
Special tool : 09411–1300 Socket wrench
SAPH311990900044
9–18
9–18
ENGINE MECHANICAL 2.
ENGINE MECHANICAL
Installation of end plate (1)
Install the end plate and a new gasket with bolts.
! CAUTION
(2)
2.
Installation of end plate (1)
• Make sure that there is no dirt or foreign
! CAUTION
matter on the installation surface of the
cylinder block and the screw holes.
cylinder block and the screw holes.
Apply sealant (Super 5M or equivalent) to the thread of
(2)
Apply sealant (Super 5M or equivalent) to the thread of the Torx bolt.
Install the Torx bolt using a special tool.
(3)
Special tool : 09411–1300 Socket wrench
Install the Torx bolt using a special tool. Special tool : 09411–1300 Socket wrench
SAPH311990900044
SAPH311990900044
Tightening torque : 55 N m {560 kgf cm, 41 lbf ft} (4) Cylinder block
• Make sure that there is no dirt or foreign
matter on the installation surface of the
the Torx bolt. (3)
Install the end plate and a new gasket with bolts.
Gasket
Cut the gasket with a scraper to be flush to the upper/ lower surfaces of the cylinder block.
End plate
Tightening torque : 55 N m {560 kgf cm, 41 lbf ft} (4) Cylinder block
Flywheel housing
Gasket
Cut the gasket with a scraper to be flush to the upper/ lower surfaces of the cylinder block.
End plate Flywheel housing
SAPH311990900045
SAPH311990900045 Replacement procedure item
Replacement procedure item
Replacement of crankshaft front oil seal
Replacement of crankshaft front oil seal
JP31199090704004
1.
Removal of front oil seal (1)
1.
Install the plate of the special tool oil seal puller on the
Removal of front oil seal (1)
Install the plate of the special tool oil seal puller on the
crankshaft using two crankshaft damper mounting bolts.
crankshaft using two crankshaft damper mounting bolts.
Special tool : 09420–1731 Oil seal puller
Special tool : 09420–1731 Oil seal puller
SAPH311990900046
SAPH311990900046
(2)
SAPH311990900047
JP31199090704004
Hook the special tool oil seal puller with the tab of the front
(2)
Hook the special tool oil seal puller with the tab of the front
oil seal and install the hook on the plate of the special tool
oil seal and install the hook on the plate of the special tool
oil seal puller with accompanying bolts.
oil seal puller with accompanying bolts.
SAPH311990900047
ENGINE MECHANICAL (3)
9–19
ENGINE MECHANICAL
Remove two bolts which installed the plate of the special
(3)
tool oil seal puller on the crankshaft. (4)
Remove two bolts which installed the plate of the special tool oil seal puller on the crankshaft.
Attach the accompanying center bolt to the special tool oil
(4)
seal puller and tighten it. Pull out the front oil seal.
Attach the accompanying center bolt to the special tool oil seal puller and tighten it. Pull out the front oil seal.
SAPH311990900048
SAPH311990900048
2. Guide
9–19
Installation of front oil seal (1)
2. Guide
Insert a new oil seal into the guide of the oil seal press.
Installation of front oil seal (1)
Special tool : 09407–1030 Oil seal press ! CAUTION
Special tool : 09407–1030 Oil seal press
• Be careful for front/rear directions of the front
! CAUTION
oil seal. (The felt surface is at the crankshaft
• Be careful for front/rear directions of the front oil seal. (The felt surface is at the crankshaft
damper side.) Oil seal
Insert a new oil seal into the guide of the oil seal press.
damper side.) Oil seal
SAPH311990900049
SAPH311990900049
(2)
Remove contamination from the joint surface of the front
(2)
oil seal and the cylinder block. (3)
oil seal and the cylinder block.
Apply small amount of engine oil to the seal area of the
(3)
front oil seal. (4)
(4)
with accompanying guide bolts on the crankshaft.
Install the oil seal press guide inserting a new front oil seal with accompanying guide bolts on the crankshaft.
SAPH311990900050
(5)
Align the oil seal press hole to the guide bolt and insert
(5)
the oil seal press. (6)
Align the oil seal press hole to the guide bolt and insert the oil seal press.
Attach the accompanying center bolt to the oil seal press
(6)
and tighten it until stop. Press fit the front oil seal.
SAPH311990900051
Apply small amount of engine oil to the seal area of the front oil seal.
Install the oil seal press guide inserting a new front oil seal
SAPH311990900050
Remove contamination from the joint surface of the front
Attach the accompanying center bolt to the oil seal press and tighten it until stop. Press fit the front oil seal.
SAPH311990900051
9–20
9–20
ENGINE MECHANICAL
ENGINE MECHANICAL
Replacement of crankshaft rear oil seal
Replacement of crankshaft rear oil seal
JP31199090704005
1.
JP31199090704005
Removal of rear oil seal (1)
1.
Install the plate of the special tool oil seal puller on the
Removal of rear oil seal (1)
Install the plate of the special tool oil seal puller on the
crankshaft using two flywheel assembly mounting bolts.
crankshaft using two flywheel assembly mounting bolts.
Special tool : 09420–1742 Oil seal puller
Special tool : 09420–1742 Oil seal puller
! CAUTION
• Align the large hole of the plate with the collar
! CAUTION
dowel of the crankshaft.
dowel of the crankshaft.
SAPH311990900052
SAPH311990900052
(2)
(3)
Hook the oil seal puller with the tab of the rear oil seal and
(2)
install the hook on the plate of the oil seal puller with
accompanying bolts.
accompanying bolts.
Remove two bolts which installed the plate of the oil seal
(3)
SAPH311990900053
(4)
Attach the accompanying center bolt to the oil seal puller
(4)
and tighten it. Pull out the rear oil seal.
Attach the accompanying center bolt to the oil seal puller and tighten it. Pull out the rear oil seal.
SAPH311990900054
SAPH311990900054
2.
Installation of rear oil seal (1)
Insert a new rear oil seal into the guide of the oil seal
2.
Installation of rear oil seal (1)
Guide of oil seal press
Insert a new rear oil seal into the guide of the oil seal
press.
press.
Special tool : 09407–1040 Oil seal press
Special tool : 09407–1040 Oil seal press
! CAUTION
• Be careful for front/rear directions of the rear
! CAUTION
oil seal. (The felt surface is at the flywheel
SAPH311990900055
Remove two bolts which installed the plate of the oil seal puller on the crankshaft.
SAPH311990900053
Rear oil seal
Hook the oil seal puller with the tab of the rear oil seal and
install the hook on the plate of the oil seal puller with
puller on the crankshaft.
Guide of oil seal press
• Align the large hole of the plate with the collar
side.)
• Be careful for front/rear directions of the rear oil seal. (The felt surface is at the flywheel
Rear oil seal SAPH311990900055
side.)
ENGINE MECHANICAL (2)
9–21
ENGINE MECHANICAL
Remove contamination from the joint surface of the rear
(2)
oil seal and the flywheel housing (3)
Apply small amount of engine oil to the seal area of the
(3) (4)
with accompanying guide bolts on the crankshaft.
! CAUTION
collar dowel of the crankshaft.
• Align the large hole of the guide with the collar dowel of the crankshaft.
SAPH311990900056
(5)
Align the oil seal press hole to the guide bolt and insert
(5)
the oil seal press.
SAPH311990900057
Align the oil seal press hole to the guide bolt and insert the oil seal press.
SAPH311990900057
(6)
Attach the accompanying center bolt to the oil seal press
(6)
and tighten it until stop. Press fit the rear oil seal.
Attach the accompanying center bolt to the oil seal press and tighten it until stop. Press fit the rear oil seal.
Setup layout Layout
SAPH311990900058
Install the oil seal press guide inserting a new rear oil seal with accompanying guide bolts on the crankshaft.
• Align the large hole of the guide with the
SAPH311990900056
Apply small amount of engine oil to the seal area of the rear oil seal.
Install the oil seal press guide inserting a new rear oil seal
! CAUTION
Remove contamination from the joint surface of the rear oil seal and the flywheel housing
rear oil seal. (4)
9–21
Setup layout Layout
SAPH311990900058
9–22
9–22
ENGINE MECHANICAL
ENGINE MECHANICAL
Main Moving Parts
Main Moving Parts
Part layout
Part layout JP31199090402004
JP31199090402004
SAPH311990900059
SAPH311990900059
11011
Thrust bearing
13260
Connecting rod assembly
11011
Thrust bearing
13260
Connecting rod assembly
11701
Main bearing
13271
Connecting rod bush
11701
Main bearing
13271
Connecting rod bush
11703
Main bearing US 0.25
13411
Crankshaft
11703
Main bearing US 0.25
13411
Crankshaft
11704
Main bearing US 0.50
13450
Flywheel assembly
11704
Main bearing US 0.50
13450
Flywheel assembly
13005
Piston, Piston ring set
13453
Ring gear
13005
Piston, Piston ring set
13453
Ring gear
13041
Connecting rod bearing
13470
Crankshaft pulley
13041
Connecting rod bearing
13470
Crankshaft pulley
13041A
Connecting rod bearing
13521
Crankshaft gear
13041A
Connecting rod bearing
13521
Crankshaft gear
13041B
Connecting rod bearing
9819A
Retainer ring*
13041B
Connecting rod bearing
9819A
Retainer ring*
900125
118N m {1, 200 kgf cm, 87lbf ft}
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
13265
69N m{700kgf cm, 51lbf ft}+90q+45q
13455
186N m {1, 900 kgf cm, 137lbf ft} Service procedure Overhaul item
900125
118N m {1, 200 kgf cm, 87lbf ft}
13265
69N m{700kgf cm, 51lbf ft}+90q+45q
13455
186N m {1, 900 kgf cm, 137lbf ft} Service procedure Overhaul item
9–23
ENGINE MECHANICAL
Replacement of piston and connecting rod
Replacement of piston and connecting rod
JP31199090702005
1. Figure is an example of work.
JP31199090702005
Removal of piston (1)
Remove bolts and remove the connecting rod cap.
! CAUTION
1. Figure is an example of work.
Removal of piston (1)
• Insert a large flat tip screwdriver into the
Remove bolts and remove the connecting rod cap.
! CAUTION
flywheel gear from the flywheel housing
inspection hole to prevent turning of the
inspection hole to prevent turning of the
crankshaft.
crankshaft. • Store removed connecting rod cap for each
cylinder number so that combinations of the
cylinder number so that combinations of the
connecting rod and the connecting rod cap
connecting rod and the connecting rod cap
SAPH311990900060
may not be changed. (2)
may not be changed.
Remove carbon on the cylinder liner inner surface with a
(2)
Remove carbon on the cylinder liner inner surface with a
scraper or a sand paper (No. 150 or so) in the
scraper or a sand paper (No. 150 or so) in the
circumferential direction.
circumferential direction.
! CAUTION
• Do not damage parts lower than the carbon
! CAUTION
deposit area. (3)
Fix the cylinder liner with bolts and a plate.
(3)
Fix the cylinder liner with bolts and a plate.
(4)
Hit the connecting rod from underneath the engine using
SAPH311990900061
(4)
Hit the connecting rod from underneath the engine using a handle of a hammer. Remove the piston together with
a handle of a hammer. Remove the piston together with
the connecting rod.
the connecting rod.
SAPH311990900062
SAPH311990900062
NOTICE Cooling jet
• In removing the piston, rotate the connecting rod as shown in the figure. Do not bend the
NOTICE Cooling jet
! CAUTION
• In removing the piston, rotate the connecting rod as shown in the figure. Do not bend the
cooling jet.
cooling jet.
• Store removed pistons and connecting rods
! CAUTION
for each cylinder number.
• Store removed pistons and connecting rods for each cylinder number.
• Be careful not to touch the cooling jet.
• Be careful not to touch the cooling jet. 0
SAPH311990900063
• Do not damage parts lower than the carbon deposit area.
SAPH311990900061
0
• Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
• Store removed connecting rod cap for each SAPH311990900060
9–23
ENGINE MECHANICAL
SAPH311990900063
9–24
ENGINE MECHANICAL 2.
9–24
ENGINE MECHANICAL
Disassembly of piston and connecting rod
2.
Disassembly of piston and connecting rod
(1)
Remove the retainer ring using snap ring pliers.
(1)
Remove the retainer ring using snap ring pliers.
(2)
Remove the piston pin using the brass bar and disconnect
(2)
Remove the piston pin using the brass bar and disconnect
the piston from the connecting rod.
the piston from the connecting rod.
SAPH311990900064
SAPH311990900064
(3)
Remove the piston ring using a special tool.
(3)
Special tool : 09442–1011 Piston ring expander ! CAUTION
Remove the piston ring using a special tool. Special tool : 09442–1011 Piston ring expander
• Since the piston ring is susceptible to
! CAUTION
damage, be careful for handling.
damage, be careful for handling.
• Store piston rings for each cylinder number.
• Store piston rings for each cylinder number.
• Store the piston rings so that the upper and
• Store the piston rings so that the upper and
lower surfaces may be identified.
lower surfaces may be identified.
SAPH311990900065
SAPH311990900065
3. "0" mark position
Assembly of piston and connecting rod
Piston
3. "0" mark position
(1) Exhaust side
Assembly of piston and connecting rod
Piston
Install the piston on the connecting rod so that the "0" mark on the piston may be opposite to the match mark
Intake side
(1) Exhaust side
(2)
(2)
Install a new retainer ring using a snap ring pliers.
Oil hole
! CAUTION
SAPH311990900066
stamp on the connecting rod
Install a new retainer ring using a snap ring pliers.
Oil hole
Install the piston on the connecting rod so that the "0" mark on the piston may be opposite to the match mark
Intake side
stamp on the connecting rod
Match mark stamp
• Since the piston ring is susceptible to
• Make sure that there is no backlash in the retainer ring.
! CAUTION Match mark stamp
SAPH311990900066
• Make sure that there is no backlash in the retainer ring.
ENGINE MECHANICAL (3)
9–25
ENGINE MECHANICAL
Face the side with the piston ring identification print
(3)
Face the side with the piston ring identification print
upward and install in the order of the oil ring, second ring
upward and install in the order of the oil ring, second ring
and top ring using a special tool.
and top ring using a special tool.
• The identification print is present only on the
NOTICE
• The identification print is present only on the
NOTICE
secondary ring and the top and bottom of the Top ring Upper surface
Second ring
top ring and the oil ring are not identified.
Oil ring
Special tool : 09442–1011 Piston ring expander (4)
Lower surface
Oil ring joint
Connect the joint of the coil expander and fit the oil ring inside the ring. Offset the coil expander joint with the ring joint by 180 deg for installation.
Clearance
(5)
secondary ring and the top and bottom of the Top ring Upper surface
Second ring
top ring and the oil ring are not identified.
Oil ring
Special tool : 09442–1011 Piston ring expander (4)
Lower surface
Oil ring joint
joint by 180 deg for installation.
Clearance
Allocate the joints of the piston ring with uniform intervals
Ring
(5)
Oil ring
SAPH311990900067
Top ring SAPH311990900067
4. Concave shape
Ring Second ring
Top ring
Oil hole
Installation of piston and connecting rod (1)
Allocate the joints of the piston ring with uniform intervals
4. Concave shape
Oil hole
Installation of piston and connecting rod (1)
as shown in the figure. Oil hole
Bearing
(2)
Install the connecting rod bearing to suit concave shape of
! CAUTION
Oil hole
Bearing
(2)
connecting rod.
SAPH311990900068
Install the connecting rod bearing to suit concave shape of the connecting rod.
• Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the
Connecting rod
Allocate the joints of the piston ring with uniform intervals as shown in the figure.
the connecting rod.
! CAUTION
• Make sure that the oil hole of the connecting rod bearing is aligned with the oil hole of the
Connecting rod
connecting rod.
SAPH311990900068
(3)
Apply engine oil to the piston, cylinder liner and
(3)
Apply engine oil to the piston, cylinder liner and
connecting rod bearing and compress the piston ring
connecting rod bearing and compress the piston ring
using a special tool.
using a special tool.
Special tool : 09441–1370 Piston ring holder
Special tool : 09441–1370 Piston ring holder
! CAUTION
• Make sure that there is no deformation or
! CAUTION
damage to the special tool piston ring holder.
SAPH311990900069
Allocate the joints of the piston ring with uniform intervals as shown in the figure.
Coil expander
Second ring
Oil ring
Connect the joint of the coil expander and fit the oil ring inside the ring. Offset the coil expander joint with the ring
as shown in the figure. Coil expander
9–25
• Make sure that there is no deformation or damage to the special tool piston ring holder.
SAPH311990900069
9–26
9–26
ENGINE MECHANICAL (4)
ENGINE MECHANICAL
Insert the piston carefully so that the connecting rod may
(4)
not come in contact with the cooling jet. ! CAUTION
Insert the piston carefully so that the connecting rod may not come in contact with the cooling jet.
• Face the "0" mark on the piston toward the
! CAUTION
exhaust side for insertion.
exhaust side for insertion.
• Set the crankshaft of the cylinder as the top
• Set the crankshaft of the cylinder as the top
dead center for assembly.
dead center for assembly.
• Do not damage the cylinder liner, crankshaft
• Do not damage the cylinder liner, crankshaft
and cooling jet during work.
and cooling jet during work.
SAPH311990900070
SAPH311990900070
(5)
Install the connecting rod bearing to suit concave shape of
(5)
the connecting rod cap.
Install the connecting rod bearing to suit concave shape of the connecting rod cap.
Cap
Cap
Bearing
Bearing
SAPH311990900071
SAPH311990900071
(6)
Align the match mark of the connecting rod cap with that
(6)
of the connecting rod and fix it with a dowel pin. Match mark Stamp
• Face the "0" mark on the piston toward the
! CAUTION
of the connecting rod and fix it with a dowel pin. Match mark Stamp
• Do not change the combination between the
! CAUTION
• Do not change the combination between the connecting rod and the connecting rod cap.
1234 1234
connecting rod and the connecting rod cap. 1234 1234
Align the match mark of the connecting rod cap with that
SAPH311990900072
SAPH311990900072
(7)
Measure the underhead length of the connecting rod bolt
(7)
using a vernier calipers. If it is out of the service limit,
using a vernier calipers. If it is out of the service limit,
replace it with a new one.
replace it with a new one.
Service limit (mm{in.})
68.0{2.6772} or less
Underhead length
Service limit (mm{in.})
68.0{2.6772} or less
Underhead length
(8)
Apply engine oil to the connecting rod bolt thread and the
(8)
seat and install it on the connecting rod. SAPH311990900073
Measure the underhead length of the connecting rod bolt
Apply engine oil to the connecting rod bolt thread and the seat and install it on the connecting rod.
SAPH311990900073
9–27
ENGINE MECHANICAL (9)
9–27
ENGINE MECHANICAL
Tighten the connecting rod bolt and mark the bolt head in
(9)
Tighten the connecting rod bolt and mark the bolt head in
Paint mark
the same direction with paint.
Paint mark
the same direction with paint.
Connecting rod cap
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft}
Connecting rod cap
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft}
(10) Retighten the connecting rod bolt 90 q.
(10) Retighten the connecting rod bolt 90 q.
(11) Retighten the connecting rod bolt further 45 q.
45°
(12) Make sure that all marks are in the same direction.
90°
! CAUTION
(11) Retighten the connecting rod bolt further 45 q.
45°
(12) Make sure that all marks are in the same direction.
90°
• If a bolt is turned excessively in retightening,
! CAUTION
do not loosen it.
• If a bolt is turned excessively in retightening, do not loosen it.
SAPH311990900074
SAPH311990900074 Inspection procedure item
Inspection procedure item
Inspection of piston and connecting rod
Inspection of piston and connecting rod
JP31199090703001
1.
JP31199090703001
Inspection of piston clearance (1)
1.
Measure the inner diameter of the cylinder liner sliding
Inspection of piston clearance (1)
surface using a cylinder gauge.
Measure the inner diameter of the cylinder liner sliding surface using a cylinder gauge.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
112{4.4095}
112.15{4.4153}
112{4.4095}
112.15{4.4153}
SAPH311990900075
SAPH311990900075
(2)
Measure the piston outer diameter using a micrometer.
! CAUTION
(2)
• The measuring position is 23 mm{0.9055 in.} above
Measure the piston outer diameter using a micrometer.
! CAUTION
the piston lower end and square to the pin hole. Standard value (mm{in.}) (3)
the piston lower end and square to the pin hole. Standard value
111.9r0.006{4.4055r0.0002}
(mm{in.})
Calculate the difference between the inner diameter of the cylinder liner and the outer diameter of the piston. If it is beyond
SAPH311990900076
(3)
(mm{in.}) 2.
Standard value
0.088 - 0.112{0.0035 - 0.0044}}
(mm{in.}) 2.
groove
0.088 - 0.112{0.0035 - 0.0044}}
Inspection of clearance between piston ring and ring groove
Measure the piston ring width using a micrometer. If it is
(1)
beyond the service limit, replace the piston ring.
SAPH311990900077
Calculate the difference between the inner diameter of the the standard value, replace the cylinder liner and the piston.
Inspection of clearance between piston ring and ring
(1)
111.9r0.006{4.4055r0.0002}
cylinder liner and the outer diameter of the piston. If it is beyond
SAPH311990900076
the standard value, replace the cylinder liner and the piston. Standard value
• The measuring position is 23 mm{0.9055 in.} above
Measure the piston ring width using a micrometer. If it is beyond the service limit, replace the piston ring.
Standard value
Service limit
Standard value
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
Top ring
2.5{0.0984}
2.40{0.0945}
Top ring
2.5{0.0984}
2.40{0.0945}
Second ring
2{0.0787}
1.90{0.0748}
Second ring
2{0.0787}
1.90{0.0748}
Oil ring
4{0.1575}
3.90{0.1535}
Oil ring
4{0.1575}
3.90{0.1535}
SAPH311990900077
9–28
9–28
ENGINE MECHANICAL (2)
ENGINE MECHANICAL
Measure the piston ring groove using a thickness gauge.
(2)
If it is out of the service limit, replace the piston.
Measure the piston ring groove using a thickness gauge. If it is out of the service limit, replace the piston.
Standard value
Service limit
Standard value
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
Top ring groove
2.5{0.0984}
2.70{0.1063}
Top ring groove
2.5{0.0984}
2.70{0.1063}
Second ring groove
2{0.0787}
2.20{0.0866}
Second ring groove
2{0.0787}
2.20{0.0866}
Oil ring groove
4{0.1575}
4.10{0.1614}
Oil ring groove
4{0.1575}
4.10{0.1614}
SAPH311990900078
SAPH311990900078
3. Cylinder liner
Inspection of piston ring joint clearance
3.
(1)
Insert the piston ring into the cylinder liner by 80 mm
(2)
Measure the piston ring joint clearance using a thickness
Cylinder liner
Inspection of piston ring joint clearance (1)
Insert the piston ring into the cylinder liner by 80 mm
(2)
Measure the piston ring joint clearance using a thickness
horizontally using piston.
horizontally using piston.
gauge. If it is out of the service limit, replace the piston ring. Piston Ring
Standard value (mm{in.}) Top ring
SAPH311990900079
Second ring Oil ring
4.
Service limit
gauge. If it is out of the service limit, replace the piston ring. Piston Ring
Standard value (mm{in.})
(mm{in.})
0.3 - 0.40 {0.0118 - 0.0157}
1.5{0.0591}
0.75 - 0.9 {0.0295 - 0.0354}
1.2{0.0472}
0.15 - 0.3 {0.0059 - 0.1181}
1.2{0.0472}
Second ring Oil ring
Inspection of piston pin (1)
Top ring
SAPH311990900079
4.
Measure the outer diameter of the contact area of the
Service limit (mm{in.})
0.3 - 0.40 {0.0118 - 0.0157}
1.5{0.0591}
0.75 - 0.9 {0.0295 - 0.0354}
1.2{0.0472}
0.15 - 0.3 {0.0059 - 0.1181}
1.2{0.0472}
Inspection of piston pin (1)
piston pin with the piston boss using a micrometer.
Measure the outer diameter of the contact area of the piston pin with the piston boss using a micrometer.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
37 {1.4567}
36.96{1.4551}
37 {1.4567}
36.96{1.4551}
SAPH311990900080
SAPH311990900080
(2)
(3)
Measure the piston boss inner diameter using a cylinder gauge.
(2)
Measure the piston boss inner diameter using a cylinder gauge.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
37 {1.4567}
37.05{1.4587}
37 {1.4567}
37.05{1.4587}
Calculate the difference between the outer diameter of the
(3)
Calculate the difference between the outer diameter of the
piston pin contact area with the piston boss and the inner
piston pin contact area with the piston boss and the inner
diameter of the piston boss. If it is out of the service limit,
diameter of the piston boss. If it is out of the service limit,
replace the piston pin or piston.
replace the piston pin or piston.
SAPH311990900081
SAPH311990900081
Standard value (mm)
Service limit (mm{in.})
Standard value (mm)
Service limit (mm{in.})
–0.002T-0.025L
0.05{0.0020}
–0.002T-0.025L
0.05{0.0020}
T : Tightening allowance, L : Clearance Replacement procedure item
T : Tightening allowance, L : Clearance Replacement procedure item
9–29
ENGINE MECHANICAL
9–29
ENGINE MECHANICAL
Replacement of connecting rod bushing
Replacement of connecting rod bushing
JP31199090704006
1. Press Sub-assembly
Wing nut
JP31199090704006
Removal of connecting rod bushing (1)
1. Press Sub-assembly
Put the special tool press sub-assembly together with the special tool guide nut and fix them using the special tool
Wing nut
Removal of connecting rod bushing (1)
special tool guide nut and fix them using the special tool
wing nut. Guide
wing nut. Guide
Special tool : 09481–1130 Guide
SAPH311990900082
! CAUTION
Put the special tool press sub-assembly together with the
Special tool : 09481–1130 Guide
09402–1530 Press sub-assembly
09402–1530 Press sub-assembly
9233–10360 Wing nut
9233–10360 Wing nut
• Face "H" mark of the guide upward for
SAPH311990900082
assembly.
! CAUTION
assembly.
• Assemble it on a level table and make sure
(2)
• Assemble it on a level table and make sure
that the lower end of the guide and the press
that the lower end of the guide and the press
sub-assembly is flat.
sub-assembly is flat.
With the large end bearing removed, assemble the
(2)
connecting rod and put it on the assembled special tool.
SAPH311990900083
(3)
Install the special tool spindle on the bushing of the
(3)
connecting rod. Special tool : 09402–1540 Spindle
Spindle
Connecting rod
With the large end bearing removed, assemble the connecting rod and put it on the assembled special tool.
SAPH311990900083
Groove
! CAUTION
• Align the press sub-assembly groove with the
Install the special tool spindle on the bushing of the connecting rod.
Groove
Special tool : 09402–1540 Spindle
Spindle
Connecting rod
! CAUTION
special tool spindle groove for installation. Press Sub-assembly
• Align the press sub-assembly groove with the special tool spindle groove for installation.
Press Sub-assembly
SAPH311990900084
SAPH311990900084
(4)
Remove the bushing of the connecting rod using a press.
! CAUTION
SAPH311990900085
• Face "H" mark of the guide upward for
(4)
• Move the press slowly.
Remove the bushing of the connecting rod using a press.
! CAUTION
SAPH311990900085
• Move the press slowly.
9–30
9–30
ENGINE MECHANICAL (5)
ENGINE MECHANICAL
Chamfer one side of the connecting rod small end
(5)
uniformly according to the figure.
Chamfer one side of the connecting rod small end uniformly according to the figure.
Chamfer
Chamfer
! CAUTION
• Remove burr completely.
! CAUTION
• After chamfering, remove dirt from the inner
• Remove burr completely. • After chamfering, remove dirt from the inner
surface at the small end and from the oil hole.
surface at the small end and from the oil hole.
SAPH311990900086
SAPH311990900086
2.
Installation of connecting rod bushing (1)
Groove
2.
Install a new bushing on the special tool spindle and Groove
install the special tool guide and the special tool bolt.
Spindle
Special tool : 09402–1540 Spindle 09481–1540 Guide
Bushing
9191–08252 Bolt
Guide
Installation of connecting rod bushing (1)
Install a new bushing on the special tool spindle and install the special tool guide and the special tool bolt.
Spindle
Special tool : 09402–1540 Spindle 09481–1540 Guide
Bushing
9191–08252 Bolt
Guide
Tightening torque :
Bolt
Tightening torque :
Bolt
5 - 6 N m {50 - 70 kgf cm, 3.5 - 4 lbf ft} SAPH311990900087
! CAUTION
5 - 6 N m {50 - 70 kgf cm, 3.5 - 4 lbf ft} SAPH311990900087
• Align grooves of the special tool guide and
! CAUTION
the special tool spindle for installation.
the special tool spindle for installation.
• Make sure that the edge of the special tool
(2)
• Make sure that the edge of the special tool
spindle and the special tool guide is in close
spindle and the special tool guide is in close
contact.
contact.
Align the connecting rod oil hole with the bushing oil hole
(2)
assembled on the special tool. Make sure that the groove
of the special tool spindle is in alignment with the groove
of the special tool spindle is in alignment with the groove
of the special tool press sub-assembly.
of the special tool press sub-assembly. Groove
! CAUTION
• Place the connecting rod so that the chamfer
Oil hole
! CAUTION
side of the connecting rod small end inner
diameter may be the bushing side
diameter may be the bushing side
of the connecting rod.
SAPH311990900088
• Place the connecting rod so that the chamfer
side of the connecting rod small end inner • Apply engine oil to the inner diameter surface
• Apply engine oil to the inner diameter surface of the connecting rod.
SAPH311990900088
(3)
Install the bushing on the connecting rod using a press.
(3)
Install the bushing on the connecting rod using a press.
(4)
Insert a rod with the diameter of 6 mm from the oil hole at
(4)
Insert a rod with the diameter of 6 mm from the oil hole at
NOTICE
the connecting rod large end and make sure that it goes
the connecting rod large end and make sure that it goes
through the oil hole at the small end.
through the oil hole at the small end.
• Displacement of oil holes may cause
NOTICE
insufficient lubrication, resulting in seizure. (5)
• Displacement of oil holes may cause insufficient lubrication, resulting in seizure.
Insert a new piston pin and check if there is no drag or
(5)
backlash. SAPH311990900089
Align the connecting rod oil hole with the bushing oil hole
assembled on the special tool. Make sure that the groove
Groove Oil hole
• Align grooves of the special tool guide and
Insert a new piston pin and check if there is no drag or backlash.
SAPH311990900089
9–31
ENGINE MECHANICAL
Replacement of crankshaft
Replacement of crankshaft JP31199090704007
1.
JP31199090704007
Removal of crankshaft (1)
1.
Remove the main bearing cap and the main shaft bearing.
Removal of crankshaft (1)
Remove the crankshaft using a hoist. ! CAUTION
Remove the main bearing cap and the main shaft bearing. Remove the crankshaft using a hoist.
• Since the part is heavy, be careful for
! CAUTION
handling.
• Store removed main bearing caps and main
bearings for each cylinder number.
bearings for each cylinder number.
SAPH311990900090
SAPH311990900090
2.
Installation of crankshaft (1)
2.
Face the groove side (front) of the thrust bearing toward
Installation of crankshaft (1)
Face the groove side (front) of the thrust bearing toward
the crankarm and the part number side (back) toward the
the crankarm and the part number side (back) toward the
main bearing cap or the cylinder block. Install it on the
main bearing cap or the cylinder block. Install it on the
cylinder block and the main bearing cap.
cylinder block and the main bearing cap.
! CAUTION
• To prevent falling in assembly, apply engine
! CAUTION
oil or grease to the back of the thrust bearing. (2)
Install the main bearing on the cylinder block and each
! CAUTION
(2)
Install the main bearing on the cylinder block and each bearing cap.
• Assemble the bearing with oil hole on the
! CAUTION
cylinder block and assemble the bearing
without oil hole on the cap.
without oil hole on the cap. • Apply new engine oil to the sliding surfaces of
each bearing.
each bearing.
Align the crankshaft with the cylinder block.
SAPH311990900091
Align the main bearing cap which has the thrust bearing and the main bearing with the cylinder block.
Align the crankshaft with the cylinder block.
(4)
Align the main bearing cap which has the thrust bearing and the main bearing with the cylinder block.
Stamp number
Front of engine
Front of engine
! CAUTION
• The pentagon mark on the main bearing cap
! CAUTION
should face the front of the vehicle. Align in 3
(3)
SAPH311990900091
(4)
2
• Assemble the bearing with oil hole on the
cylinder block and assemble the bearing • Apply new engine oil to the sliding surfaces of
(3)
• To prevent falling in assembly, apply engine oil or grease to the back of the thrust bearing.
bearing cap.
1
• Since the part is heavy, be careful for handling.
• Store removed main bearing caps and main
Stamp number
9–31
ENGINE MECHANICAL
4
5
6
7
the order of 1, 2, 3, 4, 5, 6 and 7 from the
should face the front of the vehicle. Align in 1
2
3
4
5
6
7
front.
SAPH311990900092
bearing cap with the stamp number of the cylinder block.
the order of 1, 2, 3, 4, 5, 6 and 7 from the front.
• Check the stamp number of each main Stamp number
• The pentagon mark on the main bearing cap
• Check the stamp number of each main Stamp number SAPH311990900092
bearing cap with the stamp number of the cylinder block.
9–32
9–32
ENGINE MECHANICAL (5)
ENGINE MECHANICAL
Measure the underhead length of the bearing cap bolt
(5)
using a vernier calipers. If it is out of the service limit,
using a vernier calipers. If it is out of the service limit,
replace it with a new one.
replace it with a new one.
Service limit (mm{in.})
108{4.252}
Service limit (mm{in.})
Underhead length
SAPH311990900073
(6)
Apply engine oil to the bolt seat and the bolt thread of the
(6)
bearing cap bolt. (7) 4
6
8
10
12
Tighten the bearing cap bolt according to the sequence in the figure.
14
3
5
7
9
11
13
(8)
(7) 2
4
6
8
10
12
14
1
3
5
7
9
11
13
Loosen the bearing cap fixing the thrust bearing and hit hammer.
(9) SAPH311990900093
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft} (8)
Loosen the bearing cap fixing the thrust bearing and hit the crankshaft gently at the front/rear end using a plastic hammer.
Front of engine
Loosen all bearing cap bolts.
(9) SAPH311990900093
(10) Tighten the bearing cap bolt as in (7).
Loosen all bearing cap bolts.
(10) Tighten the bearing cap bolt as in (7).
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft}
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft}
(11) Mark bearing cap bolt heads in the same direction with
(11) Mark bearing cap bolt heads in the same direction with
paint.
paint.
(12) Tighten 90 deg (1/4 turn) with the same order as in (7).
(12) Tighten 90 deg (1/4 turn) with the same order as in (7).
(13) Retighten 45 deg (1/8 turn) as in (7).
(13) Retighten 45 deg (1/8 turn) as in (7).
(14) Make sure that all paint marks are in the same direction.
Paint mark
Tighten the bearing cap bolt according to the sequence in the figure.
the crankshaft gently at the front/rear end using a plastic Front of engine
Apply engine oil to the bolt seat and the bolt thread of the bearing cap bolt.
Tightening torque : 69 N m {700 kgf cm, 51 lbf ft} 1
108{4.252}
Underhead length
SAPH311990900073
2
Measure the underhead length of the bearing cap bolt
! CAUTION
(14) Make sure that all paint marks are in the same direction.
Paint mark
• If it is excessively retightened, do not loosen
! CAUTION
it.
it.
(15) After tightening, hit the front/rear ends of the crankshaft
45ࠑ 90ࠑ
gently with a plastic hammer for initial fit.
• Make sure that the crankshaft turns smoothly. • Measure the end play of the crankshaft and
SAPH311990900094
(15) After tightening, hit the front/rear ends of the crankshaft
45ࠑ 90ࠑ
gently with a plastic hammer for initial fit. ! CAUTION
! CAUTION
• Make sure that the crankshaft turns smoothly. • Measure the end play of the crankshaft and
SAPH311990900094
make sure that it is within the standard value.
make sure that it is within the standard value.
Standard value
Repair limit
Service limit
Standard value
Repair limit
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
0.50{0.0197}
1.219{0.0480}
0.050 - 0.219 {0.0020 -
0.050 - 0.219 0.50{0.0197}
1.219{0.0480}
{0.0020 -
0.0086}} Inspection procedure item
• If it is excessively retightened, do not loosen
0.0086}} Inspection procedure item
9–33
ENGINE MECHANICAL
9–33
ENGINE MECHANICAL
Inspection of crankshaft
Inspection of crankshaft JP31199090703002
1.
JP31199090703002
Inspection of end play (1)
SAPH311990900095
Inspection of end play (1)
gauge. If it is beyond the repair limit, replace the thrust
bearing. If it is beyond the service limit, replace the
bearing. If it is beyond the service limit, replace the
crankshaft.
crankshaft.
Standard value
Repair limit
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
0.50{0.0197}
1.219{0.0480}
{0.020 - 0.0086}
SAPH311990900095
2.
• Standard width of thrust
NOTICE
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
0.50{0.0197}
1.219{0.0480}
• Standard width of thrust bearing2.5mm{0.0984in.}
2.
Measure the crankshaft rotation runout using a dial
Figure is an example of work.
Inspection of rotation runout (1)
Measure the crankshaft rotation runout using a dial
gauge. If it is beyond the repair limit, grind the crankshaft
gauge. If it is beyond the repair limit, grind the crankshaft
and use the undersize bearing.
and use the undersize bearing.
Repair limit (mm{in.})
0.15{0.0060}
SAPH311990900096
Repair limit (mm{in.})
0.15{0.0060}
SAPH311990900096
3. Measure two places. 90ࠑ
Repair limit
{0.020 - 0.0086}
Inspection of rotation runout (1)
Standard value
0.050 - 0.219
bearing2.5mm{0.0984in.}
Figure is an example of work.
Measure the end play of the crankshaft using a dial
gauge. If it is beyond the repair limit, replace the thrust
0.050 - 0.219
NOTICE
1.
Measure the end play of the crankshaft using a dial
Inspection of journal wear (1)
3.
Measure the outer diameter of the crankshaft journal using a micrometer. If it is faulty, grind or replace the crankshaft. When the crankshaft is ground, use the
Measure two places. 90ࠑ
undersize bearing. Journal standard value (mm{in.})
Inspection of journal wear (1)
Measure the outer diameter of the crankshaft journal using a micrometer. If it is faulty, grind or replace the crankshaft. When the crankshaft is ground, use the undersize bearing. Journal standard value
80{3.1496}
SAPH311990900097
(mm{in.})
80{3.1496}
SAPH311990900097
Wear value (mm{in.}) Eccentric wear 0.10{0.0039} Wear of 0.20{0.0079} or more Wear of 1.20{0.0472}
Action Regrind for correction.
Regrind Replace the crankshaft.
Wear value (mm{in.}) Eccentric wear 0.10{0.0039} Wear of 0.20{0.0079} or more Wear of 1.20{0.0472}
Action Regrind for correction.
Regrind Replace the crankshaft.
9–34
9–34
ENGINE MECHANICAL (2)
Measure the crankshaft center journal width using a vernier calipers. If it is out of the service limit, replace the
Figure is an example of work.
ENGINE MECHANICAL
crankshaft.
(2)
Measure the crankshaft center journal width using a vernier calipers. If it is out of the service limit, replace the
Figure is an example of work.
crankshaft.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
36{1.4173}
37.0{1.4567}
36{1.4173}
37.0{1.4567}
SAPH311990900098
SAPH311990900098
4.
Inspection of crankshaft oil clearance (1)
4.
Measure the outer diameter of the crankshaft journal using a micrometer.
90
Inspection of crankshaft oil clearance (1)
Measure the outer diameter of the crankshaft journal using a micrometer.
90
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
80{3.1496}
78.8{3.1024}
80{3.1496}
78.8{3.1024}
SAPH311990900099
SAPH311990900099
(2)
Do not install the crankshaft. Install the crankshaft bearing
(2)
and the main bearing cap on the cylinder block. (3)
and the main bearing cap on the cylinder block.
Measure the crankshaft bearing inner diameter using a
(3)
cylinder gauge. (4)
SAPH311990900100
Measure the crankshaft bearing inner diameter using a cylinder gauge.
Calculate the difference between the outer diameter of the
(4)
Calculate the difference between the outer diameter of the
crankshaft journal and the inner diameter of the
crankshaft journal and the inner diameter of the
crankshaft bearing. If it is beyond the repair limit, grind
crankshaft bearing. If it is beyond the repair limit, grind
the crankshaft and use the undersize bearing.
the crankshaft and use the undersize bearing.
Standard value (mm{in.}) 0.051 - 0.102 {0.0020 - 0.0040} NOTICE
Do not install the crankshaft. Install the crankshaft bearing
Repair limit (mm{in.})
SAPH311990900100
Standard value (mm{in.}) 0.051 - 0.102
0.2{0.0079}
• Standard bearing thickness : 2.5mm • Undersize bearing value : 0.25, 0.50, 0.75, 1.00
{0.0020 - 0.0040} NOTICE
Repair limit (mm{in.}) 0.2{0.0079}
• Standard bearing thickness : 2.5mm • Undersize bearing value : 0.25, 0.50, 0.75, 1.00
Bearing size
Journal outer diameter (mm{in.})
Bearing size
Journal outer diameter (mm{in.})
Standard
79.940 - 79.960 {3.1472 - 3.1480}
Standard
79.940 - 79.960 {3.1472 - 3.1480}
0.25.00US
79.690 - 79.710 {3.1374 - 3.1382}
0.25.00US
79.690 - 79.710 {3.1374 - 3.1382}
0.50US
79.440 - 79.460 {3.1276 - 3.1283}
0.50US
79.440 - 79.460 {3.1276 - 3.1283}
0.75US
79.190 - 79.210 {3.1177 - 3.1185}
0.75US
79.190 - 79.210 {3.1177 - 3.1185}
1.00US
78.940 - 78.960 {3.1079 - 3.1087}
1.00US
78.940 - 78.960 {3.1079 - 3.1087}
9–35
ENGINE MECHANICAL (5)
Dimension of fillet "R"
(5)
Crank pin Radius is incomplete.
Radius is small.
Step
Journal
R
Radius is small.
2.5 to 3.0mm {0.0984 to 0.1181 in.} Step
Step
Journal
R
2.5 to 3.0mm {0.0984 to 0.1181 in.} Good
2.5 to 3.0mm {0.0984 to 0.1181 in.} Good
Poor
SAPH311990900101
Poor
SAPH311990900101
5.
Inspection of crack and damage on crankshaft and of oil hole
Figure is an example of work.
(1)
5.
Inspection of crack and damage on crankshaft and of oil hole
Figure is an example of work.
Check for crack or damage using dye penetrant. If a faulty
(1)
condition is found, replace the crankshaft.
Check for crack or damage using dye penetrant. If a faulty condition is found, replace the crankshaft.
SAPH311990900102
SAPH311990900102
(2)
Check for clogging of the crankshaft oil hole. If faulty condition is found, replace the crankshaft.
Figure is an example of work.
SAPH311990900103
(2)
Check for clogging of the crankshaft oil hole. If faulty condition is found, replace the crankshaft.
Figure is an example of work.
SAPH311990900103
6. 90°Measurement at 2 places
Dimension of fillet "R" Crank pin
Radius is incomplete.
2.5 to 3.0mm {0.0984 to 0.1181 in.} Step
9–35
ENGINE MECHANICAL
Inspection of pin wear (1)
6.
Measure the outer diameter of the crankshaft crank pin using a micrometer. If it is faulty, grind or replace the
90°Measurement at 2 places
Inspection of pin wear (1)
Measure the outer diameter of the crankshaft crank pin using a micrometer. If it is faulty, grind or replace the
crankshaft.
crankshaft.
When the crankshaft is ground, use the undersize
When the crankshaft is ground, use the undersize
bearing.
bearing.
Crank pin standard value
65
Wear value (mm{in.})
Action
SAPH311990900104
Crank pin standard value
65
Wear value (mm{in.})
Action
SAPH311990900104
Eccentric wear 0.10{0.0039} Wear of 0.20{0.0079} or more Wear of 1.20{0.0472}
Regrind for correction.
Regrind Replace the crankshaft.
Eccentric wear 0.10{0.0039} Wear of 0.20{0.0079} or more Wear of 1.20{0.0472}
Regrind for correction.
Regrind Replace the crankshaft.
9–36
9–36
ENGINE MECHANICAL
ENGINE MECHANICAL
Replacement procedure item
Replacement procedure item
Replacement of crankshaft pulley
Replacement of crankshaft pulley JP31199090704008
1.
JP31199090704008
Removal of crankshaft pulley (1)
1.
Remove bolts and remove the crankshaft pulley.
(1)
• Insert a large flat tip screwdriver into the
NOTICE
• Insert a large flat tip screwdriver into the
flywheel gear from the flywheel housing
flywheel gear from the flywheel housing
inspection hole to prevent turning of the
inspection hole to prevent turning of the
crankshaft.
crankshaft.
SAPH311990900105
2.
Installation of crankshaft pulley (1)
2.
Apply engine oil to the bolt seat and the bolt thread of the
(2)
3
Installation of crankshaft pulley (1)
crankshaft pulley mounting bolt.
1
Install the crankshaft pulley on the crankshaft and tighten
6
(2)
3
• Insert a large flat tip screwdriver into the
NOTICE
Install the crankshaft pulley on the crankshaft and tighten it according to the figure.
Tightening torque : 118 N m {1,200 kgf cm, 87 lbf ft}
5 2
Apply engine oil to the bolt seat and the bolt thread of the crankshaft pulley mounting bolt.
1
it according to the figure. 4
Remove bolts and remove the crankshaft pulley.
NOTICE
SAPH311990900105
6
Removal of crankshaft pulley
4
Tightening torque : 118 N m {1,200 kgf cm, 87 lbf ft}
5 2
• Insert a large flat tip screwdriver into the
NOTICE
flywheel gear from the flywheel housing inspection hole to prevent turning of the
SAPH311990900106
flywheel gear from the flywheel housing inspection hole to prevent turning of the
SAPH311990900106
crankshaft.
crankshaft.
Replacement of flywheel
Replacement of flywheel JP31199090704009
1. Engine revolution sensor Flywheel Mounting bolt
JP31199090704009
Removal of flywheel (1)
Remove the engine revolution sensor.
(2)
Remove bolts fixing the flywheel.
1. Engine revolution sensor Flywheel Mounting bolt
• Insert a large flat tip screwdriver into the
NOTICE
(1)
Remove the engine revolution sensor.
(2)
Remove bolts fixing the flywheel. • Insert a large flat tip screwdriver into the
NOTICE
flywheel gear from the flywheel housing
flywheel gear from the flywheel housing
inspection hole to prevent turning of the
inspection hole to prevent turning of the
crankshaft.
crankshaft.
SAPH311990900107
SAPH311990900107
(3)
Install a special tool into the bolt hole of the crankshaft to
(3)
Install a special tool into the bolt hole of the crankshaft to
remove the flywheel.
remove the flywheel.
Special tool : 09481–1340 Guide
Special tool : 09481–1340 Guide
! CAUTION
• Since the flywheel is heavy, be careful for
! CAUTION
handling.
• Since the flywheel is heavy, be careful for handling.
• Do not give impact to the special tool during
• Do not give impact to the special tool during
work. SAPH311990900108
Removal of flywheel
work. SAPH311990900108
ENGINE MECHANICAL 2.
9–37
ENGINE MECHANICAL
Removal of ring gear (1)
2.
Heat the entire ring gear circumference with a burner until
Removal of ring gear (1)
it is about 200 qC(392qF). ! CAUTION
Heat the entire ring gear circumference with a burner until it is about 200 qC(392qF).
• Do not touch the ring gear and the flywheel
! CAUTION
with bare hand while they are hot.
SAPH311990900109
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
SAPH311990900109
(2)
Hit the circumference of the ring gear gently using a
(2)
backing rod to remove the ring gear from the flywheel. ! CAUTION
Hit the circumference of the ring gear gently using a backing rod to remove the ring gear from the flywheel.
• Do not touch the ring gear and the flywheel
! CAUTION
with bare hand while they are hot.
SAPH311990900110
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
SAPH311990900110
3.
Installation of ring gear (1)
3.
Heat the entire ring gear circumference with a burner until
Installation of ring gear (1)
it is about 200 qC(392qF). ! CAUTION
Heat the entire ring gear circumference with a burner until it is about 200 qC(392qF).
• Do not touch the ring gear and the flywheel
! CAUTION
with bare hand while they are hot.
SAPH311990900111
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
SAPH311990900111
(2)
Face the chamfered side toward the flywheel and install it
(2)
on the flywheel quickly. ! CAUTION
Face the chamfered side toward the flywheel and install it on the flywheel quickly.
• Do not touch the ring gear and the flywheel
! CAUTION
with bare hand while they are hot.
SAPH311990900112
9–37
• Do not touch the ring gear and the flywheel with bare hand while they are hot.
SAPH311990900112
9–38
ENGINE MECHANICAL 4.
9–38
ENGINE MECHANICAL
Installation of flywheel (1)
4.
Make sure that there is no burr or dirt on the joint surface
Installation of flywheel (1)
of the crankshaft and the flywheel and the screw hole. (2)
of the crankshaft and the flywheel and the screw hole.
Install the special tool into the bolt hole of the crankshaft.
(2)
Special tool : 09481–1340 Guide
Install the special tool into the bolt hole of the crankshaft. Special tool : 09481–1340 Guide
• Install one special tool on the collar dowel
NOTICE
Make sure that there is no burr or dirt on the joint surface
• Install one special tool on the collar dowel
NOTICE
and the other at the opposite side of the collar
and the other at the opposite side of the collar
dowel.
SAPH311990900113
(3)
dowel.
SAPH311990900113
Insert the flywheel until it comes in contact with the collar
(3)
dowel of the crankshaft and adjust the position. ! CAUTION
dowel of the crankshaft and adjust the position.
• Since the flywheel is heavy, be careful for
! CAUTION
handling.
• Do not give impact to the special tool during
work.
work.
Insert the flywheel until it comes in contact with the
(4)
crankshaft. (5)
Apply engine oil to the bolt seat and the bolt thread of the
(5)
SAPH311990900114
(6)
Tighten 6 bolts by 2 to 3 threads temporarily with hand in
(6)
the bolt holes without installation of the special tool. (7)
Tighten 6 bolts gradually and tighten temporarily.
(7)
Tighten 6 bolts gradually and tighten temporarily.
(8)
Remove the special tool and tighten remaining two bolts
(8)
Remove the special tool and tighten remaining two bolts temporarily as in (6) and (7).
SAPH311990900115
SAPH311990900115
(9)
Tighten the flywheel according to the order in the figure.
(9)
Tightening torque : 186 N m {1,900 kgf cm, 137 lbf ft} NOTICE 4 7
• Insert a large flat tip screwdriver into the
2
inspection hole to prevent turning of the
6
crankshaft.
5
1
NOTICE
8 4
7 2
inspection hole to prevent turning of the
6
crankshaft. (10) Loosen all bolts.
(11) Tighten the bolts again. Tightening torque : 186 N m {1,900 kgf cm, 137 lbf ft}
(11) Tighten the bolts again. SAPH311990900116
Tightening torque : 186 N m {1,900 kgf cm, 137 lbf ft}
(12) Install the engine revolution sensor. Setup layout Layout
• Insert a large flat tip screwdriver into the flywheel gear from the flywheel housing
3
(10) Loosen all bolts. SAPH311990900116
Tighten the flywheel according to the order in the figure. Tightening torque : 186 N m {1,900 kgf cm, 137 lbf ft}
flywheel gear from the flywheel housing 3
Tighten 6 bolts by 2 to 3 threads temporarily with hand in the bolt holes without installation of the special tool.
temporarily as in (6) and (7).
8
Apply engine oil to the bolt seat and the bolt thread of the flywheel mounting bolt.
SAPH311990900114
1
Insert the flywheel until it comes in contact with the crankshaft.
flywheel mounting bolt.
5
• Since the flywheel is heavy, be careful for handling.
• Do not give impact to the special tool during
(4)
Insert the flywheel until it comes in contact with the collar
(12) Install the engine revolution sensor. Setup layout Layout
9–39
ENGINE MECHANICAL
9–39
ENGINE MECHANICAL
Camshaft and Idle Gear
Camshaft and Idle Gear
Part layout
Part layout JP31199090402005
JP31199090402005
SAPH311990900117
SAPH311990900117
13501
Camshaft assembly
13572B
Idle gear thrust plate
13501
Camshaft assembly
13572B
Idle gear thrust plate
13505
Cam idle gear
13581
Idle gear shaft
13505
Cam idle gear
13581
Idle gear shaft
13505A
Sub-idle gear
13581A
Idle gear shaft
13505A
Sub-idle gear
13581A
Idle gear shaft
13505B
Main idle gear
13581B
Idle gear shaft
13505B
Main idle gear
13581B
Idle gear shaft
13520
Camshaft gear
9867A
Idle gear bush
13520
Camshaft gear
9867A
Idle gear bush
13572
Idle gear thrust plate
9867B
Idle gear bush
13572
Idle gear thrust plate
9867B
Idle gear bush
13572A
Idle gear thrust plate
13572A
Idle gear thrust plate
900125
172N m {1, 750 kgf cm, 127lbf ft}
Tightening torque 900124
59N m{600kgf cm, 44lbf ft}+90q
900124A
108N m {1, 100 kgf cm, 80lbf ft}
Tightening torque 900125 Service procedure Overhaul item
172N m {1, 750 kgf cm, 127lbf ft}
900124
59N m{600kgf cm, 44lbf ft}+90q
900124A
108N m {1, 100 kgf cm, 80lbf ft} Service procedure Overhaul item
9–40
9–40
ENGINE MECHANICAL
ENGINE MECHANICAL
Removal of camshaft
Removal of camshaft JP31199090702006
1.
JP31199090702006
Removal of rocker arm and camshaft assembly (1)
1.
Loosen the lock nut and turn the adjusting screw completely.
Rock nut
! CAUTION
Removal of rocker arm and camshaft assembly (1)
completely.
Rock nut
• Removal without turning the adjusting screw
Loosen the lock nut and turn the adjusting screw
! CAUTION
may bend the rocker shaft.
• Removal without turning the adjusting screw may bend the rocker shaft.
SAPH311990900118
SAPH311990900118
(2)
Loosen the rocker arm support bolts gradually from the
(2)
Loosen the rocker arm support bolts gradually from the
center and remove the rocker arm and the rocker arm
center and remove the rocker arm and the rocker arm
shaft.
shaft.
SAPH311990900119
SAPH311990900119
Disassembly of camshaft
Disassembly of camshaft JP31199090702007
1.
JP31199090702007
Disassembly of camshaft (1)
1.
Fix the camshaft gear using a vice to disassemble the
(1)
camshaft. ! CAUTION
Fix the camshaft gear using a vice to disassemble the camshaft.
• Prevent faulty conditions on the gear such as
! CAUTION
deformation, impact, scratch, etc.
SAPH311990900120
Disassembly of camshaft
• Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
SAPH311990900120
9–41
ENGINE MECHANICAL
9–41
ENGINE MECHANICAL
Inspection of camshaft and camshaft
Inspection of camshaft and camshaft
bearing
bearing JP31199090702008
1.
JP31199090702008
Inspection of cam height on camshaft (1)
1.
Measure the cam height using a micrometer. If it is
Inspection of cam height on camshaft (1)
beyond the service limit, replace the camshaft.
SAPH311990900121
Standard value
Service limit
Standard value
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
Cam
IN
50.067{1.9711}
49.987{1.9680}
Cam
IN
50.067{1.9711}
49.987{1.9680}
height
EX
52.104{2.0513}
52.024{2.0482}
height
EX
52.104{2.0513}
52.024{2.0482}
IN
8.067{0.3176}
(7.987{0.3144})
IN
8.067{0.3176}
(7.987{0.3144})
EX
10.104{0.3978}
(10.024{0.3946})
Cam lift EX
2.
10.104{0.3978}
(2)
SAPH311990900122
2.
Put the journal at both ends of the camshaft on the V
Inspection of camshaft runout (1)
Camshaft contact measuring area
(2)
Put a dial gauge to each journal of the camshaft and
measure runout of the camshaft. If it is beyond the service
measure runout of the camshaft. If it is beyond the service
limit, replace the camshaft.
limit, replace the camshaft.
Standard value (mm{in.})
Service limit (mm{in.})
0.04{0.0016}
0.1{0.0039}
SAPH311990900122
3.
Measure the outer diameter of the camshaft journal using
Standard value (mm{in.})
Service limit (mm{in.})
0.04{0.0016}
0.1{0.0039}
Inspection of camshaft bearing oil clearance (1)
a micrometer.
(2)
Put the journal at both ends of the camshaft on the V block.
Put a dial gauge to each journal of the camshaft and
Inspection of camshaft bearing oil clearance (1)
Cam lift
(10.024{0.3946})
block.
3.
SAPH311990900121
Inspection of camshaft runout (1)
Camshaft contact measuring area
Measure the cam height using a micrometer. If it is beyond the service limit, replace the camshaft.
Measure the outer diameter of the camshaft journal using a micrometer.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
40{1.5748}
39.85{1.5689}
40{1.5748}
39.85{1.5689}
Measure the camshaft bearing inner diameter using a
(2)
cylinder gauge.
Measure the camshaft bearing inner diameter using a cylinder gauge.
SAPH311990900123
SAPH311990900123
(3)
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
40{1.5748}
40.15{1.5807}
40{1.5748}
40.15{1.5807}
Calculate the difference of the camshaft journal bearing
(3)
Calculate the difference of the camshaft journal bearing
inner diameter. If it is beyond the standard value, replace
inner diameter. If it is beyond the standard value, replace
the camshaft or the camshaft bearing.
the camshaft or the camshaft bearing.
Standard value (mm{in.})
0.020 - 0.063 {0.0008 - 0.0025}
Standard value (mm{in.})
0.020 - 0.063 {0.0008 - 0.0025}
9–42
9–42
ENGINE MECHANICAL
ENGINE MECHANICAL
Assembly of camshaft
Assembly of camshaft JP31199090702009
1.
JP31199090702009
Measure the camshaft mounting bolt using a vernier
1.
calipers. If it is out of the service limit, replace it with a
calipers. If it is out of the service limit, replace it with a
new one.
new one.
Service limit (mm{in.})
31{1.2205}
Underhead length
Service limit (mm{in.})
31{1.2205}
Underhead length
SAPH311990900124
SAPH311990900124
2.
3.
Fix the camshaft gear using a vice. Apply engine oil to the
2.
seat and the bolt thread of the camshaft gear mounting
bolt.
bolt.
Set the dowel pin to the camshaft and the camshaft gear
3.
Tightening torque : 59 N m {600 kgf cm, 44 lbf ft}
Retighten 90 deg (1/4 turn).
! CAUTION
• If it is excessively retightened, do not loosen it. • Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
Set the dowel pin to the camshaft and the camshaft gear and tighten the camshaft gear mounting bolt.
Tightening torque : 59 N m {600 kgf cm, 44 lbf ft} 4.
Fix the camshaft gear using a vice. Apply engine oil to the
seat and the bolt thread of the camshaft gear mounting
and tighten the camshaft gear mounting bolt.
SAPH311990900125
Measure the camshaft mounting bolt using a vernier
4. SAPH311990900125
Retighten 90 deg (1/4 turn).
! CAUTION
• If it is excessively retightened, do not loosen it. • Prevent faulty conditions on the gear such as deformation, impact, scratch, etc.
9–43
ENGINE MECHANICAL
Installation of camshaft
Installation of camshaft JP31199090702010
1.
JP31199090702010
Align the No. 1 cylinder to the compression top dead
1.
center. 2.
horizontal to the upper surface of the camshaft housing. ! CAUTION
(1)
horizontal to the upper surface of the camshaft housing.
• Place a transparent plastic ruler or an edged
! CAUTION
ruler on the upper surface of the camshaft
housing and the side of the camshaft gear.
housing and the side of the camshaft gear.
Make sure that the position of the foolproof
Make sure that the position of the foolproof
drilled hole is below the ruler.
Ruler or etc
drilled hole is below the ruler. Misconnection prevention drill hole SAPH311990900126
(2)
the front of the engine, making sure the five-sided mark on
camshaft bearing caps in numerical order 1-2-3-4-5 from
the front of the engine, making sure the five-sided mark on
the cap points forward.
Engine Foreword
Engine Foreword
SAPH311990900127
SAPH311990900127
(3)
Coat the bearing parts with engine oil and then install the
camshaft bearing caps in numerical order 1-2-3-4-5 from
Coat the bearing parts with engine oil and then install the
the cap points forward.
Make sure the crosshead is correctly laid across each
(3)
valve.
Make sure the crosshead is correctly laid across each valve.
Crosshead
Crosshead
! CAUTION
• To make sure the crosshead is correctly in
! CAUTION
(4)
place, move it to the left and right by hand and
make sure it clicks against the valves.
make sure it clicks against the valves. • If the crosshead is not sitting properly on the
valves, it will push the upper seat and cause
valves, it will push the upper seat and cause
the valve to drop out.
the valve to drop out.
Make sure the rocker arm is correctly assembled on the
SAPH311990900128
(4)
rocker arm shaft. (5)
Fully unscrew the adjust screw on the end of the rocker
Make sure the rocker arm is correctly assembled on the rocker arm shaft.
(5)
arm. NOTICE
• To make sure the crosshead is correctly in
place, move it to the left and right by hand and • If the crosshead is not sitting properly on the
SAPH311990900128
• Place a transparent plastic ruler or an edged
ruler on the upper surface of the camshaft
Misconnection prevention drill hole
(2)
Place the camshaft so that two holes at 180 degrees from the three drilled holes of the camshaft gear may be
Timing decision drill hole
SAPH311990900126
Installation of camshaft and rocker arm.
Ruler or etc
2.
Place the camshaft so that two holes at 180 degrees from the three drilled holes of the camshaft gear may be
Timing decision drill hole
Align the No. 1 cylinder to the compression top dead center.
Installation of camshaft and rocker arm. (1)
9–43
ENGINE MECHANICAL
Fully unscrew the adjust screw on the end of the rocker arm.
• Securing the rocker arm and nozzle clamp
NOTICE
• Securing the rocker arm and nozzle clamp
together with a string will facilitate installation
together with a string will facilitate installation
work.
work.
9–44
ENGINE MECHANICAL (6)
9–44
ENGINE MECHANICAL
Apply engine oil to the cam threads and set the rocker
(6)
arm in position, making sure it is correctly laid on the
arm in position, making sure it is correctly laid on the
crosshead. Then, tighten the bolts in the sequence
crosshead. Then, tighten the bolts in the sequence
shown in the figure, making several passes and gradually
shown in the figure, making several passes and gradually
tightening them each time.
tightening them each time.
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
! CAUTION
• After the bolts are tightened, make sure the
! CAUTION
rocker arm moves smoothly.
• After the bolts are tightened, make sure the rocker arm moves smoothly.
Setup layout Layout
SAPH311990900129
Apply engine oil to the cam threads and set the rocker
Setup layout Layout
SAPH311990900129
9–45
ENGINE MECHANICAL
Gear train layout
9–45
ENGINE MECHANICAL
Gear train layout JP31199090402006
JP31199090402006
SAPH311990900130
SAPH311990900130
Service procedure Overhaul item
Service procedure Overhaul item
Removal of timing gear
Removal of timing gear JP31199090702011
1.
Removal of main idle gear (1)
SAPH311990900131
JP31199090702011
1.
Remove the idle gear shaft mounting bolt and pull out the
Removal of main idle gear (1)
Remove the idle gear shaft mounting bolt and pull out the
main idle gear assembly using a special tool.
main idle gear assembly using a special tool.
Special tool : 09420–1100 Sliding hammer
Special tool : 09420–1100 Sliding hammer
09420–1442 Sliding hammer
09420–1442 Sliding hammer
(2)
Remove the idle gear thrust plate.
(2)
Remove the idle gear thrust plate.
(3)
Remove the idle gear shaft from the main idle gear.
(3)
Remove the idle gear shaft from the main idle gear.
SAPH311990900131
9–46
9–46
ENGINE MECHANICAL 2.
ENGINE MECHANICAL
Removal of sub-idle gear (1)
2.
Remove the idle gear shaft mounting bolt and the idle
Removal of sub-idle gear (1)
Remove the idle gear shaft mounting bolt and the idle
gear thrust plate and pull out the sub-idle gear assembly
gear thrust plate and pull out the sub-idle gear assembly
using a special tool.
using a special tool.
Special tool : 09420–1100 Sliding hammer
Special tool : 09420–1100 Sliding hammer
09420–1442 Sliding hammer
09420–1442 Sliding hammer
(2)
Remove the idle gear thrust plate.
(3)
Remove the idle gear shaft from the sub-idle gear.
SAPH311990900132
(2)
Remove the idle gear thrust plate.
(3)
Remove the idle gear shaft from the sub-idle gear.
SAPH311990900132
Inspection of timing gear components
Inspection of timing gear components
JP31199090702012
1.
JP31199090702012
Inspection of clearance between idle gear shaft and idle
1.
Inspection of clearance between idle gear shaft and idle
gear bushing
gear bushing
(1)
(1)
Measure the idle gear shaft outer diameter using a micrometer and the idle gear bushing inner diameter
micrometer and the idle gear bushing inner diameter
using a cylinder gauge.
using a cylinder gauge.
Main idle
Shaft outer diameter
gear shaft Bushing inner diameter Sub-idle
Shaft outer diameter
gear shaft Bushing inner diameter
(2)
Measure the idle gear shaft outer diameter using a
Standard value
Standard value
(mm{in.})
(mm{in.})
57{2.2441}
Main idle
57{2.2441}
gear shaft Bushing inner diameter
50{1.9685}
Sub-idle
50{1.9685}
gear shaft Bushing inner diameter
Calculate the difference between the idle gear bushing
(2)
Shaft outer diameter
Shaft outer diameter
57{2.2441} 57{2.2441} 50{1.9685} 50{1.9685}
Calculate the difference between the idle gear bushing
inner diameter and the idle gear shaft outer diameter. If it
inner diameter and the idle gear shaft outer diameter. If it
is beyond the service limit, replace the idle gear shaft and
is beyond the service limit, replace the idle gear shaft and
the idle gear bushing.
the idle gear bushing.
SAPH311990900133
Main idle gear shaft Sub-idle gear shaft
Standard value
Service limit
(mm{in.})
(mm{in.})
0.030 - 0.090 {0.0012 - 0.0035} 0.025 - 0.075 {0.0010 - 0.030}
0.20{0.0079}
0.20{0.0079}
SAPH311990900133
Main idle gear shaft Sub-idle gear shaft
Standard value
Service limit
(mm{in.})
(mm{in.})
0.030 - 0.090 {0.0012 - 0.0035} 0.025 - 0.075 {0.0010 - 0.030}
0.20{0.0079}
0.20{0.0079}
9–47
ENGINE MECHANICAL
Installation of timing gear
Installation of timing gear JP31199090702013
1. Thrust plate
Lubricating hole
JP31199090702013
Installation of sub-idle gear
1.
Installation of sub-idle gear
(1)
Install the idle gear shaft on the sub-idle gear.
(1)
Install the idle gear shaft on the sub-idle gear.
(2)
Install the idle gear thrust plate.
(2)
Install the idle gear thrust plate.
(3)
Provide the lubricating hole of the idle gear shaft in the
(3)
Provide the lubricating hole of the idle gear shaft in the
vertical direction.
Idle gear thrust plate
9–47
ENGINE MECHANICAL
(4)
Install the idle gear thrust plate on the idle gear shaft.
(5)
Apply engine oil to the bolt seat and the bolt thread of the
Thrust plate
Lubricating hole
idle gear shaft mounting bolt.
Cylinder block
vertical direction.
Idle gear thrust plate
(4)
Install the idle gear thrust plate on the idle gear shaft.
(5)
Apply engine oil to the bolt seat and the bolt thread of the idle gear shaft mounting bolt.
Cylinder block SAPH311990900134
SAPH311990900134
(6)
Install the idle gear shaft mounting bolt.
(6)
Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}
Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}
SAPH311990900135
SAPH311990900135
2. Idle gear thrust plate
Installation of main idle gear (1)
Install the idle gear shaft on the main idle gear.
(2)
Install the idle gear thrust plate.
2. Idle gear thrust plate
Lubricating hole Cylinder Block
Lubricating hole Cylinder Block
SAPH311990900136
Install the idle gear shaft mounting bolt.
SAPH311990900136
Installation of main idle gear (1)
Install the idle gear shaft on the main idle gear.
(2)
Install the idle gear thrust plate.
9–48
ENGINE MECHANICAL (3)
9–48
ENGINE MECHANICAL
Face the lubricating hole of the idle gear shaft toward the
(3)
oil pan (downward). Install A in the figure by adjusting the
oil pan (downward). Install A in the figure by adjusting the
timing of the crankshaft gear and the main idle gear as in
Sub-idle gear
timing of the crankshaft gear and the main idle gear as in
Sub-idle gear
the detailed drawing.
the detailed drawing.
Oil pump gear
A
Oil pump gear
A
Main idle gear Crankshaft gear
Main idle gear Crankshaft gear
Arrange drilled holes in line. Detail
Arrange drilled holes in line. Detail
SAPH311990900137
SAPH311990900137
(4)
Apply engine oil to the bolt seat and the bolt thread of the
(4)
idle gear shaft mounting bolt. (5) (6)
Apply engine oil to the bolt seat and the bolt thread of the idle gear shaft mounting bolt.
Install the idle gear shaft mounting bolt.
(5)
Tightening torque : 172 N m {1,750 kgf cm, 127 lbf ft}
Install the idle gear shaft mounting bolt. Tightening torque : 172 N m {1,750 kgf cm, 127 lbf ft}
Measure backlash and end play of each idle gear. Make
(6)
sure that it is within the standard value.
SAPH311990900138
Face the lubricating hole of the idle gear shaft toward the
Measure backlash and end play of each idle gear. Make sure that it is within the standard value.
SAPH311990900138
ENGINE MECHANICAL
9–49
ENGINE MECHANICAL
Overhaul of sub-idle gear (bearing case side)
Overhaul of sub-idle gear (bearing case side)
JP31199090702014
JP31199090702014
1.
Removal of bearing case assembly (1)
1.
Remove the supply pump.
Removal of bearing case assembly (1)
"Reference : Replacement, Supply pump". (2)
(2)
• One bolt is tightened from the timing gear
• One bolt is tightened from the timing gear case.
Fix the bearing case with a vice.
SAPH311990900139
Disconnect the bearing case assembly.
! CAUTION
case. (3)
Remove the supply pump. "Reference : Replacement, Supply pump".
Disconnect the bearing case assembly.
! CAUTION
(3)
Fix the bearing case with a vice.
SAPH311990900139
(4)
Remove the sub-idle gear shaft mounting bolt and pull out
(4)
the idle gear shaft using a sliding hammer.
SAPH311990900140
SAPH311990900141
9–49
Remove the sub-idle gear shaft mounting bolt and pull out the idle gear shaft using a sliding hammer.
SAPH311990900140
(5)
Remove the sub-idle gear.
(5)
Remove the sub-idle gear.
(6)
Remove the idle gear thrust plate.
(6)
Remove the idle gear thrust plate.
SAPH311990900141
9–50
9–50
ENGINE MECHANICAL 2.
ENGINE MECHANICAL
Inspection of clearance between sub-idle gear shaft and
2.
Inspection of clearance between sub-idle gear shaft and
sub-idle gear bushing
sub-idle gear bushing
(1)
(1)
Measure the outer diameter of the idle gear shaft.
Measure the outer diameter of the idle gear shaft.
SAPH311990900142
SAPH311990900142
(2)
Measure the inner diameter of the sub-idle gear.
(2)
Measure the inner diameter of the sub-idle gear.
(3)
Calculate the clearance. If it is beyond the standard value,
(3)
Calculate the clearance. If it is beyond the standard value,
replace the shaft and the bushing.
Standard value (mm{in.})
replace the shaft and the bushing. 0.025 - 0.075
Standard value (mm{in.})
{0.0010 - 0.030}
SAPH311990900143
{0.0010 - 0.030}
SAPH311990900143
3.
Installation of bearing case assembly
3.
Installation of bearing case assembly
(1)
Install the idle gear thrust plate.
(1)
Install the idle gear thrust plate.
(2)
Install the gear shaft on the sub-idle gear.
(2)
Install the gear shaft on the sub-idle gear.
(3)
Face the lubricating hole of the gear shaft downward and
(3)
Face the lubricating hole of the gear shaft downward and
install it on the bearing case. (4)
install it on the bearing case.
Install the sub-idle gear shaft mounting bolt.
(4)
Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}
SAPH311990900144
Install the sub-idle gear shaft mounting bolt. Tightening torque : 108 N m {1,100 kgf cm, 80 lbf ft}
SAPH311990900144
(5)
Assemble the supply pump and bearing case.
(5)
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft} ! CAUTION
Assemble the supply pump and bearing case. Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
• Be careful for fall of the O-ring
! CAUTION
Inspection procedure item
SAPH311990900145
0.025 - 0.075
Inspection procedure item
SAPH311990900145
• Be careful for fall of the O-ring
9â&#x20AC;&#x201C;51
ENGINE MECHANICAL
9â&#x20AC;&#x201C;51
ENGINE MECHANICAL
Inspection of installation status for each
Inspection of installation status for each
gear
gear JP31199090703003
1.
JP31199090703003
Inspection of backlash between camshaft gear and cam
1.
Inspection of backlash between camshaft gear and cam
idle gear
idle gear
(1)
(1)
Insert a large flat tip screwdriver into the cam idle gear from the side of the camshaft gear of the camshaft
from the side of the camshaft gear of the camshaft
housing to prevent turning of the cam idle gear.
housing to prevent turning of the cam idle gear.
SAPH311990900146
SAPH311990900146
(2)
Measure backlash between the camshaft gear and the
(2)
Measure backlash between the camshaft gear and the
cam idle gear using a dial gauge. If it is beyond the
cam idle gear using a dial gauge. If it is beyond the
service limit, replace each gear.
service limit, replace each gear.
Standard value (mm{in.})
Service limit (mm{in.})
0.030 - 0.253
Standard value (mm{in.})
SAPH311990900147
Service limit (mm{in.})
0.030 - 0.253
0.30{0.0118}
{0.0012 - 0.0100}
0.30{0.0118}
{0.0012 - 0.0100}
SAPH311990900147
2.
Inspection of camshaft end play (1)
2.
Measure the end play of the camshaft using a thickness
Inspection of camshaft end play (1)
Measure the end play of the camshaft using a thickness
gauge. If it is beyond the standard value, replace the
gauge. If it is beyond the standard value, replace the
camshaft.
camshaft.
Standard value (mm)
0.100 - 0.178
Standard value (mm)
{0.0039 - 0.0070}
SAPH311990900148
0.100 - 0.178 {0.0039 - 0.0070}
SAPH311990900148
3.
Inspection of backlash between main idle gear and air
3.
Inspection of backlash between main idle gear and air
compressor idle gear
compressor idle gear
(1)
(1)
Remove the supply pump drive at the bearing case. "Reference : Replacement, Supply pump".
(2)
SAPH311990900149
Insert a large flat tip screwdriver into the cam idle gear
Remove the supply pump drive at the bearing case. "Reference : Replacement, Supply pump".
Insert a large flat tip screwdriver into the main idle gear
(2)
Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
prevent turning of the main idle gear.
SAPH311990900149
9–52
9–52
ENGINE MECHANICAL (3)
Measure backlash between the main idle gear and the air
(3)
compressor idle gear using a dial gauge and a magnet
stand. If it is beyond the service limit, replace each gear.
stand. If it is beyond the service limit, replace each gear.
• If the magnet stand is not stable, provide a
SAPH311990900150
steel plate for measurement using bolt holes
of the cylinder block.
of the cylinder block. Service limit (mm{in.})
Standard value (mm{in.}) SAPH311990900150
0.032 - 0.096
4.
Inspection of backlash between idle gear at bearing case
and supply pump drive gear
and supply pump drive gear
(1)
(1)
Remove the supply pump drive. "Reference : Replacement, Supply pump" Remove the bearing case assembly.
(3)
Fix the supply pump drive with a vice and install the
Work example (4)
Remove the supply pump drive. "Reference : Replacement, Supply pump"
(2)
Remove the bearing case assembly.
(3)
Fix the supply pump drive with a vice and install the
Work example
bearing case assembly.
0.10{0.0039}
{0.0013 - 0.0038}
Inspection of backlash between idle gear at bearing case
(2)
Service limit (mm{in.})
0.032 - 0.096
0.10{0.0039}
{0.0013 - 0.0038}
bearing case assembly.
Measure backlash between the idle gear and the supply
(4)
Measure backlash between the idle gear and the supply
pump drive gear using a dial gauge and a magnet stand. If
pump drive gear using a dial gauge and a magnet stand. If
it is beyond the service limit, replace each gear.
it is beyond the service limit, replace each gear.
Standard value (mm{in.})
Service limit (mm{in.})
0.020 - 0.083
Standard value (mm{in.})
Service limit (mm{in.})
0.020 - 0.083
0.10{0.0039}
{0.0008 - 0.0033}
SAPH311990900151
Inspection of backlash between main idle gear and sub-
5.
Inspection of backlash between main idle gear and sub-
idle gear
idle gear
(1)
(1)
Insert a large flat tip screwdriver into the main idle gear
0.10{0.0039}
{0.0008 - 0.0033}
SAPH311990900151
Insert a large flat tip screwdriver into the main idle gear
from the timing gear dust cover of the flywheel housing to
from the timing gear dust cover of the flywheel housing to
prevent turning of the main idle gear.
prevent turning of the main idle gear.
SAPH311990900152
SAPH311990900152
(2)
Measure backlash between the main idle gear and the
(2)
Measure backlash between the main idle gear and the
sub-idle gear using a dial gauge and a magnet stand. If it
sub-idle gear using a dial gauge and a magnet stand. If it
is beyond the service limit, replace each gear.
is beyond the service limit, replace each gear.
Standard value (mm{in.}) 0.030 - 0.113 {0.0012 - 0.0044}
SAPH311990900153
• If the magnet stand is not stable, provide a
NOTICE
steel plate for measurement using bolt holes
Standard value (mm{in.})
5.
Measure backlash between the main idle gear and the air
compressor idle gear using a dial gauge and a magnet
NOTICE
4.
ENGINE MECHANICAL
Service limit (mm{in.})
Standard value (mm{in.}) 0.030 - 0.113
0.30{0.0118}
{0.0012 - 0.0044}
SAPH311990900153
Service limit (mm{in.}) 0.30{0.0118}
9â&#x20AC;&#x201C;53
ENGINE MECHANICAL 6.
Inspection of backlash between sub-idle gear at cam idle
6.
Inspection of backlash between sub-idle gear at cam idle
gear and oil pump gear
gear and oil pump gear
(1)
(1)
Insert a large flat tip screwdriver into the sub-idle gear to prevent turning of the sub-idle gear.
Insert a large flat tip screwdriver into the sub-idle gear to prevent turning of the sub-idle gear.
SAPH311990900154
SAPH311990900154
(2)
Measure backlash between the sub-idle gear and the oil
(2)
Measure backlash between the sub-idle gear and the oil
pump gear using a dial gauge and a magnet stand. If it is
pump gear using a dial gauge and a magnet stand. If it is
beyond the service limit, replace each gear.
beyond the service limit, replace each gear.
Standard value (mm{in.})
Service limit (mm{in.})
0.030 - 0.131
Standard value (mm{in.})
SAPH311990900155
Service limit (mm{in.})
0.030 - 0.131
0.30{0.0118}
{0.0012 - 0.0005}
0.30{0.0118}
{0.0012 - 0.0005}
SAPH311990900155
7.
Inspection of idle gear end play (1)
7.
Measure the end play of each gear using a thickness
Inspection of idle gear end play (1)
Measure the end play of each gear using a thickness
gauge. If it is beyond the service limit, replace each gear
gauge. If it is beyond the service limit, replace each gear
or shaft.
or shaft. Standard value
Service limit
Standard value
Service limit
(mm{in.})
(mm{in.})
(mm{in.})
(mm{in.})
0.114 - 0.160 Main idle gear
SAPH311990900156
{0.0045 -
0.114 - 0.160 0.30{0.0118}
0.0063}
Main idle gear
SAPH311990900156
Sub-idle gear
{0.0016 -
0.30{0.0118}
Sub-idle gear
{0.0016 -
0.30{0.0118}
0.0037}
Inspection of backlash between cam idle gear and sub-idle
8.
gear (1)
0.30{0.0118}
0.040 - 0.095
0.0037}
8.
{0.0045 0.0063}
0.040 - 0.095
SAPH311990900157
9â&#x20AC;&#x201C;53
ENGINE MECHANICAL
Inspection of backlash between cam idle gear and sub-idle gear
Insert a large flat tip screwdriver into the sub-idle gear
(1)
Insert a large flat tip screwdriver into the sub-idle gear
from the side of the cam idle gear of the cylinder head to
from the side of the cam idle gear of the cylinder head to
prevent turning of the sub-idle gear.
prevent turning of the sub-idle gear.
SAPH311990900157
9–54
9–54
ENGINE MECHANICAL (2)
ENGINE MECHANICAL
Measure backlash between the cam idle gear and the
(2)
sub-idle gear using a dial gauge. If it is beyond the service
sub-idle gear using a dial gauge. If it is beyond the service
limit, replace each gear.
limit, replace each gear.
Standard value (mm{in.}) 0.050 - 0.218 {0.0020 - 0.0086}
Service limit (mm{in.})
Standard value (mm{in.}) 0.050 - 0.218
0.30{0.0118}
{0.0020 - 0.0086}
Setup layout Layout
SAPH311990900158
Measure backlash between the cam idle gear and the
Setup layout Layout
SAPH311990900158
Service limit (mm{in.}) 0.30{0.0118}
9–55
ENGINE MECHANICAL
9–55
ENGINE MECHANICAL
Valve System
Valve System
Part layout
Part layout JP31199090402007
JP31199090402007
SAPH311990900159
SAPH311990900159
13706
Crosshead assembly
13735
Valve spring upper seat
13706
Crosshead assembly
13735
Valve spring upper seat
13709
Adjusting screw (rocker arm)
13787
Adjusting screw (cross head)
13709
Adjusting screw (rocker arm)
13787
Adjusting screw (cross head)
13711
Intake valve
13830
Rocker arm intake
13711
Intake valve
13830
Rocker arm intake
13715
Exhaust valve
13840
Rocker arm (exhaust)
13715
Exhaust valve
13840
Rocker arm (exhaust)
13719
Valve stem seal*
13901
Rocker shaft
13719
Valve stem seal*
13901
Rocker shaft
13731
Outer valve spring
13951
Rocker arm support
13731
Outer valve spring
13951
Rocker arm support
13732
Inner valve spring
900126
Valve spring retainer
13732
Inner valve spring
900126
Valve spring retainer
13734
Valve spring lower seat
13734
Valve spring lower seat
9069B
28.5N m{290kgf cm, 21lbf ft}
9069C
28.5N m{290kgf cm, 21lbf ft}
*Parts not to be reused.
*Parts not to be reused.
Tightening torque 13788
25N m {250 kgf cm, 18lbf ft}
9069A
28.5N m{290kgf cm, 21lbf ft}
Tightening torque
Service procedure Overhaul item
9069B
28.5N m{290kgf cm, 21lbf ft}
13788
25N m {250 kgf cm, 18lbf ft}
9069C
28.5N m{290kgf cm, 21lbf ft}
9069A
28.5N m{290kgf cm, 21lbf ft} Service procedure Overhaul item
9–56
9–56
ENGINE MECHANICAL
ENGINE MECHANICAL
Overhaul of valve system
Overhaul of valve system JP31199090702015
1.
JP31199090702015
Inspection of rocker arm oil clearance (1)
1.
Measure the outer diameter of the rocker shaft using a
Inspection of rocker arm oil clearance (1)
micrometer.
(2)
micrometer.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
22{0.8661}
21.92{0.8630}
22{0.8661}
21.92{0.8630}
Measure the rocker arm bushing inner diameter using a
(2)
cylinder gauge. SAPH311990900160
(3)
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
22{0.8661}
20.08{0.7905}
22{0.8661}
20.08{0.7905}
Calculate the difference between the outer diameter of the bushing. If it is beyond the standard value, replace the
bushing. If it is beyond the standard value, replace the
rocker shaft or the rocker arm bushing.
rocker shaft or the rocker arm bushing.
Service limit (mm{in.})
{0.0012 - 0.0039}
Standard value (mm{in.})
Compress the valve spring using a special tool and
Service limit (mm{in.})
0.03 - 0.101
0.15{0.0059}
{0.0012 - 0.0039}
Removal of valve spring (1)
Calculate the difference between the outer diameter of the rocker shaft and the inner diameter of the rocker arm
0.03 - 0.101
2.
(3)
rocker shaft and the inner diameter of the rocker arm
Standard value (mm{in.})
2. Example
0.15{0.0059}
Removal of valve spring (1)
Compress the valve spring using a special tool and
remove the valve spring retainer.
remove the valve spring retainer.
Special tool : 09470–1170 Valve spring press
Special tool : 09470–1170 Valve spring press
SAPH311990900161
SAPH311990900161
(2)
Remove the intake and exhaust valves.
! CAUTION
SAPH311990900162
Measure the rocker arm bushing inner diameter using a cylinder gauge.
SAPH311990900160
Example
Measure the outer diameter of the rocker shaft using a
(2)
• Attach a tag with the applicable cylinder
Remove the intake and exhaust valves.
! CAUTION
• Attach a tag with the applicable cylinder
number to the valve so that combinations of
number to the valve so that combinations of
the valve and the cylinder head may not be
the valve and the cylinder head may not be
mixed.
mixed.
SAPH311990900162
9–57
ENGINE MECHANICAL 3. Valve stem seal
Replacement of valve stem seal (1)
Special tool
3.
After removing the valve stem seal, assemble the valve spring lower seat. Apply engine oil to the lip and the inner
Valve spring lower seat
surface of the valve stem seal. Strike the valve guide
9–57
ENGINE MECHANICAL
Valve stem seal
Replacement of valve stem seal (1)
Special tool
After removing the valve stem seal, assemble the valve spring lower seat. Apply engine oil to the lip and the inner
Valve spring lower seat
surface of the valve stem seal. Strike the valve guide
using a special tool until the special tool comes in contact
using a special tool until the special tool comes in contact
with the valve spring lower sea
with the valve spring lower sea
Special tool : 09472–2100 Bar
Special tool : 09472–2100 Bar
! CAUTION
• After assembly of the valve stem seal, make
! CAUTION
sure that there is no deformation, crack or
• After assembly of the valve stem seal, make sure that there is no deformation, crack or
inclination of the rubber.
inclination of the rubber.
Oil application
Oil application
Rubber
Rubber
SAPH311990900163
SAPH311990900163
(2)
After striking, check the height.
Standard value (mm{in.}) +0.1{0.0039in.} 22.9mm{0.9022in.} -0.4{0.0157in.}
(2) 22.5 - 23.0 {0.8858 - 0.9055}
SAPH311990900164
Standard value (mm{in.}) +0.1{0.0039in.} 22.9mm{0.9022in.} -0.4{0.0157in.}
22.5 - 23.0 {0.8858 - 0.9055}
SAPH311990900164
4.
Installation of valve spring (1) (2)
4.
Installation of valve spring
Install the valve spring upper seat on the valve spring.
(1)
Compress the valve spring using a special tool and install
(2)
Install the valve spring upper seat on the valve spring. Compress the valve spring using a special tool and install
the valve spring retainer.
the valve spring retainer.
Special tool : 09470–1170 Valve spring press
Special tool : 09470–1170 Valve spring press
! CAUTION
• Apply engine oil to the contact surface of
! CAUTION
each part before assembly. SAPH311990900165
After striking, check the height.
• Be sure to assemble each valve at the original cylinder position. • When the valve spring is compressed, avoid
• Apply engine oil to the contact surface of each part before assembly.
SAPH311990900165
• Be sure to assemble each valve at the original cylinder position. • When the valve spring is compressed, avoid
contact of the valve spring upper seat with the
contact of the valve spring upper seat with the
valve stem seal.
valve stem seal.
• Since the valve spring has equal spacing, vertical direction is not specified for assembly. • Check for scratch on the valve stem seal when the valve is reused.
• Since the valve spring has equal spacing, vertical direction is not specified for assembly. • Check for scratch on the valve stem seal when the valve is reused.
9â&#x20AC;&#x201C;58
9â&#x20AC;&#x201C;58
ENGINE MECHANICAL 5.
ENGINE MECHANICAL
Inspection of valve spring
5.
Clearance A
Inspection of valve spring
Clearance A
(1)
Measure squareness of the valve spring using a square or
(1)
a thickness gauge. If it is beyond the service limit
(clearance A), replace the valve spring.
(clearance A), replace the valve spring.
Clearance A (mm{in.})
2.0{0.0787}
SAPH311990900166
Clearance A (mm{in.})
2.0{0.0787}
SAPH311990900166
(2)
Measure the free length of the valve spring using a vernier
(2)
calipers. If it is out of the service limit, replace the valve spring. Standard value
Service limit
(mm{in.})
(mm{in.})
Inner valve spring
(64.6[2.5433])
61.6[2.4252]
Outer valve spring
(75.7[2.9803])
72.7[2.8622]
Measuring item
The value in [ ] is the reference value.
SAPH311990900167
6.
Measure the free length of the valve spring using a vernier calipers. If it is out of the service limit, replace the valve spring. Standard value
Service limit
(mm{in.})
(mm{in.})
Inner valve spring
(64.6[2.5433])
61.6[2.4252]
Outer valve spring
(75.7[2.9803])
72.7[2.8622]
Measuring item
The value in [ ] is the reference value.
SAPH311990900167
6.
Inspection of oil clearance between valve guide and valve stem (1)
Measure the outer diameter of the valve stem using a
Inspection of oil clearance between valve guide and valve stem (1)
micrometer.
Measure the outer diameter of the valve stem using a micrometer.
Measuring item
Standard value (mm{in.})
Measuring item
Standard value (mm{in.})
Intake valve stem
7{0.2756}
Intake valve stem
7{0.2756}
Exhaust valve stem
7{0.2756}
Exhaust valve stem
7{0.2756}
SAPH311990900168
SAPH311990900168
(2)
Measure the valve guide inner diameter using a cylinder
(2)
gauge.
(3) SAPH311990900169
Measure squareness of the valve spring using a square or
a thickness gauge. If it is beyond the service limit
Measure the valve guide inner diameter using a cylinder gauge.
Measuring item
Standard value (mm{in.})
Measuring item
Standard value (mm{in.})
Intake valve guide
7{0.2756}
Intake valve guide
7{0.2756}
Exhaust valve guide
7{0.2756}
Exhaust valve guide
7{0.2756}
Calculate the difference between the valve stem outer diameter and the valve guide inner diameter. If it is beyond the standard value, replace the valve or the valve guide. Measuring item Intake valve oil clearance Exhaust valve oil clearance
Standard value (mm{in.}) 0.023 - 0.058 {0.0009 - 0.0023} 0.050 - 0.083 {0.0020 - 0.0033}
(3) SAPH311990900169
Calculate the difference between the valve stem outer diameter and the valve guide inner diameter. If it is beyond the standard value, replace the valve or the valve guide. Measuring item Intake valve oil clearance Exhaust valve oil clearance
Standard value (mm{in.}) 0.023 - 0.058 {0.0009 - 0.0023} 0.050 - 0.083 {0.0020 - 0.0033}
9–59
ENGINE MECHANICAL
9–59
ENGINE MECHANICAL
Attachment procedure item
Attachment procedure item
Adjustment of valve clearance
Adjustment of valve clearance JP31199090706001
1.
Precautions before adjustment
! CAUTION
2.
JP31199090706001
1.
• Before adjustment, make sure that bolts of the cylinder head, rocker arm support, nozzle clamp, camshaft housing and camshaft bearing cap are tightened to the specified torque.
! CAUTION
Adjustment of valve clearance
2.
(1)
Make sure that there is no dirt between the crosshead and
(2)
Turn the crankshaft in the forward direction and adjust the
Precautions before adjustment
Adjustment of valve clearance (1)
Make sure that there is no dirt between the crosshead and
(2)
Turn the crankshaft in the forward direction and adjust the
the valve stem
the valve stem
cylinder to the compression top dead center. ! CAUTION
cylinder to the compression top dead center.
• Make sure that there is a roller on the cam
! CAUTION
base circle. (3) Cam base circle
Adjusting screw of rocker arm
Roller
Lock nut Adjusting screw of crosshead 10 mm or more
crosshead completely.
(3) Cam base circle
Adjusting screw of rocker arm
Roller
Lock nut Adjusting screw of crosshead 10 mm or more
• Provide the adjusting screw protrusion of 10 mm or more from the top surface of the
Loosen the adjusting screw and the lock nut of the crosshead completely.
! CAUTION
crosshead. If the adjusting screw is not
completely separated from the valve stem, Close contact
correct adjustment is not allowed.
completely separated from the valve stem, Clearance
Close contact
Lock Nut
correct adjustment is not allowed.
Lock Nut SAPH311990900170
SAPH311990900170
(4)
Insert a thickness gauge between the rocker arm and the
(4)
crosshead and adjust the clearance with the adjusting
Thickness gauge
Rocker arm
Rocker arm
screw of the rocker arm. Tighten the lock nut.
Standard value
IN
0.30mm{0.0118 in.}
Standard value
IN
0.30mm{0.0118 in.}
(cold engine)
EX
0.45mm{0.0177 in.}
(cold engine)
EX
0.45mm{0.0177 in.}
Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}
Close contact Crosshead
Tightening torque : 25 N m {250 kgf cm, 18 lbf ft}
Close contact Crosshead
SAPH311990900171
SAPH311990900171
Loosen the adjusting screw of the crosshead with the thickness gauge inserted. Make sure that feel on the thickness gauge is not lighter.
Nut fixing position
! CAUTION
• If it becomes lighter, make adjustments again from the beginning.
(Appropriate contact) Feel remains the same. Loosening of adjusting screw Large SAPH311990900172
(5) Feel of thickness gauge
Feel of thickness gauge
(5) Start
Insert a thickness gauge between the rocker arm and the crosshead and adjust the clearance with the adjusting
Thickness gauge
screw of the rocker arm. Tighten the lock nut.
(No move)
• Provide the adjusting screw protrusion of 10 mm or more from the top surface of the
crosshead. If the adjusting screw is not Clearance
• Make sure that there is a roller on the cam base circle.
Loosen the adjusting screw and the lock nut of the
! CAUTION
• Before adjustment, make sure that bolts of the cylinder head, rocker arm support, nozzle clamp, camshaft housing and camshaft bearing cap are tightened to the specified torque.
Loosen the adjusting screw of the crosshead with the thickness gauge inserted. Make sure that feel on the
Start
thickness gauge is not lighter. (No move)
Nut fixing position
! CAUTION
• If it becomes lighter, make adjustments again from the beginning.
(Appropriate contact) Feel remains the same. Loosening of adjusting screw Large SAPH311990900172
9–60
ENGINE MECHANICAL (6)
9–60
ENGINE MECHANICAL
Tighten the adjusting screw of the crosshead until the
(6)
thickness gauge does not move.
thickness gauge does not move.
Close contact
Close contact
Close contact
Close contact SAPH311990900173
SAPH311990900173
While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the
Start
position where feel on the thickness gauge is appropriate. Nut fixing position
(Appropriate contact)
Tightening torque : 25 N m {250 kgf cm, 18 lbf ft} ! CAUTION
• Do not over-loosen the adjusting screw. Overloosening of the adjusting screw reproduces
Feel remains the same. Loosening of adjusting screw Large SAPH311990900174
the original status. Although feel on the thickness gauge is appropriate, there is clearance between the adjusting screw and
(7) Feel of thickness gauge
Feel of thickness gauge
(7)
(No move)
Tighten the adjusting screw of the crosshead until the
While loosening the adjusting screw of the crosshead gradually, tighten the lock nut of the crosshead at the
Start
position where feel on the thickness gauge is appropriate. (No move)
Nut fixing position
(Appropriate contact)
Tightening torque : 25 N m {250 kgf cm, 18 lbf ft} ! CAUTION
• Do not over-loosen the adjusting screw. Overloosening of the adjusting screw reproduces
Feel remains the same. Loosening of adjusting screw Large SAPH311990900174
the original status. Although feel on the thickness gauge is appropriate, there is clearance between the adjusting screw and
the valve of the crosshead. Correct
the valve of the crosshead. Correct
adjustment is not allowed.
adjustment is not allowed.
EXHAUST
10–1
EXHAUST
ENGINE
10–1
ENGINE
10 EXHAUST
10 EXHAUST
Setup layout Layout
Setup layout Layout
Exhaust Manifold...................................................... 10-2 Part layout ............................................................. 10-2 Replacement......................................................... 10-4
Exhaust Manifold...................................................... 10-2 Part layout ............................................................. 10-2 Replacement......................................................... 10-4
10
10
10–2
10–2
EXHAUST
EXHAUST
Exhaust Manifold
Exhaust Manifold
Part layout
Part layout JP31199100402001
JP31199100402001
SAPH311991000001
17104
Gasket*
17141
Exhaust manifold
SAPH311991000001
17104
*Parts not to be reused.
Gasket* *Parts not to be reused.
Tightening torque
Tightening torque
9209A
9209A
53 N m {540 kgf cm, 40lbf ft}
53 N m {540 kgf cm, 40lbf ft}
17141
Exhaust manifold
10â&#x20AC;&#x201C;3
EXHAUST
10â&#x20AC;&#x201C;3
EXHAUST
SAPH311991000002
17104A
Gasket*
17148
*Parts not to be reused.
Plate
SAPH311991000002
17104A
Gasket*
17148
*Parts not to be reused. Service procedure Replacement procedure item
Service procedure Replacement procedure item
Plate
10–4
10–4
EXHAUST
EXHAUST
Replacement
Replacement JP31199100704001
1.
Removal of exhaust manifold (1)
2.
JP31199100704001
1.
Remove nuts and remove the exhaust manifold.
(1)
Replacement of stud bolt (1)
Removal of exhaust manifold
2.
Remove dirt (e.g. sealant) at the female thread of the
Replacement of stud bolt (1)
cylinder head and clean the thread again with tap (M10 x
1.5).
Use the Torx wrench to tighten a new stud bolt.
(2)
Tightening torque : 30 N m {300 kgf cm, 22 lbf ft} ! CAUTION
Remove dirt (e.g. sealant) at the female thread of the cylinder head and clean the thread again with tap (M10 x
1.5). (2)
Remove nuts and remove the exhaust manifold.
Use the Torx wrench to tighten a new stud bolt. Tightening torque : 30 N m {300 kgf cm, 22 lbf ft}
• Excessive tightening with over torque may
! CAUTION
• Excessive tightening with over torque may
cause crack in the cylinder head. 3.
cause crack in the cylinder head.
Installation of exhaust manifold (1)
3.
Assemble a new gasket.
! CAUTION
Installation of exhaust manifold (1)
• Since a gasket has front and back, install the
Assemble a new gasket.
! CAUTION
• Since a gasket has front and back, install the
black side on the exhaust manifold.
black side on the exhaust manifold.
Black side
Black side SAPH311991000003
SAPH311991000003
(2)
Tighten the mounting nut of the exhaust manifold
(2)
according to the order in the figure. Tightening torque : 53 N m {540 kgf cm, 40 lbf ft}
When a new exhaust manifold is used 12 11
10 9
6 5
8 7
! CAUTION
• When nuts are tightened, prevent each
Tighten the mounting nut of the exhaust manifold according to the order in the figure. Tightening torque : 53 N m {540 kgf cm, 40 lbf ft}
When a new exhaust manifold is used 12 11
10 9
6 5
8 7
! CAUTION
• When nuts are tightened, prevent each
spacer from riding on the counterbore area of 1
2
the manifold flange.
4
3
• The tightening sequence of the exhaust
When exhaust manifold is reused
8 9
2 3
5 6
manifold varies between use of a new part
11 12
and reuse. (3)
7
1
10
4
spacer from riding on the counterbore area of 1
2
8 9
2 3
5 6
! CAUTION
SAPH311991000004
• Be sure to retighten it.
manifold varies between use of a new part
11 12
and reuse. (3)
7
1
10
4
Tightening torque : 53 N m {540 kgf cm, 40 lbf ft} Spacer
• The tightening sequence of the exhaust
When exhaust manifold is reused
Tighten the same nuts again according to the order in the figure.
the manifold flange.
4
3
Tighten the same nuts again according to the order in the figure. Tightening torque : 53 N m {540 kgf cm, 40 lbf ft}
Spacer
! CAUTION
SAPH311991000004
• Be sure to retighten it.
COOLING
11–1
COOLING
ENGINE
11–1
ENGINE
11 COOLING
11 COOLING
System drawing
System drawing
Cooling System ........................................................ 11-2 Cooling system drawing........................................ 11-2 Part layout ............................................................. 11-3 Replacement of thermostat case .......................... 11-4 Inspection of thermostat ....................................... 11-5 Replacement of coolant pump .............................. 11-6
Cooling System ........................................................ 11-2 Cooling system drawing........................................ 11-2 Part layout ............................................................. 11-3 Replacement of thermostat case .......................... 11-4 Inspection of thermostat ....................................... 11-5 Replacement of coolant pump .............................. 11-6
11
11
11–2
11–2
COOLING
COOLING
Cooling System
Cooling System
Cooling system drawing
Cooling system drawing JP31199110803001
Reservoir
JP31199110803001
Reservoir Water temperature
Water temperature
Thermostat case
Thermostat case Cylinder head
Cylinder head
Cylinder block Turbo charger
Car heater
Coolant pump
Cylinder block Turbo charger
Car heater
Oil cooler
Coolant pump
Drain cock
Drain cock
Thermostat
Radiator
Radiator
Thermostat
Drain cock
Drain cock SAPH311991100001
Setup layout Layout
Oil cooler
SAPH311991100001 Setup layout Layout
11–3
COOLING
Part layout
11–3
COOLING
Part layout JP31199110402002
JP31199110402002
SAPH311991100002
SAPH311991100002
16100
Coolant pump assembly
16325
Gasket*
16100
Coolant pump assembly
16325
Gasket*
16173
Coolant pump pulley
16331
Thermostat case cover
16173
Coolant pump pulley
16331
Thermostat case cover
16303
Thermostat case
16377
Fan spacer
16303
Thermostat case
16377
Fan spacer
16306
Cooling fan
9851A
O–ring*
16306
Cooling fan
9851A
O–ring*
16323
Thermostat case cover
16323
Thermostat case cover
*Parts not to be reused.
*Parts not to be reused. Service procedure Replacement procedure item
Service procedure Replacement procedure item
11–4
11–4
COOLING
COOLING
Replacement of thermostat case
Replacement of thermostat case JP31199110704001
1.
JP31199110704001
Removal of thermostat case
1.
(1)
Remove bolts and remove the thermostat case.
(1)
Remove bolts and remove the thermostat case.
(2)
Remove the O-ring from the groove on the coolant pump.
(2)
Remove the O-ring from the groove on the coolant pump.
SAPH311991100003
SAPH311991100003
2.
Installation of thermostat case (1)
Liquid gasket
2.
Remove contamination on the joint between the
(2)
(2)
equivalent] to the thermostat case as shown in the figure. ! CAUTION
• Apply it continuously.
! CAUTION
2.5 mm{0.0591 to 0.0984 in.}. SAPH311991100004
• Install the oil cooler within 20 minutes after
• Install the oil cooler within 20 minutes after
application of the liquid gasket. Install the new O-ring on the groove of the coolant pump.
(4)
Put the thermostat case mounting bolt through the
bolt2
application of the liquid gasket.
Align the thermostat case at the mounting position and
(6)
Tighten mounting bolt 2 temporarily to the coolant pump.
(7)
Tighten bolts in the order mounting bolt 1 to the cylinder
(3)
Install the new O-ring on the groove of the coolant pump.
(4)
Put the thermostat case mounting bolt through the
bolt2
thermostat case in advance. (5)
thermostat case in advance. (5)
Align the thermostat case at the mounting position and
(6)
Tighten mounting bolt 2 temporarily to the coolant pump.
(7)
Tighten bolts in the order mounting bolt 1 to the cylinder
tighten mounting bolt 1 temporarily to the cylinder head.
bolt1
head and mounting bolt 2 to the coolant pump.
tighten mounting bolt 1 temporarily to the cylinder head.
bolt1
head and mounting bolt 2 to the coolant pump.
Inspection procedure item
SAPH311991100005
• Apply it continuously. • Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0591 to 0.0984 in.}.
(3)
Apply liquid gasket [Threebond TB1207B(black) or equivalent] to the thermostat case as shown in the figure.
• Apply the liquid gasket at the width of 1.5 to SAPH311991100004
Remove contamination on the joint between the thermostat case and the cylinder head using a scraper.
Cylinder head Opening
Apply liquid gasket [Threebond TB1207B(black) or
Installation of thermostat case (1)
Liquid gasket
thermostat case and the cylinder head using a scraper.
Cylinder head Opening
Removal of thermostat case
Inspection procedure item
SAPH311991100005
11–5
COOLING
11–5
COOLING
Inspection of thermostat
Inspection of thermostat JP31199110703001
1. Wire
Thermometer
JP31199110703001
Individual inspection of thermostat (1)
1.
Put the thermostat in water as shown in the figure and
Wire
Thermometer
Individual inspection of thermostat (1)
heat it. ! CAUTION
• Support the thermostat in the center to
! CAUTION
prevent approach to the heat source. • Stir the water well so that water temperature
Thermostat
• Stir the water well so that water temperature
Thermostat
in the container may be uniform. Valve lift
Heat source
SAPH311991100006
SAPH311991100006
(2) T1 : Valve opening temperature (start of valve opening) T2: Full open lift inspection temperature
Measure the temperature (valve opening temperature)
Valve lift
temperature standard value : T1(qC{qF}) 10°C {50°F}
T2°C{°F}
Temperature
NOTICE
74.5 - 78.5 {166.1 - 173.3}
• The thermostat valve opening temperature (T1) is stamped on the thermostat seat.
13mm {0.5122in.}
Thermostat valve opening temperature standard value :
0°C{32°F}
T1(qC{qF})
T1°C{°F}
10°C {50°F}
T2°C{°F}
SAPH311991100007
Temperature
NOTICE
74.5 - 78.5 {166.1 - 173.3}
• The thermostat valve opening temperature (T1) is stamped on the thermostat seat.
SAPH311991100007
(3)
Increase the water temperature to 95 qC{203qF} and
(3)
measure the lift of the thermostat valve.
open lift inspection L1 At cold open L2 :Temperature at (T2)°C{°F} L : Valve lift
Thermostat valve full Valve lift : L (mm{in.})
open lift inspection L1 At cold open L2 :Temperature at (T2)°C{°F} L : Valve lift
temperature : T2 (qC{qF}) 95{203}
L
(4) SAPH311991100008
10{0.3937} or more
Put the full open thermostat valve in water at normal temperature. Make sure that the thermostat valve closes
95{203}
L L 1 L 2
If faulty item is found with the inspection above, replace
(4) SAPH311991100008
10{0.3937} or more
Put the full open thermostat valve in water at normal temperature. Make sure that the thermostat valve closes completely within 5 minutes.
(5)
the thermostat. Replacement procedure item
Valve lift : L (mm{in.})
temperature : T2 (qC{qF})
completely within 5 minutes. (5)
Increase the water temperature to 95 qC{203qF} and measure the lift of the thermostat valve.
Thermostat valve full
L 1 L 2
Measure the temperature (valve opening temperature) that opens the thermostat valve.
Valve lift
Thermostat valve opening
T1°C{°F}
(2) T1 : Valve opening temperature (start of valve opening) T2: Full open lift inspection temperature
that opens the thermostat valve.
13mm {0.5122in.}
0°C{32°F}
• Support the thermostat in the center to prevent approach to the heat source.
in the container may be uniform. Valve lift
Heat source
Put the thermostat in water as shown in the figure and heat it.
If faulty item is found with the inspection above, replace the thermostat.
Replacement procedure item
11–6
11–6
COOLING
COOLING
Replacement of coolant pump
Replacement of coolant pump JP31199110704002
1.
Removal of coolant pump (1)
1.
Remove bolts and remove the coolant pump.
SAPH311991100009
Removal of coolant pump (1)
Remove bolts and remove the coolant pump.
SAPH311991100009
2. Liquid gasket
JP31199110704002
Installation of coolant pump (1)
(2)
Remove contamination on the joint surface between the
2. Liquid gasket
Installation of coolant pump (1)
Remove contamination on the joint surface between the
coolant pump and the cylinder block using a scraper and
coolant pump and the cylinder block using a scraper and
degrease the surface.
degrease the surface.
Apply the liquid gasket [Threebond TB1207B (black) or
(2)
equivalent] to the coolant pump as shown in the figure. ! CAUTION
Apply the liquid gasket [Threebond TB1207B (black) or equivalent] to the coolant pump as shown in the figure.
• Apply it continuously.
! CAUTION
• Apply the liquid gasket at the width of 2 to 3mm{0.0787 to 0.1181in.}.
SAPH311991100010
• Apply the liquid gasket at the width of 2 to 3mm{0.0787 to 0.1181in.}.
SAPH311991100010
• Install the oil cooler within 20 minutes after
• Install the oil cooler within 20 minutes after
application of the liquid gasket.
application of the liquid gasket.
• Fill the groove on the water pump flange with
• Fill the groove on the water pump flange with
the liquid gasket. (3)
the liquid gasket.
Install the coolant pump to the dowel pin of the cylinder
(3)
block. NOTICE
SAPH311991100009
• Apply it continuously.
Install the coolant pump to the dowel pin of the cylinder block.
• When the coolant pump is installed using a
NOTICE
• When the coolant pump is installed using a
guide bolt, displacement of the liquid gasket
guide bolt, displacement of the liquid gasket
does not occur.
does not occur.
SAPH311991100009
LUBRICATION
12–1
LUBRICATION
ENGINE
12–1
ENGINE
12 LUBRICATION
12 LUBRICATION
System drawing
System drawing
Oil Cooler, Oil Filter and Oil Pump.......................... 12-2 System drawing .................................................... 12-2 Part layout ............................................................. 12-3 Replacement of oil cooler ..................................... 12-5 Overhaul of oil cooler ............................................ 12-6 Replacement of oil pump ...................................... 12-9 Overhaul of oil pump........................................... 12-10 Replacement of oil strainer ................................. 12-13
Oil Cooler, Oil Filter and Oil Pump.......................... 12-2 System drawing .................................................... 12-2 Part layout ............................................................. 12-3 Replacement of oil cooler ..................................... 12-5 Overhaul of oil cooler ............................................ 12-6 Replacement of oil pump ...................................... 12-9 Overhaul of oil pump........................................... 12-10 Replacement of oil strainer ................................. 12-13
Oil Pan ..................................................................... 12-14 Part layout ........................................................... 12-14 Replacement....................................................... 12-15 Inspection of lubrication status ........................... 12-16
Oil Pan ..................................................................... 12-14 Part layout ........................................................... 12-14 Replacement....................................................... 12-15 Inspection of lubrication status ........................... 12-16
12
12
12–2
12–2
LUBRICATION
LUBRICATION
Oil Cooler, Oil Filter and Oil Pump
Oil Cooler, Oil Filter and Oil Pump
System drawing
System drawing JP31199120805001
JP31199120805001
Roller pin
Valve
Cam
Roller
Crosshead
Adjusting screw
Roller pin
Rocker arm
Rocker arm shaft
Valve
Crosshead
Adjusting screw
Rocker arm shaft
Cam idle gear shaft
Cam idle gear shaft
Sub-idle gear shaft
Sub-idle gear shaft
Turbocharger
Turbocharger
Oil cooler
Oil filter
Main oil hole
Piston pin
Connecting rod
Crankshaft
Oil pump
Supply pump drive
Piston cooling jet (check valve)
Oil cooler
Oil filter
Main oil hole
Piston pin
Connecting rod
Crankshaft
Supply pump drive
Sub-idle gear shaft (supply pump drive)
Sub-idle gear shaft (supply pump drive)
Piston cooling jet (check valve)
Sub-oil hole
Main idle gear shaft
Sub-oil hole
Main idle gear shaft : Lubrication
: Lubrication
: Return
: Return
SAPH311991200001 Setup layout Layout
Rocker arm
Camshaft
Strainer
Strainer
Oil pump
Roller
Oil pan
Oil pan
Camshaft
Cam
SAPH311991200001 Setup layout Layout
12–3
LUBRICATION
Part layout
12–3
LUBRICATION
Part layout JP31199120402001
JP31199120402001
SAPH311991200002
SAPH311991200002
15012
Oil pump cover assembly
15710
Oil cooler
15012
Oil pump cover assembly
15710
Oil cooler
15104
Oil strainer
9500-40400
Cotter pin*
15104
Oil strainer
9500-40400
Cotter pin*
15107
Driven gear
9851A
O–ring*
15107
Driven gear
9851A
O–ring*
15110
Oil pump assembly
9851B
D–ring*
15110
Oil pump assembly
9851B
D–ring*
15119
Gasket*
15139
Seat2
15119
Gasket*
15139
Seat2
15132
Relief valve spring
15139A
Seat1
15132
Relief valve spring
15139A
Seat1
15135
Safety valve
15135
Safety valve
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
9068-08160
28.5N m {290kgf cm, 21lbf ft}
9068-08750
24.5r4.9N m {250r50kgf cm, 18r4llbf ft}
9068-08160
28.5N m {290kgf cm, 21lbf ft}
9068-08750
24.5r4.9N m {250r50kgf cm, 18r4llbf ft}
9068-08250
31N m {320kgf cm, 23lbf ft}
9068-08900
24.5r4.9N m {250r50kgf cm, 18r4lbf ft}
9068-08250
31N m {320kgf cm, 23lbf ft}
9068-08900
24.5r4.9N m {250r50kgf cm, 18r4lbf ft}
9068-08320
24.5r4.9N m {250r50kgf cm, 18r4lbf ft}
9068-58100
24.5r4.9N m {250r50kgf cm, 18r4llbf ft}
9068-08320
24.5r4.9N m {250r50kgf cm, 18r4lbf ft}
9068-58100
24.5r4.9N m {250r50kgf cm, 18r4llbf ft}
9068-08550
28.5N m {290kgf cm, 21lbf ft}
9068-08550
28.5N m {290kgf cm, 21lbf ft}
12–4
12–4
LUBRICATION
LUBRICATION
SAPH311991200003
SAPH311991200003
15662
Drain plug
9644A
O–ring*
15662
Drain plug
9644A
O–ring*
15675
Safety valve
9739A
Elbow
15675
Safety valve
9739A
Elbow
15701
Oil cooler case
9851A
O–ring*
15701
Oil cooler case
9851A
O–ring*
15710
Oil cooler assembly
9851B
O–ring*
15710
Oil cooler assembly
9851B
O–ring*
15712
Oil cooler element
9851C
O–ring*
15712
Oil cooler element
9851C
O–ring*
15717
Gasket*
9851D
O–ring*
15717
Gasket*
9851D
O–ring*
15720
Oil cooler case assembly
9851E
O–ring*
15720
Oil cooler case assembly
9851E
O–ring*
*Parts not to be reused.
*Parts not to be reused.
Tightening torque 15662
Tightening torque
44.1r4.9 N m {450r50 kgf cm, 33r4llbf ft} 9201-10080 Service procedure Replacement procedure item
24.5r4.9 N m {250r50 kgf cm, 18r4llbf ft}
15662
44.1r4.9 N m {450r50 kgf cm, 33r4llbf ft} 9201-10080 Service procedure Replacement procedure item
24.5r4.9 N m {250r50 kgf cm, 18r4llbf ft}
12–5
LUBRICATION
12–5
LUBRICATION
Replacement of oil cooler
Replacement of oil cooler JP31199120704001
1.
JP31199120704001
Removal of oil cooler (1)
1.
Remove bolts and hose joint, and remove the oil cooler.
SAPH311991200004
Removal of oil cooler (1)
Remove bolts and hose joint, and remove the oil cooler.
(2)
If it is difficult to remove the oil cooler due to liquid gasket
SAPH311991200004
(2) Figure is an example of work.
If it is difficult to remove the oil cooler due to liquid gasket sticking to the cylinder block, put a flat tip screwdriver at
Figure is an example of work.
sticking to the cylinder block, put a flat tip screwdriver at
the protrusion in the figure for removal.
the protrusion in the figure for removal.
SAPH311991200005
SAPH311991200005
2. D-Ring Block
Installation of oil cooler (1)
Assemble the new D-ring into the D-ring groove of the oil
! CAUTION
D-Ring Block
cooler.
Oil cooler
2.
cooler. ! CAUTION
• Face the D-ring flat area toward the oil cooler.
SAPH311991200006
(2)
Remove contamination on the joint surface between the
(2)
oil cooler and the cylinder block using a scraper. Apply the liquid gasket [Threebond TB1207 (silver) or equivalent] to
! CAUTION
liquid gasket [Threebond TB1207 (silver) or equivalent] to the oil cooler as shown in the figure.
• Apply it continuously.
! CAUTION
• Apply the liquid gasket at the width of 1.5 to
• Apply it continuously. • Apply the liquid gasket at the width of 1.5 to
2.5 mm{0.0590 to 0.0984 in.}.
2.5 mm{0.0590 to 0.0984 in.}.
• Install the oil cooler within 20 minutes after application of the liquid gasket.
Remove contamination on the joint surface between the oil cooler and the cylinder block using a scraper. Apply the
Liquid gasket
the oil cooler as shown in the figure.
SAPH311991200007
Assemble the new D-ring into the D-ring groove of the oil
Flat area
SAPH311991200006
Liquid gasket
(1)
Oil cooler
• Face the D-ring flat area toward the oil cooler.
Flat area
Installation of oil cooler
• Install the oil cooler within 20 minutes after SAPH311991200007
application of the liquid gasket.
12–6
12–6
LUBRICATION (3)
LUBRICATION
Insert the positioning stud into the screw hole of the
(3)
cylinder block and install the oil cooler. (4)
Insert the positioning stud into the screw hole of the cylinder block and install the oil cooler.
After temporary tightening with bolts, remove the
(4)
After temporary tightening with bolts, remove the
positioning stud and tighten bolts.
positioning stud and tighten bolts.
Tightening torque :
Tightening torque :
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft}
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft}
! CAUTION
• Tighten together with the alternator ground.
! CAUTION
• Be sure to connect the turbocharger lubricating oil hose.
SAPH311991200008
(5)
• Tighten together with the alternator ground. • Be sure to connect the turbocharger lubricating oil hose.
SAPH311991200008
Install the drain plug.
(5)
Install the drain plug.
Tightening torque :
Tightening torque :
44.1r4.9 N m {450r50 kgf cm, 33r4 lbf ft}
44.1r4.9 N m {450r50 kgf cm, 33r4 lbf ft}
! CAUTION
• If a new part is used, tighten it to 58.8±4.9N·m
! CAUTION
• If a new part is used, tighten it to 58.8±4.9N·m
{600±50kgf·cm, 43±4lbf·ft} and loosen it.
{600±50kgf·cm, 43±4lbf·ft} and loosen it.
Then, tighten it again to the torque above.
Then, tighten it again to the torque above.
SAPH311991200009
SAPH311991200009
Overhaul item
Overhaul item
Overhaul of oil cooler
Overhaul of oil cooler JP31199120702001
1.
Removal of oil cooler element (1)
2.
JP31199120702001
1.
Remove nuts and remove the oil cooler element.
(1)
Inspection of oil cooler element (1)
Removal of oil cooler element
2.
Wash water and oil channels with kerosene oil or washing
Inspection of oil cooler element (1)
fluid. (2)
Check for crack or deformation on the stud bolt mounting
(2) (3)
found, replace it with a new part.
Disassembly of oil cooler case
! CAUTION
3.
• Disassembly immediately after stop of the
Disassembly of oil cooler case
! CAUTION
engine may cause blowout of engine oil. (1)
• Disassembly immediately after stop of the engine may cause blowout of engine oil.
Remove valve spring plugs and safety valves using a
(1)
hexagonal wrench.
SAPH311991200011
Blow air of approx. 0.5kgf/cm2 into the oil channel to check for leak from parts. If crack, leak or deformation is
SAPH311991200010
found, replace it with a new part. 3.
Check for crack or deformation on the stud bolt mounting area and element visually.
Blow air of approx. 0.5kgf/cm2 into the oil channel to check for leak from parts. If crack, leak or deformation is
SAPH311991200010
Wash water and oil channels with kerosene oil or washing fluid.
area and element visually. (3)
Remove nuts and remove the oil cooler element.
Remove valve spring plugs and safety valves using a hexagonal wrench.
SAPH311991200011
LUBRICATION (2)
12–7
LUBRICATION
Remove the oil pressure warning switch.
SAPH311991200012
(2)
Remove the oil pressure warning switch.
SAPH311991200012
4.
Inspection of safety valve wear and damage (1)
4.
If wear or damage is found, replace it.
SAPH311991200013
Inspection of safety valve wear and damage (1)
If wear or damage is found, replace it.
SAPH311991200013
5.
Inspection of oil pressure warning switch (1)
5.
For inspection of oil pressure warning switch, refer to
Inspection of oil pressure warning switch (1)
"Inspection of components"- "Electrical". 6.
For inspection of oil pressure warning switch, refer to "Inspection of components"- "Electrical".
Assembly of oil cooler case (1)
6.
Install a new O-ring and install valve spring plugs and
Assembly of oil cooler case (1)
Install a new O-ring and install valve spring plugs and
safety valves using a hexagonal wrench.
safety valves using a hexagonal wrench.
Tightening torque :
Tightening torque :
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft} (M14, M20)
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft} (M14, M20)
29.4r4.9 N m {300r50 kgf cm, 22r4 lbf ft} (M22)
29.4r4.9 N m {300r50 kgf cm, 22r4 lbf ft} (M22)
34.3r4.9 N m {350r50 kgf cm, 25r4 lbf ft} (M24)
34.3r4.9 N m {350r50 kgf cm, 25r4 lbf ft} (M24)
SAPH311991200011
SAPH311991200011
(2)
Apply the liquid gasket [Threebond TB1211 (white) or
(2)
equivalent] to the sealing surface of a new soft washer. (3)
Apply the liquid gasket [Threebond TB1211 (white) or equivalent] to the sealing surface of a new soft washer.
Install the soft washer in (2) and the oil pressure warning
(3)
switch.
SAPH311991200012
12–7
Install the soft washer in (2) and the oil pressure warning switch.
SAPH311991200012
12–8
12–8
LUBRICATION 7.
LUBRICATION
Installation of oil cooler element (1)
7.
Assemble new gasket and new O-ring and assemble the
Installation of oil cooler element (1)
oil cooler element with nuts.
oil cooler element with nuts.
Tightening torque :
Tightening torque :
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft}
24.5r4.9 N m {250r50 kgf cm, 18r4 lbf ft}
! CAUTION
• In handling the oil cooler element, be careful
! CAUTION
not to give damage to it. SAPH311991200010
Replacement procedure item
Assemble new gasket and new O-ring and assemble the
• In handling the oil cooler element, be careful not to give damage to it.
SAPH311991200010
Replacement procedure item
12–9
LUBRICATION
12–9
LUBRICATION
Replacement of oil pump
Replacement of oil pump JP31199120704002
1.
2.
JP31199120704002
Removal of oil pump
1.
Removal of oil pump
(1)
Dismount the engine from the machine.
(1)
Dismount the engine from the machine.
(2)
Remove the flywheel.
(2)
Remove the flywheel.
(3)
Remove the flywheel housing.
(3)
Remove the flywheel housing.
(4)
Remove the timing gear.
(4)
Remove the timing gear.
(5)
Remove the oil pump.
(5)
Remove the oil pump.
Installation of oil pump (1)
2.
Apply engine oil to the pump case and the bearing
Installation of oil pump (1)
(shaded area) of the cylinder block. ! CAUTION
Apply engine oil to the pump case and the bearing (shaded area) of the cylinder block.
• Without application of engine oil, poor oil
! CAUTION
suction may occur at the initial start, resulting in seizure or abnormal wear.
Application of engine oil (Shaded area)
suction may occur at the initial start, resulting in seizure or abnormal wear.
Application of engine oil (Shaded area)
SAPH311991200014
SAPH311991200014
(2)
To prevent bolt hole offset of the new gasket, apply
(3)
(2)
engine oil to the cylinder block in advance and place and
fix the gasket.
fix the gasket.
• Assembly with offset gasket may cause faulty
! CAUTION
sealing. Oil in the oil pump may be completely
discharged when the engine stops. Faulty
discharged when the engine stops. Faulty
sealing may cause insufficient suction of oil
sealing may cause insufficient suction of oil
at initial revolution of engine restart,
at initial revolution of engine restart,
resulting in seizure or abnormal wear.
resulting in seizure or abnormal wear.
Tighten the oil pump according to the order in the figure.
! CAUTION
(3)
Tighten the oil pump according to the order in the figure. Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
• If the tightening order is not observed, the oil
Gasket
pump may be damaged. • After tightening, make sure that the gear can
! CAUTION
• If the tightening order is not observed, the oil pump may be damaged. • After tightening, make sure that the gear can
Oil pump
be turned with hand.
be turned with hand.
Overhaul item
SAPH311991200015
• Assembly with offset gasket may cause faulty
sealing. Oil in the oil pump may be completely
Tightening torque : 28.5 N m {290 kgf cm, 21 lbf ft}
Oil pump
To prevent bolt hole offset of the new gasket, apply
engine oil to the cylinder block in advance and place and
! CAUTION
Gasket
• Without application of engine oil, poor oil
Overhaul item
SAPH311991200015
12–10
12–10
LUBRICATION
LUBRICATION
Overhaul of oil pump
Overhaul of oil pump JP31199120702002
1.
JP31199120702002
Remove the driven gear.
1.
SAPH311991200016
Remove the driven gear.
SAPH311991200016
2.
Remove the cotter pin and remove seat 2, seat 1, relief
2.
valve spring and safety valve. ! CAUTION
Remove the cotter pin and remove seat 2, seat 1, relief valve spring and safety valve.
• When the cotter pin is removed, seat 2 and
! CAUTION
the relief valve spring may eject out.
SAPH311991200017
the relief valve spring may eject out.
SAPH311991200017
3.
Inspection of clearance between drive gear and cylinder
3.
Inspection of clearance between drive gear and cylinder
block
block
(1)
(1)
Measure the outer diameter of the drive gear and the inner diameter of the pump chamber at cylinder block.
54{2.1260}
Inner diameter of pump chamber
SAPH311991200018
at cylinder block
(2)
54{2.1260}
Standard value
Measuring area
(mm{in.})
Outer diameter of drive gear
Measure the outer diameter of the drive gear and the inner diameter of the pump chamber at cylinder block.
Standard value
Measuring area
(mm{in.})
Outer diameter of drive gear
54{2.1260}
Inner diameter of pump chamber
SAPH311991200018
at cylinder block
Calculate the difference between the outer diameter of the
(2)
54{2.1260}
Calculate the difference between the outer diameter of the
drive gear and the inner diameter of the pump chamber at
drive gear and the inner diameter of the pump chamber at
the cylinder block. If it is beyond the service limit, replace
the cylinder block. If it is beyond the service limit, replace
the oil pump assembly.
the oil pump assembly.
Standard value (mm{in.}) 0.100 - 0.202{0.0039 0.0080} (reference) SAPH311991200019
• When the cotter pin is removed, seat 2 and
Service limit (mm{in.})
Standard value (mm{in.}) 0.100 - 0.202{0.0039 -
0.30{0.0118}
0.0080} (reference) SAPH311991200019
Service limit (mm{in.}) 0.30{0.0118}
12â&#x20AC;&#x201C;11
LUBRICATION 4.
End play inspection between drive gear and cylinder block (1)
4.
Measure the drive gear width and the pump chamber
End play inspection between drive gear and cylinder block (1)
depth at the cylinder block using a depth gauge.
(mm{in.})
Width of drive gear
28.5{1.1220}
Depth of pump chamber at
28.5{1.1220}
cylinder block
Standard value
Measuring area
28.5{1.1220}
Depth of pump chamber at
28.5{1.1220}
cylinder block
SAPH311991200020
Calculate the difference between the depth of the drive
(2)
Calculate the difference between the depth of the drive
gear and the pump chamber depth at the cylinder block. If
gear and the pump chamber depth at the cylinder block. If
it is beyond the service limit, replace the oil pump
it is beyond the service limit, replace the oil pump
assembly.
assembly.
Standard value (mm{in.})
Service limit (mm{in.})
0.049 - 0.113{0.0020 -
Standard value (mm{in.})
SAPH311991200021
Service limit (mm{in.})
0.049 - 0.113{0.0020 -
0.15{0.0060}
0.0044} (reference)
0.15{0.0060}
0.0044} (reference) SAPH311991200021
5.
Inspection of clearance between outer diameter of driven
5.
Inspection of clearance between outer diameter of driven
gear shaft and cylinder block hole diameter
gear shaft and cylinder block hole diameter
(1)
(1)
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the cylinder block hole
diameter using a cylinder gauge.
diameter using a cylinder gauge. Standard value
shaft Cylinder block hole diameter (2)
18{0.7087}
Standard value
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200022
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the cylinder block hole
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200022
shaft
18{0.7087}
Cylinder block hole diameter
Calculate the difference between the outer diameter of the
(2)
18{0.7087} 18{0.7087}
Calculate the difference between the outer diameter of the
driven gear and the cylinder block hole diameter. If it is
driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.
beyond the service limit, replace the oil pump assembly.
Standard value (mm{in.})
SAPH311991200023
depth at the cylinder block using a depth gauge.
(mm{in.})
Width of drive gear
(2)
Measure the drive gear width and the pump chamber
Standard value
Measuring area
SAPH311991200020
12â&#x20AC;&#x201C;11
LUBRICATION
0.040 - 0.099
Standard value (mm{in.})
{0.0016 - 0.0039}
SAPH311991200023
0.040 - 0.099 {0.0016 - 0.0039}
12â&#x20AC;&#x201C;12
12â&#x20AC;&#x201C;12
LUBRICATION 6.
Inspection of clearance betweeen outer diameter of driven
6.
Inspection of clearance betweeen outer diameter of driven
gear shaft and inner diameter of driven gear bushing
gear shaft and inner diameter of driven gear bushing
(1)
(1)
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
driven gear bushing using a cylinder gauge.
Standard value
shaft Cylinder block hole diameter
(2)
18{0.7087}
Standard value
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200024
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200024
shaft
18{0.7087}
Cylinder block hole diameter
Calculate the difference between the outer diameter of the
(2)
18{0.7087} 18{0.7087}
Calculate the difference between the outer diameter of the
driven gear and the cylinder block hole diameter. If it is
driven gear and the cylinder block hole diameter. If it is
beyond the service limit, replace the oil pump assembly.
beyond the service limit, replace the oil pump assembly.
Standard value (mm{in.})
0.030 - 0.075
Standard value (mm{in.})
{0.0012 - 0.0030}
SAPH311991200025
0.030 - 0.075 {0.0012 - 0.0030}
SAPH311991200025
7.
Inspection of clearance betweeen outer diameter of driven
7.
Inspection of clearance betweeen outer diameter of driven
gear shaft and inner diameter of driven gear bushing
gear shaft and inner diameter of driven gear bushing
(1)
(1)
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
driven gear bushing using a cylinder gauge.
driven gear bushing using a cylinder gauge.
Standard value
shaft Inner diameter of driven gear bushing
(2)
18{0.7087}
Standard value
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200024
Measure the outer diameter of the driven gear shaft using
a micrometer and measure the inner diameter of the
Measuring area
(mm{in.})
Outer diameter of driven gear
SAPH311991200024
shaft Inner diameter of driven gear
18{0.7087}
bushing
Calculate the difference between the outer diameter of the
(2)
18{0.7087}
18{0.7087}
Calculate the difference between the outer diameter of the
driven gear shaft and the inner diameter of the driven gear
driven gear shaft and the inner diameter of the driven gear
bushing. If it is beyond the service limit, replace the oil
bushing. If it is beyond the service limit, replace the oil
pump assembly or the driven gear bushing.
pump assembly or the driven gear bushing.
Standard value (mm{in.}) 0.040 - 0.083 {0.0016 - 0.0033} SAPH311991200026
LUBRICATION
Service limit (mm{in.})
Standard value (mm{in.}) 0.040 - 0.083
0.15{0.00059}
{0.0016 - 0.0033} SAPH311991200026
Service limit (mm{in.}) 0.15{0.00059}
12–13
LUBRICATION 8.
Inspection of drive gear backlash
8.
Inspection of drive gear backlash
(1)
Fix the oil pump assembly with a vice.
(1)
Fix the oil pump assembly with a vice.
(2)
Measure backlash between the drive gear and the driven
(2)
Measure backlash between the drive gear and the driven
gear using a dial gauge. If it is beyond the service limit,
gear using a dial gauge. If it is beyond the service limit,
replace the oil pump assembly.
replace the oil pump assembly.
Standard value (mm{in.}) 0.072 - 0.277 {0.0028 - 0.0109}
SAPH311991200027
9.
12–13
LUBRICATION
Service limit (mm{in.})
Standard value (mm{in.}) 0.072 - 0.277
0.30{0.0118} SAPH311991200027
Assembly of oil pump (1)
{0.0028 - 0.0109}
9.
Install the safety valve, relief valve, seat 1 and seat 2 on
0.30{0.0118}
Assembly of oil pump (1)
the oil pump cover assembly with new cotter pins.
SAPH311991200017
Service limit (mm{in.})
Install the safety valve, relief valve, seat 1 and seat 2 on the oil pump cover assembly with new cotter pins.
SAPH311991200017
(2)
Install the driven gear.
(2)
SAPH311991200016
Install the driven gear.
SAPH311991200016 Replacement procedure item
Replacement procedure item
Replacement of oil strainer
Replacement of oil strainer JP31199120704003
1.
Removal of oil strainer (1)
2.
JP31199120704003
1.
Remove bolts and remove the oil strainer.
(1)
Installation of oil strainer (1)
2.
Replace the O-ring with new ones and install the oil
Remove bolts and remove the oil strainer.
Installation of oil strainer (1)
strainer.
Replace the O-ring with new ones and install the oil strainer.
Tightening torque : 31 N m {320 kgf cm, 23 lbf ft}
Tightening torque : 31 N m {320 kgf cm, 23 lbf ft}
Setup layout Layout
SAPH311991200028
Removal of oil strainer
Setup layout Layout
SAPH311991200028
12–14
12–14
LUBRICATION
LUBRICATION
Oil Pan
Oil Pan
Part layout
Part layout JP31199120402003
JP31199120402003
SAPH311991200029
SAPH311991200029
12111
Oil pan assembly
12149
Drain plug
12111
Oil pan assembly
12149
Drain plug
12151
Oil pan gasket*
9659A
Gasket*
12151
Oil pan gasket*
9659A
Gasket*
9068-08800
30 N m {300 kgf cm, 22lbf ft}
*Parts not to be reused.
*Parts not to be reused.
Tightening torque 12149
Tightening torque
30 N m {300 kgf cm, 22lbf ft}
9068-08800 Service procedure Replacement procedure item
30 N m {300 kgf cm, 22lbf ft}
12149
30 N m {300 kgf cm, 22lbf ft} Service procedure Replacement procedure item
12–15
LUBRICATION
12–15
LUBRICATION
Replacement
Replacement JP31199120704004
1.
JP31199120704004
Installation of oil pan (1)
1.
Cut the gasket of the rear end plate to be flush to the
Installation of oil pan (1)
cylinder block lower surface using a scraper. (2) Protrusion
cylinder block lower surface using a scraper.
Make sure that there is no deformation, dirt or oil on the joint surface between the cylinder block and the oil pan.
(2)
Bolt tightening attaching direction
Apply liquid gasket [Threebond TB1207D (silver) or
Apply liquid gasket [Threebond TB1207D (silver) or
equivalent] to the front rear end of the cylinder block lower
equivalent] to the front rear end of the cylinder block lower
(5) (6)
SAPH311991200030
(3) Bolt tightening attaching direction
Position the oil pan gasket protrusion at the intake side
positioning into the cylinder block screw hole. (4)
Position the oil pan gasket protrusion at the intake side and the flywheel housing (printed seal surface at cylinder
block). Align the new oil pan gasket and oil pan to the
block). Align the new oil pan gasket and oil pan to the
cylinder block lower surface and tighten bolts in the arrow
cylinder block lower surface and tighten bolts in the arrow
order of the figure.
order of the figure.
Tightening torque :
Tightening torque :
Tighten bolts in the arrow order of the figure.
! CAUTION
• Check if the washer is not riding on the
19.6 - 24.5 N m {200 - 250 kgf cm, 14 - 18 lbf ft}
Liquied gasket application position
Remove positioning stud bolts and install the correct bolts. Tightening torque : 30 N m {300 kgf cm, 22 lbf ft}
Engine front side
(5)
Remove positioning stud bolts and install the correct bolts.
(6)
Tighten bolts in the arrow order of the figure.
SAPH311991200030
Tightening torque : 30 N m {300 kgf cm, 22 lbf ft} ! CAUTION
flange.
• Check if the washer is not riding on the flange.
• Make sure that the printed seal is not peeled
• Make sure that the printed seal is not peeled
or damaged before installation of the oil pan
or damaged before installation of the oil pan
gasket. Inspection procedure item
Insert several stud bolts (70 mm{2.7559 in.} or larger) for
and the flywheel housing (printed seal surface at cylinder
19.6 - 24.5 N m {200 - 250 kgf cm, 14 - 18 lbf ft}
Liquied gasket application position Engine front side
surface.
Insert several stud bolts (70 mm{2.7559 in.} or larger) for positioning into the cylinder block screw hole.
(4)
Make sure that there is no deformation, dirt or oil on the joint surface between the cylinder block and the oil pan.
Protrusion
surface. (3)
Cut the gasket of the rear end plate to be flush to the
gasket. Inspection procedure item
12–16
12–16
LUBRICATION
LUBRICATION
Inspection of lubrication status
Inspection of lubrication status JP31199120703001
1.
JP31199120703001
Inspection of valve system
! CAUTION
1.
• Perform inspection with the water
Inspection of valve system
! CAUTION
temperature at 60 qC{140qF}. (1)
(2)
temperature at 60 qC{140qF}.
Remove the head cover.
! CAUTION
(1)
• To prevent spread of engine oil, attach a jig
! CAUTION
• To prevent spread of engine oil, attach a jig which cuts a head cover in half. Cut it to the
degree that the camshaft is covered.
degree that the camshaft is covered.
Adjust the engine revolution to the standard idling
(2)
Adjust the engine revolution to the standard idling revolution [1,000/min{rpm}].
After start of the engine, make sure that oil is supplied to
(3)
After start of the engine, make sure that oil is supplied to
the areas below of all rocker arms within about 10
the areas below of all rocker arms within about 10
seconds.
seconds.
• Roller and cam surface
• Roller and cam surface
• Cross head and spring upper seat surface through
• Cross head and spring upper seat surface through
adjusting screw ! CAUTION SAPH311991200031
Remove the head cover.
which cuts a head cover in half. Cut it to the
revolution [1,000/min{rpm}]. (3)
• Perform inspection with the water
adjusting screw
• If time until lubrication is long or if lubrication is not performed, the oil pressure may be low
! CAUTION SAPH311991200031
• If time until lubrication is long or if lubrication is not performed, the oil pressure may be low
or the oil channel may be clogged. Seizure,
or the oil channel may be clogged. Seizure,
abnormal wear or abnormal noise may occur
abnormal wear or abnormal noise may occur
due to insufficient lubrication.
due to insufficient lubrication.
STARTING AND CHARGING
13–1
STARTING AND CHARGING
ENGINE
13–1
ENGINE
13 STARTING AND CHARGING
13 STARTING AND CHARGING
Setup layout Layout
Setup layout Layout
Starter ........................................................................ 13-2 Part layout (typical example)................................. 13-2 Disassembly.......................................................... 13-3 Inspection of components ..................................... 13-9 Assembly ............................................................ 13-14
Starter ........................................................................ 13-2 Part layout (typical example)................................. 13-2 Disassembly.......................................................... 13-3 Inspection of components ..................................... 13-9 Assembly ............................................................ 13-14
Alternator (50A) ...................................................... 13-21 Part layout (typical example of 50A) ................... 13-21 Circuit drawing (50A) .......................................... 13-22 Disassembly........................................................ 13-23 Inspection of components ................................... 13-26 Assembly ............................................................ 13-29 Inspection after assembly ................................... 13-33
Alternator (50A) ...................................................... 13-21 Part layout (typical example of 50A) ................... 13-21 Circuit drawing (50A) .......................................... 13-22 Disassembly........................................................ 13-23 Inspection of components ................................... 13-26 Assembly ............................................................ 13-29 Inspection after assembly ................................... 13-33
13
13
13–2
13–2
STARTING AND CHARGING
STARTING AND CHARGING
Starter
Starter
Part layout (typical example)
Part layout (typical example) JP31199130402001
JP31199130402001
SAPH311991300001
SAPH311991300001
28011
Clutch assembly
28138
Packing*
28011
Clutch assembly
28138
Packing*
28100
Starter
28140
Brush holder assembly
28100
Starter
28140
Brush holder assembly
28111
Bushing
28142
Brush
28111
Bushing
28142
Brush
28111A
Bushing
28142A
Brush
28111A
Bushing
28142A
Brush
28113
Lever assembly
28143
Spring
28113
Lever assembly
28143
Spring
28115
Start drive housing
28150
Center bracket
28115
Start drive housing
28150
Center bracket
28117
Packing*
28160
Armature assembly
28117
Packing*
28160
Armature assembly
28117A
Packing*
28168
Retainer clip*
28117A
Packing*
28168
Retainer clip*
28118
Plate
28199
Dust protector
28118
Plate
28199
Dust protector
28118A
Brake plate
28240
Start magnet switch
28118A
Brake plate
28240
Start magnet switch
28118B
Plate
28251
Pinion
28118B
Plate
28251
Pinion
28118C
Sim
28252
Rear side bearing*
28118C
Sim
28252
Rear side bearing*
28118D
Cover
28255
Shaft assembly
28118D
Cover
28255
Shaft assembly
28120
Yoke assembly
28253
Planetary gear
28120
Yoke assembly
28253
Planetary gear
28133
Commutator end frame
28253A
Internal gear
28133
Commutator end frame
28253A
Internal gear
28112E
15.7-17.6 N m{160-179kgf cm, 12-13lbf ft}
*Parts not to be reused.
*Parts not to be reused.
Tightening torque
Tightening torque
28112
14-16 N m{140-160kgf cm, 10-12lbf ft}
28112A
3.6-4.9 N m{37-49kgf cm, 3-4lbf ft} Service procedure Overhaul item
28112E
15.7-17.6 N m{160-179kgf cm, 12-13lbf ft}
28112
14-16 N m{140-160kgf cm, 10-12lbf ft}
28112A
3.6-4.9 N m{37-49kgf cm, 3-4lbf ft} Service procedure Overhaul item
13–3
STARTING AND CHARGING
Disassembly
Disassembly JP31199130702001
M lead wire
JP31199130702001
• Fix the starter on the working table to ease
NOTICE
M lead wire
accessibility.
M terminal
1.
• Fix the starter on the working table to ease
NOTICE
accessibility.
M terminal
MRemoval of lead wire
1.
MRemoval of lead wire
(1)
Remove the cap of the M terminal.
(1)
Remove the cap of the M terminal.
(2)
Remove nuts and remove the M lead wire.
(2)
Remove nuts and remove the M lead wire.
SAPH311991300002
SAPH311991300002
2.
Removal of commutator end frame (1)
Through bolt
13–3
STARTING AND CHARGING
Loosen and remove two through bolts.
Commutator end frame
2. Through bolt
Removal of commutator end frame (1)
Loosen and remove two through bolts.
(2)
Remove two set bolts and remove the commutator end
Commutator end frame SAPH311991300003
SAPH311991300003
(2)
Remove two set bolts and remove the commutator end frame.
Set bolt
! CAUTION
frame.
Set bolt
• Hold the M lead wire and remove the
! CAUTION
commutator end frame by lifting.
SAPH311991300004
• Hold the M lead wire and remove the commutator end frame by lifting.
SAPH311991300004
13–4
STARTING AND CHARGING 3. Brush holder Assembly
13–4
STARTING AND CHARGING
Removal of brush holder assembly (1)
3. Brush holder Assembly
Lift the spring using a flat tip screwdriver or pliers.
Removal of brush holder assembly (1)
Remove four brushes from the brush holder assembly. ! CAUTION
(2)
• Do not cut the brush lead fixing clamp.
! CAUTION
Remove the brush holder assembly from the armature
(2)
assembly.
Spring Brush
Lift the spring using a flat tip screwdriver or pliers. Remove four brushes from the brush holder assembly.
Remove the brush holder assembly from the armature assembly.
Spring Brush
Brush lead
Brush lead Clamp
Clamp
SAPH311991300005
SAPH311991300005
4. M lead wire
Removal of yoke assembly (1)
Yoke assembly
4. M lead wire
Remove the yoke assembly from the center bracket
Removal of yoke assembly (1)
Yoke assembly
assembly. ! CAUTION
• Do not hold the M lead wire and hold the yoke
Remove the yoke assembly from the center bracket assembly.
! CAUTION
assembly outer diameter for removal. Center bracket assembly
SAPH311991300006
SAPH311991300006
5. Yoke assembly
Removal of packing (1)
5.
Remove the packing from the centering parts at both ends
Yoke assembly
of the yoke assembly. ! CAUTION
SAPH311991300007
Removal of packing (1)
Remove the packing from the centering parts at both ends of the yoke assembly.
• Damaged packing must not be resued.
! CAUTION
Replace it with a new part.
Packing
• Do not hold the M lead wire and hold the yoke assembly outer diameter for removal.
Center bracket assembly
Packing
• Do not cut the brush lead fixing clamp.
• Damaged packing must not be resued. Replace it with a new part.
Packing
Packing SAPH311991300007
STARTING AND CHARGING 6.
STARTING AND CHARGING
Removal of armature assembly (1)
Armature assembly
13–5
6.
Remove the armature assembly by lifting.
! CAUTION
Removal of armature assembly (1)
Armature assembly
• When the armature assembly is removed, the
Remove the armature assembly by lifting.
! CAUTION
washer at the end of the gear may be dropped and lost. Be careful for handling.
Center bracket assembly
• When the armature assembly is removed, the washer at the end of the gear may be dropped and lost. Be careful for handling.
Center bracket assembly
SAPH311991300008
SAPH311991300008
7.
Removal of rear bearing (1)
7.
Pull out the bearing of the armature assembly using a
! CAUTION
Removal of rear bearing (1)
puller or press.
Rear bearing
Pull out the bearing of the armature assembly using a puller or press.
Rear bearing
• Removed bearing must not be reused.
! CAUTION
Replace it with a new one.
• Removed bearing must not be reused. Replace it with a new one.
Puller
Puller SAPH311991300009
SAPH311991300009
8. Packing
13–5
Cover
Removal of cover (1)
Remove the cover from the center bracket assembly.
(2)
Remove the packing.
! CAUTION
8. Packing
Cover
• Damaged packing must not be resued.
Removal of cover (1)
Remove the cover from the center bracket assembly.
(2)
Remove the packing.
! CAUTION
Replace it with a new part.
Replace it with a new part.
SAPH311991300010
SAPH311991300010
9.
Removal of planetary gear (1)
Planetary gear
9.
Remove the planetary gear from the carrier pin.
! CAUTION
• Make sure that the gear is not damaged or
Planetary gear
Remove the planetary gear from the carrier pin.
! CAUTION
• Make sure that the gear is not damaged or chipped.
Carrier pin
SAPH311991300011
Removal of planetary gear (1)
chipped. Carrier pin
• Damaged packing must not be resued.
SAPH311991300011
13–6
STARTING AND CHARGING
13–6
STARTING AND CHARGING
10. Removal of internal gear (1)
10. Removal of internal gear
Remove the internal gear from the center bracket.
! CAUTION
(1)
• Make sure that the gear is not damaged or
Remove the internal gear from the center bracket.
! CAUTION
chipped.
chipped.
Internal gear
Internal gear
Center bracket
Center bracket
SAPH311991300012
SAPH311991300012
11. Removal of shim washer (1)
11. Removal of shim washer
Remove the shim washer from the center bracket.
(1)
Shim
Remove the shim washer from the center bracket.
Shim
SAPH311991300013
SAPH311991300013
12. Removal of pinion (1)
12. Removal of pinion
Remove the retainer clip using a tool such as snap ring
(1)
pliers. Retainer clip
• Make sure that the gear is not damaged or
! CAUTION
pliers. • Retainer clip must not be reused. Replace it
Retainer clip
with a new one.
Pinion stopper
! CAUTION
• Push upward or pull out the chipped part of
NOTICE
the clip mouth. Pinion
• Retainer clip must not be reused. Replace it with a new one.
Pinion stopper
• Push upward or pull out the chipped part of
NOTICE
Remove the retainer clip using a tool such as snap ring
the clip mouth. Pinion
SAPH311991300014
SAPH311991300014
(2)
Remove the pinion stopper.
(3)
Remove the pinion.
Pinion stopper
• Make sure that the gear is not damaged or chipped.
SAPH311991300015
Remove the pinion stopper.
(3)
Remove the pinion.
Pinion stopper
! CAUTION Pinion
(2)
! CAUTION
• Make sure that the gear is not damaged or chipped.
Pinion
SAPH311991300015
STARTING AND CHARGING
13â&#x20AC;&#x201C;7
STARTING AND CHARGING
13. Removal of center bracket Center bracket
(1)
Remove two set bolts at the switch using a box
13. Removal of center bracket Center bracket
(1)
screwdriver or offset wrench. (2)
Remove two set bolts at the switch using a box screwdriver or offset wrench.
Lift and remove the center bracket.
Clutch assembly
13â&#x20AC;&#x201C;7
(2)
Lift and remove the center bracket.
Clutch assembly
SAPH311991300016
SAPH311991300016
14. Removal of lever (1)
Hold the lever holder and press the entire lever to the clutch. Remove the link with the plunger.
Plunger
14. Removal of lever (1)
Holder
Lever assembly
Lever assembly
SAPH311991300017
SAPH311991300017
(2)
Turn and pull out the lever assembly using the clutch as
(2)
the axis.
Lever assembly SAPH311991300018
clutch. Remove the link with the plunger.
Plunger
Holder
Hold the lever holder and press the entire lever to the
Turn and pull out the lever assembly using the clutch as the axis.
Lever assembly SAPH311991300018
13–8
STARTING AND CHARGING
13–8
STARTING AND CHARGING
15. Removal of brake plate (1)
15. Removal of brake plate
Hold the clutch case outer diameter and slide the clutch
(1)
assembly upward. Pinch the clip end fixing the brake plate
assembly upward. Pinch the clip end fixing the brake plate
and remove it by bending.
and remove it by bending.
SAPH311991300019
SAPH311991300019
(2)
Remove the brake plate.
(2)
Brake plate
SAPH311991300020
16. Removal of clutch assembly (1) Clutch assembly
16. Removal of clutch assembly
While pressing the clutch assembly to the center bracket
(1) Clutch assembly
assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
position and remove it.
Center bracket assembly
position and remove it.
Center bracket assembly
SAPH311991300021
SAPH311991300021
17. Removal of shaft assembly (1)
17. Removal of shaft assembly
Turn the center bracket assembly upside down. Hold the
Washer
carrier plate and pull out the shaft assembly. ! CAUTION
(1)
Turn the center bracket assembly upside down. Hold the carrier plate and pull out the shaft assembly.
• Washers are available at the upper and lower
! CAUTION
• Washers are available at the upper and lower
parts of the carrier plate. Be careful for loss of
parts of the carrier plate. Be careful for loss of
the washers.
the washers. Shaft assembly
SAPH311991300022
While pressing the clutch assembly to the center bracket assembly, offset the helical spline by one tooth.
Pull out the clutch assembly upward from the offset
Shaft assembly
Remove the brake plate.
Brake plate
SAPH311991300020
Washer
Hold the clutch case outer diameter and slide the clutch
SAPH311991300022
13–9
STARTING AND CHARGING 18. Removal of packing (1)
18. Removal of packing
Turn the center bracket upside down again and remove
(1)
the packing. ! CAUTION
13–9
STARTING AND CHARGING
Turn the center bracket upside down again and remove the packing.
• Packing must not be reused.
! CAUTION
Packing
• Packing must not be reused.
Packing
SAPH311991300023
SAPH311991300023
Inspection procedure item
Inspection procedure item
Inspection of components
Inspection of components JP31199130703001
1.
JP31199130703001
Inspection of yoke assembly (1)
1.
Make sure that the coil lead wire has electric continuity
Inspection of yoke assembly (1)
using a circuit tester. (2)
Make sure that there is no discoloration at the coil.
SAPH311991300024
(2)
Make sure that there is no discoloration at the coil.
(3)
Measure the resistance between the coil lead wire and the
SAPH311991300024
(3) Tester rod
Measure the resistance between the coil lead wire and the yoke with a circuit tester and check insulation.
Tester rod
yoke with a circuit tester and check insulation.
When the value is below the service limit, replace it. Feed coil
When the value is below the service limit, replace it. Feed coil
Service limit ! CAUTION
1k:or less
Service limit
• After cleaning and drying, take measurements.
Yoke assembly
! CAUTION
1k:or less
• After cleaning and drying, take measurements.
Yoke assembly
SAPH311991300025
SAPH311991300025
(4)
Measure the brush length using vernier calipers.
(4)
When the value is below the service limit, replace it.
SAPH311991300026
Make sure that the coil lead wire has electric continuity using a circuit tester.
Measure the brush length using vernier calipers. When the value is below the service limit, replace it.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
18{0.7087}
13{0.5118} or less
18{0.7087}
13{0.5118} or less
SAPH311991300026
13–10
13–10
STARTING AND CHARGING 2.
Inspection of armature assembly (1)
Piece of steel
STARTING AND CHARGING 2.
Turn the armature assembly using a commercially
Inspection of armature assembly (1)
Piece of steel
Turn the armature assembly using a commercially
available growler tester and put a piece of steel on the
available growler tester and put a piece of steel on the
armature assembly. Make sure that the steel piece is not
armature assembly. Make sure that the steel piece is not
vibrating on the core circumference.
vibrating on the core circumference.
Growler tester
Growler tester
SAPH311991300027
SAPH311991300027
(2)
Make sure that adjacent segments of the commutator
(2)
have electric continuity using a circuit tester. (3)
Make sure that adjacent segments of the commutator have electric continuity using a circuit tester.
Make sure that there is no discoloration at the coil.
SAPH311991300028
(3)
Make sure that there is no discoloration at the coil.
(4)
Measure the resistance between the commutator and the
SAPH311991300028
(4)
Measure the resistance between the commutator and the core using a circuit tester and check insulation.
core using a circuit tester and check insulation.
When the value is below the service limit, replace it.
When the value is below the service limit, replace it.
Core
Core Commutator
! CAUTION
Standard value
Service limit
1M:or more
1k:or less
Commutator
• After cleaning and drying, take
! CAUTION
Standard value
Service limit
1M:or more
1k:or less
• After cleaning and drying, take
measurements.
measurements.
SAPH311991300029
SAPH311991300029
(5)
Measure the commutator outer diameter using vernier
(5)
Measure the commutator outer diameter using vernier
calipers.
calipers.
When the value is below the service limit, replace it.
When the value is below the service limit, replace it.
! CAUTION
• After removing roughness on the surface
! CAUTION
(after polishing), take measurements.
(after polishing), take measurements.
Commutator outer diameter Standard value (mm{in.})
• After removing roughness on the surface
Commutator outer diameter Service limit (mm{in.})
Commutator
Standard value (mm{in.})
Service limit (mm{in.})
36{1.4173}
34{1.3386} or less
Commutator SAPH311991300030
36{1.4173}
34{1.3386} or less
SAPH311991300030
13–11
STARTING AND CHARGING (6)
Measure the undercut depth between segments. If the
(6)
undercut depth is beyond the service limit, repair it.
Segment
Undercut length: 0.5 to 0.8 mm {0.0197 - 0.0315}
Standard value (mm{in.})
Service limit (mm{in.})
0.5 - 0.8{0.0197 - 0.0315}
0.2{0.0079} or less
Undercut length: 0.5 to 0.8 mm {0.0197 - 0.0315}
• In repair, do not leave insulation material at the end of the segment.
Insulating material
0.5 - 0.8{0.0197 - 0.0315}
0.2{0.0079} or less
• In repair, do not leave insulation material at the end of the segment.
Insulating material
Measure the shaft outer diameter using a micrometer. If it
(7)
is beyond the service limit, replace the shaft.
A
Measuring area
Service limit
(mm{in.})
(mm{in.})
Area
12{0.4724}
Area
9{0.3543}
11.98{0.4717} or
A
Standard value
Service limit
(mm{in.})
(mm{in.})
B
8.98{0.3535} or less
Area
12{0.4724}
Area
9{0.3543}
11.98{0.4717} or less 8.98{0.3535} or less
SAPH311991300032
Inspection of brush holder assembly (1)
Measuring area
less
SAPH311991300032
3.
Measure the shaft outer diameter using a micrometer. If it is beyond the service limit, replace the shaft.
Standard value
B
3.
Measure the resistance between the holder (plus) and the
Inspection of brush holder assembly (1)
Measure the resistance between the holder (plus) and the
plate using a circuit tester and check insulation.
plate using a circuit tester and check insulation.
When the value is below the service limit, replace it.
When the value is below the service limit, replace it.
Service limit ! CAUTION
1k:or less
Service limit
• After cleaning and drying, take
! CAUTION
measurements.
1k:or less
• After cleaning and drying, take measurements.
SAPH311991300033
SAPH311991300033
(2)
Measure the brush length using vernier calipers. When the value is below the service limit, replace it.
Spring
(3)
(2) Brush
Measure the brush length using vernier calipers. When the value is below the service limit, replace it.
Spring
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
18{0.7087}
13{0.5118} or less
18{0.7087}
13{0.5118} or less
Make sure that the spring has pressure.
(3) Brush
SAPH311991300034
Service limit (mm{in.})
SAPH311991300031
(7)
Brush
Standard value (mm{in.})
! CAUTION
SAPH311991300031
Brush
Measure the undercut depth between segments. If the undercut depth is beyond the service limit, repair it.
Segment
! CAUTION
13–11
STARTING AND CHARGING
SAPH311991300034
Make sure that the spring has pressure.
13â&#x20AC;&#x201C;12
13â&#x20AC;&#x201C;12
STARTING AND CHARGING 4.
Inspection of shaft assembly (1)
B
4.
Measure the outer diameter of the shaft using a If it is beyond the service limit, replace the shaft.
If it is beyond the service limit, replace the shaft.
Area
Standard value
Service limit
(mm{in.})
(mm{in.})
Area
A
Measuring area
25.90{1.0197} or
26{1.0236}
less
SAPH311991300035
12.04{0.4740} or
12.1{0.4764}
Standard value
Service limit
(mm{in.})
(mm{in.})
Area
26{1.0236}
Area
12.1{0.4764}
25.90{1.0197} or less
SAPH311991300035
less
Inspection of clutch assembly (1)
Measure the outer diameter of the shaft using a micrometer
Measuring area
5.
Measure the outer diameter of the inner sleeve using a
12.04{0.4740} or less
Inspection of clutch assembly (1)
Measure the outer diameter of the inner sleeve using a
micrometer.
micrometer.
If it is beyond the service limit, replace the clutch
If it is beyond the service limit, replace the clutch
assembly.
assembly.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
25{0.9843}
24.90{0.9803} or less
25{0.9843}
24.90{0.9803} or less
SAPH311991300036
SAPH311991300036
6.
Inspection of bearing (1)
6.
Measure the bearing metal inner diameter (1 in the figure)
Inspection of bearing (1)
Measure the bearing metal inner diameter (1 in the figure)
of the pinion case using a cylinder gauge. If it is beyond
of the pinion case using a cylinder gauge. If it is beyond
the service limit, replace the bushing.
the service limit, replace the bushing.
1
1
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
25{0.9843}
25.2{0.9921} or more
25{0.9843}
25.2{0.9921} or more
SAPH311991300037
SAPH311991300037
(2)
SAPH311991300038
(1)
B
5.
Inspection of shaft assembly
micrometer
A
2
STARTING AND CHARGING
Measure the bearing metal inner diameter (2 in the figure)
(2)
Measure the bearing metal inner diameter (2 in the figure)
of the center bracket using a cylinder gauge. If it is beyond
of the center bracket using a cylinder gauge. If it is beyond
the service limit, replace the center bracket.
the service limit, replace the center bracket.
Standard value (mm{in.})
Service limit (mm{in.})
26{1.0236}
26.2{1.0315}
2
SAPH311991300038
Standard value (mm{in.})
Service limit (mm{in.})
26{1.0236}
26.2{1.0315}
13â&#x20AC;&#x201C;13
STARTING AND CHARGING (3)
Measure the bearing metal inner diameter (3 in the figure)
(3)
of the shaft assembly using a cylinder gauge. If it is
4
3
beyond the service limit, replace the shaft assembly.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
9{0.3543}
9.2{3.6220}
9{0.3543}
9.2{3.6220}
Measure the bearing housing inner diameter (4 in the
(4)
figure) of the commutator end frame using a cylinder SAPH311991300039
gauge. If it is beyond the service limit, replace the
commutator end frame.
7.
commutator end frame.
Standard value (mm{in.})
Service limit (mm{in.})
Standard value (mm{in.})
Service limit (mm{in.})
28{1.1024}
28.1{1.1063} or more
28{1.1024}
28.1{1.1063} or more
Inspection of start magnet switch assembly (resistance of
7. C terminal
P coil) (1)
M terminal
Measure the bearing housing inner diameter (4 in the figure) of the commutator end frame using a cylinder
SAPH311991300039
gauge. If it is beyond the service limit, replace the
C terminal
Measure the bearing metal inner diameter (3 in the figure) of the shaft assembly using a cylinder gauge. If it is
4
3
beyond the service limit, replace the shaft assembly.
(4)
13â&#x20AC;&#x201C;13
STARTING AND CHARGING
Measure the P coil resistance between the C terminal and
Inspection of start magnet switch assembly (resistance of P coil) (1)
M terminal
Measure the P coil resistance between the C terminal and
the M terminal using a circuit tester.
the M terminal using a circuit tester.
If it is beyond the service limit, replace the start magnet
If it is beyond the service limit, replace the start magnet
switch.
switch.
Standard value (:)
0.12 - 0.14
Standard value (:)
SAPH311991300040
0.12 - 0.14
SAPH311991300040
8.
Inspection of start magnet switch assembly (resistance of
8.
H coil) (1) C terminal
Inspection of start magnet switch assembly (resistance of H coil)
Measure the H coil resistance between the C terminal and
(1) C terminal
the body using a circuit tester.
Measure the H coil resistance between the C terminal and the body using a circuit tester.
If it is beyond the service limit, replace the start magnet
If it is beyond the service limit, replace the start magnet
switch.
switch.
Body
Body
Standard value(:)
1.13 - 1.25
Standard value(:)
SAPH311991300041
SAPH311991300041
9. M terminal
B terminal SAPH311991300042
1.13 - 1.25
Inspection of start magnet switch assembly (electric
9.
Inspection of start magnet switch assembly (electric
continuity inspection)
continuity inspection)
(1)
(1)
Check electric continuity between the B terminal and the
M terminal
Check electric continuity between the B terminal and the
M terminal using a circuit tester, and make sure that there
M terminal using a circuit tester, and make sure that there
is no electric continuity.
is no electric continuity.
B terminal SAPH311991300042
13–14
13–14
STARTING AND CHARGING (2)
STARTING AND CHARGING
Push the end of the start magnet switch assembly (close
(2)
Push the end of the start magnet switch assembly (close
the internal contact) and make sure that there is electric
the internal contact) and make sure that there is electric
continuity between the B terminal and the M terminal
continuity between the B terminal and the M terminal
using a circuit tester.
using a circuit tester.
SAPH311991300043
SAPH311991300043 Overhaul item
Overhaul item
Assembly
Assembly JP31199130702002
1.
JP31199130702002
Installation of packing (1)
1.
Install a new packing on the center bracket assembly.
Installation of packing (1)
Packing
Packing
SAPH311991300023
SAPH311991300023
2.
Installation of shaft assembly (1)
Washer
Installation of shaft assembly (1)
Washer
Turn the center bracket assembly upside down and hold
the carrier plate. Lubricate parts (refer to the lubrication
the carrier plate. Lubricate parts (refer to the lubrication
point drawing and the lubrication list) and install the shaft
point drawing and the lubrication list) and install the shaft
assembly.
assembly.
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of
Shaft assembly
2.
Turn the center bracket assembly upside down and hold
! CAUTION
! CAUTION
SAPH311991300022
• Washers are available at the upper and lower parts of the carrier plate. Be careful for loss of
Shaft assembly
the washers.
the washers. SAPH311991300022
3.
Installation of clutch assembly (1)
Clutch assembly
Install a new packing on the center bracket assembly.
3.
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and insert the clutch assembly into the
Installation of clutch assembly (1)
Clutch assembly
center bracket assembly.
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and insert the clutch assembly into the center bracket assembly.
Center bracket assembly
Center bracket assembly
SAPH311991300044
SAPH311991300044
STARTING AND CHARGING 4.
13–15
STARTING AND CHARGING
Installation of brake plate (1)
4.
Lubricate parts (refer to the lubrication point drawing and
Installation of brake plate (1)
the lubrication list) and install the brake plate.
Brake plate
SAPH311991300045
SAPH311991300045
5.
Installation of lever (1)
5.
Lubricate parts (refer to the lubrication point drawing and
Lubricate parts (refer to the lubrication point drawing and
the lubrication list). Turn and install the lever assembly
the lubrication list). Turn and install the lever assembly
using the clutch as the axis.
using the clutch as the axis.
Lever assembly
SAPH311991300018
SAPH311991300018
6. Center bracket
Installation of pinion case (1)
Install two set bolts at the switch using a box screwdriver
6. Center bracket
Installation of pinion case (1)
Install two set bolts at the switch using a box screwdriver
or offset wrench.
or offset wrench.
Tightening torque :
Tightening torque :
14 - 16 N m {140 - 160 kgf cm, 10 - 12 lbf ft}
Clutch assembly
14 - 16 N m {140 - 160 kgf cm, 10 - 12 lbf ft}
Clutch assembly
SAPH311991300016
SAPH311991300016
7.
Installation of pinion (1)
7.
Lubricate parts (refer to the lubrication point drawing and
Installation of pinion (1)
Pinion stopper
the lubrication list) and install the pinion and the pinion stopper.
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the pinion and the pinion stopper.
Pinion
SAPH311991300015
Installation of lever (1)
Lever assembly
Pinion
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the brake plate.
Brake plate
Pinion stopper
13–15
SAPH311991300015
13â&#x20AC;&#x201C;16
STARTING AND CHARGING (2)
13â&#x20AC;&#x201C;16
STARTING AND CHARGING
Install the retainer clip using a tool such as snap ring
(2)
pliers.
pliers.
Retainer clip
Retainer clip
Pinion stopper
Pinion stopper
Pinion
Install the retainer clip using a tool such as snap ring
Pinion SAPH311991300014
SAPH311991300014
8.
Installation of shim washer (1)
8.
Lubricate parts (refer to the lubrication point drawing and
Installation of shim washer (1)
the lubrication list) and install the shim washer on the
the lubrication list) and install the shim washer on the
center bracket.
Shim
SAPH311991300013
9.
Removal of internal gear (1)
9.
Lubricate parts (refer to the lubrication point drawing and
(1)
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the internal gear on the
center bracket.
center bracket. Internal gear
Center bracket
Center bracket
SAPH311991300012
SAPH311991300012
10. Installation of planetary gear (1)
10. Installation of planetary gear
Lubricate parts (refer to the lubrication point drawing and
(1)
the lubrication list) and install the planetary gear on the
Lubricate parts (refer to the lubrication point drawing and the lubrication list) and install the planetary gear on the
carrier pin.
Planetary gear Carrier pin
SAPH311991300011
Removal of internal gear
the lubrication list) and install the internal gear on the
Internal gear
Carrier pin
center bracket.
Shim
SAPH311991300013
Planetary gear
Lubricate parts (refer to the lubrication point drawing and
SAPH311991300011
carrier pin.
STARTING AND CHARGING
13–17
STARTING AND CHARGING
11. Installation of cover Packing
Cover
(1)
Install a new packing.
(2)
Install the cover on the center bracket assembly.
11. Installation of cover Packing
SAPH311991300010
Cover
(1)
Install a new packing.
(2)
Install the cover on the center bracket assembly.
SAPH311991300010
12. Installation of rear bearing (1)
12. Installation of rear bearing
Install the bearing on the armature assembly using a
(1)
press. ! CAUTION
Install the bearing on the armature assembly using a press.
• When the bearing is removed, replace it with
! CAUTION
a new one.
(1)
13. Installation of armature assembly
Install the armature assembly.
! CAUTION
(1) Armature assembly
• When the armature assembly is installed, the
Install the armature assembly.
! CAUTION
washer at the end of the gear may be dropped and lost. Be careful for handling.
Center bracket assembly
and lost. Be careful for handling.
Center bracket assembly
SAPH311991300008
14. Installation of packing (1)
14. Installation of packing
Install a new packing on the centering location at both
Yoke assembly
(1)
ends of the yoke assembly. ! CAUTION
• Damaged packing must not be resued.
Packing
! CAUTION
Packing
Packing SAPH311991300007
15. Installation of yoke assembly (1) Yoke assembly
Center bracket assembly SAPH311991300006
• Damaged packing must not be resued. Replace it with a new part.
SAPH311991300007
M lead wire
Install a new packing on the centering location at both ends of the yoke assembly.
Replace it with a new part.
Packing
• When the armature assembly is installed, the washer at the end of the gear may be dropped
SAPH311991300008
Yoke assembly
• When the bearing is removed, replace it with a new one.
13. Installation of armature assembly Armature assembly
13–17
Install the yoke assembly on the center bracket assembly.
15. Installation of yoke assembly M lead wire
(1) Yoke assembly
Center bracket assembly SAPH311991300006
Install the yoke assembly on the center bracket assembly.
13–18
STARTING AND CHARGING
13–18
STARTING AND CHARGING
16. Installation of brush holder assembly Brush holder Assembly
(1)
16. Installation of brush holder assembly Brush holder Assembly
Lift the spring using a flat tip screwdriver, long-nose pliers
(1)
Lift the spring using a flat tip screwdriver, long-nose pliers
or pliers. Install four brushes on the brush holder
or pliers. Install four brushes on the brush holder
assembly.
assembly.
Spring
Spring
Brush
Brush
Brush lead
Brush lead Clamp
Clamp
SAPH311991300005
SAPH311991300005
17. Installation of commutator end frame (1)
Through bolt
Tighten the through bolt of the commutator end frame.
17. Installation of commutator end frame (1)
Through bolt
Tighten the through bolt of the commutator end frame.
Tightening torque :
Tightening torque :
15.7 - 17.6 N m {160 - 179 kgf cm, 12 - 13 lbf ft}
15.7 - 17.6 N m {160 - 179 kgf cm, 12 - 13 lbf ft}
Commutator end frame
Commutator end frame SAPH311991300003
SAPH311991300003
(2)
Tighten two set bolts. Tightening torque :
Set bolt
3.6 - 4.9 N m {37 - 49 kgf cm, 3 - 4 lbf ft} ! CAUTION
(2)
Tightening torque :
Set bolt
3.6 - 4.9 N m {37 - 49 kgf cm, 3 - 4 lbf ft}
• Hold the M lead wire and remove the
! CAUTION
commutator end frame by lifting.
SAPH311991300004
Tighten two set bolts.
• Hold the M lead wire and remove the commutator end frame by lifting.
SAPH311991300004
STARTING AND CHARGING
13–19
STARTING AND CHARGING
18. Installation of lead wire M lead wire
(1)
18. Installation of lead wire M lead wire
Install the M lead wire.
M terminal
(1)
Install the M lead wire.
M terminal
SAPH311991300002
SAPH311991300002
19. Lubrication
19. Lubrication
Refer to the following figure and table for lubricant to be applied. ! CAUTION
13–19
Refer to the following figure and table for lubricant to be applied.
• There shall be no lubricant on the commutator surface, brush and contact.
! CAUTION
SAPH311991300046
• There shall be no lubricant on the commutator surface, brush and contact.
SAPH311991300046
13â&#x20AC;&#x201C;20
13â&#x20AC;&#x201C;20
STARTING AND CHARGING
Table of lubricant Code
1
2
Lubricating point Pinion case metal and grease reservoir Bracket center metal and grease reservoir
Table of lubricant Lubricant used
Multemp AC-N
Multemp AC-N
3
Shim washer
Multemp AC-N
4
Armature front metal
Multemp AC-N
5
Shim washer
Multemp AC-N
Amount (g{oz})
Remark
0.8 - 1.5 {0.03 - 0.05} 0.5 - 1.5 {0.03 - 0.05} 0.2 - 0.5
Applied to both sides
{0.01 - 0.02} of washer. 0.5 - 1 {0.02 - 0.04} 0.2 - 0.5
Applied to both sides
{0.01 - 0.02} of washer.
Lubricant manufacturer
Code
Armature gear
Pinion straight Spline
Kyodo Yushi
2
Kyodo Yushi
3
Shim washer
Multemp AC-N
Kyodo Yushi
4
Armature front metal
Multemp AC-N
Kyodo Yushi
5
Shim washer
Multemp AC-N
Multemp AC-N
Multemp AC-N
Multemp AC-N
9
Helical spline
Multemp AC-N
11
shifter Bracket rear bearing housing
Bracket center metal and grease reservoir
Multemp AC-N
(g{oz})
Pyroknock No.2
Pyroknock No.2
12
Planetary gear metal
Multemp AC-N
13
Lever holder
Multemp AC-N
0.8 - 1.5
0.5 - 1.5
Lever roller rod
Applied to both sides
{0.01 - 0.02} of washer. 0.5 - 1
Kyodo Yushi
Kyodo Yushi
{0.02 - 0.04} 0.2 - 0.5
manufacturer
Kyodo Yushi
{0.03 - 0.05} 0.2 - 0.5
Lubricant
Kyodo Yushi
{0.03 - 0.05}
Applied to both sides
{0.01 - 0.02} of washer.
7 -11
Kyodo Yushi
{0.25 - 0.39}
6
Armature gear
Multemp AC-N
7 -11
Kyodo Yushi
Kyodo Yushi
{0.25 - 0.39}
0.5 - 1 {0.02 - 0.04} 0.3 - 0.6 {0.01 - 0.02} 0.5 - 1 {0.02 - 0.04}
7
Kyodo Yushi
8
Inner sleeve metal
Multemp AC-N
Kyodo Yushi
9
Helical spline
Multemp AC-N
1-2
Nippon Oil
{0.04 - 0.07}
Corporation
0.2 - 0.5
Nippon Oil
{0.01 - 0.02}
Corporation
1-2 {0.04 - 0.07} 0.4 - 0.8 {0.01 - 0.03}
Pinion straight
Kyodo Yushi
10
11
Spline
Clutch case lever shifter Bracket rear bearing housing
Multemp AC-N
Pyroknock No.2
Pyroknock No.2
Kyodo Yushi
12
Planetary gear metal
Multemp AC-N
Kyodo Yushi
13
Lever holder
Multemp AC-N
0.5 - 1
Pyroknock No.2
0.2 - 0.5 {0.01 - 0.02}
after application of grease to prevent fall of the roller in
0.3 - 0.6
Kyodo Yushi
{0.01 - 0.02} 0.5 - 1
Kyodo Yushi
{0.02 - 0.04} 1-2
Nippon Oil
{0.04 - 0.07}
Corporation
0.2 - 0.5
Nippon Oil
{0.01 - 0.02}
Corporation
1-2
Kyodo Yushi
{0.04 - 0.07} 0.4 - 0.8
Kyodo Yushi
{0.01 - 0.03} Assemble the roller
Nippon Oil Corporation
14
Lever roller rod
Pyroknock No.2
assembly. Setup layout Layout
Kyodo Yushi
{0.02 - 0.04}
Assemble the roller 14
Remark
Planetary gear
Inner sleeve metal
Clutch case lever
and grease reservoir
Multemp AC-N
Amount
Internal gear
8
10
Pinion case metal
Lubricant used
1
Planetary gear 7
Lubricating point
Kyodo Yushi
Internal gear 6
STARTING AND CHARGING
0.2 - 0.5 {0.01 - 0.02}
after application of grease to prevent fall of the roller in assembly.
Setup layout Layout
Nippon Oil Corporation
13–21
STARTING AND CHARGING
13–21
STARTING AND CHARGING
Alternator (50A)
Alternator (50A)
Part layout (typical example of 60A)
Part layout (typical example of 60A) JP31199130402002
JP31199130402002
SAPH311991300047
SAPH311991300047
27017
Feed coil
27383A
Insulator
27017
Feed coil
27383A
Insulator
27040
Alternator
27389
Insulator
27040
Alternator
27389
Insulator
27310
Drive end frame assembly
27392
Cover
27310
Drive end frame assembly
27392
Cover
27311
Drive end frame
27410
Stator coil
27311
Drive end frame
27410
Stator coil
27312
Bearing cover
27412
Collar
27312
Bearing cover
27412
Collar
27330
Rotor assembly
27431
Pulley
27330
Rotor assembly
27431
Pulley
27350
End frame assembly
27441
Fan
27350
End frame assembly
27441
Fan
27353
Rectifier minus
27445A
Coupler holder
27353
Rectifier minus
27445A
Coupler holder
27356
Rectifier plus
27700
Regulator
27356
Rectifier plus
27700
Regulator
27359
End frame
28252
Front bearing
27359
End frame
28252
Front bearing
27383
Insulator
28252A
Rear bearing
27383
Insulator
28252A
Rear bearing
Tightening torque
Tightening torque
27317
7.8-9.8 N m{80-99 kgf cm, 6-7lbf ft}
27317C
1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}
27317
7.8-9.8 N m{80-99 kgf cm, 6-7lbf ft}
27317C
1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}
27317A
1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}
27391
127 - 157 N m{1, 300 - 1, 600 kgf cm, 94-
27317A
1.9-2.5 N m{20-25 kgf cm, 1-2lbf ft}
27391
127 - 157 N m{1, 300 - 1, 600 kgf cm, 94-
116lbf ft} 27317B
2.9 - 3.9 N m{30 - 39 kgf cm, 2-3lbf ft}
27391A
Internal nut : 4.9-5.9 N m{50-60 kgf cm,
116lbf ft} 27317B
2.9 - 3.9 N m{30 - 39 kgf cm, 2-3lbf ft}
3.6-4.3lbf ft} System drawing
27391A
Internal nut : 4.9-5.9 N m{50-60 kgf cm, 3.6-4.3lbf ft}
System drawing
13–22
13–22
STARTING AND CHARGING
Circuit drawing (50A)
STARTING AND CHARGING
Circuit drawing (50A) JP31199130803001
Capacitor
JP31199130803001
Capacitor
Diode
Diode Fuse L
Load
Fuse
Lamp 1.4 to 3W
L
R P
Load
Lamp 1.4 to 3W
R Starter switch
P
Feed coil
Starter switch
Feed coil N
N
Regulator
Regulator Battery 24V
Stator coil
Battery 24V
Stator coil
E
E
Alternator
Alternator
SAPH311991300048 Service procedure Overhaul item
SAPH311991300048 Service procedure Overhaul item
13–23
STARTING AND CHARGING
Disassembly
Disassembly JP31199130702003
! CAUTION
JP31199130702003
• Place a rubber mat and perform work on the
! CAUTION
• Place a rubber mat and perform work on the
mat. 1.
mat.
Disconnection of front from rear (1)
1.
Remove fixing bolts and remove the cover.
! CAUTION
Disconnection of front from rear (1)
• Press the tabs of the cover for removal. Be
Remove fixing bolts and remove the cover.
! CAUTION
• Press the tabs of the cover for removal. Be
careful not to break the tab with excessive
careful not to break the tab with excessive
force. SAPH311991300049
force. SAPH311991300049
(2)
Remove bolts with a screwdriver and remove the coupler
(2)
holder.
Remove bolts with a screwdriver and remove the coupler holder.
SAPH311991300050
SAPH311991300050
(3)
Remove three through bolts and disconnect the front from
(3)
the rear.
Remove three through bolts and disconnect the front from the rear.
SAPH311991300051
SAPH311991300051
2.
Disassembly of front (1)
2.
Remove nuts and remove the pulley, fan and collar.
! CAUTION
Disassembly of front (1)
• Tie around a general V –belt in the pulley
Remove nuts and remove the pulley, fan and collar.
! CAUTION
groove and fix the pulley with a vice.
SAPH311991300052
13–23
STARTING AND CHARGING
• Tie around a general V –belt in the pulley groove and fix the pulley with a vice.
SAPH311991300052
13–24
STARTING AND CHARGING (2)
13–24
STARTING AND CHARGING
Remove the rotor assembly using a press.
! CAUTION
(2)
• Do not damage the end of the thread.
Remove the rotor assembly using a press.
! CAUTION
• Support the rotor assembly to prevent fall of
• Support the rotor assembly to prevent fall of
the rotor assembly.
SAPH311991300053
the rotor assembly.
SAPH311991300053
(3)
Remove three bolts with a screwdriver and remove the
(3)
bearing cover.
SAPH311991300054
Remove three bolts with a screwdriver and remove the bearing cover.
SAPH311991300054
(4)
Remove the ball bearing from the front bracket using a
(4)
press or jig C. Jig C
Remove the ball bearing from the front bracket using a press or jig C.
Jig C
! CAUTION
• Place jig C at the inner race of the front
! CAUTION
bearing.
SAPH311991300055
• Place jig C at the inner race of the front bearing.
• Removed bearing must not be reused.
• Removed bearing must not be reused.
SAPH311991300055
3.
Disassembly of rear (1)
3.
Remove solder of the lead wire connecting the stator coil
Disassembly of rear (1)
Remove solder of the lead wire connecting the stator coil
and the diode using a soldering bit and suction line or a
and the diode using a soldering bit and suction line or a
solder suction device
solder suction device
! CAUTION
SAPH311991300056
• Do not damage the end of the thread.
• At solder of the stator coil and the diode, the
! CAUTION
• At solder of the stator coil and the diode, the
end of the diode is clamped. Do not damage
end of the diode is clamped. Do not damage
the diode by prying. Deformed diode must not
the diode by prying. Deformed diode must not
be reused.
be reused.
• Perform soldering in a short time (within 5 seconds).
SAPH311991300056
• Perform soldering in a short time (within 5 seconds).
STARTING AND CHARGING (2)
13–25
STARTING AND CHARGING
Remove the stator coil from the rear bracket.
! CAUTION
(2)
• Do not damage the stator coil.
Remove the stator coil from the rear bracket.
! CAUTION
SAPH311991300057
13–25
• Do not damage the stator coil.
SAPH311991300057
(3)
Remove solder of the lead wire connecting the regulator
(3)
and the field coil using a soldering bit. ! CAUTION
Remove solder of the lead wire connecting the regulator and the field coil using a soldering bit.
• Remove the lead wire of the field coil by
! CAUTION
raising the terminal of the regulator.
• Remove the lead wire of the field coil by raising the terminal of the regulator.
• Perform soldering in a short time (within 5
• Perform soldering in a short time (within 5
seconds).
seconds).
SAPH311991300058
SAPH311991300058
Terminal
Terminal
Lead wire
Lead wire
Regulator assembly
Regulator assembly
SAPH311991300059
SAPH311991300059
(4)
Loosen the nut at the B terminal.
! CAUTION
(4)
• Loosen the nut to some extent and do not
! CAUTION
remove it from the B terminal.
SAPH311991300060
Loosen the nut at the B terminal. • Loosen the nut to some extent and do not remove it from the B terminal.
SAPH311991300060
13–26
13–26
STARTING AND CHARGING (5)
STARTING AND CHARGING
Remove five bolts using a screwdriver and remove the
(5)
Remove five bolts using a screwdriver and remove the
heat sink assembly (plus), heat sink assembly (minus)
heat sink assembly (plus), heat sink assembly (minus)
and regulator all together.
and regulator all together.
! CAUTION
• Screw lock is used. Since torque is high until
! CAUTION
• Screw lock is used. Since torque is high until
bolt is removed, be careful not to damage the
bolt is removed, be careful not to damage the
groove of the bolt head.
groove of the bolt head.
• When the rear bracket is reused, clean the
• When the rear bracket is reused, clean the
screw hole.
screw hole.
SAPH311991300061
SAPH311991300061
(6)
Remove the capacitor.
(6)
Remove the capacitor.
(7)
Remove three bolts with a screwdriver and remove the
(7)
Remove three bolts with a screwdriver and remove the
field coil from the rear bracket.
field coil from the rear bracket.
SAPH311991300062
SAPH311991300062
(8)
Remove the roller bearing from the rear bracket using a
(8)
press, jig A and jig B. ! CAUTION
Remove the roller bearing from the rear bracket using a press, jig A and jig B.
• Removed bearing must not be reused.
SAPH311991300063
! CAUTION
• Removed bearing must not be reused.
SAPH311991300063 Inspection procedure item
Inspection procedure item
Inspection of components
Inspection of components JP31199130703002
! CAUTION
JP31199130703002
• Place a rubber mat and perform work on the
! CAUTION
mat. 1.
mat.
Inspection of stator coil and field coil (1)
1.
Measure the resistance between U-V, V-W and W-U
SAPH311991300064
Inspection of stator coil and field coil (1)
terminals of the stator coil using a circuit tester. Standard value (:)
• Place a rubber mat and perform work on the
Measure the resistance between U-V, V-W and W-U terminals of the stator coil using a circuit tester.
0.15 - 0.17
Standard value (:) SAPH311991300064
0.15 - 0.17
13–27
STARTING AND CHARGING (2)
Measure the resistance between the stator coil core and
(2)
each terminal using a megger tester. Standard value (M:)
Measure the resistance between the stator coil core and each terminal using a megger tester.
1 or more
SAPH311991300065
Standard value (M:)
1 or more
SAPH311991300065
(3)
Measure the resistance of the field coil using a circuit
(3)
tester.
! CAUTION
Measure the resistance of the field coil using a circuit tester.
Standard value (:)
6.4 - 7.0
Standard value (:)
• Do not damage the circumferential surface of
! CAUTION
the coil.
6.4 - 7.0
• Do not damage the circumferential surface of the coil.
• Damaged coil circumference must not be
• Damaged coil circumference must not be
reused.
reused.
SAPH311991300066
SAPH311991300066
(4)
Measure the resistance between the core and the coil
(4)
using a megger tester. Standard value (M:)
Measure the resistance between the core and the coil using a megger tester.
1 or more
SAPH311991300067
Standard value (M:)
1 or more
SAPH311991300067
2.
Inspection of rotor assembly (1)
2.
Measure the outer diameter of the shaft at the ball bearing
Inspection of rotor assembly (1)
insertion area of the rotor assembly using a micrometer.
SAPH311991300068
13–27
STARTING AND CHARGING
Measure the outer diameter of the shaft at the ball bearing insertion area of the rotor assembly using a micrometer.
Standard value (mm{in.})
25{0.9843}
Standard value (mm{in.})
25{0.9843}
Service limit (mm{in.})
24.98{0.9835}
Service limit (mm{in.})
24.98{0.9835}
SAPH311991300068
13â&#x20AC;&#x201C;28
13â&#x20AC;&#x201C;28
STARTING AND CHARGING (2)
STARTING AND CHARGING
Measure the outer diameter of the shaft at the roller
(2)
Measure the outer diameter of the shaft at the roller
bearing insertion area of the rotor assembly using a
bearing insertion area of the rotor assembly using a
micrometer.
micrometer.
Standard value (mm{in.})
17{0.6693}
Standard value (mm{in.})
17{0.6693}
Service limit (mm{in.})
16.98{0.6685}
Service limit (mm{in.})
16.98{0.6685}
SAPH311991300069
SAPH311991300069
3.
Inspection of diode, capacitor and regulator (1)
3.
Measure the resistance of the holder between the minus
Inspection of diode, capacitor and regulator (1)
Measure the resistance of the holder between the minus
diode and the heat sink holder using a circuit tester.
diode and the heat sink holder using a circuit tester.
Standard value
Standard value
Forward resistance value
Approx. 10 :
Forward resistance value
Approx. 10 :
Reverse resistance value
Infinite
Reverse resistance value
Infinite
SAPH311991300070
SAPH311991300070
(2)
Measure the resistance between the capacitor terminal
(2)
Measure the resistance between the capacitor terminal
and the body using a circuit tester. Make sure that it
and the body using a circuit tester. Make sure that it
indicates 800 k: and then immediately indicates infinite
indicates 800 k: and then immediately indicates infinite
value.
value.
SAPH311991300071
SAPH311991300071
(3)
Inspection of regulator
(3)
Inspection of regulator
Measure the resistance between regulator terminals F
Measure the resistance between regulator terminals F
and E using a circuit tester.
and E using a circuit tester. Standard value
Standard value
Forward resistance value
Approx. 10 :
Forward resistance value
Approx. 10 :
Reverse resistance value
Infinite
Reverse resistance value
Infinite
Overhaul item
SAPH311991300072
Overhaul item
SAPH311991300072
13–29
STARTING AND CHARGING
Assembly
Assembly JP31199130702004
! CAUTION
1.
JP31199130702004
• Place a rubber mat and perform work on the mat.
Jig C
! CAUTION
1.
Press fit a new ball bearing into the front bracket using a
Assembly of front (1)
press and jig C. ! CAUTION
Press fit a new ball bearing into the front bracket using a press and jig C.
• Place jig C at the outer race of the ball
! CAUTION
bearing. • Removed bearing must not be reused.
SAPH311991300073
(2)
• Place jig C at the outer race of the ball bearing. • Removed bearing must not be reused.
SAPH311991300073
Install the bearing cover with bolts.
(2)
Install the bearing cover with bolts.
Tightening torque :
Tightening torque :
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
SAPH311991300074
SAPH311991300074
(3)
Install the rotor assembly using a press.
! CAUTION
(3)
• Be sure to support the inner race of the
Install the rotor assembly using a press.
! CAUTION
bearing for press fit of the rotor.
SAPH311991300075
• Be sure to support the inner race of the bearing for press fit of the rotor.
• Do not damage the shaft.
• Do not damage the shaft.
SAPH311991300075
(4)
Install the space collar, fan and pulley on the shaft of the
(4)
Install the space collar, fan and pulley on the shaft of the
rotor assembly.
rotor assembly.
Tightening torque :
Tightening torque :
127 - 157 N m {1,300 - 1,600 kgf cm, 94 - 116 lbf ft}
127 - 157 N m {1,300 - 1,600 kgf cm, 94 - 116 lbf ft}
! CAUTION
• Tie around a general V –belt in the pulley
! CAUTION
groove and fix the pulley with a vice.
SAPH311991300076
• Place a rubber mat and perform work on the mat.
Jig C
Assembly of front (1)
13–29
STARTING AND CHARGING
• Tie around a general V –belt in the pulley groove and fix the pulley with a vice.
SAPH311991300076
13–30
STARTING AND CHARGING 2.
STARTING AND CHARGING
Assembly of rear (1)
Jig A
13–30
Press fit a new roller bearing into the rear bracket using a
2.
Assembly of rear (1)
Jig A
press, jig A and jig B. ! CAUTION
press, jig A and jig B.
• Press fit until jig A comes in contact with the rear bracket.
Roller bearing Jig B
Press fit a new roller bearing into the rear bracket using a
! CAUTION
• Press fit until jig A comes in contact with the rear bracket.
Roller bearing Jig B
SAPH311991300077
SAPH311991300077
(2)
Install the field coil on the rear bracket.
(2)
Install the field coil on the rear bracket.
Tightening torque :
Tightening torque :
2.9 - 3.9 N m {30 - 39 kgf cm, 2 - 3 lbf ft}
2.9 - 3.9 N m {30 - 39 kgf cm, 2 - 3 lbf ft}
! CAUTION
• Tighten bolts finally after temporary
! CAUTION
tightening. Tighten them evenly.
SAPH311991300078
tightening. Tighten them evenly.
SAPH311991300078
(3)
Assemble the stator coil on the rear bracket temporarily.
! CAUTION
(3)
• Do not damage the stator coil.
SAPH311991300079
Assemble the stator coil on the rear bracket temporarily.
! CAUTION
• Do not damage the stator coil.
SAPH311991300079
(4)
Install parts referring to the part layout.
(4)
Install parts referring to the part layout.
Tightening torque :
Tightening torque :
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
! CAUTION
SAPH311991300080
• Tighten bolts finally after temporary
• Apply screw lock to the ends of the heat sink
! CAUTION
• Apply screw lock to the ends of the heat sink
mounting bolt and the regulator mounting
mounting bolt and the regulator mounting
bolt.
bolt.
SAPH311991300080
STARTING AND CHARGING (5)
13–31
STARTING AND CHARGING
Solder the lead wire connecting the regulator and the field
(5)
13–31
Solder the lead wire connecting the regulator and the field
coil, and connecting the stator coil and the diode using a
coil, and connecting the stator coil and the diode using a
soldering bit.
soldering bit.
! CAUTION
• Perform soldering after tightening of bolts.
! CAUTION
• Bend and fix the regulator terminal before
• Bend and fix the regulator terminal before
soldering the lead wire of the field coil.
soldering the lead wire of the field coil.
• Clamp the end of the diode of the stator coil
• Clamp the end of the diode of the stator coil
before soldering.
before soldering.
• Perform soldering in a short time (within 5
SAPH311991300081
• Perform soldering after tightening of bolts.
• Perform soldering in a short time (within 5
SAPH311991300081
seconds).
seconds).
Terminal
Terminal
Lead wire
Lead wire
Regulator assembly
Regulator assembly
SAPH311991300082
SAPH311991300082
(6)
Tighten the nut inside the B terminal.
(6)
Tighten the nut inside the B terminal.
Tightening torque :
Tightening torque :
4.9 - 5.9 N m {50 - 60 kgf cm, 3.6 - 4.3 lbf ft}
4.9 - 5.9 N m {50 - 60 kgf cm, 3.6 - 4.3 lbf ft}
• After installation of the alternator, connect
NOTICE
• After installation of the alternator, connect
NOTICE
the wire and tighten the outside nut
SAPH311991300083
SAPH311991300083
3.
Joint of front and rear (1)
3.
Joint the front with the rear with bolts.
Joint of front and rear (1)
Joint the front with the rear with bolts.
Tightening torque :
Tightening torque :
7.8 - 9.8 N m {80 - 99 kgf cm, 6 - 7 lbf ft}
7.8 - 9.8 N m {80 - 99 kgf cm, 6 - 7 lbf ft}
! CAUTION
SAPH311991300084
the wire and tighten the outside nut
• Tighten bolts evenly.
! CAUTION
SAPH311991300084
• Tighten bolts evenly.
13–32
STARTING AND CHARGING (2)
13–32
STARTING AND CHARGING
Install the coupler holder and tighten bolts.
(2)
Tightening torque :
Tightening torque :
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
1.9 - 2.5 N m {20 - 25 kgf cm, 1 - 2 lbf ft}
SAPH311991300085
SAPH311991300085
(3)
Align the tab and install the cover. Fix it with bolts.
(3)
Align the tab and install the cover. Fix it with bolts.
Tightening torque :
Tightening torque :
3.3 - 4.4 N m {34 - 44 kgf cm, 2 - 3 lbf ft}
3.3 - 4.4 N m {34 - 44 kgf cm, 2 - 3 lbf ft}
! CAUTION
• Do not hit the cover because the tab may be
! CAUTION
broken.
• Do not hit the cover because the tab may be broken.
Inspection procedure item
SAPH311991300086
Install the coupler holder and tighten bolts.
Inspection procedure item
SAPH311991300086
13–33
STARTING AND CHARGING
13–33
STARTING AND CHARGING
Inspection after assembly
Inspection after assembly JP31199130703003
! CAUTION
JP31199130703003
• Place a rubber mat and perform work on the
! CAUTION
mat. 1.
mat.
Inspection of rotation (1)
• Place a rubber mat and perform work on the
1.
Turn the pulley with hand to check if there is no
Inspection of rotation (1)
interference with internal parts and if rotation is smooth.
Turn the pulley with hand to check if there is no interference with internal parts and if rotation is smooth.
SAPH311991300087
SAPH311991300087
(2)
Measure the resistance between B and E terminals and
(2)
Measure the resistance between B and E terminals and
between P and E terminals using a circuit tester. If it is
between P and E terminals using a circuit tester. If it is
beyond the standard value (e.g. 0 :), disassemble it
beyond the standard value (e.g. 0 :), disassemble it
again and reassemble the unit correctly.
again and reassemble the unit correctly.
Circuit tester lead
Circuit tester lead Standard value
SAPH311991300088
(+)
(–)
B
E
Approx. 20 :
E
B
Infinite
P
E
E
P
Standard value (+)
(–)
B
E
Approx. 20 :
E
B
Infinite
Approx.7 :
P
E
Approx.7 :
Infinite
E
P
Infinite
SAPH311991300088
B
R
L
N
P
B
R
L
N
P
E
E
Connector details
Connector details
SAPH311991300089
SAPH311991300089
TURBOCHARGER
14–1
TURBOCHARGER
ENGINE
14–1
ENGINE
14 TURBOCHARGER
14 TURBOCHARGER
Setup layout Layout
Setup layout Layout
Turbocharger Assembly........................................... 14-2 Part layout ............................................................ 14-2 Inspection ............................................................. 14-3 Replacement......................................................... 14-6
Turbocharger Assembly........................................... 14-2 Part layout ............................................................ 14-2 Inspection ............................................................. 14-3 Replacement......................................................... 14-6
14
14
14–2
14–2
TURBOCHARGER
TURBOCHARGER
Turbocharger Assembly
Turbocharger Assembly
Part layout
Part layout JP31199140402001
JP31199140402001
SAPH311991400010
SAPH311991400010
15407
Oil inlet pipe
24109
Gasket*
15407
Oil inlet pipe
24109
Gasket*
16691
Coolant pipe
24109A
Gasket*
16691
Coolant pipe
24109A
Gasket*
16691A
Coolant pipe
24135
Gasket*
16691A
Coolant pipe
24135
Gasket*
17291
Exhaust manifold connector
24135A
Gasket*
17291
Exhaust manifold connector
24135A
Gasket*
24100
Turbocharger assembly
9654-12100
Gasket*
24100
Turbocharger assembly
9654-12100
Gasket*
24107
Oil outlet pipe
9659A
Gasket*
24107
Oil outlet pipe
9659A
Gasket*
*Parts not to be reused.
*Parts not to be reused.
Tightening torque 9209A
Tightening torque
56 N m {570 kgf cm, 41lbf ft}
9209A Maintenance List of maintenance inspection inspection (preventive service)
56 N m {570 kgf cm, 41lbf ft} Maintenance List of maintenance inspection inspection (preventive service)
14–3
TURBOCHARGER
14–3
TURBOCHARGER
Inspection
Inspection JP31199140501001
1.
JP31199140501001
Inspection of turbine shaft axial play (1)
(2)
1.
Inspect play of the turbine shaft at the exhaust side using
Inspection of turbine shaft axial play (1)
a special tool.
Special tool : 09444-1800 Tool assembly
Special tool : 09444-1800 Tool assembly
If the measurement value is beyond the standard value,
(2)
ask the manufacturer to overhaul the unit. Standard value SAPH311991400002
(mm{in.}) NOTICE
Axial direction Radial direction
0.1 {0.0039}
Standard value SAPH311991400002
1.0 {0.0393}
• Since the assembly is replaced, disassembly
(mm{in.}) NOTICE
Axial direction
0.1 {0.0039}
Radial direction
1.0 {0.0393}
• Since the assembly is replaced, disassembly and inspection are not allowed.
Inspection procedure with special tool (1)
If the measurement value is beyond the standard value, ask the manufacturer to overhaul the unit.
and inspection are not allowed. 2.
Inspect play of the turbine shaft at the exhaust side using
a special tool.
2.
Remove dial gauge (key No. 1), loosen the bolt (key No.
Inspection procedure with special tool (1)
Remove dial gauge (key No. 1), loosen the bolt (key No.
13) of the guide (key No. 13) and turn the guide (key No.
13) of the guide (key No. 13) and turn the guide (key No.
2) 90q. Put the dial gauge into the plate (key No. 8) which
2) 90q. Put the dial gauge into the plate (key No. 8) which
is inspected for axial play, and tighten the bolt (key No.
is inspected for axial play, and tighten the bolt (key No.
19) for fixing.
19) for fixing.
SAPH311991400003
SAPH311991400003
Bolt
Bolt SAPH311991400004
SAPH311991400004
(2) Guide
SAPH311991400005
Insert the guide (key No. 9) to preventment horizontal movement of the measuring instrument.
(2) Guide
SAPH311991400005
Insert the guide (key No. 9) to preventment horizontal movement of the measuring instrument.
14â&#x20AC;&#x201C;4
TURBOCHARGER (3)
14â&#x20AC;&#x201C;4
TURBOCHARGER
When the guide (key No. 9) is fixed, move the bar (key
(3)
No. 4) vertically and fix the guide (key No. 9) with the
No. 4) vertically and fix the guide (key No. 9) with the
stopper (key No. 10) so that the needle of the dial gauge
stopper (key No. 10) so that the needle of the dial gauge
may come at the center.
may come at the center.
SAPH311991400006
SAPH311991400006
(4)
Hold the puller (key No. 5) and press it toward the turbine
(4)
in the axial direction. Set the dial gauge reading to 0.
0 point adjustment
SAPH311991400007
SAPH311991400007
(5)
Pull it to the opposite side and measure movement in the
(6)
Take three measurements and use the average value as
Hold the puller (key No. 5) and press it toward the turbine in the axial direction. Set the dial gauge reading to 0.
0 point adjustment
(5)
Pull it to the opposite side and measure movement in the
(6)
Take three measurements and use the average value as
axial direction.
axial direction.
the measurement value.
SAPH311991400008
When the guide (key No. 9) is fixed, move the bar (key
the measurement value.
SAPH311991400008
14–5
TURBOCHARGER
Special Tool Details
Key No. Assembly
14–5
TURBOCHARGER
Special Tool Details
Part name
Key No.
Key No.
Part name
Tool assembly
10
Stopper
1
Gauge (dial gauge)
11
Bolt
2
Guide
12
Sleeve
3
Stopper
13
4
Bar
14
5
Puller
6
Sleeve
7 8 9
Assembly
Part name
Key No.
Part name
Tool assembly
10
Stopper
1
Gauge (dial gauge)
11
Bolt
2
Guide
12
Sleeve
Bolt
3
Stopper
13
Bolt
Bolt
4
Bar
14
Bolt
15
Bolt
5
Puller
15
Bolt
16
Hook
6
Sleeve
16
Hook
Plate
17
Snap ring (cotter pin)
7
Plate
17
Snap ring (cotter pin)
Plate
18
Bar (spring)
8
Plate
18
Bar (spring)
Guide
19
Bolt
9
Guide
19
Bolt
SAPH311991400009 Service procedure Replacement procedure item
SAPH311991400009 Service procedure Replacement procedure item
14–6
14–6
TURBOCHARGER
Replacement
TURBOCHARGER
Replacement JP31199140704001
1.
Removal
JP31199140704001
1.
Removal
(1)
Remove the boost pipe and U-turn pipe.
(1)
Remove the boost pipe and U-turn pipe.
(2)
Disconnect all pipes connected to the turbocharger.
(2)
Disconnect all pipes connected to the turbocharger.
! CAUTION
• Loosen union bolt of the coolant pipe, drain
! CAUTION
coolant and remove the pipe. Disconnect the
lower pipe similarly and remove the oil pipe.
lower pipe similarly and remove the oil pipe.
• After removing pipes, be sure to seal oil
(3)
• After removing pipes, be sure to seal oil
holes, water holes and cylinder block holes
holes, water holes and cylinder block holes
to prevent entry of dirt.
to prevent entry of dirt.
Remove the bolts fixing the exhaust pipe and the
(3)
Remove the bolts fixing the exhaust pipe and the
turbocharger and remove the turbocharger. ! CAUTION
2.
• After removal, seal holes both at the exhaust
turbocharger and remove the turbocharger. ! CAUTION
manifold and the exhaust pipe to prevent
entry of foreign matter.
entry of foreign matter.
• If a stud bolt is sticking, remove and replace
• If a stud bolt is sticking, remove and replace
the stud bolt using a commercially available
the stud bolt using a commercially available
stud remover.
stud remover.
Install the turbocharger in the reverse order of
2.
Installation (1)
Install the turbocharger in the reverse order of
disassembly. When the turbocharger is installed on the
disassembly. When the turbocharger is installed on the
engine or after installation, observe the following
engine or after installation, observe the following
precautions for work. Pay special attention to entry of
precautions for work. Pay special attention to entry of
foreign matter inside the turbocharger.
foreign matter inside the turbocharger.
Tightening torque :
Tightening torque :
56 N m {570 kgf cm, 41 lbf ft}
56 N m {570 kgf cm, 41 lbf ft}
(Turbocharger to exhaust manifold) (2)
Lubrication and cooling system a.
Before installation on the engine, pour new engine oil
(Turbocharger to exhaust manifold) (2)
Lubrication and cooling system a.
from the oil inlet and turn the turbocharger with hand to Clean the oil pipe, oil hose, coolant pipe and hose.
lubricate the journal bearing and the thrust bearing. b.
Check for pipe deformation, hose crack or dirt or Do not use sealant at the installation surface of the oil
Clean the oil pipe, oil hose, coolant pipe and hose. Check for pipe deformation, hose crack or dirt or
foreign matter in the pipe or hose. c.
Before installation on the engine, pour new engine oil from the oil inlet and turn the turbocharger with hand to
lubricate the journal bearing and the thrust bearing. b.
• After removal, seal holes both at the exhaust
manifold and the exhaust pipe to prevent
Installation (1)
• Loosen union bolt of the coolant pipe, drain
coolant and remove the pipe. Disconnect the
foreign matter in the pipe or hose. c.
Do not use sealant at the installation surface of the oil
pipe and the coolant pipe or joint between the coolant
pipe and the coolant pipe or joint between the coolant
hose and the coolant pipe to prevent failures such as
hose and the coolant pipe to prevent failures such as
damage due to clogging or loosening of tightened
damage due to clogging or loosening of tightened
areas.
areas.
d.
Be sure to use new soft washers, O-rings and gaskets.
d.
Be sure to use new soft washers, O-rings and gaskets.
e.
Be sure to install the oil pipe, oil hose, coolant pipe and
e.
Be sure to install the oil pipe, oil hose, coolant pipe and
coolant hose correctly to prevent leak of oil or water
coolant hose correctly to prevent leak of oil or water
from connections.
from connections.
TURBOCHARGER (3)
14â&#x20AC;&#x201C;7
Air intake system a.
TURBOCHARGER (3)
Make sure that there is no dirt or foreign matter in the
Air intake system a.
air intake system. b.
c.
Do not use sealant at the inlet/outlet of air to prevent
b.
failures such as damage due to clogging or loosening of
tightened areas.
tightened areas.
Be sure to install the air feed pipe and the air hose
c.
Make sure that there is no dirt or foreign matter in the Since heat resistant steel is used for bolts and nuts, do not mix them with normal bolts for installation.
Be sure to install the air feed pipe and the air hose correctly to prevent air leak from connections.
(4)
Exhaust system a.
exhaust piping system. b.
Do not use sealant at the inlet/outlet of air to prevent
failures such as damage due to clogging or loosening of
Exhaust system a.
Make sure that there is no dirt or foreign matter in the air intake system.
correctly to prevent air leak from connections. (4)
14â&#x20AC;&#x201C;7
Make sure that there is no dirt or foreign matter in the exhaust piping system.
b.
Since heat resistant steel is used for bolts and nuts, do not mix them with normal bolts for installation.
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
16–1
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
ENGINE
16–1
ENGINE
16 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
16 FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Failure diagnosis list
Failure diagnosis list
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS .................................................................................... 16-2 Engine mechanical ............................................... 16-2 Alternator .............................................................. 16-5 Starter ................................................................... 16-6 Turbocharger......................................................... 16-7
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS .................................................................................... 16-2 Engine mechanical ............................................... 16-2 Alternator .............................................................. 16-5 Starter ................................................................... 16-6 Turbocharger......................................................... 16-7
16
16
16â&#x20AC;&#x201C;2
16â&#x20AC;&#x201C;2
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Engine mechanical
Engine mechanical JP31199160601001
Status Engine overheat (coolant)
Cause
JP31199160601001
Action
Insufficient coolant
Replenish coolant
Faulty thermostat
Status Engine overheat (coolant)
Cause
Action
Insufficient coolant
Replenish coolant
Replace thermostat
Faulty thermostat
Replace thermostat
Water leak from cooling system
Correction
Water leak from cooling system
Correction
Faulty coolant pump
Repair or replace
Faulty coolant pump
Repair or replace
Faulty head gasket
Replace head gasket
Faulty head gasket
Replace head gasket
Engine overheat
Clogging of radiator
Cleaning of radiator
Engine overheat
Clogging of radiator
Cleaning of radiator
(radiator)
Corrosion of cooling system
Clean and repair cooling system
(radiator)
Corrosion of cooling system
Clean and repair cooling system
Clogging of radiator core front part
Clean radiator
Clogging of radiator core front part
Clean radiator
Faulty radiator cap
Replace radiator cap
Faulty radiator cap
Replace radiator cap
Engine overheat (compression
Non-synchronous injection timing
Injection timing inspection
Engine overheat (compression
Non-synchronous injection timing
Injection timing inspection
pressure)
Faulty fuel injection pressure
Injection pressure inspection
pressure)
Faulty fuel injection pressure
Injection pressure inspection
Faulty fuel
Replace with correct fuel
Faulty fuel
Replace with correct fuel
Faulty injector
Replace injector
Faulty injector
Replace injector
Engine overheat (lubrication
Deterioration of engine oil
Replace engine oil
Engine overheat (lubrication
Deterioration of engine oil
Replace engine oil
unit)
Faulty oil pump
Replace oil pump
unit)
Faulty oil pump
Replace oil pump
Insufficient engine oil
Replenish engine oil
Insufficient engine oil
Replenish engine oil
Large engine oil consumption
Wear of piston ring and cylinder
Replace piston ring and cylinder
Large engine oil consumption
Wear of piston ring and cylinder
Replace piston ring and cylinder
(piston, cylinder liner and piston
liner
liner
(piston, cylinder liner and piston
liner
liner
ring)
Damage to piston ring
Replace piston ring and cylinder
ring)
Damage to piston ring
Replace piston ring and cylinder
liner Faulty fixing of piston ring
liner
Replace piston ring and cylinder
Faulty fixing of piston ring
liner Faulty assembly of piston ring
Replace piston ring and cylinder liner
Replace piston ring and cylinder
Faulty assembly of piston ring
liner
Replace piston ring and cylinder liner
Faulty engine oil
Replace engine oil
Faulty engine oil
Replace engine oil
Faulty piston ring joint
Reassemble piston ring
Faulty piston ring joint
Reassemble piston ring
Large engine oil consumption
Wear of valve stem
Replace valve and valve guide
Large engine oil consumption
Wear of valve stem
Replace valve and valve guide
(valve and valve guide)
Wear of valve guide
Replace valve guide
(valve and valve guide)
Wear of valve guide
Replace valve guide
Faulty assembly of valve stem seal
Replace stem seal
Faulty assembly of valve stem seal
Replace stem seal
Excessive oil lubrication to rocker
Inspection of clearance between
Excessive oil lubrication to rocker
Inspection of clearance between
arm
rocker arm and rocker arm shaft
arm
rocker arm and rocker arm shaft
Large engine oil consumption
Faulty oil level gauge
Replace with correct level gauge
Large engine oil consumption
Faulty oil level gauge
Replace with correct level gauge
(others)
Excessive filling of engine oil
Fill with appropriate amount of oil.
(others)
Excessive filling of engine oil
Fill with appropriate amount of oil.
Leak of engine oil
Repair or replace the part of oil
Leak of engine oil
Repair or replace the part of oil
leak. Piston seizure (in operation)
Sudden stop of engine
Perform warm-up before stop of
leak. Piston seizure (in operation)
Sudden stop of engine
engine Piston seizure (lubrication unit)
Insufficient engine oil
Replenish engine oil
Deterioration of engine oil
Perform warm-up before stop of engine
Piston seizure (lubrication unit)
Insufficient engine oil
Replenish engine oil
Replace engine oil
Deterioration of engine oil
Replace engine oil
Incorrect engine oil
Replace with correct engine oil.
Incorrect engine oil
Replace with correct engine oil.
Low oil pressure
Inspection of lubrication unit
Low oil pressure
Inspection of lubrication unit
Faulty oil pump
Replace oil pump
Faulty oil pump
Replace oil pump
16â&#x20AC;&#x201C;3
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status
Cause
16â&#x20AC;&#x201C;3
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Action
Status
Cause
Action
Piston seizure
Abnormal combustion
Refer to overheat section.
Piston seizure
Abnormal combustion
Refer to overheat section.
Piston seizure
Cooling unit
Refer to overheat section.
Piston seizure
Cooling unit
Refer to overheat section.
Insufficient engine power (air
Clogging of air cleaner element
Clean or replace air cleaner
Insufficient engine power (air
Clogging of air cleaner element
Clean or replace air cleaner
element
cleaner)
cleaner)
element
Insufficient engine power
Overheat
Refer to overheat section.
Insufficient engine power
Overheat
Refer to overheat section.
Insufficient engine power (fuel
Faulty injection of injector
Replace injector
Insufficient engine power (fuel
Faulty injection of injector
Replace injector
unit)
Faulty injector due to deposit of
Replace injector
unit)
Faulty injector due to deposit of
Replace injector
carbon
carbon
Entry of air into fuel system
Air bleeding of fuel system
Entry of air into fuel system
Air bleeding of fuel system
Faulty fuel filter
Replace element
Faulty fuel filter
Replace element
Faulty fuel
Replace with correct fuel
Faulty fuel
Replace with correct fuel
Insufficient engine power
Abnormal compression pressure
Refer to overheat section.
Insufficient engine power
Abnormal compression pressure
Refer to overheat section.
Insufficient engine power
Piston, cylinder liner and piston
Refer to overheat section.
Insufficient engine power
Piston, cylinder liner and piston
Refer to overheat section.
ring Faulty engine start (electric unit)
ring
Faulty battery
Check battery
Faulty wiring of starter Loose battery cable
Faulty engine start (electric unit)
Faulty battery
Check battery
Replace starter wiring
Faulty wiring of starter
Replace starter wiring
Tighten battery terminal connection
Loose battery cable
Tighten battery terminal connection
or replace cable
Faulty engine start (air cleaner)
or replace cable
Faulty operation of starter
Replace starter assembly
Faulty operation of starter
Replace starter assembly
Faulty start assist unit
Replace start assist unit
Faulty start assist unit
Replace start assist unit
Clogging of air cleaner element
Clean or replace air cleaner
Clogging of air cleaner element
Clean or replace air cleaner
Faulty engine start (air cleaner)
element Faulty engine start (fuel unit)
Insufficient fuel
Replenish fuel and bleed air from
element Faulty engine start (fuel unit)
Insufficient fuel
fuel system
fuel system
Clogging of fuel system
Clean fuel system.
Clogging of fuel system
Clean fuel system.
Air intake from connection of fuel
Tighten connections
Air intake from connection of fuel
Tighten connections
system
system
Clogging of fuel filter
Replace fuel filter
Clogging of fuel filter
Replace fuel filter
Loose connection of injection pipe
Tighten connecting nut of injection
Loose connection of injection pipe
Tighten connecting nut of injection
pump Faulty engine start (injector)
Injector seizure
Faulty engine start (lubrication
Excessive viscosity of engine oil
unit) Faulty engine start (others)
Piston seizure
pump
Replace injector
Faulty engine start (injector)
Injector seizure Excessive viscosity of engine oil
Replace with engine oil with correct
Faulty engine start (lubrication
viscosity
unit)
Replace piston, piston ring and
Faulty engine start (others)
Replace injector Replace with engine oil with correct viscosity
Piston seizure
cylinder liner
Replace piston, piston ring and cylinder liner
Bearing seizure
Replace bearing and crankshaft
Bearing seizure
Replace bearing and crankshaft
Low compression pressure
Overhaul engine
Low compression pressure
Overhaul engine
Damage to ring gear
Replace ring gear and replace
Damage to ring gear
Replace ring gear and replace
starter pinion gear. Faulty idling (injector)
Replenish fuel and bleed air from
Faulty injection pressure
Injection pressure inspection
Faulty injection status
Adjust or replace injector.
starter pinion gear. Faulty idling (injector)
Faulty injection pressure
Injection pressure inspection
Faulty injection status
Adjust or replace injector.
16â&#x20AC;&#x201C;4
16â&#x20AC;&#x201C;4
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status
Faulty idling (nozzle)
Faulty idling (engine)
Cause
Action
Faulty injection pressure
Injection pressure inspection
Faulty spray status
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status
Faulty idling (nozzle)
Cause Faulty injection pressure
Injection pressure inspection
Adjust or replace nozzle
Faulty spray status
Adjust or replace nozzle
Carbon deposit at nozzle end
Remove carbon
Carbon deposit at nozzle end
Remove carbon
Seizure of needle valve
Replace nozzle
Seizure of needle valve
Replace nozzle
Faulty valve clearance
Adjustment of valve clearance
Faulty valve clearance
Adjustment of valve clearance
Faulty contact of valve seat
Adjust or replace valve and valve
Faulty contact of valve seat
Adjust or replace valve and valve
Faulty idling (engine)
seat.
Gas leak (head gasket)
Gas leak (head bolt)
seat.
Low coolant temperature
Perform warm-up.
Low coolant temperature
Perform warm-up.
Large variation of compression
Overhaul engine
Large variation of compression
Overhaul engine
pressure between cylinders
Training of engine difference not
pressure between cylinders
Training of engine difference not
performed after exchange of the
performed after exchange of the
engine ECU
engine ECU
Training of engine difference not
Perform training of engine
Training of engine difference not
Perform training of engine
performed after exchange of the
difference after exchange of the
performed after exchange of the
difference after exchange of the
engine ECU
engine ECU
engine ECU
engine ECU
Reuse
Replace gasket.
Reuse
Replace gasket.
Damage
Replace gasket.
Damage
Replace gasket.
Replace gasket.
Replace gasket.
Replace gasket.
Replace gasket.
Loose head bolt
Tighten bolt.
Loose head bolt
Tighten bolt.
Incorrect tightening sequence or
Tighten bolt to correct torque
Incorrect tightening sequence or
Tighten bolt to correct torque
incorrect tightening torque
according to the correct tightening
incorrect tightening torque
according to the correct tightening
Gas leak (head gasket)
Gas leak (head bolt)
sequence. Gas leak (cylinder block)
Extension of head bolt
Replace bolt.
Crack
Replace cylinder block.
Distortion of cylinder block upper
Repair or replace cylinder block.
sequence. Gas leak (cylinder block)
surface Depression of cylinder liner
Gas leak (cylinder head)
Replace cylinder liner or block.
Replace bolt.
Crack
Replace cylinder block.
Distortion of cylinder block upper
Repair or replace cylinder block.
Depression of cylinder liner
insertion (insufficient protrusion of
insertion (insufficient protrusion of
cylinder liner)
cylinder liner)
Crack of cylinder head
Replace cylinder head.
Distortion of cylinder head lower
Repair or replace cylinder head.
Gas leak (cylinder head)
Crack of cylinder liner
Replace cylinder liner.
Corrosion of cylinder liner Insufficient protrusion of cylinder Incorrect injection timing
Replace cylinder liner or block.
Crack of cylinder head
Replace cylinder head.
Distortion of cylinder head lower
Repair or replace cylinder head.
surface Gas leak (cylinder liner)
Crack of cylinder liner
Replace cylinder liner.
Replace cylinder liner.
Corrosion of cylinder liner
Replace cylinder liner.
Replace cylinder liner or block.
Insufficient protrusion of cylinder
Replace cylinder liner or block.
liner Gas leak (others)
Extension of head bolt
surface
surface Gas leak (cylinder liner)
Action
liner Injection timing inspection
Gas leak (others)
Incorrect injection timing
Injection timing inspection
16â&#x20AC;&#x201C;5
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Alternator
16â&#x20AC;&#x201C;5
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Alternator JP31199160601002
Status
Cause
JP31199160601002
Action
Status
Cause
Action
Lamp is ON.oCharge current
Faulty regulator (open PTr)
Replace regulator.
Lamp is ON.oCharge current
Faulty regulator (open PTr)
Replace regulator.
does not run (alternator).
Faulty stator coil (disconnection,
Replace stator coil.
does not run (alternator).
Faulty stator coil (disconnection,
Replace stator coil.
rare shorting) Fault feed coil (disconnection, rare
rare shorting) Replace feed coil.
Fault feed coil (disconnection, rare
shorting) Faulty diode (open, shorting)
Replace rectifier.
Faulty diode (open, shorting)
Replace rectifier.
Disconnection or poor contact of
Repair or replace lead wire.
Disconnection or poor contact of
Repair or replace lead wire.
lead wire (plate, support, etc.) Lamp is ON.oCharge current
Replace feed coil.
shorting)
Disconnection of wire (fuse)
lead wire (plate, support, etc.) Replace wire (fuse).
does not run (wiring).
Lamp is ON.oCharge current
Disconnection of wire (fuse)
Replace wire (fuse).
does not run (wiring).
Lamp is ON.oVoltmeter
Faulty regulator (shorting of PTr)
Replace regulator.
Lamp is ON.oVoltmeter
Faulty regulator (shorting of PTr)
Replace regulator.
indicates 29V or more
Faulty tightening of voltage
Repair, replace voltage detection
indicates 29V or more
Faulty tightening of voltage
Repair, replace voltage detection
(alternator).
detection circuit (e.g. support)
circuit or replace regulator.
(alternator).
detection circuit (e.g. support)
circuit or replace regulator.
Lamp is ON.oCharge current is
Faulty regulator (open Tr)
Replace regulator.
Lamp is ON.oCharge current is
Faulty regulator (open Tr)
Replace regulator.
Lamp is OFF.oCharge current is
Faulty stator coil (disconnection of 1
Replace stator coil.
always limited.oBattery goes flat
phase, rare shorting)
(alternator).
Faulty diode (open, shorting)
Replace rectifier.
Disconnection or poor contact of
Repair or replace lead wire.
correctly running (alternator).
correctly running (alternator).
Lamp is OFF.oCharge current is
Faulty stator coil (disconnection of 1
Replace stator coil.
always limited.oBattery goes flat
phase, rare shorting)
(alternator).
Faulty diode (open, shorting)
Replace rectifier.
Disconnection or poor contact of
Repair or replace lead wire.
lead wire (plate, support, etc.) Lamp is OFF.oCharge current is
Operation load is large (Load
always limited.oBattery goes flat
balance is poor).
lead wire (plate, support, etc.) Reduce load
(operation load).
Lamp is OFF.oCharge current is
Operation load is large (Load
always limited.oBattery goes flat
balance is poor).
Reduce load
(operation load).
Lamp is OFF.oCharge current is
Faulty regulator (shorting of PTr)
Replace regulator.
Lamp is OFF.oCharge current is
Faulty regulator (shorting of PTr)
Replace regulator.
always large.oBattery fluid runs
Faulty tightening of voltage
Repair or replace voltage detection
always large.oBattery fluid runs
Faulty tightening of voltage
Repair or replace voltage detection
short in a short period of time
detection circuit (e.g. support)
circuit.
short in a short period of time
detection circuit (e.g. support)
circuit.
Battery is close to the service life.
Replace battery.
OthersoAbnormal noise
Faulty stator coil (rare shorting,
Replace stator coil.
(alternator)
grounding)
(alternator). Lamp is OFF.oCharge current is
(alternator). Battery is close to the service life.
Replace battery.
Lamp is OFF.oCharge current is
always large.oBattery fluid runs
always large.oBattery fluid runs
short in a short period of time
short in a short period of time
(battery).
(battery).
OthersoAbnormal noise
Faulty stator coil (rare shorting,
(alternator)
grounding) Contact of inner surface (faulty
Replace stator coil. Repair or replace bearing.
Contact of inner surface (faulty
bearing, wear of bracket) OthersoAbnormal noise (V belt)
Faulty tension of V belt (belt slip)
Repair or replace bearing.
bearing, wear of bracket) Correction
OthersoAbnormal noise (V belt)
Faulty tension of V belt (belt slip)
Correction
16â&#x20AC;&#x201C;6
16â&#x20AC;&#x201C;6
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Starter
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Starter JP31199160601003
Status
Cause
JP31199160601003
Action
Status
Cause
Action
Starter does not turn. Turning is
Faulty connection of starter key
Repair connecting area.
Starter does not turn. Turning is
Faulty connection of starter key
Repair connecting area.
low.
Flat battery
Charge or replace.
low.
Flat battery
Charge or replace.
Disconnection, loosening or
After cleaning, tighten.
Disconnection, loosening or
After cleaning, tighten.
corrosion of battery terminal
corrosion of battery terminal
Grounding wire is disconnected.
Be sure to connect it.
Grounding wire is disconnected.
Be sure to connect it.
Use of incorrect engine oil
Replace with correct oil.
Use of incorrect engine oil
Replace with correct oil.
Faulty contact of start magnet
Replace start magnet switch
Faulty contact of start magnet
Replace start magnet switch
switch assembly.
assembly
switch assembly.
assembly
Faulty contact or failure of starter
Replace starter relay.
Faulty contact or failure of starter
Replace starter relay.
relay
relay
Wear of starter brush
Replace brush
Wear of starter brush
Replace brush
Seizure of commutator
Repair commutator.
Seizure of commutator
Repair commutator.
Wear of commutator
Undercut
Wear of commutator
Undercut
Shorting of armature
Replace armature assembly
Shorting of armature
Replace armature assembly
Insufficient tension of brush spring
Replace brush spring.
Insufficient tension of brush spring
Replace brush spring.
Faulty operation of clutch
Clean or replace.
Faulty operation of clutch
Clean or replace.
16â&#x20AC;&#x201C;7
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Turbocharger
16â&#x20AC;&#x201C;7
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS
Turbocharger JP31199160601004
Status Exhaust smoke is black
Cause Clogging of air cleaner element
(insufficient intake air).
Action
JP31199160601004
Status
Clean or replace air cleaner
Exhaust smoke is black
element.
(insufficient intake air).
Cause Clogging of air cleaner element
Action Clean or replace air cleaner element.
Air intake inlet is closed.
Recover normal status.
Air intake inlet is closed.
Recover normal status.
Leak from connection of air intake
Check and repair.
Leak from connection of air intake
Check and repair.
system Revolution of blower impeller and
system Disassembly and repair.
Revolution of blower impeller and
turbine shaft is heavy
Disassembly and repair.
turbine shaft is heavy
Exhaust smoke is black
Oil impurities are deposited at the
Replace engine oil and
Exhaust smoke is black
Oil impurities are deposited at the
Replace engine oil and
(Turbocharger is not operating).
sealing part of the turbine and
disassemble the turbocharger for
(Turbocharger is not operating).
sealing part of the turbine and
disassemble the turbocharger for
revolution of the turbine shaft is heavy.
cleaning.
revolution of the turbine shaft is heavy.
cleaning.
Seizure of bearing
Replace turbocharger.
Seizure of bearing
Replace turbocharger.
Seizure of bearing (insufficient
Check the oil system of the engine
Seizure of bearing (insufficient
Check the oil system of the engine
lubrication or clogging of oil pipe)
and repair faulty areas. Also,
lubrication or clogging of oil pipe)
and repair faulty areas. Also,
replace engine oil.
replace engine oil.
Seizure of bearing (Oil temperature
Check the oil system of the engine
Seizure of bearing (Oil temperature
Check the oil system of the engine
is too high.)
and repair faulty areas. Also,
is too high.)
and repair faulty areas. Also,
replace engine oil. Seizure of bearing (Balance of
replace engine oil.
Replace or clean revolving part.
Seizure of bearing (Balance of
revolving body is poor.)
Replace or clean revolving part.
revolving body is poor.)
Seizure of bearing (insufficient
Observe the precautions strictly in
Seizure of bearing (insufficient
Observe the precautions strictly in
warm-up or sudden stop from
the operation manual.
warm-up or sudden stop from
the operation manual.
loaded operation: Unloaded
loaded operation: Unloaded
operation)
operation)
Contact of or damage to turbine
Check and repair engine parts.
Contact of or damage to turbine
shaft and blower impeller
shaft and blower impeller
(excessive operation)
(excessive operation)
Contact of or damage to turbine
Check and repair engine parts.
Contact of or damage to turbine
shaft and blower impeller
shaft and blower impeller
(excessive increase of exhaust gas
(excessive increase of exhaust gas
temperature)
temperature)
Check and repair engine parts.
Check and repair engine parts.
Contact of or damage to turbine
Disassemble the engine to remove
Contact of or damage to turbine
Disassemble the engine to remove
shaft and blower impeller (entry of
foreign matter completely. Check
shaft and blower impeller (entry of
foreign matter completely. Check
foreign matter)
and repair the air cleaner and
foreign matter)
and repair the air cleaner and
engine parts. Contact of or damage to turbine shaft
engine parts.
Replace turbocharger.
Contact of or damage to turbine shaft
and blower impeller (wear of bearing) Contact of or damage to turbine shaft
and blower impeller (wear of bearing) Reassemble or replace.
Contact of or damage to turbine shaft
and blower impeller (faulty assembly) Exhaust smoke is black (due to
Exhaust gas is leaking before the
exhaust gas resistance).
turbocharger. Revolution is not
Reassemble or replace.
and blower impeller (faulty assembly) Check and repair mounting area.
increased. Since pipe of the exhaust system is
Replace turbocharger.
Exhaust smoke is black (due to
Exhaust gas is leaking before the
exhaust gas resistance).
turbocharger. Revolution is not
Check and repair mounting area.
increased. Recover normal status.
Since pipe of the exhaust system is
deformed or clogged, revolution of
deformed or clogged, revolution of
the turbocharger is not increased.
the turbocharger is not increased.
Recover normal status.
16â&#x20AC;&#x201C;8
16â&#x20AC;&#x201C;8
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status
Exhaust smoke is white.
Cause Engine oil runs out to the blower or
Action Repair or replace pipe.
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status
Exhaust smoke is white.
Cause Engine oil runs out to the blower or
the turbine due to clogging or
the turbine due to clogging or
deformation of the oil return pipe.
deformation of the oil return pipe. Check and replace the pipe.
Negative pressure at the back of
Check and replace the pipe.
the blower impeller is increased and
Replace or clean the air cleaner
the blower impeller is increased and
Replace or clean the air cleaner
engine oil runs out to the blower.
element.
engine oil runs out to the blower.
element.
Seal ring is excessively worn or
Disassemble and repair
Seal ring is excessively worn or
Disassemble and repair
damaged due to excessive wear of
turbocharger.
damaged due to excessive wear of
turbocharger.
Entry of water into the cylinder
the bearing. Exchange or repair of the parts
Entry of water into the cylinder
where water has entered Seal ring is excessively worn or
Disassemble and repair
damaged due to excessive wear of
turbocharger.
Engine oil enters into exhaust gas
Oil is quickly reduced.
Seal ring is excessively worn or
Disassemble and repair
damaged due to excessive wear of
turbocharger.
the bearing. Check and service engine parts.
Engine oil enters into exhaust gas
before the turbocharger. Gas leak from exhaust system
Exchange or repair of the parts where water has entered
the bearing.
Low engine output
Repair or replace pipe.
Negative pressure at the back of
the bearing.
Oil is quickly reduced.
Action
Check and service engine parts.
before the turbocharger. Check and repair faulty areas.
Low engine output
parts
Gas leak from exhaust system
Check and repair faulty areas.
parts
Air leak from blower outlet
Check and repair faulty areas.
Air leak from blower outlet
Check and repair faulty areas.
Clogging of air cleaner element
Clean or replace air cleaner
Clogging of air cleaner element
Clean or replace air cleaner
element Contamination of or damage to
element
Replace turbocharger.
Contamination of or damage to
turbocharger
Replace turbocharger.
turbocharger
Acceleration (follow-up of
Carbon deposit at the turbine (disc
Replace engine oil and clean
Acceleration (follow-up of
Carbon deposit at the turbine (disc
Replace engine oil and clean
turbocharger) is poor (slow).
sealing area) makes revolution of
turbocharger.
turbocharger) is poor (slow).
sealing area) makes revolution of
turbocharger.
the turbine heavy. Air and gas leak from intake/
the turbine heavy. Check and repair faulty areas.
Air and gas leak from intake/
exhaust system parts Combustion is faulty.
exhaust system parts Check the engine fuel system and
Combustion is faulty.
recover correct combustion status. Abnormal noise
If the gas passage is extremely
Check and repair faulty areas.
Replace turbocharger.
Check the engine fuel system and recover correct combustion status.
Abnormal noise
If the gas passage is extremely
narrowed due to clogging at the
narrowed due to clogging at the
turbine case nozzle or if
turbine case nozzle or if
acceleration is performed, reverse
acceleration is performed, reverse
flow (usually called surging) occurs
flow (usually called surging) occurs
due to clogging of blower discharge
due to clogging of blower discharge
air.
air.
Replace turbocharger.
Revolving part is in contact.
Replace turbocharger.
Revolving part is in contact.
Replace turbocharger.
Air and gas leak from intake/
Check and repair faulty areas.
Air and gas leak from intake/
Check and repair faulty areas.
exhaust system parts
exhaust system parts
16â&#x20AC;&#x201C;9
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Vibration
Cause
Action
Loosening between turbocharger
Check the turbocharger mounting
and intake/exhaust pipe and
status and repair faulty areas.
between oil pipe and mounting area
16â&#x20AC;&#x201C;9
FAILURE DIAGNOSIS FOR EACH ENGINE STATUS Status Vibration
Cause
Action
Loosening between turbocharger
Check the turbocharger mounting
and intake/exhaust pipe and
status and repair faulty areas.
between oil pipe and mounting area
Failure of metal, contact between
Replace turbocharger. Remove
Failure of metal, contact between
Replace turbocharger. Remove
revolving part and peripheral parts,
foreign matter completely, if any.
revolving part and peripheral parts,
foreign matter completely, if any.
or damage to the blower impeller of
or damage to the blower impeller of
the turbine rotor due to entry of
the turbine rotor due to entry of
foreign matter is found.
foreign matter is found.
Balance of revolving body is poor.
Replace revolving body.
Balance of revolving body is poor.
Replace revolving body.
ENGINE DIAGNOSIS CODE
17â&#x20AC;&#x201C;1
ENGINE DIAGNOSIS CODE
ENGINE
ENGINE
17 ENGINE DIAGNOSIS CODE
17 ENGINE DIAGNOSIS CODE
General information
Engine ECU ............................................................... 17-2 Precautions ........................................................... 17-2 System block diagram........................................... 17-3 Inspection ............................................................. 17-4 Table of failure code .............................................. 17-5 Signal check harness............................................ 17-8 Computer pin arrangement ................................. 17-10 Check the ECU power supply voltage................. 17-11 Check the ground................................................ 17-11 Engine speed main sensor circuit malfunction (DTC code P0335) .............................................. 17-12 Engine speed sub sensor circuit malfunction (DTC code P0340) .............................................. 17-14 Engine speed main and sub sensor circuit malfunction (DTC code P0335) .............................................. 17-15 Coolant temperature sensor malfunction (DTC code P0117, P0118) ................................. 17-16 Engine overheat (DTC code P0217) .............................................. 17-17 Engine overrun (DTC code P0219) .............................................. 17-17 Fuel temperature sensor malfunction (DTC code P0182, P0183) ................................. 17-18 Boost pressure sensor malfunction (DTC code P0108, P0237) ................................. 17-19 Turbocharger over boost (DTC code P0234) .............................................. 17-21 Excessive common rail pressure (DTC code P0088) .............................................. 17-21 Excessive common rail pressure, supply pump excess forced feed (DTC code P0088) ........................... 17-22 Common rail pressure sensor malfunction (DTC code P0191) .............................................. 17-23 Common rail pressure sensor malfunction (DTC code P0192, P0193) ................................. 17-24 Accelerator sensor 1 malfunction (DTC code P2122, P2123) ................................. 17-26 Accelerator sensor 2 malfunction (DTC code P2127, P2128) ................................. 17-28 Accelerator sensor 1 and 2 malfunction (DTC code P2120) .............................................. 17-30 Emergency accelerator sensor malfunction (DTC code P1133) .............................................. 17-31 Atmospheric pressure sensor malfunction (DTC code P2228, P2229) ................................. 17-33
17â&#x20AC;&#x201C;1
General information
Injector common 1 ground short (DTC code P1211), Injector common 2 ground short (DTC code P1214) .............................................. 17-34 Injector common 1 power source line short (DTC code P1212), Injector common 2 power source line short (DTC code P1215) .............................................. 17-36 Injector circuit malfunction (DTC code P0201 to P0204)............................... 17-38 Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272) ....... 17-41 Supply pump SCV malfunction (DTC code P0628, P0629).................................. 17-43 Supply pump SCV sticking (DTC code P2635), Supply pump malfunction (DTC code P2635), Supply pump abnormal pressure record (DTC code P2635) .............................................. 17-45 Preheat circuit malfunction (DTC code P0540) .............................................. 17-46 Injector correction data conformity error (DTC code P1601) ............................................. 17-47 ECU internal error (DTC code P0605, P0606, P0607) ..................... 17-47 ECU charge circuit malfunction (DTC code P0200, P0611).................................. 17-48 Main relay malfunction (DTC code P0686) .............................................. 17-49 Starter signal malfunction (DTC code P0617) .............................................. 17-49
17
Engine ECU ............................................................... 17-2 Precautions ........................................................... 17-2 System block diagram........................................... 17-3 Inspection ............................................................. 17-4 Table of failure code .............................................. 17-5 Signal check harness............................................ 17-8 Computer pin arrangement ................................. 17-10 Check the ECU power supply voltage................. 17-11 Check the ground................................................ 17-11 Engine speed main sensor circuit malfunction (DTC code P0335) .............................................. 17-12 Engine speed sub sensor circuit malfunction (DTC code P0340) .............................................. 17-14 Engine speed main and sub sensor circuit malfunction (DTC code P0335) .............................................. 17-15 Coolant temperature sensor malfunction (DTC code P0117, P0118) ................................. 17-16 Engine overheat (DTC code P0217) .............................................. 17-17 Engine overrun (DTC code P0219) .............................................. 17-17 Fuel temperature sensor malfunction (DTC code P0182, P0183) ................................. 17-18 Boost pressure sensor malfunction (DTC code P0108, P0237) ................................. 17-19 Turbocharger over boost (DTC code P0234) .............................................. 17-21 Excessive common rail pressure (DTC code P0088) .............................................. 17-21 Excessive common rail pressure, supply pump excess forced feed (DTC code P0088) ........................... 17-22 Common rail pressure sensor malfunction (DTC code P0191) .............................................. 17-23 Common rail pressure sensor malfunction (DTC code P0192, P0193) ................................. 17-24 Accelerator sensor 1 malfunction (DTC code P2122, P2123) ................................. 17-26 Accelerator sensor 2 malfunction (DTC code P2127, P2128) ................................. 17-28 Accelerator sensor 1 and 2 malfunction (DTC code P2120) .............................................. 17-30 Emergency accelerator sensor malfunction (DTC code P1133) .............................................. 17-31 Atmospheric pressure sensor malfunction (DTC code P2228, P2229) ................................. 17-33
Injector common 1 ground short (DTC code P1211), Injector common 2 ground short (DTC code P1214) .............................................. 17-34 Injector common 1 power source line short (DTC code P1212), Injector common 2 power source line short (DTC code P1215) .............................................. 17-36 Injector circuit malfunction (DTC code P0201 to P0204)............................... 17-38 Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272) ....... 17-41 Supply pump SCV malfunction (DTC code P0628, P0629).................................. 17-43 Supply pump SCV sticking (DTC code P2635), Supply pump malfunction (DTC code P2635), Supply pump abnormal pressure record (DTC code P2635) .............................................. 17-45 Preheat circuit malfunction (DTC code P0540) .............................................. 17-46 Injector correction data conformity error (DTC code P1601) ............................................. 17-47 ECU internal error (DTC code P0605, P0606, P0607) ..................... 17-47 ECU charge circuit malfunction (DTC code P0200, P0611).................................. 17-48 Main relay malfunction (DTC code P0686) .............................................. 17-49 Starter signal malfunction (DTC code P0617) .............................................. 17-49
17
17–2
17–2
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Engine ECU
Engine ECU
Precautions
Precautions JP31199170102001
! CAUTION
JP31199170102001
• Make sure that each connector is connected
! CAUTION
before inspection.
before inspection.
• Do not place a tester rod on the connecting
• Do not place a tester rod on the connecting
surface of the connector. Otherwise,
surface of the connector. Otherwise,
terminals are damaged or short-circuited.
terminals are damaged or short-circuited.
• Delete the past failure memory after
• Delete the past failure memory after
recording. Perform failure diagnosis again to
recording. Perform failure diagnosis again to
check current failure.
check current failure.
• After failure analysis, delete the past failure
• After failure analysis, delete the past failure
memory. If the past failure memory is not
memory. If the past failure memory is not
deleted, the failure indicator lamp remains
deleted, the failure indicator lamp remains
ON.
ON.
• All connector drawings are viewed from the
• All connector drawings are viewed from the
connecting surface. Place the tester rod from SAPH311991700001
the back. System drawing
• Make sure that each connector is connected
connecting surface. Place the tester rod from SAPH311991700001
the back. System drawing
17â&#x20AC;&#x201C;3
ENGINE DIAGNOSIS CODE
17â&#x20AC;&#x201C;3
ENGINE DIAGNOSIS CODE
System block diagram
System block diagram JP31199170803001
ACT Relay
JP31199170803001
ACT Relay
Fuse
Each Sensor Power
Fuse
Each Sensor Power
Main relay
Key switch signal
Fuse
Main relay
Key switch signal
Starter signal -
+
Battery
Accelerator signal 1,2
Fuse
Starter signal -
+
Battery
Accelerator signal 1,2
Diagnosis tool
Diagnosis switch Accelerator sensor for operation
Diagnosis tool
Diagnosis switch Accelerator sensor for operation
I/F
Engine speed main sensor
I/F
Engine speed main sensor
Engine speed sub sensor
Engine speed sub sensor
PC Diagnosis tool
OUTPUT
OUTPUT
PC Diagnosis tool
Glow relay
Glow relay
INPUT
INPUT
Injector drive signal
Injector drive signal Supply pump
Supply pump Supply pump control valve drive signal
Supply pump control valve drive signal Supply pump drive signal
S/P
Supply pump drive signal
Others
Others Fuel temperature sensor (Supply pump)
Fuel temperature sensor (Supply pump)
Boost pressure sensor
Boost pressure sensor
Common rail pressure sensor1 Common rail pressure sensor2
S/P
Engine ECU
Common rail
Common rail pressure sensor1
Water temperature sensor
Common rail pressure sensor2
Engine ECU
Common rail
T
Water temperature sensor
T
Engine
Engine P
P
SAPH311991700002
SAPH311991700002 Service procedure Inspection procedure item
Service procedure Inspection procedure item
17â&#x20AC;&#x201C;4
17â&#x20AC;&#x201C;4
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Inspection
Inspection JP31199170703001
1.
JP31199170703001
Pre-inspection (1)
1.
If an error occurs on the system, The DTC code is
Pre-inspection (1)
If an error occurs on the system, The DTC code is
indicated in the console panel. (2)
Reading of failure code a.
(2)
Connection of HinoDX
a.
seat and connect the failure diagnosis connector
seat and connect the failure diagnosis connector
with a PC which installed HinoDX through the
with a PC which installed HinoDX through the interface box.
Engine ECU
Failure diagnosis connector
SAPH311991700003
SAPH311991700003
Special tool : 09121-1040 Hino-Bowie (Interface
Failure diagnosis connector
box)
Special tool : 09121-1040 Hino-Bowie (Interface
Failure diagnosis connector
box)
09042-1220 Connecting cable
09042-1220 Connecting cable
CD-ROM HinoDX
CD-ROM HinoDX
Hino-Bowie
Hino-Bowie
Connecting cable
Connect to the failure diagnosis connector at the unit side.
SAPH311991700004
Connecting cable SAPH311991700004
2.
Deletion method of past failure (1)
2.
To delete past failures of the engine ECU, use HinoDX on
Deletion method of past failure (1)
the PC. (Refer to "HinoDX operation manual".)
To delete past failures of the engine ECU, use HinoDX on the PC. (Refer to "HinoDX operation manual".)
Failure List of failure diagnosis diagnosis
SAPH311991700005
Connection of HinoDX 1. Remove the left side cover at the rear of the driver's
Failure diagnosis connector
Connect to the failure diagnosis connector at the unit side.
Reading of failure code
1. Remove the left side cover at the rear of the driver's
interface box.
Engine ECU
indicated in the console panel.
Failure List of failure diagnosis diagnosis
SAPH311991700005
ENGINE DIAGNOSIS CODE
17–5
Table of failure code
ENGINE DIAGNOSIS CODE
Table of failure code JP31199170601001
NOTICE
• For the system status by indication of DTC code in the table, refer to "1. Pre-inspection,
JP31199170601001
NOTICE
• For the system status by indication of DTC code in the table, refer to "1. Pre-inspection,
Inspection, Engine ECU".
Inspection, Engine ECU".
"Reference : Inspection, Engine ECU, Engine diagnosis code"
"Reference : Inspection, Engine ECU, Engine diagnosis code"
[a] Failure diagnosis and [b] Alarm display (alarm status) a. Engine does not start
DTC code P0335
Estimated failure cause Engine speed main sensor circuit malfunction
Engine stopped. b. DTC code indication.
P0606
CPU malfunction (Hard detection)
P0629
Supply pump SCV malfunction (Power source line short)
a. Low output
P0200
ECU charge circuit high input
P0611
ECU charge circuit low input
b. DTC code indication. a. Low output (LOW idle 800rpm
P2120
Page
17-12
[a] Failure diagnosis and [b] Alarm display (alarm status) a. Engine does not start
DTC code P0335
17-47 b. DTC code indication. 17-43 17-48 17-48
b. DTC code indication.
Engine speed main sensor circuit
P0606
CPU malfunction (Hard detection)
P0629
Supply pump SCV malfunction (Power source line short)
a. Low output
P0200
ECU charge circuit high input
P0611
ECU charge circuit low input
P2120
Accelerator sensor 1 and 2 malfunction
b. DTC code indication. a. Low output (LOW idle 800rpm
17-30
Estimated failure cause
malfunction
Engine stopped.
Accelerator sensor 1 and 2 malfunction
fixing)
a. Low output
fixing)
P0217
Engine overheat
a. Low output
P0217
17-47 17-43 17-48 17-48
Engine overheat 17-17
b. DTC code indication. P0540
Preheat circuit malfunction
a. Difficult to start engine.
P0540
Preheat circuit malfunction
17-46 b. DTC code indication.
b. DTC code indication.
17-12
b. DTC code indication.
b. DTC code indication.
a. Low output
Page
17-30
17-17
a. Difficult to start engine.
17–5
17-46 b. DTC code indication.
P0234
Turbocharger over boost
17-21
P0088
Excessive common rail pressure
17-21
P0088
Excessive common rail pressure, supply pump excess forced feed
P0108
Boost pressure sensor circuit high input
P0117
Coolant temperature sensor circuit low input
P0118
Coolant temperature sensor circuit high input
P0191
Common rail pressure sensor malfunction
P0192
Common rail pressure sensor circuit low input
P0193
Common rail pressure sensor circuit high input
a. Low output b. DTC code indication.
17-22 17-19 17-16
17-16 17-23 17-24
17-24
P0234
Turbocharger over boost
17-21
P0088
Excessive common rail pressure
17-21
P0088
Excessive common rail pressure, supply pump excess forced feed
P0108
Boost pressure sensor circuit high input
P0117
Coolant temperature sensor circuit low input
P0118
Coolant temperature sensor circuit high input
P0191
Common rail pressure sensor malfunction
P0192
Common rail pressure sensor circuit low input
P0193
Common rail pressure sensor circuit high input
17-22 17-19 17-16
17-16 17-23 17-24
17-24
P0201
Injector circuit malfunction -cylinder 1
17-38
P0201
Injector circuit malfunction -cylinder 1
17-38
P0202
Injector circuit malfunction -cylinder 2
17-38
P0202
Injector circuit malfunction -cylinder 2
17-38
17â&#x20AC;&#x201C;6
[a] Failure diagnosis and [b] Alarm display (alarm status) a. Low output b. DTC code indication.
DTC code
Estimated failure cause Injector circuit malfunction -cylinder 3
17-38
P0204
Injector circuit malfunction -cylinder 4
17-38
P0237
Boost pressure sensor circuit low input
17-19
P0605
Flash ROM error
P0607
Monitoring IC malfunction in CPU Supply pump SCV malfunction (Full discharge mode)
[a] Failure diagnosis and [b] Alarm display (alarm status)
ENGINE DIAGNOSIS CODE
DTC code
Estimated failure cause
Page
P0203
Injector circuit malfunction -cylinder 3
17-38
P0204
Injector circuit malfunction -cylinder 4
17-38
P0237
Boost pressure sensor circuit low input
17-19
17-47
P0605
Flash ROM error
17-47
17-47
P0607
Monitoring IC malfunction in CPU
17-47
a. Low output b. DTC code indication.
P0628
17-43
Supply pump SCV malfunction (Full discharge mode)
17-43
P1211
Injector common 1 ground short
17-34
P1211
Injector common 1 ground short
17-34
P1212
Injector common 1 power source line short
17-36
P1212
Injector common 1 power source line short
17-36
P1212
Injector common 1 open circuit
17-36
P1212
Injector common 1 open circuit
17-36
P1214
Injector common 2 ground short
17-34
P1214
Injector common 2 ground short
17-34
P1215
Injector common 2 power source line short
17-36
P1215
Injector common 2 power source line short
17-36
P1215
Injector common 2 open circuit
17-36
P1215
Injector common 2 open circuit
17-36
P1601
Injector correction data conformity error
17-47
P1601
Injector correction data conformity error
17-47
P2228
Atmospheric pressure sensor circuit low
P2228
Atmospheric pressure sensor circuit low
input P2229
Atmospheric pressure sensor circuit high input
b. DTC code indication.
Page
P0203
P0628
a. Other problems
17â&#x20AC;&#x201C;6
ENGINE DIAGNOSIS CODE
17-33
input P2229
17-33
Atmospheric pressure sensor circuit high input
17-33
17-33
P2635
Supply pump SCV sticking
17-45
P2635
Supply pump SCV sticking
17-45
P2635
Supply pump malfunction
17-45
P2635
Supply pump malfunction
17-45
P0182
Fuel temperature sensor circuit low input
17-18
P0182
Fuel temperature sensor circuit low input
17-18
P0183
Fuel temperature sensor circuit high input
17-18
P0183
Fuel temperature sensor circuit high input
17-18
P0340
Engine speed sub sensor circuit
P0340
Engine speed sub sensor circuit
malfunction
a. Other problems b. DTC code indication.
17-14
malfunction
17-14
P0686
Main relay malfunction
17-49
P0686
Main relay malfunction
17-49
P2122
Accelerator sensor circuit 1 low voltage
17-26
P2122
Accelerator sensor circuit 1 low voltage
17-26
P2123
Accelerator sensor circuit 1 high voltage
17-26
P2123
Accelerator sensor circuit 1 high voltage
17-26
P2127
Accelerator sensor circuit 2 low voltage
17-28
P2127
Accelerator sensor circuit 2 low voltage
17-28
P2128
Accelerator sensor circuit 2 high voltage
17-28
P2128
Accelerator sensor circuit 2 high voltage
17-28
P1133
Emergency accelerator sensor malfunction
P1133
Emergency accelerator sensor malfunction
high input
17-31
high input
17-31
17â&#x20AC;&#x201C;7
ENGINE DIAGNOSIS CODE
[a] Failure diagnosis and [b] Alarm display (alarm status) a. Other problems b. No indication
DTC code
Estimated failure cause
Page
P0219
Engine overrun
17-17
P0263
Cylinder 1 contribution/balance fault
17-41
P0266
Cylinder 2 contribution/balance fault
17-41
P0269
Cylinder 3 contribution/balance fault
P0272
17â&#x20AC;&#x201C;7
ENGINE DIAGNOSIS CODE
[a] Failure diagnosis and [b] Alarm display (alarm status)
DTC code
Estimated failure cause
Page
P0219
Engine overrun
17-17
P0263
Cylinder 1 contribution/balance fault
17-41
P0266
Cylinder 2 contribution/balance fault
17-41
17-41
P0269
Cylinder 3 contribution/balance fault
17-41
Cylinder 4 contribution/balance fault
17-41
P0272
Cylinder 4 contribution/balance fault
17-41
P0617
Starter signal malfunction
17-49
P0617
Starter signal malfunction
17-49
P2635
Supply pump abnormal pressure record
17-45
P2635
Supply pump abnormal pressure record
17-45
U1001
Interruption of CAN communication (unit)
-
U1001
Interruption of CAN communication (unit)
Function, movement Description of function and operation
a. Other problems b. No indication
Function, movement Description of function and operation
-
17–8
17–8
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Signal check harness
Signal check harness JP31199170301001
1.
JP31199170301001
Signal check harness
! CAUTION
NOTICE
1.
• When measuring terminal of the engine ECU,
! CAUTION
• When measuring terminal of the engine ECU,
connect the signal check harness to prevent
connect the signal check harness to prevent
damage to the connector. Place the tester rod
damage to the connector. Place the tester rod
on the contact box of the signal check
on the contact box of the signal check
harness for measurement.
harness for measurement.
• Terminal numbers in the text and the
NOTICE
• Terminal numbers in the text and the
illustrations correspond as shown below in
illustrations correspond as shown below in
the "Computer pin arrangement".
the "Computer pin arrangement".
ECU terminal name
[Example] For A8 terminal
Signal check harness
ECU terminal name
ECU terminal number
[Example] For A8 terminal
Signal check harness (contact box)
ECU terminal number
Signal check harness (contact box)
SAPH311991700006
SAPH311991700006
ENGINE DIAGNOSIS CODE 2.
17â&#x20AC;&#x201C;9
ENGINE DIAGNOSIS CODE
Connection of signal check harness (1)
2.
Set the starter key to "OFF" and disconnect the connector
Connection of signal check harness (1)
from the engine ECU. (2)
Connect the signal check harness to the engine ECU and
(2)
the unit harness.
Special tool : Signal check harness (09049-1080)
Special tool : Signal check harness (09049-1080) Specification Wiring diagram (performance)
Unit harness Signal check harness
Test lead
Signal check connector
SAPH311991700007
Connect the signal check harness to the engine ECU and
the unit harness.
Signal check harness
Test lead
Set the starter key to "OFF" and disconnect the connector from the engine ECU.
Specification Wiring diagram (performance)
Unit harness
17â&#x20AC;&#x201C;9
Signal check connector
SAPH311991700007
17–10
17–10
ENGINE DIAGNOSIS CODE
Computer pin arrangement
ENGINE DIAGNOSIS CODE
Computer pin arrangement JP31199170201001
JP31199170201001
SAPH311991700008 Failure diagnosis list
SAPH311991700008 Failure diagnosis list
17–11
ENGINE DIAGNOSIS CODE
Check the ECU power supply voltage
Check the ECU power supply voltage JP31199170601002
1
㧭
#
&
#
㧰
㧱
'
#
2.
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check harness.
'
JP31199170601002
1
Measurement of voltage between terminals 1.
1.
㧭
#
&
#
㧰
㧱
'
#
Turn the starter key "ON" and measure voltage between
Set the starter key to "OFF" and connect the signal check harness.
'
2.
terminals A5, A6, A7 and terminals D1, E4, E5.
Turn the starter key "ON" and measure voltage between terminals A5, A6, A7 and terminals D1, E4, E5.
Standard value : 20 V or more
Standard value : 20 V or more
• 0 V : Blown fuse, harness failure, ground failure,
NG
• 0 V : Blown fuse, harness failure, ground failure,
NG
etc.
etc.
• 20 V or less : Battery deterioration, ground
SAPH311991700009
• 20 V or less : Battery deterioration, ground
SAPH311991700009
failure, etc.
failure, etc.
OK
OK
Normal
Normal
Check the ground
Check the ground JP31199170601003
1
1. D1
D
E4
E
Measurement of resistance between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
E5
2.
D1
D
E4
E
Set the starter key to "OFF" and connect the signal check harness.
E5
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals D1,
Frame
JP31199170601003
1
Measurement of resistance between terminals
2.
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals D1,
Frame
E4, E5 and the terminal (-) of the battery.
E4, E5 and the terminal (-) of the battery.
Standard value : 1 : or less NG SAPH311991700010
OK
Normal
17–11
ENGINE DIAGNOSIS CODE
Standard value : 1 : or less NG
Disconnection of ground harness, contact failure, etc.
SAPH311991700010
OK
Normal
Disconnection of ground harness, contact failure, etc.
17â&#x20AC;&#x201C;12
17â&#x20AC;&#x201C;12
ENGINE DIAGNOSIS CODE
Engine speed main sensor circuit malfunction (DTC code P0335)
ENGINE DIAGNOSIS CODE
Engine speed main sensor circuit malfunction (DTC code P0335) JP31199170601004
1
1
Measurement of resistance between terminals 1. B6
B
JP31199170601004
Set the starter key to "OFF" and connect the signal check
1.
harness.
B7
2.
Measurement of resistance between terminals
B6
B
harness.
B7
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminal B6 and terminal B7. Standard value : Approx. 125.5 r 17 : (20 qC{68 qF}) NG
Set the starter key to "OFF" and connect the signal check
2.
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminal B6 and terminal B7. Standard value : Approx. 125.5 r 17 : (20 qC{68 qF}) NG
[3] Go to measurement of resistance between sensor terminals.
terminals.
SAPH311991700011
SAPH311991700011
OK
2
OK
2
Check of diagnosis code 1.
Check of diagnosis code
Connect the ECU side connector of the signal check harness.
1.
Connect the ECU side connector of the signal check harness.
After deleting the past failure, Start the engine and confirm that
After deleting the past failure, Start the engine and confirm that
no diagnostic code is put out.
no diagnostic code is put out.
Standard : No diagnostic code NG
Standard : No diagnostic code NG
Contact failure of ECU connector, ECU failure, short-circuit of harness
Normal
Contact failure of ECU connector, ECU failure, short-circuit of harness
SAPH311991700012
OK
[3] Go to measurement of resistance between sensor
SAPH311991700012
OK
Normal
ENGINE DIAGNOSIS CODE
3
17â&#x20AC;&#x201C;13
3
Measurement of resistance between terminals 1.
ENGINE DIAGNOSIS CODE
Measurement of resistance between terminals
Disconnect the connector of the main engine speed sensor and
1.
Disconnect the connector of the main engine speed sensor and
measure the resistance between No. 1 and No. 2 terminals at
measure the resistance between No. 1 and No. 2 terminals at
the sensor.
the sensor.
Standard value : Approx. 125.5 r 17 : (20 qC{68 qF}) NG
Standard value : Approx. 125.5 r 17 : (20 qC{68 qF}) NG
Failure of main engine speed sensor
SAPH311991700013
OK
Harness disconnection or connector failure
17â&#x20AC;&#x201C;13
SAPH311991700013
OK
Harness disconnection or connector failure
Failure of main engine speed sensor
17â&#x20AC;&#x201C;14
17â&#x20AC;&#x201C;14
ENGINE DIAGNOSIS CODE
Engine speed sub sensor circuit malfunction (DTC code P0340)
ENGINE DIAGNOSIS CODE
Engine speed sub sensor circuit malfunction (DTC code P0340) JP31199170601005
1
Measurement of voltage between sensor terminals 1.
JP31199170601005
1
Measurement of voltage between sensor terminals
Set the starter key to "OFF" and connect the signal check
1.
harness. GND
+5V
Set the starter key to "OFF" and connect the signal check harness.
2.
Disconnect the connector of the sub-speed sensor.
3.
Set the starter key to "ON" and measure voltage between the
GND
+5V
2.
Disconnect the connector of the sub-speed sensor.
3.
Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the sub-speed sensor
+5V terminal and the GND terminal of the sub-speed sensor
connector (at unit harness side).
connector (at unit harness side).
Standard value : 5.0 r 0.5 V
Standard value : 5.0 r 0.5 V
SAPH311991700014
SAPH311991700014
NG OK
[2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
2
NG
[2] Go to measurement of voltage between terminals.
[3] Go to measurement of voltage between terminals.
2
Measurement of voltage between terminals 1.
Measure voltage between terminal D32 and terminal D30 of
1.
the signal check harness.
D D32
Measurement of voltage between terminals
D30
Standard value : 5.0 r 0.5V NG
Harness failure
D30
Standard value : 5.0 r 0.5V NG
Engine ECU failure, connector failure
SAPH311991700015
OK
the signal check harness.
D D32
Measure voltage between terminal D32 and terminal D30 of
SAPH311991700015
OK
Harness failure
Engine ECU failure, connector failure
17–15
ENGINE DIAGNOSIS CODE
3
3
Measurement of voltage between terminals 1.
D
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the connector of the
1.
sub-speed sensor.
D19 D30
D
Set the starter key to "OFF" and connect the connector of the sub-speed sensor.
D19 D30
2.
Start the engine and keep idling status.
2.
Start the engine and keep idling status.
3.
Measure voltage between terminal D19 and terminal D30 of
3.
Measure voltage between terminal D19 and terminal D30 of
the signal check harness. 4.
the signal check harness.
After measurement, stop the engine.
4.
Standard : Pulse waveform of 0 l 5 V
SAPH311991700016
NG
After measurement, stop the engine. Standard : Pulse waveform of 0 l 5 V
SAPH311991700016
NG
[4] Go to measurement of resistance between
[4] Go to measurement of resistance between
terminals.
terminals.
OK
OK
Engine ECU failure, ECU connector failure
4
Engine ECU failure, ECU connector failure
4
Measurement of resistance between terminals 1.
Leave the connector of the sub-speed sensor connected.
2.
Measure resistance between the No. 1 terminal at the unit
Measurement of resistance between terminals
SIG
1.
Leave the connector of the sub-speed sensor connected.
2.
Measure resistance between the No. 1 terminal at the unit
SIG
D19
D19
harness of the sub-speed sensor connector and terminal D19
harness of the sub-speed sensor connector and terminal D19
of the signal check harness.
of the signal check harness.
! CAUTION
• The connector of the sub-speed sensor in the
! CAUTION
figure is viewed from the fitting surface.
• The connector of the sub-speed sensor in the figure is viewed from the fitting surface.
Standard value : 2 : or less
Standard value : 2 : or less
SAPH311991700017
SAPH311991700017
NG
NG
Harness failure
OK
Harness failure
OK
Failure of sub-speed sensor
Failure of sub-speed sensor
Engine speed main and sub sensor circuit malfunction (DTC code P0335)
Engine speed main and sub sensor circuit malfunction (DTC code P0335)
JP31199170601006
1.
Inspection item (1)
17–15
ENGINE DIAGNOSIS CODE
Take actions of (DTC code P0335) and (DTC code P0340).
JP31199170601006
1.
Inspection item (1)
Take actions of (DTC code P0335) and (DTC code P0340).
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
"Reference : Engine speed main sensor circuit malfunction (DTC code P0335), Engine ECU, Engine
diagnosis code"
diagnosis code"
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
"Reference : Engine speed sub sensor circuit malfunction (DTC code P0340), Engine ECU, Engine
diagnosis code"
diagnosis code"
17â&#x20AC;&#x201C;16
17â&#x20AC;&#x201C;16
ENGINE DIAGNOSIS CODE
Coolant temperature sensor malfunction (DTC code P0117, P0118)
ENGINE DIAGNOSIS CODE
Coolant temperature sensor malfunction (DTC code P0117, P0118) JP31199170601007
JP31199170601007
DTC
P0117
Coolant temperature sensor circuit low input
DTC
P0117
Coolant temperature sensor circuit low input
DTC
P0118
Coolant temperature sensor circuit high input
DTC
P0118
Coolant temperature sensor circuit high input
1
1
Measurement of resistance between terminals 1.
D
Set the starter key to "OFF" and connect the signal check
1.
harness.
E
D
E19
Set the starter key to "OFF" and connect the signal check harness.
E E19
2.
D34
Measurement of resistance between terminals
Disconnect the ECU side connector of the signal check
2.
D34
Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E19
harness and measure the resistance between terminal E19
and terminal D34.
and terminal D34.
Standard value (Measure either one point of the
Standard value (Measure either one point of the
following.)
following.)
: 2.45 k: (Coolant temperature at 20 qC{68 qF}) SAPH311991700018
: 2.45 k: (Coolant temperature at 20 qC{68 qF}) SAPH311991700018
: 1.15 k: (Coolant temperature at 40 qC{104 qF})
: 1.15 k: (Coolant temperature at 40 qC{104 qF})
: 584 : (Coolant temperature at 60 qC{140 qF})
: 584 : (Coolant temperature at 60 qC{140 qF})
: 318 : (Coolant temperature at 80 qC{176 qF})
: 318 : (Coolant temperature at 80 qC{176 qF})
NG
NG
[2] Go to measurement of resistance between sensor
[2] Go to measurement of resistance between sensor
terminals.
OK
OK
Engine ECU failure, ECU connector failure, harness short-circuit
2
terminals.
2
Measurement of resistance between terminals 1.
Engine ECU failure, ECU connector failure, harness short-circuit
Measurement of resistance between terminals
Disconnect the connector of the coolant temperature sensor
1.
Disconnect the connector of the coolant temperature sensor
and measure the resistance between No. 1 and No. 2 terminals
and measure the resistance between No. 1 and No. 2 terminals
at the sensor.
at the sensor.
Standard value (Measure either one point of the
Standard value (Measure either one point of the
following.)
following.)
: 2.45 k: (Coolant temperature at 20 qC{68 qF})
: 2.45 k: (Coolant temperature at 20 qC{68 qF})
: 1.15 k: (Coolant temperature at 40 qC{104 qF})
: 1.15 k: (Coolant temperature at 40 qC{104 qF})
: 584 : (Coolant temperature at 60 qC{140 qF})
: 584 : (Coolant temperature at 60 qC{140 qF})
: 318 : (Coolant temperature at 80 qC{176 qF})
: 318 : (Coolant temperature at 80 qC{176 qF})
SAPH311991700019
SAPH311991700019
NG OK
Harness disconnection, connector failure
NG
Failure of coolant temperature sensor
OK
Harness disconnection, connector failure
Failure of coolant temperature sensor
17–17
ENGINE DIAGNOSIS CODE
Engine overheat (DTC code P0217)
Engine overheat (DTC code P0217) JP31199170601008
1
JP31199170601008
1
Measurement of resistance between terminals 1.
Measurement of resistance between terminals
Set the starter key to "OFF", disconnect the connector of the
1.
Set the starter key to "OFF", disconnect the connector of the
coolant temperature sensor and measure the resistance
coolant temperature sensor and measure the resistance
between No. 1 and No. 2 terminals at the sensor.
between No. 1 and No. 2 terminals at the sensor.
Standard value (Measure either one point of the
Standard value (Measure either one point of the
following.)
following.)
: 2.45k: (Coolant temperature at 20 qC{68 qF})
: 2.45k: (Coolant temperature at 20 qC{68 qF})
: 1.15k: (Coolant temperature at 40 qC{104 qF})
: 1.15k: (Coolant temperature at 40 qC{104 qF})
: 584: (Coolant temperature at 60 qC{140 qF})
: 584: (Coolant temperature at 60 qC{140 qF})
: 318: (Coolant temperature at 80 qC{176 qF})
: 318: (Coolant temperature at 80 qC{176 qF})
SAPH311991700019
SAPH311991700019
• This code is displayed when the coolant
NOTICE
NG
• This code is displayed when the coolant
NOTICE
temperature sensor is normal and the coolant
temperature sensor is normal and the coolant
temperature is 115 qC{221 qF} or more.
temperature is 115 qC{221 qF} or more.
• While this failure code is detected, the
• While this failure code is detected, the
maximum injection volume is restricted.
maximum injection volume is restricted.
When the coolant temperature is 80 qC{176qF}
When the coolant temperature is 80 qC{176qF}
or less, normal control is resumed.
or less, normal control is resumed. NG
Failure of coolant temperature sensor Take actions of (DTC code P0117,P0118)
Failure of coolant temperature sensor Take actions of (DTC code P0117,P0118)
OK
OK
Failure of engine cooling system
Failure of engine cooling system
Engine overrun (DTC code P0219)
Engine overrun (DTC code P0219) JP31199170601009
1.
17–17
ENGINE DIAGNOSIS CODE
This failure code is displayed when the engine speed of 2,600 r/min or more is detected. While this
JP31199170601009
1.
This failure code is displayed when the engine speed of 2,600 r/min or more is detected. While this
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,500 r/min.,
failure code is detected, fuel injection is stopped. When the engine speed is lower than 2,500 r/min.,
fuel injection is resumed.
fuel injection is resumed.
NOTICE
• The objective of this failure code is not to detect overrun due to failure of this system, but to memorize high revolution of the engine. • Engine speed may be incorrectly recognized with noise on the speed sensor signal due to harness failure or modification, resulting in detection of overrun.
NOTICE
• The objective of this failure code is not to detect overrun due to failure of this system, but to memorize high revolution of the engine. • Engine speed may be incorrectly recognized with noise on the speed sensor signal due to harness failure or modification, resulting in detection of overrun.
17â&#x20AC;&#x201C;18
17â&#x20AC;&#x201C;18
ENGINE DIAGNOSIS CODE
Fuel temperature sensor malfunction (DTC code P0182, P0183)
ENGINE DIAGNOSIS CODE
Fuel temperature sensor malfunction (DTC code P0182, P0183) JP31199170601010
JP31199170601010
DTC
P0182
Fuel temperature sensor circuit low input
DTC
P0182
Fuel temperature sensor circuit low input
DTC
P0183
Fuel temperature sensor circuit high input
DTC
P0183
Fuel temperature sensor circuit high input
1
1
Measurement of resistance between terminals 1. D34
Set the starter key to "OFF" and connect the signal check
1.
harness.
E27
2.
Measurement of resistance between terminals
D34
harness.
E27
Disconnect the ECU side connector of the signal check
Set the starter key to "OFF" and connect the signal check
2.
Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminal E27
harness and measure the resistance between terminal E27
and terminal D34.
and terminal D34.
Standard value (Measure either one point of the
Standard value (Measure either one point of the
following.)
following.)
: 2.45 k: (Fuel temperature at 20 qC{68 qF}) SAPH311991700020
: 2.45 k: (Fuel temperature at 20 qC{68 qF}) SAPH311991700020
: 1.15 k: (Fuel temperature at 40 qC{104 qF})
NG
: 1.15 k: (Fuel temperature at 40 qC{104 qF})
: 584 : (Fuel temperature at 60 qC{140 qF})
: 584 : (Fuel temperature at 60 qC{140 qF})
: 318 : (Fuel temperature at 80 qC{176 qF})
: 318 : (Fuel temperature at 80 qC{176 qF}) NG
[2] Go to measurement of resistance between terminals.
OK
terminals. OK
Engine ECU failure, ECU connector failure, harness short-circuit
2
[2] Go to measurement of resistance between
Engine ECU failure, ECU connector failure, harness short-circuit
2
Measurement of sensor resistance 1.
Disconnect the connector of the fuel temperature sensor and
1.
measure the resistance between No. 1 and No. 2 terminals at
the sensor.
the sensor.
Standard value (Measure either one point of the
Standard value (Measure either one point of the
following.)
following.)
: 2.45 k: (Fuel temperature at 20 qC{68 qF})
: 2.45 k: (Fuel temperature at 20 qC{68 qF})
: 1.15 k: (Fuel temperature at 40 qC{104 qF})
: 1.15 k: (Fuel temperature at 40 qC{104 qF})
: 584 : (Fuel temperature at 60 qC{140 qF})
: 584 : (Fuel temperature at 60 qC{140 qF})
: 318 : (Fuel temperature at 80 qC{176 qF})
: 318 : (Fuel temperature at 80 qC{176 qF}) SAPH311991700021
NG
Harness disconnection, connector failure
Disconnect the connector of the fuel temperature sensor and
measure the resistance between No. 1 and No. 2 terminals at
SAPH311991700021
OK
Measurement of sensor resistance
NG
Failure of fuel temperature sensor
OK
Harness disconnection, connector failure
Failure of fuel temperature sensor
17â&#x20AC;&#x201C;19
ENGINE DIAGNOSIS CODE
Boost pressure sensor malfunction (DTC code P0108, P0237)
Boost pressure sensor malfunction (DTC code P0108, P0237) JP31199170601011
JP31199170601011
DTC
P0108
Boost pressure sensor circuit high input
DTC
P0108
Boost pressure sensor circuit high input
DTC
P0237
Boost pressure sensor circuit low input
DTC
P0237
Boost pressure sensor circuit low input
1
Measurement of voltage between sensor terminals 1.
1
Measurement of voltage between sensor terminals
Set the starter key to "OFF" and connect the signal check
1.
harness. GND
Set the starter key to "OFF" and connect the signal check harness.
GND
+5V
+5V
2.
Disconnect the connector of the boost pressure sensor.
2.
Disconnect the connector of the boost pressure sensor.
3.
Set the starter key to "ON" and measure voltage between the
3.
Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the boost pressure
+5V terminal and the GND terminal of the boost pressure
sensor connector (at unit harness side).
sensor connector (at unit harness side).
Standard value : 5 r 0.5 V
Standard value : 5 r 0.5 V
SAPH311991700022
SAPH311991700022
NG
NG
[2] Go to measurement of voltage between terminals.
OK
[2] Go to measurement of voltage between terminals.
OK
[3] Go to measurement of voltage between terminals.
2
17â&#x20AC;&#x201C;19
ENGINE DIAGNOSIS CODE
[3] Go to measurement of voltage between terminals.
2
Measurement of voltage between terminals 1.
D
D25
Measurement of voltage between terminals
Measure the voltage between terminal D25 and terminal D33
1.
of the signal check harness.
D
D25
Measure the voltage between terminal D25 and terminal D33 of the signal check harness.
Standard value : 5 r 0.5 V D33
NG
Standard value : 5 r 0.5 V D33
Engine ECU failure, ECU connector failure
SAPH311991700023
OK
Harness failure
NG
SAPH311991700023
OK
Harness failure
Engine ECU failure, ECU connector failure
17â&#x20AC;&#x201C;20
3
ENGINE DIAGNOSIS CODE
3
Measurement of voltage between terminals 1.
D
17â&#x20AC;&#x201C;20
ENGINE DIAGNOSIS CODE
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the connector of the
1.
boost pressure sensor.
D27
2.
D
2.
terminal D27 and terminal D33 of the signal check harness.
D33
D27
Set the starter key to "ON" and measure the voltage between
Set the starter key to "OFF" and connect the connector of the boost pressure sensor. Set the starter key to "ON" and measure the voltage between terminal D27 and terminal D33 of the signal check harness.
D33
Standard value : 0.2 to 4.8 V NG
Standard value : 0.2 to 4.8 V NG
[4] Go to measurement of voltage between terminals.
SAPH311991700024
SAPH311991700024
OK
OK
Engine ECU failure, ECU connector failure
4
[4] Go to measurement of voltage between terminals.
Engine ECU failure, ECU connector failure
Measurement of voltage between sensor terminals 1. GND
4
Measurement of voltage between sensor terminals
Leave the connector of the boost pressure sensor connected.
SIG
GND
2.
1.
Leave the connector of the boost pressure sensor connected.
2.
Measure the voltage between the SIG terminal and the GND
SIG
Measure the voltage between the SIG terminal and the GND terminal of the boost pressure sensor connector (at unit
terminal of the boost pressure sensor connector (at unit
harness side).
harness side).
Standard value : 0.2 to 4.8 V NG
Standard value : 0.2 to 4.8 V NG
Boost pressure sensor failure
SAPH311991700025
OK
Harness failure
SAPH311991700025
OK
Harness failure
Boost pressure sensor failure
17â&#x20AC;&#x201C;21
ENGINE DIAGNOSIS CODE
Turbocharger over boost (DTC code P0234)
Turbocharger over boost (DTC code P0234) JP31199170601012
1
JP31199170601012
1
Inspection with failure diagnosis tool 1.
Inspection with failure diagnosis tool
After failure, perform failure diagnosis with a failure diagnosis
1.
tool (HinoDX) using PC. 2.
After failure, perform failure diagnosis with a failure diagnosis tool (HinoDX) using PC.
Connect the failure diagnosis tool (HinoDX) using PC and set
2.
the starter key to "ON".
Connect the failure diagnosis tool (HinoDX) using PC and set the starter key to "ON".
SAPH311991700026
SAPH311991700026
OK
OK
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
Perform diagnosis of the boost pressure sensor (DTC code P0108, P0237).
Excessive common rail pressure (DTC code P0088)
Excessive common rail pressure (DTC code P0088) JP31199170601013
1
17â&#x20AC;&#x201C;21
ENGINE DIAGNOSIS CODE
1
Measurement of voltage between terminals 1.
D
2. D33
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
D20
D31
JP31199170601013
D
2. D33
terminals D20/D31 and terminal D33 of the signal check
harness.
D20
D31
Set the starter key to "ON" and measure the voltage between harness.
Set the starter key to "OFF" and connect the signal check
Set the starter key to "ON" and measure the voltage between terminals D20/D31 and terminal D33 of the signal check harness.
Standard value : 3.6 to 4.7 V NG SAPH311991700027
OK
Failure of common rail pressure sensor
Standard value : 3.6 to 4.7 V NG
Engine ECU failure or harness/connector contact SAPH311991700027
failure
OK
Failure of common rail pressure sensor
Engine ECU failure or harness/connector contact failure
17–22
17–22
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Excessive common rail pressure, supply pump excess forced feed (DTC
Excessive common rail pressure, supply pump excess forced feed (DTC
code P0088)
code P0088) JP31199170601014
1
1
Measurement of voltage between terminals 1.
㧰
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
D20
D31
JP31199170601014
2. D33
㧰
2. D33
gauge moves. 3.
harness.
D20
D31
Start and warm-up the engine until the coolant temperature
Set the engine speed to idling. PFIN = Approx. 30 MPa
4.
Start and warm-up the engine until the coolant temperature gauge moves.
3.
(approx. 1.5V)
SAPH311991700028
Set the starter key to "OFF" and connect the signal check
Set the engine speed to idling. PFIN = Approx. 30 MPa (approx. 1.5V)
Measure the voltage between terminal D20/D31 and terminal
4. SAPH311991700028
D33 of the signal check harness.
Measure the voltage between terminal D20/D31 and terminal D33 of the signal check harness.
Standard value : 1.56 V or less NG
NG
Failure of common rail pressure sensor
OK
2
Standard value : 1.56 V or less Failure of common rail pressure sensor
OK
2
Check of failure code 1.
2.
Make sure that other failure code is not output.
Check of failure code 1.
If other failure code is output, repair the failure code and make
If other failure code is output, repair the failure code and make
sure again that DTC code P0088 is output. In particular, if a
sure again that DTC code P0088 is output. In particular, if a
failure code of the main and sub-engine speed sensor systems
failure code of the main and sub-engine speed sensor systems
is output, make necessary repairs to prevent output of the
is output, make necessary repairs to prevent output of the
code.
code.
Check the fuel injection timing of the supply pump. If the timing
2.
is not set 0q for the top dead center, set it correctly. 3.
Make sure that other failure code is not output.
When there is no error after the check above, delete the past
Check the fuel injection timing of the supply pump. If the timing is not set 0q for the top dead center, set it correctly.
3.
When there is no error after the check above, delete the past
failure using the PC diagnosis tool and start the engine.
failure using the PC diagnosis tool and start the engine.
If the same code is output again, possible failures are the
If the same code is output again, possible failures are the
supply pump, common rail pressure sensor system and engine
supply pump, common rail pressure sensor system and engine
ECU. Perform more detailed diagnosis with failure diagnosis
ECU. Perform more detailed diagnosis with failure diagnosis
tool (HinoDX) using PC.
tool (HinoDX) using PC.
17–23
ENGINE DIAGNOSIS CODE
Common rail pressure sensor malfunction (DTC code P0191)
Common rail pressure sensor malfunction (DTC code P0191) JP31199170601015
1
D
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
D20
D31
JP31199170601015
1
Measurement of voltage between terminals 1.
2. D33
D
2. D33
terminals D20/D31 and terminal D33.
Set the starter key to "OFF" and connect the signal check harness.
D20
D31
Set the starter key to "ON" and measure the voltage between
Set the starter key to "ON" and measure the voltage between terminals D20/D31 and terminal D33.
Standard value : 0.9 to 1.1 V NG
Standard value : 0.9 to 1.1 V NG
Engine ECU failure or harness/connector contact failure
Engine ECU failure or harness/connector contact failure
SAPH311991700029
SAPH311991700029
OK
2
17–23
ENGINE DIAGNOSIS CODE
OK
2
Measurement of voltage between terminals
㧰
1.
Start the engine.
2.
While measuring the voltage between terminals D20/D31 and
Measurement of voltage between terminals
㧰
D20
D31
2.
While measuring the voltage between terminals D20/D31 and terminal D33 of the signal check harness, repeat full opening/
D33
closing of the accelerator.
Start the engine.
D20
D31
terminal D33 of the signal check harness, repeat full opening/ D33
1.
closing of the accelerator.
Standard : Voltage must change. (1.0 to 3.2 V) NG
Standard : Voltage must change. (1.0 to 3.2 V) NG
Common rail pressure sensor failure or harness/ connector contact failure
connector contact failure
SAPH311991700030
OK
Engine ECU failure, connector contact failure
Common rail pressure sensor failure or harness/
SAPH311991700030
OK
Engine ECU failure, connector contact failure
17â&#x20AC;&#x201C;24
17â&#x20AC;&#x201C;24
ENGINE DIAGNOSIS CODE
Common rail pressure sensor malfunction (DTC code P0192, P0193)
ENGINE DIAGNOSIS CODE
Common rail pressure sensor malfunction (DTC code P0192, P0193) JP31199170601016
JP31199170601016
DTC
P0192
Common rail pressure sensor circuit low input
DTC
P0192
Common rail pressure sensor circuit low input
DTC
P0193
Common rail pressure sensor circuit high input
DTC
P0193
Common rail pressure sensor circuit high input
1
1
Measurement of voltage between terminals 1. D33
D
2.
D31
Set the starter key to "OFF" and connect the signal check
1.
harness.
D20
Measurement of voltage between terminals
D33
Set the starter key to "ON" and measure the voltage between
D
harness.
D20
2.
D31
Set the starter key to "OFF" and connect the signal check
Set the starter key to "ON" and measure the voltage between
terminals D20/D31 and terminal D33 of the signal check
terminals D20/D31 and terminal D33 of the signal check
harness.
harness.
Standard value : 0.7 to 4.7 V NG
Standard value : 0.7 to 4.7 V NG
[2] Go to measurement of voltage between terminals.
SAPH311991700031
OK
OK
Engine ECU failure, ECU connector failure
2
Engine ECU failure, ECU connector failure
Measurement of voltage between sensor terminals 1.
2
Measurement of voltage between sensor terminals
Set the starter key to "OFF" and disconnect the connector of
1.
the common rail pressure sensor. GND
Set the starter key to "OFF" and disconnect the connector of the common rail pressure sensor.
GND
+5V
2.
+5V
Set the starter key to "ON" and measure voltage between the
2.
Set the starter key to "ON" and measure voltage between the
+5V terminal and the GND terminal of the common rail
+5V terminal and the GND terminal of the common rail
pressure sensor connector (at unit harness side).
pressure sensor connector (at unit harness side).
Standard value : 5 r 0.5 V NG SAPH311991700032
OK
[2] Go to measurement of voltage between terminals.
SAPH311991700031
Standard value : 5 r 0.5 V NG
[4] Go to measurement of resistance between SAPH311991700032
terminals.
OK
[4] Go to measurement of resistance between terminals.
ENGINE DIAGNOSIS CODE
3
17â&#x20AC;&#x201C;25
3
Measurement of resistance between terminals 1.
ENGINE DIAGNOSIS CODE
Measurement of resistance between terminals
Set the starter key to "OFF" and disconnect the ECU side
1.
connector of the signal check harness.
D
D 2.
Measure the resistance between terminals D20/D31 of the
D20
2.
D31
signal check harness and the SIG terminal of the common rail
Measure the resistance between terminals D20/D31 of the signal check harness and the SIG terminal of the common rail
pressure sensor connector (at unit harness side).
SIG
Set the starter key to "OFF" and disconnect the ECU side connector of the signal check harness.
D20
D31
pressure sensor connector (at unit harness side).
SIG
Standard value : 2 : or less NG
Standard value : 2 : or less NG
Harness failure
SAPH311991700033
OK
Connector contact failure
Connector contact failure
4
Measurement of resistance between terminals 1.
Measurement of resistance between terminals
Set the starter key to "OFF" and disconnect the ECU side
1.
connector of the signal check harness. 2. D24
Harness failure
SAPH311991700033
OK
4
17â&#x20AC;&#x201C;25
+5V
D
Measure the resistance between terminals D24 of the signal check harness and the +5 V terminal of the common rail
Set the starter key to "OFF" and disconnect the ECU side connector of the signal check harness.
2. D24
+5V
D
Measure the resistance between terminals D24 of the signal check harness and the +5 V terminal of the common rail
pressure sensor connector (at unit harness side).
pressure sensor connector (at unit harness side).
Standard value : 2 : or less
Standard value : 2 : or less
SAPH311991700034
SAPH311991700034
3.
Measure the resistance between terminal D33 of the signal
3.
check harness and the GND terminal of the common rail
D
GND
Measure the resistance between terminal D33 of the signal check harness and the GND terminal of the common rail
pressure sensor connector (at unit harness side).
D
GND
pressure sensor connector (at unit harness side).
Standard value : 2 : or less NG
D33
Standard value : 2 : or less
Harness failure
SAPH311991700035
OK
Engine ECU failure, ECU connector failure
NG
D33
SAPH311991700035
OK
Engine ECU failure, ECU connector failure
Harness failure
17â&#x20AC;&#x201C;26
17â&#x20AC;&#x201C;26
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 malfunction (DTC code P2122, P2123)
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 malfunction (DTC code P2122, P2123) JP31199170601017
JP31199170601017
DTC
P2122
Accelerator sensor circuit 1 low voltage
DTC
P2122
Accelerator sensor circuit 1 low voltage
DTC
P2123
Accelerator sensor circuit 1 high voltage
DTC
P2123
Accelerator sensor circuit 1 high voltage
1
1
Measurement of voltage between terminals 1.
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness. 2.
harness.
Set the starter key to "ON" and measure the voltage between
2.
terminal A21 and terminal B20 of the signal check harness. B20
A21
Set the starter key to "ON" and measure the voltage between terminal A21 and terminal B20 of the signal check harness.
B20
A21
Standard value : 0.7 - 1.5V (idle status) NG
Set the starter key to "OFF" and connect the signal check
Standard value : 0.7 - 1.5V (idle status) NG
[3] Voltage measuring at the output port of the mechatronic controller
mechatronic controller
SAPH311991700036
SAPH311991700036
OK
2
[3] Voltage measuring at the output port of the
OK
2
Measurement of voltage between terminals 1.
Measurement of voltage between terminals
While increasing the throttle, measure the voltage between
1.
terminal A21 and terminal B20 of the signal check harness.
While increasing the throttle, measure the voltage between terminal A21 and terminal B20 of the signal check harness.
Standard value A21
B20
Measuring item
Standard value Engine revolution (r/min)
Voltage(V)
A21
Engine revolution (r/min)
Voltage(V)
1,000
Approx.1.4
Low idle
1,000
Approx.1.4
High idle
2,000
Approx.3.3
High idle
2,000
Approx.3.3
SAPH311991700036
NG
Harness failure
Measuring item
Low idle
SAPH311991700036
OK
B20
NG
Defective mechatronic controller OK
Harness failure
Defective mechatronic controller
ENGINE DIAGNOSIS CODE
3
17â&#x20AC;&#x201C;27
Voltage measuring at the output port of the mechatronic controller 1.
ENGINE DIAGNOSIS CODE
3
Voltage measuring at the output port of the mechatronic controller
With the starter key set to "ON", do not open the slot and
1.
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
the mechatronics controller and B21 of the signal check
harness.
harness.
When an abnormal value is detected, the mechatronics
When an abnormal value is detected, the mechatronics
controller becomes defective.
controller becomes defective.
Abnormal value
Abnormal value
: 0.3 V or less
: 0.3 V or less
: 4.85 V or more
: 4.85 V or more NG
Engine ECU failure, ECU connector failure or disconnection of harness, short-circuit of harness
Defective mechatronic controller
With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
NG
OK
17â&#x20AC;&#x201C;27
Engine ECU failure, ECU connector failure or disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller
17–28
17–28
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 malfunction (DTC code P2127, P2128)
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 malfunction (DTC code P2127, P2128) JP31199170601018
JP31199170601018
DTC
P2127
Accelerator sensor circuit 2 low voltage
DTC
P2127
Accelerator sensor circuit 2 low voltage
DTC
P2128
Accelerator sensor circuit 2 high voltage
DTC
P2128
Accelerator sensor circuit 2 high voltage
1
1. A22
1
Measurement of voltage between terminals
㧭
㧮
Set the starter key to "OFF" and connect the signal check
1.
harness. A22 B21
2.
Measurement of voltage between terminals
㧭
㧮
harness. B21
Set the starter key to "ON" and measure the voltage between
Set the starter key to "OFF" and connect the signal check
2.
terminal A22 and terminal B21 of the signal check harness.
Set the starter key to "ON" and measure the voltage between terminal A22 and terminal B21 of the signal check harness.
Standard value : 0.7 - 1.5V (idle status) NG
Standard value : 0.7 - 1.5V (idle status) NG
[3] Voltage measuring at the output port of the mechatronic controller
mechatronic controller
SAPH311991700037
SAPH311991700037
OK
2
OK
2
Measurement of voltage between terminals 1.
A22
[3] Voltage measuring at the output port of the
㧭
㧮
Measurement of voltage between terminals
While increasing the throttle, measure the voltage between
1.
terminal A22 and terminal B21 of the signal check harness. A22
㧭
B21
㧮
While increasing the throttle, measure the voltage between terminal A22 and terminal B21 of the signal check harness.
B21
Standard value Measuring item
Standard value Engine revolution (r/min)
Voltage(V)
Measuring item
Voltage(V)
1,000
Approx.1.4
Low idle
1,000
Approx.1.4
High idle
2,000
Approx.3.3
High idle
2,000
Approx.3.3
SAPH311991700037
NG
Harness failure
(r/min)
Low idle
SAPH311991700037
OK
Engine revolution
NG
Defective mechatronic controller
OK
Harness failure
Defective mechatronic controller
ENGINE DIAGNOSIS CODE
3
17â&#x20AC;&#x201C;29
Voltage measuring at the output port of the mechatronic controller 1.
ENGINE DIAGNOSIS CODE
3
Voltage measuring at the output port of the mechatronic controller
With the starter key set to "ON", do not open the slot and
1.
measure the voltage between pin 25 of the pin connector 28 of
the mechatronics controller and B21 of the signal check
the mechatronics controller and B21 of the signal check
harness.
harness.
When an abnormal value is detected, the mechatronics
When an abnormal value is detected, the mechatronics
controller becomes defective.
controller becomes defective.
Abnormal value
Abnormal value
: 0.3 V or less
: 0.3 V or less
: 4.85 V or more
: 4.85 V or more NG
Engine ECU failure, ECU connector failure or disconnection of harness, short-circuit of harness
Defective mechatronic controller
With the starter key set to "ON", do not open the slot and
measure the voltage between pin 25 of the pin connector 28 of
NG
OK
17â&#x20AC;&#x201C;29
Engine ECU failure, ECU connector failure or disconnection of harness, short-circuit of harness
OK
Defective mechatronic controller
17–30
17–30
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 and 2 malfunction (DTC code P2120)
ENGINE DIAGNOSIS CODE
Accelerator sensor 1 and 2 malfunction (DTC code P2120) JP31199170601019
1
JP31199170601019
1
Inspection item 1.
Take action of DTC code P2120.
Inspection item 1.
Take action of DTC code P2120.
"Reference : Accelerator sensor 1 malfunction (DTC code P2122,
"Reference : Accelerator sensor 1 malfunction (DTC code P2122,
P2123), Engine ECU, Engine diagnosis code"
P2123), Engine ECU, Engine diagnosis code"
"Reference : Accelerator sensor 2 malfunction (DTC code P2126),
"Reference : Accelerator sensor 2 malfunction (DTC code P2126),
Engine ECU, Engine diagnosis code"
Engine ECU, Engine diagnosis code"
17–31
ENGINE DIAGNOSIS CODE
Emergency accelerator sensor malfunction (DTC code P1133)
Emergency accelerator sensor malfunction (DTC code P1133) JP03Z01030703026
1
JP03Z01030703026
1
Power supply voltage measuring 1.
Power supply voltage measuring
With the ECU connector connected, disconnect the sensor
1.
connector and measure the voltage between the power +5V
terminal (+5 V) and the GND terminal. ! CAUTION
With the ECU connector connected, disconnect the sensor connector and measure the voltage between the power
+5V
terminal (+5 V) and the GND terminal.
• The connector in the figure is seen from the
! CAUTION
fitting surface. GND
Standard value : 5.0 r 0.5 V ÎÇ
• The connector in the figure is seen from the fitting surface.
GND
Standard value : 5.0 r 0.5 V ÎÇ
[2] Go to measurement of voltage between terminals.
SAPH311991700038
[2] Go to measurement of voltage between terminals.
SAPH311991700038
OK
OK
[3] Go to measurement of voltage between terminals.
2
17–31
ENGINE DIAGNOSIS CODE
[3] Go to measurement of voltage between terminals.
2
Measurement of voltage between terminals 1. B23
㧮
Measurement of voltage between terminals
Measure the voltage between terminals B20 and B23 of the
1.
signal check harness. B23
B20
㧮
Measure the voltage between terminals B20 and B23 of the signal check harness.
B20
Standard value : 5.0 r 0.5 V NG
Standard value : 5.0 r 0.5 V NG
Engine ECU, engine ECU connector failure
SAPH311991700039
OK
Harness failure
SAPH311991700039
OK
Harness failure
Engine ECU, engine ECU connector failure
17–32
3
ENGINE DIAGNOSIS CODE
3
Measurement of voltage between terminals 1.
B20
ENGINE DIAGNOSIS CODE
Measurement of voltage between terminals
Connect the sensor connector and measure the voltage
1.
between terminals A23 and B20 of the signal check harness.
Standard value : Approx. 0.0 to 3.2 V (idle to full
Standard value : Approx. 0.0 to 3.2 V (idle to full
throttle)
throttle) B20
[4] Go to measurement of voltage between terminals.
NG
A23
SAPH311991700040
[4] Go to measurement of voltage between terminals.
SAPH311991700040
OK
OK
Engine ECU failure, engine ECU connector failure
4
Connect the sensor connector and measure the voltage
between terminals A23 and B20 of the signal check harness.
NG
A23
17–32
Engine ECU failure, engine ECU connector failure
4
Measurement of voltage between sensor terminals
GND
1.
Leave the emergency accelerator sensor connected.
2.
Connect the sensor connector and measure the voltage
Measurement of voltage between sensor terminals
GND
between the terminals SIG and GND of the sensor. ! CAUTION
SIG
Connect the sensor connector and measure the voltage
! CAUTION
• The connector in the figure is seen from the fitting surface.
Standard value : Approx. 0.0 to 3.2 V (idle to full
Standard value : Approx. 0.0 to 3.2 V (idle to full
throttle)
throttle) SAPH311991700041
NG
Harness failure
2.
SIG
SAPH311991700041
OK
Leave the emergency accelerator sensor connected.
between the terminals SIG and GND of the sensor.
• The connector in the figure is seen from the fitting surface.
1.
NG
Emergency accelerator sensor failure OK
Harness failure
Emergency accelerator sensor failure
ENGINE DIAGNOSIS CODE
17â&#x20AC;&#x201C;33
Atmospheric pressure sensor malfunction (DTC code P2228, P2229)
ENGINE DIAGNOSIS CODE
Atmospheric pressure sensor malfunction (DTC code P2228, P2229) JP31199170601020
JP31199170601020
DTC
P2228
Atmospheric pressure sensor circuit low input
DTC
P2228
Atmospheric pressure sensor circuit low input
DTC
P2229
Atmospheric pressure sensor circuit high input
DTC
P2229
Atmospheric pressure sensor circuit high input
1
1
Check of diagnosis code 1.
17â&#x20AC;&#x201C;33
Check of diagnosis code
After deleting the past failures with the failure diagnosis tool
1.
After deleting the past failures with the failure diagnosis tool
(HinoDX) using PC, check again if the same code (DTC code
(HinoDX) using PC, check again if the same code (DTC code
P2228, P2229) is output.
P2228, P2229) is output.
Standard : Normal
Standard : Normal
NG
NG
Engine ECU failure
SAPH311991700026
OK
Engine ECU failure
SAPH311991700026
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
normal operation.
17â&#x20AC;&#x201C;34
17â&#x20AC;&#x201C;34
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Injector common 1 ground short (DTC code P1211), Injector common 2
Injector common 1 ground short (DTC code P1211), Injector common 2
ground short (DTC code P1214)
ground short (DTC code P1214) JP31199170601021
1
1
Measurement of resistance between terminals 1.
JP31199170601021
Measurement of resistance between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
harness.
2.
Disconnect the ECU side connector of the signal check
3.
Measure the resistance between each terminal of the signal
2.
Disconnect the ECU side connector of the signal check
3.
Measure the resistance between each terminal of the signal
harness. D5
D
D6
harness.
check harness and the ECU case ground.
ECU case ground (ECU mounting bolt)
DTC code E6
E
E7
D5
NG
D
D6
check harness and the ECU case ground.
ECU case ground (ECU mounting bolt)
Terminal to measure resistance
P1211
D5, D6
P1214
E6, E7
DTC code
ECU case ground
E6
E
E7
ECU case ground
Standard value : f :
SAPH311991700042
NG
[3] Go to measurement of resistance between
OK
Terminal to measure resistance
P1211
D5, D6
P1214
E6, E7
ECU case ground ECU case ground
Standard value : f :
SAPH311991700042
injector terminals.
2
Set the starter key to "OFF" and connect the signal check
[3] Go to measurement of resistance between injector terminals.
OK
2
Check of diagnosis code 1.
Check of diagnosis code
Set the starter key to "OFF" and connect the ECU side
1.
connector of the signal check harness. 2.
connector of the signal check harness.
Start the engine and delete the past failures with the failure
2.
diagnosis tool (HinoDX) using PC. 3.
SAPH311991700026
Set the starter key to "OFF" and connect the ECU side
Start the engine and delete the past failures with the failure diagnosis tool (HinoDX) using PC.
If the same failure code is output again, replace the engine
3.
If the same failure code is output again, replace the engine
ECU. If the normal code is output, it is considered that a
ECU. If the normal code is output, it is considered that a
temporary error has occurred.
temporary error has occurred. SAPH311991700026
17–35
ENGINE DIAGNOSIS CODE
3
3
Measurement of resistance between injector terminals
Measurement of resistance between injector terminals
1.
Set the starter key to "OFF".
1.
Set the starter key to "OFF".
2.
The injector clustered connector at the front side of the engine
2.
The injector clustered connector at the front side of the engine
shall be disconnected. 1
2
12 11
7
8
6
5
3
4
10
9
17–35
ENGINE DIAGNOSIS CODE
3.
shall be disconnected. 1
2
12 11
Measure the resistance between terminals of the injector
7
8
6
5
clustered connector (at unit harness side).
3
4
10
9
DTC code
3.
Measure the resistance between terminals of the injector clustered connector (at unit harness side).
Terminal to measure resistance + side
SAPH311991700043
P1211
5, 6, 10, 12
P1214
2, 4, 7, 8
DTC code
– side ECU case ground ECU case ground
P1211
5, 6, 10, 12
P1214
2, 4, 7, 8
– side ECU case ground ECU case ground
Standard value : f : NG
Harness failure (failure including pinching of harness which has not satisfied the standard value)
OK
+ side
SAPH311991700043
Standard value : f : NG
Terminal to measure resistance
Harness failure (failure including pinching of harness which has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the ground line may
have occurred.)
have occurred.)
17–36
17–36
ENGINE DIAGNOSIS CODE
ENGINE DIAGNOSIS CODE
Injector common 1 power source line short (DTC code P1212), Injector
Injector common 1 power source line short (DTC code P1212), Injector
common 2 power source line short (DTC code P1215)
common 2 power source line short (DTC code P1215) JP31199170601022
1
D5
1
Measurement of voltage between terminals 1.
D
D6
2.
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check harness.
ECU case ground (ECU mounting bolt)
JP31199170601022
1. D5
D
D6
harness.
ECU case ground (ECU mounting bolt)
Disconnect the ECU side connector of the signal check
2.
harness and set the starter key to "ON". E6
E
E6
E
E7
Measure the voltage between each terminal of the signal check
3.
harness and the ECU case ground. ! CAUTION
• Never start the engine because it may cause
DTC code
Measure the voltage between each terminal of the signal check harness and the ECU case ground.
! CAUTION
failure of the unit or electric shock.
SAPH311991700044
Disconnect the ECU side connector of the signal check harness and set the starter key to "ON".
E7
3.
Set the starter key to "OFF" and connect the signal check
failure of the unit or electric shock.
SAPH311991700044
Terminal to measure voltage + side
P1212
D5, D6
P1215
E6, E7
DTC code
– side ECU case ground ECU case ground
Standard value : 14 V or less NG
NG
terminals.
2
Terminal to measure voltage + side
P1212
D5, D6
P1215
E6, E7
– side ECU case ground ECU case ground
Standard value : 14 V or less
[3] Go to measurement of voltage between injector
OK
• Never start the engine because it may cause
[3] Go to measurement of voltage between injector terminals.
OK
2
Check of diagnosis code 1.
Check of diagnosis code
Set the starter key to "OFF" and connect the ECU side
1.
connector of the signal check harness. 2.
connector of the signal check harness.
Start the engine and delete the past failures with the failure
2.
diagnosis tool (HinoDX) using PC. 3.
SAPH311991700026
Set the starter key to "OFF" and connect the ECU side
Start the engine and delete the past failures with the failure diagnosis tool (HinoDX) using PC.
If the same failure code is output again, replace the common
3.
If the same failure code is output again, replace the common
rail ECU. If the normal code is output, it is considered that a
rail ECU. If the normal code is output, it is considered that a
temporary error has occurred.
temporary error has occurred. SAPH311991700026
17–37
ENGINE DIAGNOSIS CODE
3
3
Measurement of voltage between injector terminals
Measurement of voltage between injector terminals
1.
Set the starter key to "OFF".
1.
Set the starter key to "OFF".
2.
The injector clustered connector at the front side of the engine
2.
The injector clustered connector at the front side of the engine
shall be disconnected and set the starter key to "ON". 1
2
12 11
7
8
6
5
3
4
10
9
17–37
ENGINE DIAGNOSIS CODE
3.
shall be disconnected and set the starter key to "ON". 1
2
12 11
Measure the voltage between terminals of the injector
7
8
6
5
clustered connector (at unit harness side).
3
4
10
9
! CAUTION
3.
Measure the voltage between terminals of the injector clustered connector (at unit harness side).
• Never start the engine because it may cause
! CAUTION
failure of the unit or electric shock.
• Never start the engine because it may cause failure of the unit or electric shock.
SAPH311991700043
SAPH311991700043
DTC code
Terminal to measure voltage + side
1212
5, 6
1215
7, 8
DTC code
– side ECU case ground ECU case ground
Standard value : 14 V or less NG
+ side
1212
5, 6
1215
7, 8
– side ECU case ground ECU case ground
Standard value : 14 V or less NG
Harness failure (harness failure of terminal that has not satisfied the standard value)
OK
Terminal to measure voltage
Harness failure (harness failure of terminal that has not satisfied the standard value)
OK
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
Inspection of harness inside head cover (Short-circuit of the harness inside the head cover to the power line may
have occurred.)
have occurred.)
17â&#x20AC;&#x201C;38
17â&#x20AC;&#x201C;38
ENGINE DIAGNOSIS CODE
Injector circuit malfunction (DTC code P0201 to P0204)
ENGINE DIAGNOSIS CODE
Injector circuit malfunction (DTC code P0201 to P0204) JP31199170601023
JP31199170601023
DTC
P0201
Injector circuit malfunction -cylinder 1
DTC
P0201
Injector circuit malfunction -cylinder 1
DTC
P0202
Injector circuit malfunction -cylinder 2
DTC
P0202
Injector circuit malfunction -cylinder 2
DTC
P0203
Injector circuit malfunction -cylinder 3
DTC
P0203
Injector circuit malfunction -cylinder 3
DTC
P0204
Injector circuit malfunction -cylinder 4
DTC
P0204
Injector circuit malfunction -cylinder 4
1
1
Measurement of resistance between terminals 1.
Measurement of resistance between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
D2 D3
2. D5
harness.
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals.
E1 E2
DTC code
Failure area
E6 SAPH311991700045
Set the starter key to "OFF" and connect the signal check
(injector)
D2 D3
2. D5
Disconnect the ECU side connector of the signal check harness and measure the resistance between terminals.
Terminal to measure
E1 E2
resistance
P0201
#1
D2 l D5
P0202
#2
P0203 P0204
DTC code E6
measure resistance
#1
D2 l D5
E2 l E6
P0202
#2
E2 l E6
#3
E1 l E7
P0203
#3
E1 l E7
#4
D3 l D6
P0204
#4
D3 l D6
Standard value : 2 : or less NG
[3] Go to measurement of resistance between injector terminals.
OK
2
(injector)
Terminal to
P0201
SAPH311991700045
Standard value : 2 : or less NG
Failure area
[3] Go to measurement of resistance between injector terminals.
OK
2
Check of diagnosis code 1.
Check of diagnosis code
Set the starter key to "OFF" and connect the ECU side
1.
connector of the signal check harness. 2.
Start the engine and delete the past failures with the failure
2.
diagnosis tool (HinoDX) using PC. 3.
SAPH311991700026
Set the starter key to "OFF" and connect the ECU side connector of the signal check harness. Start the engine and delete the past failures with the failure diagnosis tool (HinoDX) using PC.
If the same failure code is output again, replace the common
3.
If the same failure code is output again, replace the common
rail ECU. If the normal code is output, it is considered that a
rail ECU. If the normal code is output, it is considered that a
temporary error has occurred.
temporary error has occurred. SAPH311991700026
17â&#x20AC;&#x201C;39
ENGINE DIAGNOSIS CODE
3
3
Measurement of resistance between injector terminals 1.
Measurement of resistance between injector terminals
The injector clustered connector at the front side of the engine
1.
shall be disconnected. 2. 1
2
3
4
5
6
7
8
2.
clustered connector (male) at the cam housing.
DTC code
SAPH311991700046
The injector clustered connector at the front side of the engine shall be disconnected.
Measure the resistance between terminals of the injector
9 10 11 12
1
2
3
4
5
6
7
8
Measure the resistance between terminals of the injector clustered connector (male) at the cam housing.
9 10 11 12
Terminal to measure
DTC code
resistance
P0201
5 l 10
P0202
7 l 11
P0203 P0204
resistance 5 l 10
P0202
7 l 11
3l8
P0203
3l8
2l6
P0204
2l6
SAPH311991700046
Standard value : 2 : or less NG
[4] Go to measurement of resistance between injector terminals.
OK
[4] Go to measurement of resistance between injector terminals.
OK
unit harness disconnection (Check the harness between the ECU and the injector clustered connector.)
4
Terminal to measure
P0201
Standard value : 2 : or less NG
17â&#x20AC;&#x201C;39
ENGINE DIAGNOSIS CODE
Measurement of resistance between injector terminals 1.
unit harness disconnection (Check the harness between the ECU and the injector clustered connector.)
4
Measurement of resistance between injector terminals
Remove the head cover and disconnect the injector connector
1.
Remove the head cover and disconnect the injector connector
(injector side) of the cylinder indicated by the failure code.
(injector side) of the cylinder indicated by the failure code.
Measure the resistance between the No. 1 terminal and the No.
Measure the resistance between the No. 1 terminal and the No.
2 terminal.
2 terminal.
Standard value : 0.45 r 0.05 : NG
Standard value : 0.45 r 0.05 : NG
[5] Go to measurement of resistance between injector terminals.
injector terminals.
SAPH311991700047
OK
Contact failure of harness or connector inside the head cover
[5] Go to measurement of resistance between
SAPH311991700047
OK
Contact failure of harness or connector inside the head cover
17â&#x20AC;&#x201C;40
5
ENGINE DIAGNOSIS CODE
Measurement of resistance between injector terminals 1.
17â&#x20AC;&#x201C;40
5
ENGINE DIAGNOSIS CODE
Measurement of resistance between injector terminals
Remove the terminal cap of the injector of the cylinder
1.
Remove the terminal cap of the injector of the cylinder
indicated by the failure code and measure the insulation
indicated by the failure code and measure the insulation
resistance between the terminal and the upper body.
resistance between the terminal and the upper body.
Standard value : 1, 000 M: or more NG
Standard value : 1, 000 M: or more NG
Injector TWV coil disconnection (Replace the injector assembly.)
assembly.)
SAPH311991700048
OK
Injector harness disconnection (Replace the injector harness.)
Injector TWV coil disconnection (Replace the injector
SAPH311991700048
OK
Injector harness disconnection (Replace the injector harness.)
17–41
ENGINE DIAGNOSIS CODE
Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272) JP31199170601024
Cylinder contribution/balance fault (DTC codes P0263, P0266, P0269, P0272) JP31199170601024
DTC
P0263
Cylinder 1 contribution/balance fault
DTC
P0263
Cylinder 1 contribution/balance fault
DTC
P0266
Cylinder 2 contribution/balance fault
DTC
P0266
Cylinder 2 contribution/balance fault
DTC
P0269
Cylinder 3 contribution/balance fault
DTC
P0269
Cylinder 3 contribution/balance fault
DTC
P0272
Cylinder 4 contribution/balance fault
DTC
P0272
Cylinder 4 contribution/balance fault
1
1
Inspection of flow damper 1
Inspection of flow damper 1
1.
Set the starter key to "OFF" and stop the engine.
1.
Set the starter key to "OFF" and stop the engine.
2.
Wait for approx. 30 seconds and start the engine.
2.
Wait for approx. 30 seconds and start the engine.
3.
Warm-up the engine until coolant temperature is 60 qC{140 qF}
3.
Warm-up the engine until coolant temperature is 60 qC{140 qF}
or more, delete the past failure with a failure diagnosis tool
or more, delete the past failure with a failure diagnosis tool
(HinoDX) using PC.
(HinoDX) using PC.
SAPH311991700026
SAPH311991700026
4.
If the same failure code is displayed as the current failure after deleting the past failure, check the flow damper of the cylinder indicated by the failure code. DTC code
4.
If the same failure code is displayed as the current failure after deleting the past failure, check the flow damper of the cylinder indicated by the failure code.
Failure area
DTC code
(Flow damper)
(Flow damper)
#1
P0263
#1
P0266
#2
P0266
#2
P0269
#3
P0269
#3
P0272
#4
P0272
#4
SAPH311991700049
2
Inspection of flow damper 2 1.
Inspection of flow damper 2
Remove the flow damper from the common rail and run air from one side of the flow damper. Check if the damper is not blocked by release of air to the opposite side.
! CAUTION
1.
• When air is run, be careful so that dirt, water, etc. may not enter the flow damper.
Remove the flow damper from the common rail and run air from one side of the flow damper. Check if the damper is not blocked by release of air to the opposite side.
! CAUTION
Standard value : Air must flow. (Flow damper is normal.) NG
• When air is run, be careful so that dirt, water, etc. may not enter the flow damper.
Standard value : Air must flow. (Flow damper is normal.) NG
Replace the flow damper (if air is not run)
SAPH311991700050
OK
Failure area
P0263
SAPH311991700049
2
17–41
ENGINE DIAGNOSIS CODE
SAPH311991700050
OK
Replace the flow damper (if air is not run)
17–42
3
ENGINE DIAGNOSIS CODE
17–42
3
Check of failure code 1.
ENGINE DIAGNOSIS CODE
Check of failure code
Make sure that other failure code is not output.
1.
If other failure code is output, repair the failure first and delete
the past failure with the failure diagnosis tool (HinoDX) using
the past failure with the failure diagnosis tool (HinoDX) using
PC.
PC.
Then, if this failure code is output again, the following failures
Then, if this failure code is output again, the following failures
may be estimated.
may be estimated.
• Excessive fuel flow due to leak from broken pipe, crack in
• Excessive fuel flow due to leak from broken pipe, crack in
pipe or pipe connection between the flow damper and the
pipe or pipe connection between the flow damper and the
injector pipe SAPH311991700026
o Check for leak
injector pipe SAPH311991700026
o Check for leak
• Too large or too small fuel flow due to increase of leak inside
• Too large or too small fuel flow due to increase of leak inside
inside the injector
inside the injector
o Check for leak on the individual injector with a nozzle
o Check for leak on the individual injector with a nozzle
tester
tester
• Excessive fuel flow due to failure of injection nozzle and seat
• Excessive fuel flow due to failure of injection nozzle and seat
o Check for seat failure on the individual injector with a
o Check for seat failure on the individual injector with a
nozzle tester
nozzle tester
• Too large or too small fuel flow due to malfunction of the
• Too large or too small fuel flow due to malfunction of the
injector
injector
o Check with replacement of injector
o Check with replacement of injector
• Too small fuel flow due to clogging in the fuel supply system
• Too small fuel flow due to clogging in the fuel supply system
o Inspection of fuel filter 2.
Make sure that other failure code is not output.
If other failure code is output, repair the failure first and delete
To specify a failure location above, check the compensation
o Inspection of fuel filter 2.
To specify a failure location above, check the compensation
between cylinders with the failure diagnosis tool (HinoDX)
between cylinders with the failure diagnosis tool (HinoDX)
using PC and stop an injector. Then, perform diagnosis while
using PC and stop an injector. Then, perform diagnosis while
viewing the engine data.
viewing the engine data.
17â&#x20AC;&#x201C;43
ENGINE DIAGNOSIS CODE
Supply pump SCV malfunction (DTC code P0628, P0629)
Supply pump SCV malfunction (DTC code P0628, P0629) JP31199170601025
JP31199170601025
DTC
P0628
Supply pump SCV malfunction (Full discharge mode)
DTC
P0628
Supply pump SCV malfunction (Full discharge mode)
DTC
P0629
Supply pump SCV malfunction (Power source line short)
DTC
P0629
Supply pump SCV malfunction (Power source line short)
1
Measurement of resistance between solenoid terminals 1.
1
Measurement of resistance between solenoid terminals
Set the starter key to "OFF", disconnect the connector of the
1.
Set the starter key to "OFF", disconnect the connector of the
supply pump solenoid valve and measure the resistance
supply pump solenoid valve and measure the resistance
between No. 1 and No. 2 terminals at the supply pump solenoid
between No. 1 and No. 2 terminals at the supply pump solenoid
valve.
valve.
Standard value : 7.9 r 0.5 : (20 qC{68 qF}) NG
Standard value : 7.9 r 0.5 : (20 qC{68 qF}) NG
Failure of supply pump solenoid valve
SAPH311991700051
OK
2
Measurement of resistance between terminals 1.
Measurement of resistance between terminals
Set the starter key to "OFF", connect the signal check harness
1.
and disconnect the ECU side connector. 2.
E E11
E8 E9 E10
Set the starter key to "OFF", connect the signal check harness and disconnect the ECU side connector.
Measure the resistance between terminals E10/E11 of the
2.
signal check harness and the No. 1 terminal of the supply
E
pump solenoid valve (at unit harness side).
E11
E8 E9 E10
Measure the resistance between terminals E10/E11 of the signal check harness and the No. 1 terminal of the supply pump solenoid valve (at unit harness side).
In a similar manner, measure the resistance of terminals E8/E9
In a similar manner, measure the resistance of terminals E8/E9
of the signal check harness and the No. 2 terminal of the
of the signal check harness and the No. 2 terminal of the
supply pump solenoid valve connector (at unit harness side).
supply pump solenoid valve connector (at unit harness side).
SAPH311991700052
SAPH311991700052
Standard value : 1 : or less NG
OK
Failure of supply pump solenoid valve
SAPH311991700051
OK
2
17â&#x20AC;&#x201C;43
ENGINE DIAGNOSIS CODE
Standard value : 1 : or less NG
Harness disconnection, connector failure
OK
Harness disconnection, connector failure
17–44
3
ENGINE DIAGNOSIS CODE
3
Measurement of voltage between terminals
E4
E
E8 E9
17–44
1.
Turn "ON" the starter key.
2.
Measure voltage between terminal E4 and terminals E8/E9 of
ENGINE DIAGNOSIS CODE
Measurement of voltage between terminals
E4
the signal check harness.
E
E8 E9
1.
Turn "ON" the starter key.
2.
Measure voltage between terminal E4 and terminals E8/E9 of the signal check harness.
Standard value : Pulse waveform at 24V l 0V NG
Standard value : Pulse waveform at 24V l 0V NG
Failure of ECU connector
SAPH311991700053
OK
SAPH311991700053
OK
Engine ECU failure ! CAUTION
Failure of ECU connector
• After turning "ON" the starter key, take measurements within 40 seconds.
Engine ECU failure ! CAUTION
• After turning "ON" the starter key, take measurements within 40 seconds.
17â&#x20AC;&#x201C;45
ENGINE DIAGNOSIS CODE
17â&#x20AC;&#x201C;45
ENGINE DIAGNOSIS CODE
Supply pump SCV sticking (DTC code P2635), Supply pump malfunction
Supply pump SCV sticking (DTC code P2635), Supply pump malfunction
(DTC code P2635), Supply pump abnormal pressure record (DTC code
(DTC code P2635), Supply pump abnormal pressure record (DTC code
P2635)
P2635) JP31199170601026
1
JP31199170601026
1
Inspection of supply pump
Inspection of supply pump
1.
Set the starter key to "OFF" and stop the engine.
1.
Set the starter key to "OFF" and stop the engine.
2.
Wait for approx. 30 seconds and start the engine.
2.
Wait for approx. 30 seconds and start the engine.
3.
Warm-up the engine until coolant temperature is 60 qC{140 qF}
3.
Warm-up the engine until coolant temperature is 60 qC{140 qF}
4.
or more, and delete the past failure with the failure diagnosis
or more, and delete the past failure with the failure diagnosis
tool (HinoDX) using PC.
tool (HinoDX) using PC.
Run the engine at no load up to HI idle. Or repeat no-load
4.
operation from LOW idle to HI idle two or three times and SAPH311991700026
confirm that the same fault code is displayed again. NG
Replace supply pump.
OK
2
operation from LOW idle to HI idle two or three times and SAPH311991700026
confirm that the same fault code is displayed again. NG
Run the engine at no load up to HI idle. Or repeat no-load
Replace supply pump.
OK
2
Check of failure code 1.
2.
SAPH311991700054
Check of failure code
Make sure that other failure code is not output.
1.
Make sure that other failure code is not output.
If other failure code is output, repair the failure code and make
If other failure code is output, repair the failure code and make
sure again that DTC code P2635 is output.
sure again that DTC code P2635 is output.
When there is no error after the check above, delete the past
2.
When there is no error after the check above, delete the past
failure and operate the engine.
failure and operate the engine.
If the same code is output again, possible failures are the
If the same code is output again, possible failures are the
supply pump and engine ECU. Perform more detailed
supply pump and engine ECU. Perform more detailed
diagnosis with failure diagnosis tool (HinoDX) - HinoDX
diagnosis with failure diagnosis tool (HinoDX) - HinoDX
[Inspection Menu], using PC.
SAPH311991700054
[Inspection Menu], using PC.
17â&#x20AC;&#x201C;46
17â&#x20AC;&#x201C;46
ENGINE DIAGNOSIS CODE
Preheat circuit malfunction (DTC code P0540)
ENGINE DIAGNOSIS CODE
Preheat circuit malfunction (DTC code P0540) JP31199170601030
1 C2 C1
1
Measurement of resistance between terminals 1.
C
D1
D
E
E4
2.
Measurement of resistance between terminals
Set the starter key to "OFF" and connect the signal check
1. C2 C1
harness.
E5
JP31199170601030
C
D1
D
E
E4
harness.
E5
Disconnect the ECU side connector of the signal check
Set the starter key to "OFF" and connect the signal check
2.
Disconnect the ECU side connector of the signal check
harness and measure the resistance between terminals C1, C2
harness and measure the resistance between terminals C1, C2
and terminals D1, E4, E5.
and terminals D1, E4, E5.
Standard value : 25 r 2.5 : NG SAPH311991700055
NG
[2] Go to measurement of resistance between SAPH311991700055
terminals.
OK
[2] Go to measurement of resistance between terminals.
OK
Engine ECU failure, ECU connector failure
2
Standard value : 25 r 2.5 :
Engine ECU failure, ECU connector failure
2
Measurement of relay resistance 1.
Measurement of relay resistance
Remove the heater relay and measure the resistance between
1.
terminals.
Remove the heater relay and measure the resistance between terminals.
Standard value : 24.8 r 0.5 : NG
Standard value : 24.8 r 0.5 : NG
Heater relay failure
SAPH311991700056
OK
Harness failure, connector failure
SAPH311991700056
OK
Harness failure, connector failure
Heater relay failure
17â&#x20AC;&#x201C;47
ENGINE DIAGNOSIS CODE
Injector correction data conformity error (DTC code P1601)
Injector correction data conformity error (DTC code P1601) JP31199170601031
1
JP31199170601031
1
Inspection of QR code 1.
Inspection of QR code
Read the QR code data with the failure diagnosis tool (HinoDX)
1.
using PC.
NG
Read the QR code data with the failure diagnosis tool (HinoDX) using PC.
Reference value: This shall coincide with the QR code
Reference value: This shall coincide with the QR code
managed by the unit manufacturer.
managed by the unit manufacturer. NG
Write the QR code again.
SAPH311991700026
Write the QR code again.
SAPH311991700026
OK
OK
Replace engine ECU.
Replace engine ECU.
ECU internal error (DTC code P0605, P0606, P0607)
ECU internal error (DTC code P0605, P0606, P0607) JP31199170601032
JP31199170601032
DTC
P0605
Flash ROM error
DTC
P0605
Flash ROM error
DTC
P0606
CPU malfunction (Hard detection)
DTC
P0606
CPU malfunction (Hard detection)
DTC
P0607
Monitoring IC malfunction in CPU
DTC
P0607
Monitoring IC malfunction in CPU
1
17â&#x20AC;&#x201C;47
ENGINE DIAGNOSIS CODE
1
Check of diagnosis code
Check of diagnosis code
1.
Set the starter key to "OFF" and set it to "ON" again.
1.
Set the starter key to "OFF" and set it to "ON" again.
2.
After deleting the past failure, check if the same code (DTC
2.
After deleting the past failure, check if the same code (DTC
code P0605, P0606, P0607) is output again.
code P0605, P0606, P0607) is output again.
Standard : Normal NG
Standard : Normal NG
Engine ECU failure
SAPH311991700026
OK
Engine ECU failure
SAPH311991700026
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
normal operation.
17–48
17–48
ENGINE DIAGNOSIS CODE
ECU charge circuit malfunction (DTC code P0200, P0611)
ENGINE DIAGNOSIS CODE
ECU charge circuit malfunction (DTC code P0200, P0611) JP31199170601033
JP31199170601033
DTC
P0200
ECU charge circuit high input
DTC
P0200
ECU charge circuit high input
DTC
P0611
ECU charge circuit malfunction
DTC
P0611
ECU charge circuit malfunction
1
1
Check of ECU
Check of ECU
1.
Set the starter key to "OFF" and set it to "ON" again.
1.
Set the starter key to "OFF" and set it to "ON" again.
2.
After deleting the past failure, check if the same code (DTC
2.
After deleting the past failure, check if the same code (DTC
code P0611, P0200) is output again.
code P0611, P0200) is output again.
Standard : Normal NG
Standard : Normal NG
Engine ECU failure
SAPH311991700026
OK
Engine ECU failure
SAPH311991700026
OK
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
Since it may be a temporary malfunction due to radio interference, it is acceptable when the system recovers
normal operation.
normal operation.
17–49
ENGINE DIAGNOSIS CODE
Main relay malfunction (DTC code P0686)
Main relay malfunction (DTC code P0686) JP31199170601034
1
1.
A
A5
JP31199170601034
1
Measurement of voltage between terminals
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
A6 A7
1.
harness. 2.
A
A5
Set the starter key to "OFF" and connect the signal check
A6 A7
harness.
Disconnect the ECU side connector of the signal check
2.
harness and set the starter key to "ON". Measure the voltage
Frame
Disconnect the ECU side connector of the signal check harness and set the starter key to "ON". Measure the voltage
Frame
between terminals A5, A6, A7 and the chassis GND.
between terminals A5, A6, A7 and the chassis GND.
Standard value : 0 V NG
Standard value : 0 V NG
Defective harness
SAPH311991700057
Defective harness
SAPH311991700057
OK
OK
Engine ECU failure, engine ECU connector failure
Engine ECU failure, engine ECU connector failure
Starter signal malfunction (DTC code P0617)
Starter signal malfunction (DTC code P0617) JP31199170601035
1
17–49
ENGINE DIAGNOSIS CODE
1
Measurement of voltage between terminals 1.
B
C
B14
2.
Measurement of voltage between terminals
Set the starter key to "OFF" and connect the signal check
1.
harness.
C4
C3
JP31199170601035
B
Disconnect the ECU side connector of the signal check
C
B14
harness.
C4
2.
C3
harness and set the starter key to "ON". 3.
! CAUTION
OK
Engine ECU failure, ECU connector failure
3.
• Measuring shall be done in an environment
Measure voltage between terminal B14 and terminals C3/C4.
! CAUTION
where the engine may be started.
NG
Disconnect the ECU side connector of the signal check harness and set the starter key to "ON".
Measure voltage between terminal B14 and terminals C3/C4.
SAPH311991700058
Set the starter key to "OFF" and connect the signal check
• Measuring shall be done in an environment where the engine may be started.
SAPH311991700058
Standard value
Standard value
: 0 V (when starter key is at "OFF")
: 0 V (when starter key is at "OFF")
: 24 V (when starter key is at "START")
: 24 V (when starter key is at "START") NG
Harness failure
OK
Engine ECU failure, ECU connector failure
Harness failure
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Table48-1 Failure diagnosis Mode-1/Diagnosis item No.
Display
Table48-1 Failure diagnosis Mode-1/Diagnosis item
Contents of diagnosis
No.
Display
Contents of diagnosis
13 1 TRAVEL-S
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
13 1 TRAVEL-S
Is normal pressure generated in the condition that P1 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
14 2 TRAVEL-S
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
14 2 TRAVEL-S
Is normal pressure generated in the condition that P2 side flow rate is minimum, unload valve is emergency position and travel straight is stroked fully?
15 1 P1 ENGINE
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?
15 1 P1 ENGINE
Is rated engine speed obtained in the condition that P1 side flow rate increases little by little when P1 side flow rate is relieved?
16 2 P2 ENGINE
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?
16 2 P2 ENGINE
Is rated engine speed obtained in the condition that P2 side flow rate increases little by little when P2 side flow rate is relieved?
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2 PUMP" of No.10 are not given a diagnosis.
When pump regulator does not have "Total power control of Emergency mode", "1 P1 PUMP" of No.7 and "1 P2 PUMP" of No.10 are not given a diagnosis.
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display) SENSOR CHECK NG
P1 UN-LOAD PSV NG
P1 UN-LOAD SPOOL NG
P2 UN-LOAD PSV NG
P2 UN-LOAD SPOOL NG P1 B-P CUT NG P2 B-P CUT NG
P1 PUMP PSV NG
P1 PUMP NG
P2 PUMP PSV NG
Possible cause Disconnection of pressure sensor, Short circuit, Abnormal output
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy Remedy
Check each pressure sensor by service diagnosis and replace it if necessary
Secondary pressure is excessive high against the command Check P1 unload proportional valve Secondary pressure is excessive low against and replace it if necessary the command Stuck at full-stroke side
Check P1 unload spool and replace it if necessary
Stuck at neutral side
Secondary pressure is excessive high against the command Check P2 unload proportional valve Secondary pressure is excessive low against and replace it if necessary the command Stuck at full-stroke side
Check P2 unload spool and replace it if necessary
Stuck at neutral side Stuck at closing side Stuck at neutral side Stuck at closing side Stuck at neutral side
Delivery rate is excessive small against the command
P1 UN-LOAD PSV NG
P1 UN-LOAD SPOOL NG
P2 UN-LOAD PSV NG
P2 UN-LOAD SPOOL NG P1 B-P CUT NG
Check P2 by-pass cut valve and replace it if necessary
P2 B-P CUT NG
Check P1 pump regulator and replace it if necessary. Check P1 pump and replace it if necessary.
Secondary pressure is excessive high against the command Check P2 pump proportional valve Secondary pressure is excessive low against and replace it if necessary the command
48-5
SENSOR CHECK NG
Check P1 by-pass cut valve and replace it if necessary
Secondary pressure is excessive high against the command Check P1 pump proportional valve Secondary pressure is excessive low against and replace it if necessary the command Delivery rate is excessive large against the command
Diagnosis (Display)
P1 PUMP PSV NG
P1 PUMP NG
P2 PUMP PSV NG
Possible cause Disconnection of pressure sensor, Short circuit, Abnormal output
Remedy Check each pressure sensor by service diagnosis and replace it if necessary
Secondary pressure is excessive high against the command Check P1 unload proportional valve Secondary pressure is excessive low against and replace it if necessary the command Stuck at full-stroke side
Check P1 unload spool and replace it if necessary
Stuck at neutral side
Secondary pressure is excessive high against the command Check P2 unload proportional valve Secondary pressure is excessive low against and replace it if necessary the command Stuck at full-stroke side
Check P2 unload spool and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P1 by-pass cut valve and replace it if necessary
Stuck at neutral side Stuck at closing side
Check P2 by-pass cut valve and replace it if necessary
Stuck at neutral side
Secondary pressure is excessive high against the command Check P1 pump proportional valve Secondary pressure is excessive low against and replace it if necessary the command Delivery rate is excessive large against the command Delivery rate is excessive small against the command
Check P1 pump regulator and replace it if necessary. Check P1 pump and replace it if necessary.
Secondary pressure is excessive high against the command Check P2 pump proportional valve Secondary pressure is excessive low against and replace it if necessary the command
48-5
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
48. TROUBLESHOOTING (TROUBLE DIAGNOSIS MODE)
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy Diagnosis (Display)
P2 PUMP NG
S-TRAVEL PSV NG
S-TRAVEL SPOOL NG
Possible cause Delivery rate is excessive large against the command Delivery rate is excessive small against the command
Table48-2 Failure diagnosis Mode-1/Diagnosis and Remedy Remedy
Check P2 pump regulator and replace it if necessary. Check P2 pump and replace it if necessary.
Secondary pressure is excessive high against the command Check travel straight proportional Secondary pressure is excessive low against valve and replace it if necessary the command Stuck at full-stroke side
Check travel straight spool and replace it if necessary
Stuck at neutral side
Diagnosis (Display)
P2 PUMP NG
S-TRAVEL PSV NG
S-TRAVEL SPOOL NG
Possible cause Delivery rate is excessive large against the command Delivery rate is excessive small against the command
Remedy Check P2 pump regulator and replace it if necessary. Check P2 pump and replace it if necessary.
Secondary pressure is excessive high against the command Check travel straight proportional Secondary pressure is excessive low against valve and replace it if necessary the command Stuck at full-stroke side
Check travel straight spool and replace it if necessary
Stuck at neutral side
PUMP 1 PRESS. SENSOR Pressure is recognized lower than it is NG
Check P1 high pressure sensor and replace it if necessary
PUMP 1 PRESS. SENSOR Pressure is recognized lower than it is NG
Check P1 high pressure sensor and replace it if necessary
PUMP 2 PRESS. SENSOR Pressure is recognized lower than it is NG
Check P2 high pressure sensor and replace it if necessary
PUMP 2 PRESS. SENSOR Pressure is recognized lower than it is NG
Check P2 high pressure sensor and replace it if necessary
MAIN RELIEF NG ENGINE NG E/G R SENSOR NG
Set pressure decreases
Check main relief valve and replace it if necessary
Set pressure increases Output is lowered
Check engine and replace it if necessary
Characteristics is misaligned
Check engine speed sensor and replace it if necessary
48-6
MAIN RELIEF NG ENGINE NG E/G R SENSOR NG
Set pressure decreases
Check main relief valve and replace it if necessary
Set pressure increases Output is lowered
Check engine and replace it if necessary
Characteristics is misaligned
Check engine speed sensor and replace it if necessary
48-6
51. ENGINE
51. ENGINE
PREFACE
PREFACE
This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of HINO MOTOR.
This service manual explains the single engine. Note that this manual is edited without modification by based on the service manual of HINO MOTOR.
51
51
Book Code No. S5YN5123E01 51-1
Book Code No. S5YN5123E01 51-1
51. ENGINE
51. ENGINE
Issue
Date of Issue
Applicable Machines
First edition
April, 2007
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
51-2
Remarks S5YN5123E01 ASIA (HS Engine) n (NHK Russia) HS Engine
Issue
Date of Issue
Applicable Machines
K
First edition
April, 2007
SK200–8 : YN11-45001~ SK210LC–8 : YQ11-06001~
K
n
July, 2007
E215B : YN11-45001~ E215BLC : YQ11-06001~
51-2
Remarks S5YN5123E01 ASIA (HS Engine) n (NHK Russia) HS Engine
K K